The structure and tensile properties of the yarn, as well as any irregularities, depend on the filament overfeed. 14.2). 109 MJ was consumed in the entire life cycle of a single cotton t-shirt. During separation, transportation and landing they lose their orientation, and crumple as they are deposited in the yarn structure. There are many methods or mechanisms for spinning such as ring spinning, rotor spinning, air-jet spinning, friction spinning and air vortex spinning. Siro-spun yarn structure more closely resembles that of worsted yarn (Textile Horizons 1982). Login or create a free account to view the full site. Core-spun yarn by rotor-spinning process (Chellamani and Chattopadhyay, 1999: 7). rotor cleaning and doffing). the higher the speed of the rotor, the greater the twist). However, the yarn loses energy as it travels from b to a, and this is reflected in the work done by the tension through the force required to overcome the Coriolis acceleration. Krause and Soliman54 derived a theoretical relation between yarn-mass variation and the variation of yarn-spinning tension for open-end rotor spinning, and demonstrated experimentally that spinning-tension measurement represents a useful means of assessing yarn irregularity. The lower part of the rotor-spun yarn from the doffing tube navel to the rotor groove is called the yarn arm. Ring spinning is limited by factors such as the speed of the traveller, yarn tension between the front drafting roller nips and the yarn package, and the energy required to rotate the yarn package to enable twist insertion (Stalder 1982, 1984). This paper is focused on investigating the effect of different spinning parameters on cotton rotor-spun yarns. 100% desirability satisfaction can be achieved for specific yarn quality parameters by process optimization, following USTER ® benchmarks, at a rotor speed of 77,800 rpm and 700 twists per meter [35]. However, it is not suitable for worsted processing. We have produced 20's Ne, 100% cotton yarn from the above systems and their properties are tested by UT5 and lea strength tester. 2.8. A rotor then wraps the wire with staple fibers: the core filament that passes through the center of the rotor is surrounded by a spiral ring of fibers, producing metallic yarns with a fiber cover. The main advantage of this process is that the core is not twisted. Ring and rotor (open-end) spinning are quite popular for spinning cotton and cotton blends. Twist efficiency and pre-tension of filament are the influencing factors in core spinning. For instance, ring and rotor spun yarns produced in China consume 3.49 and 2.58 kWh/kg respectively, whereas in India and the US the energy consumption is 3.57–2.5 kWh/kg and 3.56–2.44 kWh/kg respectively.39, Finer yarns require more energy than coarser ones and this is applicable to all types of fibre. This method of twisting two strands produces yarns which are more compact and less hairy in comparison with conventional twisting methods. Rotor spinning Rotor Spinning is a more recent method of yarn formation compared to Ring Spinning. The fibres then come into contact with a rotating pin-covered beater, which creates a thin stream of fibres. Research into the new modified open-end rotor spinning has shown that it is able to produce hybrid yarns as shown in Fig. Worsted yarns are often plied which gives them a greater evenness and makes them easier to weave. For an ‘ideal yarn’, the relation between the force variability and mass irregularity was calculated numerically as a function of rotor diameter and mean fibre length. 2006). A spinning plant consisting of both ring and rotor spinning machines uses 11% energy for blow room, 12% for carding, 5% for drawing, 1% for combing, 7% for roving, 37% for ring spinning machines, 20% for open-end machines and 7% for winding machines.39, The process of weaving comprises many sub-processes, namely winding, warping, sizing, weaving preparation and weaving itself. 1987). Winding ( yarn package building): From a study by Visvanathan and colleagues, it was revealed that one kilogram of woven fabric consumes between 5.7 and 5.8 kWh of specific electrical energy.41 Energy consumption of weaving processes was measured by a study which found that automatic winding needs 0.4 kWh/kg, classical winding and warping each need 0.1 kWh/kg and sizing consumes 0.03 kWh/kg of electrical energy and 5 MJ/kg of thermal energy.42 In a weaving mill, 36.3% of energy is required for the machines, 29.4% for compressors, 27.1% for air conditioners, 3.4% for illumination and 3.8% for cleaning.43, Wet processing is the major component in the textile supply chain in terms of energy consumption since it demands huge amounts of thermal energy in steam and heat. Mack50 originally established the differential equations governing yarn shape and tension inside rotors. Rotor spun yarns are mainly produced in the medium count (30 Ne, 20 Tex) to coarse count (10 Ne, 60 Tex) range. After being fed to the high-speed opening roller, the fibres become individualised. Numbering is based on the relationship between the length and weight of the yarn. Centrifugal force pulls the molten sugar out of the drum, allowing it to solidify and form fibres. Printing by rotary screen consumes 2.5–8.5 GJ per ton of output. The higher crease recovery angle along the rotor spun yarn direction is due to higher diameter of … A change in the filament overfeed has been shown to affect the geometric disposition of the filament yarn in the hybrid yarn, which in turn results in irregularities and changes in the tensile properties of the yarn. This energy breakdown reveals that ring spinning is the major energy consumer in a composite textile plant. One of the most important developments in air-jet spinning is vortex spinning, which is 20 times faster than ring spinning (Goswami et al. Elhawary, in Textiles and Fashion, 2015. As can be seen from Fig. The main object of the project is to study the yarn properties (Um%, CVm%, Imperfection, Hairiness etc) of ring, rotor and air-jet spun yarn and compare among them. Production and transportation consumed 40 and 10 MJ of energy. Centrifugal force pulls the molten sugar out of the drum, allowing it to solidify and form fibres. Spinning speeds can be dramatically increased. 2.7. A sliver is fed into a drafting system that feeds the yarn into a vortex created by high-speed air jets, to impart false twist. However, ring spinning is slower than other modern spinning systems and requires more processing steps, including off-machine winding of the yarn into large packages. Ring spinning is the oldest type of fiber spinning still in use. This system is much less labour-intensive and faster than ring spinningwith rotor speeds up … [citation needed] Air jet-spun; Air-jet spinning was the next advancement in spinning technology. Even today, ring spinning makes the widest range of yarn counts with the highest strength. The first functioning of rotor spinning, machine was presented at the ITMA in 1967. Spinning speeds can be dramatically increased. The principle behind open-end spinning is similar to that of a clothes dryer spinning full of sheets. For example, 100 kg of 20 Tex yarn to be used in knitting consumes 306 kWh, whereas the same amount of yarn consumes 364 kWh if it is to be used for weaving.40, A spinning plant utilises 78% of energy in its machines, 16% for humidification plant, 3% for lighting and 3% for compressors. This study demonstrates the variations in energy profiles of different textile products in their cradle to grave assessments. These fibres are then deposited in the v-shaped groove on the outside edge of the rotor. Welcome to Spinning Processes where you will learn about “Ring Spinning”, “Rotor Spinning”, “Air Jet Spinning”, “Yarn Numbering”, “Yarn Twist” and “Yarn Plying.”. It can be concluded that if the rabbit hair/cotton blended 62.5 tex yarns are spun, the rotor-spun yarns will show more of an appearance of rabbit hairs than the ring-spun yarns. Used the new yarn tension structure and differential roller; Spinning Wheels and Accessories: The spinning wheels unit is a key component in rotor spinning machine. The system spins yarn directly from slivers, using a spinning rotor and a withdrawal system that imparts false twist to form the fibers into a yarn. According to this study, the product in question consumed 102 MJ over its entire life cycle. Yarn samples with a linear density of 50 Tex, 37 Tex, 30 Tex, 25 Tex, and 20 Tex were spun both on the aerodynamic compact and rotor spinning systems using the same finisher drawn sliver of medium staple cotton which were produced … The cotton fiber usually is just over an inch long. The low productivity and high production cost of ring spinning have forced machine manufacturers and technologists to look for other methods of yarn manufacturing. This is convenient because T0 can only be obtained by finding the boundary conditions for the differential equation given by Mack. The disposal phase consumed no energy at all.46. The rotor-spun yarn has a three-part structure, with a relatively dense core (80-90% of fibers), a loose but a continuous sheath that wraps around the core (5-20% of fibers) and tightly wound surface coils as wrapper fibers (0.5-2% of fibers). The characteristics of hybrid yarns and means of production of novel yarns depend on the yarn formation technique, filament overfeed and the twisting mechanism of rotor spinning. As can be seen from Fig. A yarn is thus spun continuously. ScienceDirect ® is a registered trademark of Elsevier B.V. ScienceDirect ® is a registered trademark of Elsevier B.V. ). This machine is characterized by its flexibility, facilitating the production of both standard rotor yarns and incorporating elastomeric yarn combination rotor yarns. The yarn structures from these techniques do not meet the accepted requirement for worsted yarn, i.e. As far as thermal energy is concerned, bleaching and finishing require 35%, dyeing and printing consume 15%, humidification and sizing demand 15% and boiler plant and steam distribution losses account for 25% and 10% respectively.34, Energy use in terms of the life cycle of a textile product deserves significant consideration and it varies widely for different textile products. He considered that the yarn is situated between the lip of the doffing tube, of radius a, and the rotor wall, of radius b. It is more economical to produce coarse core-spun yarns with a rotor machine than with a ring-spinning system (Rameshkumar and Anbumani, 2008). Mahmoudi, in Advances in Yarn Spinning Technology, 2010. Service Marks / Trademarks of Cotton Incorporated. The plying twist is in the opposite direction of the singles twist. It is simply necessary to pull this yarn out of the rotor via yarn compensation bar by means of take-off rollers and wind it up on a winding drum into the cross-wound package. Google Scholar | … Open-end/rotor spinning has its advantages with regard to production rate, use of floor space, and labour (Lawrence 2003, Goswami et al. The tension at the rotor wall, as predicted by the above equation, was too large by about 11%. The usual length of the staple of any kind, such as wool, ramie, or any type of … However, air-jet spinning produces weaker yarn in a smaller range of yarn counts; yarn sizes typically are above 24/1. The rotor then spins the yarn around the rolling yarn arm, creating yarn. Yarn tension is much lower in rotor spinning as compared to ring spinning, but controlling yarn tension is still an important factor in avoiding end breakage. The rotating doffing tube inserts a false twist and pushes the twist back to the peel-off point. Rotor spun yarns from recycled cotton spinning wastes were manufactured by means of rotor spinning process and tested for yarn imperfections and strength.Results of studies are examined the effect of cleaning intensity,cylinder speed and combing roller speed of rotor frame by using box and behnken experimental design. 1. Each system has its advantages and limitations in terms of technical feasibility and economic viability. Material is fed through the spinners to individualize the strands up to the spinning head. the yarns generally do not have the necessary smooth surface and soft hand. The use phase, assuming a 10 year life span and cleaned by vacuum cleaning, was found to be the second major hot-spot consuming 65 MJ of energy. Sliver from the card goes into the rotor, is spun into yarn and comes out, wrapped up on a bobbin, all ready to go to the next step. These yarns are used in furnishings and drapes, rather than in apparel fabrics, although they are sometimes used in denim fabrics. By introducing a break into the material between the supply package and the yarn package it is possible to introduce twist by only rotating the yarn end at the break. The fibres in manufactured yarn for the worsted industry are well arranged, i.e. Fabric production came next for this product, too, and accounted for 26% (96.9 MJ), followed by logistics/retail, which accounted for 7% (24.6 MJ) of total life cycle energy. Spun yarn is a kind of yarn made by gathering together a bundle of the staple by spinning the spindles at a very high speed to twist the staples together to form a piece of yarn. “Twist multiple” is the measure of twist per unit length, and twist direction is described as “S” or “Z.”. Since the 1960s new spinning technologies have been developed, including, Process control in ring and rotor spinning, Calculating the water and energy footprints of textile products, Assessing the Environmental Impact of Textiles and the Clothing Supply Chain. This method offers an approximate solution, which makes it possible to predict changes in internal yarn tension by a simple closed-form solution as follows: where t is the twist in the yarn and E is given by: where C, ρ and d are air drag coefficient, density of air and yarn diameter respectively. This process enables very high twisting speeds to be achieved without increasing power consumption. Yarn numbering (count) describes a yarn’s physical size — specifically, its linear density. Yarns used in denim fabrics are termed “short-staple spun yarns,” because they are formed from fibers having a staple length of less than 2.5 inches. Figure 9.10 shows the basic elements of open-end rotor spinning. The principle of rotor spinning is similar to the production of cotton candy/candy floss. The extra twist is the false twist in the yarn tail. There is no roving stage or re-packaging on an auto-coner. The principle of rotor spinning is similar to the production of cotton candy/candy floss. Core-spun yarn by modified rotor-spinning process (Alagirusamy et al., 2006: 6). The hypothesis agreed well with experimental results. By continuing you agree to the use of cookies. Sampling inspection of the yarn-spinning tension and its variability on open-end spinning machinery could well serve as a useful test for quality-control purposes. This new type of rotor-wrapping twister is used to produce novel hybrid yarns comprising a stainless steel filament, polypropylene nonwoven tape and a reinforced filament. In addition, the spinning operation no longer imposes limitations on the type and size of yarn package which may be formed. The production of suitable spun yarn for the worsted industry requires the fibres to be parallel with uniform twist angles and unidirectional twist direction to give fabric a soft and warm texture. The disposal phase was the same as for the cotton T-shirt and consumed the same amount of energy (-3 MJ).46, As far as the carpet was concerned, it was made out of nylon fibres with polypropylene and latex-foam backing. Wrapper fibres (WFs) and their formation mechanisms, as well as their effects on the pro perties of open-end rotor spun yarns, have been investigated. Fibre orientation in friction spinning is also poor (Fig. The disposal phase consumed only 0.02% of total life cycle energy.45, A study dealing with the present and future sustainability of textiles in the UK presented case studies of three products. This study showed that the energy consumed in material production varies depending on the type of material and based on the product and its function. In addition, the spinning operation no longer imposes limitations on the type and size of yarn package which may be formed. The energy used in wet processing differs between different product forms, machine types, processes, process flows and state of the final product.34 For instance, a desizing unit consumes 1.0–3.5 GJ/ton output, scouring by J-box consumes 6.5–10.0 GJ/ton output and bleaching by jig/winch requires 3.0–6.5 GJ/ton output. The level and structure of the twist are very important characteristics of all yarns: the fiber twist angle of the strand in a hybrid yarn is smaller than that of a rotor spun single yarn with the same spinning conditions. Rotor Spun yarns found with frequent breakage during knitting [6] and more irregular than ring yarn [34]. The spinning wheels unit quality can directly effect the quality of spun yarn. Great advances have been made in the automation of stages of the rotor-spinning process (e.g. The low productivity and high production cost of ring spinning have forced machine manufacturers and technologists to look for other methods of yarn manufacturing. All these new techniques have their strengths and weaknesses, depending on the type of fibre used and the resulting yarn structure required. The frictional forces created by the twist determine the yarn’s strength and elongation characteristics. Ring spun yarn is having enveloped twist, it twisted the fibres from outwards to inwards, while in the rotor spun yarn has core twist, twisting in the fibres from inwards to outwards, because of that rotor yarn showing more voluminous and open. Majumdar, in Process Control in Textile Manufacturing, 2013. Clearly, T0 is important in determining the ultimate linear density limits in rotor spinning, and needs to be calculated as a routine matter, despite the fact that it is much smaller than the yarn tension at the doffing tube. A sliver of fibres is fed into the spinner by a stream of air. This is because the yarn formation mechanism is force-restrained rather than position-restrained in rotor spinning. There are many processes and machines involved in converting a fibre to yarn. 14.4, the appearance of vortex spun yarn is closer to that of ring spun yarn rather than air-jet spun yarn (Basal and Oxenham 2003). The amount of energy required for dyeing varies depending on which type of machine is employed. Fibres fed to the rotor are incorporated into the rapidly rotating ‘open-end’ of a previously formed yarn that extends out of the delivery tube. The rotor spinning machine R 70 with the improved spinning box and optimized BYpass enables more cost-effective raw materials with a higher noil or trash content to be spun into a high-quality yarn. Air-jet spinning has grown in popularity because of its high productivity; it is about 20 times as fast as ring spinning. Yarn formation: When a spun yarn end emerges from the draw-off nozzle into the rotor groove, it receives twist from the rotation of the rotor outside the nozzle, which then continues in the yarn into the interior of the rotor. The production rate of conventional methods of yarn spinning is a challenge to technologists. It is also known as break spinning or rotor spinning. These are then woven into fabrics and converted into laminates (Lin and Lou, 2003). One of the key pieces of yarn information for the development and manufacture of denim is the choice of yarn size. You are currently viewing a preview of the CottonWorks™ website. At this stage, the quality, e.g. Yarn tail is pressed against rotor groove as well as navel by the centrifugal force caused by rotation of rotor. P.K. The present invention is an improved method for piecing together a continuous filament yarn and a rotor spun staple yarn with the broken end of a two-ply combination yarn formed by ply-twisting a continuous filament yarn with a yarn of staple fiber on an open-end rotor spinning machine which includes . Again, the process of spinning varies between natural and synthetic fibres as discussed in Chapter 1. fibres are parallel in the body of the yarn, twist angle is uniform, and direction of twist is either ‘S’ or ‘Z’. The fibres spin round a … Open-end/rotor-spun yarn has less parallel fibre arrangement in the yarn structure and completely irregular twist in terms of twist per unit length and twist angle as well as twist direction due to the distinctive wrapper fibres around the yarn core as shown in Fig. The end use of rotor-spun yarns will show better rabbit hair performance than ring-spun yarns.

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