Savio autoconers are among the most widely operated winding machines in the world. The Orion, Polar, and Espero models — produced by Savio Macchine Tessili, headquartered in Pordenone, Italy — are found in spinning mills across India, Bangladesh, Turkey, Vietnam, Pakistan, Egypt, and dozens of other textile markets.
They are precision machines. They require precision paper cones.
This guide documents the exact cone specifications required for reliable, stoppage-free operation on Savio Orion, Polar, and Espero autoconers — including taper angle, length, inner diameter tolerances, notch type, surface finish, and burst strength. It is written for production managers, maintenance engineers, and procurement teams who need to specify paper cones correctly the first time.
The Savio Winding Machine Family: A Brief Orientation
Before getting into cone specs, it helps to understand how the three main Savio autoconer models relate to each other — because cone compatibility is model-specific, not brand-wide.
Savio Orion is Savio's flagship high-speed automatic winder, designed for ring-spun yarn packages. It operates at winding speeds up to 2,000 metres per minute and uses a precision spindle-cradle cone seating system calibrated for the 5°57′ taper angle. The Orion is available in multiple head configurations and is the most widely installed Savio model globally.
Savio Polar is a high-efficiency automatic winder designed for coarse and medium-count yarns. It shares much of the Orion's mechanical architecture and uses the same 5°57′ cone specification in most configurations. Some specific Polar variants may accept both 5°57′ and 4°20′ cones — always verify against your machine model's manual.
Savio Espero is a compact automatic winder designed for medium-count natural and synthetic yarns, often found in smaller mills or as a supplementary winder alongside a primary Orion installation. The Espero also operates with the 5°57′ taper as the primary specification.
Savio Eco PulsarS is Savio's open-end (rotor) spinning machine — not an autoconer. Paper tube (cone) specifications for open-end spinning are different from autoconer cone specs. This guide covers autoconer (ring-spun output) applications only.
Savio Volufil is Savio's false-twist texturing machine for synthetic yarns. Volufil applications typically use 4°20′ cones. If you operate a Volufil, refer to our Glass 4°20′ cone specification guide instead of this document.
Primary Cone Specification: Savio Orion, Polar, and Espero
The following specifications are the standard requirements for paper cones used on Savio Orion, Polar, and Espero autoconers in ring-spun yarn winding applications. These figures are consistent with Savio's published technical documentation and industry-standard practice across multiple markets.
Taper angle: 5°57′ (five degrees, fifty-seven minutes)
This is the defining parameter. The 5°57′ taper is the global standard for high-speed automatic winders, and Savio's Orion/Polar/Espero spindle cradles are machined to this geometry. A cone with a different taper angle — even 4°20′, which is physically similar — will not seat correctly on a 5°57′ spindle cradle. The consequences range from vibration at low speed to automatic ejection at high speed.
Confirm this angle on the proforma invoice before ordering. Do not accept "standard auto-machine cone" as a specification — require the explicit degree value.
Length: 170mm (standard), 173mm (accepted on some configurations)
170mm is the global standard cone length for most Savio autoconer configurations. Some Savio Polar and Orion models are configured to accept 173mm cones when a larger package diameter is required. Check your machine's package specification settings to confirm which length your cradle is set for.
Acceptable tolerance on length: ±1mm. A cone at 168mm or 172mm is outside tolerance and will cause cradle fit problems.
Inner diameter at nose (small end): 27mm to 28.5mm
The nose inner diameter is the critical seating dimension — it is the point at which the cone contacts the winding head spindle tip. For Savio autoconers in the Orion/Polar/Espero family, the standard nose ID range is 27mm to 28.5mm.
Acceptable tolerance within this range: ±0.25mm. A nose ID at the extremes of this range (approaching 26.75mm or 28.75mm) will cause spindle contact problems — either the cone seats too tightly and risks cracking, or it seats too loosely and generates vibration.
Inner diameter at base (large end): 67.5mm to 68.5mm
The base inner diameter determines the package build geometry and how the finished cone sits in downstream handling systems. For the 5°57′ taper at 170mm length, the base ID range is 67.5mm to 68.5mm.
Acceptable tolerance: ±0.25mm.
Weight: 40g to 42g
The cone weight in grams reflects the total paper mass and determines wall thickness and structural strength at a given cone geometry. For Savio Orion winding at speeds above 1,500 m/min with medium to fine-count yarn:
- For cotton and blended natural fibres: 40g cones are typically sufficient.
- For high-speed synthetic yarn (polyester, nylon, polypropylene): 42g cones provide better burst strength and resist the higher radial pressure generated by synthetic yarn winding tension.
If your Savio Orion is running at maximum speed with compact-spun or high-count synthetic yarn, specify toward 42g and confirm the burst strength value (see below).
Paper grade: 350-450 GSM kraft paper
Standard specification. The GSM grade within this range should be selected based on the required wall thickness for your winding application. Higher GSM within the range provides better dimensional stability and burst strength.
Notch Specification for Savio Autoconers
The notch type is critical for the auto-doffer function — the mechanism that automatically catches the yarn end at the start of each new cone. Savio autoconers use different notch types across the model range and configuration variants.
Standard Savio Orion: V-notch
Most Savio Orion installations use a V-notch cone — a sharp V-shaped cut at the nose end. The V-notch allows the auto-doffer to catch the yarn tail reliably on the first rotation of the new cone.
Savio Polar: V-notch or Y-notch (confirm per machine configuration)
Savio Polar machines may use either V-notch or Y-notch depending on the installed auto-doffer configuration. Check the machine manual or ask your Savio service engineer which notch type is specified for your installation.
Savio Espero: V-notch (standard)
The Espero uses V-notch as standard across most configurations.
Critical rule: If you are unsure which notch your Savio uses, request a sample cone from your current supplier and physically test the notch-catch function on a stopped machine head before committing to a bulk order with a new supplier. A notch mismatch causes automatic re-threading failures on every cone change — a production efficiency problem that often gets misdiagnosed as a tension or clearer issue.
Surface Finish Specification
For ring-spun cotton yarn: Smooth (plain) finish is standard and appropriate. Cotton's natural surface texture grips the cone body sufficiently to prevent layer slip on the first wind.
For ring-spun synthetic yarn (polyester, nylon, polypropylene, acrylic): Velvet (rough, anti-slip) finish is strongly recommended. Synthetic yarns have very low surface friction and will slip on a smooth-finish cone, causing package telescoping and auto-doffer failures on the first few layers.
For blended yarns (poly-cotton, viscose blends): The dominant fibre type determines the finish. Cotton-dominant blends typically run adequately on smooth finish. Synthetic-dominant blends require velvet.
If your Savio Orion runs a yarn mix across shifts or styles, velvet finish is the safer default — it performs adequately on natural fibres and is essential for synthetics.
Burst Strength and Quality Requirements
Minimum burst strength: 2.5 kg/cm²
This is the industry-standard minimum for auto-machine paper cones. For Savio Orion running at speeds above 1,800 m/min or with yarn tensions above standard, consider specifying 3.0 kg/cm² minimum to provide a comfortable safety margin against cone deformation under peak winding pressure.
Ask your cone supplier for the measured burst strength value — not the specification target but the actual measured value from the production batch quality test. Any supplier running a properly controlled process will have this data.
Roundness tolerance: maximum 0.3mm ovality at nose, mid-body, and base
Roundness is the parameter most often unchecked in incoming inspection and most often responsible for vibration problems blamed on the machine. Measure the inner diameter at three points on the cone circumference at the nose, mid-body, and base. The difference between maximum and minimum diameter at any measurement point should not exceed 0.3mm.
Dimensional consistency across the batch
Individual cone dimensional checks catch individual failures. Batch consistency — whether 999 out of 1,000 cones in a batch fall within tolerance — is the production efficiency variable. Ask for the sampling plan and rejection rate data from your supplier's QC process. A rejection rate above 2 percent indicates a process that is not in control.
Common Cone-Related Problems on Savio Autoconers — and Their Fixes
Problem: Cone ejects from spindle cradle at high speed
Most likely cause: nose inner diameter slightly outside tolerance, causing the cradle to not grip correctly. Measure 20-30 cones from the current batch at the nose and base with a cone gauge. If a significant portion are at the outer tolerance limit of nose ID, you have a batch dimensional issue.
Fix: Return the batch, replace with a batch from a controlled-process supplier, confirm proforma invoice specifies ±0.25mm tolerance.
Problem: Package vibrates from first layer but machine checks out mechanically
Most likely cause: cone ovality at the nose. The cone is slightly oval rather than circular, causing an imbalance at the spindle tip that the machine amplifies at speed.
Fix: Perform roundness check at the nose on 20-30 sample cones. If roundness exceeds 0.3mm, the batch is non-conforming.
Problem: Auto-doffer cannot catch yarn end, requiring manual re-threading
Most likely cause: wrong notch type for the installed auto-doffer configuration. Perform a physical notch-catch test on a stopped head with the current cone.
Fix: Confirm your Savio model's specified notch type (V, Y, or U). Order the correct notch from your supplier.
Problem: First layers of synthetic yarn slip, package telescopes
Most likely cause: smooth-finish cone on synthetic yarn. The yarn has insufficient friction to grip the cone body on the first wind layers.
Fix: Switch to velvet-finish cones for all synthetic yarn styles.
Problem: Cones deform or collapse under winding pressure at medium count
Most likely cause: cone weight below specification (below 40g), insufficient burst strength, or moisture-softened paper from poor storage.
Fix: Confirm cone weight and burst strength with supplier quality data. Check storage conditions — cones stored above 65% relative humidity will lose burst strength.
Frequently Asked Questions
Is the paper cone spec the same for all Savio Orion generations (Orion, Orion M, Orion N)? The 5°57′ taper and 170mm length are consistent across the Orion generation. Some configuration differences may exist for cradle geometry on very early or heavily modified machines. If you are operating a pre-2010 Savio Orion, verify the cradle dimensions against the machine manual before specifying a new cone supplier.
Does Savio publish an approved paper cone supplier list? Savio (now part of Lohia Corp after the 2021 acquisition) does not publish a universal approved supplier list for paper cones as a capital equipment consumable. Machine compatibility is defined by dimensional specifications, not brand approval. Any cone meeting the dimensional, weight, and quality specifications above will be compatible.
Can I use the same cone on my Savio and my Schlafhorst Autoconer X6? In most cases, yes — both machines accept 5°57′ cones at 170mm. However, notch type may differ between machine brands. Verify the notch type required by each machine model separately. If your Savio requires a V-notch and your Schlafhorst requires a Y-notch, you will need to specify the notch type separately for each machine population.
We recently switched cone suppliers and started getting more Savio stoppages. What should we check first? Run the diagnosis in order: (1) measure 20-30 cones from the new batch at nose and base ID against the ±0.25mm tolerance. (2) Perform roundness check at three points per cone on the same sample. (3) Confirm the notch type matches your Savio's specified type. (4) Weigh a sample of 10 cones — confirm they are within 40-42g. (5) Check burst strength against the 2.5 kg/cm² minimum. In our experience, the vast majority of post-supplier-switch stoppages trace to items 1, 2, or 3.
What cone does Aziz Packaging supply for Savio Orion applications? The Alishan 5°57′ auto-machine paper cone is manufactured to the full specification set described in this guide: 5°57′ taper, 170mm length, 40-42g weight, 350-450 GSM kraft paper, ±1mm length tolerance, ±0.25mm ID tolerance, velvet or smooth finish on specification, V-notch standard (Y and U available on request), 2.5 kg/cm² minimum burst strength. Quality certificates with measured batch values are provided as standard.
Aziz Packaging Limited manufactures the Alishan 5°57′ auto-machine paper cone — compatible with Savio Orion, Polar, and Espero autoconers. Contact us for a sample batch for machine qualification or a proforma invoice against your specification.
[Request a Sample for Savio Machine Trial →] [Download the Alishan 5°57′ Full Specification Sheet →] [Read: The 2026 Paper Cone Buyer's Checklist →]
