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What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
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Muhammad Farooq Kokab 10-Ntu-031 1/29/2014

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
Contents
COMPARATIVE STUDIES ON RING, ROTOR ..................................................................................... 3 RING SPINNING: .......................................................................................................................... 3 ROTOR SPINNING: ....................................................................................................................... 3 Advantages of rotor spinning: ........................................................................................................ 3 High Elongation at break (%) ...................................................................................................... 3 Low Yarn hairiness ...................................................................................................................... 4 Less Yarn irregularity (CVm %) .................................................................................................... 4 Imperfections (thin places, thick places, neps)........................................................................... 5 No need of rewinding process .................................................................................................... 5 No special requirements on the atmosphere ............................................................................. 5 Ends down ................................................................................................................................... 6 Higher productivity, because of higher speed ............................................................................ 6 Elimination of roving, no use of simplex m/c- ............................................................................ 6 Disadvantages of rotor spun yarn:.................................................................................................. 6 Low yarn strength than ring spun yarn:...................................................................................... 6 Wide range of count cannot be spun: ........................................................................................ 7 Higher twist factor: ..................................................................................................................... 7 Very finer count cannot be spun: ............................................................................................... 7 More bulky yarn: ......................................................................................................................... 7 Economic Comparison of Rotor and Ring Spun Yarn ...................................................................... 8 Capital cost .................................................................................................................................. 8 Labour cost.................................................................................................................................. 8 Energy costs ................................................................................................................................ 8 Machine improvements .................................................................................................................. 9 Rotor speed ............................................................................................................................... 10

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
Rotor diameter.......................................................................................................................... 12 Rotor wall height....................................................................................................................... 13 References: ................................................................................................................................... 14 Fundamentals of Spun Yarn Technology ........................................................................ 14 (The mechanism and/or prediction of the breaking elongation of polyester/viscose blended open-end rotor spun yarns) .................................................................................... 14 By: OuzDemiryrek, Erdem Ko ............................................................................................... 14

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
COMPARATIVE STUDIES ON RING, ROTOR
RING SPINNING:
Ring yarn structure generally accepted as the basic structure in spun yarn technology. The Ring spun yarns have high strength, low imperfection, and good bursting strength. Ring yarn knitted fabric shows smooth feeling than the other fabrics.

ROTOR SPINNING:
The rotor spun yarn shows a bipartite structure (two-zone structures) comprising a core of fibres this are aligned with the helix of the inserted twist and form the bulk of the yarn, than an outer zone of wrapper fibres, which occurs irregularly along the core length. The wrapper fibres are classified into two types, short and long wrappers. Rotor, MVS yarns made fabrics have good abrasion resistance. The Rotor Spun yarns found with frequent breakage during knitting.

Advantages of rotor spinning:

High Elongation at break (%) Low Yarn hairiness Less Yarn irregularity (CVm %) Imperfections (thin places, thick places, neps) No special requirements on the atmosphere Less power consumption Higher productivity, because of higher speed Elimination of roving, no use of simplex m/cNo need of rewinding process

High Elongation at break (%)

In contrast to yarn tenacity, rotor-spun yarn is more or less significantly superior to ringspun yarn in terms of elongation at break (%). On the basis of Uster Statistics it is apparent that the elongation at break of rotor-spun yarns is higher than that of comparable ring-spun yarns, albeit 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. Studies by prominent weaving machinery manufacturers

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
demonstrate that 1% elongation at break produces the same improvement in working capacity as 2 cN/tex higher tenacity. At the high accelerations and loads to which yarns are exposed on modern high-performance machines, the elongation behavior of a yarn plays at least an equal, if not even a greater role than yarn tenacity. The advantages in processing are dealt with in greater detail in section processing properties.

Low Yarn hairiness

Yarn hairiness assumes a significance which should not be underestimated. This refers to the length and frequency of fiber ends that are not integrated in the yarn and therefore protrude from the yarn bundle. Rotor-spun yarns display significantly lower hairiness than comparable ring-spun yarns. The reason given for this by Bunk/Trommer (see references) is that the fiber ends facing away from the yarn take-off direction point toward the interior of the yarn and the number of free fiber ends is therefore about half that in ring-spun yarns. Furthermore, the wrapper fibers wound crosswise around the yarn help to bind-in loose fiber ends. Abrasion resistance and pilling tendency are positively influenced by these wrapping fibers. The clinging tendency, fiber abrasion and fiber fly of rotor yarns in downstream processing are less critical than for comparable ring-spun yarns. Put simply, the higher hairiness of ring-spun yarns is caused by the uncontrolled passage of edge fibers in cylinder draw frames and in the spinning triangle at the draw frame delivery end.

Less Yarn irregularity (CVm %)

Compared with other yarns, is the more uniform distribution of the fiber mass along the yarn, as expressed in the regularity of the weight per unit of length. The best possible regularity of a fiber bundle in the spinning process would be achieved if the fibers were distributed at random along the yarn. However, this ideal distribution cannot be achieved in practice, neither in ringspun, rotor-spun nor in any other staple fiber yarn. Deficiencies in machine operation or the drafting system are the cause of more or less pronounced cross-section variations. The size of the cross-section variations is expressed in mean linear irregularity (U %) or more correctly and customarily in terms of physical textile properties in mean square irregularity (CVm %). Only the rotor spinning system is able to offset this process- related deterioration in crosssection variations to some degree by back-doubling the fiber layers in the rotor. The mass

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
uniformity of the rotor-spun yarn is therefore better than for ring-spun yarn (given equal machine conditions)

Imperfections (thin places, thick places, neps)

The number of so-called yarn defects stated as the number of thick places, thin places and neps per 1 000 m of yarn also referred to in the literature as imperfections, is much lower than for comparable ring spun yarns. According to the latest Uster Statistics, the number of thick places and neps per 1 000 m of yarn are up to 60% and 80% lower in rotor-spun yarn than in ring-spun 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 inclined to produce neps during processing. However, thick places and neps also occur when spinning elements or other fiber-guiding machine components are worn or damaged. Bent, broken or notched clothing teeth on the opening roller in particular can cause steep increases in the numbers of neps and thick places. Wear or deposits in the fiber guide channel also result in fibers accumulating at these points and being fed uncontrolled to the rotor as larger or smaller clumps of fiber. Depending on their mass, these clumps result either in ends down or if spun in in defects in the yarn and the final fabric.

No need of rewinding process

The rotor spinning machine delivers cylindrical or conical packages ready for sale, which can immediately be processed further. Yarns for knitting are waxed directly at the spinning position and supplied in different package formats (cylindrical, 2, 351 and 420). Dyeing packages with appropriately reduced package density also at the outer edges permit direct processing in high-pressure dyeing equipment

No special requirements on the atmosphere

Temperature, Humidity and Air conditioning

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
Ends down
In weaving preparation (beamer, sizing machine) are as much as 75% lower than with ring-spun yarns. The reasons for this are the greater regularity. smaller number of imperfections lower hairiness, Longer lengths of knot-free yarn. Higher productivity, because of higher speed Elimination of roving, no use of simplex m/c-

Disadvantages of rotor spun yarn:

a. b. c. d. e. Low yarn strength than ring spun yarn Wide range of count cannot be spun Higher twist factor Very finer count cannot be spun More bulky yarn

Low yarn strength than ring spun yarn:

Rotor spun yarns have low strength as compared to the ring spun yarn due the poorer fire disposition in the yarn. This fiber disposition n the yarn is the result of on opening roller to open up the fibers, of transporting the fibers by airflow, and of low yarn tension during the formation of yarn. The other reason for the low yarn strength is also that yarn is formed in the close rotor, trash particle remaining in the fiber accumulate in the rotor groove so the yarn quality deteriorates and in severe cases yarn breakage The other main reason for low yarn strength is that twist in the yarn run from outer layer to inner layer, due to this inner layer of yarn tends to have higher level of twist than outer layer. Fiber landing on the rotating fiber band close to the yarn tail, or directly on the rotating yarn arm when the yarn passes the exit of the transportation

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
tube, tend to wrap around the yarn instead of being twisted in the yarn, this may result in the gradual decrease in the strength.

Wide range of count cannot be spun:

The other disadvantage of the rotor spun yarn is that wide range of count cannot be spun. This is due to the reason of technology limitation, as the in the yarn formation one end of the yarn is open and twist is generated by the rotor and transmitted by the open end entails a considerable twist loss at the yarn formation point and it is about 20%.this is due the torque developed by the rotor is small. This places a critical limit to the number of fibers at the yarn formation point below which spinning cannot take place. Open end rotor spinning is limited to the production of coarse and medium categories of yarn counts.

Higher twist factor:

To achieve the strength comparative to the ring spun yarn of the same count, high twist factor is needed. As the fiber in the outer layer is not fully twisted rather than wrapping so the yarn strength of the rotor spun yarn is low. High twist factor is required to make the yarn of strength which is comparable to the ring spun yarn. Due to this outer surface of the yarn is hard and rough as the short fiber goes into the inner layer of the surface. This also causes low hairiness in the yarn which result poor dye take up in the dying process. Due the harder and rough yarn surface luster of the yarn may also reduce.

Very finer count cannot be spun:

Fine count cannot be achieved by the rotor techniques due to low yarn strength and spinning limit. The fiber in the cross section of yarn cannot be reducing up to specific limit; otherwise it is difficult to make the yarn below this spinning limit.

More bulky yarn:

The yarn surface consist of two major portion ,one is the inner layer which is highly twisted and other outer layer in which fiber are wrapped on to the inner layer of the yarn. As the wrapping fiber are not properly twisted and the fiber wrapped the inner layer to the several point, not the full surface of inner fiber so the yarn form is more bulky than ring yarn.

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
Economic Comparison of Rotor and Ring Spun Yarn
3 Major Factors The economics of a spinning process are essentially defined by three major cost blocks Capital costs Direct labor costs Energy costs

Capital cost
Capital cost of rotor spinning is more then ring spun yarn. In rotor spinning, capital costs account for the majority of manufacturing costs, followed by energy costs. Direct labor costs figure only in third place. This applies especially to countries with low labor costs. With the ring spinning system, direct labor costs in countries with higher wage levels account for a much greater proportion of the total and are almost identical to capital costs, followed by energy cost

Labour cost
Savings in labor costs can be made if an intelligent machine and control concept helps to simplify maintenance work and shorten cleaning operations, for example by means of: operating robots of modular design; easy, rapid replacement of technology components, as far as possible without tools; oil-free and thus low-maintenance rotor bearings requiring little cleaning; working elements that can also be replaced while the machine is running (technology components, rotor bearings, etc.).

Energy costs
Machinery manufacturers make their contribution by working continuously and intensively to reduce the power input of the major consumer Higher rotor speeds can only be achieved with small rotor.

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
Rotor spinning offers especially high benefits compared to ring spinning as regards direct labor costs. High productivity, combined with the automation of the piecing and package changing process

Machine improvements
1. Improvements in feed plate design, opening roller housing and opening roller teeth 2. Improvements in design and coating to rotor and navel in another paper. 3. SC-R Spin box improves the spinning stability because of the higher false twist arising from the sharp angle between the axle of the navel and yarn direction. 4. Wax block sizes are substantially increased thereby reducing the frequency of changing the blocks. 5. Number of piecing carriages has been increased to 4 thereby reducing the waiting time for mending of a broken end. While one of the carriages is taken for maintenance the other carriages are made to attend to positions covered by it. 6. Digital piecing has improved the quality of piecing reducing the difference in strength and appearance between piecing and normal yarn. Online monitoring of quality of piecing is also available in latest models. 7. Dig winding helps to produce packages with straight face and increases weight of package. 8. Labour cost is further reduced in latest machines by increasing the number of rotors per machine up to 540 and number of piecing carriages up to 4. Automatic transportation of drawing cans to rotor machines and continuous removal and transport of rotor packages to package room and palletizing and automatic can exchange systems found in modern set ups will further reduce Labour costs. 9. By increasing the gauge between spinning positions larger cans up to 18 inches can be used. This together with bigger packages up to 6 kg reduces number of can and packages changes per hour and contributes to space utilization. Material handling costs and waste disposal costs are also brought down by the above measures.

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
10. Two sides of the rotor machine can be independently operated to enable different counts and twist factors used on the two sides. Individual feed drive enables the same machine to be used for spinning fancy yarn. In some of the latest models up to 5 lots can be spun at the same time on a single machine. 11. Autocoro 8 has independent drive and piecing for each rotor position. This eliminates waiting time for piecing and gives higher efficiency, productivity and flexibility compared to machines with central drive. 12. Online quality monitoring for yarn quality, faults and disturbed rotors help to ensure uniform defect free yarn and reduce customer complaints. 13. Thick and places of pre-set thickness and foreign fiber in the yarn will be cleared. 14. Identical piecings are ensured by improved digital piecer.

Rotor speed
Rotor speed is an important parameter as it affects productivity of the machine. Several studies have been reported on the effect of rotor speed on yarn properties. Rotor speed has insignificant or marginal effect on yarn strength. But elongation is brought down steeply with increase in rotor speed as shown in Figure 4. The fibres are peeled off and twisted at higher tension at higher rotor speed which makes the yarn compact. Further curliness in fibres are straightened. Wrapper fibres are also increased at higher rotor speed because of higher centrifugal force which increases the pressure of yarn on navel. This increases frictional resistance leading to higher false twist. Twist difference % at the naval increases with rotor speed as shown in Figure 5. As a result elongation drops with increase in rotor speed. Yarn irregularity U% and imperfections increase markedly with increase in rotor speed (Figures 6 and 7). With increase in rotor speed fibre individualisation and trash removal by opening roller will be inferior. Neps in particular increase steeply with rotor speed. Fibres have also less time to align themselves in rotor groove and fibre alignment will be poor7. As a result U% and imperfections increase.

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them

Steep increase in neps is partly because of close wrapping of wrapper fibres, which increases the mass and these places therefore get counted as neps. Examination of nep portions, collected with the help of imperfection selector of Uster tester, under a low power microscope revealed a significant proportion is due to wrapper fibres5. Such neps increase markedly with increase in rotor speed because of higher false twist and consequently higher incidence of wrapper fibres. Tandem card has not shown any consistent improvement over normal card in rotor spinning. This may be because individualisation at opening roller region minimises the benefits from tandem card. Imperfections increase with rotor speed in cotton, no such effect is found with polyester and polypropylene. This may be because of better tying in of wrapper fibres because of longer fibre length, which minimises strip back effect. Simpson and Patureau 8 on the other hand found increase in yarn strength up to 40,000 rpm and reduction thereafter with 49 tex yarn and continuous reduction in strength with rotor speed in 25 tex yarn. This is partly because deterioration in fibre parallelisation at higher speed7. Good carding and strong and finer fibre enable higher rotor speed. Fibre orientation deteriorates with increase in rotor speed. Difference in strength between combed and carded rotor yarn decreases at higher rotor speed because of wrapper fibre. Simpson and Murray7 found increased deterioration in yarn quality with rotor speed with combed material. Not only yarn regularity and imperfections deteriorate with higher rotor speed but also number of wrapper fibres/unit length and frequency of incidence of wrapper fibres increases 9. Rotor speed affects yarn tenacity, elongation and regularity in a linear manner 10. Box and Behnken factorial design however showed best yarn quality at lowest rotor speed 11.

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
Rotor diameter
Increase of rotor diameter up to 46 mm did not have much effect on strength with tandem card but increasing it up to 56 mm leads to a significant drop in strength. But with normal card, strength decreases continuously from 46 to 56 mm diameter (Figure 8). Yarn elongation is very sensitive to rotor diameter and drops markedly with increase in diameter (Figure 9). This is because of higher centrifugal force on yarn tail, which increases wrappers and makes yarn more compact. While U% and thick and thin places are not much affected, neps increase markedly with increase in rotor diameter (Figure 10). Increase in irregularity due to higher wraps per unit length of wrapper fibres is compensated by the improvement from back doublings with higher diameter and as a result U% is unaffected. Neps increase with rotor diameter because of higher wraps per unit length and strip backs at navel. Numbers of wrapper fibres per unit length decrease, wraps are more tightly wound with more wraps per unit length with higher rotor diameter. Tandem card has resulted in lower nep incidence than normal card with waste mixing because of improved fibre individualisation. Increase in rotor diameter from 33 to 40 mm results in significant deterioration in yarn evenness. Simpson and Patureau8 found that fibre orientation deteriorates with increase in rotor speed, rotor diameter and use of grooved navel. Rotor diameter affects tenacity and regularity both linearly and quadratically. Vila et al13 concluded that rotor speed, rotor diameter and preparatory process influence hairiness of rotor yarns. However, hooked fibres will reduce with increase in rotor diameter and will therefore improve yarn quality. Rotor diameter should be sufficiently large to enable formation of fibre ring on the rotor groove. Normally rotor diameter should be at least 1.2 times that of fibre length. Higher rotor diameters should be used as count becomes coarser. Energy consumption and spinning tension increase with rotor diameter and so lower rotor diameters should be used at higher rotor speeds. Speed range for different rotor diameters are broadly given in Table 1

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them

Rotor wall height

By increasing rotor wall height and increasing the distance between peeling point and navel, wild fibres in yarn wrapper decreases and strength is improved15. This enables spinning of finer count.
Rotor groove Important dimensional characteristics of rotor and groove are (Figure 11).

1. Angle of rotor wall to vertical, A. 2. Design and location of rotor groove, G. Rotor groove angle G is made of two components G1 and G2, angles with respect to horizontal. Rotor wall angle A ranges from 12 - 500. Smaller angle facilitates higher rotor speed. Groove angle G ranges from 30 - 600. Large angle is used for coarser counts. With narrower groove angle, compaction of yarn is improved leading to higher strength. But dust and trash accumulation will be higher. Higher rotor groove is conducive to self-cleaning. Different types of rotor groove offered by Rieter are given in Figure 12.

What are the advantages and Disadvantages of Rotor Spun Yarn and Approach to minimize and reduced them
U and DS have wide groove angle and are intended for coarse and denim yarns. TC groove has a wider groove and extended groove angle compared to T but with same groove shape. TC is therefore preferred for very coarse counts and denims and leads to yarns with higher abrasion resistance. T and K grooves are narrow with small groove radius and are universally suitable for all counts of cotton and man-made fibres for weaving. G has also a narrow groove but larger groove radius and is suitable for bulky knitting yarns. Compared to the G rotor, groove angle and groove radius are larger in GM, but with same groove shape. The latter has therefore merits for use in fine count range.

References:
http://www.rieter.com/en/rikipedia

Fundamentals of Spun Yarn Technology

By Carl A. Lawrence

http://www.textileschool.com

http://link.springer.com/article/10.1007%2Fs12221-010-0694-4 (The mechanism and/or prediction of the breaking elongation of

polyester/viscose blended open-end rotor spun yarns)

By: OuzDemiryrek, Erdem Ko