Yarn breakage practically found in warping and its

remedy

Yarn breakage practically found in

warping and its remedy

TOPIC

Prepared By : Mazadul Hasan sheshirID: 201000040000813th Batch (session 2009-2013)Department : Wet Processing Technology Email: mazadulhasan@yahoo.comBlog : www. Textilelab.blogspot.com (visit)

Southeast University Department Of Textile

EngineeringI/A 251,252 Tejgaon Dhaka Bangladesh

Prepared By :

SUBMITTED TO

MR. MUZAHIDUR RAHMAN CHOWDHURYLECTURER

SOUTHEAST UNIVERSITYDEPARTMENT OF TEXTILE

SOUTHEAST UNIVERSITYDEPARTMENT OF TEXTILE ENGINEERING

PROJECT OBJECTIVE

Research.Analysis various yarn Fault in Warping process of weavingRemedies of these faults. Selection of raw materials. Product testing.Product Quality improvementReduce wastageTo improve warping efficiencyTo improve yarn quality in spinning

During processing, textile materials are subjected to various stresses not only during the machine operation but also during its stoppage. If these stresses exceeded a given limits it will adversely affect the quality of the produced yarns, fabrics and the efficiency of the machines .In weaving process, the strains on warp ends can lead to thread breaks, loss of quality and shutdowns. Warp breaks still represent major problem especially for today's high-speed weaving machines .Generally, warp yarn break occurs due to excessive tension greater than the strength of the yarn.

INTRODUCTION

YARN FAULTS FOR WARP YARN BREAKAGE

1 SLUBS

2 NEPS

3 SNARL

4 THICK AND THIN PLACES

5 SOFT YARN

6 OIL STAINED YARN

7 CRACKERS

8 BAD PIECING

9 OILY SLUB

11 HAIRINESS

12 FOREIGN MATTERS

13 SPUN IN FLY

14 CORK SCREW YARN

15 STITCHING ON CONE

16 RIBBON WOUND CONE

17 SOFT BUILD CONES

18 BELL SHAPED CONE

19 NOSE BULGINGG

20 COLLAPSED CONE

21 RING SHAPED CONE10 KITTY YARN

SLUBS

An abnormally thick place or lump in yarn showing less twist at that place.

RECTIFICATION1. Machine surfaces to be maintained clean. 2. Rotors are properly maintained.3. Better fiber individualization at cards to be achieved. 4. Optimum top roller pressure &back zone 5. Setting at rotor to be maintained.

EFFECT1. More end breaks in warping process. 2. Damaged fabric appearance.3. Shade variation in dyed fabrics.

CAUSES1. Accumulation of fly and fluff on the machine parts. 2. Poor carding. 3. Defective rotor drafting and bad piecing

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

1

NEPSYarn containing rolled fibre mass, which can be clearly seen on black board at close distance; measurable on USTER imperfection Indicator

RECTIFICATION1. Machine surfaces to be maintained clean. 2. Damaged rotor to be avoided and proper maintained. 3. Better fiber individualization at cards to be achieved.

EFFECT1. Damaged fabric appearance 2. Shade variation in the dyed fabrics 3. An abnormally thick place or lump in yarn showing less twist at that

place is called slubs

CAUSES1. Accumulation of fly and fluff on the machine parts 2. Poor carding. 3. Defective rotor and bad piecing of robot

2

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

SNARL

Yarn with kinks (twisted onto itself) due to insufficient tension after twisting

RECTIFICATION1. Optimum twist to be used for the type of cotton processed 2. Drafting parameters to minimize thin places in the yarn to be

adopted 3. Correct tension weights and slub catcher settings to be employed

at winding

EFFECT1. Entanglement with adjacent ends causing a break 2. Damaged fabric appearance 3. Shade variation in dyed fabrics 4. Mixing of cottons varying widely in fiber lengths and use of

immature cottons

CAUSES1. Higher than normal twist in the yarn 2. Presence of too many long thin places in the yarn

3

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

THICK AND THIN PLACES

Measurable by USTER Imperfection Indicator and observable on appearance

RECTIFICATION1. Defective rotor to be avoided 2. Right the card setting3. Wide variation in the properties of cottons used in the mixing to be

avoided 4. Better fiber individualization at cards to be achieved. Correct

spacers to be utilized

EFFECT1. Damaged fabric appearance 2. Shade variation in dyed fabrics 3. Mixing of cottons varying widely in fiber lengths and use of

immature cottons 4. More breakage in warping

CAUSES1. Non-uniform sliver2. Problem in mixing3. Defect rotor surface4. Mixing of cottons varying widely in fiber lengths and use of

immature cottons

4

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

SOFT YARNYarn which is weak indicating lesser twist

RECTIFICATION1. Proper yarn clearing to be ensured 2. Periodic replacement of rotor to be effected

EFFECT1. More end breaks in subsequent processes such as warping, winding

etc.2. Shade variation in dyed fabrics

CAUSES1. Improper feed in rotor2. Less twist in the yarn 3. Bad rotor

5

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

OIL STAINED YARN

Yarn stained with oil

RECTIFICATION1. Appropriate material handling procedures to be followed 2. Oilers to trained in proper method of lubrication 3. Clean containers to be utilized for material transportation

EFFECT1. Damaged fabric appearance 2. Occurrence of black spot in fabric

CAUSES1. Careless oil in the moving parts, over head pulleys etc2. Piecing made with oily or dirty fingers 3. Careless material handlings

6

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

CRACKERSVery small snarl-like places in the yarn which disappear when pulled with enough tension or Yarn with spring -likeshape

RECTIFICATION1. Feed roller to be maintained 2. Mixing of cottons varying widely in fiber length to be avoided 3. Use of optimum roller settings 4. Use of properly buffed rollers free from eccentricity to be ensured

EFFECT1. More breaks in winding 2. More noticable in polyester and cotton blended yarns

1. CAUSES2. Mixing of cottons of widely differing staple length 3. Closer roller settings 4. Eccentric top feed roller5. Non optimum temperature and relative humidity in the spinning

shed 6. Over spinning of cottons

7

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

BAD PIECING

Unduly thick piecing in yarn caused by over End piecing

RECTIFICATION1. Correctly robot setting and proper repier 2. Separators to be provided 3. Excessive end breaks in spinning to be avoided

EFFECT1. More end breaks in subsequent process 2. Increase in hard waste

CAUSES1. Wrong method of piecing and over end piecing of robot.2. Twisting the ends instead of knotting

8

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

OILY SLUB

Slub in the yarn stained with oil

RECTIFICATION1. Yarn contact surfaces to be kept clean2. Proper segregation of oily waste from process waste3. Oilers to be trained in correct procedures of lubrication

EFFECT1. More end breaks in the warping process 2. Damaged fabric appearance 3. Shade variation in dyed fabrics

CAUSES1. Accumulation of oily fluff on machinery parts 2. Poor methods of lubrication in preparatory processes 3. Negligence in segregating the oily waste from process waste

9

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

KITTY YARN

Presence of black specks of broken seeds, leaf bits and trash in yar

RECTIFICATION1. Cleaning efficiency of blow room and cards to be improved 2. Optimum humidity in the departments to be ensured

EFFECT1. Damaged fabric appearance 2. Production of specks during dyeing 3. Poor performance during winding

CAUSES1. ineffective cleaning in Blow room and cards 2. Use of cottons with high trash and too many seed coat fragments

10

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

HAIRINESS

Protrusion of fiber ends from the main yarn structure

RECTIFICATION1. Proper mixing or blending2. Periodic maintenance of different parts3. Roller settings to be maintained 4. Optimum relative humidity to be maintained in the spinning room5. Wide variation in the properties of cottons used in the mixing to be

avoided

EFFECT1. More breaks in winding and warping2. Formation of holes and stains in cloth

CAUSES1. Use of cottons differing widely in the properties in the same mixing 2. Improper mixing3. Maintaining low relative humidity, closer roller settings and very

high spindle speeds

11

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

HAIRINESS

FOREIGN MATTERS

Metallic parts, jute flannel and other similar foreign matters spun along with yarn

RECTIFICATION1. Improper setting of cleaning zone. 2. Removal of foreign matters(such as jute fibres, colour cloth bits) to

be ensured during preparation of mixing 3. Installation of permanent magnets at proper Places in blow room

lines to be ensured

EFFECT1. reaks during winding and warping2. Formation of holes and stains in cloth

CAUSES1. Damaged fabric appearance 2. Improper preparation of mixings3. Improper setting of foreign material separator in blow room.

12

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

SPUN IN FLY

Fly fluff either spun along with the yarn or loosely embedded on the yarn

RECTIFICATION1. Malfunctioning of humidification plant 2. Machinery surfaces to be kept clean by using roller pickers 3. Fanning by workers to be avoided 4. Performance of over head cleaners and humidification plants to be

closely monitored

EFFECT1. More breaks in winding and warping

CAUSES1. Accumulation of fluff over machine parts 2. Fanning by workers 3. Failure of over head cleaners

13

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

CORK SCREW YARN

It is a double yarn which one yarn is straight and other is coiled over it

RECTIFICATION1. proper maintenance of robot2. proper mixing

EFFECT1. Breaks during winding and warping2. Causes streaks in the fabric

CAUSES1. Bad piecing by robot2. Improper mixing3. Improper feeding

14

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

STITCHING ON CONE

Ends not laid properly on the cone at reversal of yarn path

RECTIFICATION1. Maintenance cone winders to be good 2. Cone holder settings and alignment of tension 3. Brackets with drum to be carried out as frequently as possible

EFFECT1. More end breaks in the subsequent process 2. Excessive yarn waste

CAUSES1. Vibrating and wrongly set cone holder 2. Yarn coils wrapped round the base of cone holder 3. Traverse restrictors fixed at incorrect position 4. Improper alignment of tension brackets with the drum

15

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

RIBBON WOUND CONE

Formation of ribbon like structure on the circumference of the cone

RECTIFICATION1. Over hauling of cone winders to be periodically carried out 2. Anti ribboning mechanism to be checked at frequent interval 3. Free movement of the cone holders to be ensured by proper

lubrication

EFFECT1. Overall density of package is lower 2. Soft packing either at the base or at the nose of cones

CAUSES1. Winding spindle not revolving freely 2. Cone holders incorrectly set 3. Defective settings of cam switch4. Improper traverse motion5. Vibration of cone and traverse

16

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

SOFT BUILD CONES Unduly soft structure of cone

RECTIFICATION1. Unwinding tension to be maintained at 6 to 8% of single yarn

strength

EFFECT1. Overall density of package is lower 2. Soft packing either at the base or at the nose of cones

CAUSES1. Improper alignment of cone holder and traverse2. Insufficient unwinding tension

17

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

BELL SHAPED CONE

Cones which are tightly built at centre, presents a shape of bell

RECTIFICATION1. Quality of cones to be checked at that time of procurement 2. Optimum unwinding tension to be maintained

EFFECT1. Excessive breaks during warping and winding processes

CAUSES1. High yarn tension during winding 2. Cone holders incorrectly set to the winding drum 3. Damages in paper cone centre

18

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

NOSE BULGING

Bulging of bunches of the yarn at the nose of the cones

RECTIFICATION1. Periodical inspection of settings in winding machines 2. Tenters to be instructed to adopt correct work practices 3. Avoiding usage of damaged paper cones

EFFECT1. Slough during warping/unwinding 2. Excessive yarn waste in next process

CAUSES1. Improper setting of cone holders to the winding drum 2. Damaged nose of the paper cones

19

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

COLLAPSED CONE

Collapse of the structure of the cone(paper cone)itself

RECTIFICATION1. Using of poor quality/damaged paper cones should be avoided 2. Winding tenters should be trained by proper work methods 3. Proper material handling devices such as cone transport trolleys to

be used 4. Cone inserts to be used for paper cones

EFFECT1. Yarn breaks in warping process2. Wastage increase in yarn preparation

CAUSES1. Use of poor quality/damaged paper cones2. Poor system of material handling 3. Maintaining non optimum unwinding tension

20

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

RING SHAPED CONE

Formation of ring shaped bulge across the cross section of the cone

RECTIFICATION1. Due to replacement of defective drums and stop motion

wires to be ensured ,2. Periodic inspection of cone holder settings and tension

assembly to be carried out ,

EFFECT1. More end breaks in the subsequent processes 2. Slough off during unwinding

CAUSES1. Incorrect setting of the cone holder 2. Wrong placement tensioners in the tensioning assembly 3. Traverse of yarn affected due to defects in the grooves of the

drum

21

1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21

SL # BEAM LENGTH

WEAK YARN SLOUGHING OFF OVER LAPPING KNOTS/BAD SPLICE SLUBS LOOSE YARN PIGTAIL CUT YARN BAD TIP CONE

1 12400 7 0 0 0 1 0 0 3 0

2 12400 5 0 0 1 2 0 6 0 0

3 12400 6 0 0 1 4 0 3 0 0

4 12400 4 0 0 0 1 2 6 2 3

5 12400 5 0 3 0 2 0 4 0 0

6 6500 2 0 0 1 1 0 2 0 0

7 6500 1 0 1 0 1 0 0 0 0

8 12400 4 0 2 0 1 0 3 1 0

9 6550 3 0 0 0 1 0 0 1 0

10 6550 3 0 0 1 1 0 0 0 0

11 6550 5 0 1 0 1 1 4 0 0

12 5150 2 0 0 0 0 0 0 0 0

13 6550 3 0 2 0 0 0 0 0 0

14 6550 5 0 0 0 1 0 0 0 0

15 12400 5 0 0 1 2 0 0 0 3

16 12400 6 0 0 0 3 0 5 0 0

17 12400 4 0 2 0 0 0 4 0 0

18 12400 4 0 0 0 2 1 4 1 1

19 12400 5 0 1 0 0 0 3 0 0

20 12400 5 0 0 0 1 0 2 0 0

Total 199700 84 0 12 5 25 4 46 8 7

Table-1: Data for 20/1 Ne Yarn breakage in Warping

EXPERIMANTAL DATA

SL # BEAM LENGTH WEAK YARN SLOUGHING OFF OVER LAPPING KNOTS/BAD SPLICE

SLUBS LOOSE YARN PIGTAIL CUT YARN BAD TIP CONE

1 12400 4 0 1 0 1 0 2 3 0

2 12400 2 0 0 0 2 1 1 0 0

3 12400 1 0 1 1 1 0 3 0 1

4 12400 2 0 0 0 1 2 1 2 0

5 12400 3 0 1 2 2 0 4 0 0

6 6500 2 0 0 0 1 0 2 2 0

7 6500 1 0 1 2 1 0 1 0 1

8 12400 3 0 2 0 1 0 1 1 1

9 6550 3 0 0 1 2 0 2 1 0

10 6550 1 0 2 0 0 0 0 0 1

11 6550 4 0 1 0 1 1 2 0 0

12 6550 1 0 0 0 0 0 1 4 0

13 6550 1 0 1 0 2 0 0 0 0

14 6550 1 0 0 1 1 0 2 0 0

15 6550 1 0 3 0 2 0 0 0 0

16 6550 1 0 0 0 0 0 2 0 0

17 6550 3 0 1 0 1 0 1 0 0

18 6550 4 0 0 1 0 0 4 0 1

19 6550 1 0 1 0 0 0 1 0 0

20 6550 5 0 0 1 1 0 2 0 0

Total 166000 44 0 15 9 20 4 32 13 5

Table-2: Data for 10/1 Ne Yarn breakages in Warping

EXPERIMANTAL DATA

SL # BEAM LENGTH WEAK YARN SLOUGHING OFF OVER LAPPING KNOTS/BAD SPLICE

SLUBS LOOSE YARN PIGTAIL CUT YARN BAD TIP CONE

1 12400 5 0 1 0 0 0 2 2 0

2 12400 4 0 0 0 1 0 3 0 0

3 12400 4 0 1 1 4 0 2 0 0

4 12400 3 0 1 0 1 1 2 1 2

5 12400 4 0 0 0 0 0 4 0 0

6 12400 1 0 1 0 1 1 2 0 2

7 12400 1 0 0 1 1 0 0 0 0

8 12400 3 0 0 0 2 0 1 1 1

9 12400 2 0 1 0 1 2 2 1 0

10 12400 2 0 0 0 1 0 0 0 1

11 12400 4 0 1 0 1 0 3 1 0

12 12400 2 0 0 1 0 0 0 0 1

13 12400 1 0 0 0 0 0 0 0 1

14 12400 2 0 1 0 1 0 1 1 0

15 12400 3 0 0 0 2 0 0 0 1

16 12400 4 0 0 0 2 0 4 0 0

17 12400 4 0 0 1 0 0 3 0 0

18 12400 5 0 0 0 1 0 3 1 1

19 12400 1 0 1 0 0 0 3 0 0

20 12400 3 0 0 0 1 0 1 0 0

248000 58 0 8 4 20 4 36 8 10

Table-3: Data for 16/1 Ne Yarn breakages in Warping

EXPERIMANTAL DATA

From Table-1: Data for 20 Ne

0

10

20

30

40

50

60

70

80

90

Fig: Effect of different types of yarn faults in warping for 20/1 count carded yarn

DATA ANALYSISN

o of

bre

akag

e WEAK YARN 44%

OVER LAPPING6%

KNOTS/BAD SPLICE3%

SLUBS13%

LOOSE YARN

2%

PIGTAIL24%

CUT YARN4%

BAD TIP CONE4%

From Table-2: Data for 10 Ne

WEA

K YARN

SLOUGHING O

FF

OVER LA

PPING

KNOTS/B

AD SPLIC

ESLU

BS

LOOSE

YARN

PIGTAIL

CUT YARN

BAD TIP CONE

0

5

10

15

20

25

30

35

40

45

50

Fig: Effect of different types of yarn faults in warping for 10/1 count carded yarn

DATA ANALYSISN

o of

bre

akag

e

WEAK YARN 31%

OVER LAPPING

11%KNOTS/BAD SPLICE

6%

SLUBS14%

LOOSE YARN

3%

PIGTAIL23%

CUT YARN9%

BAD TIP CONE4%

From Table-2: Data for 16 Ne

0

10

20

30

40

50

60

70

Fig: Effect of different types of yarn faults in warping for 16/1 count carded yarn

WEAK YARN 39%

OVER LAP-PING5%KNOTS/BAD SPLICE

3%

SLUBS14%

LOOSE YARN

3%

PIGTAIL24%

CUT YARN

5%

BAD TIP CONE7%

No

of b

reak

age

DATA ANALYSIS

1. Found different types of yarn and package faults from warping. the main cases of warp yarn breakage is improper raw material mixing and cleaning in spinning because majority percentage of yarn faults is weak yarn.

2. The number of breaks varied directly with the yarn count.3. Improper maintenance of spinning.

KEY FINDINGS

1. We had a very limited time. In spite of my willing to study more details it was not possible to do so.

2. This while process is not possible to bind such a small frame as this report, hence our effort spent on summarizing them

3. We cannot manage data perfectly. Some fault cannot recovery such as parallel winding which is occur from robotic miss action in rotor spinning ,mixing ratio is not perfectly, large amount of wastage uses as for the rate of beating action is high and create more amount of neps which neps carding cannot remove perfectly. If Feed material is quality full then produce goods also be good.

LIMITATION

Considering the objective of the work, a systematic investigation on ‘Yarn Faults in warping and its Remedies’ were performed in the training period. All the activities had been done maintaining in sequence of the machinery of the production. From the thorough investigation it is seen that the following faults are yarn faults, yarn package faults, mechanical faults in spinning. Reducing warp breaks on warping machinesuplift the efficiency of this process and the efficiency of weaving machines, and finally enhances the quality of yarns and produced fabrics. Yarn faults tend to not fulfill the target of production of a industry. As a result the production capacity of these industries falls significantly. These are the common faults which I have tried to find out the causes & their Remedies against them.

CONCLUSION

1. Yarn Manufacturing TechnologyLink : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808

2. Fabric Manufacturing TechnologyLink : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605

3. Garments Manufacturing TechnologyLink : http://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126

3. Wet processing TechnologyLink : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404

4. Fashion-Design-and-TechnologyLink : http://www.facebook.com/pages/Fashion-Design-and-Technology/587655294583875?ref=ts&fref=ts

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