While most cotton spinning mills still struggle with labor costs exceeding 40 workers per 10,000 spindles, a striking contrast emerges from Alar, Xinjiang: the arrival of a 2,448-spindle ultra-long intelligent spinning frame cuts labor to under 25 workers per 10,000 spindles. This implies a potential 40% drop in per-ton labor costs, and the 150,000-spindle project by Xiangrun Textile, backed by a 400 million yuan investment, is just the beginning of this equipment race.
Background
Xiangrun Textile's 150,000-spindle cotton spinning project is located in the Alar Economic and Technological Development Zone, covering a factory area of 43,800 square meters, with production scheduled for October 2026. The project's highlight is not its scale but its equipment—the 2,448-spindle ultra-long ring spinning frame, co-developed with equipment manufacturers, is currently the longest in China, creating a generation gap in intensification compared to conventional 480- or 720-spindle models.
The machine integrates automatic doffing and digital data collection modules, seamlessly connecting to MES systems for real-time monitoring of output, energy consumption, and breakage rates. For buyers, this means enhanced traceability of yarn quality; for factories, it signals the end of the 'experience-based management' era.
From an industrial cluster perspective, Alar has hosted spinning projects before, but this one explicitly follows a dual path of 'smart transformation and green upgrade,' with custom development by the enterprise and equipment makers, rather than off-the-shelf purchases. This model may set a precedent in Xinjiang's cotton spinning sector, encouraging more companies to shift from 'buying equipment' to 'building equipment.'
Industry Impact
Labor under 25 per 10,000 spindles and 300 kWh saved per ton of yarn—if these metrics are widely adopted in Xinjiang's spinning industry, they will directly reshape cost structures. Currently, Xinjiang mills are labor-intensive, with management difficulties and skilled worker shortages. Ultra-long frames reduce repetitive manual tasks, precisely addressing this pain point.
More critical is energy consumption. Saving 300 kWh per ton of yarn, the annual savings for a 150,000-spindle capacity are substantial. Under the 'dual carbon' goal, energy metrics are becoming hard thresholds for orders and park entry. The green upgrade may give the project a carbon footprint advantage in high-end markets like the EU, indirectly benefiting Xinjiang's cotton export chain.
On the equipment side, the deployment of the 2,448-spindle model marks an attempt for domestic spinning frames to move from 'following' to 'leading.' Previously, ultra-long spindles were dominated by imports. If this co-development succeeds, it could reduce dependence on foreign equipment and spawn new supply ecosystems. However, caution is needed: ultra-long frames require higher standards for factory floor flatness and temperature/humidity control. Small and medium factories that blindly follow may face rising maintenance costs.