Bangladesh University of Textiles

Tejgaon , Dhaka

Project Work on
“Analysis of rejected ring cops in Autoconer Winding
Machine”
Supervised by :

Dr. Mohammad Ali

Associate Professor & Head

Industrial & Production Engineering (IPE)

Bangladesh University of Textiles (BUTex)

Submitted by :

Taukir Kabir Tusar (ID : 2011-1-169)

Dept.of Yarn Manufacturing Engineering (YME)

1
 Acknowledgement
First of all, our gratefulness goes to Almighty Allah who gave us strength and ability to complete
the project work and prepare this report.

We would like to pay special thanks to Dr. Mohammad Ali, Associate Professor, Head of the
department of Industrial Production and Engineering, Bangladesh University of Textiles,
for continuously guiding us about the development and preparation of this report . He has
enriched us with necessary ideas and concepts for improvement of the report.

We would also like to express our heartfelt thanks to Dr. Hosne Ara Begum , Associate
Professor & Head of Department of Yarn Manufacturing Engineering , Bangladesh
University of Textiles for all necessary information for preparing this report .

We would like to express our sincere gratitude to Moksed Alam Tonmoy , Deputy Manager ,
Badsha Textiles Limited & Golam Rabbani , Assistant General Manager , SQUARE
Textiles Limited who has allowed us to work in their organization in a congenial atmosphere .
Their valuable opinion has enriched our knowledge to carry out the project and portray the
information in a logical sequence.

2
 Abstract
This work describes the causes of rejections of rejected ring cops in autoconer winding machine
with assessment of various experimental datas from various quality instruments . This causes
includes count variation , co efficient of variation (CV%) , Thick and thin places , neps , slubs ,
hairiness and some miscellunous causes like oil stained yarns , crackers in yarns , half and excess
full cops , coca cola shaped cops etc . This work also suggest a few ways to solve the problems
and to reduce the rejection rate of cops in an acceptable range . Sufficient amount of figures and
graphs are also included here to make this work more accurate .

3
Contents

4
Content No Chapter Name Page No

01 Introduction 6-8

02 Literature Reviews 9-14

03 Experimental Work 15-45

04 Conclusion 46-47

05 Reference 48-49

5
Chapter 1
Introductio
n

6
Introduction
Winding is the last process that is involved in the production line of a spinning factory , specially
in the ring yarn production line . It has a number of parameters and variables – embraces
different technologies and improving the winding operational productivity and efficiency by the
developments in several sciences and fields, such as machinery , materials science, automation
and control. On the ring cops obtained from ring spinning machine , contains a very small
amount of yarns (approx. 50-80 grams) which is not economically feasible for trading of
yarn .So a larger package formulation from this cops are essential . For satisfaction of that need ,
a winding machine comes in vision of textile experts .This makes the use of the subsequent
machines both easier and more economical .

In autoconer winding machine, generally 6 to 8 ring cops (or bobbins) in the magazine are
wounded up into a bigger package called cone. From this number of cops, at first the yarns get
unwound , then they get necessary winding tension by tension assembly of the machine and then
finally they are wounded to the cone. Cleaning of yarns are also done in this machine by various
separate cleaning units like EYC (Electronic Yarn Clearer) , Zenit+ , Uster Quantum, Oerlikon,
LOEPFE, Uster Quantum-3 , Yarn Master etc. , used in autoconer machines of different
manufacturers . Various modern features have come with the passage of technology like
Automatic Splice Initiation, Web break detection, Automatic knife cut off, Automatic roll or
package change etc. But the feeding of the ring cops in magazine are still done manually by
workers.

But the operation of winding machine is not swift all the time. It has a number of modern and
well optimized sensors and they frequently rejects ring cops to be wound in the cone. The main
target of our project work is to find out the reason of the rings cops of being rejected by the
autoconer winding machine by the analysis of rejected ring cops and also to find out some ways
to avoid this unwanted situation .

7
1.1 Ring Cops
Ring cops are the final package got from the ring spinning machine which contains a small
amount of yarn of a definite count . This cops contains 50-80 grams (1.5-3 ounces) yarns.

1.2 Rejected Ring Cops

The ring cops that are rejected by the autoconer winding machine to wound into larger
cones due to various kinds of faults within the yarn are called rejected ring cops

1.3 Aim of this project

1. To know about rejected ring cops.

2. To know about the reasons of cops rejections in autoconer winding machine

3. To sort out some ways to slow down the rejection rates of cops.

8
Chapter 2
Literature
Revie
w

9
2.1 Winding
In spinning , winding is the process of creating large yarn packages called cone from some
numbers of smaller yarn packages called ring cops in order to make the use of yarn in subsequent
machineries both easier and economical .

2.2 Objects of winding

1. To prepare the bigger packages from ring cops

2. To remove spinning faults like neps, hairiness of yarn etc.

3. To wax the yarn as finishing process (if necessary)

4. To improve the quality of yarns by cleaning them

2.3 Types of winding

1. Spindle drive: Where the spindle upon which the package is placed is driven directly.

a. Constant speed winder

b. Variable speed winder

2. Friction drive: Where the spindle upon which the package is placed is free to rotate and the
package is driven through friction by the contact of a driven drum.

2.4 Zones of winding

1. Unwinding zone

2. Tension and clearing zone

3. Winding zone

10
2.5 Working Principle of Autoconer Winding Machine
1. In the creeling zone, in all the winding positions of the machine, there is a magazine of
ring cops which can carry 6 to 8 ring cops for winding

2. Yarn from a single cop goes tension and cleaning zone of winding machine through yarn
guide which function is to provide sufficient tension to the yarn required for continuous winding
of the yarn.

3. A yarn cleaning attachment is present in there in order to clean the yarn to maintain the
optimum quality of yarn in the final package.

4. A sensor is also there called “Stopped motion feeler” to check if there is any breakage of
yarn or absenteeism of yarn due to any reason like cops with no yarns

5. An splicing mechanism is also present there to untwist the ends of both previous and
newcomer cop yarn and joining them by re twisting there ends.

6. Finally in winding zone , the yarns of all cops are wounded as a single yarn with the help
of surface contact of a grooved cylinder.

Fig 2.1 : Working Principle of Autoconer Winding Machine

11
2.6 Autoconers used in factories along with specifications

Company Model No. Origin No of Heads

Schlafhorst Saurer Autoconer 388 Germany 60

SAVIO Machine Polar M Italy 64

TESSILI S.p.A

Sclafhorst Saurer Autoconer X5 Germany 60

Muratec 21C Germany 60

Fig 2.2 : Winding machine

12
2.7 Faults and Defects arising in winding which forms
winding wastes
1. Formation of patches on the yarn.

2. Incorrect or variable winding speed

3. Too much knots in the yarn.

4. Variation of yarn tension.

5. Dirty or trashy packages

6. Incorrect shape of yarn package.

7. Excessive full bobbin.

8. Piecing up.

9. Over lapping.

10. Two end winding.

11. Mixing yarns of different linear density i.e. of different count.

12. Greasy and dirty yarns.

13. Poor yarn cleaning and snarling.

13
2.7 Reasons of formation of wastages on winding for faulty
ring cops
1. Due to knots in the yarn on ring cops.

2. Remaining ends after tying off the yarns on the package

3. Slough off of yarns from the ring cops due to variation of yarn tension.

4. Remaining coils on the yarn package.

5. Dropped short ends while threading.

6. Greasy or dirty yarns in the ring cops.

7. Negligence of workers working in the winding department.

The amount of wastage depends upon the size of the spinning bobbin and breakage rate.
With the increase of package size and reduced of breakage rate of yarn, wastage of winding is
reduced.

14
Chapter 3
Experiment
al
Work

15
3.1 Ring cops collection
Ring cops samples were collected from each of the autoconer winding machine . The
collection of this cops are done on the basis of three points , one of them is either they are reject
by the autoconer or not and the second one is if the yarn in ring spun cops are of spun from
staple fibres , filaments or any special blends of natural or manmade fibres , third one is if they
are any type of special yarns like core spun , SIRO , mélange or conventional 100% natural or
manmade fibre yarn .

So the sample is collected on the basis of –

A. Either rejected or not rejected by the autoconer.

B. Specification of the yarn present in ring cops in that sense of their origin of fibres like
100% natural like cotton , 100% manmade like polyester or if there is any blend of the
two.
C. The type of yarn that means if they are normal ring spun yarn or they are ring spun but
of special types of yarns.

16
3.2 Procedure of the work
After collection of samples of ring cops , we went to the quality department of our factory to
assess the type of fibres used in the yarns of different cops and also to sort out the causes that has
given rejection of the cops in the autocoro . And some additional tests are also executed to find the
causes of their rejections.

Test 1 : Uster AFIS test

To find out the neps present in the yarn and also to find out the average length of
fibre and the maturity of fibres

Test 2 : DYNAJET test

To find out the weak points present in the yarn

Test 3 : Tectechno COVATEST

To find out the irregularity , hairiness and imperfection index (IPI) , unevenness U
% , Coefficient if variation of mass (CVm%) of the yarns

Test 4 : Autostretch 5C test

To find out the CSP value of different yarns by finding out their individual lea
strength

Test 5 : MAG-SITRA Ele Trash test

To find out the trash content present in our collected samples

Test 6 : MESDANLAB Autotwist test

To get the TPI and TPM value of samples

Test 7 : Yarn Count test

To recheck if there is no count variations in our sample

17
3.3 Causes of rejections
After getting all of our test results in hand , we went for a comparative analysis of the rejected
cops with the accepted ones with the help of the personnel’s of quality department of the factory and
get a numerous causes of rejections and they are described in the next article . We also tried to go to
the backward of the production line to find out the cause that made the yarn in the ring cop that faulty
so it was rejected by the autoconer winding machine .

3.4 Desprective discussion of the causes of rejection

3.4.1 Count Variation

At first three ring cops from the same magazine of the same autoconer tested and found
that they were of two different counts that means two different linear density yarns. When two cops
were wounded on the cone and autoconer started to fetch the yarn of the third cop , the sensors
detected the variation of the counts and so it rejected the cop.

Causes

1. Negligence of workers in the winding section

2. Negligence of workers of any previous sections like carding, drawing, simplex, ring
etc. sections that they mixed up different products which didn’t matched to the
production plan and schedule.

Experimental Data
Table : 3.1

Sample Type Count or Linear Density Result

Carded Yarn 30 Ne Accepted
Carded Yarn 30 Ne Accepted
Carded Yarn 32 Ne Rejected

18
 Remedies

1. Careful monitoring of all segments of production line from blowroom to final

winding.
2. Recruitment of experienced and well trained workers in all the segments so that this
type of unwanted incidents should never occour

3.4.2 Product Type Variation

Once again we tested three ring cops from collected from the same magazine and
tested them for any product type variation , two of them were accepted by the machine and one
was rejected . And we found two were carded yarn but the third one was combed yarn, but of the
same counts.

Causes

1. Negligence of workers in the winding section

2. Negligence of workers of any previous sections like carding, drawing, simplex, ring
etc. sections that they mixed up different products which didn’t matched to the
production plan and schedule.

Experimental Data
Table : 3.2

Count of the Sample Yarn Type Result

26 Ne Carded Accepted
26 Ne Carded Accepted
26 Ne Combed Rejected

Remedies

19
 1. Careful monitoring of all segments of production line from blowroom to final
winding.
2. Recruitment of experienced and well trained workers in all the segments so
that this type of unwanted incidents should never occour.

3.4.3 Low Cop Content

We took cops from the same magazine and measured there length using wrap reel and
found that the rejected one has lower cop content than the accepted ones that means low
amount of yarn in weight than the accepted ones.

Causes

1. Under utilization of bobbin height in ring frame

2. Lower number of coils /inch
3. Higher chase length in ring frame
4. Cop bottom bracket properly not set in ring frame
5. Improper selection of ratchet in ring frame
6. Ratchet pawl pushing number of teeth's /movement in the ratchet wheel
7. Spinning empties wall thickness is high

Experimental Data

Table : 3.3

Sample Specifications Cop Content Result

30 Ne Combed Hosiery 58 gm Accepted
30 Ne Combed Hosiery 58 gm Accepted
30 Ne Combed Hosiery 58 gm Accepted
30 Ne Combed Hosiery 58 gm Accepted
30 Ne Combed Hosiery 28.2 gm Rejected

20
 Sample Vs Cop Content Graph
60
40
20
Cop Content

0
in grams

ed ed ed ed te
d
ept ept ept ept je ec
c c c c
Ac Ac Ac Ac yR
ry ry ry ry r
sie sie sie sie osie
Ho Ho Ho Ho H
d d d d d
be be be be be
m m m m m
Co Co Co Co Co
Ne Ne Ne Ne Ne
30 30 30 30 30

Samples

Graph 3.1 : Sample Vs Cop Content

Fig 3.1 : Low cop content

21
 Remedies
1. Optimum chase length, coil spacing and wall thickness of empty cops tube
ensured in ring frame
2. Ratchet/pawl movement to be properly set
3. Free space of only 7.5mm to be maintained at the top and bottom of the cop
4. Free space only 0.75mm only to be maintained between full cops and the ring

3.4.4 Neps
We tested some accepted and rejected cops by the autoconer winding machine and found
that some cops are rejected due to presence of excessive neps onto the yarns . This test is done
by Uster AFIS Tester. In general , neps are accepted to a certain limit , above that limit it is
rejected ( exceptional is neppy yarn , where neps are given to yarn at a predetermined fashion )

Causes
1. Accumulation of fly and fluff on the machine parts.
2. Poor carding
3. Defective ring frame drafting and bad piecing
4. Improperly clothed top roller clearers.

Experimental Data

Table 3.4

Sample Neps/km Neps/km Neps/km Result

Specifications
+140% +200% +280%
34 Ne Carded
782.0 198.0 32.0 Accepted
Woven
34 Ne Carded
786.8 199.2 33.02 Accepted
Woven
34 Ne Carded
789.2 201.53 34.25 Accepted
Woven
34 Ne Carded
852.69 254.78 71.25 Rejected
Woven
34 Ne Neppy 912.25 927.29 936.84 Accepted

22
 Sample Vs Neps/km Graph
1000
800
600
400 Neps/km
+140%
200
Neps/km

0 Neps/km
ed ed ed te
d ed +200%
ept ept ept jec ept
c c c Re c
Ac Ac Ac Ac Neps/km
en en en en ar
n
ov ov ov ov Y +280%
W W W W py
ed ed ed ed ep
rd rd rd ard N
Ca Ca Ca C Ne
Ne Ne Ne Ne 34
34 34 34 34

Sample

Graph 3.2 : Sample Vs Neps/km

Fig 3.2 : Neps in yarns

Remedies

23
 1. Proper functioning of pneumaphil/roller clearers to be ensured.
2. Broken teeth gear wheel to be avoided and proper meshing to be ensured.
3. Better fiber individualization at cards to be achieved.

3.4.5 Slub

Slub is an abnormally thick place or lump in yarn showing less twist at that place . We
took some cops both rejecting and not rejecting by the machine and were tested in Uster AFIS
Tester for result . In general this slubs are directly rejected for conventional ring yarns , unless
they are special yarns where slubs are given intentionally.

Causes
1. Accumulation of fly and fluff on the machine parts.
2. Poor carding.
3. Defective ring frame drafting and bad piecing
4. Improperly clothed top roller clearers.

Experimental Data

Table 3.5

Sample Slubs/km Slubs/km Slubs/km Result

Specifications +400% +460% +520%
40 Ne Carded
2.59 2.87 3.12 Accepted
Woven
40 Ne Carded
2.42 2.77 2.99 Accepted
Woven
40 Ne Carded
2.36 2.69 2.87 Accepted
Woven
40 Ne Carded
3.52 3.09 2.96 Rejected
Woven
40 Ne Carded 15.2 14.9 14.4 Accepted
Slub yarn

24
 Sample Vs Slubs/km Graph
16
12
8
4 Slubs/km +400%
Slubs/km

0
Slubs/km +460%
ed ed ed te
d ed
ept ept ept jec ept Slubs/km
c c c Re c
Ac Ac Ac Ac +520%
en en en en b
ov ov ov ov Slu
W W W W ed
ed ed ed ed rd
rd rd rd ard Ca
Ca Ca Ca C Ne
Ne Ne Ne Ne 40
40 40 40 40

Sample

Graph 3.3 : Sample Vs Slubs/km

Fig 3.3 : Slubs in yarns

25
 Remedies:

1. Machine surfaces to be maintained clean.

2. Proper functioning of pnemafil /roller clearers to be ensured.
3. Broken teeth gear wheel to be avoided and proper meshing to be ensured.
4. Better fiber individualization at cards to be achieved.
5. Optimum top roller pressure &back zone
6. Setting at ring frame to be maintained.

3.4.6 Thick places in yarns

Thick places are the one of the imperfections of yarn that makes the yarn more thicker in
some place according to its lengthwise which is not accepted by the autoconer winding machine . We
took some samples and tested them in Textexchno COVATEST Tester to find out this variation .

Causes

1. Eccentric top and bottom rollers

2. Insufficient pressure on top rollers
3. Worn and old aprons and improper apron spacing
4. Improper meshing of gear wheels
5. Mixing of cottons varying widely in fibre lengths and use of immature cottons

Experimental Data
Table 3.6

Sample Thick/km Thick/km Thick/km Thick/km Result

Specifications+35% +50% +70% +100%
60 Ne Carded
450 32 2 0 Accepted
Hosiery
60 Ne Carded
350 40 5 0 Accepted
Hosiery
60 Ne Carded
822 621 379 128 Rejected
Hosiery

26
 Sample Vs Thick places/km Graph
800
600 Thick/km
400 +35%
Thick places/km

200 Thick/km
0 +50%
ed ed te
d
ept ept je ec Thick/km
cc cc +70%
ry
A
ry
A
r yR
sie sie osie
Ho Ho H Thick/km
ed ed ed +100%
rd rd ard
Ca Ca C
Ne Ne Ne
60 60 60

Sample

Graph 3.4 : Sample Vs Thick places/km

Remedies

1. Eccentric top and bottom rollers to be avoided

2. Top arm pressure checking schedules to be Maintained strictly
3. Wide variation in the properties of cottons used in the mixing to be avoided
4. Better fiber individualization at cards to be achieved.
5. Correct spacers to be utilized

3.4.7 Thin places in yarns

Thin places are another of the imperfections of yarn that makes the yarn more thinner in
some place according to its lengthwise which is not accepted by the autoconer winding machine . We
took some samples and tested them in Textexchno COVATEST Tester to find out this variation .

Causes

1. Eccentric top and bottom rollers

2. Insufficient pressure on top rollers
3. Worn and old aprons and improper apron spacing
4. Improper meshing of gear wheels
5. Mixing of cottons varying widely in fibre lengths and use of immature cottons

27
 Experimental Data
Table 3.7

Sample Thin/km Thin/km Thin/km Thin/km Result

Specifications-30% -40% -50% -60%
60 Ne Carded 1435.0 110.0 5.0 5.0 Accepted
Hosiery
60 60 Ne Carded 1245.0 78.0 2.0 2.0 Accepted
Hosiery
60 Ne Carded 2512.0 498.0 412.0 376.0 Rejected
Hosiery

Table 3.8

Sample Thick/km Thick/km Thick/km Thick/km Result

Specifications+35% +50% +70% +100%
60 Ne Carded 450.0 32.0 2.0 0.0 Accepted
Hosiery
60 60 Ne Carded
350.0 40.0 5.0 0.0 Accepted
Hosi Hosiery
60 Ne Carded 850.0 672.0 612.0 516.0 Rejected
Hosiery

Remedies

1. Eccentric top and bottom rollers to be avoided

2. Top arm pressure checking schedules to be Maintained strictly
3. Wide variation in the properties of cottons used in the mixing to be avoided
4. Better fiber individualization at cards to be achieved
5. Correct spacers to be utilized

28
 Fig 3.4 : Thick and Thin places in yarns

Sample Vs Thin places/km Graph

3000
Thin/km
2500 -30%
2000
1500
1000 Thin/km
Thin places/km

500 -40%
0
d d d
te te te
cep cep je ec Thin/km
Ac Ac R -50%
y y ry
sier sier osie
Ho Ho d
H
ed ed de Thin/km
ard ard Ca
r -60%
C C
Ne Ne Ne
60 60 60

Sample

Graph 3.4 : Sample Vs Thin places/km

29
 Sample Vs Thick places/km
800
600 Thick/km
+35%
400
Thick places/km

200 Thick/km
+50%
0
ed ed te
d Thick/km
ept ept je ec
cc cc +70%
ry
A
ry
A
r yR
sie sie osie Thick/km
Ho Ho H
d d ed +100%
r de r de ard
Ca Ca C
Ne Ne Ne
60 60 60

Sample

Graph 3.5 : Sample Vs Thick places/km

3.4.8 Imperfections

Imperfections are known as the combinational term of all imperfections of yarns like
thick places , thin places , neps , slubs etc . It is a number which is obtained by testing the
sample yarns in Textechno COVATEST Tester. We took some samples in this test to find out
the amount of imperfections in the rejected cops.

Causes

1. Insufficient pressure on top rollers

2. Defective rubber coating of cot rollers
3. Poor carding and drafting efficiency
4. Older and worn out aprons
5. Inappropriate mixing of raw fibres
6. Miss positioning of spacer
7. Bad waste collection system of the facility

Experimental Data

30
 Table 3.9

Sample Specification Imperfection Index (IPI)Result

50 Ne Combed Woven 123.29 Accepted
50 Ne Combed Woven 112.26 Accepted
50 Ne Combed Woven 126.27 Accepted
50 Ne Combed Woven 269.61 Rejected

Sample Vs IPI Graph

300

250
Imperfection Index (IPI)

200

150

100

50

0
50 Ne Combed 50 Ne Combed 50 Ne Combed 50 Ne Combed
Woven Accepted Woven Accepted Woven Accepted Woven Rejected

Sample

Graph 3.5 : Sample Vs IPI Graph

31
 Fig 3.5 : Imperfection Index (IPI) Spectogram

Remedies

1. Scheduled checking of top roller arm pressure

2. Wide variation of fibre properties in mixing should be avoided
3. Right apron and right spacer to be used
4. Waste extraction and suction system should always keep efficient
5. Higher efficiency to be targeted in carding and drafting

3.4.9 Unevenness in yarns

Yarn unevenness deals with the variation in yarn fineness. This is the property
commonly measured as the variation of mass per unit length alongside the yarn . We tested
some of the ring cops in Textechno COVATEST Tester for the assessment of Um%
(Unevenness per meters) and found that some rejected cops have higher Um%
Unevenness is expressed in two ways –
1. The Irregularity per meter Um%
2. The Co efficient of variation per meter Cvm%

Causes

1. Variations in processed raw materials gives rise to higher unevenness of the end
product
2. Variation in the spinning process like in correct drafting arrangement in drawing ,
simplex and ring frame
3. In correct setting of auto leveling unit in the finisher drawframe
4. Worn out machine parts in any production stage
Experimental data
Table 3.10

Sample Irregularity per Co efficient of Result

Specification Meter (UVm%) Variation per
Meter (CVm%)
42 Ne Carded 11.07 14.10 Accepted
Hosiery
42 Ne Carded 10.66 13.55 Accepted
Hosiery
42 Ne Carded 10.98 13.91 Accepted

32
Hosiery
42 Ne Carded 22.24 27.93 Rejected
Hosiery

Sample Vs IPM (UVm%) Graph

25

20
IPM (UVm%)

15

10

0
42 Ne Carded Hosiery 42 Ne Carded Hosiery 42 Ne Carded Hosiery 42 Ne Carded Hosiery
Accepted Accepted Accepted Rejected

Sample

Graph 3.6 : Sample Vs IPM (UVm%)

33
 Sample Vs CVM (CVm%) Graph
30

25

20

15
CVm %

10

0
42 Ne Carded 42 Ne Carded 42 Ne Carded 42 Ne Carded
Hosiery Accepted Hosiery Accepted Hosiery Accepted Hosiery Rejected

Sample

Graph 3.7 : Sample Vs CVM (CVm%)

Remedies
1. Proper inspection of the raw materials so the variation in their unevenness remains
always low
2. Scheduled observation of all process involved in spinning in drawing , simplex and
ring frame so that excessive variation can’t occour
3. Setting of auto leveler in finisher drawframe should always try to keep as much
fixed as possible for a definite count and process
4. Proper maintenance activities to check and rectify any mechanical damages
happened to any machine part like aprons , bottom and top rollers of drawframe ,
simplex and ring frame , broken gear teeths , displaced chains etc.

34
3.4.10 Some Miscellaneous Causes
A. Soft Yarn

Some yarns in cops are so much soft that they can’t bear the winding tension
provided by autoconer ending machine and so they got torn out during winding and as a result
the whole cop is rejected by the machine . This is the result of containing lesser twist in the
yarn and this is assessed in DYNAJET Tester for the identification of weak point on the yarn
and autostretch 5C Tester for checking if the TPI and TPM of required value is present in the
yarn or not.

Causes

1. Slack tapes dirty jockey pulleys

2. Less twist in the yarn
3. Bad clearing at the traveler

Fig 3.6 : Soft Yarns

Remedies

35
 1. Vibration of bobbins on the spindles to be avoided
2. Proper yarn clearing to be ensured
3. Periodic replacement of worn rings and travellers to be effected

B. Yarn Hairiness

Yarn hairiness means the projecting or protreuding fibres that remains outside of the
yarn’s surface and the give numerous problems or further processing . Excessive hairy
fibres containing yarns gives problems onto winding and sometimes the cops containing
hairy fibred yarn gets rejected by the autoconer winding machine . This hairness test is
done in Textechno
COVATEST Tester

Causes

1. Use of low matured cottons

2. Higher MIC vale of fibres that means coarser the fibres , higher the hairiness
3. Uniformity Ratio (UR) less than 50% of the fibres
4. In appropriate drafting and poor orientation in spinning triangle in ring
frame
5. Rubbery surfaces damage , worn out machine parts etc

Experimental Data
Table 3.11

Sample Specification Hairiness Index H Result

60 Ne Carded Hosiery 4.58 Accepted
60 Ne Carded Hosiery 4.37 Accepted
60 Ne Carded Hosiery 8.29 Rejected

36
 Sample Vs Hairiness Index (H) Graph
9
8
7
Hairiness Index (H)

6
5
4
3
2
1
0
60 Ne Carded Hosiery 60 Ne Carded Hosiery 60 Ne Carded Hosiery
Accepted Accepted Rejected

Sample

Graph 3.8 : Sample Vs Hairiness Index (H)

Fig 3.7 : Hairiness in yarns

Remedies

1. Higher removal of short fibres in carding

2. Higher removal of neps in carding
3. Higher cleaning and opening efficiency of blowroom machineries
4. Better lubricating of machine points that can form static electricity during
running

C . Oil stained yarns

37
 Sometimes during lubrication or any tyoe of maintenance work or by any lickage in
the lubrication system the yarn gets oil stained and when it goes to autoconer it gets
rejected . We tested some ring cops and found that some of the cops that are rejected are
oil stained

Causes
1. Careless oil in the moving parts, over head pulleys etc
2. Piecing's made with oily or dirty fingers
3. Careless material handlings

Fig 3.8 : Oil stained yarns

Remedies

1. Appropriate material handling procedures to be followed

2. Oilers to trained in proper method of lubrication
3. Clean containers to be utilized for material transportation

D . Crackers in yarn
In some bobbins of polyester yarn , we found there very small snarl like places which
disappeared when we pulled the yarn with sufficient tension given by our hands but when
the tension released , this effect was again visible . This are called crackers and only

38
shown in thermoplastic man made fibres like nylon , polyester etc. These are also a cause
for bobbin rejection on autoconer winding machine. They are also visible in cotton
polyester blend yarns.

Causes

1. Mixing of cottons of widely differing staple length

2. Closer roller settings
3. Eccentric top and bottom rollers
4. Non optimum temperature and relative humidity in the spinning shed
5. Over spinning of cottons

Fig 3.9 : Crackers in yarn

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 Remedies

1. Optimum top roller pressure to be maintained

2. Mixing of cottons varying widely in fibre length to be avoided
3. Use of optimum roller settings
4. Use of properly buffed rollers free from eccentricity to be ensured

D . Coca cola shaped bobbins

We found some type of different shapes of bobbins in the basket and coca cola
shaped bobbin in one peculiar shaped bobbin and it is named coca cola bobbin due to
its shape like a coca cola bottle . This shaped bobbins are directly rejected in autoconer

Causes

1. Uneven or variable speed of spindle

2. It occurs during giving knots to the yarn in ring frame
3. In appropriate building mechanism of ring frame by the cradle

Fig 3.10 Coca cola bobbin

Remedies

40
 1. Always maintaining the speed of spindle at a constant rate
2. Through monitoring of the workers not giving knots in wrong fashion
3. Train the workers and allocate trained workers piecing section

D . Excessive Full bobbin

As the autocoro machine has an input panel and in this panel it is always given as
input that how much amount of yarn it will be in a single cop . But when any excess cop
or bobbin containg excess yarn is given into the magazine , after finishing its
predetermined length , when autocoro wants a new cop but can’t take it cause previous
one has still yarn in it , it rejects the previous excess full cop.

Causes

1. Spindle speed variation that means higher speed than planned in production
2. Carelessness of workers for collecting the full cops
3. Improper piecing done by the workers

Fig 3.11 : Excessive full bobbin

Remedies

1. Always to keep the spindle speed at a constant

41
 2. Workers should be made more careful and skilled
3. Piecing should be done by experienced workers
4. Excessive full bobbins should locate at the ring section quickly that it can’t
create any problem in winding

E . Half fulled bobbins

This bobbins are not completely fulled that means the yarn length wounded on it in
the ring frame is almost half to the length it should be wounded. Any partial winding on
ring cop yarns are fallen into this type of bobbins and autoconer also rejects all of them
because machine can’t complete any one cope into cone that it was comanded by the
technicians.

Causes

1. Improper piecing
2. Carelessness of operators
3. Variation of count onto the same lot

Fig 3.12 : Half fulled bobbin

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 Remedies

1. Careful and perfect piecing of yarns

2. Careful observations of machineries so that there should not be any
possibility of count variation
3. Sometimes one spindle stops in a ring frame but all others run , so that one
remained stopped is surely half fulled bobbin . So it should be located as
soon as possible because if it goes to winding , it will must be rejected by
autoconer winding machine

3 .5 Some reports regarding winding

A. Characteristics : 60 Ne Short Staple

Textechno COVATEST

Test Um CVm Inde Thin/ Thick/ Neps/ H

No % % x km km km
3m -40% +35% +200%
1 10.5 2.58 1.29 110 450 198 4.5
8
2 10.23 2.57 1.29 78 350 165 4.3
7
3 10.35 2.39 1.26 100 348 182 4.3
3
4 10.60 2.94 1.27 145 445 238 4.3
4
5 10.53 2.16 1.31 130 405 222 4.4
2
Avg. 10.44 2.53 1.29 113 400 201 4.4
1
CVb 1.43 11.33 1.64 23 12 15 2.3
% 2
Q95 0.19 0.36 0.03 32 61 37 0.1
% 3

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 B . Report : Autoconer Reject Ring Cops Study

Types of Shift A Shift A Shift B Shift B Shift C Shift C

rejected
ring cops Quantity Quantity Quantity Quantity Quantity Quantity

Pcs % Pcs % Pcs %

Coca Cola 2 .2 13 1.29 5 .5
Bobbin
Over 25 2.48 32 3.17 24 2.38
Piecing
Full Ring 9 .89 16 1.59 31 3.08
Cops
Half Ring 12 1.19 18 1.79 17 1.69
Cops
Total 48 4.76 79 7.84 77 7.64

3.5

44
Chapter 4
Concl
usion

45
Conclusion

Winding has important influence and aspect on spinning because it is the last step where
spinners can rectify their faults if there is any fault present in the previous stages.
We tried our best to do our project work more accurately . We tried to visualize not only
the conventional ring carded and ring combed yarn but also tried with some special yarns. We
collected ring cops from various type of winding machines in the winding section of the
production facility . We tried to keep in mind of collection of samples of same counts and of
same processes. After collecting our samoles , we tested them in Uster AFIS , DYNAJET ,
Textechno COVATEST , wrap reel , MESDANLAB Tester , AUTOStretch 5C twist tester for
various required values to complete our project work like co efficient of variation per meter
CVm% , Hairiness index H% , imperfection index IPI , Neps and slubs content over length of
yarn , irregularity per meter Um% , thick and thin places over various length of the samples etc.
Not only quality parameters , but also we have seen various type of shaped bobbins like
coca cola bobbin , half and excess full bobbins and found that they are directly rejected by the
autoconer winding machine.
We want to finish our project work by thanking Almighty Allah for giving us physical
and mental strength , our respective teachers for helping us by providing many technical datas
and careful monitoring and finally our both factory authorities for giving us all necessary helps
and and friendly environment.

46
Chapter 5
Referen
ce

47
Reference

1. Manual of Textile Technology (Vol 1-6)

By W. Klein
2. Application of Handbook of Uster AFIS PRO
The fibre processing system
3. Handbook of Textile Fibres (Vol 1&2)
By J. Gordon Cook
4. Principles of Textile Testing
By J.E. Booth
5. Process Control in Spinning
By A.R.Grate
6. Physical Properties of Textile Fibres
By W.E.Morton & J.W.S. Hearle
7. Lectures of Dr. S. Subramanium
Associate Professor and Head of the IOC
Anna University
8. Various slides from online www.slideshare.net
9. Fundamentals of spun yarn technology
By Carl A. Lawrance
10. The RIETER Manual of Spinning
RIETER Spinning Solutions
11. Physical Testing of Textiles
By B. P. Saville
12. Dictionary of Textiles
By B Y Luis Harmuth
13. Website : www.uster.com
14.Website : www.muratec.net
15.Website : www.schlafhorst.de
16. Website : www.saviotechnologies.com

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