Sustainable and intelligent: The TC 19i sets the benchmark for carding

Sustainable and intelligent: The TC 19i sets the benchmark for energy-efficient carding.
Global energy consumption reached a record high in 2019, following a 40-year trend for rapidly
increasing energy demand that was only halted by the Coronavirus pandemic.1 It’s estimated
that more than 80 % of this energy is still generated from fossil fuels that produce CO2
emissions and contribute to climate change.2 Renewable energy offers a solution to this
problem, but saving energy whenever possible is an even more effective approach. That’s why
Trützschler has developed the intelligent card TC 19i, which sets a new benchmark for energy-
efficient carding.
Only the intelligent Trützschler card TC 19i features the unique T-GO gap optimizer, which
continuously and automatically monitors and adjusts the carding gap to an ideal position during
production. By now, more than 2000 intelligent cards sold worldwide prove quality and production
leaps in the double-digit percentage range daily, thereby reducing energy demand per kilogram
produced.3 Innovative drive- nd air technology further reduce energy consumption of the TC 19i. In this
way, the TC 19i saves energy to help protect the planet – and also boosts profitability for yarn
production.
The most energy-intensive elements in a carding machine are the drive, the dust suction process and
the compressed air system. Permanent suction is needed to remove dust and cotton waste in key
places. In contrast to Trützschler cards, many cards on the market also use compressed air for suction
hoods in the pre-carding and post-carding areas, for example. Smart optimization of these areas has
made the intelligent card TC 19i a benchmark for energy efficiency in carding because it uses less
electricity, lower suction pressure and less compressed air than other machines, while providing the
highest production rates currently available on the market.

In a head-to-head comparison between the TC
19i and a high-performance card from a
competitor, the TC 19i consumed at least 10 %
less energy per kilogram of material produced
when manufacturing rotor yarn from a cotton and
cotton waste mix. The compared energy values
included electric power consumption and energy
required for suction and compressed air and was
measured in both cards at the same production of
180 kg/h. A 10 % reduction in energy per kilogram
of sliver produced, as proven here by TC 19i, can
have a significant impact on a spinning mill’s
profitability; annual savings worth a five-digit sum
are frequently possible, depending on factors
such as the output of the mill.

The customer trial also showed TC 19i’s excellent reliability at the
customer’s usual production rate of 180 kg/h, and even
demonstrated stable performance at 300 kg/h in the same
application. Because the TC 19i with T-GO gap optimizer realizes
maximum production rates at no compromise in quality,
manufacturers can reduce their energy demand and investment
costs drastically: Less machines are needed to achieve the
desired output, and energy consumption per production is
reduced.
Energy-efficient air technology
Next to increased productivity, air technology plays a pivotal role
in the energy balance of the TC 19i. Christian Freitag, Head of Air
Technology at Trützschler, explains how he optimized the TC 19i
in this area: “First, we reduced the need for compressed air
wherever possible,” he says. “And second, we reduced suction
pressure and air requirements for suction.

All of our air collectors, for example, are carefully developed to eliminate potential resistance and
facilitate an ideal flow.” This improvement was made possible by a long and sometimes challenging
innovation process involving mathematical models of air flows, as well as flow simulations and
prototypes. By combining the final flowoptimized parts in the TC 19i, Trützschler’s experts have
developed a card that operates with suction pressure of just -740 Pa and with an air requirement of
only 4200 m³/h. This translates into 40 % less energy demand for air technology compared to the latest
high-performance competitor model.
“These achievements are fantastic – but we didn’t stop there,” says Ralf Helbig, R&D Engineer for Air
Technology at Trützschler. “We have also made it possible to further reduce energy demand in
polyester applications, which are increasingly important to our customers. In a polyester configuration,
the TC 19i can reduce the necessary pressure for waste suction by a further 14 % because of
improvements to elements in the pre-carding and post-carding areas, and the removal of suction
hoods. The suction is still just as reliable – but it needs much less energy.”

Good for the environment – and for the balance sheet
With its unique gap optimizer T-GO, its state-of-the-art drives and optimized air technology, the
intelligent card TC 19i is leading the market for energy-efficient carding. No other card can match its
stable performance at such high levels of productivity, or its consistent quality and energy efficiency.
As a result, the TC 19i makes a valuable contribution to global sustainability – and makes mills even
more profitable too.
For more details, please contact:
Trützschler GmbH & Co. KG
Postfach 410164
D-41241 Mönchengladbach
Press Relations Contact:
Kleo Knippertz
kleo.knippertz@truetzschler.de
+49 2166 607 8052