Definition Of Winding

• Winding is one of the most important operation,

which is mainly occurred in spinning section.
Besides, it is also important in fabric manufacturing.
• The creation of large yarn packages that can be
easily unwound, is called winding.
• This makes using the yarn on subsequent machines
both easier and more economical.
• So we can say that, the process of transferring yarns
from ring, bobbin, hank into a suitable package is
called winding. It may be electrical or mechanical.
• For warp winding → Cone, cheese, flanged bobbin.
• For weft winding → Pirn, cop.
 Objects Of Winding
• To transfer yarn from one package to another suitable
package, this can be conveniently used for weaving
process.
• To remove objectionable yarn fault up to optimum level
• To remove yarns fault like hairiness, naps, slabs,
foreign matters.
• To make yarn smooth by applying wax on the yarn
surface
• To remove dirt and dust from the yarn up to some
extent
• To clean yarn.
• To increase the quality of yarn.
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• To get a suitable package.
• To store the yarn.
• To enlarge the yarn package.
• To transfer the yarn from a small package to a
bigger package suitable for the next processes.
• To eliminate yarn knots and bad piecing by using
auto splicing in the winding process.
• To increase the efficiency of warping and weaving
by bigger size of a package of yarn
• To make the handling of yarn easy, smooth and
safe.
principles of cone winding machines
• The winding speed of the
machine can be adjusted
from 200 to 400
meters/minute to suit
yarns of different
qualities and counts.
• For cotton the yarn speed
is 400 m/min
• For spun rayon the yarn
speed is 400 m/min
• For nylon the yarn speed
is 350 m/min
principles of cheese winding machines
• Supply package consist of
ring bobbin
• Fitted on the bobbin holder,
which holder vertical position
• The yarn passes through
thread eye , situated at 1, ½
inches over the tip of the
bobbin.
• Then yarn pass though
slub-catcher, removes yarn
defects such as slubs, neps,
thick places, foreign
impurities
• Tension device not attach in
this m/c becouse m/c run high
speed so maintain yarn
tension itself.
 Drum and precision winding
Non Precision Winding
By this type of winding the package is formed by a
single thread which is laid on the package at
appreciable helix angle so that the layers cross one
another and give stability to the package. The
packages formed by this type of winding are less
dense but is more stable.
 Features of drum winding
• Only one coil is used to make this package.
• Cross winding technique is used.
• The package density is low.
• Minimum number of yarn is wound.
• The package formed is soft and less compact.
• The stability is high.
• Flanges are not required.
• The rate of unwinding is high and the process is
easy.
 Precision Winding

• By precision winding successive coils of

yarn are laid close together in a parallel
or near parallel manner.
• By this process it is possible to produce
very dense package with maximum
amount of yarn stored in a given volume.
 Features of Precision Winding
• Packages are wound with a reciprocating traverse.
• Patterning and rubbing causes damage of
packages.
• Package contains more yarn.
• Package is less stable.
• The package is hard and compact.
• The package is dense.
• Rate of unwinding of package is low and the
process of unwinding is hard.
• The unwound coil is arranged in a parallel or near
parallel manner.
 Different between drum and
precision winding:
Drum winding
• The wound coil is arranged
parallel or near parallel
• Yarn density of the package is
high
• No air gaps
• Winding angle is 0 or near 0
• Yarn tension is relatively more
at the time of winding
• Yarn withdrawal process is
relatively difficult
Precision winding
• Yarn coil is cross wise wound.
• Yarn density of the package is
low
• Air gaps of found
• Winding angle is greater than
15.
• Yarn tension is relatively less
at the time of winding.
• Yarn withdrawal process is less
difficult.
 Uniform build of yarn package
Package build Packages may be broadly categorized into two
groups, namely :
(1) flanged and
(2) flangeless.
• A flanged package (Fig. 1.3) is equipped with two discs
mounted on the package tube. These discs are provide
lateral support to the yarn wound in the intervening space.
• The flangeless package (Fig. 1.2) does not exhibit any such
support. The build of the package, i.e. the exact manner in
which yarn is wound around and along the tube, the yarn
mass has to be self-supporting.
 Control of balloons
Thread guide and balloon
breaker:
The yarn after being unwound
from the supply package is
immediately made to pass through
a metallic thread guide above it.
The yarn passes to the other
devices of the winding machine
after passing through the thread
guide. Different types of thread
guides are used. Some of the
well-known ones are the roller
guide, winding accelerator etc.
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• This balloon breaker for high-speed winding is
mounted in the pocket of the active bobbin and
comprises a U-shaped stamping with parallel legs
disposed horizontally and formed with upper and
lower alined eyes which are open to respectively
receive the running thread and the upper end of the
supply
• Problem to be solved: To reduce the yarn-taking
resistance of a balloon breaker to facilitate a yarn
taking work.
• Solution: The balloon breaker disposed between a
yarn winder and a yarn guide disposed apart from the
yarn winder is characterized that the balloon breaker.
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• Purpose: Fabric structure and a manufacturing method
thereof are characterized by weaving normal doubled weft
and normal doubled warp to increase tensile strength and
tearing strength, having light weight per a unit area as
compared with fabric arranged vertically and repeatedly to
make weight.
Effect of balloon breaker:
• Increase in balloon height causes increase in yarn tension.
• Reduction in balloon count cause increase in yarn tension
• Highest possible tension is seen with single balloon
formations.
• With the same balloon count an increase in unwinding
speed causes increase in yarn tension.
• Unwinding direction influence the balloon tension.
 Classification of yarn faults and its
removal
• Slubs,
• Neps,
• Snarl,
• Thick & Thin places,
• Soft yarn,
• Oil stained yarn,
• Crackers,
• Bad piecing,
• Hairiness,
• Spun in fly,
 Slubs
• An abnormally thick place or
lump in yarn showing less
twist at that place.
• Effect: More end breaks in the
next process.
• Damaged fabric appearance.
• Shade variation in dyed fabrics.
 SLUBS
Causes:
• Accumulation of fly and
fluff on the machine parts
• Poor carding
• Defective ring frame
drafting and bad piecing
• Improperly clothed top
roller clearers
Rectification:
• Machine surfaces to be
maintained clean
• Proper functioning of
pnemafil/roller clearers to be
ensured.
• Broken teeth gear wheel to be
avoided and proper meshing to
be ensured.
• Better fibre individualization
at cards to be achieved.
• Optimum top roller pressure
and back zone
• Setting at ring frame to be
maintained
 Neps
• Containing rolled fibre mass,
which can be clearly seen on
black board at close distance,
measurable on Uster
imperfection Indicator.
• Effect:
• Damaged fabric appearance
• Shade variation in the dyed fabrics
• An abnormally thick place or
lump in yarn showing less twist at
that place is called slubs
 NEPS
Causes:
• Accumulation of fly and
fluff on the machine parts
• Poor carding
• Defective ring frame
drafting and bed piecing
• Improperly clothed top
roller clearers.
Rectification:
• Machine surfaces to be
maintained clean.
• Proper functioning of
pnemafil/roller clearers to be
ensured.
• Broken teeth gear wheel to
be avoided and proper
meshing to be ensured
• Better fibre individualization
at cards to be achieved.
 Snarl
• Yarn with kinks (twisted onto
itself) due to insufficient tension
after twisting.
• Effect:
• Entanglement with adjacent ends
causing a break
• Damaged fabric appearance
• Shade variation in dyed fabric.
• Improper meshing of gear wheels
• Mixing of cottons varying widely
in fibre lengths and use of
immature cottons.
 Snarl
Causes
• Higher than normal twist in
the yarn
• presence of too many long
thin place in the yarn
Rectification:
• Optimum twist to be used
for the type of cotton
processed
• Drafting parameters to
minimize thin places in the
yarn to be adopted
• The yarn to be conditioned
• Correct tension weights and
slub catcher settings to be
employed at winding
 Thick & Thin places
• Measurable by Uster
Imperfection Indicator and
observable on appearance
• Effect:
• Eccentric top and bottom
rollers
• Insufficient pressure on top
roller
• Worn and old aprons improper
apron spacing
• Improper meshing of gear
wheels
• Mixing of cottons varying
widely in fiber lengths and use
of immature cotton.
 Thick & Thin places
Causes:
• Eccentric top and bottom
rollers
• insufficient pressure on top
roller
• Worn and old aprons and
improper apron spacing
• Improper meshing of gear
wheels
• Mixing of cottons varying
widely in fibre length and
use of immature cottons
Rectification:
• Eccentric top and bottom
rollers to be avoided
• Top arm pressure checking
schedules to be maintained
strictly
• Wide variation in the
properties of cotton used in
the mixing to be avoided
• Better fibre individualization
at cards to be achieved
• Correct spacers to be utilized
 Soft yarn
• Yarn which is
indicating lesser twist
• Effect:
• More end breaks in
subsequent processes
• Shade variation in dyed
fabrics
 Soft yarn
Causes: Rectification:

• Slack tapes dirty jockey • Vibration of bobbins on the

pulleys
• Improper bobbin feed on the
spools
• Less twist in the yarn
• Bad clearing at the traveller
spindles to be avoided
• Proper yarn clearing to be
ensured
• Periodic replacement of
worn rings and travellers to
be effected
 Oil stained yarn
• Yarn stained with oil • Rectification:
• Effect: Appropriate material
• Damaged fabric appearance
• Occurrence of black spot in
handling procedures
fabric to be followed
• Causes: • Oilers to trained in
• Careless oil in the moving parts, proper method of
over head pulleys etc.
• Piecing’s made with oily or dirty
lubrication
fingers • Clean containers to be
• Careless material handlings utilised to be utiliced
for material
transportation
 Crackers
• Very small snarl-like places in
the yarn which disappear when
pulled with enough tension or
yarn with spring-like shape
• Effect:
• More breaks in winding
• More noticeable in polyester and
cotton blended yarn
 Crackers
Causes:
• Mixing of cotton of widely
differing staple length
• Eccentric top and bottom
rollers
• Non optimum temperature
and relative humidity in the
spinning shed
• Over spinning of cotton
•
Rectification:
• Optimum top roller pressure
to be maintained
• Mixing of cottons varying
widely in fibre length to be
avoided
• Use of properly buffed
rollers free from eccentricity
to be ensured.
 Hairiness
• Protrusion of fibre ends from
the yarn structure
• Effect:
• More end breaks in winding
• Uneven fabric surface
• Beads formation in the fabric in
the case of polyester/cotton
blends
 Hairiness
Causes:
• Causes:
• Use of cotton differing
widely in the properties in
the sme mixing
• Use of worn rings and
lighter travellers
• Maintaining low relative
humidity, closer roller
setting and very high spindle
speeds
• be avoided
Rectification:
• Use of travellars of correct size
and shape and rings in good
condition to be ensured
• Periodic replacement of
travellars and suitable
• Roller settings to be maintained
• Optimum relative humidity to
be maintained in the spinning
room
• Wide variation in the properties
of cottons used in the mixing to
 Spun in fly
• Fly or fluff either spun
along with the yarn or
loosely embedded on
the yarn
• Effect:
• More breaks in winding
 Spun in fly
Causes
• Accumulation of fluff over
machine part
• Fanning by workers
• Failure of over head
cleaners
• Malfunctioning of
humidification plant
•
Rectification:
• Machinery surfaces to be
kept clean by using roller
pickers
• Performance of over head
cleaners and humidification
plants to be closely
monitored
 Concepts in yarn clearing
• Yarn clearers After crossing the splicer, the yarn
reaches in clearing zone of yarn winding machine
where it gets checked for splice, long defects, and
repetitive defects such as thick and thin places &
foreign fibers.
• The yarn passing through a clearer at a speed of
1000–1500 m/min is scanned either for its
dielectric properties by a sensor working on
capacitance principle or for its optical diameter
reflectivity by optical sensors.
• Yarn clearer is a device that is used to remove the
objectionable faults of yarn in order to increase
the yarn quality and weaving efficiency.
 Mechanical yarn clearers:

• This is conventional class of yarn clearers in which

simple mechanisms are employed to clear the yarn
as much as possible. The efficiency of mechanical
type clearer remains less than electronic yarn
clearers. Mechanical yarn clearers can be divided
in two parts.
(a) Conventional blunt type
(b) Serrated blade type
Both conventional and serrated blade-type yarn
clearers are shown in Fig. 1.56
 Electronic-type yarn clearers

Capacitance-type electronic yarn clearer

Capacitance is the property of a
capacitor to store energy in the form of
an electric field between two conducting
plates.
 Functioning principle of
capacitance-type electronic yarn
clearer :
• When the yarn passes through this measuring field
(between the capacitor plates), an electrical signal is
produced which is proportional to the change in mass per
unit length of the yarn. (as shown in Fig 1.57. )
• This signal is amplified and fed to the evaluation channels
of the yarn clearing installation.
• The number and type of evaluation channels available are
dependent on the sophistication and features of the model
of the clearer in use. Each of the channels reacts to the
signals for the corresponding type of yarn fault.
• When the mass per unit length of the yarn exceeds the
threshold limit set for the channel, the cutting device of
the yarn clearer cut the yarn.
Optical type electronic yarn clearer :

• Optical sensors employ suitable light sources,

reflectors, and receivers for recording the extent of
light scattered and absorbed with and without the
yarn in the way (Fig. 1.58). The light imaging
system of a photo-optical type yarn clearer is
shown in Fig. 1.59.
• Such a system can measure the thickness of the
yarn, as the nature of light reflected can detect
presence of foreign substance in the body of the
yarn. Assuming circular cross-section of the yarn
and a certain degree of homogeneity of the body of
twisted fiber assembly, it can be stated that the
mass per unit length of yarn is proportional to the
square of its diameter
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• Hence the sensitivity of the capacitance system, which
measures variation in mass per unit length, is significantly
higher than that of the optical system, which measures the
variation in the optical diameter of the yarn. For example,
the doubling of yarn mass (100% increase) would result in
a diameter increase of 42%, all other factors remaining the
same.
• In spite of its higher sensitivity, the capacitance system
suffers from two drawbacks namely, the sensitivity to
moisture and inability to isolate the signals for hairs/loops,
and foreign matters from that of the core yarn body. In this
regard, the optical system has been found to be superior.
 Knotting and splicers

• Knotting and splicing Joining of broken yarn ends

on a winding machine is a basic requirement to
prepare yarn packages of desired length, shape,
and size for efficient working of the subsequent
processes like warping, sizing, and weaving.
• Earlier, knotting was the only process for joining
of yarns together; but now this is being gradually
replaced by splicing.
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• Knot itself is an objectionable fault due to its
physical dimension, appearance, and problems
during downstream processes. A high quality
yarn cannot be produced without replacement
of knots.
• Splicing is the best option to eliminate the
problem of knotting and piecing; although, the
tensile strength of yarn with knot is superior to
that of the yarn with splice.
 Dog knot

• The fastening of dog knot is

very simple and quick, but
its size is bigger than
Fisherman’s and weaver’s
knot. Dog knot is very much
suitable for creeling, but it
can be incorporated into
fabrics.
 Fisherman’s knot
• The tying of Fisherman’s
knot is not convenient to tie
by hand at all. This knot is
very popular in textile
industry particularly in
cotton, woolen, worsted,
blended, and filament yarn
industry
 Weaver’s knot
• Weaver’s knot is most popular in cotton
and worsted textile industry. The diameter
of weaver’s knot is 2–3 times that of the
parent yarn. Both single and double
weaver’s knots are frequently used in
textile industry, depending on the
requirement of knot slippage and slippery
properties of the parent yarn.
• The resistance to slippage (knot slippage
or passing through reed and heald eyes,
etc.) for three basic knots is as under
Fisherman’s knot < Weaver’s knot < Dog
knot
 KNOT EFFICIENCY
• Knot efficiency is defined as the ratio of strength
of the knot to the strength of the yarn without knot.
• The strength and flexibility of a knot are
represented by an index called “knot efficiency”.
• In case of conventional winding machine, the
quality of knot depends entirely on the winder’s
skill and operating skills.
 Splicing
The next important element in the winding process is
the splicer. Splicing is the technique of joining two yarn
ends by inter-mingling the constituent fibers as shown
in Fig. 1.41, so that joint is not significantly different in
the mechanical properties and appearance with respect
to parent yarn. Yarn splicer comes in varied forms for
different types of yarns. A splicer may function on
pneumatic, hydraulic, thermal or mechanical principles.
Splicers are employed for joining single yarn spun from
staple fibers or from continuous filaments. Splicers can
also be employed for joining broken plied or even
cabled yarns.
 Splicing
• Yarn tucking or yarn intermingling The middle
portion of the spliced joint is a region (2–5 mm)
with no distinct order. The fibers from each yarn
end intermingle in this splice zone, just by tucking.
The studies on quantitative contribution of splice
elements showed
• that intermingling/tucking contributes the most to
the strength of splice (52%), followed by twisting
(33%) and wrapping (about 15%) as shown in Fig.
1.42.
• Quality assessment of yarn splice joint:
Appearance and strength are two important
characteristics of a splice joint
 Types of splicing Principally, yarn
splicing can be classified into four
distinct classes.

• Pneumatic splicing
• Mechanical splicing
• Electrostatic splicing
• Thermo splicer
 Principles of pneumatic splicing:

• The principles of splicing are simple to explain,

although the process is quite complex.
• When the pad is closed and the waste ends are
cut to length by the integral knives, an air blast
is introduced into the splicing chamber at very
high speed as shown in Fig. 1.44.
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• The resulting splice has a characteristic form. The
central section, which corresponds to the air entry
point, appears essentially unchanged, with the fibers
lying largely parallel.
• Turbulence is random, so no two splices are
identical on the micro-scale. Nevertheless, the
whole splice is much longer than the scale of the
intermingling, so splices for all practical purposes
are identical. With continuous-filament yarns, using
even a very simple splicing process, very high
splice strengths can be achieved, typically 90–95%
of that of the parent yarn.
Object of weft winding or pirn
winding
• The pirn winding machine is used to
produce a suitable package on wooden pirns
after rewinding the yarn from cones, cheese,
bleached, and dyed hanks, etc.
• Pirn winding is the process of transferring
yarn from one package (cone or cheese) to
another preferable yarn package(Pirn).
• Pirn is a rod made of wood, plastic, or metal
that is used in shuttle during weaving.
• Large package convert into small package
Types of pirn winding machines:

• Ordinary Pirn winding machine

• Automatic Pirn winding machine
• Cop winding machine
WORKING PRINCIPLE OF PIRN
WINDING MACHINE
• In the weft winding machine, the Pirn is driven by
a spindle.
• In the weft winding process a parallel winding
packages results.
• Also, instead of winding them back and forth, the
weaver winds them a half-inch at a time.
• The pirn is mounted on the spindle driven by a
mechanism that consists of gears and cam.
• The pirn rotates at a very high and constant
speed.
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• When the diameter of Pirn increases. The yarn winding
tension increases up to a little extent due to the less amount
of yarn on the Pirn.
• When it rotates, it drags the yarn and winds on it.
• In the pirn winding process a parallel winding packages
results.
• The yarn receives to fro motion through the yarn traverse
guide.
• This yarn guide performs the traversing motion of yarn.
• yarn traverse guide which makes nearly parallel coils of yarn
on the Pirn
• Almost half-inch of pirn (chasing length) gets wound at a
time.
• At a time the yarn moves to and fro between half inches
distance of Pirn.
Continue
• When this half inches
distance is filled, the
winding of the next half
inches begins, thus the
winding of complete Pirn is
performed.
• The chasing length get
shifted gradually during
winding.
• The weft bobbin or Pirn
contains a very less amount
of yarn length on it because
it is very difficult to throw
(fekna) a shuttle with Pirn
containing a high amount
of yarn on it
 Modern automatic winders
• The winding unit travels round the machine, and it
has only one automatic head to a complete
machine of about 100 spindles.
• At a time, four different type of yarns (differ in
color or count) can be processed on this machine.
• Various winding units automatically discharge the
full pirn into their respective bins.
• Winding operation takes place when the units are
traveling round the machine.
• The rate of travel is so regulated that the winding
of pirns is completed in one round of the machine.
 Modern automatic winders
• The empty pirns are placed randomly into a large
hopper attached to the automatic head. From this
hopper, empty pirns are automatically placed in
winding position to replace the full pirns
• The continued movement of the winding unit
causes the thread guide to assume its correct
position for winding the bunch. Winding starts by
means of an electrical switch, a bunch of any
desired length is then formed. Stationary cams
control the movement of guide during the building
of bunch.
Modern automatic winders
 DRAWBACKS OF PIRN WINDING
MACHINE:
• The main features of the Pirn winding machine are
given below:
• In the Pirn winding machine, the resulting (output)
package is many times smaller than the supply
package.
• It is almost not capable to eliminate objectionable yarn
faults during winding.
• Re-joining of yarn does not take place.
• It necessitates building a bunch.
• At the time of beginning the winding tension is less.
As the diameter increase, winding tension also rises.