COTTON YARN MANUFACTURING

PROCESS
DIPLOMA IN TEXTILE & APPEREL TECHNOLOGY
Sri Lanka institute of Textile & apparel
2014/2015

Name : E.C.Maduranga Ediriweera

Reg. No : DTAT-P/21/2014
Name Of Dep. : Courtaulds Clothing (pvt) ltd
Name Of Lecturer: Mr. N P P S K Pathirana
Date : 21/02/2015
 Introduction
Cotton is a soft, fluffy staple fiber that grows in a boll, or protective capsule,
around the seeds of cotton plants of the genus Gossypium. The fiber is
almost pure cellulose. Under natural conditions, the cotton bolls will tend to
increase the dispersion of the seeds.

The plant is a shrub native to tropical and

subtropical regions around the world,
including the Americas, Africa, and India.
The greatest diversity of wild cotton
species is found in Mexico, followed by
Australia and Africa. Cotton was
independently domesticated in the Old and
New Worlds.
 History
Cotton was used in the Old World at least 7,000 years ago (5th millennium BC). Evidence of cotton use has
been found at the site of Mehrgarh, where early cotton threads have been preserved in copper
beads. Cotton cultivation became more widespread during the Indus Valley Civilization, which covered
parts of modern eastern Pakistan and northwestern India. The Indus cotton industry was well developed
and some methods used in cotton spinning and fabrication continued to be used until the industrialization of
India. Between 2000 and 1000 BC cotton became widespread across much of India. For example, it has
been found at the site of Hallus in Karnataka dating from around 1000 BC.

Cotton fabrics discovered in a cave near Tehuacn,

Mexico have been dated to around 5800 BC,
although it is difficult to know for certain due to fiber
decay. Other sources date the domestication of
cotton in Mexico to approximately 5000 to 3000 BC.
 Types
Egyptian Cotton
Sea Island Cotton
Pima Cotton
Asiatic Cotton
American Upland Cotton
Canton Cotton
French Terry Cotton
Organic Cotton
Bamboo Cotton
and many more
 Cultivation
Successful cultivation of cotton requires a long frost-free period, plenty of sunshine, and
a moderate rainfall, usually from 600 to 1200 mm (24 to 48 inches). Soils usually need to
be fairly heavy, although the level of nutrients does not need to be exceptional. In
general, these conditions are met within the seasonally dry tropics and subtropics in the
Northern and Southern hemispheres, but a large proportion of the cotton grown today is
cultivated in areas with. less rainfall that obtain the water from irrigation. Cotton grows in
any part of the world where the growing season is long and the climate temperate to hot
with adequate rainfall or irrigation Cotton grows best in best climate
 Organic production
Organic cotton is generally understood as cotton, from
plants not genetically modified, that is certified to be
grown without the use of any synthetic agricultural
chemicals, such as fertilizers or pesticides. Its production
also promotes and enhances biodiversity and biological
cycles. United States cotton plantations are required to
enforce the National Organic Program (NOP). This
institution determines the allowed practices for pest
control, growing, fertilizing, and handling of organic
crops. As of 2007, 265,517 bales of organic cotton were
produced in 24 countries, and worldwide production was
growing at a rate of more than 50% per year
 Harvesting
Most cotton in the United States, Europe, and Australia is harvested
mechanically, either by a cotton picker, a machine that removes the cotton from
the boll without damaging the cotton plant, or by a cotton stripper, which strips
the entire boll off the plant. Cotton strippers are used in regions where it is too
windy to grow picker varieties of cotton, and usually after application of a
chemical defoliant or the natural defoliation that occurs after a freeze. Cotton is
a perennial crop in the tropics, and without defoliation or freezing, the plant will
continue to grow.
Cotton continues to be picked by hand in developing countries.
 Processing of Cotton
Processing of cotton Involves: Spinning
Most spinning today is done
Preparatory Processes using Break or Open-end
Spinning spinning, this is a technique
Weaving where the staples are blown by
Finishing air into a rotating drum, where
they attach themselves to the
tail of formed yarn that is
continually being drawn out of
Preparatory the chamber. Other methods of
process break spinning use needles
Preparatory and electrostatic forces. This
process involves method has replace the older
ginning, methods of ring and mule
Blending, spinning. It is also is easily
Carding, adapted for artificial fibers.
Combing,
Drawing
 Cotton Industries
The first industries set up in India us cotton industries. The first modern cotton
industries was set by Cawassji Dawar in Mumbai in 1854 AD.

The major centers of the cotton industries in India are following

Places-
Mumbai, Akola, Sholapur, Pune, Nagpur, Sata (Maharashtra); Ahmadabad, Surat,
Baroda, Rajkot, Bhavnagar (Gujarat); Indore, Gwalior, Jabalpur, Bhopal (Madhya
Prades Kanpur, Lucknow, Agra, Saharanpur, Modinagar, Varan; Rampur (Uttar
Pradesh); Kolkata (W. Bengal); Chennai, Coimbator Madurai (Tamil Nadu);
Ludhiana, Amritsar (Punjab); Bangalore (Kamataka); Panipat (Haryana) and Delhi.
 Leading Producers of Cotton
Top 10 Cotton Producing Countries(in million metric
tons)
The five leading exporters of cotton
in 2011 are (1) the United States, Ran
Country 2009 2010 2011
k
(2) India, (3) Brazil, (4) Australia,
and (5) Uzbekistan. The largest 1 China 6,377,00 5,970,000 6,588,950
nonproducing importers 2 India 4,083,400 5,683,000 5,984,000
are Korea, Taiwan, Russia, , and
Japan. 3 United States 2,653,520 3,941,700 3,412,550

In India, the states of Maharashtra 4 Pakistan 2,111,400 1,869,000 2,312,000

(26.63%), Gujarat (17.96%) and
Andhra Pradesh (13.75%) and also 5 Brazil 956,189 973,449 1,673,337

Madhya Pradesh are the leading 6 Uzbekistan 1,128,200 1,136,120 983,400

cotton producing states, these
7 Turkey 638,250 816,705 954,600
states have a predominantly tropical
wet and dry climate. 8 Australia 329,000 386,800 843,572

9 Turkmenistan 220,100 330,000 330,000

10 Argentina 135,000 230,000 295,000

World 19,848,921 22,714,154 24,941,738

 Uses of Cotton
Cotton is used to make a number of textile products. These
include terrycloth for highly absorbent
bath towels and robes; denim for blue jeans; cambric,
popularly used in the manufacture of blue work shirts (from
which we get the term "blue-collar"); and corduroy,
seersucker and cotton twill. Socks, and most T-shirts are
made from cotton. Bed sheets often are made from cotton.
Cotton also is used to make yarn used in crochet
and knitting Fabric also can be made from recycled or
recovered cotton that otherwise would be thrown away
during the spinning, weaving, or cutting process. While
many fabrics are made completely of cotton, some
materials blend cotton with other fibers, including rayon
and synthetic fibers such as polyester. It can either be used
in knitted or woven fabrics, as it can be blended with
elastine to make a stretcher thread for knitted fabrics, and
apparel such as stretch jeans.
YARN MANUFACTURING
PROCESS
BLOWROOM

CARDING

DRAWING

COMBING
ROVING

RING FRAME
BLOWROOM BLOWROOM

CARDING

first step of cotton yarn production

DRAWING
for opening, cleaning and dust removal,
COMBING
blending, and prepared for carding process. ROVING

RING FRAME
CARDING
BLOWROOM

FUNCTIONS:
Opening to the individual fibers. CARDING

Elimination of impurities
DRAWING

Elimination of dusk COMBING

ROVING
Disentangling of neps
Elimination of short fibers RING FRAME

Fiber blending
Fiber orientation
Sliver formation
 CARDING BLOWROOM

CARDING
Main Parts:
1. Taker in - to open flocks out DRAWING

of the feed batt, to lead them COMBING

to the dirt-eliminating parts ROVING

under the roller and to deliver

them to the main cylinder RING FRAME

2. Main cylinder - separate the

fibers, pull them into
somewhat parallel form.
3. Doffer - to take the individual
fibers from the main cylinder
and condense them to web
form
 BLOWROOM

DRAWING
CARDING

Functions: DRAWING

To improve evenness of the sliver ROVING

COMBING

To arrange fiber in parallel

RING FRAME
Blending
Dust removal

Draw frame has a series of rollers (drafting arrangement) rotating at

different rates of speed.
 BLOWROOM

COMBING CARDING

to upgrade the raw material by DRAWING

removing the short fibers. ROVING

COMBING

Combed yarn is stronger,

RING FRAME
more uniform, has greater
shine, smoother and purer
Functions:
Eliminate short fibers
Eliminate remaining impurities
Eliminate neps
 BLOWROOM

ROVING
CARDING

Functions: DRAWING

The attenuation of the sliver. COMBING

ROVING
Impart protective twist in order to
increase the strength of slivers. RING FRAME

Winding of the roving into a

package that can be transported,
stored and used on the ring
spinning.
 BLOWROOM

SPINNING CARDING

final step on producing yarn

DRAWING

COMBING
Functions: ROVING

Attenuate the roving until required RING FRAME

fineness is achieved
To impact strength to the fiber strand
by twisting it
To wind up the resulting yarn in a
suitable for storage, transportation
and further processing
SPINNING

Back zone
draft

Middle zone
draft

Front zone
draft
 YARN
Yarns can be produces in different sizes and
texture, and also vary in other characteristics.
Performance and end use of the fabrics are
affected by these yarn characteristics.
TYPES OF YARN

Staple or filament
Single or plied or cord
Simple or complex
DIRECTION OF YARN
Yarns are twisted to hold the fiber together.

S Direction Z Direction
YARN SIZE / NUMBER

1) Direct System
Denier Weight in grams of 9000 meters of yarn

Tex Weight in grams of 1000 meters of yarn

Decitex Weight in grams of 10000 meters of yarn

2) Indirect System
Yarn count (s) Length in hank of 1 pound of yarn (weighs)
1 hank = 840 yards
 DIFFERENT TYPES OF YARN DEFECTS/FAULTS

Introduction:
Yarn quality is influenced by various types of yarn faults which also
affects the quality of fabric produced . During the yarn manufacturing
process various types of irregularities are generated in the yarn
diameter regularly or at intervals which are known as yarn faults .
These faults are mainly categorized as below :
Frequently Occurring Faults( Analyzed by Uster Evenness Tester)
Seldom Occurring Faults( Scanned by Uster Classimat Tester)
FREQUENTLY OCCURRING FAULTS

Thick Places Neps

Thin Places
SELDOM OCCURRING FAULTS

Spun in Slubs
fly
Thank You