TSP helps synthetic filament yarn manufacturers identify the causes of production and quality problems and put practical corrective actions into operation. We work with plant teams to reduce yarn breaks, improve yarn consistency and make better use of existing machinery.
TSP also assesses and improves plant procedures, operating protocols and maintenance practices. This includes reviewing standard operating procedures, preventive maintenance schedules, inspection routines and departmental responsibilities to support consistent working methods, reduce unplanned downtime and sustain improvements.
Each assignment has a scope and targets mutually agreed between the customer and TSP. Recommendations take account of the yarn, machine condition and working practices, with results assessed against the agreed production and quality requirements.
Reduce Breaks and Improve Efficiency
Investigate recurring breaks, autodoffing losses and unstable running. Establish which causes contribute most to the problem and prioritise corrective action.
Improve Yarn Quality
Address tensile properties, crimp, barré, package build and yarn aesthetics. Relate laboratory results to production conditions to identify sources of variation.
Develop Products and Capability
Develop speciality and fancy yarns, assess reference samples and identify suitable machine modifications or upgrades.
Strengthen Plant Performance
Support commissioning, preventive maintenance and process control. Equip plant personnel with the procedures and understanding needed to maintain improvements.
Led by Practical Industry Experience
Bipin Chauhan leads TSP consultancy. His experience includes senior technical roles with Rieter Scragg and Rieter ICBT, covering texturing technology, research and development, customer service and aftersales engineering. Earlier production roles with Intex Yarns Limited and EXSA UK Limited included supervision, quality control and product development.
Extensive international plant work provides practical knowledge of different machine brands, their strengths and limitations, and the demands of everyday production.
Consultancy Services
Support can focus on a specific production issue or combine process, maintenance and engineering work within one assignment.
Process Control and Yarn Quality
Review supply yarn, machine settings, tension behaviour and production records to identify causes of high breaks, reduced first quality output and inconsistent yarn properties.
Evaluate corrective changes through agreed trials and suitable testing, including investigation of dye uniformity and barré.
Maintenance and Plant Operations
Assess component condition, maintenance priorities, production flow and unplanned downtime.
Develop practical preventive maintenance schedules and working procedures that support stable running and consistent quality.
Product and Fancy Yarn Development
Assess target samples and develop speciality yarns within the capabilities of the customer’s machinery.
Where modifications are needed, recommend suitable changes and, where feasible, design or supply the required hardware or software.
Yarn Path and Machine Upgrades
Examine guides, friction discs, rollers and other yarn contact components for causes of damage or tension variation.
Assess revised geometry, replacement components, control systems and automation against the machine’s interfaces and intended application.
Commissioning and Recommissioning
Support process setup, yarn quality assessment and performance stabilisation on new, older or relocated machines.
Identify the maintenance, settings or engineering work required to establish reliable production.
Equipment Selection and Benchmarks
Provide independent technical advice on machinery, replacements and upgrades for the intended yarn range.
Help define production and quality requirements, trial conditions and acceptance measures for discussion with the equipment supplier.
Machine experience includes Rieter Scragg, Rieter ICBT, Barmag, Murata TMT, Aalidhra, Bhagat, Himson, RPR and Guidici. Recommendations reflect the capabilities and condition of the particular machine.
Practical Consultancy Experience
TMT AFT21 Autodoff Machines
An assignment addressed excessive yarn breaks and reduced autodoffing efficiency on TMT AFT21 machines. The investigation identified four main areas: creel management, previously unexplained process breaks, autodoffing, and alignment or maintenance. The contribution of each area to the total break rate was assessed.
Bipin worked with the relevant departments to identify and rectify the individual causes. The work brought yarn breaks down to normal operating levels and improved autodoffing efficiency. Recommended process control and maintenance procedures were adopted successfully.
Barmag AFK Machines
A separate assignment in another country applied the same practical approach to Barmag AFK machines. Work with the plant’s departments focused on identifying the sources of yarn breaks, correcting operating and maintenance issues, and improving autodoffing performance.
The assignment likewise returned breaks to normal operating levels, improved autodoffing efficiency and supported the successful adoption of recommended process control and maintenance procedures.
These examples describe completed assignments. The work required and results achievable depend on the condition of the equipment, the yarn and the agreed scope.
How Support Is Delivered
On Site and Remote Support
Plant visits allow direct observation, measurements and trials. Remote consultancy is available where the issue can be assessed effectively using production data, test results, photographs and discussions.
Visit duration depends on the assignment. Multiple visits may be agreed to support implementation and review progress.
Training and Follow up
Training can cover all levels of personnel, including process control, quality control, maintenance and preventive maintenance.
Follow up support may include reviewing trial results and production data, refining actions or returning to the plant, as agreed with the customer.
Deliverables are agreed for each assignment and may include a written diagnosis, recommended settings, trial findings, corrective actions, maintenance priorities and operating procedures. Where further engineering is needed, TSP can prepare a technical proposal.
How a Consultancy Assignment Works
The six stages below provide a clear route from the initial enquiry to implementation and review. Their depth and timing depend on the assignment.
01 Agree the Scope and Targets
Clarify the problem or development objective, responsibilities, timing and expected outputs. Agree how success will be measured, using relevant measures such as break rate, first quality yield, yarn properties, production speed or equipment availability.
02 Review the Operation
Examine production records, supply yarn details, laboratory results, machine settings and maintenance history. Discuss the issue with the plant team and establish a starting position for comparison.
03 Establish the Root Causes
Investigate the interaction between the yarn, machine components, operating conditions and working practices. Use measurements and trials where needed to distinguish the underlying causes from the visible symptoms.
04 Apply Corrective Actions
Agree practical actions with the customer and support implementation within the assignment scope. Actions may involve settings, components, maintenance, control procedures or an engineering modification.
05 Assess the Results
Compare production and quality results with the starting position and agreed targets. Record the operating conditions and any remaining constraints so the plant can understand and reproduce the improvement.
06 Handover and Further Support
Communicate the findings, recommended practices and outstanding actions to the responsible personnel. Agree any further trials, training, remote review or return visits needed to support continued progress.
Working with TSP
An initial discussion establishes the information needed to assess the enquiry. TSP then agrees the proposed scope, deliverables, duration and commercial terms with the customer. Assignments may combine troubleshooting, training, commissioning and engineering support where this is appropriate.
Selected International Experience
The selected companies below reflect work undertaken during Bipin Chauhan’s career, both while employed by Rieter Scragg and Rieter ICBT and through TSP consultancy. They are examples of industry experience rather than a statement of current contracts or endorsement.
United Kingdom and Europe
United Kingdom: DuPont, Autofil, Wykes International and Heathcoat Fabrics.
Germany: Trevira and Schill & Seilacher. France: Contifibre. Italy: Contifibre and SSM Guidici. Romania: Yarnea. Belarus: Bel Tex.
China and Taiwan
China: Shenghong, Huading, Yizheng, Xiamen Xianglu, Kaiping and Tongkun Group.
Taiwan: Hong Ho.
South East Asia
Indonesia: Indorama, PolyChem, Asia Pacific Fibre and Mutu Gading Tekstil.
Thailand: Indorama, YRC and KL & Sons.
North and South America
United States: Unifi Inc. and Milliken. Mexico: AKRA.
Brazil: Polyenka and Alpek Polyester.
Indian Subcontinent
India: AYM, Sanathan (Daman) and RIL (Naroli).
Sri Lanka: FiloTex.
Middle East
Iran: Tehran Tak Nakh.
Discuss Your Consultancy Requirements
Contact Bipin Chauhan to discuss a production issue, development project or machinery requirement. Please include the machine model, yarn type and count, supply yarn details, operating conditions and the outcome you want to achieve.
Production records, test results, photographs and representative samples help TSP assess the requirement and propose an appropriate scope.