Technical Article August 2025-Nest

Purpose and the Process:

In today's spinning industry, two pressing challenges stand out: rising cost of labour and the significant loss of good fibre during contamination removal. Contamination detected and ejected from the contamination sorter carries good opened fibres along with it. Huge manpower is being deployed to segregate good fibres from contamination (@ 25 to 40 kg | Person | day). Expected efficiency of manual segregation may be around 40 to 50% and it is not a consistent also. The possibility of mixing up of contamination in fresh cotton is high due to improper manual segregation of ejected cotton. Hence, the mechanized process is very much required for segregating the contamination from ejected Cotton efficiently. This Matters most as we commit to growing together!

In continuation of pursuing the vision of creating value for customers, Nestling proudly introduces the : The Recovery Plant. This customised, state-of-the-art experience redefines how mills recover good fibres from ejected cotton.

The system eliminates these issues with automated precision, preserving fibre quality while boosting operational efficiency.

Purity of cotton at an affordable cost - Driven by "Nest-Tech".

Ejected cotton with contamination is processed for mild pre-opening. Smart-feeding system ensures regulated feed of ejected cotton for better opening of fibres. During mild opening, trash, Seed coats present in the fibres falls down and opened fibres with contamination pass-through high resolution scanning elements where contamination (Colour and White PP) will be detected, ejected and collected separately. Good fibres are sucked through fibre separator and get dropped from where it is taken forward for baling or further process. Expected cleaning efficiency of contamination is around 80 to 90%, at the production of 50kg / hour.

Expected Experiences:

In the pursuit of "Purity in Cotton at an affordable cost", 1,00,000 spindles power through each day to deliver an impressive 45,000 kilograms of yarn for weaving, not just fabric but the future. This vision, driven by the need for 21,360 tons of cotton annually, ensures optimal resource utilisation. Even from what is often overlooked, a remarkable 216,000 kilograms of fibre is recovered from the ejected cotton- testament to innovation at its finest, through "Nest-Tech". The transformation isn't just mechanical-8,640 person-days of manpower are liberated, unlocking human potential for higher pursuits. This translates to a significant Rs.43.2 lakhs saved annually in manpower costs. With an investment of Rs.60 lakhs and minimal yearly running costs of just Rs.3 lakhs, the enterprise achieves Rs.40.2 lakhs in annual savings, attaining payback in a swift 1.5 years. (Data provided is just for calculation purposes.)

It's not just about numbers; it's about weaving efficiency, elegance, foresight, and empowerment into every fibres.

At the heart of every great spinning mills lies a commitment to purity, dignity and elegance.

Next gen "Nest-Tech" is built to preserve the soul of cotton, maintaining fibre integrity and its natural essence, even as it tackles the toughest contaminants with unwavering efficiency. From stubborn seed coats to disruptive foreign particles, everything unwanted is gently swept away, leaving only quality behind.

Designed to work with you, not against, it's a fully automated marvel - intuitive, operator-friendly, and virtually maintenance-free. It doesn't just clean; it liberates, drastically reducing the need for manual intervention and empowering your workforce to focus on what truly matters.

Born and built in India, it carries within it the spirit of indigenous innovation, tailored for our spinning mills, our people, and our future. And with a dedicated support network that stretches across the nation, you're never alone on this journey.

In Short, Every Customer can have the Experience of,

• Recovering the good fibres without any damages of it's Qualities.
• Consistent in cleaning of contaminations and other foreign matters like trash, seed coats etc….
• Fully automated process, easy to operate and maintain.
• Huge manpower savings and an attractive ROI.
• The spirit of indigenous innovation.
• Effective after sales-service with spare parts supports through our nationwide service network

Join us as we shape brighter, cleaner, and more efficient spinning mills - together

Discover the power of precision with —where learning meets impact.