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    Yarn Manufacturing 1

    Uploaded by

    Muhammad Farooq Kokab
    The document discusses various types of yarn manufacturing processes. It describes staple spun fiber yarn production which uses staple fibers assembled together through techniques like ring spinning, open-end spinning, and friction spinning. It also describes continuous filament yarn production which combines filaments simultaneously to produce polyester or silk yarn. The document provides details on specific processes like carding, combing, drafting, and twisting involved in ring spinning of staple fiber yarns. It summarizes different yarn manufacturing techniques including their workings, applications and limitations.

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    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd

    Yarn Manufacturing 1

    Uploaded by

    Muhammad Farooq Kokab
    4K views30 pages
    The document discusses various types of yarn manufacturing processes. It describes staple spun fiber yarn production which uses staple fibers assembled together through techniques like ring spinning, open-end spinning, and friction spinning. It also describes continuous filament yarn production which combines filaments simultaneously to produce polyester or silk yarn. The document provides details on specific processes like carding, combing, drafting, and twisting involved in ring spinning of staple fiber yarns. It summarizes different yarn manufacturing techniques including their workings, applications and limitations.

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    The document discusses various types of yarn manufacturing processes. It describes staple spun fiber yarn production which uses staple fibers assembled together through techniques like ring spinning, open-end spinning, and friction spinning. It also describes continuous filament yarn production which combines filaments simultaneously to produce polyester or silk yarn. The document provides details on specific processes like carding, combing, drafting, and twisting involved in ring spinning of staple fiber yarns. It summarizes different yarn manufacturing techniques including their workings, applications and limitations.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    4K views30 pages

    Yarn Manufacturing 1

    Uploaded by

    Muhammad Farooq Kokab
    The document discusses various types of yarn manufacturing processes. It describes staple spun fiber yarn production which uses staple fibers assembled together through techniques like ring spinning, open-end spinning, and friction spinning. It also describes continuous filament yarn production which combines filaments simultaneously to produce polyester or silk yarn. The document provides details on specific processes like carding, combing, drafting, and twisting involved in ring spinning of staple fiber yarns. It summarizes different yarn manufacturing techniques including their workings, applications and limitations.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 30

    Yarn Manufacturing

    YM-2011

    Yarn
    A textile yarn is an assembly of substantial length

    and relatively small cross-section of fibers and/or filaments with or without twist. Yarn types

    According to fiber length (staple, continuous filament) According to structure (single, plied, cabled) According to fiber type (fiber material like metal, glass, cellulose) According to twist (zero twist)

    Staple Spun Fiber Yarn


    These consist of staple fibers assembled and bound

    together by various means to produce the required characteristics such as strength, handle, appearance etc. Examples include, cotton, wool, jute yarn etc.

    Continuous Filament Yarn


    It is a produced by combining the required number

    of filaments and thickness of filaments simultaneously in one spinning operation. Examples include polyester filament yarn, silk filament yarn etc. The typical filament yarn is a collection of parallel filaments lying close together and virtually straight running the whole length of the yarn. Monofilament yarn (yarn with one filament) Multifilament (yarn with more than one filament)

    Staple Fiber Yarn Production


    Different techniques are used which depends upon

    the factors as;


    Manufacturers preference of equipment Economic implications Fibers to be used Desired properties of the yarn

    Staple Fiber Yarn Production


    Techniques Ring spinning Open-end spinning Friction spinning Self twist spinning Electrostatic spinning Vortex spinning Air-jet spinning Twistless spinning

    Ring Spinning
    Widely used process

    Flexible process
    Large count processing range Easy process

    Basic manufacturing processes are; Carding Combing Drafting Twisting Winding

    Blending, Opening & Cleaning


    It is the first stage of staple fiber yarn formation process. Fibers are compressed in high density in bale form. Blending-uniform fiber quality Opening-loosen hard lumps of fiber Cleaning-remove trash like dirt, leaves, burrs etc Bale pickers are first machine of this line Number of openers or beaters are used depending upon the fiber quality. When cotton is opened, trash falls through a series of grid bars. Feeding to upcoming machine is done by lap or chute. File

    Carding
    It is used to arrange the fibers in parallel lengthwise direction. In case of cotton, it also removes the rest of the trash during

    opening. This process is carried on carding machine. It has a beater, which beats up the large wads of fiber proceeding by a rapidly revolving large cylinder covered with fine teeth/wire brushes. A moving belt of wire brushes slowly moves concentrically above the cylinder. Fiber passes through this small gap between cylinder and belt when cylinder rotates causing teasing action which removes trash, disentangle the fibers and arranges them in parallel manner in form of thin web.

    Examine it in full screen mode and consider the direction of rotation of all rollers here

    Combing
    It is used for fine and expensive yarn production.

    It is an additional fiber straightening process with

    such a high degree of fiber parallelism that the short fibers are combed out and completely separated from longer fibers. It uses fine toothed combs for process. It produces a smoother and more even yarn. It removes 25% of the original card sliver fibers.

    Drawing
    It eliminates irregularities that would cause too

    much variation if slivers would put through singly. Slivers are combined and drafted to achieve this process. Drawframe has several pair of rollers, each advanced set of which revolves at progressively faster speed. Drafting action pulls the staple lengthwise over each other, thereby producing longer and thinner slivers.

    Roving
    Sliver is placed on roving frame to further reduce its

    weight/unit length. It is the first stage of twist insertion to secure the fiber strand. It is a preparatory stage for final twist insertion

    Spinning
    The roving on bobbins are placed on spinning frames

    to produce the yarn by reducing weight/unit length and insertion of twist along with winding on bobbin in a single stage. It also uses several sets of rollers running at successively higher rate of speed. Spinning frame are of two types: Ring frame (faster process, relatively coarse yarn) Mule frame (slow process, fine yarn such as worsted) Twist in ring

    Open End Spinning


    Also called as break spinning Coarser yarn counts of up to about 40 Ne Use carded sliver Directly converts sliver into yarn Spiked rollers completely open/breaks the sliver Individual fiber form is fed to funnel shaped rotor A thin layer of fibers form in groove on the inner surface of rotor Rotor rotates at very high speed The centrifugal force of rotor builds up a multilayer of fibers which is peeled away from the collecting groove as it is simultaneously twisted by the rotation of the rotor and withdrawn continuously and being formed into a yarn.

    Open End Spinning

    Ring & Open End Yarn


    Ring Spun Yarn Open End Yarn

    Spool is rotated to put twist in yarn


    Small Spools Labor intensive Low automation 20-22 m/min production speed Good quality High elongation, high hairiness and low evenness

    Spool does not need to rotate for twisting


    Larger spools can be wound with knot free yarn Reduction in handling of spools Greater automation and hence better production economy 3-5 times higher rate of production than ring spun Quality approx. equivalent to ring Better evenness, less hairiness and low elongation

    Yarn Structures

    Limitations of Open End Spinning


    Cant spun 100% man made fibers due to fiber finish

    deposition in rotor groove and cause clogging Slivers should be free of foreign matter to prevent clogging Yarn have carded character and have rougher, sandier hand Counts generally lower than 40 Ne, and limit to coarser fabrics like denim, towel, interlinings etc 20% more twist than ring, they are 15-20% weaker due to their coarseness Yarn structures of ring and open end yarns are different so cant be mixed in manufacture

    Friction Spinning
    Direct transformation of sliver into yarn Fibers are opened by cylinder and transferred to

    spinning rollers Fibers are compressed by the action of nip of rollers Friction by same directional rotating rollers cause the fibers to twist around each other. Card sliver can also be used in DREF II system. Wide variety and quality of fibers can be processed Yarn may lack uniform distribution of twist through the cross section Bulky yarn with low tensile strength Count range is 6 to 18 Ne.

    Friction Spinning System

    Self Twist Spinning


    Pairs of rovings are drawn out on a succession of

    drafting rollers Last set of rollers reciprocates axially, causing a rolling action of the strands as they emerge. This sideway movement of the drafting rollers cause the strands to wrap around each other. The resultant yarn have alternate lengths of right and left hand twist. To increase strength some additives may be used for cohesion or spun on conventional machine hereafter.

    Self Twist Spinning

    Electrostatic Spinning
    Use to separate the fibers on behalf of their type and

    length. For cotton, short fibers can be removed and increase in yarn strength and substantial improvement in yarn spinning efficiency. Careful control of humidity is essential for separation of short fibers in electrostatic field Carded sliver is drafted and are fed over rotating cylindrical electrodes of high field intensity which direct the long fiber to enter an air current for transport to the combed sliver stage. The short fibers, which move slowly, are carried by rotating electrodes of low field intensity to where they are moved to a receptacle.

    Electrostatic Spinning

    Air Vortex Spinning


    Variation of open end spinning technique

    Rotor is replaced by a tangential air inlet that draws


    fibers down a tube The free yarn end rotates in the air stream catches the fibers and twist them up by rotation of end The yarn is continuously drawn out of the tube keeping a standard length which rotates in the tube for further grasping of fibers It is a considerable cost saving process Yarn produced are weak and irregular.

    Air Vortex Spinning

    Air Jet Spinning


    Sliver is drafted by rollers and passed into a cylindrical

    pneumatic twisting chamber The walls of the chambers release compressed air from jets sets in the wall at predetermined angles to the central axis of the tube. Fibers whirled around each other With suction aid, strand is passed to second chamber and equal amount of twist in opposite direction in given. Yarn is stabilized and wound onto a takeup package. Yarn has uniform diameter and harsh hand.

    Air Jet Spinning

    Twistless Spinning

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