Yarn Manufacturing Process

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Ginning:
The process of separating the seeds and debris from the cotton fibers is known as ginning.
Cotton ginning process is done by cotton gin machine but before ginning was done by
hand.

Types of ginning process:

There are three types of ginning. They are

1. Knife roller gin for Indian and Pakistani cotton

2. Macarthy roller gin for long staple cotton
3. Saw gin- Used for American, west African, Pakistani cotton

Point should be considered for fiber during processing:

Main factors:

Length
Fineness
Maturity
Uniformity
Trash content

Other properties:
Pliability
Cohesiveness
Tensile strength

Mixing and blending:

Mixing:
In mixing, different grades of same fibers are kept together for yarn production. It is
generally meant as the intermingling of different classes of fibers of the same grade. E.f
USA pima grade 2, CIS.

Blending:
It is meant as the intermingling of different kinds of fibers are kept together for yarn
manufacturing. E.g. polyester & cotton, Viscose & cotton.

Objectives of Mixing and blending:

Economy
Processing performance
Functional properties

Flow chart of yarn manufacturing process

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 Fig: Yarn production flow chart

Blow room:
Blowroom is the first stage of yarn manufacturing. In this section fiber is opened, cleaned,
mixed , micro dust removed. Fiber bale is the input material of blow room and output
product is uniform lap or fiber sheet.

Objectives of blow room:

To open the compressed bales of fibers.

Remove dirt and dust, broken leaf, seed particles or any other foreign impurities from
the fibers.
To transfer the opened and cleaned fibers into a sheet form of definite width and
uniform wt./ unit length which is called lap.
To roll the lap predetermined length into a cylindrical shape around a lap pin.
To transfer the lap from the lap pin to a lap road to suitably handle and feed it to the
subsequent m/c (carding)

Action of blow room line:

Action of opposing spikes
Action of air currents
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 Action of beaters
Regulating action

Wastage of blow room:

Dropping
Dust
Filter waste

Faults in blow room:

Irregular lap
Knocking off before completion of full lap
Rough appearance of full lap
Lap sheet thicker at one side than at the others
Soft lap
Lap licking
Dropping under beater and grid bars
Formation of conical lap
Formation of split lap
Barrel shaped lap
Ragged lap selvedges.

Types of beater in blow room:

Porcupine beater
Bladed beater
Multiple beaters
Krishner beater

Carding:
Carding is the second stage of yarn manufacturing process in conventional spinning line.
Carding is called heart of spinning . Main function of carding is to breaks up locks and
unorganized clumps of fiber. Blending, opening, parallelizing each fiber is also done by
carding. Fiber sheet or lap is the input material of carding and sliver is the output product of
carding.

Objects of carding machine:

To open the tuft of fibers

To make the fibers parallel and straight
To remove remaining trash particles
To remove short fibers
To remove naps
To produce a rave like fiber called sliver, which is uniform in per unit length.

Main actions of carding machine:

Action between feed roller and taker in.
Action between taken in and cylinder.
Action between cylinder and flat.
Action between cylinder and doffer

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Useful sliver hanks of different count:

Count of yarn: 10s 20s 32s 40s 60s 80s

Hank of carded sliver: 0.125 0.125 0.13 0.135 0.145 0.165

Wastage in carding:

Taker in waste
Flat strip
Motes and files
Sliver cut
Filter waste

Draw frame:
Draw frame is a machine for combining and drawing slivers. Carded slivers are fed into the
Drawframe. In this stage fiber are straighten and fiber blending can also be done. In
drawing slivers are elongated when passing through a group of pair rollers, each pair is
moving faster than previous one.

Objects of draw frame:

Straightening of crimped and hooked fibers.

Paralleling of fibers.
To produce more uniform of sliver of definite wt./yd
To reduce the wt./yard of materials fed.
To make perfect blending/ mixing of the component fibers.

Wastage in draw frame:

Filter waste
Cleaner waste
Sliver cut.

Comber:
Combing operation is done by comber machine. Normally combing process is used to
produce smoother, finer, stronger and more uniform yarns.

Objects of comber:

To remove the fibers shorter than a predetermined length.

To remove remaining impurities in the comber lap.
To remove naps in the carded sliver.
To make the fibers more parallel and straight.
To produce a uniform sliver of required per unit length.

Necessary of combing:
The essential requirements to produce quality yarn are-
Clean fiber
Uniformity in length of fiber
Absence of naps
More parallel arrangement of fibers.
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 Straight fibers.
The above quality of fibers can only be obtained by combing.

Comber noel:
The wastage which is removed from comber machine during processing ia known as
combers noel. It is expressed as percentage. It is mainly of short fibers and naps. Noel is
used for lower count as raw material.

Speed frame:
In yarn manufacturing technology, speed frame is situated after the comber. Speed frame
or simplex machine draft the sliver to reduce weight per unit length. In speed frame give
some twist to give strengthen the yarn.

Objects of speed frame:

Attention of draw sliver to a suitable size for spinning.

To insert a small amount of twist to strengthen the roving.
To wind the twisted strand roving into a bobbin.

Operation involved in speed frame:

Drafting
Twisting
Laying out
Winding
Building motion

Ring frame:
Ring frame is the last machine to manufacture yarn. It gives draft the roving until the
required fineness is achieved. And give insert twist the drafted strand to form yarn of
required count and strength.
Objectives of ring frame:
To draft the roving fed to the ring spinning frame.
To insert the necessary amount of twist.
To wind the twisted thread or yarn on a cylindrical bobbin or tube.

Operation involved in ring frame:

Creel in.
Drafting
Twisting
Laying out.
Building
Doffing.
Winding.

Wastage in ring frame:

There are two types of wastage in ring frame. They are

Soft waste:

Pneumafil
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 Bonda
Roving
Sweeping

Hard waste:
Broken end of yarn
Yarn waste in winding

Factors governing optimum spinning condition:

Spindle speed
Ring dia
Lift
Traveler wt.
Relative humidity

Yarn quality assessment:

Yarn count and its variation
Twist and its variation
Evenness CV% or U% of yarn
Strength and its variation (csp of yarn)
Imperfections.

Causes of end breakage/ End down:

If spinning tension is grater than yarn strength in ring frame, then end breakage is occurred
and also due to roller lapping.

A. Technological causes:

Insufficient twist in yarn

If traveler fly off.
Subbing through
Stretched roving
Faulty drafting roller setting.
Faulty traveler selection.
Excessive yarn tension.
Improper atmospheric conditions.

B. Mechanical causes:
Faulty drafting system
Worn out ring and traveler
Faulty gear and wheels
Worn out of rollers
Faulty apron
Spindle vibration
Eccentric ring.

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