#Spinning

2023-09-07

Rieter ROBOdoff: Automation reduces labor costs in rotor spinning

Gaoyi Delida Textile Co., Ltd., China, has upgraded their 30 semi-automated rotor spinning machines R 35, R 36 and R 37 with ROBOdoff, Rieter’s automatic doffing solution. ROBOdoff reduces the operator’s workload and labor costs thanks to a doffing success rate of up to 98%. The yarn package length and weight are consistently maintained, resulting in a lower conversion cost.

Delida faced difficulties in recruiting skilled operators for its rotor spinning mill. The noisy and dusty mill environment paired with the heavy workload involved in manual doffing don’t provide an attractive work environment. Finding qualified operators therefore became critical, resulting in increased labor costs.

Based on market requirements, Delida produces a wide range of yarn counts with the rotor spinning machines, which require frequent batch changes, adding additional workload to the operators.

The weaving and knitting markets demand for consistent yarn package length and weight to minimize downstream yarn waste. In addition, the yarn package with the target length and weight is also a very popular requirement in the market. For Delida, this was a constant challenge with the traditional manual doffing, as the weight deviation between the yarn packages is greater, leading to increased conversion costs.

ROBOdoff installed on an existing rotor spinning machine R 35. © 2023 Rieter

Delida aims to increase the level of automation to overcome the problems of growing labor costs, improve the flexibility of the batch process and meet the market requirements of delivering consistent yarn package weight. Managing these challenges will help to further strengthen its competitive advantage and consolidate its market leadership position. Delida turned to Rieter to learn about automation solutions.

Automated Doffing with ROBOdoff as an Upgrade

Rieter’s after sales team recommended the ROBOdoff upgrade for Delida’s rotor spinning machines R 35, R 36 and R 37. ROBOdoff is a device for automated package change that runs on each side of the machine. Given the solution's promising potential to mitigate the persistent labor shortages, Delida ordered 30 devices. ROBOdoff has the following three smart setting features that meet multiple customer needs and provide maximum flexibility during operation:

• automated block doffing regardless of the package length,

• doffing in delta length securing that all doffed packages contain the target length, which ensures the weight deviation of the yarn packages is minimal, and

• ROBOdoff works as a traveling cleaner when doffing is not required, which cleans the rail and the machine's spinning positions.

Reliable performance with 24/7 working mode reduces the operator's workload of manual doffing. The customer was so satisfied with the stable performance of ROBOdoff that they will choose ROBOdoff again when investing in new machines.

ROBOdoff with smart setting features enables maximum flexibility during operation. © 2023 Rieter

Improved Operational Agility Resulting in Labor Cost Reduction

The automatic doffing system ROBOdoff delivers an impressive doffing success rate of 98%, eliminates the need for manual doffing and reduces the operational workload, resulting in labor cost savings. The enhanced flexibility of the block doffing option allows Delida to manage frequent changes in yarn production batches with ease, improving overall operational agility significantly and ultimately reducing labor costs.

Zhang Xiuzhen, Factory Director of Gaoyi Delida Textile Co., Ltd., China © 2023 Rieter

ROBOdoff does not only automate the unpleasant task of manual doffing. With the option of the delta length securing feature, the doffed packages are maintained with the same package length, resulting in a uniform package weight. The operator can set the package length and ROBOdoff will automatically doff packages whose length lies within the defined tolerance. The yarn waste in subsequent weaving or knitting processes is minimized to a greater extent. Another signature advantage of the ROBOdoff is a consistent and proper formation of the transfer yarn tail.

The uniform doffing process reduces the damage and replacement cost of the doffing arms, which helps extend the lifetime of the rotor machine in general. ROBOdoff also works as a traveling cleaner when doffing is not required, which cleans the rail and the machine's spinning positions from micro dust offering maximum flexibility to customers.

ROBOdoff enables more efficient work organization. The physically exhausting process of manual doffing is now a thing of the past and operators are free to focus on more value-adding tasks. This investment pays off in about two to three years.

"ROBOdoff ensures that all doffed packages contain the consistent target length thanks to the delta length module. This is extremely helpful for our customers in the weaving and knitting segment. At the same time, ROBOdoff has significantly reduced our labor costs, increased yarn profitability and improved the efficiency of our mill operations."

Zhang Xiuzhen, Factory director of Gaoyi Delida Textile Co., Ltd., China

Rieter advances strategic repositioning amid market volatility

Rieter successfully completed the acquisition of Barmag on February 2, 2026, and reached an important milestone in the company’s repositioning. Barmag will be integrated into the Rieter Group as the “Man-Made Fiber” Division. With this strategically transformative acquisition, Rieter is expanding its core business beyond the short-staple fiber business in a targeted way. This positions Rieter as the global market leader along the entire value chain for natural and man-made fibers. In addition, as a complete systems supplier, Rieter is further strengthening its technological leadership in the areas of automation and digitization.

Rieter responds to higher raw material prices

Global political and economic developments have been leading to rising raw material and energy costs for some time. The textile machinery industry is also affected by this trend. Rieter machines and components consist to a large extent of steel, copper, aluminum and electronics. These materials in particular have seen higher demand and higher prices in recent months.

Rieter adjusts group structure in preparation for Barmag integration

The planned acquisition of the “Barmag” Division of OC Oerlikon will create the leading system provider worldwide for natural and man-made fibers. Rieter is confident it will receive all regulatory approvals to complete the acquisition in the fourth quarter of 2025. The Rieter Group is therefore adjusting its Group structure as of January 1, 2026, to take this acquisition into account and to be able to provide an even more agile response to market challenges.

RETECH showcases high-precision godets for high-performance fiber processing at Techtextil 2026

RETECH designs and manufactures godets and draw frames for heated, ambient and cooled processes, enabling precise heat treatment and consistently high yarn quality for a wide range of polymers and applications, with process temperatures of up to 400 °C for high-performance fibers. The company’s key competence lies in exact and stable temperature and speed control, individually adapted to the specific material and process requirements.

Barmag presents the next generation of POY production – energy-efficient and partial-automated

With POY 2.0, Barmag is introducing a completely redesigned spinning concept that takes the production of partially oriented yarn (POY) to a new level in terms of technology and economy. The solution, which was presented to a selected audience of experts for the first time at ITMA Asia + CITME 2025, was met with great enthusiasm: several yarn producers worldwide immediately expressed their interest in a pilot plant.

Development of bio-based polyethylene fibers for textile applications – BB Engineering partici-pates in the bioPEtex research project

In the German research project bioPEtex, BB Engineering (BBE) is working with other partners to develop textiles made from 100% bio-based polyethylene (PE). The aim is to make use of this poly-mer, which has hardly been used in the chemical fiber industry to date. BBE is contributing its spinning and texturizing expertise and developing the texturing process on an industrial scale. The first promising results are already available – opening up new opportu-nities for sustainable and economically attractive applications in the textile industry.

BW Converting expands Southeast Asian presence with new agency partnerships in Vietnam and Indonesia

BW Converting is strengthening its presence in Southeast Asia through new agency partnerships in Vietnam and Indonesia, reinforcing the company’s commitment to supporting textile manufacturers across the region. The expansion comes as BW Converting prepares to exhibit at SaigonTex 2026 (April 8–11, Saigon Exhibition and Convention Center, Ho Chi Minh City, Vietnam) and INDO INTERTEX 2026 (April 15–18, Jakarta International Expo, Indonesia).

Driving WARP KNIT Inspiration

KARL MAYER sees performance fabrics and next-level textile solutions in particular as potential growth drivers for its customers, as a motor for business development and as real game changers for the entire textile industry. Innovation does not happen by chance. It is the result of close exchange with customers & brands, textile expertise and competence in textile machine engineering. This is why KARL MAYER is investing in progress and collaborative development and opening its TEXTILE INNOVATION CEN-TER (TIC) – a place to be for the entire textile world.