1. Yarn Manufacturing TECHNOLOGY

2. Types of Yarn
Carded Yarn.
Combed Yarn.

3. Comparison of Combed Yarn & Carded Yarn
Comber is used
No Comber is used
Less short fibers
More short fibers
Less Hairiness
More Hairiness
More Luster
Less Luster

4. Bale of Fiber

5. Flow Chart For Carded Yarn
Input
Process/ Machine
Output
Bale →
Blow room
Lap
Carding m/c
Sliver
Breaker Draw Frame
Finisher Draw Frame
Roving Frame
/Speed Frame/Simplex
Roving
Ring Frame
Yarn

6. Flow Chart For Combed Yarn
Input
Process/ Machine
Output
Bale →
Blow room
Lap
Carding m/c
Sliver
Pre comb drawing
Lap former
Combing
Post comb drawing
Simplex
Roving
Ring Frame
Yarn

7. Blow Room
Blow Room is called the mother of yarn manufacturing. It consists of a number of machines used in succession to open and clean the cotton fiber to the required degree. 40 to 70% trash is removed in this section.

8. Blow room line

9. Bale plucker

10. Opener

11. Mixer

12. Step cleaner

14. Objects of Blow Room 1. Opening :
To open the compressed bales of fibers &
To make the cotton tuft a small size as for as possible.
2. Cleaning :
To remove the dirt, dust, broken seeds broken leafs and other foreign materials from the fibers. More…

15. Objects of Blow Room
3. Blending & Mixing:
To make good value of yarn and to decrease the production cost by mixing different grade of fibers.
4. Lap forming :
To transfer the opened and cleaned fibers into a sheet form of definite width and uniform unit length which is called lap.

16. TECHNOLOGICAL POINTS IN BLOW ROOM
Opening in blow room means opening into small flocks
The larger the dirt particle , the better they can be removed   
The higher the degree of opening, the higher the degree of cleaning. A very high cleaning effect is almost always purchased at the cost of a high fiber loss. Higher roller speeds give a better cleaning effect but also more stress on the fiber.

17. Rollers Drums & Beaters

18. Actions involved in Blow Room
1. Action of opposite spike: (opening)
By The action of opposite spikes opening the cotton fiber is done.
2. Action of Air flow: (Transport + Cleaning)
During processing, the movement of cotton from machines to machine is done by air flow. It also helps the separation of lint and trash More…

19. Cleaning by Air flow

20. Actions involved in Blow Room
3. Action of Beaters: (Cleaning & Opening)
Beaters are responsible for removing almost all of the impurities extracted in the blow room. Beater also helps in opening of cotton fiber.
4. Action of regulating motion: (Uniform output)
The action of regulating motion gives the uniform output.

21. Cleaning Efficiency
Cleaning efficiency of blow room can be fin out by the following simple calculation.
(Input Trash - Output Trash)*100
Input Trash

22. Problem Solve: (6-1.6)*100/6 =73% Find the Blow Room cleaning effy :
Raw cotton trash= 6%
Lap trash = 1.6%
Solve: (6-1.6)*100/6
=73%

23. Carding
Carding may be defined as the reduction of an entangled mass of fibers to a filmy web by working between two closely spaced, relatively moving surface closed with sharp wire points.

24. Objects of Carding Opening to individual fibers.
Elimination of Impurities and dust.
Fiber blending.
Sliver formation.

25. Flow diagram of Carding m/c
A = Cylinder
B = Flat
C = Taker in
D = Feed roller
E = Feed plate
F = Doffer

26. Actions of Carding m/c 1. Carding Action
This is the action between flat & cylinder.
Pin direction: Opposite.
Rotation: Opposite.

27. Actions of Carding m/c 2. Stripping Action Pin direction: Same.
This is the action between Cylinder - Taker in
Pin direction: Same.
Rotation: Same.

28. Actions of Carding m/c 3. Doffing Action
This is the action between Doffer & Cylinder.
Pin direction: Opposite.
Rotation: Same.

29. Actions of Carding m/c 4. Combing Action
This is the action between Feed roller & Taker in.
Pin direction: Same.
Rotation: Same.

30. Carding Machine

31. Carding Machine

32. Draw frame
It is a process of yarn manufacturing in which the sliver is elongated when passing through pairs of rollers, each pair faster than the previous one.

33. Actions involved in Draw frame:
Drafting: The process of increasing length per unit weight of sliver. It is mainly due to varying speed of the rollers.
Doubling: The process of combining two or more carded sliver into a single form is called doubling. In draw frame m/c generally six to eight slivers are fed and converted into one.
Drawing = Drafting + Doubling.

34. TASKS OF DRAW FRAME Through draft fibers get parallelized
Hooked fibers are straightened.
Through the suction ,intensive dust removal is achieved.
Blending can be done here.

36. Drawing Machine

37. Find out the production/shift in lbs of a modern draw frame, from
the following particulars: Delivery speed = 600 m/min, No of
delivery/frame = 2, Draft = 8, No of doubling = 8, Feed sliver wt
= 0.01 lb/Yd, Efficiency = 90%
Solution:
Draft= (Feed wt/Delivery wt)* Doubling
So, Delivery wt= (Feed wt/ Draft)* Doubling
So, Delivery wt= (0.01/8)* 8 = 0.01 lb/yd
Production = 600 m/ min = 600*1.09 yds/min = 654 yds/min
= 654*0.01 lbs/min = 6.54 lbs/min = 6.54*60*8 lbs/shift
= lbs/shift
For 90% efficiency and no. of delivery, the ultimate production is, *0.9*2 = lb/shift (Ans)

38. Lap former
Lap former is the machine where lap is produced from slivers. It is necessary for producing combed yarn. Because the output of comber machine is lap.

40. Comber
Combing :
Combing may be defined as to remove short fibers , neps and remaining impurities of card sliver by using comb with the help of knives, brushes and rollers.

41. Objects of combing
To remove short fibers below a preselected length so that the spinner enable to produce finer / better yarn.
To remove neps and foreign matter from the cotton / sliver.
Make the fiber straight and parallel.

42. Blow room lap Comber lap
Short fiber high
Short fibre low
Uniformity low
Uniformity high
Trash high
Trash low
Lap count Ne
Lap count
Lap wt /yds ounce
Lap wt /yds ounce
Lap width 1m
Lap width 300 mm

43. Combing figure A= Feed roller B= Feed plate C= Nipper D= Top comb
E= Detaching roller
F= Cylinder

44. Combing Action
Firstly, Sliver comes through feed plate, After passing the edge, the nipper comes down to clamp the fiber between feed plate & itself. Then the first combing is done by the cylinder.

45. Combing Action
Then, nipper moves upward. Sliver feeding starts again. When sliver comes to detaching roller, the rollers give a backward movement to join it with previously combed sliver. That time Top comb comes down and by the forwarding movement of detaching roller, second time combing is done by top comb.

46. This process is a intermittent process
This process is a intermittent process. Because all these are carried out up to 300 times per minute.

47. Combing Machine

48. Speed frame Task of ring frame: To produce roving from sliver.
To impact strength to the fiber by twisting.
To wind up the resulting roving on to roving bobbin.

49. Speed frame machine

50. Operation involved in Speed Frame
Creeling: Sliver feeding with the help of several rollers. 40 drawn slivers can be creeled at a time.
Drafting: To reduce wt per unit length of roving in speed frame so that produces roving can be converted into yarn easily with draft in drafting Zone. For this normally 3 pairs of rollers are used.

51. Operation involved in Speed Frame
Twisting:
To insert small amount of twist to get required strength of roving . so that no breakage of yarn and possible to wind of roving in convenient package. Usually turns per meter twist is given which are created by flyer. But twist in roving are given such that the fibers hold its constituent fibers together and not create hinder during drafting in Ring frame.

52. Winding:
To wind the roving on to a suitable bobbin which will help handling , transfer and feeding to ring frame. Due to winding , as dia of bobbin is gradually increased, the speed of bobbin is continuously decreased with the help of building motion so that no breakage of roving for too much tension.

53. Doffing : To replace empty bobbin at a place of full bobbin.
Building : With the help of building motion , the correct or proper shaped package is made by winding of roving on bobbin in some consequent process.
Doffing : To replace empty bobbin at a place of full bobbin.

54. Speed frame action A= Sliver can B= Drafting zone C= Flyer
D= Roving bobbin
E= Gearing

55. Sliver & Roving

56. Ring frame
Ring frame is the machine where yarn is finally produced from the roving.

57. Function of a Ring frame:
To satisfy the roving to form yarn of the required count/ fineness of yarn by drafting & twisting.
To increase strength.
To build up the yarn on to bobbin in form of a suitable package for storage, transportation and processing.

58. Operation involved in ring frame
Creeling
Roving bobbin is fitted on the top of the m/c on the creel on both sides of the m/c. creel helps to freely rotate of roving bobbin and hold such that roving feed to the drafting zone on tension.

60. Drafting
Drafting operation reduces wt per unit length of roving . roving comes from the bobbin are passed through the drafting.
Twisting:
Spiral turns are inserted along the fiber axis . It increases yarn strength .The traveler which helps to insert twisting yarn, gets drive indirectly from spindle.

61. Winding:
After twisting the yarns are wound on a suitable package , layers of yarn are wound properly are above another on the package . It should be suitable for unwinding
Building:
For proper size and shape of the package the bobbins are lifted gradually. The resultant bobbins are conical shape full bobbin.

62. Doffing:
After the required length of yarn is wound on the package , the m/c is stopped . Doffing is the process of replacing the full bobbin by an empty bobbin.

63. Flow diagram of Ring Frame
A= Roving bobbin. B= Roving guide. C= Drafting zone. D= Balloon control ring. E= Ring. F= Traveler. G= Yarn bobbin. H= Gearing.

64. Traveler
Traveler is the most tiny & important part made by metal through which yarn passes its way from balloon control ring to the yarn package. It has no drive of its own. But it is dragged round by the yarn. During its rotation it produces twist.

65. Traveler

66. Ring Frame

67. Ring Yarn & Rotor Yarn
If there is a simplex machine in the process of yarn manufacturing, that is ring yarn. And if there is no simplex or ring frame, but a rotor spinning machine which converts sliver to yarn directly, the yarn manufactured is a rotor yarn.

68. Rotor spinning machine

69. Y1 = Ring Yarn & Y2= Rotor Yarn