IDEAL Products

HCC Tube (Higher machine efficiency and lower power consumption)
Ideal is manufacturing innovative design slim tubes with very special polymer .These tubes have been found to increase machine efficiency and reduce power consumption.

Major features

1. Weight of the tube reduces by almost 35% compared to standard 3 mm tube.
2. Cop content increased by 12-15%.
3. Made up of special polymer with high stability and low coefficient of friction.
4. Suitable for steaming / heat setting of yarn upto 130 deg C.

The major gains can be summarized as below:

1. Winding machine efficiency increased by 3-5%.
2. Reduction in ring frame power consumption by 3-5%; depending on yarn count and the machine speed
3. Increased life span of doffing m/c by 20%.
4. No of doffs reduce by 15%, thereby improving the yarn quality and ring frame efficiency.

Available in wide range of colors.

HIG TUBE (Efficient auto doffing and high durability)
Ideal comes with another innovative product “HIG” tubes for high speed ring spinning machines.
The Tubes are made out of two components i.e. Durable main body with low friction long bush. The main body is made of high impact polymer which can withstand all type of stress while working on the machine. A long bush is made up of polymer having very low coefficient of friction which helps spinning tube to glide on the spindle.

• The tubes are with Pressing load on the spindles Less than 1500 N. in order to ensure trouble free doffing process.
• For this combination spindle/ tube require concentric running which guarantees that both spinning elements run without vibration.
• Suitable for steaming / heat setting of yarn upto 100 deg C.

• Ideal successfully developed special design Tubes for processing elastomeric yarn also called Lycra- Spandex yarn on IDLS machines.
• The Yarn by its nature has tendency to come out of bobbins, which are prepared for feeding to winding drums. In order to have better grip of elastin yarn and avoid rejections on winding heads the tubes developed have specific shape and the star portion for retaining the yarn end.
• The geometry of tip retaining yarn end is maintained for all the lengths.
• The star portion is ensured to remain free from burrs & damaged edges.

Ideal offer cone and cylinders for winding & dyeing process.

• These are manufactured combining in-house developed high accuracy moulds, engineering expertise, state of art modern injection moulding facility having wide range of capacities and capabilities.
• Ideal uses prime quality resins which results in optimal mechanical and surface properties in line with customer requirements.
• Surface textures like precision micro grooves are for controlled frictional properties.
• The optimal surface properties, precise dimensional and geometrical accuracies and stabilities produce higher quality yarn packages.
• Significant processing efficiencies are achieved in subsequent processes.
• The dimensional stability includes:
  1. Precisely controlled length of cones & cylinders.
  2. Absolutely consistent diameter at the base and top.
  3. Absolute dimensional stability regardless of relative humidity.

Ideal has successfully launched family of Dyeing cheese.

These comprise of:

• Axially Flexible, One-way dyeing cheese with protected transfer tail.
• Fix one-way and reusable dyeing cheese with protected transfer tail in various designs.
• Manufactured with best in the class moulds from:
  • Base Resin compounds
  • Filled Resins.
• These are available for:
  • Yarn steaming and dyeing at full range of temperatures and pressures.
  • With wide range of textures & colors
  • Multiple use and single use – both types are available.
  • Multiuse dye cheese and cones are available for multiuse dyeing of polyester yarn at higher temperatures.

• Ideal developed Sure Lock Tubes with continuous groove to support spindles assembled with 3 point centrifugal clutch.
• The groove provides reliable positioning and holding of the tubes in axial direction.
• Change over from normal tube to Sure Lock Tubes is instantaneous and does not require any addition skill or toolings.
• There is no lifting of the tubes on the spindles with 3 point centrifugal.

ABC Rings are used to contain the Yarn-loop by reducing yarn tension and decreasing the balloon flutter instability. Flutter instability here refers to uncontrolled changes in ballooning yarn under dynamic forces including the air drag and significance variation in the length and radius of the balloon during the bobbin filling process.

• ABC ring are manufactured as per OEM specification
  • The ring are manufactured from high grade steel and rolled strip in well equipped production facility by trained personnel.
  • The ring and strap or studs are welded by special clean resistance welding process without any filler metal with crystal clear joint.
  • The welded joints are as strong as parent materials and are tested by:
    • Bend Test
    • Impact Test
    • Ultrasonic Test and
    • Radiographic Test

• The ABC ring are Hard chrome plated by modern plating process followed by polishing for:
  • High hardness which provides high wear resistance & prolonged trouble free performance.
  • Coating provides total prolection against corrosion under severe working environment.
  • Polished smooth surfaces with low co-efficient of friction provide smooth contact, free from potential end breaks.

• The available Designs include
  • “S” Twist
  • “Z” Twist
  • “SZ” Twist
  • In various diameters.

All above designs are available with

• Plain strap with mounting slot
• Bend Strap with mounting slot
• With mounting stud

• Now manufactured from Best in class Bright Cold drawn fine grained polished stainless steel wires.
• The perishable parts of devices are now manufactured from High grade Tool Steels from Sweden to get extended life span free from potential deterioration from forming marks.
• Surface Treatment with upgraded cycle under planned strict process control to achieve new Bench Marks standards of Hardness, Optimum Diffusion depth & well defined surface.
• “TOTALLY FIBRE-ADHESION FREE SURFACE”, with this now right from the moment of installation you can achieve the required performance without End “BREAKAGES”.
• Ongoing Monitoring of surface Qualities of Yarn Contact Path with CNC Multifunctional Proven Inspection System.

• Due to ongoing use, in course of time the tubes develop the following undesirable deviations:
  • The fitment of the tubes on the applicable spindles require high pressing load which interrupts the smooth doffing process.
  • In extreme cases the tubes fail to fit on the spindle due to groove formation.
  1. The spindles, from repeated use in a humid environment, would accumulate debris on the outside diameter of the spindles and the tubes also have the accumulated sticky substances inside the tubes. Due to this the tubes do not enter smoothly on the spindles as per the required feel of the smoothness and the force required to press the tube on the spindle. To overcome the above problems, from time to time the tubes have to be cleaned/polished on the inside so as to ensure the pressing load in specified load range which is one of the important requirements for the smooth and positive doffing process.
  2. Due to repeated use, the tubes sometimes develop shallow groove formation due to inadequate entry of the tube on the spindle or due to out of square entry on the spindles. This groove displaces the material of the tube which prevents the entry of the tubes on the spindles. Ideal has developed user friendly TWO IN ONE SET UP as per the Photo No. 01 for the cleaning of the tubes from inside and reaming where required so as to regain the required characteristics within the permissible fine limits so as to achieve uninterrupted performance till the rated life span of the tubes.
     The Photo No. 02 shows the setup for reaming of the tubes.