INTRODUCTION TO TEXTILE MANUFACTURING

(TXT-175)

By: Nirmal Malik

Session # 6

FIBER TO YARN

YARN

Continuous strand of fibers grouped or twisted together and used to construct textile fabrics. Yarns are made from both natural and synthetic fibers

 

PROPERTIES OF YARNS• Appearance• Strength• Uniformity• Flexibility• Pliability• Hand feel• Hairiness

YARN FORMATION FLOW CHART

Fiber Plucking• Manual• Automated

Ginning and Lap Formation• Separation of cotton fibers from its seed.• Manual and Automated.• Reduce moisture content. (Dryers)• Removes foreign matter. (Cleaning equipment)• Improve fiber quality. • Compressed into bales weighing approximately 500 pounds. • Cotton is then moved to a warehouse for storage until it is shipped

to a textile mill for use.

Blow Room ProcessesTASKS OF BLOWROOM

OPENING• Bale opening• Loses hard lumps of fiber.

CLEANING• Removes trash, such as dirt, leaves, burrs and remaining seeds.• Cleaning efficiency should be optimized not maximized

BLENDING• Uniformity of quality.• Even feed of material to the card.

Blow Room Processes

Carding• Heart of the spinning mill• Well carded is half spun.

TASKS OF CARDING• Opening to individual fibers• Removes remaining impurities.• Detangles fibers.• Straightens fibers.• Necessary for all staple fibers.• Arranging the fibers in parallel fashion is called carding.

Carding

Doubling• After carding, several slivers are combined. • This results in a relatively narrow lap of compactly placed

staple fibers. • Narrower sliver is formed.

Combing• For fine yarns.• Additional straightening process• Fine tooth combs straighten the fibers until they are

arranged in parallel fashion and all noils or neps are completely separated from long fibers.

• Not for man made fibers.• Wastes 25% of the card sliver.

TASKS OF COMBING• Smoothens fiber.• Separates long fibers from short fibers.• Arranged in flat bundles.

Drawing• Combining of several slivers for drawing or drafting.• Eliminates irregularities.• Longer and thinner slivers.• Passed through slubber.• First twist is added.• Collected in Roving cans.

Roving• Further drawing out and twisting takes place.• Fine as pencil lead.• Two stages: Intermediate and fine.• Final drawing out process.• Enough twist for holding fibers together but have no tensile

strength.• Change sliver in to thinner sliver for the convenience of

subsequent processes

TASKS OF ROVING• Drafting the sliver in to a roving• Insert a twist in to the roving• Wind the roving in a bobbin

Spinning• The act or process of converting staple or short lengths of

fiber, as cotton or rayon, into continuous yarn or thread.• The extrusion of a solution of fiber forming substances

through holes in a spinneret to form filaments.