Open end spinning

Method:
It is also known as break spinning or rotor spinning. The principle behind open end spinning is
similar to that of a clothes dryer spinning full of sheets. If you could open the door and pull out a
sheet, it would spin together as you pulled it out. Sliver from the card goes into the rotor, is spun into
yarn and comes out, wrapped up on a bobbin, all ready to go to the next step. There is no roving
stage or re-packaging on an auto-coner. This system is much less labour-intensive and faster
than ring spinning with rotor speeds up to 140,000rpm. The Rotor design is the key to the operation
of the open-ended spinners. Each type of fibre may require a different rotor design for optimum
product quality and processing speed.
The first open-end machines in the United Kingdom were placed, under great secrecy,
by Courtaulds into Maple Mill, Oldham in 1967.
One disadvantage of open-end spinning is that it is limited to coarser counts, another is the structure
of the yarn itself with fibres less in parallel compared to ring spun yarns for example, consequently
cloth made from open-end yarn has a 'fuzzier' feel and poorer wear resistance.
History
The global demand for spun fibre is huge. Converting raw fibre to yarn is a complicated process.
Many manufacturers compete to provide the spinning machines that are essential to meeting the
demand by delivering increases in spinning productivity and additional improvements in yarn quality.
Over the past three centuries spinning technology has been continuously improved through
thousands of minor innovations, and occasional major advances that have collectively increased the
quality and lowered the cost of producing yarn dramatically.
Major technology advances have included:
Hand spinning,
Mule spinning
Ring spinning
Rotor spinning
Dref Friction Spinning
Open-End spinning.

Characteristics
A good Open-end machine should have,
Higher productivity
Higher Productivity:- This is a major criteria as productivity reduces the cost of
manufacturing. The O.E machines which are now in market boasts of many a basic needs
like, longer length of machine, higher speeds, able to process coarser hank, fewer changes
for Count, easy access to parts (less downtime for cleaning), longer production time between
cleaning schedules, computerized controls for less power consumption and lower downtime
and complete report generation giving leads to problem area are some points to discuss.
High content sliver cans (up to 18)
Large Sliver Can:- In early days large machines were equipped with less distance between
Rotors (Gauge of machine). This led to creeling of very small cans, which required frequent
can changes. Each can change requires a break in the yarn. All major manufacturers
currently allow cans up to 18 diameter leading to less breakage, less joining of yarn, hence
better quality and higher productivity. Originally round cans were used. Rectangular cans are
used because they double sliver capacity in the same sliver can footprint.
Larger packages of yarn (4 to 5 kg)
Large Final Package:- The final package size has continued to increase. The final package
size is important because it reduces tube change frequency and thus reduces idle time for
creeling. Current yarn packages typically weigh 4 to 5 kgs. The Savio Super Spinner 3000
currently has the largest package size at 6kgs.
Less power consumption
Less Power Consumption:- Using individual motors and electronic controls for each of the
various drives of the machine maximize energy efficiency and minimizes downtime.
Automation
Automation:- All spinning machines, whether ring or open end, need yarn joining to repair
breaks or start new sliver cans. Joining the yarn has historically been a labor intensive
activity and a source of quality defects. Autopiecing units are robots that automate this
process. Market leaders like Schlafhorst, Rieter, Savio have machines that incorporate good
quality autopiecers and autodoffing. This automation leads to less material handling costs
and helps improve quality of the final product.
Flexibility of spinning components
Flexibility of spinning component:- Many vendors are offering machines that can be
programmed to produce many different types of yarns. The ability to rapidly change
production results in the flexibility to serve multiple markets. A contemporary spinning mill
should be able to produce a range of products: denim, knitting, towels, structured fabrics,
construction fabrics and various other products like core spun, multi count etc.
Handling count range.
Handling count range:- Machines need to be easily programmed to spin yarns from 4sNe to
60sNe. This ability allows a single machine to produce yarns that cater to many different end
user requirements.