Experiment No: 01

Experiment Name:

Introduction of spinning machines and their objects with the name of wastage and
wastage percentage.

Objects:

• Considering this experiment we are going to know about the basic machinery
procedures of spinning activities.

• We are going to know the basic concepts of machineries functions.

• We are going to know about the working principle on the basis of particles.

• We are going to gain knowledge about the operation and running fundamentals.

• We are going to gain basic how yarn or fibers can be used into spinning
machine.

• We are going to earn experience about the wastage range and the wastage
percentage on the spinning function.
Carded Yarn:

Introduction:

The word is derived from the Latin carduus meaning teasel, as dried vegetable teasels
were first used to comb the raw wool. Carded or carding yarn means in yarn production,
a process of separating individual fibers, causing many of them to lay parallel and
removing most of the remaining impurities.

These ordered fibers can then be passed on to other processes that are specific to the
desired end use of the fiber: batting, felt, woolen or worsted yarn, etc. Carding can also
be used to create blends of different fibers or different colors. When blending, the
carding process combines the different fibers into a homogeneous mix.

Process Flow Chart of Carded Yarn Manufacturing:

Input Material Processing Machines Output Materials

Bale management

Raw cotton Blow room Lap

Lap Carding machine Carded Sliver

Carded Sliver breaker draw frame 1 Drawn Sliver

Breaker Sliver Breaker draw frame 2 Finisher Drawn Sliver

Finisher Drawn Sliver Simplex / Speed Frame Roving

Roving Ring Frame Yarn

 Yarn Winding Yarn in large package

Objectives:

Bale management:

It is the most effective and preliminary steps for spinning. Testing, sorting and mixing
bales according to the properties of fibers for producing specific good quality yarn at
minimum cost. An objective of bale management is given below.

• By management consistency of yarn quality can be found

• A means of avoiding quality jumps
• Cost saving by bale management

Blow room:

Objects:

• Opening: Opening of compressed cotton bales and cotton are made into small tufts.

• Cleaning: to eliminate dust, dirt, broken leaf, seeds, glass and other foreign
impurities from the fibers.

• Blending/ Mixing: To produce comparatively good quality cotton fiber by mixing

different types cotton together.

• Lap forming: To convert the opened and cleaned fiber into a sheet of particular width
and uniform weight unite length is called lap.

• To give a cylindrical shape to the predetermined lap by winding it in lap pin and to
make it suitable for the next process carding.
Carding machine:

It is used for -

• To remove the small trash particles which have not been taken out in the opening
and cleaning.

• To remove naps and motes.

• To give some degree of bending.

• Elimination of the remaining impurities.

• To produce a thick untwisted rope of fibers called sliver which is suitable for
subsequent processing which is more or less uniform in weight / length.
 Figure: Carding Machine

Draw frame:

• It is straighten; the crimped and hooked fiber in the carded sliver.

• To mix the fibers more intimately by doubling several slivers and to achieve more
uniform blend of the component fibers from different bales must from the card
sliver.

• To achieve a fairly through parallelization of the fibers along the sliver axis so
that when they come to be spun on the spinning frame they will be evenly drafted
and twisted to produce an acceptable yarn.

• To improve the short medium and long term unevenness of sliver s by doubling.

• To produce more uniform sliver of definite weight / unit length.

 • To reduce the weight / unit length of the card sliver.

Simplex:

• Design of simpler machines, less liable to faults

• Increase in spendable rotation rate.

• Produce larger package.

• Attenuation of sliver.

• Automation of the machine and package transport.

Ring frame:

It is used as -

• Attenuation of the roving until the regarded fineness is achieved.

• To impact strength to the fiber strand by twisting it.

• To wind up the resulting yarn, suitable for shortage, transportation and further
processing.

Wastage range and wastage percentage:

1. Blow room (wastage≈3%)

a. Droppings-2

b. Lap wastage etc.

2. Carding (wastage≈4%)

a. Droppings-1

b. Vacuum wastage

c. sliver wastage

3. Draw frame (wastage≈0.5%)

a. Lap wastage

b. Sliver wastage

c. vacuum wastage

4. Simplex (wastage≈0.5%)

a. Roving wastage

b. Sliver wastage

5. Ring frame (wastage≈2-3%)

a. Hard wastage

b. Pneumatic

c. Sweeping

d. vacuum wastage
 6. Winding (wastage≈1%)

a. Hard wastage

Combed Yarn:

Introduction:

Combing is a process that helps to smooth and prepare fibers for use in spinning.
Combing also helps to separate short fibers from longer ones, which also helps to make
the process of spinning much easier. While the combs used in this process of fiber
preparation do function with a combing action, the actual devices have no more than a
passing resemblance to the combs used on hair. For textile purposes, the fiber combs
are equipped with long metal teeth. Two combs are utilized in tandem, with one comb
holding the strand of fiber in place while the other comb moves across the surface of the
fiber.

Process Flow Chart of Combed Yarn Manufacturing:

Input Material Processing Machines Output Materials

Bale management

Raw Cotton Blow Room Lap

Lap Carding Carded Sliver

Carded Sliver Pre-Comb Drawing Pre-comb drawn sliver

Pre-comb Drawn Sliver Super Lap Former Mini Lap

Mini Lap Comber Combed Sliver

Combed Sliver Post Comb Drawing Post Comb Drawn Sliver

 Post Comb Drawn Sliver Speed Frame / Sample Roving

Roving Ring Frame Yarn

Yarn Winding Yarn in large package

The Combed manufacturing process flowchart has been mentioned above is followed
by the textile mills.

Objective:

Comber machine:

The combing machine is located in the spinning process between the drawing frame
and the flyer. Its use is optional, and it is used to improve the yarn quality. This goal is
achieved by combing out the shorter fibers, thus increasing the effective fiber length.

• Elimination of a precisely predetermined quantity of short fiber.

• Elimination of a large proportion (not all) of the naps in the fiber materials.

• Elimination of the remaining impurities.

• Formation of a sliver having maximum possible evenness.

 Figure: Comber Machine

Lap formation:

It may use for -

• To reduce the strain to delicate comberring

• To lessen fiber damage

• To migrate the charge of good fiber wastages

• To remove short fibers

• To balance thick and thin places in the sliver

• To control marginal wastage

• To parallel and straight of fiber in carded sliver changing pashing of fiber

Wastage range and wastage percentage:

• Comber (wastage≈5%)

a. Nail

b. Lap wastage

c. Sliver Wastage

• Lap former (wastage≈12-18%)

a. Lap wastage

b. Sliver wastage

Rotor Yarn:

Introduction:

The more parallel the fiber orientation in the sliver, the better will be the fiber
arrangement in the rotor groove & ultimately in the yarn. This means a minimum two
draft passages, possibly three, if combed sliver is used. Special attention should be paid
to the careful mixing.
The number of doublings in the drafting passages is more significant. Fine slivers are
readily subject to the draft faults such as the splitting of the web or licking up of fibers
which ruins the desired final assembly of the fiber mass.

Hence the number of draft passages has to be limited to the point beyond which
splitting could occur. For the same reason, the delivery speed of draw frame must be
reduced for very fine slivers.

Process Flow Chart of Rotor Yarn Manufacturing:

Input Material Processing Machines Output Materials

Bale management

Raw materials Blow Room Lap

Lap Carding Carded yarn

Carded yarn breaker draw frame Draw sliver

Draw Sliver Finisher draw frame Draw sliver

Draw sliver Rotor frame Rotor yarn (con)

 Figure: Rotor Machine

Objectives:

• Opening ( and attenuating ) almost to individual fibers (fiber separations)

• Cleaning
• Combing, forming a coherent linear strand into fibers.
• Ordering (the fibers in the strand must have an orientation as far as possible in
the longitudinal direction).
• Improving evenness through “Back Doubling”.
• Attaining strength by twisting and winding.

Wastage range and wastage percentage:

• Rotor frame (wastage≈2-4%)
a. Hard wastage
b. Vacuum wastage
c. Sweeping wastage
d. Lab wastage.
Comments: