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uTESTER5

The yarn inspection system

Precise yarn quality control for optimized profitability

The USTERTESTER5 is acknowledged throughout the textile value chain


as the global standard in evenness testing, enabling spinners to control
yarn quality levels precisely and optimize profitability. There are two
latest-technology models in the range: the USTERTESTER5-S800 and
USTERTESTER5-S400.
The tremendous processing capability of the USTERTESTER5 is unique,
with testing at 800m/min using the S800 model.
To ensure every important quality characteristic can be measured
accurately, the USTERTESTER5 range of sensor options includes both
optical and capacitive technology. This combination is currently the
only way to monitor and control increasingly complex yarn properties.
The proven capacitive measuring method is key to the USTERTESTER5s
highly accurate control of mass variations in yarns, rovings and slivers.
The optical sensor options, such as the OH Module for hairiness, measure
all relevant yarn parameters for a complete yarn specification or process
management in the mill.

The global standard in yarn quality testing

A key feature of the USTER TESTER 5 is its focus on the


CV m value, an authoritative and communicable percentage
level for evenness. The proven capacitive measuring
method used by the USTER TESTER 5 is the key to its highly
accurate control of mass variation in yarn, roving and
sliver, allowing users to achieve an ideal balance between
quality and processing cost. The capacitive sensor also
ensures comprehensive and finely tuned detection of imperfections, with precise measurement of thick and thin places
and neps down to 12 levels of sensitivity, for different
yarn types.
USTER s range of sensor options includes both optical
such as the OH Module for hairiness and capacitive
technology. This combination is currently the only way to
monitor and control increasingly complex yarn properties.
This advantage is also offered by the USTER TESTER 5 -S400 ,
the alternative system, with testing speeds of 400 m/min
and a comparable range of vital test functions.

Foreign fibers are a major headache for modern spinners


and can make yarns virtually worthless in subsequent
weaving or knitting. The latest USTER foreign- matter
optical sensor for the USTER TESTER 5 provides fast and
accurate laboratory measurement and classification
of all foreign-matter in the yarn, at speeds that maintain
optimum production efficiency.

Even where environmental conditions are variable or


difficult, the USTER TESTER 5 ensures that results are not
skewed, thanks to its inbuilt temperature and humidity
sensor, which takes readings directly at the test units.
With 60 years of experience in the industry, USTER
has become synonymous with quality management in
textiles. The USTER STATISTICS benchmarking tools
are the industrys accepted global standards for quality
comparisons and a basis for the trade and certification
of textiles. Results from the USTER TESTER 5 can be
correlated automatically with USTER STATISTICS values.
USTER s ability to produce precise and accurate data
reliably is unmatched in the industry. Without this, there is
no basis for process optimization or quality measurement
to industry standards, set out in the USTER STATISTICS .

For export-oriented international spinners, quality


management with USTER products is a must, to supply
customers worldwide with a guarantee of constant quality.
Any doubts about the quality characteristics of a textile
product can be eliminated if that product has been tested
with USTER instruments!

Capacitive measuring sensor for


slivers, rovings and yarns

Global standards for yarn


evenness testing acknowledged
by spinners, yarn buyers and
retailers
Precise control of yarn, roving
and sliver mass variation by the
genuine capacitive measuring
system
Measurement of imperfections
with 12 sensitivity levels of thin
and thick places plus neps for
different yarn types
Optical sensor options to
meas ure every important quality
characteristic
Up to 800 m/min testing speed
Fast laboratory indication of
foreign-matter with the FM Sensor
Temparature and humidity sensor
to disclose the environmental
conditions during the test
Only the USTER TESTER can
produce the accepted
USTER STATISTICS standards

Precision and accuracy at highest speed

USTER pioneered evenness testing more than 60 years ago


and that experience, backed by Swiss manufacturing
excellence, gives the USTER TESTER 5 an unbeatable
advantage. The unique USTER sensor technology
guarantees precision and accuracy in testing, proven
by extensive industrial experience. That explains why the
USTER TESTER 5 is the only instrument whose results
correlate with evenness standards accepted throughout
the textile sector.

The high speed of the USTER TESTER 5 up to 800 m/min


with the S800 model is another USTER breakthrough.
It opens the door to total testing in tandem with online
yarn clearing. Users also have the option to tailor lab
testing routines to individual needs: shorter test durations
can be chosen, to maximize throughput; or more material
can be tested within existing timings, to provide results
that are statistically more significant.

Total Quality Testing is the testing principle that enables


complete process optimization to minimize waste and
maximize profits. It is a principle that is unique to USTER
and depends upon the close correlation of data measured
in the laboratory, under controlled conditions, with
data measured in production, often in an uncontrolled
environment. Production machinery settings can be
optimized in the conventional way using data from samples
measured in the laboratory. The running production can
be analyzed to check for deviations from these ideal settings
to ensure consistency of production.
Deviations can be further analyzed in the laboratory to
determine the source in the production process, which
can then be corrected. The USTER TESTER 5 and its classleading laboratory test capabilities can be allied with
USTER QUANTUM yarn clearers, running during mill
production on the winding machine, to create a closedloop quality monitoring and feedback solution for the entire
spinning mill. That means 100 % of the yarn production is
checked, rather than random extracts, to move from
uncertain results to consistent quality and predictable profits.

Unique 800 m/min testing speed


By selecting the same test length,
the throughput per 24 hours
can be increased by 70 % =
shortened overall testing time
By selecting the same test time,
more material is tested = the
results are statistically more
significant
The sequence of yarn sample
testing can be optimized in
a way that every testing system
in the laboratory requires the
same duration to measure 10 to
20 bobbins

For closed loop quality monitoring


and feedback provided with the
combination of USTER TESTER 5
and USTER QUANTUM

Beyond measuring hairiness levels

Hairiness problems are estimated to account for up to 15 %


of faults in fabric, affecting production in the spinning
mill as well as reducing the value of the yarn. The resulting
extra costs and delays in processing, as well as customer
complaints, can be extremely damaging. Hairiness
variation showing up in a fabric after dyeing is just one
example of a potentially negative and costly effect of
unmonitored yarn hairiness.
Spinners want to ensure equipment is running correctly
and the yarn meets all the needs of the end-use. It is even
more critical in the compact spinning process which
creates a smoother, less hairy yarn where any variations
are particularly disturbing.

Two-dimensional sensor technology

USTER HAIRINESS has the definitive solution, with


technology for the two globally accepted standards for
hairiness measurement, which together provide the
full picture.

In finishing, it is estimated that 12 % of customer complaints


about color variation and shadowing can be traced back
to unexpected differences in yarn diameter, density and
shape. These are serious problems, and because they
are not mass-related, they can be detected only by twodimensional sensor technology.

With the OH Module, the USTER TESTER 5 offers


reprod ucible and comparable hairiness measurement at
800 m/min, determining the USTER HAIRINESS value,
which is supported by USTER STATISTICS benchmarking,
allowing comparisons with USTER HAIRINESS grades.
The H value from the OH Module of the USTER TESTER 5
acts as an early warning system for potential problems
and as a basis for yarn trading.

The USTER OM Module for the USTER TESTER 5 uses latest


optical sensors to measure the diameter variation, shape
and density of the yarn, giving vital quality information and
enabling accurate prediction of how the yarn will look in
the finished fabric. The lustre has a considerable influence
on the visual aesthetics and value of the fabric and the
OM Module can help to assess these aspects at the yarn
stage.

The perfect complement to the OH Sensor for the USTER


TESTER 5 is the USTER ZWEIGLE HL400 instrument, which
enables highly accurate measurement and classif ication
of hairiness length. The S 3 figure, from the USTER
Diagram Mass
ZWEIGLE HL400 system, is an aid to yarn engineering
and problem solving in manufacturing.

The OM Module can determine a yarns CV FS percentage


for quantifying variations in its fine structure, which
can then be applied to help prevent knitted goods from
appearing cloudy and in improving the density,
structure and smoothness of compact-spun yarns.

These two systems together amount to an integrated total


solution for all hairiness testing requirements.

200

300

400

500

600

700

800

900

1000 m

0.8



0.6


0.4

0
400

450

cm 500
5

10

550
20

50

Ring-spun yarn

1m600 2

5 65010

Compact yarn

20

70050

750

Top:
Mass diagram, showing stable
spinning process
Middle:
Faulty hairiness diagram (left)
and spectrogram (right) showing
hairiness variation caused by
reversal arrangement of the drawbox
at the ring spinning machine

4 . 9

2.5

Bottom:
Comparison of a ring- s pun and
compact yarn
( Rieter Machine Works Ltd)

OH Sensor application range


and benefits
Yarn profiling, yarn trading
and comparison to USTER
STATISTICS
Identification of periodic faults
Continuous monitoring of mill
hairiness levels
Monitoring of the life cycle
of rings and travelers
Early-warning mechanism in
production
Indication of hand/feel of
a finished product

HL400 hairiness length


classification application range
and benefits
Yarn engineering
Control of new spinning
machine settings, especially
compact spinning systems
Identification of long protruding
fibers which cause pilling

Two - d imensional
sensor technology
Optical measurement of
diameter, shape, density and
surface structure
CV FS figure helps prevent
production of cloudy knitgoods
OM Sensor a must for compact
spinners, with critical
information on density and
variation in the fine structure
( CV FS )

24
20

95%
50%

15

5%
10

CVd

6
Nm

10

Ne
Tex

15

5
200 150

10
100 80

20

30
15

60 50 40

Ring-spun yarn

50

70

90

150

20

40

60

80

30 25 20

15

10

Compact yarn

Top:
USTER STATISTICS for diameter
variation
12 . 21 %
9 . 20 %
0 . 53 g/cm 3

CV m
CV FS
D

12 . 61 %
7 . 28 %
0 . 63 g/cm 3

Bottom:
Comparison of a ring-spun and
compact yarn
( Rieter Machine Works Ltd)

Breakthrough in impurity assessment

Mastering slub yarn measurement

Dust and trash content trapped within the fibers of a


yarn can cause serious problems in subsequent fabric
manuf acturing processes. Up to 25 % of downtime on
weaving machines is directly attributable to trash and
seed coat fragments in yarn. Dust contamination in yarn
also leads to rapid wear of needle heads and friction
surfaces in both circular and flat knitting machinery.

Controlling slub effects while at the same time making


them look random and irregular is the special
requirement for producers of fancy yarns used in a
wide range of fashion fabrics.
The USTER Fancy Yarn Profile reaches new heights in
precise slub yarn measurement, and offers an array of tools
to simplify the complex process of fancy yarn manufacture.
Available as an option for the USTER TESTER 5 , the Fancy
Yarn Profile solves the irregularity problem with slub yarns.
It provides constant and detailed quality analysis, detailing
slub numbers, length and distance, as well as checking for
unwanted mass increases and decreases around slubs and
any disturbing patterns in the yarn.

The USTER TESTER 5 can eradicate these problems


through the OI Module, which uses optical technology
to give accurate measurement of these potentially
harmful impurities. For the first time, this module allows
users to test for trash and dust particles in the yarn
at the same time as the evenness testing procedure.
The OI Module also offers a special benefit for rotor
spinning, with a facility for monitoring the cleaning
efficiency of an open-end spinbox for removal of trash
and dust.

An extended range of targeted reports is available with


the USTER TESTER 5 and Fancy Yarn Profile, so that users
can quickly, easily and accurately assess slub yarn quality,
assisted by the famed USTER scatter plot for a quality
overview, spectrogram analysis of periodic faults, and a
unique sequence diagram of the complete slub cycle.

Mass incr.

400
300
200

Used in combination with the USTER AFIS PRO fiber


analysis instrument, the OI Module provides a solution for
improved trash and dust monitoring in the fiber-to-yarn
engineering process.

100
0
0

10

20

30

40

50

60

70

Slub length (m)


0 20 %

Improved trash and


dust monitoring
Accurate optical measurement
of dust and trash content
Compact yarns show up to 20 %
less dust content than standard
ring-spun yarns
Monitoring of the cleaning
efficiency of an OE spin-box
for trash and dust removal

20 40 %

40 60 %

60 80 %

80 10 0 %

cm
120

80

40

0
0

100

200

300

400

Slub number
Slub length

Slub distance

Optimum clearing
efficiency

No clearing
efficiency

120

120

80

80

40

Top:
Seed coat fragment in compact
yarn. Higher test requirements
because of missing hairiness

40

0
Sliver

Yarn

Top:
High transparency in slub
yarn manufacturing shown by
a scatter plot of two different
slub populations

Sliver

Yarn

Bottom:
Comparison of the trash cleaning
efficiency of two spinning mills
from card sliver to yarn
Sliver test: USTER AFIS PRO 2
Yarn test: USTER TESTER 5

300 %
200
0

10
Slub length

100
20

30

40

50 cm

Mass incr.

Middle:
Slub sequence diagram with
faulty slubs
Bottom:
Clear separation of four slub
populations in a 3 - d imensional
histogram

Precise analysis of slub yarns


Extended range of reports to
determine the quality of slub
yarns precisely
The standard for slub yarn
measurement
Measures the three major
requirements for a consistent
slub yarn production
Constant quality number
of slubs, slub length and mass
increase, no mass decrease
after a slub (weak place), no
disturbing patterns through
wrong settings on the
machine
No disturbing patterns in
the yarn

Pinpointing machine faults


Essential count determination
KBS : USTER s vast fund of textile quality know-how is
available to USTER TESTER 5 customers in the form of the
patented Knowledge Based System (KBS ). Using the yarn
measurements made by the USTER TESTER 5 , the KBS
uses spectrogram analysis to detect periodic and semiperiodic faults attributable to defective rotating parts
during the various stages of the yarn preparation and
manufacturing processes.

This software-based system can pinpoint the source of


faults through the textile production sequence, as far back
as the carding machine, using easy-to-read graphic
displays. It enables users to identify and rectify processing
problems or damaged machine parts quickly.
The accuracy of this procedure, combined with USTER s
unique simulation software, gives users a rapid and clear
visual representation of the faults caused in this way, so
that potential problems with damaged or worn components
can be diagnosed early, preventing the production of
second-quality yarn.

The simplicity and effectiveness of the KBS means it can


be readily used by laboratory staff, without the need for
special training.
FA Module: In textile spinning processes, accurate count
determination is paramount through the entire fiber-toyarn sequence, because the count is one of the essential
characteristics in yarn trading. The USTER TESTER 5 - S800
features an additional optional sensor, the FA Module,
which takes care of this task.

It allows automatic separation and determination of yarn


count for a given length of material. Both the average yarn
count and the count variation are calculated, for yarns or
preparatory products.
Together with USTER STATISTICS , the FA Module provides
internationally accepted benchmarks, and guarantees
modern, systematic and comparable yarn testing in the
textile mill.

Spectogram Mass
6
5
4
3
2
1
0
5 cm

10

20

50

1m

3
9
12

10

20

50

100

1 G33

1
6

2 Count In (0.709 Nec)

3 E1 pulley ~ 90.05 mm
4 Draft (1.189)

5 Tot. draft (58.30)


6 ZE ~90.05 mm

7 Count out (40.00 Nec)

8 Del speed = 22.23 m/min


9 ZW ~ 90.05 mm

10 Twist (0 T/m)

10

11 Twist RPM = 0/min


12 E6 pulley ~ 90.05 mm

11

13 In production = 0 kg/h

N
13

Left:
Spectrogram and the
corresponding gearing diagram
evaluate the source of the fault
Right:
FA Module for count measurement

Product configuration

S800
(table included)

S400
Modules and their functionalities

The future has a past

1948

1961

1974

1987

Automatic Changer
Automatic transfer of the yarn from
the package changer and insertion into
the measuring slot (24 positions)
Fineness Automatic
Automatic determination of the
absolute count

USTER GGP
First generation
First evenness tester

OI Sensor (optical impurity)


Determination of trash and dust
particles in the yarn
OH Sensor (optical hairiness)
Determination of the yarn hairiness

1997

USTER GGP
First generation
First complete
evenness testing
system

USTER TESTER 1
USTER TESTER 2
Second generation
First high-speed
testing of 400 m/min

USTER TESTER 3
First digital evenness
tester
First hairiness and
automatic count
measurement

2005

OM Sensor (optical multifunctional)


Determination of the diameter, roundness,
density and the surface structure of the yarn
MS 120
Measuring unit for heavy sliver,
wool tops in the range
12 8 0 ktex
Capacitive Sensor
Determination of the unevenness and
imperfections (thin and thick places
plus neps)
Foreign - M atter Sensor
Determination of foreign-matter

Temperature and Humidity Sensor


Integrated sensor for measurement
of humidity and temperature in the
environment of the test unit
Basic

Options

Choice of one optical sensor

A modular system allows to tailor


the product configuration to once
need. Starting from the basic
module further modules can be
added.

USTER TESTER 4
First dust, trash,
density, shape,
diameter and surface
measurement of yarns

USTER TESTER 5
First high-speed, multipurpose
laboratory system

For more than 60 years, USTER has been a pioneer of


quality control in the textile industry, and this reputation is
largely attributable to the development of the instrument
which today represents a watchword for accuracy,
reliability and performance in yarn testing.
The first evenness tester, launched in 1948 , was the
model GGP , designed for the measurement of textile slivers,
rovings and yarns and later developed to provide the
U% value for evenness, which is still in use today. Constant
innovations included spectrograph analysis and the
measurement of imperfections such as thick and thin places
and neps.

The 21 st Century family of USTER TESTER 5 is the latest


in that line of ground-breaking evenness-testing instruments.
The basic principles are the same: technical expertise
in quality assurance, cutting- e dge features, unrivalled
accuracy, and the highest test speed, give customers an
edge in facing tomorrows spinning challenges.
The USTER STATISTICS program has a pedigree dating
back to 1948 , when the first evenness tester was introduced
to the market. In response to demands of mill owners and
spinning managers, Uster Technologies AG introduced
the first USTER STATISTICS in 1957 . Today, the USTER
STATISTICS are acknowledged benchmarks throughout the
global textile industry.

USTER STATISTICS the textile industry standards


We set the standards for quality control in the global textile
industry. With USTER STATISTICS , we provide the benchmarks that are the basis for the trading of textile products
at assured levels of quality across global markets.

Think quality
Our commitment to state - o f - t he - art technology ensures the
comfort and feel of the finished product satisfying the
demands of a sophisticated market. We help our customers
to benefit from our applied knowledge and experience
to think quality, think USTER.

USTERIZED brand your products with quality


USTERIZED stands for defined quality assured within
the textile chain. We invite selected customers to join
the USTERIZED Member Program. More information at
www.usterized.com.

Broad range of products


USTER occupies a unique position in the textile industry.
With our broad range of products, we have a wide reach
across the textile chain that is unmatched by any other
supplier in the market.

USTER worldwide
With three technology centers, five regional service
centers and 50 representative offices around the world,
USTER is always sure of delivering only the best to its
customers. USTER committed to excellence, committed
to quality. And that will never change.

Optimal service
Know-how transfer and instant help we are where our
customers are. A total of 200 certified service engineers
worldwide grants fast and reliable technical support.
Benefit from local know-h ow transfer in your specific
markets and enjoy our service la carte.

USTER Switzerland
Knoxville, USA

Adana, Turkey
Charlotte, USA

Uster Technologies AG
Sonnenbergstrasse 10
8610 Uster
Switzerland
T. +41 43 366 36 36
F. +41 43 366 36 37
sales@uster.com
www.uster.com

Osaka, Japan
Shanghai, China

Coimbatore, India

So Paulo, Brazil

Suzhou, China

Bangkok, Thailand

240842-15020/04.13/ Copyright 2013 by Uster Technologies AG

The standard from fiber to fabric


USTER is the worlds leading supplier of total quality
solutions from fiber to fabric. USTER standards and
precise measurement provide unparalleled advantages
for producing best quality at minimum cost.