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Yarn Realization

Yarn Realization (YR) is a critical metric for spinning mills, reflecting the conversion of raw materials to finished yarn and significantly impacting profitability. Factors such as cotton quality, short fiber content, and process parameters play essential roles in optimizing YR, with even minor improvements leading to substantial financial gains. Effective lot management, moisture control, and maintenance of quality indicators are vital for enhancing operational efficiency in a competitive market.

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50 views

Yarn Realization

Yarn Realization (YR) is a critical metric for spinning mills, reflecting the conversion of raw materials to finished yarn and significantly impacting profitability. Factors such as cotton quality, short fiber content, and process parameters play essential roles in optimizing YR, with even minor improvements leading to substantial financial gains. Effective lot management, moisture control, and maintenance of quality indicators are vital for enhancing operational efficiency in a competitive market.

Uploaded by

shobsundar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Yarn Realization (YR): It's the vital measure of raw material conversion to finished

yarn, crucial for assessing spinning mills' technical performance and profitability.
Cost Impact: Raw material costs,
constituting 55-65% of sales turnover, emphasize the need to optimize YR for
profitability.

Improvement Potential: Even slight YR Net Profit Margin enhancements can yield
significant operational efficiency and financial gains, pivotal for the survival of
spinning mills in a fiercely competitive global market.

Vital components for cotton yarn realization are


Cotton quality specifications & customer quality requirements
Short Fiber Content
In cotton fibres, fiber length whose length is shorter than 12.5 mm are usually
considered as short fiber content % (i.e. SFC(n) & SFC(w) %) as determined by
AFIS instrument.It is eliminated as waste in blow room, carding and also in
comber noils. However, SFC(n) is ignored by majority of the mills being a critical
factor driving the Yarn Realisation% (YR%). SFC(n) broadly ranging from 15 to
35%
Cotton Trash%
Trash content removed in blow room & carding processes along with some
amount of good cotton fibers ultimately reduce the yarn realisation. Heavy
particles are extracted easily due to their denser in nature but elimination of
lighter leaf particles pose a big challenge and lead to higher waste extraction.In
addition to that, other fibre properties such as Micronaire, immature fiber content
(IFC) and fiber strength also influences YR%. Trash % broadly ranging from 1 to
10%.
Lot management and mixing issue system
As cotton is a natural fiber, within bale and between bale fiber quality variations
is also an inherent characteristic. Hence, it is essential to ensure homogeneity in
the mixing lay down. Mixing lay down charts are prepared in novel way to
maintain mixing quality consistency, to minimize quality variations. For example,
mixing lay down chart based on Micronaire is given in Figure 1 can be designed
manually or by using software.Ginners have a practice of spraying excess water,
bypassing pre/post cleaners and even supplying false packing by adding comber
noil before dispatching to the spinner. In those bales, variation in Micronaire CV
%, Trash %, SFC(n) CV% and high moisture % which indicates the quality of
ginning and exposes false packing. Mixing specification standards shall be fixed
and maintain the same parameters as much as possible for all the lay downs.
Customer Quality requirements
Yarn realisation is also widely affected by end use of the product or for specific
quality requirement. For high quality and sensitive end use applications such as
shirting’s, suiting’s & garments etc., higher waste has to be extracted by the
mills to meet the requirements.
Process Parameters
Improper selection of process parameters lead to poor quality & working
performance of the spinning process, which ultimately forces the spinner to
generate high amount of waste.
Spinning Limits
Under or over limit of spinning also impacts on yarn realisation%. Mills should
use the optimum cotton quality parameters suitable for each count based on
yarn quality requirements to minimize the mixing cost

Machine Working Performance


Process parameters
Relative humidity%
To retain the moisture in cotton to specific level, the relative humidity shall have
to be maintained around 65% in mixing, winding and packing. Cotton yarn
absorbs adequate moisture which in turn with less fluff liberation. This will lead
to lower invisible losses by maintaining commercially acceptable moisture range
in the finished products.
Invisible loss / gain
Moisture in cotton bales shall be within commercially acceptable moisture range
(8.5 to 9) to minimize invisible loss.
Key factors influencing invisible loss are
Moisture content in cotton bales. Lower the moisture, better gain and vice versa.
Imported cotton are supplied with < 6 % moisture too. However, Indian spinners
are accepting cotton moisture up to 9%.
Relative humidity for proper working which reduces fly liberation.
Moisture of cotton waste such as blow room waste, card waste & comber noil
have to be ensured.
Moisture gain on finished packages after yarn conditioning
system have to be ensured periodically
Carton box weight tolerance shall be minimized and tare shall be checked on
regular basis.
Finished yarn weight tolerance

Tare weights
The tare weight of cotton bales, carton boxes and waste bales shall be
maintained precisely. The weighing balance used for weighment shall be
periodically calibrated for its accuracy.
Permissible Levels of Lint in Process Waste
Acceptable quantities of lint within process waste

Lint in blow room Waste <25%


Lint in Licker in waste <25%
Lint in Flat tops <55%
Lint in Stationary flats <65%
Short fibres (SFC(n)) in Comber noil >85%

The Quality Vs Noil Curve

The curve flattens after 20% noil elimination which is an indicator for the mills to
fix their noil level
Dependence of Various Quality Parameters on noil elimination (Source Rieter)
A – Improvement of yarn Quality in %:
B – Noil elimination in %:, a – Yarn strength: b – Yarn evenness: c – yarn
imperfections
Approach for Re- Engineering

Key Quality Indicators in spinning mills


Productivity
– Efficiency per production step (for each department)
– Efficiency comparison per shift
– Machine availability
– End breaks per 1000 spindle hours at ring spinning machines
– Yarn joints per 100 km at winder
– Clearer cuts per shift
– Amount of rewinding per week
– Throughput time from bale to yarn
Production yield
– Grams of yarn per spindle (per day, shift, month or year)
– Kg of yarn (per day, shift, month or year)
– Waste in % per process step
– General fiber yield in % (ratio of input to output) based on kg of fiber
material to kg of yarn
– Tonnage of yarn produced (per month or per year)
– Amount of 2nd quality (in kg or in % of total production)
– Moisture amount of final yarn
Maintenance
– Total maintenance time per month
– Maintenance hours per kg of yarn produced per year
– Main reasons for maintenance
– Average time of stops in the spinning preparation per week
– Reasons for efficiency losses
– Cost for maintenance (personnel and maintenance material)

Pricing and cost


– Average production cost
– Raw material cost
– Waste cost
– Energy cost
– Labor cost
– Auxiliary material cost
– Interest rates
– Depreciation
– Sales price and margins
– Cost-price balance per article

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