RING SPUN YARNRING SPUN YARN

03/17/1503/17/15

Md.Azmeri Latif BegMd.Azmeri Latif BegMSc. in Textile Engineering(DIU)MSc. in Textile Engineering(DIU)BSc. in Textile Engineering(CU)BSc. in Textile Engineering(CU)

Comparative study on 24s,30s & 40s ring spun yarn with machine setting & different production parameter (Bale management to finishing).

Historical development of natural fibreHistorical development of natural fibre

The first uses of natural fibers are occurred in 8000 B.D. in Egypt. In Indian sub- continent man tried to use the natural fiber from many years ago. Especially in this continent men tried to use the silk firstly.

Cotton : The seed hair of a wide variety plants of the Gossypium family is called cotton.

Botanical name of cotton: Gossypium herbaceum.

Gossypium arboretum.

Gossypium hirsutum.

Gossypium barbedense.

Production in percentage of cotton In different countries:Production in percentage of cotton In different countries:

Country (%)America 60-65India 10-12Pakistan 5-6Egypt and Sudan 5-6Russian 3-4China 3-4Brazil 2-2.5Others countries 10 Total 100%

Influence of Raw Material on SpinningInfluence of Raw Material on Spinning

Raw material represents about 50% of the production cost of a short staple yarn. The influence becomes still more apparent when the ease in processing one type of fiber material is compared with the difficulties, annoyance, additional effort and the decline in productivity and quality associated with another, similar material. Hardly any spinner can afford to use a problem-free raw material, because it would normally be too expensive. Adapting to the anticipated difficulties requires an in time knowledge of the starting material and its behavior in processing and subsequent.

Optimal conditions can be obtained only through mastery of the raw material. Admittedly, however, the best theoretical knowledge will not help much if the material is already at the limits of spin ability or beyond. Excessive economy in relation to raw material usually does not reduce costs, and often increases them owing to deterioration of process ability in the spinning mill.

Machinery set – up Machinery set – up

• Blow Room Line with Foreign Fibre Detector

Uniflock – A11 Uniclean – B12 Unimix – B70 Uniflex – B60 Jossi Brand: RIETER

Machinery set – upMachinery set – up

• Carding Machine( Chute feed card)

Model: C 60, RIETER• Drawing Machine: RIETER, SB40, RSB-D40• Lap former: Rieter, E32• Comber machine: Rieter, E65• Simplex: TOYOTA FL 100 • Ring Frame: MARZOLI, DTM-129• SPINDLE – Novibra• Drafting system- Texpart, PK 3025 series.• Ring Cup: Braker • Winding Machine: MURATA – 21C (With USTER QUANTUM-2)• Heat setting Machine: Elgi Korea

PROCESS FLOWCHART FOR CARD YARNPROCESS FLOWCHART FOR CARD YARN

• Bale Management• Blow room (chute feed for modern blow room line)• Carding (Carded Sliver)• Breaker Draw frame (B/D/F sliver)• Finisher Draw frame (Finisher sliver)• Simplex (Roving)• Ring frame (Yarn in bobbin form)• Autoconer / Finishing (Yarn in cone form)• Heat setting (Heat setted yarn)• Cooling• Packing (finished bag)

PROCESS FLOWCHART FOR COMB YARNPROCESS FLOWCHART FOR COMB YARN

• Bale Management• Blow room (chute feed for modern blow room line)• Carding (Carded Sliver)• Pre comb draw frame (precomb drawing sliver)• Lap former (comber lap)• Comber / combing ( comber sliver)• Post comb draw frame (Finisher combed sliver)• Simplex (Roving)• Ring frame (Yarn in bobbin form)• Autoconer / Finishing (Yarn in cone form)• Heat setting (Heat setted yarn)• Cooling• Packing (finished bag)

Bale Management:Bale Management:

Testing, sorting and mixing bales according to fibre properties for producing specific good quality yarn at minimum cost is called Bale Management.

• Objects of Bale Management: An evening out of the quality characteristics of a yarn. A means of avoiding quality jumps. A possibility of reducing cost.• Managing Bales: To manage the bales we need four modules of fibers and the

relation exist between fibers and yarn. They are: Strength Length Color grade and Micronaire value.

Important task of Bale Management:Important task of Bale Management:

• Micronaire range of the cotton bales used should be same for all the mixing of a lot.

• Micronaire average of the cotton bales used should be same for all the mixing of a lot.

• Range of color of cotton bales used should be same for all the mixing of a lot.

• Average of color of cotton bales used should be same for all the mixing of a lot.

• Range of maturity co-efficient of cotton bales used should be same for all mixing of a lot.

• Average of maturity co-efficient of cotton bales used should be same for all mixing of a lot.

Procedure of Bale Management:Procedure of Bale Management:

• Sample test and collect.• SCI value calculation and arrange

according to class.• Arrange bale according to SCI and mic.• Calculation for required bale perday.• Choosen bale according to properties and

arrange daily use.• Mixing properties and condition.

Mixing & Blending :Mixing & Blending :

• Mixing:

When different grade of same fibers are mixed together is called mixing.

Example: low graded cotton + High graded cotton = Mixing

• Blending:

When different types of fiber are mixed together is called Blending.

Example: 65% polyester + 35% cotton = Blending

Objects of Mixing and Blending:Objects of Mixing and Blending:

• To achieve uniform quality.• To improve processing performance.• To reduce and control of production cost. • To meet function and end user

requirements.• It influences to increase aesthetic

properties.i.e.,appearance, color, luster etc.• It influences to increase physical properties

i.e., tensile strength, elasticity, abrasion resistance etc.

Blow Room: Blow Room:

The section where the supplied compressed bale is turnt into a uniform lap of particular length by opening, cleaning, blending or mixing is called blow room section. It is the first steps of spinning.

• Basic operations involved in the Blow Room:

Opening.

Cleaning.

Dust removal.

Blending or mixing.

Even feed of the material.

Blow Room: Blow Room:

• Machines used in Blow Room:

Opening machines

Cleaning machines

Blending and Mixing machines

Lap forming machines.• FLOW CHART OF MODERN BLOW ROOM LINE (Rieter):

Unifloc – A11

Uniclean – B12

Unimix – B70

Vision shield

Uniflex – B60

Chute feed

CARDING:CARDING:

After the blow room, the next process is Carding. The cleaned fiber goes to a machine called a Card which further opens and cleans the cotton, removes immature bundles of fibers called neps, and starts to parallel the fibers. The Card forms the fiber into a sliver, which is a soft, loose, untwisted strand of rope fibers. Carding machines loosen and separate the cotton fibers by passing the fibers between two rotating metal drums covered with wire needles. This aligns the cotton in a thin web of parallel fibers which is formed into a ropelike strand ( sliver). The sliver is collected in a sliver can in preparation for further process like drawing and combing.

Function of Carding: Function of Carding:

• Individualization of fiber.• To remove the Dust particles e.g. broken

seed, leaf, seed coat, dirt etc from the cotton fibre, which are not removed by Blow Room.

• To remove the Neps from the cotton fibre.• To remove short and immature fibres from

the cotton fibers.• To make a uniform fibrous Strand / sliver,

this is suitable for next subsequent process.

Drawing: Drawing:

A process in short staple spinning in which the sliver are blended, doubled, leveled and drafted by passing the sliver through a series of pairs of rollers each pair moving faster than the previous one is called drawing.

• Function of drawing: Parallelization of fibre on sliver axis.

To remove the fine dust and hooked fiber from the sliver.

Mixing and blending of the cotton fiber.

To reduce the unevenness of the sliver by doubling and drafting.

To produce a uniform Sliver.

Drafting in Drawing: Drafting in Drawing:

The reduction of weight per yard of sliver is called draft.

Actual draft: hank of delivery materials/ hank of feed materials

Mechanical draft: S.S. of delivery roller/ S.S. of feed roller.

• Faults in drawframe: End missing.

Irregular drafting.

Roller lapping.

Irregular selvedges.

Fuzzing at the front roller.

Impurities in the sliver.

Lap former: Lap former:

• Function of lap former: To produce a uniform lap for comber machine.

• Technical data of lap former machine( unilap): Raw material : cotton up to 1.5 inches.

Feed stock: up to 120 ktex or grain/yds.

Doubling: 24

Range of draft: 1.3 – 3.0

Lap wt/meter: 70 gm/meter.

Total lap wt.: 12 – 15 kg.

Delivery speed: 85 – 100 meter/min

Production/machine: 400 – 500 kg/hour.

Efficiency: 90 – 95%

Combing:Combing:

For high quality yarns the sliver is combed after carding to make the fibers more parallel and remove smaller fibers.

• Function of comber: To reduce the Neps from the sliver.

To remove the maximum short fiber the sliver.

Mixing and blending of fiber.

To remove the fine dust and seed coat from the sliver.

To produce a more uniform sliver.

Combing:Combing:

• Technical points in Combing: The basic operation is to improve the mean length or staple

length by removing the short fibers.

Since fineness of short fibers ( noil) is low, the overall micronaire of the sliver after combing is high.

Combing % = 5 – 25% (quality dependent)

Because of combing, fiber parallelization increases.

drawback : high degree of parallelization can reduce inter- fiber adhesion in the sliver…fibers slide apart …may lead to sliver breaks or false draft.

Lap width is around 10.5”

Noil % = ( weight of Noils / weight of lap feed) * 100

SIMPLEX:SIMPLEX:

Roving frame is complicated, liable to faults, adds to production cost and delivery a product that is sensitive in both winding and unwinding.

• The important parameters of simplex m/c: Feed hank. Delivery hank. Roving tension. Break draft. Drafting

system. Bottom roller setting .Top roller setting. Condenser. Twist in the roving. Bobbin content. Flyer speed.

Creel and creel draft. Draw from sliver. Bobbin height. Breakage rate.

• Function of simplex: To produce a rope like ribbon by drafting that is called Roving.

To insert the twist on roving for increasing its strength.

To wind the roving on the bobbin.

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PRODUCTION PARAMETER FOR PRODUCTION PARAMETER FOR 24KH,30KH,40KH AND 24CH,30CH YARN24KH,30KH,40KH AND 24CH,30CH YARN

• For 24KH,30KH: Hank: .76Ne

Total draft: 0.76/0.111 = 6.84

DCP: 48

TCP: 44 BDCP: 63

TWIST: 1.05

• FOR 40KH:Hank: 0.90Ne

Total draft: 0.90/0.111 = 8.1

DCP: 41

TCP: 44

TWIST: 1.05

BDCP: 63

• FOR 24CH, 30CH:Hank: 0.80Ne

Total draft: 0.80/0.111 = 7.20

TWIST: 1.1

Ring frame:Ring frame:

Ring frame is a m/c where our desired yarn is produced from various fibers like cotton, silk, hemp, sisal, polyester, nylon etc. For producing yarn in Ring frame m/c a roving is required. From the roving Ring frame produce yarn by drafting or drawing and twisting.

• Function of Ring frame: To produce yarn from roving by drafting.

To insert the twist on yarn for increasing its strength.

To wind the yarn on the bobbin.

AUTO CONE MACHINEAUTO CONE MACHINE

Bobbin from ring frames are not suitable for further processing, the winding process is needed.

• Function of Winding machine: To wind the yarn on cone.

To reduce the yarn fault such as thick, thin , neps and slub by using Electronic Yarn Clearer.

To reduce pre-set weight of yarn package.

To insert the wax on knit yarn.

HEAT SETTING:HEAT SETTING:

• Heat setting m/c is suitable for increasing elasticity and strength of yarn, which removes snarling and curling effects of yarn. Twist setting, establishing moisture level in dry yarn.

• To increase moisture regain of yarn.

• To increase strength of yarn.

• To reduce hairiness of yarn.

• To set the twist on yarn.

PACKING: PACKING:

After heat setting, the heat setted yarn to keep the floor for cooling at 5 to 10 minute. Then the cones inter into the PP and finally 24 cones are packaged into one plastic bag.

THANK YOU EVERYBODYTHANK YOU EVERYBODY