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SUCCESSFUL CASE

Client: VICUNHA TEXTIL

Prepared by: Eduardo Llangar

What is Vicunha Textil ?


Vicunha Ecuador S.A. is an innovative
company based in Quito since 2007,
dedicated to the production and
marketing of denim fabric in rigid and
stretch lines in natural options to
provide greater opportunities to color
and indigo in its various tinctures. It has
a broad products portfolio that has been
structured based on market needs and
trends.
During these years they have invested
in machinery, technological renovation
of its processes and mainly on training
and motivational development for
The company is part of the multinational group VICUNHA
TXTIL
, a leader
the
professional
among
its 907inemployees
global textile industry , the third largest producertoofbecome
denim and
in the
whatgabardine
they are today.
world. The headquarters is located in Brazil and has branches in Ecuador , Argentina
and other countries in the Andean region and Europe.

Background - Spinning process


Vicunha has a rotor spinning
system, where the yarn obtained
by this system is called open end
spinning for making fabrics.
In the rotor based spinning
system there are combed bales
of cotton and proceeding to the
opening and cleaning, then go to
the carding , from there to the
draw frames and finally to the
open end spinning machines,
from where the thread is ready
to be wound in cones.

Events in Open End Machines


The Vicunha Open - End machine
has two panelboards, one at the
beginning of the line called Testera
and another one at the end called
Frame.
Each one of the boards has variable
frequency drives , power supplies ,
control systems that allow the
spinning process to be carried out
continuously and permanently
automatic.
The main problem is the damage on
variable frequency drives and
sometimes the presence of false
alarms in the control system (touch
screen )

Open End Machines / Spinning Process

SINETAMER Solution Proposal

TESTERA PANELBOARD PROTECTION


VFD Protection

Service Entrance
Protection

FRAME PANEL PROTECTION


Service Entrance and VFD
protection

CONTROL PANEL PROTECTION


24VDC busbar protection

Protection of small capacity VFDs

RETURN ON INVESTMENT
The calculation of return on investment was established based on the replacement
costs of a variable frequency drive and unexpected system stops due to false
alarms in the control system. It was not considered the full production stop because
they have other machines on stand by that are relieving others.
SineTamer SPDs investment : $ 3,200
Variable Frequency Drive cost : $ 18,000
Cost per false alarm in an Open End machine (1 production hour = $ 1200) : 2
alarms per week = 8 stops per month x $ 1,200 = $ 9,600 per month
Total cost of loss : $ 27,600
ROI : Investment $ 3200 / $ 27600 = 10 days

Conclusion
The pilot protection was implemented in 2015 and we are awaiting the
budget from Brazil to protect an additional of 5 machines.
In the pilot plan Surge Suppressors with transient events counter were
installed; on the display was evidenced the presence of transients,
especially at the input of the variable frequency drives.
This pilot plan has given feasibility to protect other Open/End machines