1 - Advanced Spinning Techniques

INTRODUCTION
Prepared by: Wardah Anam

Wardah Anam
“wardahanam@uet.edu.pk”
LECTURER
DEPARTMENT OF TEXTILE ENGINEERING
UET Lahore
Faisalabad Campus.
TEX - 306
Advanced Spinning
Techniques
EVALUATION CRITERIA
• S essional Marks 30%

• Quizzes (Announced, Surprized)
• Assignments (Individual, Group)
• Presentations
• Class participation
• Mid Term Exam 30%
• Final Term Exam 40%

WHAT IS SPINNING?
• Spinning is an ancient textile art in which plant, animal or synthetic fibers are drawn out
and twisted together to form yarn. For thousands of years, fiber was spun by hand using
simple tools, the spindle.
• Spinning is a major part of the textile industry. It is part of the textile manufacturing process
where three types of fiber are converted into yarn, then fabrics, which undergo finishing
processes such as bleaching to become textiles. The textiles are then fabricated into clothes
or other products.
DEFINITION
Spinning could be defined as;

• The drafting and, where appropriate, the insertion of twist in natural or staple
man-made fibers to form a yarn.
• The extrusion of filaments by spiders or silkworms.
• The production of filaments from glass, metals, fiber-forming polymers or

ceramics.
SPINNING PROCESS
• Spinning process basically consists of three stages;

1) Reduction of strand thickness from supply roving or sliver to required yarn
count. This is usually done by roller drafting.
2) Prevention of fiber slippage usually by twist insertion, although there are new
methods invented now. Simply binding of individual fibers.
3) Winding on to a package which is convenient for handling and which
protects yarn.
SPINNING HISTORY & 1ST SPINNING TECHNIQUE
• The origins of spinning fiber to make string or yarn are lost in time but some history
researchers said that it was some 20,000 years ago. Spinning was totally done by hand.
• Then man invented a hand wheel to produce yarn. This was the 1 st mechanical method
produced to make yarn.
ADVANTAGES OF WHEEL SPINNING:
• Spin any kind of thread with the same wheel.

• There is no limit to how large or small in diameter the thread can
be.
• It is also simple to construct, and the bearings (plaited straw) are
inexpensive to replace.
DISADVANTAGES OF WHEEL SPINNING:
• The wheel needs to be very large, since the larger the wheel, the
greater the number of twists that are put into the yarn, per wheel
rotation.
• It is not that much faster than spinning from a drop spindle, but the
winding process is quicker and less energetic.
SPINNING MACHINES
• With passage of time human always try to make everything easy.
• Man tried to improve the spinning wheel to omit personal effort (Wheel was run
by hand or foot manually).
• Gradual improvements in manual spinning methods lead to different type of

spinning techniques and human becomes successful to omit personal efforts.
SPINNING WHEEL VIDEO

CLASSIFICATION OF SPINNING MACHINES
• Spinning machines are divided into two main groups;

1) Intermittent
These machines only carry winding section, while drafting and binding are interrupted.
Mule and centrifugal spinning lies in this category.
2) Continuous
Machines of this type perform the three stages of spinning process (drafting, binding,
winding) simultaneously on consecutive lengths of material. It is sub-divided in different
categories.
CONTINUOUS SPINNING MACHINES
• These are sub-divided as;
i. Conventional frame spinning machines

These machines were invented during late 18th and early 19th centuries;
a. Flyer Spinning
b. Ring spinning
c. Cap spinning
ii. Modern commercial machines
These machines became available during 1960s and 1970s as the result of intensive research effort;
a. Open-end spinning
b. Repco self-twist spinning
CONTINUOUS SPINNING MACHINES
iii. Other spinning machine developments

This group include machines which have not yet been adopted widely for commercial stage of
application;
a. Twistless spinning
b. Spin-folding and wrapped yarn spinning
c. Front folding
d. Jet Spinning
e. Bobtex A.B.S. (aerodynamic brake spinning)
f. Bobtec I.C.S. (integral composite spinning)
BACKGROUND FOR DEVELOPMENT OF NEW

SPINNING TECHNIQUES
• New spinning processes have been available in practicable form for almost 40 years and
still the most of short staple yarns are spun on conventional systems.
• Some pros and cons of each system are always there. Keeping in mind these pros and
cons, a system is adopted and commercialized.
• Ring spinning is one of the most used conventional spinning technique, which is still used
in a great proportion.
• Now the question is “Why new systems were developed and why ring spinning is still
used.
Why is ring spinning still in use?
Ring spinning is still in use for its following salient features, to which no
replacement is available;
• Production of high strength yarns.
• Spinning of fine count yarns.
• Proper for special yarns.
• It is universally applicable (any material can be spun).
• The know-how for operation of machine is well established accessible to
everyone.
• It is flexible as regards quantities (blend and lot size).
• Since the speeds in drawing section are best controlled, yarn evenness is
excellent. But if short fibers are too much, yarn unevenness occurs.
• Fine yarns can be produced as Prepared
compared to open end system.
by: Wardah Anam
POTENTIAL TO DEVELOP NEW TECHNIQUES
What was the potential to develop new processes to produce yarn?

Ring spinning has following drawbacks due to which man think to develop new processes;
• Process stages are more numerous. Roving stage exists as an extra process compared to
the other systems.
• Yarn breakages are more numerous as a result of ring traveler friction and yarn air friction.
• Interruptions, broken ends and piecing up problems exist because of the yarn breakages.
POTENTIAL TO DEVELOP NEW TECHNIQUES
• The high speed of the traveler damages the fibers.

• The capacity of the cops is limited.
• Energy cost is very high.
• Low production rate.
• Additional winding process is required at the end to make bigger packages.
Due to these disadvantages of ring frame, researchers try to develop new systems to omit
these negative points but new systems also have their individual limitations and are
confined to restricted sectors of the market.
DISADVANTAGES OF NEW SYSTEMS
• A yarn character different from that of the ring spun yarn, which still represents the basic standard for
comparison.
• Characteristics occasionally bordering on unusable.
• Difficulties in maintaining consistently uniform characteristics.
• Greater demands on the raw material.
• Market segments limited to (narrow count range, specific raw material types and specific end product).
• A high level of process know how.
• Expenditure on repair and maintenance.
ADVANTAGES OF NEW TECHNIQUES
• High production rates

• Elimination of process stages
• A considerable reduction in personnel and space
• Relative ease of automation
• In some cases, with the use of auto-leveller at the cards, elimination of even the draw
frame passage.
• Less labor and power cost per kilogram of yarn.
RING SPINNING IN FUTURE
• Researches are on and in future may be researchers got success to eliminate

disadvantages of new systems. So, these systems may eliminate ring spinning in future.
• The ring frame can only survive in longer term if further success is achieved in
automation of the ring spinning process. Also, spinning costs must be markedly reduced
since this machine is significant cost factor in spinning mill.
Ring and rotor spun yarn properties
Yarn properties depend on raw material used, twist, fiber length, fiber density,
individual fiber strength and many more basic terminologies but generally ring
spun yarn has following properties:
• Strongest yarn
• Softer yarn
• Possibility for both "Z" and "S" twist
• Lowest productivity
• More uneven
• Most expensive
• More hairy
• Widest range of yarn countsPrepared by: Wardah Anam
Ring and rotor spun yarn properties
Generally rotor spun yarns have following properties:
• More even
• Higher strength uniformity
• Higher production rate
• Fewer processes
• Lower cost
• Fewer imperfections
• Harsher hand (feel)
• Not as strong as ring spun yarn
• Limited counts-coarser yarns
• “Z” twist only
Ring Spun Yarn Rotor Spun Yarn
Uniform with more strength than rotor spun. Uniform but less strength than ring spun.
Low flexibility. Higher flexibility than ring spun.
Dye ability is less than open end yarn. Dye ability is easy and more than ring spun.
These yarns are made coarser to medium and medium to These are limited to coarser to medium counts.
finer.
Used for multiple applications. Used for heavier fabrics such as denims, towels and
poplins.
Production rate is lower. 3-5 times faster production rate than ring spun.
Stronger at optimum twist. It has 20% more twist and 15-20% weaker than ring spun.
All staple fibers could be ring spun. Universally applicable. Man-made fibers except rayon could not be rotor spun.
Ring spun Yarn Rotor Spun Yarn
It is expensive because of some additional manufacturing It is cheaper because of elimination of some manufacturing
steps. steps such as roving and comber.
It is less abrasion resistant as compare to rotor spun. It has a good abrasion resistance.
It is less absorbent because of tight packing of fibers. It is more absorbent because of loose packing of fibers.
It breaks at ring frame because of ring traveler friction. Yarn breakage is very low so less production loss.
It has more hairiness because of fiber migration during It has 20-40% low hairiness as compare to ring spun because of
spinning. less fiber migration.
It feels harsh because of tight packing of fibers and more It is soft because of loose packing and less hairiness.
hairiness.
Fiber packing is uniform and more towards surface. Fiber packing is not uniform, more towards yarn axis and less
towards the surface.
It has less hooked and looped fibers. More hooked and looped fibers in rotor yarn.
It has higher C.V% in strength than rotor spun. It hasAnam
Prepared by: Wardah less variation in strength.
COMPARISON
Ring Spun Yarn Rotor Spun Yarn

Ring spun could have more yarn faults. Yarn faults are decreased by 80%.
Fiber blending is not good in ring spun. It has much better fiber blending.
It has more fly liberation. It has less fly liberation.
More end breaks in spinning. 75% less end breaks.
Air permeability is low because of tight Air permeability is 15-25% better.
packing.
It gives less cover in fabric formation. It gives 10% better cover.
At this time 76% staple spun yarns are ring 24% are rotor spun as compare to ring spun
spun as compare to rotor spun in world. production.
STRUCTURE OF RING AND ROTOR SPUN YARN
• The yarn structure is dependent primarily upon the raw material, spinning
process, spinning unit, machine, machine settings, twist, etc.
• The structure can be open or closed; voluminous or compact; smooth or rough or
hairy; soft or hard; round or flat; thin or thick, etc.
• Both ring and rotor spun yarns are produced by twisting but there lot of
differences in both yarns due to difference of their structure.
• Structure of yarn influence a lot of yarn properties.
Structure of ring and rotor spun yarn
Yarn structure is not simply appearance. It has a greater or lesser
influence on;
• Handle
• Strength
• Elongation
• Insulating capacity
• Covering power
• Ability to resist wear, damage, strains, etc.
• Resistance to abrasion
• Ability to accept dye
• Wearing comfort, etc.
STRUCTURE OF RING AND ROTOR SPUN YARN
COMPARISON OF U%
11.2
10.8
10.4
10
9.6
U%
Ring yarn rotor yarn
Reason for difference in U%
• Rotor spun yarn shows higher evenness than ring spun yarn.
• Ring yarn is more uneven than rotor yarn. In processing in the spinning mill, the
unevenness of the product increases from stage to stage after draw frame. There
are two reasons for this. The number of fibres in the cross section steadily
decreases. Uniform arrangement of the fibres becomes more difficult, the smaller
their number.
• Each spinning operation increases the unevenness. Each machine in the spinning
process adds a certain amount to the irregularity of finished yarn. After draw
frame rotor yarn is produced directly from rotor, but in terms of ring yarn it is
passed a several process & draft is also imparted. That’s why ring yarn is more
uneven than rotor yarn.
Comparison of imperfections
250
200
150
100
50
0
ring yarn rotor yarn
thin -50 thick +50 neps +200
Reason for difference in IPI
• Imperfection of rotor spun yarn is very much lower than ring spun yarn
but rotor spun yarn contains more thin places.
• It is found that the Neps are originated more in ring yarn than rotor
yarn. However, if the number of imperfections rises above the usual
level, this can be attributable to both raw material and machine-related
causes. For example, immature cottons are very predisposed to
produce Neps during processing.

Comparison of hairiness
5.6
5.4
5.2
4.8
4.6
4.4
hairiness
REASON FOR DIFFERENCE IN HAIRINESS
• Rotor-spun yarns display significantly lower hairiness than

comparable ring yarns. The reason is that the fibre ends facing
away from the yarn take-off direction point toward the interior of
the yarn and the number of free fibre ends is therefore about half
that in ring-spun yarns. Furthermore, the wrapper fibres wound
crosswise around the yarn help to bind-in loose fibre ends.
IS LESS HAIRINESS IS ADVANTAGE OR DRAWBACK..???
• However, low hairiness is a drawback where a large number of

protruding fibre ends contributes to a soft hand, for example in
knitted fabrics. Here ring-spun yarn has an advantage, since its high
hairiness is especially beneficial for a soft hand in the final fabric.
• But performance of yarn having high hairiness will be poor.

Comparison of strength
2500
2000
1500
1000
500
0
strength
REASON FOR DIFFERENCE IN HAIRINESS
• Strength of ring spun yarn is higher than rotor spun yarn. This is
believed due to the removal of short fibres during the ring spinning
process and hence only long fibres remains, which can twist together
with good fibre to fibre friction and hence the overall strength of the
fibre is increased. But in case of rotor spinning short fibres are not
removed efficiently which causes the yarn to lose its strength.
• Moreover the ring spun yarns are re-winded to remove any thick,
thin places and Neps.
COMPARISON OF TENACITY
• Ring-spun yarn contains envelope twist, twisting in the fibres from
outside to inwards, whereas rotor-spun yarn in contrast has core twist,
twisting in the fibres from the inside to outwards.
• Rotor spun yarn is therefore more voluminous, more open & rougher
than ring spun yarn. The fibres in the envelope layer of a rotor-spun yarn
can partly escape the twisting action during spinning & therefore take up
turns of twist. They thus contribute relatively little to yarn strength & can
more easily be rubbed together axially to form slubs, etc. Furthermore,
the fibres in a rotor-spun yarn are less parallel than those in a ring-spun
yarn. The core twist structure & the lower degree of parallelism are the
causes of lower strength of rotor spun yarn.
COMPARISON OF ELONGATION
CONT.
• Rotor-spun yarn is superior to ring-spun yarn in terms of elongation

at break (%), in contrast to yarn tenacity. Based on Uster Statistics it
is apparent that the elongation at break of rotor-spun yarns is higher
than that of comparable ring-spun yarns, only marginally in some
cases. This is especially positively noticeable in the working
capacity of rotor-spun yarn, in that the differences relative to ring-
spun yarn are smaller than for count related yarn tenacity.
OPEN-END SPINNING
• Open end spinning is a technology for creating yarn without using a

spindle.
• It is also known as break spinning or rotor spinning.
• In this process the fiber sliver is separated into single fibers and in which
the separated fiber material is brought by an air stream to a collecting
surface from which it is drawn off while being twisted.
PRINCIPLE OF OPEN-END SPINNING
• The principle behind open end spinning is similar to that of a clothes dryer
spinning full of sheets.
• If you could open the door and pull out a sheet, it would spin together as
you pulled it out.
• fiber from the sliver goes into the rotor, is spun into yarn and comes out,
wrapped up on a bobbin, all ready to go to the next step.
OPEN-END SPINNING TECHNIQUES
Following spinning methods lie in open-end spinning;

1) Rotor spinning
2) Air vortex spinning
3) Electro static spinning
4) Friction spinning
5) Break spinning
6) Disc spinning
SHORT DESCRIPTION
Rotor Spinning: Individual fibers converted to yarn through rotary motion.
Friction Spinning: External surface of two rotating rollers is used twist individual
fibers into a yarn.
Air-jet Spinning: Utilizes air to apply the twisting couple to the yarn during its
formation.
Electrospinning uses an electrical charge to draw very fine (typically on the micro or
nano scale) fibers from a liquid.
ROTOR SPINNING
HISTORY
• The idea of producing yarn by the Rotor-Spinning technique is far from

new.
• Patent applications for this method were filed before the Second World
War.
• However, the first usable design was put forward only in the mid-1950s by
J. Meimberg at the Spinnbau company in Spinnbau showed this machine at
Brussels exhibition in 1955, but further development of the machine was
discontinued because performance proved unsatisfactory.
DEVELOPMENT
• 1960s; The idea was taken up again in Czechoslovakia.

• 1965; The first machine really suitable for industrial application was shown at Bruenn
fair.
• 1967; followed by the presentation of the BD200 machine at an exhibition in parallel to
the ITMA of that year.
• This was also the point of time at which the rotor-spinning came into practical industrial
use in spinning mills.
• The current market share is 20% of total staple yarn production and is steadily
increasing.
• 1970s; rapid development in technological and economical aspects.
DEVELOPMENT
• Earliest yarn used to be a woolen-spun character (open,

voluminous and rough with low strength).
• After further research and development, now it is hardly

possible to distinguish rotor spun yarn from ring spun yarn.
ECONOMICAL ASPECTS
• Rotor speed used to be 30,000 rpm. After 20 years of development, today

speed of rotor is around 175,000 rpm.
• Production of rotor spinning is four to ten times more than that of the ring
spinning spindle.
• Rotor spinning is more economical than the ring spinning for yarn counts
up to Ne 40.
ECONOMICAL ASPECTS
• The rotor spinning is an excellent recycling device as the

spinning mill-waste (secondary materials) is utilized and used.
It was not previously possible in ring spinning.
• Rotor spinning is the first final-spinning machine to be

practically fully automated.
GENERAL OVERVIEW
This is normally used in cotton carded

spinning. The frame is fed with slivers
from the draw frames which transform
the yarn directly into packages,
eliminating the passage on the roving
frame and, in many cases, further
packaging operations.
PRINCIPLE
The main function of the spinning unit is as follows;

The sliver from the draw frame is introduced by a feeder cylinder and
is subject to the action of an opener with saw-toothed wiring which
rotates at a speed of between 6000 and 9000 rpm, separating the sliver
into single fibers, then the fibers are sent to the rotor through a vacuum
channel. The rotor, whose diameter is between 32.5 and 54 mm,
rotates at a very high speed over 100,000 rpm, and compacts the fibers
partly thanks to its special shape, twisting the fibers at the same time.
PRINCIPLE OF ROTOR
OPERATIONAL SEQUENCE
Sequence of operations performed on a rotor spinning machine is;

1) Sliver feed
2) Sliver opening
3) Fiber transport into rotor
4) Fiber collection
5) Yarn formation
6) Yarn take-up and winding
SCHEMATIC DIAGRAM
SLIVER FEED
• A card or draw frame sliver is fed through a sliver guide via a feed
roller(F) and feed plate (B) to a rapidly rotating opening roller(O).
SLIVER FEED
• Sliver fed via trumpet into the feed shoe. If the yarn breaks the sliver
fed is ceased immediately.
• Feed roll has diagonal fluted to increase the clamping. Sometimes the
distance between the feed shoe and opening roller is adjusted.
SLIVER OPENING
• The opening roller removes the fiber from the sliver as it is fed in, and, after two
or three rotations, delivers them to the feed tube in which the airflow takes them to
the rotor.
• Removal of fibers from the opening roller is by controlled air flow, aided by
centrifugal acceleration.
• The ratio of air speed to opener surface speed should be in the region of 1.5 to 4.0.
The higher ratios result in a higher yarn tenacities because of the improved fiber
orientation.
OPENING ROLLER
• Opening roller, comparable to that of the carding in-feed taker-in, but

the assembly is much smaller. Opening roll rotate at 35 m/s and passes
through the fiber beard that is slowly fed by feed roll.
Opening roller
• It rotates at 5,000 to 10,000 rpm, usually 6,500 to 8,000 rpm.
• The diameter lies between 60 and 80mm.
• High speed may lead to fiber deterioration or even damage
melt spot and tearing out of fiber bunches.
• Basically the opening roller speed should be as low as possible.
It is important to note, that too slow a speed tends to cause
fiber lapping and irregularly spaced thick and thin places in the
yarn.
• On the other hand, increased opening roller speed causes
higher dust formation, higher fiber damage, reduction in yarn
strength and breaking elongation.
OPENING ROLLER
• The opening roller surface speed usually depends on the type of fiber and the roller design.
• A higher opening speed may be required to provide increased opening force in the following
circumstances;
i. increased feed sliver count.
ii. increased fiber length.
iii. the use of three-dimensional crimped fiber (compared with two-dimensional crimp).
iv. the use of finer fibers, because of the increased fiber surface area.
OPENING ROLLER
• The clothing on the opening roll naturally exerts a great influence;

a) Type of clothing
b) Shape of teeth
c) Point density
• The card clothing used on the opening roller is usually of the rigid metallic type,
varying from a face angle of about 65° and 18.5 points/cm 2 for cotton and 80° to
100° with 15 points/cm2 for manmade fibers.
OPENING ROLLER
Clothing of opening roller is selected as;

• For carded, combed and viscose – clothing with more agressive front flank, higher
density (2.5 mm) (type B 174)
• Cotton with honeydew – clothing with wider tooth space (4.8mm) & type used (type B
174 - 4.8)
• For man-made fibers especially polyster and blends – clothing with less sharply
inclined and less sharp point (S 21)
• For man-made fibers especially polyacrylic – clothing with low height and low density
(S 43)
OPENING ROLLER
Geometry of wire clothing is as;

OPENING ROLLER
• Opening roller service life is considerably affected by the fiber

material as well as by the dirt content in the fiber.
• The main wear points are the tooth face and tooth tip.
• Service life can be extended by the shape of the tooth (e.g. sickle
shape, rounded tooth tip) and by tooth coating. Coated teeth show
much lower levels of wear.
Opening unit
a) rotating teeth of opening

roller
b) feed table
c) feed roller
d) fixed fiber beard support
e) trash removal
f) adjustable bypass system

TRASH REMOVAL
• The trash particles are extracted by centrifugal forces in the first 90

degree of the opening roller revolution.
• The higher the peripheral speed, the coarse trash will be thrown away
due to centrifugal force.
• Trash can be eliminated by either pneumatically or mechanically by
small transport tube on the chamber.
FIBER TRANSFER TO ROTOR
• Centrifugal forces and a vacuum in

the rotor housing causes the fibers to
disengage at a certain point from the
opening roller and to move via the
fiber channel to the inside wall of the
rotor.
FIBER TRANSFER TO ROTOR
• After opening, the fibers must be passed to the rotor, so a closed tube serves as a
means of guidance and feed the fibers directly into the rotor wall for deposition.
• While the air-together with the dust flows over the rotor rim towards the collection
unit.
• This feed has got the shape of convergent tip towards the rotor which helps
accelerate the fiber, hence draft occur and remain the 1 to 5 fiber in section.
Fiber transfer to rotor:
• Ideally the fiber should pass down the feed tube one at a time, but in practice
the average number of fibers in the feed tube cross section can be as many as
four.
• If too many fibers are fed along side each other, the rotor tends to accumulate
tufts of fibers, thereby increasing yarn irregularity.
• The fibers passing along the feed tube are in a relaxed state.
• As a result fiber tensions are much more evenly distributed in yarn, causing
less fiber migration than in ring spun yarns.
SHAPE & DIRECTION OF FIBER TRANSFER TUBE
There are two ways of feed tube arrangements;

1) Axially
2) Tangentially
• The shape of the fiber guide channel is crucial for fiber transport and the desired
longitudinal orientation of the fibers.
• The inlet and outlet openings of the fiber guide channel must be designed and produced so
that the transfer of fibers from the opening roller, fiber transport in the guide channel itself
and the transfer of fibers to the inside wall of the spinning rotor are trouble-free.
SHAPE & DIRECTION OF FIBER TRANSFER TUBE
• The fiber channel narrows toward the rotor, which causes acceleration of the air and fiber
flows.
• This acceleration is of great significance because it leads to further separation of the fibers,
down to between one and five fibers in section, and also straightens the fibers.
• The narrowing region represents a second draft zone (following the feed roller/ opening
roller).
FIBER COLLECTION IN ROTOR GROOVE
• The centrifugal forces in the rapidly rotating rotor cause the fibers to move
from the rotor wall toward the rotor groove and be collected there to form a
fiber ring.
• The amount of rotation given to a fiber as it moves into the collecting

groove depends on the rotor diameter, the slide wall angle, and the axial
distance from the feed tube exit to the collecting groove.
YARN FORMATION
• The rotor rotates at high speed creating a centrifugal force.

• To start spinning, a length of yarn already wound onto the package of the take-up mechanism
is threaded through the nip line of the delivery rollers and into the draw-off tube.
• Because of the vacuum, the tail end of this yarn is sucked into the rotor.
• The rotation of the rotor pulls the yarn end onto the part collected ribbon of fibres through the
air drag and the centrifugal forces, and simultaneously inserts twist into the yarn tail.
• A little of this twist propagates into that part of the ribbon in contact with the yarn tail,
binding it to the yarn end.
YARN FORMATION
YARN FORMATION
• The yarn is pressed against the rotor wall by the high centrifugal
force, and the separation point therefore rotates within the rotor.
• Each revolution of the yarn at this point inserts one turn of twist.
The yarn twist penetrates in to the fiber ring in the collection
groove, where the fiber are bound together to form a yarn.
ROTOR CLEANING
• An essential element of a functioning spinning unit is automatic rotor

cleaning capability. This is one of the major advantages of the rotor
spinning system compared with other spinning processes, which are
unable to clean the raw material fed in again at the spinning position
itself.
• Essentially, two systems are used to clean the rotors: pneumatic cleaning
by means of compressed air and mechanical cleaning by means of
scrapers. Both systems are also used in combination.
• During rotor cleaning the surface of the draw-off nozzles and the draw-off
tube are also cleaned.
ROTOR CLEANING
ROTOR DRIVE AND BEARING
• Nowadays, the rotors on all rotor spinning machines are driven using the friction drive
principle, i.e. by a tangential belt in contact with the rotor shafts on each side of the
machine.
• Rotor drives are classified in two types;

1) Direct
2) Indirect
DIRECT DRIVE
• Direct rotor bearing in which tangentially driven rotor shaft(a) is encased in ball bearing
housing(b).
• The ball bearing rotates at the same speed (rpm) as the rotor shaft driven by the tangential
belt. This bearing principle limits rotor speeds to approx. 110 000 rpm.
INDIRECT DRIVE
• Indirect rotor bearing, in which the rotor shaft, also driven tangentially, runs on two pairs
of supporting discs arranged side by side.
• With the support disc bearing the rotor speed is reduced at a ratio of 1:8 to 1:10 relative to
the bearing of the supporting discs, depending on the diameter of the discs.
INDIRECT DRIVE
• For one thing, this bearing system permits much higher rotor speeds than
direct bearings, and at the same time the service life of indirect bearing
systems is significantly higher than that of directly driven bearing systems.
• High-performance rotor spinning machines operating at speeds of up to

160 000 rpm are therefore operated only with indirect rotor bearing.
INDIRECT DRIVE
Tangential belt (a) is engaged with the rotor shafts via pressure rollers (b) to drive the
rotors.
YARN TAKE-OFF
The yarn is taken from the rotor by the delivery shaft and pressure roller (a), diverted
virtually at right angles in the process by draw-off nozzle (b) projecting into the rotor and
guided out by draw-off tube (c) immediately following this.
Yarn take-off
• At take-off the yarn continuously rolls off on the surface of
the draw-off nozzle due to the rotation of the rotor.
• This rolling-off temporarily inserts additional twist into the

yarn (contrary to the direction of twist of the yarn), thus
creating the false-twist effect required for spinning stability,
which can be up to 60 % of the set yarn twist.
• The greater the false-twist effect, the higher the spinning

tension. Prepared by: Wardah Anam

1 - Advanced Spinning Techniques

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1 - Advanced Spinning Techniques

Uploaded by

Copyright:

Available Formats

INTRODUCTION

Prepared by: Wardah Anam

• S essional Marks 30%

Prepared by: Wardah Anam

Spinning could be defined as;

• The extrusion of filaments by spiders or silkworms.

• The production of filaments from glass, metals, fiber-forming polymers or

• Spinning process basically consists of three stages;

SPINNING HISTORY & 1ST SPINNING TECHNIQUE

ADVANTAGES OF WHEEL SPINNING:

• Spin any kind of thread with the same wheel.

DISADVANTAGES OF WHEEL SPINNING:

• With passage of time human always try to make everything easy.

• Gradual improvements in manual spinning methods lead to different type of

SPINNING WHEEL VIDEO

CLASSIFICATION OF SPINNING MACHINES

• Spinning machines are divided into two main groups;

CONTINUOUS SPINNING MACHINES

• These are sub-divided as;

i. Conventional frame spinning machines

CONTINUOUS SPINNING MACHINES

iii. Other spinning machine developments

BACKGROUND FOR DEVELOPMENT OF NEW

POTENTIAL TO DEVELOP NEW TECHNIQUES

What was the potential to develop new processes to produce yarn?

POTENTIAL TO DEVELOP NEW TECHNIQUES

• The high speed of the traveler damages the fibers.

DISADVANTAGES OF NEW SYSTEMS

ADVANTAGES OF NEW TECHNIQUES

• High production rates

RING SPINNING IN FUTURE

• Researches are on and in future may be researchers got success to eliminate

Low flexibility. Higher flexibility than ring spun.

Ring Spun Yarn Rotor Spun Yarn

STRUCTURE OF RING AND ROTOR SPUN YARN

Prepared by: Wardah Anam

REASON FOR DIFFERENCE IN HAIRINESS

• Rotor-spun yarns display significantly lower hairiness than

IS LESS HAIRINESS IS ADVANTAGE OR DRAWBACK..???

• However, low hairiness is a drawback where a large number of

• But performance of yarn having high hairiness will be poor.

REASON FOR DIFFERENCE IN HAIRINESS

• Rotor-spun yarn is superior to ring-spun yarn in terms of elongation

• Open end spinning is a technology for creating yarn without using a

• It is also known as break spinning or rotor spinning.

PRINCIPLE OF OPEN-END SPINNING

OPEN-END SPINNING TECHNIQUES

Following spinning methods lie in open-end spinning;

Rotor Spinning: Individual fibers converted to yarn through rotary motion.

• The idea of producing yarn by the Rotor-Spinning technique is far from

• 1960s; The idea was taken up again in Czechoslovakia.

• Earliest yarn used to be a woolen-spun character (open,

• After further research and development, now it is hardly

• Rotor speed used to be 30,000 rpm. After 20 years of development, today

• The rotor spinning is an excellent recycling device as the

• Rotor spinning is the first final-spinning machine to be

This is normally used in cotton carded

The main function of the spinning unit is as follows;

Sequence of operations performed on a rotor spinning machine is;

• Opening roller, comparable to that of the carding in-feed taker-in, but

• The clothing on the opening roll naturally exerts a great influence;

Clothing of opening roller is selected as;

Geometry of wire clothing is as;