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Stronger the fibre stronger will be the rotor yarn. Since lower
strength is one of the drawbacks of rotor yarn, stronger cottons
should be used.Louis2 reported that fibre strength has more
influence on yarn strength than fibre length.
Length
Though fibre length is important its effect is not that pronounced
as in ring yarns. With increase in fibre length, reduction in yarn
strength with respect to ring spinning will be higher and reduction
in irregularity will be less. This is partly because of higher
disorientation and wrapper fibre incidence with longer fibres.
Louis2 found more wrapper fibres with longer cotton (31.8mm)
than a shorter cotton(25.1mm) Heap and Price 3 found higher
shrinkage of bleached knitted fabrics with shorter, coarser and
weaker cottons compared to long, fine and strong cottons. Long
staple cottons have poorer utilization of fibre strength because of
higher incidence of wrapper fibres1.
Variability in length is not that critical in rotor spinning as in ring
spinning as there is no drafting system. So comber noil and flat
strips are added to some extent to reduce raw material cost.
Manohar,Rakshit and Balasubramanian4 found that improvements
in yarn irregularity and imperfections are more marked in waste
mixing and the fall in strength is also lower. Taher 5 et al found that
yarn count, rotor parameters and speed have as much influence
on yarn quality as waste % added in mixing. Up to 25 % waste
could be added to mixing without affecting yarn quality if rotor
diameter and speed are properly chosen. 92% of yarn strength is
accounted by fibre properties in rotor yarns as against 94 % in
ring yarns6.
Micro dust and Trash
Rotor spinning is more sensitive to trash and micro dust in cotton
than ring spinning. Micro dust and trash increase end breakages
and contribute to periodic irregularities in yarns that result in
rejections. Irregularity, hairiness, abrasion resistance and
resistance to abrasion deteriorate with yarns produced without
periodic cleaning of rotor7.Trash content in input sliver should be
below 0.2 % to get satisfactory performance. Trash particles get
wedged in the rotor and result in periodicity with wavelength
equal to rotor circumference. Micro dust in cotton should be within
5 35 mg/kg. Small deposits first form in rotor which acts as
nuclei for further deposits until a complete ring of deposits is
formed. End breaks occur when the ring size increases beyond a
level8. Naarding9 found that micro dust in cotton consisted of
particles of 5 to 40 m diameter. Langley and
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found that front take off of yarn gives inward rotation which
pushes dust particles into the groove. Back take off gives outward
rotation which keeps rotor groove clean. Rotor groove shape
affects rotor deposits15.Rotation of yarn around its axis during
peeling off has considerable influence on movement of trash in
rotor groove16.
Man made Fibre
Rotor yarns from man made fibres and blends are 20-30 % weaker
than ring yarns with lower elongation. Improvements in evenness
and imperfections are negligible. Wrapper fibre incidence is
higher, because of longer fibre length, leading to inferior fabric
appearance. Problems with polyester are
1. Static charge development
2. Rapid wear and tear of opening roller, rotor and transport tube
due to titanium dioxide. Special fibres with lower TiO 2 content of .
03 % are preferred for rotor spinning.
3. Powdery deposit in rotor due to broken fibre tips and oligomeric
material.
4. Crimp in the fibre should be lower as higher crimp hampers
opening and affect smooth flow in transport tube
5. Pilling tendency with knitted fabric is encountered especially with
high tenacity fibre.
Fibre stiffness
Stiffness in fibre resists bending and twisting and integration into
yarn. Fibre type, length and diameter influence stiffness. Ratio of
diameter to fibre length is a measure of stiffness. Shorter fibre of
same type and diameter will be stiffer. Larger diameter fibre of
the same type and length will be stiffer. Twist efficiency will be
lower with stiffer fibres.
Yarn quality
Yarn strength is generally lower in rotor yarns than ring yarns by
15 25% and the extent of difference depends upon quality of
mixing, count and upon type of strength test (Lea or single
thread). Manohar, Rakshit and Balasubramanian 4 found that
reduction in lea strength ranges from16 22% with normal mixing
and from 5 14% in waste mixing which means that the drop in
strength is of much lower order with inferior mixing.
Balasubramanian17 showed that the difference in strength
between rotor and ring yarns depends upon the type of strength
test, being more in single thread than in lea. This is because of
higher lea ratio in rotor yarns which again is due to lower strength
variability. Sultan and Elhawary18 confirmed that the extent of
reduction in strength of rotor yarns compared to ring yarns can be
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Wash and wear rating of rotor yarn fabrics is better than ring yarn
fabrics38. However Iqbal and Kolhatkar40 found inferior rubbing and
washing fastness of denim fabrics made from rotor yarns is
comparable to that from ring yarns.
Shrinkage in Knitting
Heap and Price3 found that shrinkage of bleached knitted fabric
from rotor yarn increased by 1.5 % in length and 1 % in width with
increase of twist factor from 3.6 to 4.
Influence of Preparatory
Blowroom
Preparatory is similar to ring spinning except for the absence of
speed frame and use of smaller size cans in finisher drawing.
Since trash and micro dust have a critical influence, Blowroom
cleaning efficiency should be given great importance. The line
should also be equipped with micro dust extractors or de dusters.
Passage of material over perforated drum with suction inside
helps to remove micro dust.
Carding
Rakshit and Balasubramanian41 showed that lower production rate
in carding reduced trash level in sliver and brought down the
opening roller waste in rotor spinning.55 % reduction in end
breakages in rotor spinning and markedly improved yarn are other
benefits from lower card production rate. Use of crush rolls in
carding pulverizes trash and is recommended in rotor spinning.
Simpson and Louis42 found that double carding reduces trash
accumulation in rotor, brings down end breakages and improves
yarn quality.
Drawing
Normally two drawing passages are recommended. The second
passage not only improves fibre parallelization and sliver
uniformity but also acts like a de dusting equipment to remove
micro dust and small particles. But in waste mixing having very
short fibres single drawing passage with autolevelling is
adequate particularly in applications where demand on quality
is not stringent. In extreme cases, direct feed of card sliver with
draw frame module is done for counts 100Ne and below. Idzite43
concludes that one drawframe would be adequate for spinning
polyester yarn if card is equipped with draft regulator. Yarns can
be produced conforming to Uster 25 % standards with this set
up. Barella and Vigo44 concluded that omission of one drawing
passage affects tenacity significantly but has only marginal
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8. R.Nield and E.F. Abadeer, Deposits in the rotor groove in openend spinning Part II The initiation and development of rotor
deposits, J Textile Institute, 1979, 70, p275
9. W.J. Naarding, A new approach to microdust removal to improve
rotor spinning performance of cotton, Meliandtextilber, 1976, 57,
p5.
10. K.D.Langley and H.Haasma, A microscopic method for
analyzing microdust accumulation in rotor spinning, Textile
Research J, 1979, 49, p 465
11. J. Simpson Single vs Double Carding, Am Textile Rept Bull. ATT
1978, Nov.
12. J.Foulk, D.McAlister, D. Himmelsach and Ed Hughs, Mid
infrared spectroscopy of trash in cotton rotor dust, J of Cotton
Science, 2004, 8, p 243
13 A.Barella and J.P.Vigo, Introduction to the influence of rotor
cleanliness on properties of open end yarns, Textile Research J,
1974, 44, p 612
14. R.Nield and E.F. Abadeer, Deposits in the rotor groove in openend spinning Part III The effect of yarn rotation in the peripheral
twist zone, J Textile Institute, 1979, 70, p367.
15. R.Nield and E.F. Abadeer, Deposits in the rotor groove in openend spinning Part IV The effects of groove shape,yarn linear
density, direction of take off, rotor direction and twist in the yarn, J
Textile Institute, 1979, 70, p371.
16. R.Nield and E.F. Abadeer, Deposits in the rotor groove in openend spinning Part II Entry of particles in rotor groove, J Textile
Institute, 1979, 70, p282
17. N.Balasubramanian, Merits of Lea CSP and Lea Ratio, J. Textile
Association, 2005 April, p94
18. M.A. Sultan and L.A. Elhawary, A comparison of the properties
of open end spun and ring spun yarns produced from two
Egyptian cottons, J Textile Institute, 1974, 65, 4, p194.
19. N.A. Jameel, A.H. Khan, I.H.Reshamwala and M.S. Aghai,
Pakistan JAgric, 1982, 3, No 3, p 112.
20. Cotton/Polyester blens spun with the use of rotor spinning
frame, http://textile2technology.com/2009/11/cottonpolyesteryarn-blends-spun-with-the-use-of-a-rotor-spinning-frame.html
21. P.R. Lord, Structure of open end yarns, Textile Research J,
1971, 41, p 778
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