Semester: 3rd

NATIONAL TEXTILE UNIVERSITY, FAISALABAD

Yarn Manufacturing Department
TE-2111

Yarn Manufacturing
Semester 3

Laboratory Manual

Prepared by:

 Mr. Muhammad Bilal (Assistant Professor)

National Textile University, Faisalabad

 Semester: 3rd

BS Textile Engineering Program Learning Outcomes (PLOs)

BS Textile Engineering Program aims at achieving the following
learning outcomes in the students by the time of graduation:
No. ATTRIBUTES Revised Program Learning Outcomes (PLOs)
An ability to apply knowledge of mathematics, science, engineering
Engineering
1 fundamentals and an engineering specialization to the solution of
Knowledge
complex engineering problems.
An ability to identify, formulate, research literature, and analyze
complex engineering problems reaching substantiated conclusions
2 Problem Analysis
using first principles of mathematics, natural sciences and
engineering sciences.
An ability to design solutions for complex engineering problems
Design/Development and design systems, components or processes that meet specified
3
of Solutions needs with appropriate consideration for public health and safety,
cultural, societal, and environmental considerations.
An ability to investigate complex engineering problems in a
methodical way including literature survey, design and conduct of
4 Investigation
experiments, analysis and interpretation of experimental data, and
synthesis of information to derive valid conclusions.
An ability to create, select and apply appropriate techniques,
resources, and modern engineering and IT tools, including
5 Modern Tool Usage
prediction and modeling, to complex engineering activities, with an
understanding of the limitations.
An ability to apply reasoning informed by contextual knowledge to
The Engineer and assess societal, health, safety, legal and cultural issues and the
6
Society consequent responsibilities relevant to professional engineering
practice and solution to complex engineering problems.
An ability to understand the impact of professional engineering
Environment and
7 solutions in societal and environmental contexts and demonstrate
Sustainability
knowledge of and need for sustainable development.
Apply ethical principles and commit to professional ethics and
8 Ethics
responsibilities and norms of engineering practice.
Individual and Team An ability to work effectively, as an individual or in a team, on
9
Work multifaceted and /or multidisciplinary settings.
An ability to communicate effectively, orally as well as in writing,
on complex engineering activities with the engineering community
10 Communication and with society at large, such as being able to comprehend and
write effective reports and design documentation, make effective
presentations, and give and receive clear instructions.
An ability to demonstrate management skills and apply engineering
11 Project Management principles to one’s own work, as a member and/or leader in a team,
to manage projects in a multidisciplinary environment.
An ability to recognize importance of, and pursue lifelong learning
12 Lifelong Learning in the broader context of innovation and technological
developments.

Fall-2019 1 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

This course aims at achieving the the following PLO after completion of this
course.

PLO PLO Description

number
from PLOs
list

4 An ability to investigate complex engineering problems in

a methodical way including literature survey, design and
Investigation conduct of experiments, analysis and interpretation of
experimental data, and synthesis of information to derive
.valid conclusions

Contibution of Course learning outcomes to Porgram learning outcomes

After completion of this course, the students will be able to:

CLO CLO Description Domain Taxonomy Linking to

No. level PLOs
3. Differentiate the type of wastes Psychomotor P4 4
extracted from different
spinning machines and
calculate cleaning efficiency
and count of lap, sliver and
roving. Also, investigate and
calculate various types of drafts
and twist on different spinning
machines by direct method.

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 Semester: 3rd

LABORATORY SCHEDULE
OURSE CODE TE-2111 SEMESTER: 3rd (Fall-2019)
COURSE TITLE: INTRODUCTION TO YARN MANUFACTURING
ACTIVITY: PRACTICAL DEPTT: YMD
WEEKS TITLE OF PRACTICAL
1 Inspection of wastes extracted by various machines of spinning departments and also
input and output of each machine of spinning process and mounting of samples on lab
report.
2 Determine the lint percentage and trash percentage in the given sample of bale cotton
cleaning efficiency of whole Blow Room and Scutcher machine.
3 Determine the count of lap and sliver, roving and ring yarn.
4 Study of different parts of card machine and their functions along with drawing their
diagram.
5 Investigation of various drafting methods on Card. Calculate the different drafts of carding
machine.
6 Study of different parts of draw frame (especially drafting system) and their functions.
Also draw the sketch.
7 Investigation of drafting method on drawing frame machine and calculate different drafts
on RSB D-40 drawing frame machine (roller drafting).
8 Determine the twist & draft by direct method on Roving frame.
9 Determine the twist & draft by direct method on ring frame.

10 Practical observation of material flow on auto cone

11 Practical observation of material flow on rotor spinning

12 Practical observation of working principle and operation of slub/multicount and core yarn
attachments

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PRACTICAL # 1
Inspection of wastes extracted by various machines of spinning departments and also
input and output of each machine of spinning process and mounting of samples on lab
report.

Objectives:
 Inspection of wastes extracted by various machines of spinning departments.
 the collection of wastes

Equipment, tools and material:

1. BLOW ROOM MACHINES:
Purcupin opener/ Coarse Cleaner
Axi-flow machine.
Step cleaner machine.
Kishner beater/Finer Opener waste.
Scutcher machine.
2. CARD MACHINE:
Taker in waste.
Cylinder under casing waste.
Flat strip waste.
Doffer waste.
3. DRAWING FRAME MACHINE.
4. ROVING FRAME MACHINE.
5. RING FRAME MACHINE.
6. WINDING MACHINE.

Procedure:
- Run the machines.
- Collect the samples of wastes.
- Comment the wastes collected.

Safety measures:
 Run the machines carefully.
 Keep yourself away from the machine at running.
 Handle the machine parts carefully.
 Do not collect the waste from the machine at running

Questionnaire:
 What are the opening and cleaning Principles of m/c?
 What are different types of impurities?
 What is name of m/c based on opposing spikes?
Conclusion:
Briefly describe your finding

Fall-2019 4 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 2

Determine the lint percentage and trash percentage in the given sample of bale
cotton cleaning efficiency of whole Blow Room and Scutcher machine
Objectives:
To understand the method to calculate the lint percentage and trash percentage in the given
sample of bale cotton.
To calculate the cleaning efficiency of the blowroom and Scutcher.

Equipment, tools and material:

1. Shirley Analyzer machine
2. bale cotton
3. weight balance

Procedure:
 Take 100 gm cotton sample from the blow room department.
 Open the sample manually and feed it to the Shirley analyzer.
 Collect the trash along with lint (useful, good fibers) and feed to the machine.
 Collect again the small amount of lint containing impurities from the trash box and feed to
the machine.
 Weight this lint. L2
 Then, collect the trash from trash box (T1+T2 ) and weigh it on an electronic weight balance.
 The lint was then again feed to analyzer and L4 was gotten.
 Finally, collect the trash from trash box again and weigh it on an electronic weight balance.
Also, L5 was there.
 Weight the final trash also.
Total Pure Lint = L2 + L4 + L5
Cage loss = 100 – Sum of lint and trash

Safety measures:
 Select the sample of bale cotton carefully so that it should be true representation of the
bale cotton.
 Trash from the box and the lint from delivery box of the Shirley analyzer machine must be
collected carefully for accuracy.
 Weight the trash and lint carefully.
 Weight balance should free from errors.

Questionnaire:
1. What is cage loss?
2. What is the use of Shirley Analyzer machine?

3. What is the range of trash in cotton throughout world?

Conclusion:
Briefly describe your finding

Fall-2019 5 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 3

Determine the count of lap and sliver, roving and ring yarn
Objectives:
To understand the method to determine the count of lap, sliver, roving and yarn in English system.

Equipment, tools and material:

 Template for preparing the samples of lap
 Wrapping drum for preparing the sample of slivers.
 weight balance
 Samples of lap and sliver

Procedure:
o Separate the lap sheet with Wooden Template of standard length of 1 yard.
o Weight the lap.
o For the count of cotton yarn, length of 1 Hank = 840 yards.
o Measure the count by
 Count = 8.33 * Length in yards / weight in grains
o Take the sliver by wrapping drum, sliver standard length for weighing is6 yards.
o Take the roving by wrapping drum, standard length for roving is 15 yards.
o Calculate the count.
o Measure With the help of wrapping reel, 120 yards.
o Calculate the count.
Count = 8.33* L/W
o Then, calculate the count by using the formula and assuming length in yards while weight in
grains ( 1 gram x15.42 = grains)
o All testing will be performed under standard atmospheric condition which are temperature
20±2 degree and Relative humidity 65 %±2.

Safety measures:
 Make the samples of sliver by wrapping drum using carefully.
 Measure the count.
 Separate the lap sheet with Wooden Template carefully.

Questionnaire:
 What type of numbering systems are there for textile materials?
 What is the Hank length for different textile materials (fibres)?
 Drive the relation to calculate the count of cotton material.
 What is Tex system and Metric system of counting?
 Drive the relation b/w the English system count and denier
Conclusion:
Briefly describe your finding

Fall-2019 6 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 4
Study of transmitted speeds of different organs of card and drawing RSB D-40
machines by gearing method.

Objectives:
1. To become familiar with the transmition of speed gearing diagram.
2. To make relationship to find rpm of driven organ from driver organ.
3. To make familiar with RSB D-40 drafting zone roller by tracing the gearing sequence.

Equipment, tools and Material:

1. Platts carding m/c in spinning lab,

2. copy, pencil, tool box and calipers,

3. Rieter Drawing RSB D-40

4. White Chalk

5. Tachometer

Procedure:
- Open the covers.
- Make the sketch of drive transmission system.
- Note the rpm of main motor.
- Measure the diameters of the driver and driven pulleys
- Count number of teeth of driver and driven gears.
- Measure the thickness of flat belt used
- Calculate the speed of functional parts of carding (feed roller, ticker-in, Cylinder, doffer,
flats, calendar and coiler calendar roller) by gearing methods.
- Similarly, calculate drafting rollers speed by tracing the gears of drawing frame (RSB D
-40).
- Verify the calculated speeds as above by comparing with the speed taken by tachometer
speed where applicable.
Safety Measures:
 Cut off the electrical connections before opening the covers
 Remove the belts before touching any gear or moveable part of the machine
 Measure the diameters of the concerned pulleys accurately
 Use gloves to touch any oily and greasy part
Questionnaire:
 What are the different driving methods of transmition of speed?
 What are cylinder type pulleys?
 Describe about consideration of belts or ropes thickness.
Conclusion:
Briefly describe your finding.

Fall-2019 7 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 5
Study of transmitted speeds of drafting system of Roving and Ring machines
by gearing method.

Objectives:
1. To become familiar with the transmition of speed by gearing diagram.
2. To make relationship to find rpm of driven organ using formula of gear train.
3. To make familiar with gear driving system.

Equipment, tools and Material:

1. Simplex FL-16 and Ring RY-5,

2. copy, pencil, tool box and calipers,

3. Measuring tape

4. White Chalk

5. Tachometer

Procedure:
Open the covers to become aware about the hidden parts and mechanisms.
Make the sketch of gearing diagram till drafting rollers. Trace out roller speed by gearing train
method. Motor rpm= Driver gear teeth/Driven gear teeth etc. Count the teeth of all gears to
calculate speed of main organ (drafting rollers) and match with actual running rpm checked by
tachometer.
Repeat this process for FL -16 roving and RY-5 Ring machine.
Close the covers.
Safety Measures:
 Cut off the electrical connections before opening the covers
 Remove the belts before touching any gear or moveable part of the machine
 Handle the machine parts carefully.
Questionnaire:
 What is gear train?
 Describe the different types of gears.

Conclusion:
Briefly describe your finding.

Fall-2019 8 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 6
Investigation of various drafting methods on Card. Calculate the different drafts on
carding machine.
Objectives:
1. To learn about Roller and Dispersion drafting system.
2. To make familiar with actual drafts and mechanical drafts.
3. To calculate D.C.

Equipment, tools and materials:

 Platts Card.
 Lap roll and Sliver to check actual draft
 Stop Watch to check RPM
 Tools to open the covers
Procedure:
- First of all calculate or measure the diameter of moving parts of carding (feed roll ,Ticker-
in ,Cylinder, Doffer ,Calendar roller and coiler calendar rollers)
- Measure the diameters of different rollers
- Count the teeth of all gears
- By Tachometer calculate speeds
- Count the DCP
- Calculate D.C.
Safety Measures:
 Remove the belts before touching any gear or moveable part of the machine
 Use gloves to touch any oily and greasy part
 Handle the machine parts carefully.
 Count the teeth of all gears carefully

Questionnaire:
 What is the DCP and identification?
 What is Relation of DCP and draft
 Why we use Draft constant?
Conclusion:
Briefly describe your finding.

Fall-2019 9 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 7
Investigation of drafting method on drawing frame machine and calculate the different drafts on
RSB D-40 drawing frame machine (roller drafting).

Objectives:
1. Doubling.
2. Increase the uniformity of sliver.
3. Mixing and blending of fibers.
4. Drafting.
5. Straighting of fibers.
6. Make the fibers parallel.
7. Decrease the weight per yard of the material.

Equipment, tools and materials:

 Drawing frame machine
 Slivers.
Procedure:
- First of all, feed the given material on drawing frame machine.
- Then, calculate the draft between assisting roller and back roller (tension draft).
- For calculating the tension draft, the RPM of back draft roller and assisting roller and
diameter of back drafting roller
- Then, calculate total draft of drafting system machine.
- Then, calculate total draft of drawing frame.
- Then, calculate DCP.
- Then, D.C can calculate by multiplying total draft with DCP.

Safety Measures:
 Remove the belts before touching any gear or moveable part of the machine
 Use gloves to touch any oily and greasy part
 Handle the machine parts carefully.
 Count the teeth of all gears carefully

Questionnaire:
 What is the DCP and identification?
 What is Relation of DCP and draft
 Why we use Draft constant?
 Define Draft constant?
Conclusion:
Briefly describe your finding.

Fall-2019 10 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 08
Determine the twist & draft by direct method on Roving and ring frame
Objectives:
 To become familiar with principle of twisting on roving.
 To calculate the twist level i.e. TPI and TPM and use tachometer.
 To know about the TCP (Twist change Pinion) on roving.

Equipment, tools and materials:

 ROVING FRAME:
 MS-2-speed frame.
 FL-16 roving frame.
 Tachometer.
 Calliper.
 Measuring tape.
 Sample.
Procedure:
 With the help of calliper and measuring tape the diameter of front drafting roller was
calculated.
 With the help of tachometer the RPM of front drafting roller and spindle or flyer was
observed.
 TPI = Flyer rpm
Front roller Delivery

Front roller Delivery = Front roller rpm × π D

Where D is in inches

Safety Measures:
 Use the tachometer carefully and take at least three observations when using it.
 Take the diameter of front drafting roller carefully.
 Cut off the electrical connections before opening the covers.
 Handle the machine parts carefully.
Questionnaire:
 What are different types of twists?
 Why twist is imparted in roving material?
 What is principle of twisting in roving frame?
Conclusion:
Briefly describe your finding.

Fall-2019 11 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 09
Practical observation of material flow on carding, drawing frame and roving
frame.

Objectives:
 To become familiar with principle of carding process and its importance.
 To Access fibres condition after passing through the Drawing machines.
 To identify importance of roving machine for ring spun yarns.

Equipment, tools and materials:

 CARD FRAME:
 Platts Card.
 Howa CM 80
 DRAWING FRAMES:
 Drawing Breaker.
 Drawing Finisher
 ROVING/SIMPLEX/SPEED FRAME
o FL-16

Procedure:
o Run the machine in sequence (Card, Drawing and Roving frame)
o Observe the card moving parts, role of these parts in processing the fibers.
o Identify Flats, taker-in, cylinder and doffer role by observing the flow of material.
o Run the drawing machine and observe its functionality while running.
o Observe the effect of drawing on drawn sliver by comparing with input sliver.
o Observe the role of Auto leveling device for drawing finisher
o Run the simplex/speed/roving frame.
o Observe its moving parts
o Make material flow chart at all these three machines and label it.

Safety Measures:
 Keep a specific distance while machines are running.
 Wear Close shoes to observe while machines are in working mode.
 Remove the belts before touching any gear or moveable part of the machine.
 Cut off the electrical connections before opening the covers.
 Handle the machine parts carefully.
 Use gloves to touch any oily and greasy parts.

Questionnaire:
 How the lap sheet is converted to a very fine sliver form?
 Why drawing second passage is necessary?

Fall-2019 12 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 10
Practical observation of material flow on ring frame, autocone, and rotor spinning.
Objectives:
 To become familiar with principle of Ring spinning process and its importance.
 To Access need of Auto cone machine.
 Observe working of all moving parts
 To make yarn path at all machine

Equipment, tools and materials:

 RING FRAMES:
 RY-5 (non-compact)
 K-44 (Compact)
 AUTO CONES:
 Mach Coner (Suplicer).
 Mach Coner (Knotter)
 AUTO CORO MACHINE
o SCHALFHROST
o OPEN END MACINE

Procedure:
o Run the machine in sequence (Ring, Auto Cone and Auto Coro machine)
o Observe the Ring moving parts, role of these parts in processing the roving.
o Identify yarn paths at all machine, role of each parts in manufacturing the yarn at ring
frames.
o Differentiate yarn (Compact and Non-Compact) types and manufacturing procedure.
o Run the drawing machine and observe its functionality while running.
o Observe the Suplice of yarn after cutting yarn faults.
o Run Auto Coro machine to observe its moving parts.
o Run the Auto cone/ Yarn Winding machines.
o Observe machine moving parts.

Safety Measures:
 Keep a specific distance while machines are running.
 Wear Close shoes to observe while machines are in working mode.
 Remove the belts before touching any gear or moveable part of the machine.
 Cut off the electrical connections before opening the covers.
 Handle the machine parts carefully.
 Use gloves to touch any oily and greasy parts.

Questionnaire:
 What is the difference between compact and non -compact yarns?
 Why auto cone winding machine is necessary?

Fall-2019 13 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 11
Practical observation of working principle and operation of slub/multicount
and core yarn attachment.

Objectives:
1. To make familiar of types of yarns exists in premises.
2. To collect different yarn samples.
3. To understand the use of different yarns in different clothing
4. To understand the working of core yarn on sample spinner machines (dual core yarn )

Equipment, tools and materials:

 Yarn Sample spinner (Edera Ring Spinning)
 SARMATES machine (Dual Core yarn)
 DirecTwist (2C6& 2 D6)

Procedure:
 Run the machine sample spinners
 Make the yarn path with all possible feeding yarns and their location must be distinguished
via diagrams.
 Observe operation of manufacturing Core yarn, Dual core yarn and elastomer yarns.
 Elaborate your observation in lab report
 Role of high and low twisted yarn in clothing.
 Take sample and untwist yarns to access yarns and raw material types.
 Require to highlight complete procedure of manufacturing process of these yarns.

Safety Measures:
 Keep a specific distance while machines are running.
 Wear Close shoes to observe while machines are in working mode.
 Remove the belts before touching any gear or moveable part of the machine.
 Cut off the electrical connections before opening the covers.
 Handle the machine parts carefully.
 Use gloves to touch any oily and greasy parts.

Questionnaire:
 Define multi-count and slub yarns?
 What is the difference between core yarn and dual core yarns?
 What is best possible range of draft for Lycra?
 Differentiate plan yarns and core spun yarns?

Fall-2019 14 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 12
Practical observation of different types of yarns and yarn faults.

Objectives:
o To list down the types of yarns.
o To collect different yarn samples with its type and name.
o To understand the use of different yarns in different clothing
o To identify yarn different faults.

Equipment, tools and materials:

 Yarn Samples.
 Magnify glass

Procedure:
 Collect different yarns types and take samples of these yarns.
 Elaborate each yarn.
 Purpose of yarn for different products and its use.
 Role of high and low twisted yarn in clothing.
 Take sample and untwist yarns to access yarns and raw material types.
 Identification of yarn faults and their categories.

Safety Precaution:
 Equip yourself with proper dress coat while working in testing.
 Keep a distance while machine is running.
 Try not to contaminate yarn samples
 Perform your testing under standard testing conditions.

Questionnaire:

Which type of yarn is best?

What are types of yarn?

Fall-2019 15 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)

 Semester: 3rd

PRACTICAL # 13
Comparison of yarn quality parameters developed by different yarn manufacturing
techniques (compact, non-compact, Rotor spun and doubling)

Objectives:
o To understand the quality parameters of yarn
o To compare quality parameters of yarns developed through different techniques
o To identify the optimal yarn for its end use
o To understand the differences in process in several yarn manufacturing techniques

Equipment, tools and materials:

 Yarn Samples (Non Compact- spun, Compact spun , Rotor spun and doubled)
 Wrapping reel
 Lea strength tester
 Tensorapid
 Uster tester 5

Procedure:
 Manufacture different yarn on RY-5, K-44, Auto Coro and directwist machine.
 Perform testing on Uster tester 5 and collect reports for each samples
 Perform testing on Tensorapid machine of all samples and collect results of each.
 Calculate count and CLSP of all 4 types of yarns.
 Compare all reports with respect to yarn quality parameters.
 Identify each yarn for its potential usage based on their quality parameters.

Safety Precaution:
 Equip yourself with proper dress coat while working in testing.
 Keep a distance while machine is running.
 Try not to contaminate yarn samples
 Perform your testing under standard testing conditions.

Questionnaire:

Which type of yarn is best?

Define IPI and its importance in yarn parameters?
Define CLSP ?

Fall-2019 16 Lab Manual, Introduction to Yarn Manufacturing (TE-2111)