BGMEA UNIVERSITY OF FASHION AND

TECHNOLOGY

Course Title: Yarn Manufacturing and Engineering-II (LAB)

Course Code: TEX-3102

Final submission
Submitted To
Mahmuda Chowdhury

Lecturer

Department of Textile Engineering (TE)

BGMEA University of Fashion & Technology (BUFT)

Submitted By:

ID:181-103-801,181-105-801,181-89-801,181-116-801,181-
117-801
 INDEX

Exp. Exp. Name Page No.

No
01 Study on layout plan of a cotton spinning mill/spinning
lab.
02 Study on determination of different card settings by
using leaf gauge.
03 Study on different card clothing’s used in carding 3-6
Machine
04 Study on usable and unusable cotton waste produced in 7-10
cotton spinning mill.
05 Study on auto-leveler used in modern draw-frame. 11-12
06 Study on determination of shore hardness of rubber 13-14
coated top roller.
07 Study on determination of roller settings of draw- 15-16
frame.
08 Study on material passage diagram of simplex machine. 17-18
09 Production Calculation of Simplex machine. 19-21
10 Material Passage diagram of Ring-frame. 22-23
11 Study on different types of ring traveler and selection of 24-26
ring traveler.
12 Production calculation of ring frame 27-28
13 Different types of attachment used in ring spinning 29-34
system for the production of different special yarn.
Experiment No. : 03
Experiment Name: Study on different card clothings used in
carding machine
Introduction:
Carding is a mechanical process that disentangles, cleans and intermix
fibers s to produce a continuous web or sliver suitable for subsequent
processing. In this process fibers are opened, parallelized & removes
dust, impurities, short fibers to produce continuous strand of sliver. This
is achieved by passing the fibers between differentially moving surfaces
covered with card clothing. The word is derived from the
Latin “CARDUUS” meaning thistle or teasel, as dried vegetable
teasels were first used to comb the raw wool.

Objectives:
1. Opening the tufts into individual fibers
2. Eliminating all the impurities contained in the fibers
3. Extracting of neps
4. Fiber blending & orientation
5. Removal of short fibers
6. Parallelizing and stretching of the fibers
7. Transformation of the lap into a sliver
Figure:

Card clothing is used on the surface of

1. Taker in;
2. Cylinder;
3. Doffer;
4. Flat.

Types of card clothing:

1. Flexible card clothing
2. Semi-rigid card clothing
3. Metallic card clothing
1. Flexible clothing: Flexible clothing have hooks of round or oval
wire set into elastic, multi-ply cloth backing. Each hook is bent into
a U-shape and is formed with a knee that flexes under bending load
and returns to its original position when the load is removed.

Advantages of flexible clothing:

1. Higher point density so better carding action

2. Fiber damage is less due to flexible wire point
3. Only the damaged part of the clothing is needed to be repet.
 Disadvantages of flexible clothing:

1. Requires textile fabric or rubber as foundation material.

2. The wires can be loosened
3. Production less due to stripping

Fig: Flexible card clothing

2. Metallic clothing:

These are continuous, self-supporting, square wire structures in which teeth are cut
at the smallest possible spacing’s by a process resembling a punching operation.

Advantages of metallic card clothing

1. Does not require separate foundation material. The metal surface of

the machine works as foundation material.
2. The teeth do not get loose as teeth and foundation both are metallic rigid.
3. Can choose any carding angle.

Disadvantages of metallic card clothing

1. Fiber damage is more as the wire points are metallic.

2. Difficult to repair in the mill when a portion of it is worn out
3. If any part of the wire is damaged, then the total clothing is rewind.
4. Expensive
 Fig: Metallic card clothing

3. Semi-rigid clothing: Semi-rigid clothing have wires with square or

round cross-sections and sharp points are set in backing which is less
elastic than that of flexible clothing. This backing is a multi-ply structure
with more plies than the backing of flexible clothing, comprising layers of
both cloth and plastics.

Advantages of semi-rigid clothing:

1. Does not choke with fiber

2. Eliminate less flat stripping
3. Does not need sharpening

Fig: Semi rigid card clothing

Conclusion : Carding is the process of arranging the fiber in parallel

fusion. This is necessary for all staple fiber. Otherwise it would be
impossible to produce fine yarn
Experiment No. : 04
Experiment Name: Study on usable and unusable cotton waste
produced in cotton spinning mill.
Introduction:

Every being in this world has an expiration date, even the world itself
possibly has one. This situation is the same for man-made products too.
We produce them, use them, and try to find a way to get rid of them,
when the time comes. One of the hardest questions of today comes to
mind at this point: How will we manage the resultant waste of the
products we created? Should we dump the waste to proper waste yards
and reuse or recycle them? The answers to these questions are crucial.
Scientists, governments, and local authorities work for finding answers
to these questions. Wastes can be a problem for local authorities
because of their environmental effects.

Textile wastes can be divided into two main groups: production wastes
and postproduction wastes. Production wastes are basically raw
materials of each production step which cannot be put into end product
due to different reasons. For yarn spinners, these wastes can occur
during cleaning of the fibers or combing out short-staple fibers from the
long ones in combing machine, etc. These clean/unclean wastes in fiber
form or not can be reused. After spinning mill, there are wastes in yarn
and fabric forms, and they need recycling to be put again in production.
Postproduction wastes are generally worn out cloths, which can be
recycled and may be used again in textiles or utilized in other products.

 In practical,
Input – Output = Wastage
List of Blow room wastages:
  Droping-1
 • Droping-2
• Seeds
• Leaf
 • Dust
• Lap cut
• Filter waste
 • Filter dust
• Floor sweep
• Contamination
List of Carding wastages:
• Motes & fly
• Flat strip
• Taker in waste
• Sliver cut
• Filter waste
• Filter dust
• Floor sweep

Draw Frame wastages:

• Filter waste
• Bonda Waste (lapping on wooden roller)
• Sliver cut
Wastages in Simplex:
• Roller Waste/Bonda
• Roving Waste (Hard Waste)
• Sweeping Waste
• Clearer waste
• Invisible Waste
• Note: Above 0.50% of total amount of wastage is
not acceptable
Cotton wastes in spinning mill:

Klein classified cotton fibers used in short-staple spinning as virgin fiber (from
ginning mill), clean waste, comber waste, recycled fibers from dirty waste, and
fibers torn out of hard waste (roving, yarn, and twisted threads) . Spinning wastes
and their sources are given in

Figure.Spinning mill wastes in different sources.

Broken ends of sliver, lap, web, and filter strippings from draw frame, roving
frame, ring spinning frame, and rotor spinning frame are known as clean waste,
having more than 95% of good fiber. Comber and roving wastes’ good fiber ratio
is around 95–97%. Wastes generated in blowroom machines, and cards are dirty
wastes with 35–55% good fiber ratio. Besides, another dirty waste, flat and filter
stripping waste, has a higher amount of good fiber (65–80%). As the waste fibers
are processed in different number of machines and therefore stressed fibers, their
good fiber content is less than virgin fibers. For this reason, spinners prefer to feed
the waste fibers into normal spinning process, in a controlled manner, with a
constant percentage in order to avoid quality variations. Generally, wastes arising
in the mills can be returned to the same blend from which they arose; comber
wastes are mostly used in rotor spinning. In carded ring-spun yarn and fine rotor-
spun yarn production, waste fibers can be used, up to 5%, but for combed yarns,
waste fiber ratio can be lower, up to 2.5%. Higher waste fiber amounts can be used
for medium and coarser rotor yarns, about 10 and 20%, respectively.
Wastage Reduction Procedure/ Factors for
Wastage Reductions:
• Raw materials selection
• Spindle speed
• Setting(Rollers, Ring traveller, Traveller cleaner etc)
• Twist of yarn
• Machinery condition
• RH% and Temperature
• Proper material handling
• Adequate supervision

Conclution:
In this study, the waste of yarn spinning mill and recycled cotton fiber from fabric
waste were blended different blending ratios (10, 30, and 50%) with virgin cotton
fiber. The yarn physical properties of these yarns were tested. The effects of waste
ratio and waste type on yarn properties were investigated. According to the test
results, the dirty waste (blowroom waste and card waste) used in this study showed
a different tendency from the clean waste (sliver waste and fabric waste fiber). The
blowroom and card waste occurred during the cleaning of the fibers. On the other
hand, the content of the blowroom waste in the yarns has not influenced the yarn
properties except for thick places and nep values up to ratio of 30%. When fibers
recycled from the fabric have been used, it has been seen that the results are
similar to those obtained when using the blowroom waste On the other hand, the
card waste has the highest short fibers content. It is thought that the short fibers are
easily removed from the fabric surface after forming the pills in the fabric by itself
and thus do not cause deterioration in appearance.
Experiment: 05
Experiment Name: Study on auto leveler used in modern draw frame.
Introduction: Auto leveler is an additional device which is meant for
correcting the linear density variations in the delivered sliver by changing either
the main draft or break draft of the drafting system, according to the feed
variation. There are two types of Auto leveling systems.
1) Open loop system.
2) Closed loop system.
In closed loop system, sensing is at the delivery side and correction is done by
changing either a break draft or main draft of the drafting system. Most of the
earlier card auto levelers are closed loop auto levelers. But the latest cards have
sensing at the feed rollers and as well as at the delivery calendar rollers. We can
say, both closed loop and open loop systems are being used in such auto levelers.
Open loop system is very effective, because the correction length in open loop
system is many folds lower than closed loop system. But in case of closed loop
system, it is confirmed that the delivered sliver is of required linear density. In case
of open loop system, since the delivered material is not checked to know whether
the correction has been done or not, Sliver monitor is fixed to confirm that the
delivered sliver has the required linear density.

Objective:
1) To maintain consistent hank of sliver.
2) Adjust the draft continuously, which will depend on thickness of material fed.
Figure:Autoleveler
Main parts:
1)Scanning roller
2)Signal convertor
3)Leveling processor
4)Servo drive
5)Quality monitor sensor

Important parameters for quality leveling:

1)Leveling intensity:
A)It indicates the amount of correction to be done.
B) It is to decide the amount of draft change required to correct feed variation.
C) The correlation between mass and volume for different fibers is not same.
2) Leveling action point:
A) The calculated correction should be done on the corresponding defective place.
B) The time required for defective material to reach the correction point should be
known. C) Leveling action point depends on breaks draft, main draft roller setting
And delivery speed.
Advantage of Auto leveler:
1)All variations are corrected.
2) Count CV% will be consistent.
3) Thin places in silver and hence in the yarn will be low.
4) Higher efficiency in further process.
Conclusion: For obtaining good yarn quality, installation of auto leveler is
must. As long as the auto leveling system is set properly, advantages’ mentioned
above can be achieved. Otherwise the negative impact will be very big compared
to working without auto-leveler.
Experiment: 06

Experiment Name: Study on determination of shore hardness of rubber coated top roller.

Introduction: The Shore hardness is measured with an apparatus known as a Durometer

and consequently is also known as 'Durometer hardness'. The hardness value is determined by
the penetration of the Durometer indenter foot into the sample. Because of the resilience of
rubbers and plastics, the indentation reading change over time so the indentation time is
sometimes reported along with the hardness number.

Objective:
1) To shore hardness test is a quick and convenient way to measure hardness of elastomers.
2) To the aim of this study was to investigate the effect of thickness on the measured hardness.
3) To a theoretical analysis was derived.

Apparatus:
1)Laser Doppler vibrometer
2)Recorder
3)Specimen
4)Mirror
5)Laser beam
6)Reflecting tape
7)Hammer

Figure: (shore hardness tester)

Working procedure:

1) As illustrated in the figure, the load-stroke curve can be divided into

three zones.
2) In zone (I) the force rises rapidly from zero to 115 kN after a 4 mm
punch displacement.
3) This dramatic increase in the punch force is mainly due to the elastic behavior of
the rubber pad and the resistance of the work piece to deformation.
4) In zone (II) the bending force increases very slightly between the punch stroke
from 4 mm to 8 mm which is mainly due to the developing and spreading of the
plastic zone in the work piece. 5) In zone (III) the force rises again with the
movement of the punch. This is the final stage of the V-bending operation and
the work piece is in full contact with the metallic punch.

Conclusion:
In this conclusion the use of shore hardness testing as a quick and continent way of
monitoring properties of silicon rubber during manufacturing is investigate. Two
silicon rubber samples are manufactured with different mass ratios between
silicone solvent and curing agent via the silicon room temperature vulcanization
process. Synthetic shore hardness test has performed on different molding plains to
evaluate potential anisotropy in the hardness.
Experiment: 07

Experiment Name: Study on determination of roller setting of draw frame.

Introduction: Draw frame is a very critical machine in the spinning process.

Drawing is the operation by which slivers are blended, doubled and leveled. In
short staple spinning the term is only applied to the process at a draw frame. It’s
influence on quality, especially on evenness is very big. If draw frame is not set
properly, it will also result in drop in yarn strength and yarn elongation at
break. The faults in the sliver that come out of draw frame cannot be corrected.
It will pass into the yarn.

Objective:
1) To know about general specification of the M/C.
2) To know the gearing diagram of the M/C.
3) To know about its production, draft, faller drops/min etc.
4) More straightening & parallelization of remaining irregularity fibre of first
draw frame along the fibre axis by drafting.
5) To have proper mixing & blending of fibre.

Figure:(diagram draw frame)

Parts name:
1) Back retaining roller;
2) Front retaining roller;
3) Jockey/ Slip roller;
4) Role;
5) Fluted feed roller;
6) Fluted feed roller;
7) Slide;
8)Faller bar;
9) Drawing roller;
10) Drawing pressing roller;
11) Guide roller;
12) Doubling Plate;
14) Delivery roller;
15) Crimping Box;
16) Can

Conclusion:
Draw frame is a machine for combining and drawing slivers of a textile fibers(as
of hemp for rope manufacture and cotton for spinning).Drawing is the operation by
which slivers are blended, double and leveled. In short staple spinning the term is
only applied to the process add the draw frame. In drawing sliver are elongated
when passing through a group of pair rollers each pair is moving faster than
previous one.
Experiment No: 08
Experiment Name: Study on material passage diagram of simplex machine.
Introduction:
Draw frame slivers are fed to the roving frame in large cans. The slivers are passed
through separators and then over the guide rollers and tension rollers. Now the
slivers are passed through the drafting rollers. There is dead weight over these
drafting rollers. Here generally 6-15 draft is given. The delivered slivers are too
thin to hold themselves together and so twist is needed. The drafted strands of
fibers are then passed through flyers. These flyers create twist in the fibre strands
by rotating and twist is usually 30-65 per meters. There are spindles in the flyers
on which the twisted fibers i.e. roving are wound.

Objectives:
1.To draft the sliver to reduce weight per unit length.
2. To insert small amount of twist to strengthen the roving to prevent
breakage during next processing.
3. To make conical or tapper shape of the bobbin.
4. To wind twisted strand on the bobbin.

Main parts:
1. Separators
2. Guide rollers
3. Drafting rollers
4. Dead weight
5. Flyers
6. Spindles
7. Motor
8. Apron
9. Rubber coated Top roller
Diagram : Material passage diagram of Simplex machine.

Required data:
1. Pitch of spindle = 7.5 inches
2. No. of flyers = 40
3. Bobbin length = 11.5 inches
4. Lift of bobbin = 10.3 inches
5. Outer diameter of bobbin = 1.75 inches
6. Inner diameter of bobbin = 1.3 inches

Conclusion:
The passage of material through the simplex m/c is easy. During this passage, three
works are done on the sliver: drafting, twisting and winding. The output of this
machine is roving which is then fed into the Ring-frame. Ring-frame is the last m/c
of yarn spinning and after that m/c, we get yarn.
Experiment: 09

Experiment Name: Production calculation of simplex machine.

Introduction: Simplex is an important process in ring spinning. In this process

fibers are converted into low twist lea called roving. So it is also called roving
frame. The main function of roving frame is the attenuation of sliver. To draft the
sliver to reduce weight per unit length. The sliver which is taken from draw
frame is thicker so it is not suitable for manufacturing of yarn. By speed frame
sliver are converted to roving. This is appropriate for next process. Speed frame
is used to the carded and combed yarn process but for the rotor spinning system
this process can be eliminated.
Figure: (simplex m/c)

Specification:
1) Front roller carrier wheel :80T(A)
2) Twist constant change pinion carrier:30T(B)
3) Twist constant change pinion:30T(C)
4) Twist change pinion:28T(D)
5) Sprocket wheel:34T(E)
6) Sprocket pinion:36T(F)
7) Spindle carrier wheel:40T(G)
8) Spindle wheel:22T(H)
Simplex Production Calculation:
Problem 01: Calculate the TPI (twist per inch) produced on a simplex with
diameter of front roller 28 mm and its rpm be 30. The rpm of flyer is 1000.
Solution: Here, Diameter of front roller = 28 mm = 2.8 cm = 1.1024 inch
rpm of front roller = 30
rpm of flyer = 1000
TPI =?
We know,
Surface speed of front roller = π × Diameter of front roller ×rpm of front roller = π
× 1.1024 × 30 = 103.9 inch/min
Twist or TPI =Flyer speed or spindle speed (rpm)/Delivery speed (inches/min)
= 1000/103.9 = 9.63 (Ans.)
Problem 2: Calculate the TPI on simplex if the diameter of back roller is
15/16’’, rpm of B.R is 10, rpm of flyer is 1000 and draft is 6.
Solution: Here,
Diameter of B.R. = 15/16 = 0.9375 inch
Draft = 6
rpm of F.R.= 30
rpm of B.R = 10
rpm of flyer = 1000
TPI=?

We know,
Surface speed of B.R. = π × Diameter of B.R. × rpm of B.R = π × 0.9375 ×10 =
29.45 inch/min
Total draft= Surface speed of F.R./Surface speed of B.R
=> Surface speed of F.= 6 × 29.45 = 176.7 inch/min
Twist or TPI
= Flyer speed or spindle speed(rpm)/Delivery speed(inches/min)
= 1000/176.7 = 5.66 (Ans.)

Problem: 3 If, Spindle speed = 1600 rpm, Roving count = 90 Ne, TM (Twist
Multiplier) = 4.2, Efficiency = 85% then calculate the production of a speed
frame in lb/hr.
Solution: We know,
Spindle speed Production = Spindle speed /TPI
TPI = TM√(Roving count)
Efficiency = 85% = 85/100 =0.85
Now,
Spindle speed Production = Spindle speed /TPI
=1600 × 60 × 1 × 0.85 × 120 /4.2√.90 × 36 × 840 × 0.90
= 90.297 (Ans.)

Conclusion: Speed frame is the first machine which enables the winding of the
fibrous material on to a package. From this machine the fibre gets a circular shape
which is very advantageous to be used in ring spinning. So the importance of this
machine is very much. In this experiment we indicate different gearing diagram
of the twist inserting portion; specify it and calculate twist and twist constant. We
found a satisfactory result. So the experiment is a successful one.
Experiment: 10
Experiment name: Study on the material passage of Ring frame.
Object:
1. To produce required count of yarn from the supplied roving by the drafting.
2. To insert sufficient amount of twist to the yarn.
3. To wind the yarn on to the bobbin.
4. To build the yarn package properly.
Main Parts Ring Frame:
1. Creel
2. Guide roller
3. Trumpet
4. Drafting rollers
5. Yarn guide
6. Lappet
7. Balloon controlling ring
8. Traveler
9. Ring
10. Spindle
Specification:
1) Name of manufacturer: Platts.
2) No of spindle: 64
3) Ring diameter: 6.2 cm
4) Lift of the bobbin: 9”
Passage diagram:

Fig: Passage Diagram of Ring frame

Description:
The feed material come from speed frame i.e. roving bobbin is placed on the creel.
The creel which is attached to the machine is umbrella type. Then feed material is
passed under the guide rollers and through the trumpet in to the drafting zone. Here
some draft is inserted in to the roving. The draft system is 3 over 3 drafting system
with apron. The delivery material that is delivered from the front roller is reached
to the traveler over pneumatic waste collector, lappet and through balloon
controlling ring. Lappet is used to control the material path and balloon controlling
ring is used to control the balloon formation and spinning tension. Here roving is
twisted by the movement of the traveler around the ring. The yarn is then wound
on the ring cop.

Conclusion:
Our teacher and lab assistants are very much helpful to us. Their well teaching
and instruction help us greatly to understand this practical. I think this practical
will be very helpful in my future career.
Experiment No. :11
Experiment Name: Study on different types of ring traveler
and selection of ring traveler.
Introduction:

Traveller is a tiny element which is used in ring spinning system , acts

as the main of twist imparter during yarn production. On the other word
, it is also called the twisting element merely responsible for twist
impartion.It is a C-shaped, metal clip that revolves around the ring on a
ring spinning frame. It guides the yarn onto the bobbin as twist is
inserted into the yarn. The traveller allows the twisting and the correct
delivery of the yarn on the bobbin. The take up speed of the yarn, which
corresponds to the difference between the peripheral speed of the bobbin
and the peripheral speed of the traveller, is equal to the peripheral speed
of the delivery cylinders of the drafting unit. The difference between
spindle rpm and the traveler rpm, within a specific unit of time, gives the
number of coils deposited on the bobbin within a specific unit of time.
Therefore, with the same spindle speed, the traveller rpm increases
along with the bobbin diameter while the number of coils wound on the
bobbin decreases.

Objective:
1. To know about the types of traveler.
2. To know how selection ring traveler.
3. To know about function of ring traveler.
Figure (ring traveler):

Features of a Traveller:
1. Generate less heat.
2. Dissipate heat fastly.
3. Have sufficient elasticity for easy insertion and to retain its original
shape after insertion.
4. Friction between ring and traveller should be minimal.
5. It should have excellent wear resistance for longer life.
6. Hardness of the traveller should be less than the ring.
Types of Traveller:
Traveller are normally three types. They are:
1. OS -Type
2. 2)C-Type
3. 3)G-Type
Factors for Ring Traveller Selection :
1. Count of yarn to be spun
2. Fiber used in the yarn
3. Ring cup diameter
4. Spindle speed
Functions of Ring traveler:
1. Imparts twist to the yarn
2. It is responsible for winding the yarn onto the cop.
3. It defines Spinning tension.
4. It defines Winding Tension.
5. Traveller imparts twist to the yarn.
6. Traveller and spindle together help to wind the yarn on the
bobbin. Length wound up on the bobbin corresponds to the
difference in peripheral speeds of the spindle and traveller. The
difference in speed should correspond to length delivered at the
front rollers. Since traveller does not have a drive on its own but is
dragged along behind by the spindle.

Conclusion: Traveler is the most tinny and simple mechanical element

in ring frame which carries the most important function like simultaneous
twisting, winding, thread guide etc. We have discussed about features of
Ring traveller in another article.
Experiment: 12
Experiment name: Calculation of Ring Frame.
Introduction:
Ring spinning machine or ring frame is used to produce required count of
yarn from the supplied roving by the drafting.
Objective:
1) To insert sufficient amount of twist to the yarn.
2) To wind the yarn onto the bobbin.
3) To build the yarn package properly.

Production:
Spindle Speed x 60 x 24 x Total no of Spindles
1. Ring Frame (100% Production) = Count x TPI x 840 x 36 x 2.2046
2. Ring Frame (Actual Production) = 100% Production x Required
Efficiency Actual Production
3. Ring Frame (Required Input) = (100 – std waste)/100
4. Required TCP X Required TPI = Existing TCP X Existing T
5) TPI Calculation: TPI= T.M X √(Count)
(TM= Twist Multiplier)
6. Traveler speed = spindle speed – winding speed
7. Winding speed = front roll delivery (inches per min)/bobbin circumference
8. Traveler angle = bare bobbin diameter/full bobbin diameter
Ring Frame Production Calculation:
1. In a ring frame 30 Ne carded yarn is to be spun in which spindle speed is 17000
r.p.m and there are 504 working spindles. If the machine runs at 9% efficiency and
twist multiplier is 4.6 . Find out its production in lbs/shift.
Solution:
Given that, No of working spindle = 504 Spindle speed 17000 r.p.m Efficiency =
95% Time of production = 8 hrs Yarn count =30 T.M = 4.6 We know that,
T.P.I = T.M X √(Count)
= 4.6 X √(30)
= 25.195
Production per Shift = Spindle rpm X 60 X 8 X No of spindle X Efficiency T.P.I
X 36 X 840 X Count
=17000 X 60 X 8 X 504 95 X 25.195 X 36 X 840 X 30 100
= 170.93 lbs (Ans.)
2. Find out the required T.C.P to produce 49 Ne carded woven yarn when twist
multiplier is 4.6, existing T.C.P is 48T and existing T.P.I is 21.7
Solution: Given
that, Existing T.C.P
= 48T Existing T.P.I
= 21.7 T.M = 4.6

Produced yarn count = 40 Ne

Required T.P.I = ?
We know that, Required TCP X Required TPI = Existing TCP X Existing TPI
…………(1)
Again, we know,
Required T.P.I = T.M X √(Count)
= 4.6 X √(40)
= 29
From equation (1) we get,
Required T.C.P X 29 = 48 X 21.7
Required T.C.P = 48X 21.7 /29
= 35.8
= 36 T (Ans.)

Conclusion: This a very important experiment for us. From this experiment
we learnt how to insert sufficient amount of twist to the yarn, how to build the
yarn package properly which will help in our future life.
Experiment no: 13
Experiment Name: Different types of attachment used in ring spinning
system for the production of different special yarn.
Introduction:
The developments in spinning systems from mule spinning, cap spinning, flyer
spinning and then ring spinning to the today’s latest spinning systems like rotor
spinning, air-jet spinning shows an ultimate ways to produce yarn. However, the
versatility of ring spinning has created its own root in today’s spinning world. The
slub, compact and siro spinning are major developments in the history of spinning.

Objective:
1) To learn about ring spinning system.
2) To learn about special yarns produced in different spinning system.
3) To learn about different types of attachment used in ring spinning machine for
the production of special yarn.

Slub spinning: Slub yarn refers to yarn that has been purposely spun with
slubs (thicker sections along the yarn) while it was once seen only as a defect,
slub yarn is now intentionally created to give fabric more personality.

Fig: slub yarn

Affect the visual effect of slub yarn: There are four factors are affect the
visual effect of slub yarn. They are:
1) Number of slubs per kilometer (NSm)
2) Diameter (dia) of slub - Length of slub
3) Distance between slub.
Types of slub yarn on the basis of visual effect:
1) Pattern/regular slub yarn
2) Non-pattern/irregular slub yarn.
3) Multi-count slub yarn.
4) Both are pattern and non-pattern slub yarn.
Production of slub yarn in ring frame:
1. In the ring frame, there is a servo motor with slub gear and another with twist
gear.
2. Back and middle rollers get motion from the same gearing and the front
rollers get motion from separate gearing.
3. Slub is produced by the speed variation of back and middle rollers.
4. Break draft is always maintained properly, otherwise roving breakage will be
created.
5. Back roller speed will be increased continuously after a certain time. As a result
more material will be feed, whereas during that time the draft of front zone remains
constant. So a thick place in the final yarn will be created after a certain time.
6. The controller controls the following: After how much time (mili second) the
speed of back roller will be increased. How longer the increased speed will
remain. Amount of speed that to be increase.
7. Twist gear is optional; the speed of front roller is fixed when twist gear is
not used.
8. Twist is controlled by changing the speed of front roller.
Fig: Slub yarn production in ring frame.
End use of slub yarn:
Slub yarn is used in traditional fabrics such as upholstery, lace, curtains and
household fabrics in general. But it is becoming more popular in the production
of denim on ring spinning, shirting and knitwear.
Compact Spinning:
The compact spinning is a process where fiber strand drawn by drafting system is
condensed before twisting it. Following methods are used by machine manufacturers
to condense the fiber strand. - Aerodynamic condensing. - Mechanical condensing. -
Magnetic condensing. The most important requirement for perfect compact yarn is
complete parallel arrangement of fibers and close position before twist is imparted.
By keeping this point into consideration different machine manufacturers have
developed different methods of compact spinning.

Fig: Compact yarn production in ring frame.

Advantages of Compact Spinning:
Improvement in tensile properties, reduced hairiness as well as improved regularity
of a yarn are the key benefits of compact spinning. Here some of the advantages of
compact spinning are discussed.
Advantages in Spinning:
1) As maximum number of fibers are integrated into yarn body during spinning,
so better utilization of fibers at the same time less fly generation and clean
atmosphere is spinning department.
2) Yarn twist can be reduced by 10% while maintaining the same strength as
the conventional ring yarn.
3) Therefore, it is possible to increase the machine speed which ultimately
results into increased production.
4) The weak point in the spinning zone (spinning triangle) is eliminated, the
end breakage rate is considerably reduced which again leading to higher
machine efficiency.
5) Increased strength and breaking elongation of yarn due to less protruding fibers
and improved orientation of fibers, which leads to full realization of fiber strength.
6) Appreciable reduction in hairiness due to virtually elimination of spinning
triangle.
7) Less expensive raw material can be used to produce good quality yarn.
8) Significant reduction in IPI, results better yarn quality. Singeing can
be completely eliminated.
9) Noil % at comber can be reduced as short fibers are better integrated into yarn
body during spinning.
10) The improved characteristics of compact yarns gives higher yarn sales price.
Disadvantages of Compact Spinning:
1) Higher capital cost of the machine due additional condensing zone in
drafting system.
2) Increased maintenance of condensing zone which adds to cost.
Siro Spinning:
Traditionally, two-fold yarns have been used for weaving because they are stronger,
and the twisting operation binds the surface fibers into the yarn structure so that it is
smoother and more resistant to abrasion during weaving. The Siro spinning process
adapted some of the self-twist discoveries of CSIRO to the ring spinning technology
of the worsted system, and combined spinning and doubling in the one operation.
The technology maintains two separate strands during the
spinning process, and this allows a number of fibre-binding mechanisms to
operate before the strands are twisted about each other. An important aspect of the
Siro spinning system is a simple device to break out the remaining strand if one of
the strands should be accidentally broken. Siro spinning is especially suited to the
production of lightweight trans-seasonal fabrics, and a significant proportion of
the world’s worsted spinning installations have been converted to this cost-saving
and innovative SIRO technology.

Fig: Siro yarn

With the Siro spinning process, a special spin-twisted yarn can be produced directly on the ring-
spinning machine. In this process, two ravings are led in parallel through the drafting system,
separated by two specially developed condensers, and drafted separately. The twist is introduced
as for a normal single yarn by means of ring and traveler. The roving strands, which are drafted
parallel, are combined after passing the front rollers at the exit from the drafting system, with
some twist being produced in the individual strands right up to the nip point. Once past the front
roller of the drafting system, the two strands are combined producing a twofold-like yarn. The
yarn has uni-directional twist like a singles yarn but the fibers are bound sufficiently for the yarn
to survive weaving.
Fig: Siro yarn production in ring frame

Advantages of siro spinning:

1) Reduces wool spinning costs by avoiding one stage.
2) Advantageous to fabric producers.
3) Advantageous to garment makers, and wool growers.
Conclusion:
Present review is taken to understand the root causes which are influencing the
major yarn characteristics on conventional ring frame. Many researcher's and
industrialists have already shown the improvements in yarn characteristics and
thereby improvement in subsequent process efficiency by adoption of compact,
slub and siro spinning technology. However, despite of few disadvantages the
compact, slub and siro spinning system can be a system of future.