2010

Thesis Report

Comparative Study of Productive Potential

of Ring Spinning and New Yarn
Manufacturing Technologies

Project Coordinator:
Sir Hafeez ur Rehman Sheikh
By:
Syed Sohaib Hussnain Kazmi (Textile Institute of Pakistan)
Objectives:
The main or primary objective of this thesis report is to understand the working principals of the
machines on the production floor ,the productive potential of those machinery, the flaws in the
working which interfere during the production and results in loss of production, Quality,
Efficiency, and material loss and in short results in the increase of yarn manufacturing cost.
These faults can be of different types, It could be a manufacturing fault, or it could be because of
poor handling of the material, or it could be because of the Quality of material processed,
because if we are dealing with material of not a very good quality then it will no doubt effect the
production, quality, efficiency of the machine.

There are different types of yarn manufacturing technologies available i.e.

o Ring Spinning

o Compact Spinning

o Rotor Spinning

o Air jet Spinning

o Vortex Spinning

o Misc

Above mentioned are the technologies that are mostly used for the manufacturing of yarn. Each
of the above mentioned techniques for yarn production compromises of different working
principal and work on whole different idea of yarn manufacturing. They differ in yarn quality,
production speed, efficiency, and material processing method.

Production Speed/Quality:
When talking about the capacity of a machine to manufacture a good, production speed is a very
important factor along with the Quality prospective. Because it is permissible to obtain a very
high production speed but neglecting the Quality factor. The above mentioned technologies
differ with each other very much in production speed and quality of yarn produced by these
machines. e.g.

o Rotor spinning is 7 times faster than Ring Spinning

o Compact spinning is also faster than Ring spinning

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 o Air jet spinning is 3 times faster than Rotor spinning it means Air jet is 10 times faster
than Ring Spinning.

o Similarly Vortex spinning is a technology that is the fastest technology available in the
market.

o Rotor Spinning shows produced less hairy in yarn than Ring spinning

o Compact Spinning by eliminating spinning triangle produced finer, high quality and less
hairy yarn.

o Air jet produced very fine yarn with less hairiness than Ring Spinning.

But besides of so much advantages achievable with the technologies other than Ring
Spinning still RING SPINNING is considered to be the most reliable technology when
dealing with different types of fibers for different end uses.

o Rotor spinning is used only for manufacturing of coarser yarns because of low torque
generation for the twist insertion, therefore its usage has restricted only to coarser
yarns.

o Air jet Spinning is no doubt very fast yarn manufacturing technology but still a
limitation of this machine is that it cannot be used for the production of coarser
yarns. So, its usage has restricted only to finer yarns.

o Vortex spinning is a technology, which has been implemented successfully only by

Murata Tech and its usage has restricted mostly to fashion purposes.

But Ring Spinning vs. All Technologies:

o Production of high strength yarns.
o Spinning of fine count yarns.
o Proper for special yarns.
o It is universally applicable (any material can be spun).
o The know how for operation of machine is well established accessible to everyone.
o It is flexible as regards quantities (blend and lot size).
o Since the speeds in drawing section are best controlled, yarn evenness is excellent. But if
short fibers are too much, yarn unevenness occurs.
o Fine yarns can be produced as compared to open-end system

But Also Disadvantages:

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 o Process stages are more numerous. Roving stage exists as an extra process compared to
the other systems.
o Yarn breakages are more numerous as a result of ring traveler friction and yarn air
friction. Interruptions, broken ends and piecing up problems exist because of the yarn
breakages.
o The high speed of the traveler damages the fibers.
o The capacity of the cops is limited.
o Energy cost is very high.
o Low production rate.

Industrial Revolution
After the Industrial revolution (1764-1784) Mule Spinning gained attention throughout the
world. Continuous efforts were being made to refine this system of spinning. Later, Ring
Spinning was introduced after some modifications in Mule Spinning System. The basic
technology of the Ring Spinning remained unchanged.
In spite of significant developments and refinements of the system, following the commercial
acceptance of the Open-end spinning, many new spinning systems were developed, some of
which have gained popularity.
Open-end spinning machine, specifically manufactured for short staple fibers, was considered a
good rival because of much higher production and better evenness of the yarn. However, further
development of this system showed that the best performance of the OE system is limited to the
coarse categories of yarn.
On the other hand, Ring Spinning Systems have been refined during the last 30 years, the
ultimate objectives of spinning dialectologists are focused on higher production speed, combined
with adequate quality. The quest for higher yarn quality has become in line with the much more
exacting requirements and the performance criteria of the knitter, weaver etc.
Structure of a Model of Yarn Formation
Qualitative assessment of model yarn can be deduced by the mechanical behavior of fibers when
bundled into yarn. A textile fiber is mechanical body of extreme length and flexibility; even the
cellulosic fibers with a breaking elongation lower than 10%.
The formation of yarn should fulfill following conditions:
* The fibers must overlap in staggered way so that they join as assembly.
* The fibers must stick together so that tensional force is transmitted from fiber to fiber and this
way distributed within the bundle.
* The number of individual fibers in the section must be sufficient so that discontinuity in force
distribution due to the fiber ends does not significantly weaken the yarn.

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The figure shows self-locking arrangements of the fibers within a yarn, as the tension is imposed
on the yarn and the sticking force of fibers at the periphery increases.
The self locking effect depends upon the surface properties of fibers, providing the sticking and
path of the fibers within the body of yarn, to facilitate compressing force at least part of the fibers
must wrap around the yarn.
A simple way to achieve this to introduce an even twist with constant pitch throughout the yarn
(as in Ring frame). The same effect can be produced by a core sheath arrangement with the large
section with low twist in the center, compressed by wrapper fibers to the periphery (in case of
open-end yarn). It is also possible to produce this with a mixture of fibers that are twisted in
opposite direction It is called false twist spinning process i.e. Air jet Spinning.

Consider the Process of Yarn Formation

Ring spinning is a three-step process of drafting, twisting and winding. As the roving strand
passes through the draft zone of the spinning frame, from the back rolls to the front roll, the
roving strand is drafted into fiber stand that has the linear density of the yarn. The yarn emerging
from the front roller nip is in the shape of a flat ribbon, that is twisted, forms a triangle generally
expressed as 'spinning triangle'. The traveler , ring and spindle are responsible for twisting and
formation of yarn.
Yarn structure which was examined microscopically revealed that all the fibers do not contribute
in the formation of yarn (i.e. not bounded fully in the yarn structure) particularly longer fibers,
causing hairiness, also the short fibers which are not part of the body contribute to the 'fly lint'
waste.

Limitations in Present Systems of Spinning

The limitations during formation of yarn in order to get appropriate quality product at desired
speed of production lead the technologist and researcher to develop the new spinning techniques
and modify the present systems of spinning.
When we look at ring spinning the major limitation is metal to metal rubbing contact between
ring and traveler , which restricts the spindle speed. Secondly, the necessity of bobbin rotation
for twist insertion restricts the output rate. Another important limitation of the ring spinning
frame is the formation of spinning triangle by the ribbon of drafted fibers emerging from the nip
of the front drafting rollers as shown in the above figure. Also it is further reported that fibers,
being twisted into the yarn due to formation of spinning triangle, are under unequal initial
tension that may cause a break in yarn either individually or in small groups and not
simultaneously.
The open-end rotor spinning system overcomes the limitations of the ring spinning system in
respect of output rate. However, the open-end rotor spinning systems also subject to limitations
e.g. the disorientation of the fibers, deposited in the rotor groove, the twist loss due to rotation of

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the free end results in development of low spinning tension which require the minimum number
of fibers at the yarn formation point. This drawback limits the spinning limit in open-end rotor
spinning to coarser yarn counts as compared to that in ring spinning.
New Spinning Systems
In 70's many spinning system were introduced which lead to latest technique in the formation of
yarn. As a matter of fact the productive capacity of system was about 10/ 11 times higher than
that of conventional machines, the quality of the product has also improved and a wide range for
further developments exist.
Arrangement of fibers in the cross-section of an Open-end yarn structure shows an irregular
picture irrespective that there are not much loose fibers; also wrapper fibers are twisted in wrap
direction. However, these odd arrangements of fibers do not show an adverse impact on the
eventless of yarn.
In the Air Vortex Spinning the fiber arrangements are much improved defining more close
spinning and real twisted yarn Murata Vortex Spinner is an improved shape of Murata Air-jet
spinning machine and is claimed that it is capable of spinning 100% carded cotton at high
speeds. MVS frame imparts real twist in the fibers. as opposed to the 'false twist' principle, used
by Murata's jet spinning. Instead of using a pair of opposing air blasts from air nozzles to impart
structural integrity to the yarn mass against as previously used by MJS, a unique guide called a
spindle, a needle holder and a single air nozzle is used. The MVS utilizes a four-line roller/apron
drafting system similar to that used in MJS technology.
One more intriguing feature of the MVS machine is that relatively high percentage of short fibers
less than 12.5mm in length is removed in the spinning zone thus a small scale of combing is
achieved at this stage converting the resultant yarn into a more valuable-added product.
Compact Spinning is the modified version of ring spinning in which the process of twisting is
improved by minimizing or eliminating the spinning triangle. After the draft zone the ribbon is
condensed into a strand before twist insertion. Airflow is used to condense the fiber ribbon. The
compacted fiber strand is twisted into yarn with little or no spinning triangle, resulting in
essentially ideal yarn formation conditions.
Summary Ring Spinning System, compared to rotor and air-jet spinning, is capable of giving
much stronger yarn and a fabric of much better hand but rotor and air-jet spinning because of
faster way of spinning have gained increasing importance. Still rigorous research and efforts are
being made and spinders are hoping to produce new systems that deliver improved quality at
higher speeds.
Recently textile manufacturer has developed new technologies for the spinning of short-staple
yarns of higher quality at higher speeds.
Besides, to make higher-quality products at lower cost textile technologist are putting more
emphasis on value-added products and product differentiation.

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Two major spinning technologies have been introduced in the recent years: Murata vortex
spinning and Compact Spinning. The characteristics of the yarns spun on these two systems are
much improved but still area could be broadened towards yarn compatibility to value added
fabric formation.
Newly evolved systems i.e. compact yarn spinning system unlike open-end spinning is not
diverted form of ring spinning system. These systems are based on ring spinning machine;
improvement is made by introducing condensing zone, fitted immediately after the delivery nip
of the conventional drafting unit, eliminate the spinning triangle and its adverse effects on yarn
characteristics.
Development in Spinning
During the 1970s, there appeared to be a myriad of spinning systems, such as twist less spinning,
self-twist spinning, fascinated yarns, composite yarns, wrap-spun yarns, pot spinning,
continuously felted yarns; and the many possible variants in open-end spinning such as rotor,
electrostatic, friction spinning, and vortex spinning (the original “Polish” system). At the same
time, there were continued developments in ring spinning, with ventures into rotating ring and
traveler systems, individual spindle drives, high draft systems, modified travelers, double roving
spinning and hybrid system.

A look at today’s industry reveals that while some systems have established a successful but
small niche wrap spinning for fancy yarns, and friction spinning for specialty industrial markets
very few systems have survived. Indeed, this is also true of the manufacturers of these machines.
Figure 1 represents the current offerings in spinning machines and their comparative spinning

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speeds.

Table 1 summarizes the number of spinning positions for the major technologies, together with
their share of the spun yarn market. It is evident that, when judged from the perspective of the
number of installed spindles, ring spinning is still the most dominant spinning system there are
about three times more spindles than installed rotors. If judgment is based on the quantity of yarn
produced, it is clear that even though there are only one-third as many positions of rotors
installed, rotor spinning produces three times more yarn than ring spinning.

Ring Spinning

The technology behind ring spinning has remained largely unchanged for many years, but there
have been significant refinements. Changes, which on their own offered only slight advantages,
provided the following synergies when combined. The introduction of longer frames reduced the
relative costs of automatic doffing. The combination of spinning frame and winding (link
winders) further enhanced the adoption of automation. The introduction of automatic doffing
meant that doffing time was reduced and thus package (and ring) size was less critical.
The introduction of splicing on the winder meant that yarn joins became less obtrusive again
offering the potential of smaller package. Smaller rings meant that for a limiting traveler velocity

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(40 meters per second [m/s]), higher rotational speeds (and hence twisting rates) could be
achieved. These combinations meant that the potential maximum speed of ring spinning was
raised from about 15,000 to 25,000 revolutions per minute. There also have been several other
proposed developments that have met with mixed success.

Drafting systems

While double apron drafting dominates, the system can be tweaked to enable higher drafts.
Recent exhibitions have featured machines operating at potential drafts of 70 to 100. The use of
high drafts has significant impact on the economics of the total system.

Individual spindle drives

Several manufacturers demonstrated this possibility in the 1980s. While the concept offered
advantages with respect to lower energy requirements, less noise and better control of speed, it
suffered higher initial costs and bigger spindle gauge.

Ring Design

Several approaches to reducing the limitations of traditional rings and travelers have been
proposed.

Orbit ring

This development from Rieter was aimed at increasing heat dissipation from the traveler.
Ceramic rings (Ceratwine system)

The combination of a ceramic ring and ceramic-coated traveler offered the promise of
significantly better wear resistance, which translates into long traveler life. More consistent yarn
quality and shorter break-in time are other claimed benefits.

Rotating rings

This idea was tried by several ring frame manufacturers in the 1970s. Other ventures into this
area included systems such as Cerifil, Magnetic Spinning and Super Traveler Spinning. The
problem with these types of devices is, while they appear to operate at lower spinning tensions,

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and thus potentially offer lower end breakage rates, they suffer the drawbacks of short duration
and high-magnitude tension peaks because of the inertia of the twisting element, which is
significantly higher than a traveler.

Spindle identification (Schlafhorst, Barco)

The tracking of spindles from the ring frame has great potential for process quality control. This
enables the identification of those spindles on the ring frame that are responsible for producing
defective yarns, as assessed on the winding frame. It is believed this type of system will result in
improvements not only in yarn quality, but also in efficiency, by more readily indicating faulty
positions on the spinning frame.

Longer machines

Improvements in the drives used on spinning frames have enabled the number of spindles per
machine to be further increased up to 1,488 (Zinser). This has a positive impact on the cost per
spindle. Additionally, as indicated above, longer machines favor the use of automation,
particularly link-winding.

Compact spinning

Systems that use additional drafting components and pneumatics to create yarns that are less
hairy and stronger are available from several machinery makers. The many claims made for these
systems are usually mutually exclusive in that one can either have a stronger yarn or spin at
higher production speeds with lower twist. Moreover, there is a significant increase in the cost of
these machines, and the yarn thereby produced, when compared to traditional spinning frames.
While the use of compact spinning machines is claimed to have made significant inroads in
Europe, the system has not been well-received in the United States. It is evident that several
other machinery makers will venture into this market, such as Marzoli and Cognetex, and this
added competition may result in reduced machinery costs.

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Rotor Spinning

Rotor or open-end spinning is now a mature technology, and since the 1960s, it has seen a five-
fold increase in twisting speeds. During the early stages of development, debates concerned such
questions as Were self-pumping or evacuated systems better? Was roller drafting feed superior to
a beater opener? Was spin through better than feed and withdrawal from the same face of the
rotor? Were twin disc bearings the best solution for higher speeds? These issues were seemingly
resolved, and most modern rotor machines are very similar in layout with relatively subtle
differences between machines from the major manufacturers.

These differences are typically associated with the aerodynamics of the transfer tube, rotor
design and navel design. While it is still possible to obtain low-tech rotor spinning frames,
present state-of-the-art machines have significant integrated automation such as doffing, piecing,
cleaning and process/product monitoring. Additionally, the machine can be part of a material
handling system from sliver through to packaged yarn.

It is generally accepted that, while rotor yarns are different from ring-spun yarns, they tend to
offer advantages in processing through weaving and knitting. This difference is a result of
structural differences introduced during yarn formation. This structure which is responsible for
the lower strength of rotor yarns, but improved hairiness and yarn abrasion is an inherent feature
of the system. While it is possible to control the formation of wrapper fibers by optimizing rotor
and navel designs,

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it is impossible to eliminate them. Unfortunately, while smaller rotors are required for higher
processing speeds, this also negatively impacts wrapper fibers, and thus higher speeds often carry
the penalty of a reduction in yarn quality. Developments in rotor spinning include the use of
longer machines. Additionally, there is interest in potentially using rotor technology to produce
core yarns and using additional components to create effect yarns.

Murata Vortex Spinning

Murata Vortex Spinning (MVS) is best judged as a development of jet spinning specifically
created to overcome the limitations of fiber type. The major marketing feature of MVS was that
it was capable of spinning uncombed cotton slivers into acceptable yarns at speeds that were
significantly higher than with any other system. The yarn structure is different from jet-spun yarn
with many more wrapper fibers, and in parts the vortex yarn resembles a two-fold yarn. There
were concerns that there is excessive fiber loss using this spinning machine. But, even though the
fiber loss may be about 8 percent, most of this is short fiber, which would not contribute to yarn
quality.
MVS was introduced with a remarkable potential processing speed of 350 to 400 m/min.
Successful spinning systems historically have had a significant increase in production speed
within a few years of introduction. If this trend were to be true of MVS, it is possible that the
industry could have a staple spinning frame capable of speeds in excess of 500 m/min.

Even though it is claimed that MVS is capable of processing 100-percent cotton, it is believed
that the major use of this system is in the processing of cotton-rich blends with polyester. The
machine utilizes a roller drafting system working at high drafts and high speeds. There is proof
that indicates these systems may give rise to unacceptable yarn variations, which become
apparent in terms of fabric defects or weak spots in the yarn. This is a problem that could be
addressed by using the rotor spinning beater opener.

New developments likely for MVS include modifications to enable the production of coarser
counts and a possible re-examination of the concept of spin assembly winding, where yarns from
two spinning positions are combined onto one package that is subsequently two-for-one twisted.
It is also evident, from a cursory review of patents, that other machinery makers have invested in
significant research into technology similar to vortex spinning and perhaps there soon may be
alternative machines available.

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It is clear that at the present time, there is a lull in investment in new spinning machinery in the
United States. This could be explained partly by a downturn in the industry, which seems to be
supported by the reduction in positions shown in Table 1, and partly by the fact that the current
technologies are mature.

An additional factor in this consideration is that as spinning machines become more productive,
the number of machines needed to satisfy a particular market will decline. It is quite evident from
the data shown in Table 2, that among all the major spinning technologies used in the United
States, there has been a very substantial increase in productivity over the past 10 years. The table
does not include the impact of changing from jet spinning to vortex spinning, which would show
an even greater increase in productivity for this type of yarn

RING FRAME

The ring spinning will continue to be the most widely used form of spinning machine in the near
future, because it exhibits significant advantages in comparison with the new spinning processes.

Following are the advantages of ring spinning frame

o It is universally applicable, i.e. any material can be spun to any required count
o It delivers a material with optimum characteristics, especially with regard to
structure and strength.

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 o it is simple and easy to master
o the know-how is well established and accessible for everyone
o Functions of ring frame

o to draft the roving until the required fineness is achieved

o to impart strength to the fiber by inserting twist
o to wind up the twisted strand (yarn) in a form suitable for storage, transportation
and further processing.

DRAFTING

Drafting arrangement is the most important part of the machine. It influences mainly evenness
and strength. The following points are therefore very important

o drafting type
o design of drafting system
o drafting settings
o selection of drafting elements like cots, apron, traveler etc
o choice of appropriate draft
o service and maintenance

. The following draft limits have been established for practical operation:

o carded cotton- up to 35
o carded blends - up to 40
o combed cotton and blends(medium counts) - up to 40
o combed cotton and blends(fine counts) - up to 45
o synthetic fibers - up to 50

o The break draft must be adapted to the total draft in each case since the main draft should
not exceed 25 to 30. It should be noted that higher the break draft, more critical is the
break draft setting
o Three kinds of top roller weighting(loading) are presently in use
o spring loading
o pneumatic loading

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 o magnetic weighting
o With pneumatic loading system, the total pressure applied to all top rollers is obtained by
simple adjustment of the pressure in the hose using pressure reducing valve. Moreover
the rubber cots will not get deformed if the machine is stopped for a longer duration,
because the pressure on top rollers can be released to the minimum level.

RING and TRAVELLER COMBINATION

The following factors should be considered

o materials of the ring traveler

o surface characteristics
o the forms of both elements
o wear resistance
o smoothness of running
o running-in conditions
o fiber lubrication
o A good ring in operation should have the following features:
o best quality raw material
o good, but not too high, surface smoothness
o an even surface
o exact roundness
o good, even surface hardness, higher than that of the traveler
o should have been run in as per ring manufacturers requirement
o long operating life
o correct relationship between ring and bobbin tube diameters
o perfectly horizontal position
o it should be exactly centered relative to the spindle
o The position, form and structure of lubricating film depends on
o yarn fineness
o yarn structure
o fiber raw material
o traveler mass
o traveler speed

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 o height of traveler bow
o Modern ring and traveler combination with good fiber lubrication enable traveler
speeds up to 40m/sec.
o The spinning tension is proportional
o to the friction coefficient between ring and traveler
o to the traveler mass
o to the square of the traveler speed
o and inversely proportional
o to the ring diameter
o and the angle between the connecting line from the traveler-spindle axis to the
piece of yarn between the traveler and cop.
o The yarn strength is affected only little by the spinning tension. On the other hand
the elongation diminishes with increasing tension, for every tensile load of the
fibers lessens the residual elongation in the fibers and hence in the yarn.
Increasing tension leads also to poorer Uster regularity and IPI values.
o If the spinning tension is more, the spinning triangle becomes smaller . As the spinning
triangle gets smaller, there is less hairiness.

SHAPE OF THE TRAVELLER:

The traveler must be shaped to match exactly with the ring in the contact zone, so that a single
contact surface, with the maximum surface area is created between ring and traveler. The bow of
the traveler should be as flat as possible, in order to keep the centre of gravity low and thereby
improve smoothness of running. However the flat bow must still leave adequate space for
passage of the yarn. If the yarn clearance opening is too small, rubbing of the yarn on the ring
leads to roughening of the yarn, a high level of fiber loss as fly, deterioration of yarn quality and
formation of melt spots in spinning of synthetic fiber yarns.

WIRE PROFILE OF THE TRAVELLER:

Wire profile influences both the behavior of the traveler and certain yarn characteristics, they are

o contact surface of the ring

o smooth running
o thermal transfer
o yarn clearance opening

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 o roughening effect
o hairiness

MATERIAL OF THE TRAVELLER

The traveler should

o generate as little heat as possible

o quickly distribute the generated heat from the area where it develops over the
whole volume of the traveler
o transfer this heat rapidly to the ring and the air
o be elastic, so that the traveler will not break as it is pushed on to the ring
o exhibit high wear resistance
o be less hard than the ring, because the traveler must wear out in use in preference
to the ring.

SPINNING GEOMETRY

From Roving bobbin to cop, the fiber strand passes through drafting arrangement, thread guide,
balloon control rings and traveler. These parts are arranged at various angles and distances
relative to each other. The distances and angles together are referred to as the spinning geometry,
has a significant influence on the spinning operation and the resulting yarn. They are

o yarn tension
o number of end breaks
o yarn irregularity
o binding-in of the fibers
o yarn hairiness
o generation of fly etc.

Spinning Triangle

Twist in a yarn is generated at the traveler and travel against the direction of yarn movement to
the front roller. Twist must run back as close as possible to the nip of the rollers, but it never
penetrates completely to the nip because, after leaving the rollers, the fibers first have to be

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diverted inwards and wrapped around each other. There is always a triangular bundle of fibers
without twist at the exit of the rollers, this is called as SPINNING TRIANGLE. Most of the end
breaks originate at this point. The length of the spinning triangle depends upon the spinning
geometry and upon the twist level in the yarn.

o The top roller is always shifted 3 to 6 mm forward compared to bottom roller. This is
called top roller overhang. This gives smoother running and smaller spinning triangle.
The overhang must not be made too large, as the distance from the opening of the aprons
to the roller nip line becomes too long resulting in poorer fiber control and increased yarn
irregularity.
o Continuous variation of the operating conditions arises during winding of a cop. The
result is that the tensile force exerted on yarn must be much higher during winding on the
bare tube than during winding on the full cop, because of the difference in the angle of
attack of the yarn on the traveler. When the ring rail is at the upper end of its stroke, in
spinning onto the tube, the yarn tension is substantially higher than when the ring rail is at
its lowermost position. This can be observed easily in the balloon on any ring spinning
machine.
o The tube and ring diameters must have a minimum ratio, between approx. 1:2 and 1:2.2,
in order to ensure that the yarn tension oscillations do not become too great.
o Yarn tension in the balloon is the tension which finally penetrates almost to the spinning
triangle and which is responsible for the greater part of the thread breaks. It is reduced to
a very small degree by the deviation of the yarn at the thread guide. An equilibrium of
forces must be obtained between the yarn tension and balloon tension.

COMPACT SPINNING :

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In traditional ring spinning, fibers in the selvedge of strand emerging from front roller nip do not
get fully integrated into the yarn because of the restriction to twist flow by the spinning triangle.
These fibers show up partly as protruding hairs or as wild fibers. The spinning triangle is because
of higher width of the strand as compared to final yarn diameter. Further the fibers are tensioned
to varying extent depending upon their position in the spinning triangle. As a result full
realization of fiber strength is not achieved in the yarn. The hairiness gives a rough feel to the
yarn. Variation in hairiness is a source of weft bars and warp way streaks in the fabric. Long

protruding hairs from the yarn contribute to multiple breaks in weaving and fabric faults like
stitches and floats.

The length of the spinning triangle depends upon the spinning geometry and upon the twist level
in the yarn. If the spinning triangle is too short, then the fibers on the edge must be strongly
deflected to bind them in. This is not possible with all fibers, and lost as fly. Thus with shorter
triangle, smaller weak point resulting into fewer end breaks but makes the yarn hairy. On the
other hand, a long spinning triangle implies a long weak point and hence more end breaks giving
smoother yarn and less fly.

In Compact Spinning, incorporating a condensing zone after main drafting zone, thereby
overcoming the drawbacks of conventional spinning, eliminates spinning triangle. This will be
clear from a comparison of mode of yarn formation in the two systems as shown in figure.

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The condensing zone has a revolving perforated apron with suction underneath. The fibers

collected on the perforated track of the apron and get condensed. A low-tension draft is kept in
the condensing zone to assist in the condensation.

Compact Spinning systems are offered by:

1 REITER [COMFOURSPIN]
2 SUESSEN [ ELITE SPINNING SYSTEM ]
3 LAKSHMI [ RoCos COMPACT SPINNING SYSTEM ]
4 ITV-ZINSER [ CompACT3 ]

REITER

In Reiter Comfor spin, a perforated drum replaces front bottom roller of drafting system. A
second top roller also presses on the drum. There is a suction system-generating vacuum under
the drum. Condensing of strand takes place between the two top rollers under the perforated
drum non-rotating insert inside the drum with specially shaped slots helps in achieving
condensation.

SUESSEN

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In the Elite system of Suessen, condensing zone consists of profile tube with a perforated lattice
apron running over it. A delivery top roller pressed on the apron drives the apron. A suction
system under the profile tube causes condensation of the strand.

ZINSER

In ITV-Zinser system, illustrated in figure, condensing zone consists of a revolving perforated

apron. The size of perforations in the apron is varied as per the count of the yarn to get the
desired condensation.

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.

SALIENT FEATURES:

o Magnetic compacting is more user friendly & avoids

o Air suction
o Air pipes
o Perforated drums or apron
o Additional air conditioning requirements
1

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ADVANTAGES OF COMPACT SPINNING TECHNOLOGY
o 15-20% reduction in hairiness of yarn, the
o reduction being more pronounced in long length hairs
o 10-15% improvement in yarn tenacity
o Twist in yarn can be reduced by 10% while maintaining same yarn strength
o Better evenness of diameter and hairiness.
o Better abrasion resistance of yarn leading to fewer ends
o Breaks in weaving. Loom shed droppings and linting in knitting are reduced.
o Singeing can be omitted.
o Lower twist can be employed in doubling.
o Improved appearance and luster of fabric with a softer.
o Reduced pilling and better dye uptake.

Progress to date:
Till now, in literature review the following technologies have been covered briefly

o Ring Spinning

o Compact Spinning

o Rotor Spinning/OE Spinning

The main focus was on the Production capacity along with the Quality Prospective and machine
Efficiency. As discussed above it is permissible to obtain a very high production by neglecting
Quality and machine efficiency. So, the process should such that it facilitates all the elements in
the yarn production process either these are on the floor or after the order delivery.

Also couple of mills surveys have also been conducted to understand the process line of these
technologies, surveys conducted are given below

o Sapphire Fibers Ltd unit 3 Sheikhupura

o Siara Textile Mills Sheikhpura

o Akram Textile Mills Lahore

o Gul Ahmed Textile mill unit 6 Landhi Karachi

System installed on the above mentioned industries compromised of RING SPINNING and
COMPACT SPINNING. Sapphire Fibers and Gul Ahmed were operating with COMPACT
SPINNING system. Whereas, Siara Textiles and Akram were operating with RING SPINNING

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system, talking more specifically Siara and Akram textiles were operating with Chinese made
Ring Spinning frames.

System Installed:
Sapphire Fibers Ltd

o RX 240 SF-1008

Toyota made 2003-04

Gul Ahmed Textile Mills

o Sussen Compact on Sussen frame

o Zinser Compact on Zinser frame

o Sussen Compact on China BJM 168

o China Compact on China BJM 168

Future Plans:
At the moment Ring Spinning, Compact Spinning and Rotor Spinning have been discussed
briefly. Production Speeds, Quality, and Efficiency and also advantages and disadvantages and
limitations of these Spinning systems have been discussed briefly. Furthermore other yarn
manufacturing technologies will be discussed along with Industrial surveys of the related
technology. And also these all technologies will be discussed in details along with their related
Industries surveys. First of all the technologies that could not been covered in this report will be
discussed briefly just for the introduction. Then all the related technologies will be discussed
individually chapter wise for the better understanding of these technologies. In the coming
vocations of semester break surveys will be conducted in the Punjab region. These technologies
will be discussed in a manner that it will cover the machine details, parts used and their functions
and the importance of those parts, also the productive potential of these technologies will be
calculated keeping in view the Quality prospective and machine efficiency. And this report will
tells us what are the technologies that are dominating the Pakistan Textile sector and why Ring
Spinning besides of so many of disadvantaged and limitations still is the dominating technology
in the whole World. And also this project will be helpful in finding new ways to produce yarn
other than Ring Spinning in Pakistan.

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References:
1. www.compactspinning.in
2. www.textileworld.com
3. www.campuscorner.fiber2fashion.com
4. www.textile2technology.com

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