Yarn manufacturing

By Tekalgn M.

ታሕሳስ/2015 ዓ/ም

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 Lap former
• Lap: is the sheet of fibers (flock) wounded on lap
tube
• Why lap forms for combing?
• If card slivers were fed to the comber,
• true nipping by the nipper plates would
occur only on the high points,
• with the risk that the nippers could not
retain the less firmly compressed edge
zones of the slivers
• If the fibers lie across the strand ,
• even long fibers are removed by the
circular combs as those of short fibers.
• This represents an unnecessary loss of
good fibers
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 Conti…

• Drafting:
• The web created by the draft of 1.3 to 2.5 passes over two deflecting plates
onto the web table on which the webs are superimposed
• The UNIlap machine features a 3-over-3 roller, two-zone
drafting arrangement.
• The pneumatically weighted top rollers can be continuously adjusted from
minimum to maximum per top roller.
• Draft distances are individually variable, as are the draft levels in each of
the break and main draft zones.
• Upper and lower clearer aprons in combination with a suction system keep
the rollers clean.
• The easily accessible drive for the drafting arrangement is in an enclosed
housing and is fitted with appropriate change gears and oil spray
lubrication

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 Lap winding systems(system)
• Calender rollers
• Draw these superimposed webs
from the table to the lap winding
assembly.
• The strong compression created
between the calender rollers
forms a new web, which is rolled
into a lap in the lap forming
assembly.
• Empty tubes are automatically
exchanged for full laps
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 Omega (ω) lap winding system

• It has a unique belt winding technology

• Lap wrapping and optimal pressure distribution for
the best possible lap production
• the belt wraps around the infeed batt and
thus the lap.
• The wrapping angle is regulated during lap
build-up.
• At the start of the process, the contact circumference
amounts to 180° whereas at the end of the process it
reaches 270°.
• The lap build-up process is significantly supported
by an optimal pressure distribution range.
• This is also reflected in the production speed which
is up to 50% higher in comparison with conventional
systems.
 Conti…
Inserting the empty
tubes, and pneumatic
closing of the two
winding discs for axial
fixation of the tubes.
Machine stop, opening of the
belt unit, front ejection of
the full lap
Inserting the empty
tubes, pneumatic
closing of the two
winding discs for
axial fixation of the
tubes.
Winding up of the
batt at constant
speed until the full
lap diameter is
reached.
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 Combing
• Combing is a process that minimizes the number of:
• short fibers and
• remnant fragments of impurities present in a carded or
drawn sliver are minimized Combed sliver has a ‘silkier/silk-like’ appearance
• to give a clean sliver, than card sliver because of the enhanced fiber
alignment
• Combing, therefore, makes possible the spinning of yarns of:
• fine counts with low irregularities and a cleaner
appearance.
• The comber is used in the production of medium, medium
fine, and fine yarns, and enables a positive influence to be
exerted primarily on the yarn characteristics of:
• evenness;
• strength;
• cleanliness;
• and on the fabric characteristics of:
• smoothness;
• visual appearance; and
• handle 7
 Tasks of combing
• Elimination of a precisely pre-determined
quantity of short fibers;
• Elimination of the remaining impurities;
• Elimination of a large proportion (not all can
be removed) of the neps in the fiber material;
• Formation of a sliver having the optimal
possible quality parameters.
The high degree of parallelization
might reduce inter-fiber adhesion in
the sliver to such an extent that the
fibers slide apart, e.g. while being
pulled out of the can – i.e., sliver
breaks or false drafts might be caused.
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 Basic elements of combing
• 2= laps from lap former
• 3= Two fluted rollers, driven at a constant speed to
feed the lap
• 4 = An eccentric shaft is fitted between the rollers
and feed cylinder (5).
• The web is fed over this shaft, which is rotated
intermittently in time with the nipper cycle. Each
shaft rotation represents less than a full revolution,
first in a forward direction and then in backward
feed.
• This back-and-forth rotation ensures even tension in
the web and hence prevents false drafts, which
could otherwise arise as a result of fluttering of the
web as the distance between the stationary rollers
and the feed rollers increases and decreases with
the backward and forward movement of the nippers.
• The eccentricity of the shaft compensates for these
changes in distance.
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 Sequence of operation in a comber

1. Feeding, lap is fed by feed roller

2. fed lap gripped by the nipper
3. gripped lap is combed by circular comb
4. detaching roller grips the combed lap and moves forward
5. while the detaching roller delivers the material, top comb comes into
action to further clean the lap
6. While going back, nipper opens and receives a new bit of lap

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 Influence of the feed stock on combing
• Parallelization of the fibers in the batt
• Batt thickness (weight)
• Evenness of the batt /sheet
• The disposition of the hooks

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 Roving frame

❖Technologists call it the necessary evil !!

Why??
 Roving frame

❖The draw frame produces a sliver that already exhibits all

the characteristics required for the creation of a yarn,
namely an
 Roving frame

❖The draw frame produces a sliver that already exhibits

all the characteristics required for the creation of a
yarn, namely an
✓ Ordered,
✓Clean strand of fibers
✓Fibres laying parallel to one another.
 Roving frame

❖The roving machine itself is

➢Complicated,
➢Liable to faults,
➢Causes defects,
➢Adds to production costs and
➢Delivers a product that is sensitive in both
winding and unwinding.

❖ Yes it is evil but necessary!! Why??

 Roving frame

❖The need for Roving

✓ Draft required (300-500 folds);
The current position of Ring spinning is not
capable
✓ Draw frame-can feeding problem;
how that too big can be presented to ring?

❖ sorry!! We need Roving!!

 Roving
Tasks of roving
• Drafting
• Attenuating the drawn/combed sliver
• Twisting
• Imparting protective twist to control strand breakage and suitable
for drafting in ring frame
• Winding
• Build package that is suitable for transportation and feeding of for
the next process (ring spinning)

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 Basic operating regions of roving frame
• Creel zone
• It has positively driven transporting rollers to control
the false draft of sliver due to friction
• Here the sliver cans are accommodated in number of
rows

• Drafting arrangement
• This is the basic objective of roving used to reduce the
thickness of the sliver for fine yarn spinning in ring
frame after two stage drafting in addition to this
drafting in roving

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 Basic regions of roving frame
• Winding (package building ) zone
• The second basic objective of the roving process
• Which has complicated processes:
• Bobbin and flyer rotational motions
• Reduction of bobbin rotational speed by belt
shifting mechanism
• Reducing lifting of layers after completion of each
layer
• Reversing of the rising or lowering of the bobbin
rail (for reverse coiling)
• It can be categorized as:
• Bobbin lead (common in short-staple processing)
• Flyer lead winding mechanism

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 Ring spinning
Objectives:
• Drafting
• draw the roving to its final count in the drafting system
• Twisting
• impart tenacity to the bundle of fibers
• Winding
• wind up the resulting yarn in a suitable form for storage,
transport and downstream processing

Ring spinning process is:

• The ring and traveler spinning method that utilizes roller drafting for fiber

mass attenuation

• And the motion of a guide, called a traveler, freely circulating around a ring to

• insert twist and simultaneously wind the formed yarn onto a bobbin.

The ring and traveler combination is effectively a twisting and winding

mechanism 20
 Textile terms
• roving bobbin (1)
• Roving (2)
• holder (3)
• on the creel guide bars (4)
• drafting system (5)
• thin ribbon of fibers (6)
• yarn guide eyelet (7)
• spindle (8)
• traveler (9)
• ring (10)

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 Operating principle
• The drafting system is a 3-over-3 apron-drafting unit
• The fibrous material to be spun is fed to the drafting system
• the back zone draft (break draft) is small, on the order
of 1.25, and the front zone draft (main draft) is much
higher, around 30 to 40.
• The aprons are used to control fibers as they pass through
the front zone to the nip of the front rollers
• a yarn guide, called a lappet, is positioned below the
front pair of drafting rollers.
• The ring, with the spindle located at its center, is
situated below the lappet. Importantly, the lappet, the ring,
and the spindle are
coaxial
• The ring rail is geared to move up and down the length of the
spindle;
its purpose is to position the ring so that the yarn is wound onto
the bobbin in
successive layers, thereby building a full package
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Open-end spinning
• With the open-end (OE) spinning method, twisting and package building are separated
by employing the false-twist principle
• Real twist is, achieved in the yarn by forming a break in the attenuated mass at the
point of twist insertion.
• The break is obtained by drafting the fiber mass to the point of individual fiber
separation
• Open-end spinning or break spinning is a process in which fibrous material is highly
drafted, ideally to the individual fiber state, creating a break in the continuum of the
fiber mass.
• The individual fibers are subsequently collected onto the open end of a yarn that is
rotated to twist the fibers into the yarn structure to form a continuous yarn length.
• The length of yarn spun is then wound to form a package. Thus, the twisting action
occurs simultaneously but separately from winding
• basic requirements for any OE spinning system
• A device for drafting the fibrous mass into individual fibers
• Fiber transporting device
• Fiber collecting device to yarn end that enables the correct yarn count to be
obtained
• Twisting device
• Winding device
• A number of spinning techniques exploit the OE method,18 but only two have
achieved commercial success: rotor spinning and friction spinning.
• Of the two, rotor
spinning is the more widely used commercially, because a wider range of yarn counts
can be spun with suitable yarn properties.
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Rotor spinning
• Incomparably higher production potential than ring
spinning due to its high rotor and winding speeds
• It produces five to ten times as much as a ring-spinning
spindle.
Basic machine elements
• The feed roller and feed plate
• A saw-tooth or pin-covered roller called an opening
roller
• A tapered tube termed the fiber transport channel
• A shallow cup, called a rotor (A groove is cut into the
circumference at the maximum internal radius of the
rotor and is referred to as the rotor groove.)
• A flanged tube facing the rotor base and coaxial to
the rotor, termed the doffing tube
• A pair of delivery rollers that feed the spun yarn to
the package build device
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 Basic Principle of Rotor Spinning
• Sliver feed:
• The sliver is fed through a sliver guide via:
• The feed roller and feed table to a rapidly rotating opening
roller.
• Sliver opening:
• The rotating teeth of the opening roller comb out the individual
fibers
• from the sliver clamped between feed table and feed roller.
• After leaving the rotating opening roller, the fibers are fed to the
fiber channel
• Fiber transport to the rotor:
• fiebers disengage from opening roler by:
• Centrifugal forces and a vacuum in the rotor housing
• Then move via the fiber channel to the inside wall of the rotor for
twisting
• Fiber collection in the rotor groove:
• The centrifugal forces in the rapidly rotating rotor cause the fibers to
move from the conical rotor wall toward the rotor groove and be
collected there to form a fiber ring.
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 Basic Principle of Rotor Spinning

• Yarn formation:
• When a spun yarn end emerges from the draw-off nozzle
into the rotor groove, it receives twist from the rotation of
the rotor outside the nozzle,
• then continues in the yarn into the interior of the rotor.
• The yarn end rotates around its axis and continuously twists
in the fibers deposited in the rotor groove,
assisted by the nozzle, which acts as a twist retaining
element.
• Yarn take-off, winding:
• The yarn formed in the rotor is continuously taken off by the
delivery shaft and the pressure roller through the nozzle and
the draw-off tube and wound onto a cross-wound package.
• Between takeoff and package, several sensors control yarn
movement as well as the quality of the yarn and initiate yarn
clearing if any pre-selected values are exceeded

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 Friction spinning
• Categorized as open spinning because:
❖ the drawn sliver must be opened (individualized) and
reassembled again to a yarn.
• Individualized fibers are engaged together and twisted by
suction of rotating (to similar direction) perforated drum
❖perforated drums have an internal vacuum for fiber
engagement
• The twisting (rotation) of the yarn end arises from:
❖ the rotary movement of the two drums and generated by
frictional contact at the drum surface.
• The yarn formed in the convergent region by
❖collecting fibers and binding them in can be continuously
withdrawn and wound onto a cross-wound package
• the number of turns is determined by:
❖ the relationship between yarn end revolutions and
withdrawal speed
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 Twist spinning
• It is used mainly in worsted spinning mills.
• Two rovings are passed individually through a slightly modified
drafting arrangement of a ring spinning machine
• attenuated by a draft in the normal range and leave the delivery roller
separately
• At this point, they are each subjected to twist generated by a common
spindle
• thus, within the spinning triangle, they are twisted into two single
yarns,
• And these are simultaneously bound together to form a composite
yarn.
• Each of the two single strands and the resulting composite yarn
contains twist,
• and the direction of twist is the same for both the single ends and the
composite product.
• This twist-on-twist (ZZ or SS) produces a yarn that is somewhat more
compact, with a firmer core, than the usual ply yarn with opposing
twist (ZS or SZ)
• It is necessary to add auxiliary components to the ring frame
• and to provide an enlarged creel to accommodate twice the usual
number of packages

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 Wrap spinning (hollow spindle method)
• A roving or sliver feedstock is drafted in a three-, four-
or five-roller drafting arrangement.
• The fiber strand delivered runs through a hollow spindle
without twist.
• In order to impart strength to the strand before it falls 1. roving or sliver feedstock
apart, a continuous-filament thread is wound around 2. Drafting arrangement
the strand as it emerges from the drafting arrangement. 3. hollow spindle
• The continuous-filament thread comes from a small, 4. continuous-filament thread
rapidly rotating bobbin (5) mounted on the hollow 5. filament yarn bobbin
spindle. Take-off rollers lead the resulting wrap yarn to a a. Yarn core
winding device. b. Wrap filament
• The wrap yarn thus always consists of two components,
one twist-free staple-fiber component in the yarn core
(a),
and a filament (b) wound around the core.
• This process has been offered by several manufacturers,
e.g., Leesona, Mackie, etc. The most common wrap
spinning system is ParafiL by the Suessen company, and
this process will be briefly described in greater detail.

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 Air jet spinning
• referred to as air-jet spinning or Murata jet
spinning
• consists o:
• 3-over-3 high-speed roller drafting unit
• Two compressed-air twisting jets arranged
in tandem,
• a pair of take-up rollers, and
• Yarn package build unit
• Inclined to the spinning channel axis, but
tangential to the circumference,
• compressed air is injected into the channel
to create a vortex flow (through 4 nozzles)
• The vortex grasps the yarn end
and whirls it around in circles in the same way
as the fibers.

• Since the upper yarn length is held by the

withdrawal rollers and the lower end is rotating,
• each revolution of the yarn end
in the vortex inserts a turn of twist into the
yarn
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