u TESTER 5

The yarn inspection system

Precise yarn quality control for optimized profitability

The USTER® TESTER 5 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 USTER® TESTER 5 -S800 and
USTER® TESTER 5 -S400.

The tremendous processing capability of the USTER® TESTER 5 is unique,

with testing at 800 m/min using the S800 model.

To ensure every important quality characteristic can be measured

accurately, the USTER® TESTER 5 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 USTER® TESTER 5 ’s
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 imper-
fections, 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.
Capacitive measuring sensor for
slivers, rovings and yarns
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 industry’s 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 manage-
ment 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!
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
measure 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 guaran-
tees 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 S 800 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.
For closed loop quality monitoring
and feedback provided with the
combination of USTER ® TESTER 5
and USTER ® QUANTUM
“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 sam-
ples 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 class-
leading laboratory test capabilities can be allied with
USTER ® QUANTUM yarn clearers, running during mill pro-
duction on the winding machine, to create a closed-loop
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 un-
certain 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
Beyond measuring hairiness levels Two-dimensional sensor technology

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.
USTER ® HAIRINESS has the definitive solution, with In finishing, it is estimated that 12 % of customer complaints
technology for the two globally accepted standards for about color variation and shadowing can be traced back
hairiness measurement, which together provide the to unexpected differences in yarn diameter, density and
full picture. shape. These are serious problems, and because they are
not mass-related, they can be detected only by two-dimen-
With the OH Module, the USTER ® TESTER 5 offers repro- sional sensor technology.
ducible and comparable hairiness measurement at
800 m/min, determining the USTER ® HAIRINESS value, The USTER ® OM Module for the USTER ® TESTER 5 uses latest
which is supported by USTER ® STATISTICS benchmarking, optical sensors to measure the diameter variation, shape
allowing comparisons with USTER ® HAIRINESS grades. and density of the yarn, giving vital quality information and
The H value from the OH Module of the USTER ® TESTER 5 enabling accurate prediction of how the yarn will look in
acts as an early warning system for potential problems the finished fabric. The lustre has a considerable influence
and as a basis for yarn trading. on the visual aesthetics and value of the fabric and the
OM Module can help to assess these aspects at the yarn
The perfect complement to the OH Sensor for the stage.
USTER ® TESTER 5 is the USTER ® ZWEIGLE HL400 instrument,
which enables highly accurate measurement and classi- The OM Module can determine a yarn’s CV FS percentage
fication of hairiness length. The S3 figure, from the for quantifying variations in its fine structure, which can
USTER ® ZWEIGLE HL400 system, is an aid to yarn engineer- then be applied to help prevent knitted goods from appear-
ing and problem solving in manufacturing. ing “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.

300 400 500 600 700

OH Sensor application range Two - dimensional

24
and benefits sensor technology
– Yarn profiling, yarn trading 20 – Optical measurement of
95%
and comparison to USTER ® diameter, shape, density and
STATISTICS 15 50% surface structure
– Identification of periodic faults 5%
– CV FS figure helps prevent
– Continuous monitoring of mill production of “cloudy” knitgoods
hairiness levels 10 – OM Sensor – a must for compact
– Monitoring of the life cycle spinners, with crititical
of rings and travelers information on density and
CVd
– Early-warning mechanism in variation in the fine structure
6
production Nm 5 10 15 20 30 50 70 90 150
( CV FS )
– Indication of hand/feel of Ne 5 10 15 20 40 60 80
450 500 550 1m 2 5 10 20
a finished product Tex 200 150 100 80 60 50 40 30 25 20 15 10 7

Ring-spun yarn Compact yarn 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
HL400 hairiness length Ring-spun yarn Compact yarn
classification application range
and benefits
– Yarn engineering
– Control of new spinning
machine settings, especially
compact spinning systems
– Identification of long protruding Top:
fibers which cause pilling USTER ® STATISTICS for diameter
variation

4.9 H Bottom: 12 . 21 % CV m 12 . 61 % Bottom:

2.5 Comparison of a ring - spun and Comparison of a ring-spun and
9 . 20 % CV FS 7 . 28 %
compact yarn 0 . 53 g/cm 3 D 0 . 63 g/cm 3 compact yarn
(© Rieter Machine Works Ltd) (© Rieter Machine Works Ltd)
Breakthrough in impurity assessment Mastering slub yarn measurement

Dust and trash content trapped within the fibers of a yarn Controlling slub effects – while at the same time making
can cause serious problems in subsequent fabric manu- them look random and irregular – is the special require-
facturing processes. Up to 25 % of downtime on weaving ment for producers of fancy yarns used in a wide range of
machines is directly attributable to trash and seed coat fashion fabrics.
fragments in yarn. Dust contamination in yarn also leads
to rapid wear of needle heads and friction surfaces in The USTER ® Fancy Yarn Profile reaches new heights in
both circular and flat knitting machinery. precise slub yarn measurement, and offers an array of
tools to simplify the complex process of fancy yarn manu-
The USTER ® TESTER 5 can eradicate these problems facture. Available as an option for the USTER ® TESTER 5 ,
through the OI Module, which uses optical technology the Fancy Yarn Profile solves the irregularity problem
to give accurate measurement of these potentially with slub yarns. It provides constant and detailed quality
harmful impurities. For the first time, this module allows analysis, detailing slub numbers, length and distance,
users to test for trash and dust particles in the yarn – as well as checking for unwanted mass increases and
at the same time as the evenness testing procedure. decreases around slubs and any disturbing patterns
in the yarn.
The OI Module also offers a special benefit for rotor
% Mass incr.
spinning, with a facility for monitoring the cleaning An extended range of targeted reports is available with
400
efficiency of an open-end spinbox for removal of trash the USTER ® TESTER 5 and Fancy Yarn Profile, so that users
and dust. 300 can quickly, easily and accurately assess slub yarn quality,
assisted by the famed USTER ® scatter plot for a quality
200
Used in combination with the USTER ® AFIS PRO fiber overview, spectrogram analysis of periodic faults, and a
analysis instrument, the OI Module provides a solution for 100 unique sequence diagram of the complete slub cycle.
improved trash and dust monitoring in the fiber-to-yarn
0
engineering process. 0 10 20 30 40 50 60 70
Slub length (m)

0 –20 % 20 – 40 % 40 – 60 % 60 – 80 % 80 –10 0 %

Improved trash and Precise analysis of slub yarns

cm
dust monitoring – Extended range of reports to
120
– Accurate optical measurement determine the quality of slub
of dust and trash content yarns precisely
– Compact yarns show up to 20 % 80 – The standard for slub yarn
less dust content than standard measurement
ring-spun yarns – Measures the three major
– Monitoring of the cleaning 40 requirements for a consistent
efficiency of an OE spin-box slub yarn production
for trash and dust removal – Constant quality – number
0
0 100 200 300 400
of slubs, slub length and mass
Slub number
increase, no mass decrease
after a slub (weak place), no
Slub distance Slub length disturbing patterns through
wrong settings on the
machine
– No disturbing patterns in
Optimum clearing No clearing
efficiency efficiency
Top: the yarn
120 120 High transparency in slub
yarn manufacturing shown by
Top: a scatter plot of two different
Seed coat fragment in compact slub populations
80 80
yarn. Higher test requirements
because of missing hairiness Middle:
Slub sequence diagram with
300 %
40 40 Bottom: faulty slubs
Mass incr.
Comparison of the trash cleaning 200
efficiency of two spinning mills Bottom:
100
from card sliver to yarn 0
10 Clear separation of four slub
0 0 20
Sliver test: USTER ® AFIS PRO 2 Slub length 30 populations in a 3 - dimensional
Silver Yarn Silver Yarn 40
50 cm
Yarn test: USTER ® TESTER 5 histogram
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 semi-
periodic 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 dis-
plays. 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-to-
yarn 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

0
5 cm 10 20 50 1m 2 5 10 20 50 100

1 G33
1
2 Count In (0.709 Nec)
6 2
3 E1 pulley ~ 90.05 mm
3
4 4 Draft (1.189 )
9
5 Tot. draft (58.30 )
5 6 ZE ~90.05 mm
12
7 Count out (40.00 Nec)
7
8 Del speed = 22.23 m/min
9 ZW ~ 90.05 mm
8
10 Twist (0 T/m)
10 11 Twist RPM = 0/min
12 E6 pulley ~ 90.05 mm
Right:
11 13 In production = 0 kg/h
Spectrogram and the
corresponding gearing diagram
N evaluate the source of the fault

13 Left:
FA Module for count measurement
Product configuration The future has a past

S800 S 400
(table included)
Modules and their functionalities 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
USTER ® GGP USTER ® GGP USTER ® TESTER 1 USTER ® TESTER 3
absolute count First generation First generation USTER ® TESTER 2 First digital evenness
First evenness tester First complete Second generation tester
evenness testing First high-speed First hairiness and
OI Sensor (optical impurity) system testing of 400 m/min automatic count
Determination of trash and dust measurement

particles in the yarn

OH Sensor (optical multifunctional)

Determination of the diameter, roundness,
1997 2005
density and the surface structure of the yarn

OM Sensor (optical hairiness)

Determination of the yarn hairiness

MS 120
Measuring unit for heavy sliver,
wool tops in the range
12 – 80 ktex
Capacitive Sensor
Determination of the unevenness and
imperfections (thin and thick places
plus neps)
Foreign - Matter 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, reliabil-
ity 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 - edge features, unrivalled accu-
racy, and the highest test speed, give customers an edge in
facing tomorrow’s spinning challenges.
The USTER ® STATISTICS program has a pedigree dating
back to 1948 , when the first evenness tester was intro-
duced 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.
The standard from fiber to fabric USTER ® STATISTICS – the textile industry standards

240842-15020/08.11/© Copyright 2011 by Uster Technologies AG

USTER is the world’s leading supplier of total quality We set the standards for quality control in the global
solutions from fiber to fabric. USTER standards and textile industry. With USTER we provide the benchmarks
precise measurement provide unparalleled advantages that are the basis for the trading of textile products
for producing best quality at minimum cost. at assured levels of quality across global markets.

Think quality USTERIzED® – brand your products with quality

Our commitment to state - of - the - 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.
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.
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.
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 - how transfer in your specific
markets and enjoy our service à la carte.

USTER Switzerland

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