Some variations in Siro spinning

Siro yarns are superior in yarn characteristics and have an edge over the normal
yarns of equivalent count spun from both a single roving feed and double roving
feed, observe Hiral D Barodia and Dr Ashok Khare.
Traditionally, two-fold yarns have been used for weaving because they are
stronger, smoother and more resistant to abrasion during weaving. It also helps
in either reducing the size percentage or even eliminates the very process.
Spinners have long demanded spinning and doubling in one single operation.
The Siro spinning process offers the solution. When two rovings are led separately through the drafting system
and running parallel to each other are combined once they have passed the nip point of the front top and front
bottom roller, a twofold-like weaveable yarn -- Siro yarn is the result.
The reason why Siro yarn is still commercially in its infancy is possibly because of comparatively higher end
breakage rate and difficulties experienced during piecing. Earlier research work had mainly compared Siro
yarns with single yarns and double yarns. However, as Siro yarns are single yarns made from two separate
roving strands, it was thought to be more appropriate to compare them with
double feed normal single yarns.
It had also been customary to spin Siro yarns from equal roving hanks, wherein
both the roving strands would receive nearly the same share of twist before
merging in. However, though the strands delivered in normal Siro spinning are
expected to be equal, there are bound to be some normal variations in roving
hanks, which would reflect in their linear density variations, the effect of which
is unknown. The above factor was, therefore forced by using unequal roving
hanks to see their contribution on the final Siro yarn tenacity.
Review of literature
The Siro process invented around 1975 - 76 by CSIRO was later joined by Repco Ltd, Australia to manufacture
components for Siro process. Since 1991, Zinser had been licensed to modify then existing machines to come
out with new machine.
Sun & Cheng [1] produced Siro yarns with 9 mm spacing of roving guides and found that Siro yarns were
stronger than single yarn at all twist multipliers. This, according to them was due to strand twist. Su et al
[2]measured the drafting force, which is an important parameter correlated to twin-yarn properties, of twin-
spun yarns and found that with increase in roving spacing, the drafting force increased.
Salhotra [3] while producing Siro yarns with 38 mm and 1.5 denier Viscose stated that with reduction in draft
employed, there was substantial decrease in irregularity. The strand of ribbon being narrow with lower draft,
the yarn packing coefficient improved. As the strength of Siro yarns depends little on migration, the proportion
of fibre-rupture being higher with finer yarns, the tenacity is expected to improve.
Cheng [4] stated that higher spreading width improves blend uniformity and lowers the colour difference, thus
improving dyeing uniformity. Gupte & Chiplunkar [5] found that with increase in roving spacing, the yarn
strength increased, whereas hairiness reduced. They also found that in some instances, the strength of Siro yarn
was even greater than doubled yarns of equivalent count.
Sarvanan [6] blended cotton fibres with long staple strands of silk and polywool. He mentioned that with lower
spindle speeds, it was possible to spin Siro yarns. He found that when short staple cotton component was added,
yarn hairiness increased; however tensile properties of the yarn were more affected by major fibre component.
Beceren et al [7] focused on dimensional and selected physical properties of plain jersey fabrics made from
viscose Siro yarns.
Sawney et al [8], Dhawan reported about 14% higher strength with Siro yarns whereas Dhawan & Salhotra [9]
stated that yarn quality improves with increase in spacing; attains an optimum value and thereafter deteriorates
with further increase in spacing. Dhawan & Jai Prakas [10] reported that DRF yarns, at optimum spacing, were
slightly superior to normal doubled yarns.
Experimental procedure
Single feed single yarn, double feed single yarn and Siro yarn of 32.8 tex count were produced using 369.1 tex
of roving. Each of these yarns was spun with three twist multipliers 3.1, 3.4 & 3.7. In the second phase, using
the same roving hank and using 3.4 as TM, these three yarns were compared for tenacity, imperfections and
hairiness.
Later the comparison was made between double feed single yarns and Siro yarns; using singles TM as 3.4 with
three doubling ratios 0.4, 0.7 and 1.0 with doubling twist in the S direction.
A comparison was also made using two combinations of unequal roving hanks of (468.7 tex & 269.6 tex) and
(399 tex & 341.3 tex) to produce 32.8 tex yarn in both forms; Siro yarns and single yarn made from double
roving feed. In all the experiments the roving spacing at the emergence of the threads in the front of front roller
was 10 mm and kept constant, though the spacing of roving at the back happened to be slightly greater than
this. All the yarns were made on Trytex ring spinning machine and yarn properties tested.

Plain Single Jersey weft knitted samples of 35"diameter were knitted on a Knit Mac Hand knitting machine.
The samples were dyed using CB turquoise blue reactive dye and tested for dye absorption in terms of shade
differences on Spectrophotometer.
Results & discussion
Optimum Twist Multiplier
As mentioned earlier, in all the experiments, the roving spacing for Siro yarns at front roller was constant. It is
very interesting to note that with all the three twist multipliers used in the experiment, the Siro yarn has an edge
over the other yarns, the difference being quite significant at optimum twist multiplier. However, all the three
types of yarns show the maximum strength at nearly the same twist multiplier [Figure 1]. This is possibly
because of strand angle, the fibre-strength contribution to the yarn strength being optimum at this level of twist.
Equally interesting is the fact that the drop in the strength beyond optimum level is comparatively less for Siro
yarns. This again is possibly due to better integration of the edge fibres. This is because the fibres are trapped
within and between the strands in Siro spinning.
 Single thread tenacity & elongation
It is evident [Figure 2] that the average tenacity of Siro yarn is higher than single
yarn made from both double rove feed and single rove feed of equivalent linear
density due to the fibres being more firmly bound within the yarn structure. In
Siro yarn, the majority of the fibres get trapped in the structure so as to increase
inter-fibre cohesion in the yarn, thus making the yarn withstand higher breaking
forces. This gives a more compact yarn with a firmer core. The better tenacity
of Siro yarn could also be ascribed to the fact that single strands have comparatively low twist, which results in
better and more even load sharing by the constituent fibres.
Imperfections
As regards the thin and thick places, the Siro yarn appeared to be lying in
between S feed single yarns and D feed single yarns [Figure 3]. The draft used
in producing S feed single yarn was 11.25 as compared to 22.5 for D feed single
yarns and Siro yarns. This possibly seems to be the reason for thick, thin places
showing lower values for S feed single yarns. The nep count was however
lowest with Siro yarns. It is expected that as against the neps freely appearing
on the surface of single yarns made from S feed and D feed, with Siro spinning
they are entrapped within the yarn core. U% of Siro yarns also lies between S feed single yarn and D feed single
yarn.
Hairiness
Hairiness of Siro yarns in terms of Hairs per metre is much less [Figure 4] than Double feed and Single feed
single yarns. Siro yarns have less hairiness and a much cleaner appearance than the normal ring spun single
yarns. The main reason for this could be attributed to the fact that two roving strands are separately drafted and
twisted to a certain extent before uniting, which greatly limits the extent of
protruding fibres.
Effect of doubling ratio on yarn strength
Doubled Siro yarns followed traditional trend; in that, strength reached its
maximum at doubling ratio 0.7 and fell thereafter [Figure 5]. However the trend
with the D feed single yarns is ambiguous and
requires further investigation.
At doubling ratio=0.7, tenacity of Siro yarn was
higher than double feed single yarn and it was
significant at 1%.
Unequal roving hank combinations
Two different combinations (a) 468.7 tex and 269.6 tex [2] 399 tex and 341.3
tex were worked in which the difference in the two roving hanks was varied
and single yarns of 32.8 tex were produced. It was observed that with both these
combinations, single thread tenacity of Siro yarns was higher than those produced with double roving feed
single yarns, the difference being statistically significant at 1% [Figure 6].
Comparison of imperfections with unequal hank combinations
Interestingly it was observed that, with higher difference in roving hanks [Figure 7] Siro yarns showed markedly
better results. However when the difference in roving hanks was lower [Figure 8], Siro yarns were better only
in respect of nep count. With both the combinations of unequal roving hanks [Figure 9], Siro yarns were seen
to be much less hairy.
Shade variations of knitted samples
Fancy knitted goods owing to their flexibility and their ability to adapt shapes add to the general comfort.
However it is important to achieve bright shades without streakiness. Against this background, the possible use
of Siro yarns was considered. Knitted dyed samples when tested for shade difference spectrophotometrically
[Figure 10] shows deviation in dye uptake for the samples.
The higher dye uptake K/S value = 6.5162 for Siro knit sample could be attributed to its better uniformity.
Hairiness values for Siro yarn are much less as compared to D feed and S feed single yarn, thereby supporting
the fact that Siro knit samples dye darker with comparatively less streakiness, which is apparently visible in the
other two samples.
Conclusion
It was interesting to note that all the three yarns in this experiment showed their
maximum strength at the same Twist Multiplier. Single thread tenacity of Siro
yarns was the highest among the three yarns however elongation of the three
yarns did not differ appreciably.
The thick and thin places values for Siro yarns lied between S feed and D feed
yarns while it was superior in nep count. As found in earlier research, the Siro
yarns were much less hairy. Doubling ratio of 0.7 seemed to be optimum ratio
for Siro yarn strength whereas the trends were not clear for D feed yarns.
For both the unequal roving hank combinations, Siro yarn was stronger than D
feed single yarn. When the difference in the roving hanks was more, Siro yarns
were markedly superior to D feed single yarns.
The highest K/S for Siro knitted fabrics reflected in uniform dye uptake could be attributed to its better
uniformity and less hairiness.