Yarn Manufacturing - Yarn Spinning

 

Yarn Manufacturing

Yarn manufacturing is a sequence of processes that convert raw cotton fibers into yarn suitable for use in various end-products. A number of processes are required to obtain the clean, strong, uniform yarns required in modern textile markets

Yarn manufacturing produces yarns for various woven or knitted end-products (e.g., apparel or industrial fabrics) and for sewing thread and cordage. Yarns are produced with different diameters and different weights per unit length. While the basic yarn manufacturing process has remained unchanged for a number of years, processing speeds, control technology, and package sizes have increased. Yarn properties and processing efficiency are related to the properties of the cotton fibers processed. The end-use properties of the yarn are also a function of processing conditions.

Yarn Manufacturing Processes

Blow Room

Input:  Fiber Bales

Output: Lap

Objective:

·         To open the fibers.

·         To remove the trash.

·         To mix the fibers.

·         To make a uniform lap sheet.

 

Carding

Input: Lap

Output: Carded Sliver

Objective:

·         To remove fine trash.

·         To remove short fibers, neps, motes, and foreign materials too.

·         To produce regular sliver.

 

 

 

 

Draw Frame

Input: Carded Sliver

Output: Regular Sliver

Objective:

·         To parallel the fibers.

·         To blend and mix the fibers.

·         To reduce weight per unit length.

·         To make a uniform sliver.

 

Lap former

Input: Regular Sliver

Output: Lap

Objective:

·         Forming the interfacing or lap, which is employed to feed the combing machine.

 

Combing

Input: Lap

Output: Combed Sliver

Objective:

·         To remove short fibers.

·         To remove fine trash and dirt.

·         To parallel and straight the fibers.

·         To make a uniform sliver.

 

Drawing (finisher)

Input: Combed Sliver

Output: Drawn Sliver

Objective:

·         To parallelize the fibers.

·         To make a uniform sliver.

 

 

 

 

 

Simplex

Input: Drawn Sliver

Output: Roving

Objective:

Draft the material.

·         Insert a small amount of twist.

·         To make bobbin with roving of conical shape.

 

Ring Spinning

Input: Roving

Output: Yarn

Objective:

·         Drafting (attenuation).

·         Insertion of twist for strengthens the yarn.

·         To wind the yarn on to the ring tube/bobbin

 

Cone Winding

Input: Yarn

Output: Yarn Cone

Objective:

·         To transfer the yarn from ring cop/tube. To a large package (weight: 2-2.5 lbs)

·         To remove the faults present in the yarn.

·         To get better quality of yarn

 

Reeling

Input: Yarn Cone

Output: Hanks

Objective:

·         To clean the slub.

·         To make hanks (1680) each.

 

 

 

 

 

Bundling and Bailing

Input: Hanks

Output: Bails

Objective:

·         To make a Bundle. (bundles of 10 Lbs)

·         To make a bale for marketing. (Bales of 40 Lbs)

 

End Notes:

Yarns processes summary (Blow room, Carding, Draw frame, Lap former, Combing,  Drawing, Simplex, Ring, winding, Reeling, and bundling)