Spinning | Describe yarn manufacturing process step by step

Introduction

Yarn is the longest length of interconnected fibers suitable for use in textile, sewing, crocheting, sewing, knitting, embroidery, or rope making. Spun yarn is mainly made by bending the fibers together and making yarn or single. The spinning of the fibers twisted into yarns in the process is called spinning. Spun yarns may contain a single type of fiber or a mixture of different types. The yarn consists of a combination of curved strands of fiber, known as pluses when grouped together. Filament yarns contain filament fibers that are either twisted together or simply grouped together. Textured yarns are made by the process of air texturing filament yarns, which connect multiple filament yarns to the yarn with some characteristics of the cut yarn. The slab effect means that the thick and thin parts are yarn that changes regularly or irregularly.

What Is Spinning?

Spinning is the twisting process where the fiber is drawn out, twisted, and wound onto a bobbin. The yarn issuing from the drafting rollers passes through a thread guide, round a traveler that is free to rotate around a ring, and then onto a tube or bobbin, which is carried on a spindle, the axis of which passes through the center of the ring. The spindle is driven and the traveler is dragged around a ring by the loop of yarn passing around it.

Yarn manufacturing process step by step

Yarn manufacturing is a sequence of processes that convert raw cotton fibers into yarn suitable for use in various end products. Some processes are required to obtain the clean, strong, uniform yarns required in modern textile markets. Beginning with a dense package of tangled fibers containing varying amounts of non-lint materials and unusable fiber, continuous operations of opening, blending, mixing, cleaning, carding, drawing, roving, and spinning are performed to transform the cotton fibers into yarn. While the basic yarn manufacturing process has remained unchanged for many years, processing speeds, control technology, and package sizes have increased. Its properties and processing efficiency are related to the properties of processed cotton fibers. The end-use properties of the yarn are also a function of processing conditions.

Cotton cultivation and yield

Cotton grows anywhere with long, hot dry summers with plenty of sunshine and low humidity. Indian cotton, Gossypium arboreum is fine but mainly suitable for hand processing. American cotton produces the longest main product required for the production of Gossypium hirsutum machines. Planting takes place between September and November and the crop is harvested between March and June. The cotton balls are harvested by a stripper harvester and collected by a spindle picker who removes the whole ball from the plant. Cotton bolls are the seed pods of the cotton plant which are fibrous with a few thousand seeds about 2.5 and a half centimeters long.

Ginning

Seed cotton goes to a cotton gin where the ginning process is done. The cotton gin separates the seeds and removes debris from the fibers. In the saw gin, the circular saws grab the fiber and pull it through a jolt that is too narrow for the seeds to pass through. A roller gin has long been used with the main cotton. Here, a leather roller captures the cotton. A knife blade, set near the roller, drawing through the teeth in the seed circular saw and rotating brush that separates it from their cleaning. Ginned cotton fiber, also known as lint, is then compressed into strands that are about 1.5 m long and weigh about 220 kg. 

Bell opening and cleaning

The cotton is driven into the mills in large 500-pound bells. When the cotton comes out of a mound, it is all packed together and still contains vegetable matter. The bell is opened using a machine with a large spike, called an opener. The cotton is sent through a picker or similar machine to pick up and remove the vegetable matter. In any picker, the cotton is beaten with a beater bar to make it lose. It is then fed through various rollers, which help to remove the vegetable matter. The cotton, with the help of fans, is then collected on a screen and fed through more rollers until it emerges as a constant soft bouncy sheet, known as a lap.

Blending and Mixing

In the spinning process, when various fibers of different or the same grades are kept together then it is called blending. For example, yarn is produced by using 65% cotton yarn and 35% polyester yarn then it’s called blending. The mixture is based on the movement of important fiber properties such as length, fineness, strength, etc., and quantitatively proportioning and combining the properties under controlled conditions. In the blending process must be a particular ratio of fibers mix with each other.

Porcupine opener

The cotton fed by the previous opener is advanced with the help of a feed lattice. The cotton sheet now moves between the paddle and the paddle roller. The weight of cotton fed per unit time is fixed by the speed of this paddle feed control. The pedal roller feeds the sheet of cotton into a pair of feed rollers that are heavy to give the required grip on the cotton. 16 round discs are mounted on the shaft of this opener. 14 to 18 striker blades are alternately riveted on each round disc. Each striker is bent at a slightly different angle. The narrow sheet of cotton delivered from the feed roller is severely beaten by the fast-rolling striker of the porcupine beater opposite the grid bar. Due to this beating action, the cotton is effectively opened and the lifted waste particles pass through the gaps in the grid bar. At the end of the grid bar, a stripping rail is provided, this is a metal bar that is set about 1/16 inch away from the end of the striker. This small clearance between the stripping rail and the striker prevents a bunch of cotton from being carried near the beater.

Step cleaner

In the condenser step, the cleaner is employed to feed the cotton. The photo-cell configuration of the reserve tower unit monitors the height of the reserve fiber and signals stop or start commands on the processing machine. Cotton is fed from the reserve tower with a pair of feed rollers. According to the height of the cotton level, the feed cell of the reserve tower of the next machine, the motorized gear reduction unit, uninterruptedly feeds the feed. The grid bars combine effectively with the centrifugal force and the rapid revolution of beating the cotton striking cylinder and the spike on the cotton against gravity to open the cotton and remove the heavy impurities. From cotton heavy impurities, dust and dirt particles, short fibers, etc. pass through the bar interval and are collected outside the grid bar.

Scotching process

Scotching refers to the process of cleaning cotton from seeds and other impurities. The first scotching machine was invented in 1797 but did not become mainstream until 1808 or 1809 when it was introduced and used in Manchester, England. By 1816, it was generally accepted. The scotching machine worked by twisting the cotton through a pair of rollers and then hitting the iron or steel bars known as bitters. The beetles, which turn very quickly, hit the cotton hard, and scatter the seeds. This process is carried out by holding a series of parallel bars that allow the seeds to pass through. At the same time, the air is blown across the bars, which takes the cotton to a cotton chamber.

Carding process

In the carding process, the fibers are separated and then tied together in a loose strand. The cotton comes out of the picking machine in the lap and is then taken to the carding machine. The fibers are neatly arranged to make the carders easier to spy. The carding machine basically carries a large roller with smaller ones around it. All the rollers are in small teeth and the cotton in the teeth becomes finer as it progresses further. The cotton leaves the carding machine in the form of a sliver: a large rope of fibers.

Combing process

Combing is a method of preparing carded fibers for spinning. It is divided into linear and circular combing. For circular combing, a noble comb is an excellent example. Example of French comb linear glass. The combing process grills out the evening with the process of making the carded or scratched top suitable for spinning. The combing separates the short fibers through a rewritten row of rotating rings or steel pins. The strands at the top of it are straightened and located parallel to each other. The short fibers that are thrown away when combing wool are called nails and become fun to ground.

Draw Frame

The production cost of the draw frame is less than 3% of the total yarn cost. However, it has a great effect on the quality of yarn, especially in the evening. The draw frame is a guaranteed compensation point for removing errors. High-performance drawing frames currently produce 400 kg of sliver per hour in each distribution. The main goal of the drawing frame is equalization. One of the main tasks of the draw frame is to increase parity in the short, medium, and - especially - in the long run. In order to get the best value of strength in parallel yarn properties, the fibers must be arranged parallel to the fiber strand. Creating this parallel layout is basically the work of the draw frame. It accomplishes this task through the draft as each draft step leads to straightening the fibers.

Ring frame

The ring frame was submitted to John Thorp of Rhode Island in 1828/9 and was developed by Mr. Jencks of Pawtucket, Rhode Island, who named Richard Marsden as the inventor. A ring frame was made by pressing cast iron and later steel. There are spindles on each side of the frame, on top of which rollers are drafting, and on top, there is a krill loading the roving bobbins. Roving goes down from the bobbins to the drawing rollers. Here the rear roller fixed the incoming thread, while the front rollers rotated faster, pulling the roving and making the fibers more parallel. The rollers are individually adjustable, mainly by lever and weight. Short roving now goes through a thread guide that is adjusted to the center above the spindle. The thread guides are on top of a thread rail that allows any broken threads to be wrapped around them for duffing or piking. The low-rowing spindle moves to the assembly, where it is threaded through a small D-ring known as the Traveler. Move along the traveling ring. This is the name given to the ring frame. From here the thread is connected to the existing thread in the spindle.

Doffing

Doffing is a separate process. A servant is descending the rails of the ring below. The device shuts down. The thread guides are hinged. Complete bobbin coils are removed from the spindles. The new bobbin tube holds the thread over the spindle and holds the cup to the neck of the spindle, lowering the thread guides and restarting the machine. Now all the process is done automatically. The yarn is taken in a cone winder. The machines are currently manufactured by Reiter (Switzerland), Toyota (Japan), Zinser, Suessen, (Germany), and Marzoli (Italy). Reiter's Compact K45 system has 1632 spindles, while Toyota has a machine with 1824 spindles. All control, and atmospheric conditions are required.