Open-end spinning

Open-end spinning is a technology for

creating yarn without using a spindle. It
was invented and developed in
Czechoslovakia in Výzkumný ústav
bavlnářský / Cotton Research Institute in
Ústí nad Orlicí in 1963.[1][2]

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
140,000 rpm. 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 optimal 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
Development stages of open-end spinning
1937 Berthelsen developed a relatively perfect open end.

1965 Czech KS200 rotor spinning machine was introduced at 30,000 rotor rpm.

Improved BD200 with G5/1 Rieter were presented with first mill of OE coming under
1967
production.

There was a considerable increase in machine manufacturer and newer and improved
1971–
1975 version of machines were launched with increased speed at 100,000 rpm.

Also witnessed first automated machine from Suessen equipped with Spincat and
1975
Cleancat which opened up the industrial rotor spinning breakthrough.

Witnessed Schlafhorst with Autocoro machines, which made a mark in open-end

1977
market.

The number of manufacturers who can

successfully compete has been reduced,
as the technical complexity of the spinning
machines has increased. However, there
are many competent companies serving
the global market for spinning machines
who continue to pursue innovative ways to
increase spinning productivity and yarn
quality.

Characteristics
A good open-end machine should have:

Higher productivity
This is a major criterion, as
productivity reduces the cost of
manufacturing. The O.E. machines
that 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”)
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)
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 4–5 kg. The
Savio Super Spinner 3000 currently
has the largest package size at 6 kg.
Less power consumption
Using individual motors and electronic
controls for each of the various drives
of the machine maximizes energy
efficiency and minimizes downtime.
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
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.
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.

Advantages
Disappearance of simplex frame.
Under certain circumstances,
elimination of the second passage draw
frame.
In some cases, with the use of auto-
leveller at the cards, elimination of even
the draw frame passage.
Bigger supply of cans to open-end and
bigger packages to weaving.
Elimination of winding.
Less labor and power cost per kilogram
of yarn.
Higher productivity almost 7 times in the
case of 10s and high efficiency.
Fully automated mill a reality.
Disadvantages
Restricted only coarse counts.
High capital cost.
Usage restricted in case yarn is weak.
Yarn realization in the case of waste
mixing will be poor, resulting in
increased mixing cost.
Wear and tear of rotors, combing rollers,
and navels are very high when highly
trash content mixing is used resulting in
heavy replacement cost.
In case reeling is done additional reeling
cost is involved resulting in higher
manufacturing cost.
Products
Linen / Flax yarns
Cotton Yarns
Polyester Cotton Blended yarn
Tencel 100%
Polyester 100%
Polyester / Cotton / Linen / Viscose
Multi blend
Dyed yarn (and fibre)
Acrylic
Recycle Polyester 100% and different
Blends

References
1. Carl A Lawrence (2010) Advances in Yarn
Spinning Technology pp. 261–273,
Woodhead Publishing, Oxford ISBN 978-1-
84569-444-9
2. Zdeněk Pospíšil (1981) Příručka
textilního odborníka pp. 411–425, SNTL,
Prague OCLC 40091412 (Czech)

Bibliography

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