Textile Yarns

Process of Yarn Manufacturing

Classification of Yarns
Yarn Numbering
Sewing Threads
Prepared by
P.Lakshmana kanth
Senior Faculty – IFTK
Process of Yarn Formation
• Yarn is continuous strand which is made up of filaments
or fibers. It is used to make fabric/textiles of different
kinds.
• Yarn formation methods were originally developed for
spinning of natural fibers including cotton, linen, wool
and silk.
• ‘Yarn’ is defined by the American Society for Testing and
Materials (ASTM) as “A generic term for a continuous
strand of textile fiber, filament, or material suitable for
knitting, weaving to form a textile fabric. Yarn occurs in
the following forms.
Yarn forms
• A number of fibers twisted together.
• A number of filaments laid together without
twist.
• A number of filaments laid together with more
or less twist.
• A single mono filament. e.g. Silk
Yarn Manufacturing System
• Yarn is defined as a linear assemblage of the fibers twisted
together. The process of making the yarn from a textile fiber
is called Spinning.
• Spinning is the art of producing continuous, twisted Strands,
of a desire size, from fibrous materials.
• In a broad sense, the term is used to include all the
operations through which cotton fibers are passed until they
become yarn.
• Spinning includes all the processes required to prepare and
clean the fibers from the opening of the bale to the twisting
of the yarn in its preparation for the textile loom .
Process of Yarn Manufacturing
Bale Opener Mixing Blowroom

Combing Drawing Carding

Spinning
Simplex (Ring
Frame)
• The basic process sequence involved in the
manufacturing of the cotton yarn is shown above in the
chart.
• Some of the process like combing can be skipped when
some low quality yarn is required.
• The final end product of the spinning mill will be yarn
which can be delivered in different forms of packages like
cones, cheeses, hanks etc.
• The package may be selected according to the
convenience and for easy transportation as the weaving
or knitting mill will be away from the spinning mill in
normal.
Bale Opener
Bale Opener
• The cotton tufts are opened in this process.
• As the cotton arrives in an extremely compressed
condition the first operation is to loosen the matted
fibers
• The cotton fiber is loosened by means of rotating
spiked rollers of the bale opener.
Mixing
Mixing
• This is a process of mixing the same/different
category of fibers to get desired properties
and cost effectiveness.
• Mixing is done after the study of the essential
properties of fiber like staple length, Tensile
strength, fineness, uniformity etc.
Blow room
Blow room
• In this process the cleaning and opening of the
cotton is done by beaters and openers.
• The foreign materials like dust particles, seeds
of cotton and other impurities are partially
removed in this process.
• The cotton tufts are opened and cleaned in
this process and the cotton lap is made out.
Carding
Carding
• Carding is the heart of spinning in this process
the minute impurities like small seed particles,
immature fibers etc. are removed.
• The straightening and aligning of fibers are
done in this process.
• In carding the Blow room lap is attenuated to
the card sliver.
Drawing
Drawing
• Through drafting fibers get paralleled
• Up to Eight Carded Slivers are fed into the Draw-
Frame and they are stretched/Straightened and
made into a single sliver.
• Also fiber blending can be done at this stage.
Simplex (Speed Frame)
 Simplex (Roving)
• Further drafting is done here to get the fibers
more aligned/paralleled.
• The Sliver from Draw-Frame is thicker and will
be difficult to be fed into the Ring-frame as is,
hence here the Slivers are stretched and were
made thinner by Drafting and mild twisting (so
as to strengthen the Roving).
• The End-Product from the Simplex is called as
Roving
 Ring Spinning
• The roving is fed into the Ring-frame and is made
into yarn by further Drafting & Twisting.
• Basic Functions of Ring Frame are
• to draft the roving until the required fineness is
achieved
• To impart strength to the fiber, by inserting twist.
• Depending upon the yarn count required, the
drafting and twisting can be adjusted.
Ring Spinning
Lap Formation - Diagram