Basic Things of Spinning, Weaving, Dyeing and Garments

Basic of Textile Engineering! Spinning, Weaving, Knitting, Dyeing, Printing, Finishing, Garment or Apparel are the Parent sections of the Textile Mill. In several of Textile Thesis published in different magazine are found the contemporary articles about the modern mechanism and articles about Spinning, Weaving, Dyeing and Garments Technology. But sometime we need to know about the fundamentals of Textile. Very few of the thesis and articles contain it. So I will try my best to provide you the basic of Textile. And of course I will include everything about Textile successively. So let me start now………
Textile Fibre In Textile industry we have to work with fibre and fibre related components. That means without fibre it’s not possible to make a yarn. If yarn is not possible, making fabric and garments are impossible. So it is seen that Fibre is very important. First of all I will give you some basic knowledge about Textile Fibre. Later… I will tell you elaborately in the certain post that is collected from the various thesis and magazine. Fibres are used to production of Yarn and Fabric called Textile Fibres.
It is essential to know that a Textile Fibre must have some definite characteristics.
These are- 1. Minimum Length. It should be 100 times of long than its diameter. 2. Strength 3. Elongation and Elasticity 4. Moisture absorbency 5. Tendency to be twisted. 6. Fibre Fineness.
Classification of Textile Fibre: 1. Natural Fibre 2. Man-made Fibre Natural Fibre are derived from a) Tree i,e, Seed, Leaf, Bast Fibres b) Animal i,e, Silk, Wool c) Mineral i,e, Asbestos d) Metal Fibre i,e, Gold, Silver Mane-made Fibre are derived from a) Regenerated–Cellulose Base, Protein Base, Mineral Base. b) Synthetic—Organic Base (Polyamide, Polyester, Thermoplastic, Hydrocarbons), Inorganic Base

Textile Classes According To It’s Manufacturing Processing Methods

The whole textile processing; from the fibre to garment are classified in several segments. The classes are 1. Spinning 2. Weaving or Knitting 3. Dyeing or Printing 4. Finishing 5. Garments or Apparels.

The short descriptions of Textile Classes:

Spinning:

It is very initial process amongst the Textile Classes. In spinning section fibre are processed in order to make yarn. Several spinning machines are used here to make a fibre to yarn completely.

Weaving or Knitting:

Two types of fabric are produced in Textile. One is Woven Fabric, another is Knit Fabric. Woven fabric is produced by looms with the interlacement of warp and weft yarns. In knitting section the knit fabric are produced with the loops of yarns. Loops of yarns are bound together by passing one series of loop through other series of loops and form the fabric. Textile Knitting follows some knit structure.

Dyeing or Printing:

Textile Dyeing is a process where the fabric is dyed by different dyestuff mixing with water and other chemicals in a certain temperature. It is the main part of textile classes in the basis of textile trade issue. On the other hand, Printing is done by following a pre-determined design and printing paste is used here. Thickener or gum or printing rubber gum are used to fix the print paste on the fabric according to design.

Finishing:

Finishing is one of the important classes of textiles, where all of the textile processes holds the good appearance. Mercerization, Calendaring and done here.

Garments or Apparels:

After getting a woven or knit fabric it is the time to make the fabric to be wearable. Garments section takes the responsibility to do this. In apparel section the fabric is cut according to marker, pattern and then sewed.

Fibres Mixing & Blending Procedures for Textile Spinning blowroom section

What is Mixing in Spinning Blowroom:

If different grade of same fibres are kept together, then it is called mixing.

Types of Mixing:

1. volume mixing
2. weight mixing
3. hand stock mixing
4. bin mixing
5. mixing by hopper
6. lap mixing
7. card mixing
8. sliver mixing

Blending:

When different fibres of same or different grades are kept together, then it is called blending.

Types of Blending:

1. hand stock blending
2. bin blending
3. lap blending
4. card blending
5. draw frame blending

Why Fiber Mixing & Fiber Blending Is Done In Spinning Blowroom

You have already knew the difference between Mixing and Blending in spinning. But what is the benefits of Mixing & Blending? Well Mixing is done in spinning mill in order to reduce the cost of fibers. Suppose buyers have ordered a higher class cotton yarn from you. But if you spend all of high class cotton fibers to make that yarn; your overall price will be higher which might not be too much profitable. So, if you mix some other grade of fibers with the higher graded same fibers; then your overall cost will be lower and this its profitable in the sense of business. Now what is the benefits of Blending?  Well, blending is to mix several types of fibers with different grades in different versions. These days, we wear various trousers and sandal shirts where we see it is labeled as 60% Cotton and 40% Polyester. Here this is a blended fabric as Cotton & Polyester both have been used to make this cloth. You know, a fabric with 100% cotton might be too much costly and this is why some portion of Polyester is being used to make the price of this apparel reasonable.

What is Yarn Count |How to Find Out Direct, Indirect, Tex, Denier Count

Here is the process terms on how to find out a yarn count and the basic things of count:

Yarn Count:

Count is the numerical expression of coarseness or fineness of the yarn.

Types of Yarn Count:

Count is basically two types- 1. Direct Count 2. Indirect Count.

Direct Count:

In direct system length unit is fixed but weight unit is variable. In this system the weight of fixed length of yarn is calculated and expressed by different weiht unit especially gram. In this system yarn will be coarser if the number is increased. Direct system is classified normally into two- 1. Denier 2. Tex.

Denier Yarn Count System:

In this system, the length of yarn is 9000 m. if weight of 9000 m length of yarn is 40 gram the count of that yarn will be 40 denier.

Tex:

In tex system weight of 1000 m length of yarn is considered and expressed by gram. Such as, if weight of 1000m length of yarn is 20 gram, the count of that yarn will be 20 tex.

Lbs/ Spindle:

Weight of 14,400 yds jute yarn is calculated and expressed by lbs. That means, if 14,400 yds jute yarn weight is 8 lbs, the count of that jute yarn will be 8 lbs/ spindle.

Indirect Count:

In indirect system the count is classified into two groups. One is English cotton count system and another is Metric system.

English Cotton Count System:

Here weight unit is fixed but length unit is variable. In this system the number of hank of 840 yds yarn in one lbs is the number of English cotton count. Higher the number of count, finer the yarn. the lower the number of count, the coarser the yarn. It is expressed by (Ne).

Metric System:

In this count system number of hank of 560 yds yarn in one kg is the number of metric count. It is expressed by (Nm).

Blowroom | Blow-room & Blending Importance in Textile Spinning

In this post I will tell you about the very first section of making a Textile Yarn named “Blowroom”. The blowroom is “must needed” type section of a spinning factory where different type of works are done like fibre opening, cleaning and some other further acts which is needed to boost up the yarn quality.

What is Spinning Blowroom:

Definition of Blowroom: Blowroom consists a number of machines used on succession to open and clean the cotton fibre. About 40% to 70% trash is removed in blow-room section.

Objects of Blow-room:

1. Opening:
a) To open the compressed bales of fibres.
b) To make the cotton tuft as small as far as possible.
2. Cleaning:
To remove dirt, dust, broken seeds, broken leaves, and other foreign materials from the fibre.
3. Mixing & Blending:
To make good value of yarn and to decrease production cost mixing and blending is done.
4. Lap or flocks formation:
To transfer opened and cleaned fibre into sheet form of definite width and length which is called lap or in modern system directly feed to the carding machine into flocks form.

Importance of Blowroom in Yarn Spinning:

1. Blowroom is installed to achieve uniform quality.
2. to improve processing performance.
3. to reduce and control production cost.
4. to meet end use requirement
5. to facilitate the cotton for regaining its moisture content lost during boiling.

Besides the factors mentioned above, you may find more features of textile spinning’s blowroom. Wish you good textile spinning journey.

General Concept About Jute Spinning Process || Batching To Winding

Jute fiber is the golden fiber. This fiber is used for manufacturing different types of environment friendly products. Day by day the demands of jute goods are increasing rapidly. Lots of jute mills are established to satisfy the present requirement of jute goods. So, one should have the knowledge about the processing line up of jute products manufacturing.

Two types of jute mills are generally established, one types produces yarn only and others manufacturing both yarn and finished goods (Hessian, Sacking or CBC). Here I like to give concept about spinning unit which is started from batching unit to winding unit.

Spinning division is divided into following:

• Batching


• Carding


• Drawing


• Spinning


• Winding

Batching: Batching is the first section of spinning division. Raw jute is entered in this section which is processed here by the help of softener or spreader machine. Emulsion is applied on jute by this machine. This emulsion is the combination of JBO, Water and Emulsifier. Then, jute fiber is placed for pilling.

Purpose of batch section:

1. To produce qualified yarn.


2. To control the batch value.

Carding: Carding is the second section of jute spinning. In the mill, drawing and carding section is combindly called as preparing section. Carding is called the heart of spinning. Main objects of carding are to produce straight and parallel fiber, to remove dust and small fiber.

Two types of carding machines are used. They are-

1. Breaker card: Breaker card is used to produce sliver roll to facilities next process. Long jute is feed in the feeding side of the breaker card. In breaker card, 32 lbs are feed within 1 clock length.


2. Finisher card: finisher card is used to make more parallel the fibers. It is used to select a batch for produce selected count. Two types of finisher card are available. One is half circular another is full circular machine.

Draw frame: Draw frame is used to reduce weight in per unit length. By using drawing roller, length of finisher roll sliver is elongated. The setting of drawing unit is varying for CBC, Hessian and Sacking unit. Normally, 1^st drawing, 2^nd drawing and 3^rd drawing are used for CBC and Hessian. On the other hand, 1^st drawing and finisher drawing is used for Sacking Weft unit.

Spinning: Spinning frame is used to produce yarn from drawn sliver. Sliver is feed to drafting zone and twisting is done by the flyer. Twisted yarn is worned on the bobbin. Generally, two types of draft is use-

1. Apron draft


2. Slip draft

Warp spinning frame (4.25”) contains 100 spindles (CBC, Hessian warp & weft and Sacking Warp). 5.25” spinning frame is used for sacking weft side, which contains 80 spindles.

Different count yarn is produced in the spinning frame. Follings are the range of yarn count:

3.5-6 lbs/spyndle is for fine yarn.

6.5-8.5 lbs/spyndle is for CBC yarn.

7-9 lbs/spyndle is for hessian warp yarn.

7-12 lbs/spyndle is for hessian weft yarn.

8-10 lbs/spyndle is for sacking warp yarn.

20-40 lbs/spyndle is for sacking weft yarn.

Winding: Winding is the last section of jute spinning. Two types of winding is use, they are-

1. Cop Winding (produce weft yarn)


2. Spool or roll winding (produce warp yarn).

After winding section, twin yarn is produced. Spool and cop are delivered into weaving section to produce finished jute goods.

So, that’s the short concept about jute spinning.

Process Flow Chart of Combed Yarn Manufacturing

Process Flowchart of Combed Yarn Manufacturing:

Combed yarn is more precise than card yarn. Here is the process flowchart of Combed Yarn.

I said it before that the Carded Yarn needs less steps to follow to make a yarn than the Combed yarn. The main purpose of Combed yarn manufacturing is to create a yarn which is highly finer and highly qualified.

Here i will give you a chart from where you will be able to know about How A Yarn is made by the combed yarn manufacturing process”.

Input ———Processing Machineries ———-Output

Raw Cotton>>>>>>>>Blow Room>>>>>>Lap

Lap>>>>>>>>>>>Carding>>>>>>>>>>>>Carded Sliver

Carded Sliver>>>>Pre-Comb Drawing>>>>>Pre-comb drawn sliver

Pre-comb Drawn Sliver>>>>Super Lap Former>>Mini Lap

Mini Lap>>>>>>Comber>>>>>>Combed Sliver

Combed Sliver>>>>>>Post Comb Drawing>>>>>>Post Comb Drawn Sliver

Post Comb Drawn Sliver>>>>>Speed Frame/ Simplex>>>>>Roving

Roving>>>>>>>>>>>Ring Frame>>>>>>>>>Yarn

Yarn>>>>>>>>>>>>>Winding>>>>>>>>>Yarn in large package

The Combed manufacturing process flowchart has been mentioned above is followed by the textile mills.

What is Yarn Geometry, Classification & Designation

Basic of Textile Engineering! Spinning, Weaving, Knitting, Dyeing, Printing, Finishing, Garment or Apparel are the Parent sections of the Textile Mill. In several of Textile Thesis published in different magazine are found the contemporary articles about the modern mechanism and articles about Spinning, Weaving, Dyeing and Garments Technology. But sometime we need to know about the fundamentals of Textile. Very few of the thesis and articles contain it. So I will try my best to provide you the basic of Textile. And of course I will include everything about Textile successively. So let me start now………

Textile Fibre In Textile industry we have to work with fibre and fibre related components. That means without fibre it’s not possible to make a yarn. If yarn is not possible, making fabric and garments are impossible. So it is seen that Fibre is very important. First of all I will give you some basic knowledge about Textile Fibre. Later… I will tell you elaborately in the certain post that is collected from the various thesis and magazine. Fibres are used to production of Yarn and Fabric called Textile Fibres.

It is essential to know that a Textile Fibre must have some definite characteristics.

These are- 1. Minimum Length. It should be 100 times of long than its diameter. 2. Strength 3. Elongation and Elasticity 4. Moisture absorbency 5. Tendency to be twisted. 6. Fibre Fineness.

Classification of Textile Fibre: 1. Natural Fibre 2. Man-made Fibre Natural Fibre are derived from a) Tree i,e, Seed, Leaf, Bast Fibres b) Animal i,e, Silk, Wool c) Mineral i,e, Asbestos d) Metal Fibre i,e, Gold, Silver Mane-made Fibre are derived from a) Regenerated–Cellulose Base, Protein Base, Mineral Base. b) Synthetic—Organic Base (Polyamide, Polyester, Thermoplastic, Hydrocarbons), Inorganic Base

Types of Cotton Yarn Produced In Spinning Mills | Cotton Yarn

Cotton yarns are the most produced yarn of the world. Mainly cotton yarns are divided into three types as carded, combed and rotor yarn depending on the manufacturing techniques. There are various types of cotton yarns are produced by different spinning machine. Each having its own characteristics. These characteristics vary according to the construction and treatment given in the manufacture of the yarn.



Types of Cotton Yarn Produced in Spinning Mills: In spinning mill; various types of cotton yarns are produced from the cotton fiber. Followings are the most common cotton yarn types.

1. Fly Yarn


2. Cabled Yarn


3. Doubled Yarn


4. Novelty Yarn


5. Slub Yarn


6. Flake Yarn


7. Spiral Yarn


8. Ratine Yarn


9. Loop or Curl Yarn


10. Knot or Spot Yarn


11. Chenille yarn

All of the above yarns are used in the knit or woven fabric manufacturing process.

List Of Machineries Used For Cotton Yarn Preparation | Spinning Process

In spinning process; various types of textile machineries are used for cotton yarn preparation. Cotton fibers are spanned for preparing rotor, carded and combed yarn. Each of the yarn is prepared in various techniques. The sequence of machineries used for yarn preparation is differing from one to another.



List Of Machineries Used For Cotton Yarn Preparation: Generally cotton fibers are supplied to the spinning mill as the bale form. From the bale form to the yarn formation a lots of spinning machineries are used. Here, I have listed the common spinning machineries used for making cotton yarn, which facilities the next fabric preparation process. List of machineries are given below:

• Blow Room’s Machineries: Following machineries are used in blow room line for making yarns:

1. Mixing or Blending Machine


2. Hopper bale breaker or Hopper bale opener


3. Axo flow cleaner


4. Crighton opener or Vertical opener


5. Step cleaner or Ultra cleaner


6. S.R.L.L cleaner


7. R.N beater


8. Porcupine opener


9. Mono cylinder beater


10. Hopper feeder


11. Bladed beater


12. Krishner beater


13. Scutcher or Lap former

• Carding Machine


• Draw Frame


• Lap Former


• Comber


• Roving Frame or Simplex


• Spinning Frame


• Winding Machine

Various types of spinning machineries manufacturers manufacture spinning machine. All of are not in same quality and price. So, choose your requries one which is suitable for your yarn preperation.

What Is Spinning? | Types Of Spinning Process

Spinning is the first steps of textile product processing. The process of making yarns from the textile fiber is called spinning. There are various types of spinning methods for producing various types of yarn. If we notice, we will see that the cotton fibers are converted into carded yarn, combed yarn and rotor yarn. For producing this three types of cotton yarn, spinning methods also different.



Types of Spinning Process: Spinning process is varying depending on the fiber types which we want to process. There are different methods of spinning for yarn preparation. Such as-

• For Staple Yarn:

1. Ring Spinning


2. Rotor Spinning


3. Friction Spinning


4. Self Twist Spinning


5. Electro-Static Spinning


6. Vortex Spinning


7. Air Jet Spinning


8. Twist Less Spinning

• For Spinning Filament Yarn:

1. Wet Spinning


2. Dry Spinning


3. Melt Spinning


4. Bi-Component Spinning


5. Film Splitting Reaction Spinning

• For Integrated Multi-Component Yarns:

1. Integrated Composite Spinning


2. Cover Spun


3. Selfil Yarn Spinning


4. Acro dynamic Spinning

By the spinning process; various counted yarns are produces. Spinning frames are set for producing specific counted yarn.

Simplex Frame | Functions Of Simplex/Roving Frame/Speed Frame

In yarn manufacturing process; simplex or speed frame is situated after the comber. The sliver which is produced from the comber that is thicker and it is not suitable to feed into the ring frame directly to produce yarn. For this reason, drawn sliver is treated before entering into the ring frame. An intermediate process is done before ring frame. That process is done by simplex or speed frame. This roving frame converted the thick drawn sliver into thin sliver with low twist and produce fine roving which is suitable to produce yarn by feeding into the ring or others. Followings are the principle of roving frame.

Drawn sliver→ Speed frame/Roving frame/Simplex →   Roving

↓

Roving →        Ring frame →          Yarn

In this process drawn sliver is input and fine roving is output. This roving is feed into ring frame for yarn production. It is noted that, simplex is essential for the production of cotton yarn in case of ring spinning by ring spinning system.



Functions of Simplex Frame: Various types of objectives are achieved by the simplex frame like carding or combing action. Followings are the main functions of simplex or roving or speed frame.

1. Creeling: Creeling is the first objective of simplex frame arrangement. By the creeling, small amount of draft is applied to the drawn sliver.


2. Drafting: Attenuation of drawn sliver to produce required amount of roving by drafting. Thick drawn sliver is converted into thin roving by the drafting system.


3. Twisting: Small amount of twist is inserted in the drafted stand of fibers by the twisting. The amount of twist is very low.


4. Building: Build the roving on to bobbin such a form which will facilitate unwinding handling and transfer to the next process.


5. Winding: Produced or twisted roving is wound on the bobbin by the winding process. This bobbin is feed to the ring frame and this bobbin accelerates the next process. So, it is important.


6. Doffing: It is the optional functions of speed frame. Doffing could be done manually or automatically.

So, simplex frame plays an important role in the spinning process. Various types of yarn faults could be appear for the wrong drafting or twisting. For this reason, the operator should be careful during the process. Machine parameters should be set properly for producing specific count yarn.

Proper roving can give better yarn properties. So, we should be care full about the selection of simplex or speed frame or roving frame.

Combing Process || Objectives And Contribution Of Combing In Spinning Technology

In spinning technology; combing is considered as an additional process. If we want to produce finer yarn then we need to pass combing process. Combed yarn is produce in this method. After carding process combing is done simultaneously to produce combed yarn. Combing process is done to upgrade the quality of the raw materials. Combing is done by the comber.



Objectives of combing process: After carding action, combing is done for produce finer yarn or high count yarn in English counting system. Following objectives are achieved by the combing process.

1. To remove short fibers before a pre-selected length.


2. Fiber parallelization is improved by the combing action.


3. Various types of foreign materials and impurities are removed by the combing action.


4. Neps are eliminated by the combing action.

Contribution of combing: Combing action improves different types of fiber properties as well as yarn quality. Followings are the contribution of combing.

1. Spinning value (count of yarn) is improved by the combing action.


2. Yarn strength is improved by the combing.


3. Combing reduces hairiness of the yarn.


4. It accelerates the next process.


5. Combing reduces imperfection like- neps, thick and thin places of the yarn.


6. Better twist distribution is achieved by the combing action.


7. Cleaner yarn is achieved by the combing process.


8. It improves the smoothness of the yarn.


9. Lustrous yarn is achieved by the combing process.

Combed yarn is generally used for produce knitted and woven fabrics. Fineness of the fabric depends on the properties of the yarn. Better quality yarn can give better knitting or weaving efficiency. Most important is that, yarn should have evenness, should be regular in diameter and CV% should be low and quality ration should be high.

Yarn properties also affect the dyeing efficiency. So, yarn should be free from different types of yarn faults.

What is Tensioning Device | Effects Of Tensioning Device | Requirements Of Tensioning Device

In winding process; yarns are transferred from one package to another. During winding process; the tension of the yarns should be in controlled, otherwise yarn breakage will be increased for high tension or low tension will hampered the winding operation. So, tensioning device plays an important role in winding.



During the time of winding; to give proper tension to the yarn is the object of a tension device. Tensioning device is used to control the tension of the yarn. If the yarns are irregular or thick or thin place is in yarn then it have chance to break down due to over tension.

Effects of tensioning device: During winding, tension is applied on the yarn stand. Tension may be high or low. Tension has some effects, which is required to know. Followings are the effects of tensioning device.

• Too high tension can damage the yarn. Breakage rate may be greater due to high tension. Too high tension also changes the elongation property.


• Too low tension can lead to unstable or loose package which will not unwind clearly.


• Variation in yarn tension in different parts of wound package can cause undesirable package.


• Tension also effect on manmade filament yarn. It can cause molecular changed in their physical structure. It also effects on the color shading.


• For too high tension, staple or spun yarn may break at thin place.

Requirements of tensioning device: There have different factors which influence the selection of tensioner. Followings are the requirements of tensioning device.

• The tension must be reliable to control uniform tension.


• Tensioning device must be threaded.


• It must neither introduce non magnify tension variation.


• It must not introduce difference in twist.


• It must not be affected by wear.


• It must be easily adjustable.


• It must not be affected by presence of oil or dirt.


• It must not encourage the collection of dirt and lint.


• It must be capable of easy cleaning.


• The operating surfaces must be smooth.


• It must be inexpensive or cheap.


• It must be simple in design or operation.


• It must not be cause of yarn damage.


• Tensioning device should be like that it would not affect the properties of the yarn.

So, design of the tensioning device should be perfect.

 

Yarn Guides || Types Of Yarn Guides Used In Textile Industry

Yarn guides are the one of the helping instrument to control the yarn path. Yarn guides are required to perform the winding or unwinding process properly. In every operation where yarns are transferred from one package to another, yarn guides are required there. Yarn guides are used during winding, warping, beaming and weaving process.



In winding and unwinding it is necessary to control the yarn path. For side withdrawal it is possible for the yarn to pass along a smooth varying yarn path. But for over end withdrawal the yarn must be controlled by placing guides along the yarn path.

Yarn guides are normally made of hard smooth steel or ceramic. Different yarn guides are made by the yarn guide manufacturer. Yarn guides should be perfect in size otherwise winding process will be hampered. The yarn path should keep clean during withdrawal of the yarn. Yarn cleaner also placed along the yarn path.

Types of yarn guides: There are two types of yarn guides which are used during withdrawal or unwithdrawal of yarn. They are:

• A yarn end is required for threading: It takes extra time in threading. So, speed of operation is increased. The yarn experienced more friction. Shape of the yarn guides are may be as follow:

1. Ceramic insert type


2. Trumpet type


3. Bush or roller type

• A yarn end is not required for threading: Threading is very easy. So, the speed of operation increased. The yarn experienced less friction. Shape of the yarn guides may be as follow:

1. Pig tail


2. Slotted type


3. Post type

So, yarn guide plays an important role in winding operation. We should be careful during the selection of yarn guide.

Yarn Cleaner | Types Of Yarn Cleaner | Use Of Yarn Cleaner

Yarn is the final product of spinning process. Yarns may be carded, combed or rotor. Any types of yarn which is produced in spinning that may have some faults; it requires removing for getting better weaving efficiency. To perform this, a device is used that is called yarn cleaner.



Yarn cleaner: Yarn cleaner is the device which is used to remove the faults of yarn. Yarn cleaner is used to increase the yarn quality and weaving efficiency. Following yarn faults are removed by yarn cleaner.

• Thick and thin place in the yarn.


• Slubs and neps of yarn.


• Loose fibers of the yarn.


• Foreign materials of the yarn.

During operation it should ensure that the yarn cleaner is clean otherwise their contamination with dust may cause additional knots. So, we should keep clean the yarn cleaning device.

Types of yarn cleaner: There are different types of cleaning device which is used for clean the yarn. Followings are the most used yarn cleaning device.

1. Ordinary metal sheet type


2. Comb type


3. Ordinary metal slit type


4. Blade type


5. Disc type


6. V-type


7. Capacitance type


8. Solar type

Use of yarn cleaner: The scope of yarn cleaner use is one of the most important factors. Yarn cleaner is used for the following cases.

• Before the pirn winding.


• Before the beaming of warp or weavers beam.


• Mounted on the winders behind the tension device.

So, yarn cleaning device is essential for remove unwanted faults or defects of yarn. Various textile machine manufacturing companies are produced yarn cleaning device. Choose your favorite one from there.

Features Of Precision And Non Precision Winding | Comparison Between Precision And Non Precision Winding

Winding is the process of transferring yarn from one spinning bobbin to another suitable package. Winding is classified in different ways. Depending on the density of the package; winding is classified as

1. Precision winding


2. Non precision winding

Precision winding: When the successive coils of yarn on a package and laid close together and parallel or nearly parallel with each other, then it is possible to produce a very dense package in which maximum amount of yarn is stored in a given volume is called precision winding.

Features of precision winding: There are a lot of features of precision winding. Followings are the features of precision winding:

• Reciprocating motion is used for wound the package.


• Patterning or robbing causes damage of package.


• It contains more yarn.


• Its stability is low.


• It is hard and more compact.


• Flange may be used.


• Packages are dense.


• Unwinding process rate is low and process is harder.


• The wound coil is arranged parallel or near parallel.

Non precision winding: This type of package consists of single thread which is laid on the package at appreciable helix angle, so that the large cross one another and give stability and a less dense package is produced is called non precision winding.

Features of non precision winding: Low density package is produced in non precision winding. Followings are the features of non precision winding.

• Only one coil is used.


• Winding is done in cross angle.


• Minimum yarn is stored.


• Packages are soft and less compact.


• Stability of this package is high.


• Low density package.


• Flanged is not necessary.


• Unwinding rate is high and process is easier.

Difference between Precision Winding and Non Precision Winding

Precision Winding	Non Precision Winding
The wound coil is arranged parallel or near parallel.	The coil is cross wise wound.
The yarn density of the yarn package is high.	The yarn density of the yarn package is low.
The stability of the package is low.	The stability of the package is high.
The unwinding rate is low and process is harder.	The unwinding rate is high and process is easier.
The yarn package is hard and more compact.	The yarn package is soft and less compact.
The flanged package may be used.	The package is not necessary to be flanged.
Difficult to dye, only surface of the yarn is dyed properly.	Easy to dye.
process is less hairy.	Process is more hairy.

After winding, warping and sizing is done for make a weavers beam.

Faults And Defects In Winding | Wastage In Winding

In winding; transformation of spinning bobbin yarn to the yarn package is done by manually for this reason it has chance to occur some faults. During winding, different types of winding defects are found. Followings are the main faults or defects of winding.

Faults and defects of winding:

• If patches are formed on the yarn.


• If winding speed is incorrect.


• Variation of yarn tension.


• If packages are dirty.


• Incorrect shape of yarn package.


• Too much knots in the yarn.


• Excessive full bobbin.


• Piecing up.


• Over lapping.


• Two end winding.


• Mixing yarns of different linear density.


• Pattern winding which is the result of the coincidence.


• Greasy and dirty yarn.


• Poor yarn cleaning and snarling.

So, during winding process; production officer should be concern about the defects and faults of winding.

Wastage in winding: In winding section; wastage is produced due to different causes. Followings are the main causes of winding wastage.

• Due to knots.


• Ends remaining after tying.


• Yarn slough off.


• Remains of coil on the yarn package.


• Short ends dropped at threading.


• Greasy and dirty yarn.


• Workers negligence.

The amount of wastage depends upon the size of the spinning bobbin and breakage rate. With the increase of the package size and reduced of breakage rate of yarn, wastage of winding is reduced.

So, we should reduce the wastage of winding.

What Is Winding | Objectives And Requirements of Winding Process

In spinning process; winding are the last steps. After winding yarn packages are used for making woven or knitted fabrics. Winding process can be defined as the transfer of spinning yarn from one package to another large package (cone, spool, pirn etc). On the other hand it can be defined as the transfer of yarn from ring bobbin, hanks etc into a convenient form of package containing considerable long length of yarn. A process of accumulating yarn on a package to facilitate the next process is called as winding.



Objectives of winding: Winding process has some objectives which are given as below:

• To transfer yarn from spinning bobbin package to a convenient yarn package.


• To improve the quality of yarn.


• To get suitable yarn package.


• To get a quality fabric.


• To get good warp yarn.


• To empty the spinner’s bobbin so that it can be used again.


• To remove dust and clean the yarn.


• To reduce labor cost.


• To store the yarn.


• To improve the efficiency of yarn for next process.

Requirements of winding: Winding process should be accurate for accelarate the next fabric manufacturing process. Winding process should fulfill the following requirements.

• Winding process should be easy.


• Characteristics of the yarn should not be changed.


• Winding faults should be minimize.


• Yarn package size and shape should be suitable.


• Winding process should be economical.


• Yarn package should be cheap in cost.


• Avoid excess looseness or tightness.


• Exact package hardness.


• In winding, yarn knots should be small in size and amount of knots should be minimum.

So, that’s all about winding process and objectives and requirements of winding.

Process Flow Chart of Rotor Yarn Manufacturing | Cotton Fiber to Yarn Manufacturing

Rotor spinning process is fully different from carded or combed spinning. Rotor yarn is coarser than carded or combed yarn. The count of rotor yarn is very low. Most of rotor yarn count is below 20’^s but highest yarn count may be 40’^s . Coarser fabric is formed by rotor yarn. Most of the jeans or pant is made by rotor yarn. Denim is fully depends on rotor yarn. The price of rotor yarn fabric is very low than combed and carded yarn fabric.



Rotor yarn manufacturing flow chart is given below:

 

Fiber/Bale →    Blow Room →     Lap/Chute

↓

Lap/Chute    →   Carding   →   Sliver (Carded)

↓

Carded Sliver →  1^st Drawing frame   →   Drawing Sliver

↓

Drawing Sliver   →   2^nd Drawing frame →   Drawing Sliver

↓

Drawing Sliver   →   Rotor Spinning   → Rotor Yarn

↓

Winding

↓

Reeling

↓

Bundling

↓

Bailing

In modern rotor spinning line; blow room and carding machine are use at a time. This technique is called “Chute to feed card” or “Chute to feed drawing”.

Rotor spinning number is less than combed or carded spinning. Low graded fiber spin in rotor spinning.