Advance_spinning_System_Introduction (1).pptx

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1.  Spinning and its types Introduction Ring spinning Open end or Rotor spinning Advance spinning system COMPACT SPINNING AIR JET SPINNING VORTEX SPINNING FRICTION SPINNING SIRO SPINNING

2.  Spinning – technique to convert short staple fibers to continuous filament called yarn by adding twisting and winding Spinning Process - as in picture Types Ring spinning Open end/ rotor spinning Air jet spinning Friction spun Core spun Siro spun

3.  Invented : 1830 in America It is the most common method of spinning cotton, flax, or wool into a yarn In this process, the staple fibers is twisted into yarn and simultaneously wounded on to the bobbin for storage Here, roving (creating extension- length), is done by using drawing rollers , then spun and wound around a rotating spindle which in its turn is contained within an independently rotating ring flyer spindle Drawing rollers does roving work

4. Drawing rollers Spindle and ring

5. Any natural fiber can be spun in ring spinning Any variation in twist , count, strength and density can be made. Thus making it extremely popular yarn making technique The fine fibres are tightly twisted together in ring spinning, which results in stronger, cable-like yarn. Ring spun yarns yield a strong and more durable fabric . Thus ring spun yarns have superior yarn quality and extremely versatile yarn. Low cost of labour is one more merit Machine generates more heat & low production Rate – DEMERITS Video Link: https:// www.youtube.com/watch?v=AqbSILhN0LM

6.  Invented in 1963 in Czechoslovakia  Other names OE, rotor, break spinning  Open end spinning is a technique that is used to make yarns without using a spindle (unlike ring spinning)  Process: In this the sliver is separated into single fibers and brought into the region using jet of air , and further twisting and winding is done Video Link: https:// www.youtube.com/watch?v=TEk9KM835kg

7. The uniform texture of ring spun yarn and the coarse surface of open end yarns

8. • • • the carded sliver is fed into the roller then into the combing roller which eliminates the trash Further through the transport channel it reaches the doffing tube , where with the help of air the loose fibers are twisted and made into a yarn and wound

9.  Principle: The working mechanism of OES resembles that of a washing machine/ domestic wet grinder used in a kitchen  Where when one set of item is tried to pull out , it will be pulled back by the motor inside due to the kind of pressure it creates.  The sliver is passed into the rotor, where it is spun and the yarn comes out which is wrapped on a bobbin  Properties: Open end spinning result in rough fabrics since there is no proper mechanism involved in making the yarn but just the fibers are blown together which results in a bound thick yarn.

10.  The yarn will have fibers that are not arranged uniformly : fibers are not parallel and just crisscross laid.  These OE spun yarns are mostly thick and coarse and can be used for bed sheet and carpets . The cloth has fuzzier feel and poor wear properties There is no roving stage and re-packaging stage in this OE spinning process Less labour intensive Faster than ring spinning with rotor speed of 140,000 rpm . Typical yarn count : 6s to 50s

11. Carding waste is used for making an OE yarn Common method of spinning – ring spinning

12. Compact spinning  Rotor spinning,  Air Jet spinning,  Vortex spinning, Friction spinning,  Siro spinning  Ring spinning  Open end spinning  Dry  Wet  Melt spinning

13. ADVANCE SPINNING SYSTEMS – USES A FORM OF ENERGY COMPACT SPINNING AIR JET SPINNING VORTEX SPINNING FRICTION SPINNING SIRO SPINNING Spinning system began with mule spinning (wool), cap spinning and flyer spinning to ring spinning, rotor spinning and air-jet spinning shows an ultimate ways to produce yarn

14. T h i s i s u s e d t o c r e a t e be tt e r q u a l it y y a r n s t h a n t h e c o nv e n t i o na l ring spinning. T h i s i s do ne i n t he d r a f t i n g a re a , w he r e t h e f i b r e i s c o nde ns e d before twisting it. T he p r o c e s s o f c o n de n s i n g i s do ne b y u s i n g a e r o d y n a m i c , mechanical and magnetic energy . Video Link: https:// www.youtube.com/watch?v=FcZmVL941Lw

15. W o r k i n g : E g : C o n de n s ing u s ing aerodynamic force (air)  The delivery bottom roller of drafting system is replaced by perforated (holes) drum.  The fixed suction system under the perforated drum creates vacuum, which generates air current on drum and this air current helps to condense the fiber strand.  This condensing of fiber strand considerably reduces the width and we get compact spun yarn. Perforated drum that works like vacuum to suck and condense fiber

16. Point to remember: To get the perfect compact yarn, a very good parallel arrangement of fibers and also close positioning of the fibers before twisting is imparted should be observed Picture: Compactness in ring and compact yarn

17. Advantages of Compact Spinning Improvement in tensile ( strength ) properties Reduced hairiness as well as improved regularity Less dust : As maximum number of fibers are integrated into yarn body during spinning B e t t e r ut i l i z at io n o f f i ber s – l e s s f l y i n spin n i n g m i l l – c le an a t m o s p h e r e - EFFICIENT PRODUCTION Faster and efficient production Better character of yarn – high price Singeing – not needed for compact yarns (SINGEING is a process of subjecting yarn to flame, where short fibres are burnt away- resulting in a smoothen yarn)

18.  In this method – yarn is formed by twisting in two directions resulting in an air jet spun yarn  Air is used in creating the twist in both the regions  extremely high production rate – SPEED is the most important feature of air jet spinning

19.  Usually number of twist affects the production rate but in air jet spinning, no matter what the twist is, production rate is always high  Air jet yarns are made at a faster speed regardless of any yarn count Video Link : https:// www.youtube.com/watch?v=MR0KcJYp5Ic

20. TWO DIFFERENT TWISTS ARE GIVEN IN TWO DIFFERENT AREAS

21. The PRODUCTION RATE OF AIR JET / vortex spinning is 10 - 20 times high than ring spinning 3 - 5 times higher than rotor spinning and, similar to rotor spinning, vortex is also cheap to produce with less number of steps  Air jet yarns are more uniform that rotor , but more weak and harsh than ring spun yarn  Air jet spun yarns are mainly used in polyester/cotton blended yarns Eg.: Polycotton shirts and woollens.

22. Properties of Air-jet spun yarn  Less hairiness & Clear appearance  High resistance to Pilling & abrasion  High moisture absorption  Less shrinkage  High wash resistance  Less elastic and rough than ring and rotor Ring Compact spun R o t o r Air jet

23. RING SPINNING ROTOR SPINNING/ OE COMPACT SPINNING AIR JET SPINNING VORTEX SPINNING FRICTION SPINNING SIRO SPINNING

24.  As a variation of air jet spinning - Vortex spinning use high speed airflow to insert twist  In the vortex system, drafted fibers are fed using spindle and air to make a yarn (drafted fibers are introduced into a spindle orifice by an air vortex)  While entering and passing th r o u gh the o r i f i c e , f i ber s ar e t w i st e d b y th e s w i r l i n g (mo v i n g ) air VORTEX SPINNING Imagine sucking rice flakes (aval/pori) using a straw - technique

25. VORTEX SPINNING

26. Vortex yarn has core and sheath It can deliver yarn at up to 400 mpm (meters per minute) Better resistance to pilling and abrasion Less hairiness Less shrinkage B e t t e r M o i st ure a b s o rp t i o n a nd d r y i ng – make it better than a ring & rotor spun yarn VORTEX SPINNING

27.  N o w , i t i s v e r y d e s i r a bl e s pi n n i ng system  High productivity rate  Y a r n s t r uc t ur e i s s i m il ar t o r i ng yarn  Low hairiness  possible to use a wider fibre length – different structures can be created  Spinning rayon & polyester products – vortex – commonly used – moderate anti-pilling property, luxurious lustre and softness VORTEX SPINNING

28.  Invented - 1973 – Ernst Fehrer Process of yarn making is done by means of friction in the spinning zone ( similar to OE ) – drum rotate in opposite direction and impart twist to fiber  Also called as DREF spinning  C r eate s c o a r s e y arn ( 1 00 - 140%more bulky than ring) High delivery rate of 300 mpm

29.  Opening and individualisation of fibres from slivers by opening (carding) roller  Reassembling of the individualised fibres by suction system  Twisting of fibre assembly by friction drums  Withdrawal of resultant yarn by take up roller

30. PRINCIPLE  Pre-opened fibres were made to fall onto a perforated cylindrical drum, the rotation of which imparted twist to the fibre assembly  Due to the problems in controlling the flow , yarn slippage will occur between the fibre assembly and the perforated roller , which will reduce the twist efficiency

31. Advantage :  No of twist per unit length in 1 revolution is high in friction spinning  Very high production rate - Upto 300 m/min  Wide range of fibers can be made  Large package can be made  Rewinding is not required

32. Merit  The yarn will look like a ring spun yarn but the fiber orientation is different  Higher production speed than conventional system  Can produce multi component and hollow yarns  Bulky and soft than ring and rotor De- Merit  Inferior fiber orientation & loose packing of fibers  Twist not uniform – loopy structure  Lower tenacity (strength) – weaker than other yarns  Higher snarling (curl in a yarn)  Poor performance as a yarn  Fibers easily get disorted (damaged)  Air consumption is high (energy)

33. APPLICATION OF FRICTION SPUN YARNS  Blankets, carpet, cleaning rags and mops from cotton waste  fancy yarns for interior decoration and domestic textiles shoes, ropes and cables filter cartridges for liquid filtration leisure wear, pullovers , suits and outer wear fabrics. heavy protective industrial fabrics such as heavy flame retardant fabrics, conveyor belts, clutch and brake linings for the automobile industry, packing materials, gaskets and other asbestos substitutes, recycling of selvedge wastes from the weaving sector, aramid- fibre yarns used in fire protection clothing , bullet proof vests insulators etc.

34. PRINCIPLE TWIST ON TWIST METHOD (ZZ OR SS IS USED. AND CREATES A MUCH COMPACT YARN THIS IS BETTER THAN ZS OR SZ

35. Invented by Jim Lappage (CSIRO) – 1968 Similar to ring spinning – but two rovings are fed and twisted together and made as a double yarn Usually two ply are used in weaving to ensure strength and smoothness Considering that, spinning and doubling combined as one was done in Siro spinning , where the resulted siro spun yarn can be directly used for weaving Today 7% of world wide spinning is siro spinning. Mainly for wool and cotton Low production cost, low hairiness and imperfections Used in making lightweight and very good quality fabrics

36. RING ROTOR FRICTION AIRJET