Name Ali Hasan

Reg no. 2020-NTU-MSTT-6062

Advancements in fiber and yarn manufacturing industry

Textile Industry of Pakistan:

The  textile industry  is the largest  manufacturing industry  in  Pakistan.  Pakistan is the 8th
largest exporter of textile commodities in  Asia. Textile sector contributes 8.5% to the GDP of
Pakistan.  In addition, the sector employs about 45% of the total labor force in the country
(and 38% of the manufacturing workers). Pakistan is the 4th largest producer of  cotton  with
the third largest spinning capacity in Asia after  China  and  India  and contributes 5% to the
global spinning capacity.  At present, there are 1,221 ginning units, 442 spinning units, 124
large spinning units and 425 small units which produce textile.

History:
The origin of the Indian textiles is thought to be the  Indus Valley civilization, situated in
modern Pakistan, where people used homespun cotton to weave garments. Historically, the
Indus valley region engaged in significant trade with the rest of the world. The silk from the
region, for example, is known to have been popular in Rome, Egypt, Britain, and Indonesia.

Significance:
Textile Sector of Pakistan is the heart and soul of this nation since Independence. It is the
largest Manufacturing Industry in Pakistan. Export of $3.5 billion (6.5% of total exported
cotton in world) in 2017-2018. Pakistan is the 8th largest exporter of textile commodities in
Asia. Contribution in economy is equal to approx. 8.5%of total GDP. Textile Sector employs
about 45% of the total Labor force in the country. In the year 2017-18 Exports of textile
sector grew by $4.4 billion. Pakistan is also 3rd largest consumer of Cotton in the World.
Total Textile mills are 464 in Pakistan out of which 5% are on the PSX .Textile has a total
processing capacity of 5.2 billion square meters. International brands working in Pakistan
with local textile mills are namely; H&M, Levis, Nike, Adidas, Puma, Target etc. Textile
businesses are concentrated in Karachi with a share of 38% and 18% in Faisalabad. Out of
464, 316 textile units in Punjab, 116 in Sindh. Pakistan’s exports are under threat mainly
from regional competitors because the governments of these countries support their textile
industry a lot as compared to Pakistan’s government. Rs.185 million has been approved in
Pakistan for the Export Development Fund for the development of the textile sector. The
textile industry provides 40% of the bank credit in Pakistan.
In the 1950s, textile manufacturing emerged as a central part of Pakistan's industrialization,
shortly following  independence  from the British rule in the  South Asia. In 1974, the Pakistan
government established the Cotton Export Corporation of Pakistan  (CEC). The CEC served as
a barrier to private manufacturers from participating in international trade. However, in the
late 1980s, the role of the CEC diminished and by 1988-89, private manufacturers were able
to buy cotton from ginners and sell in both domestic and foreign markets. Between 1947
and 2000, the number of  textile mills  in Pakistan increased from 3 to 600. In the same time
period, spindles increased from 177,000 to 805 million.
There are 423 textile industries working in the country. Pakistan has a supply base for
almost all man-made and natural yarns and fabrics, including cotton, rayon and others. This
abundance of raw material is a big advantage for Pakistan due to its beneficial impact on
cost and operational lead time.
Innovation and Advancements in Textile Sector

Innovation and competitiveness are considered to be the backbone of private sector led
economic growth and its sustainability. However, in Pakistan, very little is known about the
nature and the extent of innovation as well as its determinants and obstacles. In the
absence of such evidence, policies can be misdirected and ineffective. In this pilot study, we
propose to conduct a survey of textile manufacturers of Pakistan to determine the nature
and extent of innovation in this key export sector.

Textiles is the major manufacturing sector of Pakistan contributing one-fourth of industrial

value added, employing 40 percent of industrial labor force, and on average 60 percent
share of national exports. Since, it is competing in a global market; a continuous flow of
innovation is required to at least maintain its share in the World trade. In Pakistan, two
particular characteristics of textiles, scope and production chain posit both opportunities
and challenges for this sector to be more innovative and competitive. Firstly scope; even
though textiles share is 60 percent in national exports, its share is less than 2 percent (1.94
in 2011) in the World trade. There is a greater scope of increasing its world share through
innovation, and particularly given an increasing trend in wages in China the leading textile
exporter country coupled with recent GPS plus status granted by Europe, openings are more
likely for competitive textile firms. Secondly, textiles have the longest production chain, with
inherent potential for value addition at each stage of processing, from cotton to ginning,
spinning, fabric, processing, made-ups and garment.

Main technologies of spinning

The major technologies of staple fiber spinning are ring, rotor, air-jet and open-end friction.
These technologies are all used commercially and compete with each other for their share of
the market. With the largest share by far, ring spinning accounts for more than 80% of the
market, mainly catering for apparel applications, both knitted and woven, tents, and
tarpaulins. Air jet yarns find applications in shirting and ladies’ outerwear. Open-end (OE)
friction yarns find applications in technical and recycling products, carpets and home
textiles. Rotor yarns are used for apparel, especially denim and knitwear. A brief comparison
of these spun-yarn technologies.

  Developments in blowroom card & draw frame:

The trend in Indian spinning mills is now to replace manual bale opener with automatic
bale opener and carding and draw frames have also gone through an evolution in the
last one decade. So, what are the changes that have happened in these pre-spinning
departments? 
The conventional short staple spinning system involves different machines to convert raw
cotton to quality yarn. The quality of a yarn is judged by many parameters, like evenness,
count CV%, strength, imperfections, yarn appearance, etc. Now-a-days, various
parameters relating to comfort like yarn water absorbency, yarn surface friction, etc, are
also given importance. Thus, in short staple spinning system, to produce yarn of
acceptable quality, the raw material has to be processed through a sequence of machine.
Developments in these machines are carried out to enhance yarn quality. The machine
manufacturers are coming out with different models of the machines featuring different
modification/innovations, which enhance quality.
Different categories of developments:

These developments or innovations can be divided in different categories:

1. Minor modifications.

2. Modification related to quality/production monitoring or enhancement in

production/speed.

3. Major modifications.

Minor modifications are the simple alteration of the previous version/model of the
machine that has nothing to do much with the quality or production/speed of the
machine. So these modifications are aimed at just giving the customers a new look to the
machine. Second type of modification relates with enhancement in production/speed or
with the online quality/production monitoring. Major modifications are really significant
modifications, which are helpful in improving the product quality.
There are the changes that have been brought in the machine to improve the product
quality not only on the same machine but also at subsequent machines. As so far machine
manufacturers are concerned, they are providing machines with all the above stated
categories, but publicized the machines under the category of major developments though
these developments may be coming under first two categories. These developments will
be analyzed in the subsequent section.

To discuss modern developments in detail, subsequent sections are divided in the

according to the machines used to spin the yarn.

Developments in blowroom:
Main objective of the blowroom is opening and cleaning of the material without over-
stressing or damaging the fibers. The opening means to increase the specific volume (cc/g)
of the feed material and is adjudged from the tuft size whereas cleaning means to remove
impurities. The tuft size of 2 - 3 mg is considered to be optimum, but as low as 0.1 mg is
achievable. The visual appearance of the waste extracted at different stages of opening and
cleaning. Increase in the opening/cleaning intensity increases waste removal, but also leads
to fiber damage, fiber loss and increase in neps level. Hence it is very important to find out
optimum opening/cleaning. The modern developments in blowroom will be discussed in the
subsequent sections.
1. Difference between types of plucking roller of automatic bale opener:
The trend in Pakistan spinning mills is now to replace manual bale opener to automatic bale
opener. The automatic bale opener gives smaller tuft size thus results in better opening and
cleaning efficiency of the subsequent machines]. The manual bale opening process relies
more on the sincerity and efficacy of the worker, and has more variation in the tuft size fed
to the bale opener.
 Rieter Automatic Bale Opener (UNIfloc A 11):
Rieter UNIfloc A 11 uses single plucking roller, called as take-off roller. The take-off roller
along with narrow grid results in small tufts size]. The same roller can be used for processing
cotton as well as man-made fibers. The roller teeth can also be replaced individually. The
automatic bale opener regularly measures the profile of the lay down material for gradual
level out the bales.
Trützschler Automatic Bale Opener:
Trützschler's BLENDOMAT BO-A is fitted with two plucking rollers rotating in opposite
direction. But at any given time, only one plucking roller is working while other is raised
according to the travel direction of the machine. Thus, direction reversal of the plucking
roller and, hence wear-intensive braking and acceleration after every passage of the bales is
avoided. The plucking roller strips off the tufts by penetrating into the bale surface while the
three supporting rollers give a firm grip over the bales]. This is what they call 'Penetration
inversion mechanism', which ensures gentle fiber removal and gives good opening. It can
process three different cotton/blend lots simultaneously that can be fed into three separate
cleaning lines.

Marzoli Automatic Bale Opener (SuperBlender B12SB):

Marzoli automatic bale opening Super Blender B12SB has two plucking rollers with 254
blades on each roller, which ensures small flock size]. Automatic bale opener can process
four different mixings. The detacher of the bale opener follows the contour of the lay-down
and plucks the raw material down to the ground. The production, with a working width of
2,250 mm, is stated to be 1,600 kg/hr.
  Compact Blowroom Line (Shorter Blowroom Line):
Automatic bale opener efficiently makes the tuft size smaller leading to better
opening/cleaning of the subsequent machines. The modern
cleaners give intensive but gentle cleaning. The use of 3 to 4
beaters in series (CVT-4 Cleaner of Trützschler) in the same
machine rather than 2 or 4 machines in tandem in line gives
same cleaning. Thus, the modern  blowroom line becomes
shorter without any compromise on the quality of the material.
 Compact Blowroom Line of Trützschler:
Trützschler compact blowroom line consists of automatic bale
opener, Multi-Function Separator along with waste re-feeding,
Pre-Cleaner (CL-P), Integrated Mixer (MX-I with 10 trunks)
along with CLEANOMAT Cleaner (CL-C 4), and Foreign Part
Separator. The compact blowroom requires less space and lower energy consumption in
transporting the fiber tufts to the next machine. The installation size comparison of normal
blow room line (1,000 kg/h of blow room production) against Trützschler compact
blowroom (2,000 kg/h production).
Blow room Line of Rieter:
The Rieter blow room line consists of automatic bale opener UNIfloc A 11, intensive pre-
cleaner UNIclean B 11, homogeneous mixer/blender UNImix B 70 and gentle fine cleaner
UNIflex B 60.
Mote knife with suction in place of grid bars: 

The trend of using mote knife with an open slot along suction was initially incorporated on
carding in the pre-carding and post-carding zones. Recently, the same principle was
adopted by Trützschler on cleaning machines in blowroom. Such a cleaning system consists
of deflector blade, mote knife and suction hood. Trash particles released due to centrifugal
forces are separated at the knives and are continuously taken away by suction keeping the
hood clean permanently. The deflector blade setting depends upon the type of cotton
processing.
When processing clean cottons or for low degree of cleaning, deflector blades can be kept
almost closed, but fully opened for high trashy cotton and/or high degree of cleaning. The
blade adjustment can be made manually or via, motor. It also gives trouble free processing
of sticky cottons as such cotton otherwise sticks to the grid bars. The removal of dust by
suction results into good running behavior in OE and ring spinning and gives better yarn
quality.

Multiple beaters instead of single beater in a single machine:

The trend of using multiple beaters/cleaners in tandem on the same machine has been
introduced by Trützschler. The machine has the combination of clamped and unclamped
feeding of the material to the beaters. The initial feeding of the material to the first beater is
clamped through the feed rollers, thus giving intensive beating. Subsequently, material is
transferred to other beaters in web form in unclamped manner, thus giving gentle cleaning
action.

Rieter UNImix B71/B75 blending machine:

Rieter UNImix blending machine claims to have random distribution of the tufts to the 8
mixing chambers and then the fiber blending takes place at three different points within the
UNImix. This technology has been termed as a '3-point mixing process'. The first stage is a
controlled time offset of the tuft layers in the mixing chambers by 90° deflection of the tufts
in the tuft storage. The second mixing point comprises a spiked feed lattice, which picks
small tufts at random out of the layers of the 8 mixing chambers and transports them to the
next mixing point. The third blending level is achieved by mixing of the fine tufts in the active
mixing chamber above the spiked feed lattice. This results in constant homogeneity of the
fiber blend and constant yarn quality subsequently. Different raw materials can be
processed and required setting can be made via, the control panel during machine
operation. 

Trützschler Multimix MPM:

Trützschler mixer can have 6 or 10 trunks depending upon the

application. The rotating flaps forward the material in
sequence to the individual  trunks but these trunks are
emptied at the same time resulting in homogeneity of the
mix. Once all the trunks are filled, the transport air is routed
past the trunks to prevent material compaction. As soon as
the trunks are empty, refilling starts immediately so that a
loose layer of tufts is formed on the conveyor belt from the
individual trunks. At the end of the conveyor belt, material from all the trunks lies in layers
in a sandwich form that ensures ideal feeding for the CLEANOMAT Cleaner. For better
mixing and homogeneity, two mixers can also be set in tandem.

Trützschler Foreign Part Separator SECUROPROP SP-FP:

Trützschler's patent-pending process, Foreign Part Separator SECUROPROP SP-FP, detects

coloured as well as white and transparent particles such as PP or PE foil. Foreign fibers can
only be separated, if these are optically detected. To avoid tiny foreign particles hiding in
or behind the tufts, a fiber web is formed by an opening roll within the SECUROMAT   [17].  A
colour camera scans the web on the surface of the opening
roll and on detection of a foreign particle compressed air
impulse of a nozzle blows it into a waste suction device.

The distance between the place of detection and the

separating unit is very short, thus ensuring a high reliability of
the separation. SECUROPROP SP-FP uses the physical
properties of plastics, which make them appear coloured in
polarized light. This light is generated in the background of a rectangular fiber channel and
the tufts are scanned by two cameras. These detect the false colors or contrasts generated
by the polarization in light polypropylene and transparent or semi-transparent PE foils and
can detect contaminants of as small size as 2 x 2 mm.

Modern Development in Cards:

The card is the heart of the spinning mill because if we see the
card sliver, it is just the magnified replica of the yarn. Quality
of yarn is directly  related to the quality of card sliver. Thus the
modern developments, in the carding machine, are carried
out to produce better sliver. The following sections discuss
some of the modern developments in the carding machine.

1. Unidirectional feed Unidirectional feed:

Results in gentle fiber treatment because fiber feed and licker-

in rotation is in the same direction. The latest version of Rieter
card C60 and Trützschler TC 07 feature with unidirectional
feed system.

2. Multiple Licker-in:
The concept of using three licker-in place of one is basically for better cleaning of the feed
material. Here the concept of clamped and unclamped feeding is used. The latest version of
Rieter card and Trützschler card feature with multiple licker-in system. The modular design
of Rieter C 60 card makes it possible to convert from 3 licker-in units to 1 unit.

3. Increase in the carding zone/width of card:

The modern machines achieve production rates of 60 - 220 kg/h, compared with output of 5
- 15 kg/h in 1970. One of the many factors behind increase in the production, without
deteriorating quality, is increase in the carding zone area, particularly width of the card
and/or long carding section.

Use of Autoleveller:

To control card sliver count variations, count CV% and unevenness, modern cards are
equipped with autoleveller.

Developments in Draw frame:

Auto break-draft setting:

Incorrect break draft increases yarn U%, imperfections and neps whereas the total draft
does not affect yarn quality much. Break draft plays a very significant role in yarn quality,
thus must be set correctly.

Ring spinning:
Ring spinning occupies a unique position among the various spinning technologies because
of its versatility in producing stronger yarns from very fine to coarse counts from many
fibers. Ever since its inception, it has undergone developments at a snail’s pace. The
productivity of ring spinning has improved over the years, yet it is very much lower
compared to that of other spinning systems. The recent developments in ring spinning are
mainly concerned with improvements in drive systems, drafting arrangement, design
aspects of ring and traveller, machine monitoring, automation that includes roving stop
motion, roving bobbin transfer, doffing and cop transfer to winding. Other developments
that have taken place such as compact, solo, double-rove and core-sheath spinning, etc.,
have improved the versatility of ring spinning without change in the very basic concept of
ring spinning. Ring spinning celebrated its bicentenary in 2008 but, unlike blow-room,
carding and drawing machines, the basic shape of the ring-spinning machine has not
undergone much of a change. The capacity of ring-spinning machines has increased greatly,
now housing 1680 spindles. In addition, there have been developments in variants of ring
spinning such as ‘double-rove spinning’,

‘solo-spinning’, ‘core-sheath spinning’ catering for hard and soft cores, and ‘compact ring
spinning’. There have also been improvements in productivity and ease of operation,
process and product monitoring, auto-doffing, the linking of roving and winding machines
and in yarn quality.
The productivity of ring spinning has improved over the last two decades, but not at a
satisfactory pace, being several degrees lower than that of other spinning systems. The
productivity of ring spinning is limited by the sliding friction of the traveller that determines
its wear and yarn breaks, despite the incorporation of new designs of rings and travellers
made with new materials and finishes. No major breakthrough in productivity appears likely
in the near future because the traveller is a restrictive factor. A traveller that slides at high
speeds develops considerable frictional heat, and it is extremely difficult to dissipate this
heat in the short time available. Nevertheless, ring spinning is unique among the various
commercial spinning systems, setting the benchmark for yarn strength. Ring spinning is the
most flexible system with regard to the fibers which can be used and the number of yarn
counts that can be spun, which no other spinning system so far has been able to challenge.

Developments in ring spinning:

There are two categories of developments in ring spinning: (1 developments in the machines
with regard to drives, automation, monitoring (process and machine) and the linking of the
ring spinning machine to roving and winding machines to improve productivity and process
efficiency for classical, single ring-spun yarns; and (2) developments leading to derivatives or
offshoots of ring-spinning technologies such as compact, nozzle-ring, double-rove, solo and
core-sheath spinning systems that produce non-classical ring yarns.
Roving guide drive:
In the conventional roving guide, the wear on the roller at the extreme ends of strokes is
quite high due to the sine-curve-like movement of the guide. Zinsser has developed a roving
guide, where the movement of the guide is a combination of small straight lines that evens
out wear on the top roller over the whole traversing width with an improved roving guide
drive, wear on the top drafting cylinders is reduced, increasing the service life of the top
rollers.
Delayed start-up of drafting rollers:
The drive for the drafting rollers is a rigid one (by gears) and the spindle is driven by a
flexible drive (belt). The initial belt tensions on both sides of the spindle are the same while
the machine is at rest. When the ring-spinning machine is started, the belt tension in the
forward direction increases, and at the back it decreases enough to build up the required
torque on the spindle. Additional slackness present on the spindle belt compounds the
problem. The acceleration of the spindle lags behind that of the drafting rollers and the yarn
slackens; if it slackens too much, this might lead to balloon instability and the end breaks.
Delaying the starting of the drafting rollers by a few seconds would solve this problem. In
the Marzoli ring-spinning machine, at the beginning of cop build-up, the starting of the
drafting rollers is delayed so that the spindle starts to rotate first, which tightens the initial
yarn ends. Modification in drafting arrangement
Rotating ring:
A new system, termed ‘magnetic spinning’, has been developed in which the ring is a
magnetically suspended rotor kept inside a fixed stator. The ring can freely carry the
pigtail/traveller at 40,000 rpm. The stator is equipped with four magnetic actuators that
always keep the ring in its central position.
Ring and traveller:
The ring is the race track over which the traveller has to revolve to impart twist to the yarn
balloon. Running at a speed of 110–170 km/hour, the traveller generates heat at its
interface with the inner edge of the ring. As the traveller is very light, its temperature can
reach as high as 300°C in spite of heat losses due to conduction and convection, leading to
localized melting and rapid wear. The problem is aggravated with increased spindle speed
and ring diameter.
Considerable research work has been carried out by the ring and traveller manufacturers,
aimed at reducing the frictional wear of the ring and travellers and increasing heat
conduction at the traveller–ring interface. This has resulted in the use of carbon-rich steel,
lubricated rings, ceramic rings, special finishes (diffusion treatment, nickel plating) and new
designs of ring and traveller combinations with an increased area of contact. Other
developments leading to a revolving ring are yet to be commercialized. The travellers used
for short staple spinning are C-type on a low crown ring/T-ring, Orbit and SU The area of
contact between the ring and traveller is greater in the case of SU and Orbit types, providing
better heat dissipation. The traveller describes an up-and-down motion and tilts in the radial
and tangential planes continuously due to the variation in the balloon size and its tension
and also the change in the lead angle with the ring rail movement. In SU and Orbit rings, the
design of the ring itself provides a certain balancing effect on the traveller while it is tilting/
oscillating. The resultant lifting force on the traveller.
Drive systems:
Changing the yarn count and twist (level and directions) can now be carried out
automatically without any mechanical intervention (change of gears). Another trend is the
division of drafting systems on long ring-spinning machines into two halves, each driven
independently. Ring-spinning machines such as the Rieter G35 Flexi start and the Marzoli
MPT-N and MP1-N have these features. Front and back rollers are driven individually by
frequency controlled synchronous motors running separately on the two halves of the
machine. This facilitates processing two separate lots of fibers that differ in twist and yarn
count. A combination of these two methods offers advantages
such as:
 Time-saving during start-up and doff of the machine
 Spinning of small lots or samples
  Setting of twist, total draft and yarn count by the push of a button.
 Automation in ring-spinning machines
 Automation in ring spinning consists of:
 Transferring the roving bobbin into the creel of the ring-spinning machine
 Stopping the roving feed when an end breaks
 Machine and production monitoring
 Doffing
 Transporting cops to the winder.
Roving bobbin transfer:
On the creel of the ring-spinning machine, optical sensors are placed near each of the roving
bobbins. Full roving bobbins move in the area near the ring-spinning machine. If a bobbin is
exhausted, the movement of roving bobbins is stopped and a T-shaped lever, with pegs at
each end for holding the roving bobbin, comes into action. One side of that lever takes the
new bobbin and the other end takes the empty roving bobbin from the ringspinning
machine’s creel. The lever then rotates through 180° and transfers the fully wound bobbin
to the ring-spinning machine’s creel and the empty bobbin to a creel nearby. The operator
only joins the roving ends, which saves them time and reduces roving bobbin run-out time
caused by operator error in a manual system.
Roving stop motion:
When a yarn breaks during spinning, the drafting rollers continue to process the fiber
strand, and fibers are sucked into an aspirator and go as waste. In poor spinning conditions
(high relative humidity), the drafted fibers lick on to the drafting rollers and form a lap. This
can damage the top rollers and aprons and causes ends-down on the neighboring spindles.
The removal of roller lap also causes additional problems. All the costs (labor, power and
indirect costs) incurred in converting the fibers into roving become unproductive. It would be
desirable to have a roving stop motion that interrupts the flow of fibers from the time an
end breaks until joining is carried out. Roving stop motions can be provided as part of the
travelling device or as assemblies at each individual position. The former is more economical
but the roving stop would not be immediate as in the case of integrated equipment.
Automatic doffing:
There are two types of automatic doffing for ring-spinning machines: stationary and
travelling devices; the former is mostly used in new machines. After completion of a doff,
the doffer, which contains empty ring bobbins and also the provision for holding the fully
wound bobbins, rises from below. Fully wound cops are then gripped by the doffer and
transferred to it, and then empty bobbins are transferred from the doffer to the spindle of
the ring-spinning machine. Subsequently the doffer comes back to its original position and
transfers all the full cops to a conveyor belt, which might be used to transfer them to the
winding machine.
Compact spinning:
Compact spinning is such a system where the yarn can be produced with higher speed, and
better quality and which gives benefit in the downstream. Consequently, fabric made from
the compact yarn gives better look. In conventional ring spinning system, the width or
spread of the fibers emerging out from the front roller is greater than width or diameter of
the yarn. Since the twist is not fully penetrated into the front roller nip, there is always a
'Delta Zone' called "Spinning Triangle".

If the twists are imparted, the fibers at the edges are either loosely bound or lost as a fly and
produce hairy yarn. The main purpose of the Compact Spinning is to eliminate spinning
triangle at front roller, technically speaking the 'weakest point' of the ring spinning. The
elimination of the spinning triangle results in permanent change of yarn structure, which
distinguishes the compact spinning from conventional ring spinning.
Com4Spin® of Rieter:
 The abrasion resistance (Staff tester) of COM4®  yarn is between 40% to 50% higher.
 Hairiness (UT4) is 20-30% lower.
 Hairiness (Zweigle S3 values) is much more sensitive and measured values are up to
60% lower by comparison.
 Yarn strength is 8-15% higher.
 Capacitive uniformity (UT4) also shows better results for yarns finer than 40s Ne.
 Degree of sizing can be reduced thus reduces the cost of sizing and subsequent
desizing.
Suessen Elite® Compact Spinning
 Higher work capacity by 30% (max).
 Higher yarn strength (Figure 12a) by 20% (max).
 Better elongation (Figure 12b) by 20%.
 Lower hairiness (Figure 12c) by 85% (max) Zweigle S3.
 Better yarn evenness.
 Lower imperfection value (IPI).
CompACT3 by Zinser
The UT4 hairiness for carded cotton CompACT3  yarn is 20% lower as compared to
conventional ring spinning. The S3 hairiness value according to Zweigle reduced by 93%
(max).
 Yarn irregularities (Zellweger Uster) show improvements of 6% (max).
 25% (max) lower IPI values (Zellweger Uster).
 20% higher tenacity values compared to the values of conventionally spun yarns.
 Productivity increase at the spinning machine is 10% (max) through increasing the
spinning speed and/or reducing the yarn twist.
 Displacement of the spinning limit by 15% (max).
Toyota's compacting method

RX240NEW-EST-make Toyota's ring spinning frame is equipped with compact spinning

system. The condensing device consists of suction slit and perforated apron and works on
aerodynamic compacting principle.
  Smooth collection of fleece fibers by suction slit and perforated apron.
 Precise slip-free rotation of the perforated apron because of positive drive of the top
and bottom delivery rollers.
 Inverter-controlled adjustable suction pressure.
 Easily detachable condensing unit.
 Perforated apron, driven by a bottom roller, is not affected by top roller diameter.
 Easy switching over to compact and conventional spinning.
Magnetic Compacting System:

Magnetic Compact Spinning, as the name implies, is a compacting system that makes the
compact yarn with the use of magnetic compactor. The RoCoS compact spinning system,
developed by Hans Stahlecker of Rotorcraft Maschinenfabrik, Switzerland is incorporated
into LMW's Ring Spinning Frame.
Self-cleaning apron system:
Zinser CompACT3 is one such development of self-cleaning aprons. Reportedly (Oerlikon
Schlafhorst, 2008) this system gives more uniform and consistent yarn quality. Staff- and
time-intensive inspections for quality assurance purposes are therefore much reduced.

Plied yarn

Efforts to spin two-ply yarn directly on the ring spinning frame have been based on drafting
two fiber strands in parallel but separated a relatively large distance apart. The two fiber
strands are then combined immediately after passing the nip of the front rollers of the
drafting system at the insertion point (Figs 9.14, 9.15 and 9.16), where they are both twisted
in the same direction. This results in a plied or two-fold yarn with the same twist direction as
the individual constituent strands.
Friction Spinning:
Friction spinning has made substantial progress and established itself well in the medium-
and coarse-count sector. It has potential for high production speeds and twisting rates. The
spinning tension is very low and very high twisting rates are possible without the need to
rotate the friction roller at higher speeds. It stands unique in the production of a variety of
multicomponent yarns, which are preferred for technical textiles. The system is also more
versatile in handling all types of natural and synthetic fibers. Friction-spun yarns are not
normally used in the manufacture of conventional textiles, though they find some
applications, especially as pile yarns, as weft yarns, and in certain knitted goods, where bulk
and compressibility are desired. The hollow yarns may provide a new trend for DRE F-3
friction-spun yarns.
TECHNOLOGİCAL DEVELOPMENTS OF DREF SYSTEM
 Dref-2 is one of the earliest friction spinning machines introduced in the market
somewhere around 1977 primarily for long staple fibers to produce coarser yarns was
exhibited in the year 1975 at ITMA exhibition. Dr Ernst Fehrer began work on the
development of the DREF 3 friction spinning system, which was first presented to the public
at the 1979 international textile machinery exhibition (ITMA'79) in Hanover.  Dref-3 is a
development over of Dref-2 system for improving the quality of yarn, productivity and count
range came to the market in the year 1981, and this is a core-sheath type spinning
arrangement and produce component yarns which cannot be produce by other spinning
machines.
Dref 5 was developed by Schalafhorst, Suessen and Fehrer after Dref 3, but this spinning
system was not commercialized due to to various technical difficulties. In 1999 Dref 2000
was demonstrated. It has ‘S’ and ‘Z’ direction is possible without mechanical alterations to
the machine. And this machine also has dust extraction for secondary fibers and low energy
costs due to the use of only 1 fan for 12 spinning heads.
The latest innovation of spinning system is exhibited in the ITMA 2003, the first public
appearance of the DREF 3000 was made. Higher bobbin weights through 200 mm winding
traverse was used (fig.12).  Apart from other dref types, in Dref 3000,the drafting unit can
handle all types of synthetic fibers.
Hollow spindle spinning:
 Application of new materials for hollow spindle construction in order to reduce the
weight and to increase the amount of the wrapping component on the pirn.
 Slow progress in further extending the field of application for hollow spindle yarns,
though this is expected to lead to better acceptance of fancy yarns than of wrap
yarns.
 Developments of finishing treatments for improved appearance of the fabrics,
woven or knitted, made from straight wrap yarns.
Hollow spindle spinning has reached a position in its development that can hardly be
followed by further revolutionary changes. The main challenges of the method are related
to its efficiency, as in the case of the ring spinning method. However, potential
improvements to ring spinning are much more feasible than for hollow spindle spinning. The
main reason is that further increases in ring spindle speeds would have a major impact
owing to the worldwide acceptance of this technology compared with the hollow spindle
process.
Other developments:
The problems associated with air-jet spinning using two nozzles have been harsh and rigid
yarns, difficulty in spinning cotton fibers and poor yarn strength. The method of air-jet
spinning with a single nozzle developed by Murata can produce yarn at 400 m/min. The
problem of generating more wrapper fibers during spinning and consequently improving the
yarn strength has been tackled to a major extent by this new technology.
Development of open-end rotor spinning system:

In ring spinning drafting, twisting and winding of the yarn is carried out simultaneously. By
the end of 19th century process of ring spinning was fairly well perfected. Its output rate
was much than that of self-acting mule which was an intermittent process. Consequently,
the world textile industry made a major shift from mule to ring spinning in the first quarter
of the 20th century. The developments of ring frame were accelerated after its adoption as
 a major system of yarn manufacturing. However, during mid of the twentieth century it was
realized that output rate of ring spinning frame cannot be increased because of inherent
limitations. It was concluded that it has reached a pinnacle of achievement!

The textile institutes, universities and machinery manufacturers accelerated research work
for development of new technologies, which did not suffer from the limitations of ring
spinning frame. The research work led to the development of some new technologies based
on the concept of performance of the processes of drafting, twisting and winding separately
and independently of each other so that following objects can be achieved:

 Full speed of twisting mechanism is utilized for twist insertion.

 Full speed of the winding mechanism is utilized for winding of the yarn for
substantial enhancement of output rates.
Substantial improvements in rotor spinning have increased productivity by 8 - 10 times of
ring spinning. Manufacturing cost benefits from rotor spinning increase with increase in
labor wages and reduction in capital costs. Increased number of rotors per machine, 4
piecing carriages, automatic transportation of drawing cans to rotor machine, and
transport of rotor packages to packing with palletizing reduce labor, and independent
operation of two sides, and individual rotor drive, improve flexibility. Rotor diameter has to
be reduced at high rotor speeds to keep down power consumption. Increased twin disk
diameter, magnetic bearing, and automatic evacuation of filter waste and cooling system
for inverter and motor reduce power consumption. Rotor spinning is one of the
commercially well-established and viable technologies offering high productivity and unique
properties compared to ring spinning. About 35 - 40% yarns are made out of rotor spinning.
Denims, sportswear, upholstery, furnishings, fancy fabrics and even knitted goods are made
from rotor yarns. Marked improvements in machine features with high level of automation
and computerization make rotor spinning more attractive even in medium to fine counts.
Proportions of these machines have gone up by 32 - 37%. Rotor speeds have been increased
by 40 - 50% and power consumption has been reduced by 15 - 20%. Some of the earlier
drawbacks have also been overcome. Merits and limitations of modern rotor spinning in
relation to ring spinning are briefly summarized in this article.
Future trends
The problems associated with air-jet spinning using two nozzles have been harsh and rigid
yarns, difficulty in spinning cotton fibers and poor yarn strength. The method of air-jet
spinning with a single nozzle developed by Murata can produce yarn at 400 m/min. The
problem of generating more wrapper fibers during spinning and consequently improving the
yarn strength has been tackled to a major extent by this new technology. The strength of
yarn produced from this ‘air-vortex spinning’ technology is considerably higher than that
from the previous method but a little lower than that of ring yarns. The air-vortex yarn
surface looks like a ring-spun yarn. Air-vortex spinning has the potential to replace ring
spinning in the medium count range (10–60 Ne). Rotor spinning will expand its market share
for yarns in the range 6–20 Ne. For the production of fine and very fine yarns (60–160 Ne),
especially from cotton fibers, ring spinning will continue to dominate the market.

Future trends for friction spinning:

Friction spinning has reached a plateau with regard to machine design and modifications.
The main drawbacks of friction spinning are the lower yarn strength and the inability to spin
medium and fine counts. Thus, the technical problem still existing at present is that the
individual fibers fed into the spinning nip between the two friction rollers should be – as far
as possible – stretched and evenly distributed, in order to be able to produce finer-count
yarns with tenacities comparable to those of a rotor-spun yarn. Further developments on
friction-spinning machines are clearly focused on optimizing the fiber feed for finer yarn
counts. Nevertheless, the current systems offer ample scope to researchers and textile
technologists for engineering yarns with desired characteristics through optimization of a
wide range of process parameters and the processing of a wide variety of selected raw
materials. New developments and modifications are, however, essential in order to further
improve friction-spun yarn quality and extend the count range.
References:

1.  "Textile Industry of Pakistan - An Analysis - Ravi Magazine".  Ravi

Magazine. 2015-04-22. Retrieved  2017-09-24.
2. ^ "Factsheet Pakistan" (PDF).
Jump up to:a b c d
3. ^         "Textile Industry of Pakistan".
4. ^ Statistics on textile industry in Pakistan
5. ^ "Antique Textile History".  www.textileasart.com. Retrieved 2016-09-
28.
6. ^ Pakistan's Cotton and Textile Economy  – via Google Books.
Jump up to:a b c d e f g
7. ^               Siddique, Rizwan.  "FBR Syndicate Report
8. New Cloth Market: June 2010