The procedure used to convert fibres into yarns in their finished state is known as spinning. Despite how straightforward it may seem, there are several stages to this process, and issues with any of them can affect the output quality and productivity as a whole. For this reason, it is imperative that all mill operators—indeed, all parties involved in the textile industry—have a thorough understanding of the various stages of spinning. Knowing the best techniques for using them is essential since the dependability and usability of spinning cans and associated items also directly affect operational efficiency levels.
Opening and Mixing the Bale
The opening of the bale initiates the spinning process. The cotton is transformed from its tightly compressed state in bales to a cleaner, looser state. Variations and irregularities in the yarn are reduced through meticulous blending, improving overall homogeneity. To ensure that the mixing of the fibres is done uniformly, high-quality compressed air is employed. It's crucial to keep this homogeneity.
Unicleaning
There are numerous accumulated dirt and contaminate particles in raw cotton. They must be removed from the cotton bale and contain seeds, sand grains, leaves, and more. The cotton fibre needs to be streamlined into sheets for this. The "lap" is generated at the conclusion of this "unicleaning" stage, which needs to be further prepared and processed. The fibre can continue on to the next stage once all the "fibre-fragments" and other similar exterior components have been removed.
Blowroom
This could be regarded as the process' first step of core spinning. In the blowroom, opposing spikes, air current, and beaters are utilised. The removal of impurities from the cotton fibres is done smoothly and effectively. When the material has been opened and the tufts have been created, a thorough cleaning and, if necessary, blending is performed (if required, between two or more fibre types). The flocks (or laps) that are created are uniform in height and width. In some circumstances, the open fibres might also be fed into a chute.
Carding
The carding machine uses a methodical series of splitting and redividing operations to meticulously untangle and combine the fibres. During this phase, the "laid," which is essentially a thin fibre sheet, is created. The fibres are arranged in this with them parallel to one another. At this point, neps and impurities that were not removed in the blowroom are eliminated. The lap can be made into sliver and opened individually to untwist and smoothen the fibre. According to length, fibres are chosen, and the shortest ones are rejected.
Draw Framing
In general, the sliver that emerges from the carding stage is fairly uneven or non-uniform. As a result, the sliver is not yet appropriate for making yarn. The drawframing stage is crucial in this situation since it is when the doubling and drafting equipment is utilised to turn the many strands obtained in the previous stage into single strands.
Combing
The actual creation of sliver occurs during the crucial combing phase of yarn spinning. Before that happens, all contaminants in the comber lap are removed, along with any short fibres. Several essential steps are involved in the comber process, such as lap feeding and nipping, roller detaching, piecing, and cylinder comb cleaning. At the combing stage, a significant portion of fibre neps are eliminated. Moreover, the fibres are straightened, which improves sliver evenness.
Speed Frame or Roving
For feeding the drawn slivers and giving them an appropriate twist at this step, a conventional roving frame is present. These "roving strands" are gathered by spinning can goods before being fed into the spinning equipment. The speed of the roller is gradually raised (through which the sliver is passed). To make it suited for yarn spinning, the linear fibre density is reduced, and the overall sliver size is decreased.
Ring Frame
The use of ring frames significantly improves the fiber's fineness. The roving is designed to increase this fineness, and yarns with the necessary counts and strengths are created (by twisting). The twisted yarn is wound in a bobbin to guarantee safe, damage-free storage and processing. The ring frame is constructed using the following techniques: drafting, creeling, doffing, twisting, winding, and building.
Winding and Spinning
Last but not least, a certain amount of "twit" is added to the yarn during the spinning process to strengthen it. After that, the ring bobbin is wound. To achieve greater production and efficiency, the package size should preferably be somewhat large. Auto coners are employed specifically for this function. Moreover, splicing and/or cutting is done to remove any potential yarn flaws (poor thickness, slubs, etc.). Advanced auto coners typically use automated equipment for cutting and splicing.
The selection of a spinning can, in particular, as well as material handling systems in general, is crucial to the process of spinning yarn on mill floors. For instance, severe production issues and downtimes may result if the cans selected by a mill are not compatible with the existing spinning equipment (such as Rieter, Trutzschler, or any other OEM). To ensure that the final yarn quality is on par with the best, each stage of spinning must be completed with great attention and accuracy.
Original article posted at : From Sliver To Yarn – The Complete Yarn Spinning Process You Need to Know