Articles

• COTTON MIXING
• BLOWROOM PROCESS
• CARDING PROCESS
• THEORY OF CARDING
• CARD CLOTHING
• Open End Spinning
• RING FRAME
• RINGS AND TRAVELLER
• COM-4 AND ELITE SPINNING
• WINDING
• YARN CONDITIONING
• Textile Research Projects
Process Parameters
• PROCESS PARAMETERS IN BLOWROOM
• PROCESS PARAMETERS IN CARDING
• PROCESS PARAMETERS IN COMBING
• PROCESS PARAMETERS IN DRAW FRAME
• PROCESS PARAMETERS IN SPEED FRAME
• PROCESS PARAMETERS IN RING SPININING
• CONSTANTS AND CALCULATIONs
• Technological value of cotton fibre
Used (pre-owned) Textile Machinery Dealers
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ELECTRICAL DEPARTMENT
• ELECTRICITY
• INDUCTION MOTOR
• POWER FACTOR
Humidification in spinning mill
• HUMIDIFICATION
• COMPRESSED AIR
Most popular Textile Articles
• DRAWING PROCESS
• AUTOLEVELLING
• COMBING PROCESS
• SPEED FRAME
YARN QUALITY ASSURANCE
• FIBRE TESTING-1
FIBRE TESTING-2
• COTTON FIBRE
COTTON FIBRE-1
• EFFECT OF COTTON PREPARATION ON HVI AND AFIS
• HVI-FIBER TESTING
• COTTON LENGTH PROPERTIES
 • EFFECT OF FIBER LENGTH ON YARN QUALITY
• PROCESSING STICKY COTTON
Polyester manufacturing
• POLYESTER FIBRE
YARN TESTING
• YARN TESTING
• YARN EVENNESS-1
• YARN EVENNESS-2
• YARN HAIRINESS
• STUDIES ON YARN HAIRINESS BY MR.KAMATCHI SUNDARAM-
VOLTAS, INDIA
• BARRE IN FABRIC
• BARRE CONTROL
• YARN REQUIREMENT FOR KNITTING
LINEAR PROGRAMMING
• PRODUCT MIX USING LP FOR A SPINNING MILL
• TEXTILE COSTING
• FACTORS AFFECTING OVERALL CONTRIBUTION- CASE STUDY USING
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• PREPARATION TO YARN MANUFACTURE
• TEXTILE RESEARCH PAPERS
MIXING

MIXING (COTTON)
Cotton is a hygroscopic material , hence it easily adopts to the atmospheric airconditions.
Air temperature inside the mxing and blowroom area should be more than 25 degree
centigrade and the relative humidity(RH%) should be around 45 to 60 %, because high
moisture in the fibre leads to poor cleaning and dryness in the fibre leads to fibre
damages which ultimately reduces the spinnability of cotton.
Cotton is a natural fibre. The following properties vary very much between bales
(between fibres) fibre micronaire fibre length fibre strength fibre color fibre maturity
Out of these , fibre micronaire, color, maturity and the origin of growth results in dye
absorption variation.
There fore it is a good practice to check the maturity , color and micronaire of all the
bales and to
maintain the following to avoid dye pick up variation and barre in the finished fabric.
BLOWROOM
• Basic operations in the blowroom:
opening
cleaning
mixing or blending
microdust removal
uniform feed to the carding machine
Recycling the waste
•
Blow room installations consists of a sequence of different machines to carry out
the above said
operations.Moreover Since the tuft size of cotton becomes smaller and smaller,
the required intensities of processing necessitates different machine configuration.

•
CARDING

INTRODUCTION
"Card is the heart of the spinning mill" and "Well carded is half spun" are two proverbs
of the experts.
These proverbs inform the immense significance of carding in the spinning process.High
production in carding to economise the process leads to reduction in yarn quality.Higher
the production, the more sensitive becomes the carding operation and the greater danger
of a negative influence on quality.The technological changes that has taken place in the
process of carding is remarkable. Latest machines achieve the production rate of 60 - 100
kgs / hr, which used to be 5 - 10 kgs / hr, upto 1970.

THE PURPOSE OF CARDING:

to open the flocks into individual fibres
cleaning or elimination of impurities
reduction of neps
elimination of dust
elimination of short fibres
fibre blending
fibre orientation or alignment
sliver formation

TECHNOLOGICAL POINTS IN CARDING

There are two types of feeding to the cards
1. feeding material in the form of scutcher lap
2. flock feed system (flocks are transported pneumatically)
Introduction to Open End Spinning
• 1.In conventional spinning ,the fibre supply is reduced to the required mass per
unit length by drafting & then consolidated into a yarn by the application of twist.
• 2.There is no opportunity for the internal stresses created in the fibres during
drafting to relax.
• 3.In open end spinning, the fibre supply is reduced, as far as possible , to
individual fibres, which are then carried forward on an air-stream as free fibres.
• 4. This permits internal stresses to be relaxed & gives rise to the term “free fibre
spinning”.
• 5.These fibres are then progressively attached to the tail or “open end” of already
formed rotating yarn.
• 6.This enables twist to be imparted by rotation of the yarn end.
• 7.Thus the continuously formed yarn has only to be withdrawn & taken up on a
cross-wound package.

Why conditioning is required?

Moisture in atmosphere has a great impact on the physical properties of textile fibres and
yarns.

Relative humidity and temperature will decide the amount of moisure in the atmosphere.
High relative humidity in different departments of spinning is not desirable. It will result
in major problems. But on the otherhand, a high degree of moisture improves the
physical properties of yarn. Moreover it helps the yarn to attain the standard moisture
regain value of the fibre. Yarns sold with lower moisture content than the standard value
will result in monetary loss. Therefore the aim of CONDITIONING is to provide an
economical device for supplying the necessary moisture in a short time, in order to
achieve a lasting improvement in quality.
PROCESS PARAMETER IN BLOW ROOM
With all harvesting methods, however, the cotton seed, together with the fibers, always
gets into the ginning plant where it is broken up into trash and seed-coat fragments. This
means that ginned cotton is always contaminated with trash and dust particles and that an
intensive cleaning is only possible in the spinning mill.
Nep content increases drastically with mechanical harvesting, ginning and subsequent
cleaning process. The reduction of the trash content which is necessary for improving
cotton grade and apperance unfortunately results in a higher nep content level.
The basic purpose of Blow room is to supply
small fibre tufts
clean fibre tufts
homogeneously blended tufts if more than one variety of fibre is used to carding
machine without increasing fibre rupture, fibre neps , broken seed particles and without
removing more good fibres.

The above is achieved by the following processes in the blowroom

• Pre opening
• pre cleaning
• mixing or blending
• fine opening
• dedusting

PROCESS PARAMETERS IN CARDING

INTRODUCTION:
Carding is the most important process in spinning. It contributes a lot to the yarn quality.
The
following process parameters and specfications are to be selected properly to prodce a
good quality
yarn with a lower manufacturing cost.
cylinder wire(wire angle, height, thickness and population) flat tops specification licker-
in wire specification doffer wire specification feed weight draft between feed roller and
doffer cylinder grinding doffer grinding flat tops grinding cylinder, falt tops, doffer wire
life Licker-in wire life Cylinder speed flat speed Licker-in speed setting between cylinder
and flat tops setting between licker-in and feed plate setting between licker-in and
undercasing elements like , mote knife,combing segement etc. setting between cylinder
and doffer setting between cylinder and back stationary flats setting between cylinder and
front stationary flats setting between cylinder and cylinder undercasing
CYLINDER WIRE AND CYLINDER SPEED

Cylinder wire selection is very very important , it depends upon cylinder speed ,the raw
material
to be processed and the production rate. The following characteristics of cylinder wire
should be
considered.
• wire angle
• tooth depth
• wire population
• rib thickness
• tooth profile
• tooth pitch
• tooth point
• overall wire height

• Wire front angle depends on mainly cylinder speed and coefficient of friction of
raw material.
Higher the cylinder speed, lower the angle for a given fibre. The cylinder speed in
turn depends upon the production rate.

• Higher production means more working space for the fibre is required. It is the
wire that keeps the fibre under its influence during carding operation.Therefore
the space within the wire should also be more for higher production. Higher
cylinder speed also increase the space for the fibre. Therefore higher cylinder
speed is required for higher production.
•
• In the case of high production carding machines, the cylinder surface is very
much higher,
therefore even with higher number of fibres fed to the cylinder, the cylinder is
renewing the
carding surface at a faster rate.

• Higher the cylinder speed, higher the centrifugal force created by the cylinder,
this tries to eject
the fibre from the cylinder, along with the trash.It is the cylinder wire's front angle
which overcomes the effect of this force. Low front angle With too low cylinder
speed and with high frictional force, will result in bad quality, because the fibre
transfer from cylinder to doffer will be less. Hence recyling of fibres will take
place, whihc result in more neps and entanglements.

• The new profile with less free blade avoids loading of the cylinder with fibre
and/or trash.
This helps in keeping the fibres at the tip of the tooth. The movement of the fibres
towards the
tip of the tooth, coupled with centrifugal action demands an acute front angle to
hold the fibre in
place during carding.

• Lack of stiffness associated with fine and/or long fibres necessitates more control
during the
carding process.This control is obtained by selecting the tooth pitch, which gives
the correct
ratio of the number of teeth to the fibre length. Tooth pitch reduction is therefore
required for
exceptionally short fibres and those lack stiffness.

• Number of points across the carding machine is decided by the rib width. It is
selected based on the production rate and fibre dimensions. Finer the fibre, finer
the rib width. The trend is to finer rib width for higher production.

• The population of a wire is the product of the rib thickness and tooth pitch. The
general rule
is higher populations for higher production rates, but it depends upon the
application.

• Sharp tooth points penetrate the fibre more easily and help to intensify the carding
action. Cut-to-point wires are sharp and they have no land at all.-

• The effective working depth of a cylinder wire tooth for cotton is approximately
0.2mm and
 for synthetic materials approx.0.4mm. Manmade fibres require more space in
their cylinder wire
than does cotton.More tooth depth allows the fibre to recyle, resulting in damaged
fibres and neps. If tooth depth is insufficient, there will be loss of fibre contro.
This will result in even greater
nep generaion. Looking into the above details, the following specifications can be
used as a guideline
• RI
B
• PROD
• MATERI W • ANGLE(degre • POPULATI
N.
AL ID es) ON
RATE
T
H
Cotton low grade low 0.6 65 700
Cotton low grade high 0.5 55 840
Cotton Medium low 0.6 60 800
Cotton Medium high 0.4 to 0.5 55 840 to 950
Cotton fine low 0.5 60 840
Cotton long high 0.4 to 0.5 55 900 to 1100
Synth.coarse low 0.7 to 0.5 70 550 to 650
synth.coarse high 0.6 65 760
Synth.medium low 0.7 65 700
synth.medium high 0.5 65 760
Synth.fine low 0.6 65 700
synth.fine high 0.5 60 840
MATERIAL PRODCUTION RATE CYLINDER SPEED
cotton low 360 to 400
cotton medium 430 to 470
cotton high 500 to 550
synthetic low 300
synthetic medium 380
synthetic high 460
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PROCESS PARAMETERS IN COMBING

INTRODUCTION
Combing is a process which is meant for upgrading the cotton raw material so that the
following yarn
properties will improve compared to the normal carded yarn. U% of yarn tenacity
gms/tex trash in the yarn(or kitties in the yarn) Lustre and visual appearance

POINTS TO BE CONSIDERED
Following parameters are very critical as far as the yarn quality of combed yarn is
concerned
• Noil percentage(waste percentage)
• Type of feed
• feed length
• feed wight in grams per meter
• Piecing length
• Top comb penetration depth
• The distance between unicomb to nipper
• unicomb specification
• Number of needles in top comb
• The cleaning of unicomb
• Variation in nipper grip
• Variation in noil percentage
• type of lap preparation
• total draft between carding and comber i.e total draft employed in lap preparation
• Drafting roller settings in comber
• Drafting roller settings in lap prepartion machines
• No of doublings in lap preparation
 • Short fibre content
• Fibre micronaire
• the type and the amount of trash in the card sliver

INTRODUCTION:
Drawframe is a very critical machine in the spinning process. It's influence on quality,
especially on evenness is very big.If drawframe is not set properly, it will also result in
drop in yarn strength and yarn elongation at break.The faults in the sliver that come out
of drawframe can not be corrected . It will pass into the yarn.

The factors that affect the yarn quality are

• the total draft
• no of drawframe passages
• break draft
• no of doublings
• grams/meter of sliver fed to the drawframe
• fibre length
• fibre fineness
• delivery speed
• type of drafting
• type of autoleveller
• autoleveller settings
• The total draft depends upon
1. material processed
2. short fibre content
3. fibre length