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AIR-JET SPINNING

PRESENTED BY:

PERERA H. A. A. E 051034J

PERERA M. S. N 051036R

PERERA M. Y. A 051037V

PERERA P. S. P 051038B
BACKGROUND
Air Jet entered the market in the mid
eighties as a promising new technology to
replace ring spinning. Yarns produced by this
system have outside binding fibres wrapped
around a core of parallel fibres. This yarn
structure offers many potential advantages, one
of the most important being that since no real
twist is present in the final yarn it should be
possible to achieve high production rates.

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TWIST TRANSFERENCE
The potential of using twist transference to
create this “new” yarn structure was first promoted by
Du Pont in their early patent, which utilized an air-jet to
false twist the yarn. This system achieved little
commercial success.

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DUPONT SYSTEM

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RIETER AIR-JET
A fluid generating
device creates eddy
currents around the
inlet mouth aperture to
incorporate individual
fibres into an end of a
yarn being formed in
the yarn guidance
channel.

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MURATA JET SPINNING
The introduction of Murata Jet Spinning
seemed to address the issue of wrapper fibre
distribution, since the use of two contra-rotating
jets promotes better wrapping by ensuring later
capture of the edge fibres. This was the first
commercialisation of Air-Jet Spinning . The
following graph shows a comparison of yarns
formed with single jet, two jets twisting in the
same direction (Dual jets) and two contra-
rotating jets (Twin jets as with MJS).
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INFLUENCE OF JET PRESSURE &
CONFIGURATION ON YARN TENACITY

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MURATA JET SPINNING PRINCIPLE
• Two air jet nozzles,
which create air-
vortices rotating in
opposite directions.

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DEVELOPMENT OF MURATA
AIR-JET MACHINES

• MURATA JET SPINNER (MJS)


• MURATA TWIN SPINNER (MTS)
• MURATA VORTEX® SPINNER (MVS)

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MJS & MTS VS RING SPINNING

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IMPORTANT PARTS OF MJS & MTS
1. Sliver - Two-ply or Single ply.
2. Draft Unit - Super High Draft. Super high draft ratio up to
330 enables to use heavier sliver. Stable and high quality
spinning of finer count is also possible.
3. Spinning Unit - Energy Saving. Each spindle of air supply
is controlled by solenoid valve. During end break, air
supply is stopped to save energy.
4. Yarn Clearer
5. Waxing Device (Optional) - Alarming for residual wax
amount is indicated on the unit to facilitate quality
control and operation management.
6. AD Carriage - The compact and simple designed
Automatic Doffer is installed on the knotting carriage. The
package is doffed in 19 seconds cycle and is automatically
loaded onto the front shelf.
7. Package
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MJS & MTS SPINNING SYSTEM
After passing
drafting zone, the
fibre strand passes a
device with two
nozzles. A counter
clockwise vortex is
set up in jet 1 to give N1 – 2.5 Kg/cm2
Z false-twist, and a
clockwise vortex in
jet 2 gives S false N1 – 4.0 Kg/cm2
twist.
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MJS & MTS SPINNING SYSTEM…
• As the pressure of jet 2 is larger than that of jet 1, it
enables S twist from jet 2 to propagate along the
false-twisted core and null the Z twist of jet 1, leaving
some S-twist to travel toward the nip line of the front
rollers.

• Because of the reduced twist at front roller, some


of the fibres in the bundle gets separated from
the main fibre bundle and become wound around
the fibre bundle by the force of the N1 nozzle. The
fibre stand coming out of N1 is then twisted by N2.
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SPINNING SPEEDS OF MJS & MTS

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MURATA JET SPINNER (MJS)

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MJS YARN COUNT RANGE
The possible yarn count range that can be
spun on Air-Jet machines depends on the Jet
architecture, fibre length, fibre type and also the
blending ratio of fibres.

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MURATA TWIN SPINNER (MTS)

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MTS YARN COUNT RANGE
The possible yarn count range that can be
spun on Air-Jet machines depends on the Jet
architecture, fibre length, fibre type and also the
blending ratio of fibres.

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LIMITATIONS OF MJS & MTS AIR-
JET SPINNING
• Coarser yarn are weaker

• Difficult to spin 100% cotton yarns with


adequate strength
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VORTEX® SPINNING PRINCIPLE

• changing
the system
from “two
dimensional”
to “three
dimensional”.

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VORTEX® SPINNING SYSTEM - JET
Hollow Spindle

N1 – 5.5 Kg/cm2

Drafted Sliver Vortex Chamber

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VORTEX® SPINNING SYSTEM
The leading ends of the fibre bundle are
drawn into the hollow spindle by the fibres of
the preceding portion of the fibre bundle
being twisted into a spun yarn. The trailing
ends of the fibres are inverted at the inlet,
separated from each other, and exposed to the
swirling air blown through the nozzles. The
trailing ends of the fibres are thereby caused
to twist around the porting of the fibre bundle
being converted into a spun yarn.
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VORTEX® MACHINE (MVS)

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VORTEX® VS RING SPINNING

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IMPORTANT PARTS OF VORTEX®
1. Sliver - Two-ply or Single ply.
2. Draft Unit and Cleaner - The inverter
controlled draft roller is easily set and
ensures stable and high quality spinning.
3. Spinning Unit - The unique yarn formation
that all fibres are formed from centre
toward outside, makes the functional and
fashionable yarn, “VORTEX®”.
4. Muratec Spin Clearer (MSC) - The MSC
enables easy and accurate centralized
operation with quality control. When
equipped with the MSC-F (optional), it is
able to detect foreign fibre.
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IMPORTANT PARTS OF VORTEX®...
5. Tension Ruler - The Tension Ruler ensures
uniformed winding tension. This makes
the packages optimal for the following
process.
6. Waxing Device (option) - Wax up to the
size of 45mm can be equipped, assuring
higher production efficiency.
7. Splicer - The optimum timing cycle control
contributes to improvement of
productivity through reduction of waste
yarn and splicing error. You can also select
knotter.
8. Package
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IMPORTANT PARTS OF VORTEX®...
Core Yarn (Optional) - There is a special device which is used
to supply the core yarn to the spinning system. This device
is optional and can be attached only if intend to manufacture
core yarns. This special core yarn supplying device has the
following features.
• Automatic core yarn supply function
• Core yarn detection
• 3 kinds of core yarn devices
– Filament core yarn device
– Spandex core yarn device
– Hybrid type which is combined with filament and
spandex core yarn device.
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VORTEX® SPINNING SPEEDS

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VORTEX® MACHINE YARN
COUNT RANGE

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COMPARISON OF RING YARN &
VOTEX® YARN FORMATION

Ring Yarn VOTEX® YARN

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VOTEX® YARN STRUCTURE
In VORTEX® spinning, the tip of the
fibre is focused to the centre of the yarn by
the vortex of compressed air so that the
centre of the yarn is always made straight
without twisted. The other tip forms the
outer layer that twists another fibre. The
yarns manufactured from this technology
are called VORTEX® yarns.

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VOTEX® YARN STRUCTURE
Recent analysis of the general structure of VORTEX®
yarns, indicate that they are quite different from Air-Jet
spun yarn in respect of the Wrapper fibres.

Before Untwisting After Untwisting


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TWIST STRUCTURE OF VOTEX® YARN
• The vertical axis in the
graph shows the tightness
of twisting. Z-twist and S-
twist indicate the
directions of twisting
centring on “0”.

• The horizontal axis in the


graph shows the distance
from the centre in a cross
section of the yarn.
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RING YARN TWIST SEEN FROM SIDE
There is no non-twisted section. Twist of a
certain level are given to the entire yarn from the
centre to the surface of the yarn. The yarn
thickness is uneven. Twisting is concentrated at
the thinner sections, while twisting is loose at
the thicker sections and hairiness tends to come
out.

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ROTOR YARN TWIST SEEN FROM SIDE
All fibres are twisted from the centre to
the outer side. For fibres near the surface of the
yarn, twisting is uneven, and sometimes,
twisting can happen in the opposite direction
from around the centre.

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VORTEX® YARN TWIST SEEN FROM SIDE
The centre of the yarn is not twisted.
Twisting is given toward the outer side of the
yarn, twisting at the centre of the yarn is loose,
while the outer side is fully twisted.

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VORTEX® CORE YARN

• VORTEX® can offer


not only the original
functional
characteristics, but
also specialized
yarns such as core
yarn which use
filament for the
core component.

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VORTEX® CORE YARN FEATURES
• Fewer knots - Unlike ring spinning, VORTEX®
directly spins yarns throughout a process from
spinning to winding, and forms fewer knots which may
lead to fabric defects.

• The core is not twisted - The core, which is of


multi filament or spun yarn, is not twisted during yarn
formation. Therefore, the core yarn is free from the
damage of core filament, which is especially fragile
under torsion load, minimizing reduction of yarn
strength.
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VORTEX® CORE YARN FEATURES...
• The core is located in the centre of yarn - The
core tends to move into the centre of the yarn and
covering fibres are firmly rooted in the core. This is
why the VORTEX® do not expose the core when
stretched.

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VORTEX® CORE YARN FEATURES...
• Spandex core yarn that free from ‘Slip in’ trouble
As the core is
properly held by
covering fibres, 'Slip
in' at fabric ends is
eliminated, reducing
the possibility of 'no
core fabric' or
problems at sewn
fabric ends.
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VORTEX® YARN TYPES – 100% COTTON

Carded US-Upland Combed US-Upland Combed Egypt-Giza


cotton cotton cotton

Ne10/1 (59/1 Tex) Ne40/1 (15/ Tex) Ne80/1 (7.4/1 Tex)

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VORTEX® YARN TYPES – COTTON
BLENDED
Linen/Cotton (15%/85%) Acrylic/Cotton (50%/50%)

Ne16/1 (37/1tex) Ne20/1 (30/1tex)

Combed cotton/Modal Carded cotton/Polyester (1.3dtex, 38mm)


(50%/50%) (60%/40%)

Ne30/1 (20/1tex) Ne30/1 (20/1tex)


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VORTEX® YARN TYPES – SYNTHETIC &
REGENERATED
100% Synthetic fibre 100% Acrylic 100% Polyester (1.7dtex, 38mm)
(1.3dtex,38mm)

Ne20/1 (30/1tex) Ne20/1 (30/1tex)

100% Regenerated fibre 100% TENCEL 100% Functional polyester


(1.3dtex, 38mm) (1.7dtex, 38mm)

Ne24/1 (25/1tex) Ne40/1 (15/1tex)


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VORTEX® YARN TYPES – SYNTHETIC &
REGENERATED CONTD…
100% Viscose/Rayon 100% LYOCELL

Ne30/1 (20/1tex) Ne40/1 (15/1tex)

100% MICRO MODAL TENCEL/MODAL (1.3dtex, 38mm)


(1.0dtex, 38mm) (50%/50%)

Ne80/1 (7.4/1tex) Ne40/1 (15/1tex)


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VORTEX® YARN TYPES –
SYNTHETIC/REGENERATED FIBRE BLEND
Polyester/Bamboo-Rayon Acrylic/Viscose-Rayon
(50%/50%) (50%/50%)

Ne40/1 (15/1tex) Ne16/1 (37/1tex)

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TWIST STRUCTURES OF VOTEX® YARNS
• In the case of 100%
cotton, twisting starts
near the centre of the
yarn, and the outer side is
fully twisted.

• In the case of the


synthetic fibre, the zero
twist area is larger, and
twisting is made stronger
toward the outer side.
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TWIST STRUCTURES SEEN FROM SIDE

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FEATURES OF VORTEX® YARN
Less Hairiness Moisture Absorption
VORTEX® has the least of VORTEX® yarn structure makes
hairiness among all the types of absorbed water diffuse instantly
spun yarn, which maintains the which provides refreshing feeling
clear appearance of VORTEX®. when wearing.
FEATURES
OF VOTEX®
YARN
Resistance to Pilling Wash Resistance
The structure of VORTEX® hardly VORTEX® prevents waste fibre
emits hairiness, so pilling is from being generated, so
extremely suppressed. repeated washing hardly deforms
cloths.

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HAIRINESS
In VORTEX® spinning, each fibre is spun
toward the centre of the yarn and wrapped by
other fibres. Therefore, fibre is firmly kept
in internal layers of the yarn to prevent
fibre from sliding. This reduces the hairiness
of the yarn and gives a clear appearance. Due
to this, occurrence of lint is also suppressed,
and this reduces troubles in post-spinning
processes
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Hairiness – Yarn Comparison

Ne 38/1 (16/1 Tex) Carded cotton Ne 38/1 (16/1 Tex) Combed cotton
of VORTEX® yarn of Ring yarn

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Hairiness – Garment Comparison

Ne 38/1 (16/1 Tex) Carded cotton Ne 38/1 (16/1 Tex) Combed cotton
fabric of VORTEX® yarn fabric of Ring yarn

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Comparison of Hairiness – 100% Cotton

Carded cotton 100%, Ne 30/1 (20/ 1 Tex)


The number of hairiness per 100m measured
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Comparison of Hairiness – 100% Polyester

Polyester 100%1.7 dTex, 38 mm


Ne 20/1 (30/1 Tex) for weaving, Ne 30/1 (20/1 Tex) for knitting
The number of hairiness per 10m
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MOISTURE ABSORPTION
VORTEX®’s fibre structure itself is good
in moisture absorption and diffusion, which
provides refreshing comfortableness absorbing
moisture. VORTEX® yarn structure makes
absorbed water diffuse instantly which
provides refreshing feeling when wearing (Dry
Touch). This is because the core is not twisted in
the yarn; therefore the water can diffuse
through the core quickly.
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Absorbing Sweat

Cotton 100% pile Ne 20/1 (30/1 Tex)

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Diffusion of Absorbed Water

Dropping ink at the


start line, and
comparing the speed
of absorbing water

Single jersey Ne 30/1


(20/1 Tex) 28G

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RESISTANCE TO PILLING
Pilling is a phenomenon where fibres are
inter-twisted into a ball-like shape by frictions
between the surface of a textile and that of
another. Since it is of structure with less
hairiness, VORTEX® remarkably suppresses
pilling, and has created new markets. Because
VORTEX® not only has less long hairiness but also
is structured so that fibres forming the textile
hardly slide because they are inside, so fibre
friction makes textiles resist pilling.
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Comparison of Pilling (Weaving)

200 - count sheet: Ne 41/1 (14/1 Tex) PE50/C50

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Comparison of Pilling (Knitting)

Piling rate 3.5 Piling rate 1.0


ICI Method

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Comparison of Pilling – 100%
Carded Cotton

Random pilling test 60 min exposure

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Comparison of Pilling – Polyester
Cotton Blend

ICI pilling test


10 hours for weaving, 5 hours for knitting

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WASH RESISTANCE
• VORTEX® structure reduces fibre bring washed
away at washing, so repeated washing hardly
deforms cloths. Despite repeated washing and
drying, the VORTEX® pile (In towels) significantly
reduces lint shedding.
• This advantage derives from yarn structure itself
having less fluffs and firmly retaining fibres inside.
VORTEX® is also resistant to size changes,
skewness or colour fading due to wash resistance.
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Knit Fabrics (Rib) after Five
Laundry Sessions

Ne40/1 (15/1 Tex) Rayon Ne40/1 (15/1 Tex) Rayon


100% of VORTEX® yarn 100% of Ring yarn

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100% Cotton Pile after Five
Laundry Sessions

Ne13/1 (45/1 Tex) Ne13/1 (45/1 Tex)


Carded cotton of Carded Cotton of OE-Rotor yarn
VORTEX®

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Dimensional Stability after Laundry

Single Jersey
Combed cotton 100% Ne 40/1 (15/1 Tex)

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Skewness after Laundry

Single Jersey
Combed cotton 100% Ne 40/1 (15/1 Tex)

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Colour Loss after Laundry

5.0 = Negligible or no colour alteration 2.0 = Considerable colour alteration


4.0 = Slight colour alteration 1.0 = Much colour alteration
3.0 = Noticeable colour alteration
Polyester 100% Ne 12/1 (50/1 Tex)

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Suppression of Lint Shedding

Cotton 100% pile Ne 20/1 (30/1 Tex)


Lint shedding rate: Accumulated lint

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Lint Shedding at 100% Cotton

Lawson-Hemphil lint tester


Testing speed: 150m/min
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END USES OF VOTEX® YARN
The new yarn VORTEX® created by VORTEX®
spinning provides diversified excellent functions.
VORTEX® has many characteristics with a rich
combination of functional and fashionable features.
These functional and fashionable features make
VORTEX® highly recognized as the most appropriate
material for some end uses. This unique spinning
technology makes many apparel companies able to
develop products with VORTEX®.

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TOWEL

Features of VORTEX® yarn


such as bulkiness and
quick drying are very
effective for manufacturing
highly-functional towels.
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SOCKS

The structure of VORTEX®


yarn that causes less pilling
and quick drying fits socks
exposed to hard frictions.

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INNER WEAR

Good inner wears can be


produced with VORTEX®’s
features of wash resistance
and less pilling. Innerwear also
requires dry touch feeling.
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KNIT WEAR

Knitwear clothes can be


made with VORTEX®’s
features of less hairiness,
resistance to pilling, quick
drying and stability against
deformation.
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BOTTOMS

The structure of VORTEX® yarn


that has clear appearance and
less pilling and less hairiness
fits bottoms exposed to hard
movements.
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SWEAT SHIRTS

Sweat shirts require a dry-touch


feeling. VORTEX® with less pilling
and hairiness provides a pleasant
texture and a refreshing feeling.
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BED SHEETS

VORTEX® causes less hairiness


and pilling, and can produce
bed sheets with a refreshing
and pleasant texture.
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PYJAMA

Pyjamas require high-level


functions to absorb sweat and
regulate body temperature.
VORTEX® yarn structure can
meet such requirements.
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T-SHIRTS

For T-shirts, the typical everyday


wear, comfortable feelings such
as touch of cotton, in addition
to quick drying, are essential
requirements.
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POLO SHIRTS

VORTEX® restrains hairiness and


pilling, and provides a dry-touch
feeling. So, it can be used for
polo shirts. Stability against
deformation is another essential
requirement.
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WORKING WEAR

Since working wear undergoes


hard movements, wash
resistance and quick drying are
very important. It also needs to
be stable against deformation.
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ADVANTAGES OF AIR-JET SPINNING

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ADVANTAGES OF AIR-JET SPINNING…

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ADVANTAGES OF AIR-JET SPINNING…

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ADVANTAGES OF AIR-JET SPINNING…

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ADVANTAGES OF AIR-JET SPINNING…
• Wide yarn count range

• Higher production rates • Quick Response


• Process Integration • Automation
• Easy Quality Control • Reduced Labour
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DISADVANTAGES OF AIR-JET
SPINNING

• Low yarn Strength


• No accurate TPM value for the yarn
• High investment cost

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RESEARCHES DONE
USING AIR-JETS

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Yarn Formation with a False-twist Method
in the Air-jet Spinning Chamber
• Combination of MJS(Murata jet spinning)
and OE(Open end) spinning
• Main parts of the developed machine
 forked (Y-shaped) inlet channel
 Two air jet nozzles

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Yarn Formation with a False-twist Method
in the Air-jet Spinning Chamber...
• Length of the inlet channel l has to be
significantly lower than the length of the
fibres
• Draft is obtained by the velocity
difference between feeding rollers and
yarn pulling velocity from the first nozzle
• Two nozzles rotates the yarn in to same
direction.
 Nozzle speed = 2350 r.p.s.
 Twist=1175 turns/m
• S twist - feeding rollers to 1st nozzle
• Z twist - 2nd nozzle to take down rollers
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Yarn Formation with a False-twist Method
in the Air-jet Spinning Chamber...
• The yarn in the formation zone between feeding and take-off
rollers has a form of a helix with an opposite inclination to the
air vortex direction, and it rotates along the drive direction
with the speed of 2200 – 2500 r.p.s.
• The yarn in the spinning start-up process is formed according
to the open-end (OE) principle.
• The number of twists in the yarn between the chamber and
take-off rollers is too low to ensure sufficient strength of the
yarn that guarantees the continuity of the spinning process.

Surface of a output yarn

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Using Air Jet Nozzles for Ring
Spinning to reduce the Hairiness
• Hairiness in Ring Spinning
• Specially Cotton being a finer and shorter fibre would
present more ends per unit length, which increases the
number of fibres protruding out of the yarn surface and
affects its surface and structural properties.

• Reducing Hairiness in Ring Spinning


• before the fibre strand is delivered out of the front roller nip
• surface fibres bound inside the yarn
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Air Vortex Ring Spinning

• The air vortex ring


spinning system
combines air jet
and ring spinning
technologies.

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Air Jet Nozzle Design Vs Yarn
Properties
Experiment:
1. Produce yarn with ring spinning without the air jet
nozzle
2. Two air jet nozzles were designed. They are similar
in all dimensions, but different in the direction of air
flow
• Type 1 nozzle: produce air vortex to same direction of
yarn twist
• Type 2 nozzle: produce air vortex to opposite direction
to yarn twist
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Experiment Results

Hairiness Tenacity Elongation


Type of Nozzle
(above 3mm for 100m) (g/Tex) (%)

No nozzle 150.9 20.77 5.41

Type 1 74.5 21.6 5.71

Type 2 109.5 20.36 5.31

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Effect of Direction of Rotation of
Air Vortex on Hairiness
• Test results shows that employment of air jet
nozzles reduces the hairiness level in the yarn
• The quantum of reduction is more with Type 1
nozzle when compared to that achieved with
Type 2 nozzle.
• The hairiness reduction with Type 1 nozzle is
50.6%, whereas the hairiness reduction with
Type 2 nozzle is 27.4%.
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Effect of Direction of Rotation of
Air Vortex on Hairiness...
• In case of Type 1 nozzle the air vortex produced by the
upward swirling air current tucks the protruding fibres,
particularly the trailing hairs, onto the yarn surface.
• In case of Type 2 nozzle, the air vortex produced by the
upward swirling air current false twists the partially twisted
yarn in the direction opposite to that of yarn twist. It loosens
the fibre strand, when by the tucking of fibres on to the body
of the yarn takes place. As the yarn comes out of the nozzle
the loosened fibre strand gets tightened by the flow of twist
from the mechanical twisting agency, when by the binding of
the tucked fibres takes place.
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Effect of Direction of Rotation of
Air Vortex on Tensile Properties

• Type 1 nozzle increases the tenacity and


elongation percentage by 4% and 7.3%, over
parent yarn,

• Type 2 nozzle there is not much difference


(rather decreasing) in the tensile properties
over parent yarn.

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Effect of Direction of Rotation of
Air Vortex on Tensile Properties…
This could be explained as:

• with Type 1 nozzle there is a reduction of 50% in hairiness. This


substantially reduced hairiness in the yarn structure makes all the
component fibres to share the tensile load which results in
increased tenacity as well as elongation percentage.

• In case of Type 2 nozzle, even though there is a reduction of


hairiness to the tune of 27.4%, it is not significant enough to
increase tensile properties and since the fibre strands are
loosening the tensile strength and elongation may drop.
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RESEARCH SUMMARY
• Air vortex ring spinning system in general improves the
quality of cotton yarn with marked reduction in
hairiness.
• Air vortex ring spinning system fitted with air jet nozzle
creating the air vortex in the direction same as that of
the yarn twist gives better results in terms of hairiness
reduction, increase in tenacity and elongation and
reduction in imperfection level when compared to that
with the air jet nozzle creating the air vortex in the
direction opposite to that of the yarn twist.

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CONCLUSION
The road from the original DuPont set up to the
VORTEX® system has been viewed as an evolution since,
at each stage, sources of problems and limitations have
been determined and elegant solutions have been
found. VORTEX® spinning system is more versatile and
economical compared to other spinning systems.
VORTEX® spinning represents the next logical
development and there is no doubt that experience
gained with the system and ongoing refinements in
component design, will lead to potential improvements
in both yarn quality and productivity.
8/21/2008 AIR-JET SPINNING 101
THANK YOU

8/21/2008 AIR-JET SPINNING 102

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