What is Yarn? A product of substantial length & relatively small cross-section consisting of fibers or filaments with or without twist.
a Process Blow Room Carding Precomb Drawing Lap Former Comber Post comb Drawing Simplex Input Raw Cotton Output Lap/ Chute mat Card Sliver Drawn Sliver Lap Comb Sliver Lap/ Chute mat Card Sliver Drawn Sliver Lap Comb Sliver Roving Ring Spinning Winding/ Autoconer Yarn(Cone Package) Yarn (Ring Cops) Drawn Sliver Roving Yarn (Ring Cops) Drawn Sliver Scope of development in Yarn Manufacturing
Ring spun yarn Rotor/ OE/ auto coro yarn Air jet yarn Vortex yarn Friction Specialized spinning: Melt blowing Electrospinning Force spinning Developments of yarn according to spinning system
Ring spun yarn The ring spinning machine was invented by an American named Thorp in 1828, and Jenk – another American – added the traveler rotating around the ring in In the intervening period of more than 170 years the ring spinning machine has undergone considerable modification in detail, but the basic concept has remained the same. For many years any noteworthy further development hardly seemed possible, yet a significant process of evolution took place during this time.
Tensile strength properties is good. Good evenness High hariness Low stiffness High tendency to snarl Properties of Ring spun yarn
Ring Spun Yarn widely used in: Textiles Fabric Manufacturers sheeting & denim cloth manufacturers Weaving and knitting companies Application areas of Ring spun yarn
Rotor spun yarn Rotor yarn is formed by twisting of rotor by rotor spinning machine. This yarn can be formed from short fiber. Normally rotor yarn is coarse. Rotor yarn is also called open end yarn & Rotor yarn is widely used yarns in Denim production.
Production principle of Rotor spun yarn
Properties of Rotor spun yarn Breaking strength lower than ring spun Yarn CV% of strength better than ring spun yarn Elongation at break higher than ring spun yarn Mass irregularity ( over short lengths) better than ring spun yarn Imperfection index lower than ring spun yarn Volume greater than ring spun yarn Abrasion resistance higher than ring spun yarn Stiffness higher than ring spun yarn Handle harder Possible yarn counts rotor Ne 3 – 60 and Ring Ne 6 – 200
Rotor Spun Yarn widely used in: Denim fabric production Terry towel production Application areas of Rotor spun yarn
A minimum fiber length is required for production of air jet yarn. Air-jet spinning systems using one nozzle, like vortex-spun allow higher percentages of wrap fibers, resulting in better yarn properties and higher productivity. Air jet yarn yarn
Characteristics of Air jet yarn yarn
Production process of Air jet yarn yarn
Vortex yarn yarn
In Vortex yarns, the Centre of the yarn is not twisted. Twisting occurs at the outer sides of the yarn. Fibers at the Centre of the yarn remain loose while those at the outer side are fully twisted. The yarn thickness in vortex yarns is uneven. Twisting is concentrated at the thinner sections, while twisting is loose at the thicker section, leading to greater yarn hairiness. Twisting is more uneven for fibre s near the surface of the yarn. Table 1 provides a comparison between the three types of yarn Characteristics of Vortex yarn
Production principles Vortex yarn yarn The basic principle of operation is sliver is fed to 4-over-4 (or a four-pair) drafting unit. As t he fibers come out of the front rollers, they are sucked into the spiral-shaped opening of the air jet nozzle. The nozzle provides a swirling air current which twists the fibres. A guide needle within the nozzle controls the movement of the fibres towards a hollow spindle. After the fibers have passed through the nozzle, they twine over the hollow spindle. The leading ends of the fiber bundle are drawn into the hollow spindle by the fibers of the preceding portion of the fiber bundle being twisted into a spun yarn. The finished yarn is then wound onto a package.
Friction spinning Friction Spinning or Dref Spinning is a textile technology that suitable for spinning coarse counts of yarns and technical core-wrapped yarns. Dref yarns are bulky, with low tensile strength making them suitable for blankets and mop yarns, they can be spun from asbestos, carbon fibres and make filters was water systems. Yarns such as Rayon and Kevlar can be spun using this method. The technology was developed around 1975 by Dr. Ernst Fehrer.
Production principle of friction yarn
Compact spinning allows the spinning mill to produce a true ring yarn, which in many physical yarn parameters (hairiness, tenacity, elongation…) is vastly superior to non-compact (conventional) ring yarn. The purpose of a genuine compact spinning process is to arrange the fibers in a completely parallel and close position before twist is imparted. This is the most important criteria for perfect compact yarn. Compact spinning
Principle of Compact spinning
Up to 60% reduced ends-down rate. Up to 10% reduction in yarn twist. Up to 25% increased yarn strength. Up to 85% reduced hairiness (Zweigle S3 fibers>3 mm) Up to 30% reduced hairiness (Uster H) Improved IPI imperfection values Fiber loss reduced by up to 0.01% Substantially improved spinning stability. Advantages of spinning by means of the compact system
“ Fancy yarns” are those in which some deliberate decorative discontinuity or interruption is introduced, of either color or form, or of both color and form. Different types of fancy yarns are given below : Slub yarn Siro yarn Snow yarn Injected yarn Vario-siro yarn Melange yarn Nappy yarn Mosaic yarn Dotted yarn Fancy tops yarn What is fancy yarn
A yarn with thick and thin sections alternating regularly or irregularly. Slub yarn
Siro yarn is made into 2 ply on the ring spinning machine. Siro yarn
Snow Yarn is made with a process of Siro Spinning or Elitwist spinning.. Snow yarn
In Injected process, two roving are twisted together and short fibres are injected into the form-locking connection Injected yarn
In Vario-Siro process, Yarn injection system as same as Injected process only siro effect given by this fancy yarn. Vario-Siro yarn
“the yarn produced by the combination of at least two or more than two fibers” Mélange yarn
“Napes is the entangled mass of fibres. Neps are produced by the action of beating.By changing some process parameters in spinning section nappy yarn are produced. ” Nappy yarn
In Mosaic yarn, sliver injection system as same as Injected process only mosaic effect given by this fancy yarn. Mosaic yarn
“Dotted yarn produced by the combination of at least two or more than two fibre dust” Dotted yarn
In fancy tops process, two sliver are injected into the form-locking connection. By using this process rainbow effect comes. Fancy tops yarn