Spinning [Compatibility Mode]

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12/1/2012

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Yarn Manufacturing

TECHNOLOGY

Types of Yarn

• Carded Yarn.

• Combed Yarn.

Comparison of

Combed Yarn & Carded Yarn

Combed Yarn Carded Yarn

Comber is used No Comber is used

Less short fibers More short fibers

Less Hairiness More Hairiness

More Luster Less Luster

Bale of Fiber Flow Chart For Carded Yarn

Input Process/ Machine OutputBale → Blowroom → Lap

Lap → Cardingm/c → Sliver

Sliver → Breaker Draw Frame → Sliver

Sliver → Finisher Draw Frame → SliverSliver → Roving Frame

/Speed Frame/Simplex→ Roving

Roving → Ring Frame → Yarn

Flow Chart For Combed Yarn

Input Process/ Machine Output

Bale → Blow room → Lap

Lap → Cardingm/c → SliverSliver → Pre comb drawing → SliverSliver → Lap former → LapLap → Combing → SliverSliver → Post comb drawing → SliverSliver → Simplex → RovingRoving → Ring Frame → Yarn



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Blow Room

Blow Room is called the mother of yarn

manufacturing. It consists of a number of

machines used in succession to open and

clean the cotton fiber to the required degree.

40 to 70% trash is removed in this section.

Blow room line Bale plucker

Opener

Mixer

Step cleaner



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Objects of Blow Room

1. Opening :

To open the compressed bales of fibers &

To make the cotton tuft a small size as for aspossible.

2. Cleaning :

To remove the dirt, dust, broken seeds brokenleafs and other foreign materials from the fibers.

More…

Objects of Blow Room

3. Blending & Mixing:

To make good value of yarn and to decrease theproduction cost by mixing different grade of fibers.

4. Lap forming :

To transfer the opened and cleaned fibers into asheet form of definite width and uniform unitlength which is called lap.

TECHNOLOGICAL POINTS IN BLOW

ROOM

Opening in blow room means opening into smallflocks

The larger the dirt particle , the better they canbe removed

The higher the degree of opening, the higher thedegree of cleaning. A very high cleaning effect isalmost always purchased at the cost of a highfiber loss. Higher roller speeds give a bettercleaning effect but also more stress on the fiber.

Rollers Drums & Beaters Actions involved in Blow Room

1. Action of opposite spike: (opening)

By The action of opposite spikes opening the

cotton fiber is done.

2. Action of Air flow: (Transport + Cleaning)

During processing, the movement of cotton frommachines to machine is done by air flow. It alsohelps the separation of lint and trash.

More…



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Cleaning by Air flow Actions involved in Blow Room

3. Action of Beaters: (Cleaning & Opening)

Beaters are responsible for removing almost allof the impurities extracted in the blow room.Beater also helps in opening of cotton fiber.

4. Action of regulating motion: (Uniformoutput)

The action of regulating motion gives theuniform output.

Cleaning Efficiency

Cleaning efficiency of blow room can be fin outby the following simple calculation.

(Input Trash - Output Trash)*100

Input Trash

Problem

Find the Blow Room cleaning eff y :

Raw cotton trash= 6%

Lap trash = 1.6%

Solve: (6-1.6)*100/6

=73%

Carding

Carding may be defined as the reduction of an

entangled mass of fibers to a filmy web by

working between two closely spaced,relatively moving surface closed with sharp

wire points.

Objects of Carding

1. Opening to individual fibers.

2. Elimination of Impurities and dust.

3. Fiber blending.

4. Sliver formation.



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Flow diagram of Carding m/c

• A = Cylinder

• B = Flat

• C = Taker in

• D = Feed roller

• E = Feed plate

• F = Doffer

Actions of Carding m/c

1. Carding Action

This is the action between flat & cylinder.

• Pin direction: Opposite.

• Rotation: Opposite.


2. Stripping Action

This is the action between Cylinder - Taker in

• Pin direction: Same.

• Rotation: Same.


3. Doffing Action

This is the action between Doffer & Cylinder.

• Pin direction: Opposite.

• Rotation: Same.


4. Combing Action

This is the action between Feed roller & Taker

in.

• Pin direction: Same.

• Rotation: Same.

Carding Machine



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Carding Machine Draw frame

• It is a process of yarn manufacturing in which

the sliver is elongated when passing through

pairs of rollers, each pair faster than the

previous one.

Actions involved in Draw frame:

Drafting: The process of increasing length perunit weight of sliver. It is mainly due tovarying speed of the rollers.

Doubling: The process of combining two ormore carded sliver into a single form is calleddoubling. In draw frame m/c generally six toeight slivers are fed and converted into one.

Drawing = Drafting + Doubling.

TASKS OF DRAW FRAME

• Through draft fibers get parallelized

• Hooked fibers are straightened.

• Through the suction ,intensive dust removal is

achieved.

• Blending can be done here.

Drawing Machine



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Find out the production/shift in lbs of a modern draw frame, from

the following particulars: Delivery speed = 600 m/min, No of

delivery/frame = 2, Draft = 8, No of doubling = 8, Feed sliver wt

= 0.01 lb/Yd, Efficiency = 90%

Solution:

Draft= (Feed wt/Delivery wt)* Doubling

So, Delivery wt= (Feed wt/ Draft)* Doubling

So, Delivery wt= (0.01/8)* 8 = 0.01 lb/yd

Production = 600 m/ min = 600*1.09 yds/min = 654 yds/min

= 654*0.01 lbs/min = 6.54 lbs/min = 6.54*60*8 lbs/shif t

= 3139.2 lbs/shift

For 90% efficiency and no. of delivery, the ultimate production is, 3139.2*0.9*2 =

5650.56 lb/shift (Ans)

Lap former

• Lap former is the machine where lap is

produced from slivers. It is necessary for

producing combed yarn. Because the input of

comber machine is lap.

Comber

• Combing :

Combing may be defined as to remove short

fibers , neps and remaining impurities of card

sliver by using comb with the help of knives,

brushes and rollers.

Objects of combing

• To remove short fibers below a preselected

length so that the spinner enable to produce

finer / better yarn.

• To remove neps and foreign matter from the

cotton / sliver.

• Make the fiber straight and parallel.

Blow room lap Comber lap

Sh ort fibe r hi gh Sh ort fibre low

Uniformity low Uniformity high

Trash high Trash low

Lap count .0011-.0019 Ne Lap count .0075 -.009

Lap wt /yds 12-16 ounce Lap wt /yds 1.6-2.5 ounce

Lap width 1m Lap width 300 mm



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Combing figure

• A= Feed roller

• B= Feed plate

• C= Nipper

• D= Top comb

• E= Detaching roller

• F= Cylinder

Combing Action

• Firstly, Sliver comes through feed plate, After

passing the edge, the nipper comes down to

clamp the fiber between feed plate & itself.

Then the first combing is done by the cylinder.

Combing Action

• Then, nipper moves upward. Sliver feeding starts again. When

sliver comes to detaching roller, the rollers give a backward

movement to join it with previously combed sliver. That time

Top comb comes down and by the forwarding m ovement of

detaching roller, second time combing is done by top comb.

This process is a intermittent process. Because

all these are carried out up to 300 times per

minute.

Combing Machine Speed frame

• Task of Speed frame:

• To produce roving from sliver.

• To impact strength to the fiber by twisting.

• To wind up the resulting roving on to roving

bobbin.



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Speed frame machine Operation involved in Speed Frame

• Creeling: Sliver feeding with the help of

several rollers. 40 drawn slivers can be creeled

at a time.

• Drafting: To reduce wt per unit length of

roving in speed frame so that produces roving

can be converted into yarn easily with draft in

drafting Zone. For this normally 3 pairs of

rollers are used.

Operation involved in Speed Frame

Twisting:

To insert small amount of twist to get requiredstrength of roving . so that no breakage of yarnand possible to wind of roving in convenientpackage. Usually 30-65 turns per meter twist isgiven which are created by flyer. But twist inroving are given such that the fibers hold itsconstituent fibers together and not create hinderduring drafting in Ring frame.

Winding:

To wind the roving on to a suitable bobbinwhich will help handling , transfer and feedingto ring frame. Due to winding , as dia ofbobbin is gradually increased, the speed ofbobbin is continuously decreased with thehelp of building motion so that no breakageof roving for too much tension.

• Building : With the help of building motion ,

the correct or proper shaped package is made

by winding of roving on bobbin in someconsequent process.

• Doffing : To replace empty bobbin at a place

of full bobbin.

Speed frame action

• A= Sliver can

• B= Drafting zone

• C= Flyer

• D= Roving bobbin

• E= Gearing



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Sliver & Roving Ring frame

• Ring frame is the machine where yarn is finally

produced from the roving.

Function of a Ring frame:

• To satisfy the roving to form yarn of the

required count/ fineness of yarn by drafting &

twisting.

• To increase strength.

• To build up the yarn on to bobbin in form of a

suitable package for storage, transportation

and processing.

Operation involved in ring frame

• Creeling

• Roving bobbin is fitted on the top of the m/c

on the creel on both sides of the m/c. creelhelps to freely rotate of roving bobbin and

hold such that roving feed to the drafting zone

on tension.

• Drafting

• Drafting operation reduces wt per unit length

of roving . roving comes from the bobbin arepassed through the drafting.

• Twisting:

• Spiral turns are inserted along the fiber axis . It

increases yarn strength .The traveler which

helps to insert twisting yarn, gets drive

indirectly from spindle.



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Winding:

After twisting the yarns are wound on a suitablepackage , layers of yarn are wound properly areabove another on the package . It should besuitable for unwinding

Building:

For proper size and shape of the package thebobbins are lifted gradually. The resultantbobbins are conical shape full bobbin.

• Doffing:

• After the required length of yarn is wound on

the package , the m/c is stopped . Doffing is

the process of replacing the full bobbin by an

empty bobbin.

Flow diagram of Ring Frame

A= Roving bobbin.

B= Roving guide.

C= Drafting zone.

D= Balloon control ring.

E= Ring.

F= Traveler.

G= Yarn bobbin.

H= Gearing.

Traveler

• Traveler is the most tiny & important part

made by metal through which yarn passes itsway from balloon control ring to the yarn

package. It has no drive of its own. But it is

dragged round by the yarn. During its rotation

it produces twist.

Traveler Ring Frame



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Ring Yarn & Rotor Yarn

If there is a simplex machine in the process of

yarn manufacturing, that is ring yarn. And if

there is no simplex or ring frame, but a rotor

spinning machine which converts sliver to yarn

directly, the yarn manufactured is a rotor yarn.

Rotor spinning machine Y1 = Ring Yarn & Y2= Rotor Yarn

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Spinning [Compatibility Mode]