Spin-and-Yarn
Spinning, count, twist & yarn quality
Controls draft, twist and speed across ring, rotor and air-jet frames to hold count (Ne), CV%, twist and tenacity inside buyer spec, and predicts end-breaks before they cascade.
Products
Vireon sees the fabric. Spindra, Loomix and Shadeon run the spinning, formation and dyeing stages. Doffex keeps the lines fed. Twinly simulates every run before it happens. They share one edge runtime, one genealogy and one audit log.
The ecosystem
Vireon is the perception layer every agent acts on. Spindra, Loomix and Shadeon own the sequential stages and pass genealogy downstream. Doffex is the handling layer. Twinly qualifies runs before production and pushes validated actions back to the line.
Mill-edge vision that sees every defect on the roll before the buyer does.
Autonomous spinning that holds count, twist and evenness, roll after roll.
Autonomous weaving and knitting that stops the fault before the pick.
Right-first-time dyeing. The shade hits before the bath fills.
Robotic hands for the mill: doffing, rolls and beams moved without operators.
The as-produced fabric twin that hits quality, shade and takt before the run.
Product · Perception layer feeding every other agent
Inspection is still the labour-heavy bottleneck of the mill. Human inspectors on greige and finished rolls miss slubs, holes, streaks, stains, floats, barré, skew and width faults at line speed, fatigue on night shifts, and disagree roll to roll. A missed defect becomes a second-quality roll, a re-dye or a buyer chargeback. An over-call scraps good fabric.
What it does
Line-scan and RGB/NIR cameras over inspection frames, looms, knitting machines and finishing ranges feed GPU segmentation and classification models that detect, localise and grade faults in real time, with a per-metre defect map, a severity grade and an immutable roll genealogy that Spindra, Loomix, Shadeon and Twinly all consume.
| Component | Role |
|---|---|
| Jetson Orin | Mill-edge inference on inspection frames and looms; Thor later ASPIRATIONAL |
| RTX / L4 edge servers | Multi-camera line aggregation and heavier models per cell |
| DeepStream + TensorRT | Line-scan video pipelines and low-latency inference |
| Metropolis + Holoscan | Vision application framework and sensor fusion with spectrophotometers, evenness meters and PLC events |
| Triton | Serves defect, shade and anomaly models per cell |
| DGX/HGX | Training on roll images ASPIRATIONAL |
Product · Spinning stage; publishes yarn genealogy downstream
Spinning fibre into yarn of consistent count, twist, strength and evenness drifts constantly with fibre lot, humidity and machine wear. Slubs, thick and thin places and count variation created at the frame propagate into weaving faults, barré and shade variation that only surface rolls later, as seconds and buyer rejects.
| Component | Role |
|---|---|
| Jetson Orin | Frame-edge inference for evenness and vision fusion |
| RTX / L4 edge server | Multi-frame aggregation and prognostics |
| TensorRT | Low-latency evenness and anomaly inference at the frame |
| Holoscan | Fuses evenness meters, tension and speed sensors and inline vision |
| Triton | Serves yarn-quality, drift and prognostics models |
| cuOpt | Spindle and lot assignment, doffing schedules under quality constraints |
What it does
Spindra fuses yarn-evenness meters, tension and speed sensors and inline vision with fibre-lot context to sense and predict count, twist and evenness drift and slub formation in real time, then recommends or, with graduated autonomy, applies draft, twist, speed and tension corrections at the frame.
Product · Fabric-formation stage; consumes Vireon and Spindra, feeds Twinly and Shadeon
Broken picks and ends, holes, floats, tension bands and barré form in milliseconds and run for metres before an operator reacts. Tension, speed and construction setpoints are craft-bound and machine-specific, and a skilled weaving and knitting workforce is scarce and cannot watch every machine.
What it does
Loomix fuses warp, weft or knit-loop tension, speed, stop events and inline vision from Vireon with construction specs to predict faults before they propagate, then recommends or applies tension, speed, let-off and take-up corrections at the loom or knitting machine.
| Component | Role |
|---|---|
| Jetson Orin | Loom and knit-edge inference for tension and vision fusion |
| RTX / L4 edge server | Many-loom aggregation and prognostics |
| Holoscan | Fuses tension, speed, stop events and camera streams into loom state |
| TensorRT | Sub-100 ms fault prediction per machine ASPIRATIONAL |
| Triton | Serves tension, fault and prognostics models per cell |
| cuOpt | Loom and style assignment, rework sequencing under delivery constraints |
Product · Dyeing and finishing stage; consumes upstream genealogy, feeds Twinly
Dyeing and finishing are the most chemistry-, water- and energy-hungry stages in textiles and the biggest source of rejects. Shade matching depends on scarce colourists, fixed recipes and spot lab checks. A shade miss forces a re-dye or scrap, wasting water, energy, chemicals and time, and triggers buyer chargebacks.
| Component | Role |
|---|---|
| RTX / L4 edge servers | Real-time spectral colour science and recipe inference |
| Jetson Orin | Dye-line-edge dosing and shade control, spectrophotometer fusion |
| CUDA + RAPIDS | GPU spectral and colour-science maths and recipe search |
| TensorRT + Triton | Low-latency shade and recipe inference, served per line |
| NeMo Retriever and Guardrails | Grounds colour and sustainability answers in OEKO-TEX, ZDHC and bluesign standards |
| cuOpt | Dye-lot sequencing and water and energy allocation |
What it does
Shadeon predicts dye recipes and spectral shade outcomes from substrate, fibre-blend and machine context, matches to the buyer standard under multiple illuminants, and drives adaptive dosing, temperature ramp and process correction toward right-first-time, cutting re-dyes, water, energy and chemistry.
Product · Handling layer keeping every line fed at takt
Mills are paced by heavy, repetitive, injury-prone material handling: doffing full packages off spinning frames, lifting and transporting greige and finished rolls, changing warp beams and feeding inspection and dye lines. The work is understaffed and a hidden bottleneck that starves autonomous lines of throughput.
What it does
Doffex is vision-guided mobile manipulation that doffs packages, grips and transports rolls and beams, and feeds spinning, weaving, knitting, inspection and dye lines. Policies are trained and validated in simulation, adapt to package and roll variety and mill layout, and synchronise with the line agents’ takt.
| Component | Role |
|---|---|
| Jetson Orin | On-robot perception, planning and control; Thor later ASPIRATIONAL |
| RTX / OVX | Isaac Sim training and digital-twin cells |
| Isaac Sim, ROS, Manipulator, Lab | Train, simulate and deploy handling policies |
| Omniverse + Replicator / Cosmos | Mill-cell twin for layout validation; synthetic package, roll and lighting variety |
| TensorRT | Optimised on-robot inference |
| DGX/HGX | Large-scale policy training ASPIRATIONAL |
Product · Optimisation brain over every product; qualifies runs before production
Mills commit fibre, yarn, machine time, water, energy and chemicals to a run and only discover whether it hits quality, shade, hand and takt after the fabric is made. Dye-lot sequencing, line balancing and utility allocation are set by experience, and there is no way to test a change before the line runs it.
| Component | Role |
|---|---|
| OVX / RTX | Runs the Omniverse fabric-line twin and simulation |
| Omniverse + Replicator | Builds the as-produced twin and synthetic scenarios |
| cuOpt | Dye-lot sequencing, line balancing, water, energy and machine allocation |
| Cosmos | Rare production scenarios for robustness |
| Modulus | Physics-informed surrogates per process stage ASPIRATIONAL |
| Triton | Serves surrogate and prediction models |
What it does
Twinly builds an Omniverse-based twin of spinning, weaving, knitting, dyeing, finishing and roll flow, fed by real Vireon, Spindra, Loomix and Shadeon genealogy. It simulates a run to predict quality, shade, hand, takt, yield, water and energy, then optimises construction, recipe, sequencing, line balance and resources, and pushes validated actions back to the line agents.
Shared platform
Orchestrator
The mill orchestrator, the nine agents, the policy engine, the approval gates and the run record. This is the layer that decides and acts.
Genealogy
Fibre to yarn to greige to dyed to finished roll, metre-indexed, shared by all six products.
Conformance
Hold and release decisions, buyer packets and the signed record of every autonomous action.
Mill edge appliance
A GPU appliance that runs the loop locally and keeps running when the uplink is lost.
Console & HMI
A web console with a ⌘K palette for engineers, and a machine-side panel for operators who never open a laptop.
Shared models
Defect and shade datasets improve shared models across fibres, constructions and shades while each tenant’s data stays its own.
Agent graph
This is the shape of a dye lot on Yarneon, shown as an illustrative scenario rather than a customer run. Ingest and simulation fan out, converge on a colourist approval gate, then dosing, verification, finishing, inspection and release. The accent traces the active path; every node opens in the inspector.
Scroll the graph sideways · or open the text equivalent below
| Step | Stage | Depends on | Status | Duration |
|---|---|---|---|---|
| ingest | conformance | none | SUCCEEDED | 0.8s |
| twin | simulate | ingest | SUCCEEDED | 46s |
| recipe | dye + colour | ingest | SUCCEEDED | 2.4s |
| approve | human gate | twin, recipe | APPROVAL | 4m 12s |
| dose | bath control | approve | SUCCEEDED | 118m |
| shade | verify ΔE | dose | SUCCEEDED | 9.1s |
| finish | stenter | dose | SUCCEEDED | 64m |
| inspect | vision | shade, finish | FAILED | 38m |
| rework | replan | inspect | SUCCEEDED | 1.6s |
| grade | release | rework | SUCCEEDED | 3.0s |
Run timeline
The same scenario run as an ordered timeline: step, status, duration and the tool result behind it. Inspection failed on one roll, the run recovered, replanned the cut and still held the ship date.
Goal: Dye lot DL-4471 · 3,180 kg · 40s combed cotton poplin · shade Indigo 19-4028 TCX · ΔE ≤ 0.8 · due Thu 06:00
Pulls greige genealogy for 14 rolls: yarn lots, loom, greige GSM 138, absorbency and residual size from the prep line.
agent Quality-and-Conformance
result ← 14 rolls · 3,180 kg · mean GSM 138.2 (σ 1.1) · prep OK
Omniverse fabric-line twin simulates the exhaust curve, machine loading and takt for three candidate recipes before a drop of dye is used.
agent Yield-and-Takt
result ← 3 candidates scored · best predicted ΔE 0.52 · 118 min cycle
Spectral recipe model proposes a 3-dye combination against the buyer standard, corrected for this substrate’s absorbency and the current water hardness.
agent Dye-and-Color
result ← 2.14% Navy RGB · 0.61% Blue BRF · 0.08% Black B · salt 62 g/L
Recipe deviates >5% from the standing card, so autonomy is capped: the colourist approves, rejects or edits before any dosing. Guardrail policy MILL-02/DYE-APPROVAL.
agent Dye-and-Color
result → awaiting colourist · approved on shift 04:18
Closed-loop dosing and ramp control against live bath spectrophotometry; two mid-cycle corrections applied when exhaustion ran 4% ahead of model.
agent Dye-and-Color
result ← exhaust 96.4% · 2 corrections · bath ΔE 0.41 at drain
Per-roll spectral read against Indigo 19-4028 TCX under D65/TL84/A; metamerism scored and rolls sorted into shade bands.
agent Shade-and-Quality
result ← mean ΔE 0.58 · 13 rolls band A · 1 roll band B
Stenter chemistry, overfeed and curing profile set to hold hand, 148 cm width and residual shrinkage under 3%.
agent Finish-and-Hand
result ← width 148.3 cm · shrink 2.1% warp / 1.4% weft
In-line vision flags a recurring 6 cm weft streak on roll 09 between 412 m and 445 m, traced to a stenter pin-chain slip, not a dye fault.
agent Defect-and-Inspect
result ← 1 defect cluster · roll 09 · 33 m affected · class WEFT_STREAK
cuOpt re-plans the cut and rework route: 33 m diverted to seconds, remaining 14,890 m re-sequenced so the buyer’s Thursday ship date still holds.
agent Yield-and-Takt
result ← 33 m to seconds (0.22%) · ship date held
Four-point grading, roll genealogy and the conformance packet (AATCC 61, ISO 105-C06, ZDHC MRSL declaration) are assembled and released to the buyer portal.
agent Quality-and-Conformance
result ← 13 rolls Grade A · 1 roll Grade B · packet signed
| Measure | Value | Context |
|---|---|---|
| Final mean ΔE | 0.58 | against a 0.80 tolerance |
| Re-dyes avoided | 1 | the standing card would have missed shade |
| Seconds | 0.22% | versus the scenario mill baseline of 1.9% |
| Water used | 46 L/kg | versus 59 L/kg on the scenario recipe card |
| Human decisions | 1 | the recipe approval gate |
Why this matters
A mill does not fail on the good lots. It fails on the lot where the substrate drifted, the recipe card was wrong, and nobody found out until the buyer opened the carton. Yarneon makes that lot legible while it is still in the machine.
The agent roster
Each agent owns a stage of the mill, senses its own signals and actuates its own setpoints. The orchestrator plans across them, escalates on policy, and keeps one record of the whole run.
Spinning, count, twist & yarn quality
Controls draft, twist and speed across ring, rotor and air-jet frames to hold count (Ne), CV%, twist and tenacity inside buyer spec, and predicts end-breaks before they cascade.
Loom & knitting-machine control
Holds warp and weft tension, pick density, let-off and take-up on air-jet, rapier and circular-knit machines so construction stays on spec without broken picks, ends-out, floats or holes.
Dyeing chemistry, recipe & shade
Predicts and doses dye recipes from substrate state, then closes the loop on exhaust curves, temperature ramps, pH and salt so the lot lands on shade first time instead of after two re-dyes.
Finishing chemistry, hand & stability
Controls stenter chemistry, overfeed, residence and temperature to hit hand, GSM, width and dimensional stability, with shrinkage and skew held to buyer tolerance across the roll.
Vision fabric-defect sensing
Line-scan and NIR vision detects and classifies slubs, holes, streaks, stains, floats, barré, skew and width faults in-line at full loom and stenter speed, then maps every fault to roll position.
Colour, fastness & grade optimisation
Spectral models score every roll against the buyer standard (ΔE, metamerism, fastness risk) and sort rolls into shade bands so cutting rooms never mix two shades in one garment.
Yield, waste, water, energy & balancing
Sequences dye lots and balances the line against takt, then allocates water, steam and electricity to cut the mill’s two biggest costs after fibre, reprocessing and utilities.
Roll, beam & doffing automation
Drives doffing, beam changes and roll transport with vision-guided manipulators and AMRs, so the scarce labour on the floor moves from lifting rolls to supervising the run.
Right-first-time, genealogy & traceability
Keeps immutable roll genealogy from bale to bolt and assembles the conformance packet, test methods, chemistry declarations and audit trail, that buyers and auditors demand.
Text equivalent
The same roster as a table, because an agent that will move a setpoint on your machine should be legible in plain rows before it is legible in a diagram.
| Agent | Senses | Actuates | Metric watched |
|---|---|---|---|
| Spin-and-Yarn | Evenness (Uster CVm%) · Imperfections IPI /km · Twist per inch · End-break rate · Roving/draft state | Draft ratio · Spindle speed · Twist multiplier · Doffing schedule | Watches: yarn IPI and CV% variance |
| Weave-and-Knit | Warp tension curve · Pick/course density · Stop causes · Loom efficiency % · Beam depletion | Let-off / take-up · Machine speed · Tension setpoints · Stop-and-repair routing | Watches: loom stops and construction faults |
| Dye-and-Color | Bath spectrophotometry · Exhaustion curve · Liquor ratio, pH, conductivity · Temperature ramp | Dosing schedule · Ramp rate & hold · Salt/alkali addition · Sampling & release | Watches: right-first-time shade |
| Finish-and-Hand | GSM, width, overfeed · Residual shrinkage · Handle/stiffness proxy · Curing temperature profile | Pad-bath concentration · Overfeed & pin width · Line speed · Curing profile | Watches: shrinkage and width out of tolerance |
| Defect-and-Inspect | Line-scan RGB + NIR frames · Defect class & severity · Metres between faults · Roll position map | Stop / slow line · Cut-plan marking · Rework routing · Grade assignment | Watches: defect escape rate |
| Shade-and-Quality | ΔE 2000 vs standard · Metamerism index · Fastness test history · Shade band assignment | Shade banding · Release / hold / re-dye · Buyer submission packet | Watches: shade-related chargebacks |
| Yield-and-Takt | Takt vs actual per stage · Litres water / kg fabric · kWh & steam per lot · Seconds & waste % | Dye-lot sequence · Machine assignment · Rework queue · Utility allocation | Watches: water and steam per kg |
| Robot-and-Handling | Roll/beam pose estimate · Gripper force feedback · AMR fleet state · Handling queue depth | Doff & beam-change cycles · Roll transport moves · Package palletising | Watches: manual handling hours |
| Quality-and-Conformance | Roll genealogy graph · Non-conformance records · AATCC/ISO test results · Chemistry declarations | Hold / release decisions · CAPA creation · Buyer & audit packet export | Watches: audit packet assembly time |
Trust signals
No customer results are published yet. These are platform facts and plan terms from our own documents. Outcomes will be measured against each mill’s own trailing twelve months, in shadow mode before anything is controlled.
Mill agents, one per stage, from spinning to release.
Products in the loop: Vireon, Spindra, Loomix, Shadeon, Doffex and Twinly.
Design partners we are onboarding first, one wedge workflow each.
Per line per month on the Line plan. Mill and Enterprise sit above it.
Items marked ASPIRATIONAL are design targets ahead of production validation.
Integrations
Yarneon is not a rip-and-replace. It connects to the looms, frames, jets, stenters, cameras, spectrophotometers and MES already on your floor.
Picanol, Toyota, Tsudakoma, Karl Mayer and Mayer & Cie controllers over OPC UA and vendor PLC tags.
Rieter, Trützschler, Saurer and Murata frames, draft, twist, speed and end-break telemetry.
Thies, Fongs, Brazzoli jets and Monforts/Brückner stenters via PLC, recipe systems and dosing units.
Datacolor and X-Rite spectrophotometers, colour libraries, Pantone TCX standards and lab-dip workflows.
Line-scan RGB and NIR cameras, Uster and Elbit inspection frames, existing light boxes.
SAP, Datatex, TIM, Coats Digital and homegrown mill MES over REST, files and database CDC.
Water, steam and electricity meters; ZDHC Gateway, Higg FEM and OEKO-TEX reporting.
Vision-guided manipulators and AMRs on NVIDIA Isaac and Jetson for doffing, beams and roll transport.
Vendor names are listed for compatibility reference only and do not imply endorsement or partnership.
Guardrails
Nothing here is a global "AI on" switch. Autonomy is granted per setpoint, bounded by policy, reversible by any operator and logged permanently.
Pricing
Priced per line, per mill or per group, with outcome-based components on the workflows where the value is measurable.
Mills validating ROI on a single wedge workflow.
Scaling mills adopting the full perceive–decide–act loop.
Integrated textile groups standardising on Yarneon.
Annual prepay saves 15 to 20% depending on term. Full detail, including outcome-based terms, on the pricing page.
Questions
Bring your machine list and your defect history. We will show you exactly which product touches which line.