PRESENTATION ON YARN

SPINNING PROCESS

SUBMITTED BY:

ABHINAV SETH
OFFICER
EXPORTS MARKETING
 WHAT IS YARN?

o A long continuous twisted bundle of natural or

synthetic fibers.
o Used for sewing, knitting, weaving, embroidery
and rope making.
o Thread is a type of yarn used for sewing by hand or
by machine.
o The most common plant fiber used to manufacture
yarn is ‘cotton- a natural fiber.’
o Most commonly used animal fiber is ‘wool.’
 TYPES OF YARN BASED UPON
MANUFACTURING PROCESS
 Ring Spun Yarn- It is the yarn that is manufactured in our
units. The yarn used in weaving process which is set
vertical/horizontal to the loom in different parallel layers. It is
also used in knitting process.
 Compact Yarn- This yarn has its fibers compacted inside. It
has good strength and is also of fine quality.
 Open end Yarn- It is a type of yarn that is manufactured on
Autocoro- 480 machine, consisting of 480 rotors.
 Eli- twist Yarn- When two bobbins are placed in a ring- frame,
drafting of yarn is done from them and the yarns from both
bobbins are twisted to form a finer form with very less
hairiness. It is different from two- plied yarn.
 Two plied Yarn- It is a type of yarn manufactured on TFO
(Two For One) machine.
 TERMS RELATED TO YARN
CONTINUED….

ZERO TWISTED YARN

The PVA (Poly Vinyl Alcohol) yarn of higher count
is generally twisted in opposite direction with the
yarn of required count.
By twisting the yarn in opposite direction, the
cotton fibers open up and adds benefit to the yarn.
De- twisting allows the air to reach the inner parts
of the yarn much faster and decreases the time for
the fabric to dry.
The PVA is added to make cotton yarn intact
during the weaving process. When yarn is dyed,
the PVA dissolves, and leaves behind the zero-
twisted yarn.
 TERMS RELATED TO YARN
CONTINUED….

ZERO TWISTED YARN

 When yarn is dyed, the PVA dissolves, leaving

behind the zero- twisted yarn.
 This yarn is 30% lighter than the regular twisted
yarn.
 It is softer than regular twisted fabrics.

 It dries much faster. It is manufactured for making

towels.
 Warp Yarn

Zero Twist Yarn YARN Weft Yarn

Elite/ Compact
Yarn
 YARN SPINNING PROCESS
Blow Room

Bale Vario Clean

Plucker

Loptex Flexi Clean Unimix

Carding Draw Frame Lap Former

Breaker
If required

Draw Frame
Combing
Finisher

Speed Frame Ring Frame Winding

 BLOW ROOM PROCESS

BALE PLUCKER MACHINE

 In a blow room bales are laid down.

 Each bale avg. weight of 170kg.

 Hand plucking is done first.

 Bale plucker machine passes over through the bales

to open the bales and loosen the cotton fiber.
 It has large spikes which pluck the cotton fiber and
opens the bales to fluff- up cotton.
 BLOW ROOM PROCESS
CONTINUED….

VARIO CLEANER MACHINE

 It cleans the cotton.

 It is also known as coarse cleaner.
 It opens the cotton, cleans it and de- dusting is
done.
 It removes micro- dust and seeds.
 It has a roller that strike cotton with iron/steel bars
known as beaters.
 Beaters strike the cotton and knock out the seeds.
 BLOW ROOM PROCESS
CONTINUED….

UNIMIX MACHINE

 The word has been derived from two words- ‘Uni’

derived from Rieter machine and ‘Mix’ derived
from process of mixing cotton.
 It acts as a blender.

 In most cases it has 6-8 chambers.

 It stores the cotton and mixes it.

 Mixing is done to provide uniformity in cotton.

 BLOW ROOM PROCESS
CONTINUED….

LOPTEX (SORTER MACHINE)

 It is also known as sorter machine.

 It works on two principles- optic and sonic.

 Optic sensors- It detects the colored material and

removes them from the cotton.
 Sonic sensors- It detects the uncolored material
and removes them from cotton. It detects same
color material as of cotton, such as feathers, white
polythene.
 BLOW ROOM PROCESS
CONTINUED….

FLEXI CLEAN MACHINE

 It removes trash from cotton with the help of saw

tooth or needle beaters.
 It removes contamination such as dust, plastic, rope
and wrapper.
 Most contamination is removed by this machine.
 CARDING PROCESS
CARDING MACHINE

 After blending, the cotton is blown with the help of

air to the chute- feeds and passed on to carding
machine.
 It is the heart of spinning process.

 It has spikes through which cotton passes over.

 It forms the web of cotton in the machine.

 It has a big roller surrounded with the smaller ones

having small teeth to make cotton finer and form
sliver. The sliver has trailing hooks.
 Sliver is drawn out of the machine and rolled in the
cans.
 CARDING PROCESS

DRAW FRAME BREAKER

 It takes input of 4 or more cans of the carded sliver

from both the sides. The input has leading hooks.
 It parallelizes the fibers of sliver.

 It makes the fibers parallel and even.

 The output contains trailing hooks.

 COMBING PROCESS
LAP FORMER

 It takes input of trailing hook sliver of draw frame

breaker.
 The laps are formed.

 Rollers compress the sliver.

 The sliver is collected in the form of lap and contain

leading hooks.
 COMBING PROCESS
CONTINUED….
COMBER

 It takes input of 6-8 laps.

 Top comb combs the leading hooks.

 Removes short fibers (or noil).

 The combed sliver is drawn out and may contain

minimized number of hooks.
 FINAL STAGE
DRAW FRAME FINISHER

 It
 It has an autoleveller to maintain the count
variation of the sliver, so that yarn of required
count can be manufactured further.
 It also extracts dust through dust system.
 FINAL STAGE
CONTINUED….
SPEED FRAME

 It includes drafting and winding process.

 It has top and bottom clearer device with suction of
waste.
 It drafts the sliver of draw frame finisher.

 Roving is made from the sliver.

 The roving is false twisted.

 Roving is winded on to the bobbins.

 FINAL STAGE
CONTINUED….
RING FRAME

 It takes input of speed frame.

 It has drafting system.

 Processes yarn out of the roving.

 Yarn is winded on to the tube.

 It also evacuates waste through drum filter.

 OPEN END SPINNING
INTRODUCTION

 The reusable waste from the ring spinning and

some virgin cotton is taken to the blow room in
open end.
 It is a process of creating yarn without the use of
spindles.
 It is also known as rotor spinning.

 Less cost is involved in this process as compared to

ring- spinning.
 BLOW ROOM PROCESS

BLENDOMAT MACHINE

 The bales are laid down.

 This machine passes over the bales.

 It sucks cotton fiber from the bales.

 With the help of blades attached in it, it opens the

bales and makes the cotton fluffy.
 BLOW ROOM PROCESS
CONTINUED….

FRASSO MACHINE

 After Blendomat machine, the material is sent to

the Frasso machine.
 It helps in removing dust particles, iron and wood
contents and cotton seeds from the cotton.
 BLOW ROOM PROCESS
CONTINUED….

SPARK DETECTOR

 After removal of dust, wood contents and cotton

seeds in Frasso, the cotton is sent to the Spark
Detector.
 It detects any sparking material in the cotton.

 If any sparking material is detected by its sensors in

the cotton, then the whole process stops and that
material is sent for dumping.
 BLOW ROOM PROCESS
CONTINUED….

VETAL

 After getting passed through Spark Diverter the

cotton is then sent to Vetal.
 It is a metal detector.

 If any metal is detected the Vetal will stop

functioning and metal is sent to the waste removal
system.
 BLOW ROOM PROCESS
CONTINUED….

CL-P

 It helps in removing contamination from cotton.

 It detects any colored material in the cotton.

 Its function is similar to Vario Cleaner machine.

 BLOW ROOM PROCESS
CONTINUED….

ASTA/MK

 After passing through CL-P, the cotton is sent to

ASTA/MK.
 It detects the heavy material like dust particles
and stones and sends them to the dump.
 BLOW ROOM PROCESS
CONTINUED….

MPM (MULTI PRE MIXTURE)-8

 It has 2 lines having 8 chambers in each line to store

cotton in advance if there is any breakage in CL-P.
 Both the lines store cotton and keep the further
process to continue for production.
 BLOW ROOM PROCESS
CONTINUED….

DX- DUSTEX

 After MPM-8, the cotton is then passed or sent to

the DX- Dust Tex machine.
 It opens the cotton by stretching it more and
removes dust with the help of filters attached in it.
 BLOW ROOM PROCESS
CONTINUED….

MATERIAL TRANSPORT FAN

 The material of both the lines is sent for carding

process with the help of Material Transport
Fan at two ends for both the lines.
 CARDING PROCESS
CARDING MACHINE

 The material sent through the material transport

fan is used for carding process.
 The carding process is similar to the previous
carding process of yarn spinning.
 The material then passes through the draw- frame
breaker and draw- frame finisher.
 The only difference lies in open- end spinning is,
there is no comber, no speed frame and no ring
frame involved in this process as compared to ring-
spun yarn spinning.
 CARDING PROCESS
DRAW FRAME BREAKER

 After carding the sliver is then sent to the Draw

Frame Breaker machine.
 It is used to make more fine sliver from the input of
4 cans sliver.
 The input is turned to a single sliver by
compressing the sliver and stretching it to form fine
sliver.
 It is again rolled in the cans and sent for further
processing.
 CARDING PROCESS

DRAW FRAME FINISHER

 After draw frame breaker, the material is sent to

finisher draw frame.
 Here the material is turned to more fine form of
sliver.
 WINDING PROCESS
WINDING MACHINE

 At last, the material is then sent to the Autocoro 480

machine.
 The 480 here refers to the number of rotors in the
machine to produce yarn.
 The sliver is put in condenser.

 Feed roll opens the sliver.

 Sliver is then sent to the rotor, to make final yarn

out of it.
 WINDING PROCESS
WINDING MACHINE

 The rotor moves at very high speed. Higher the

speed, finer will be the yarn.
 The navel then passes the material to doff cube
to manufacture yarn.
 Yarn is then winded on to the cones according
to the count.
 The Autocoro 480 has Coromat machine
attached to it to remove any breakage in the
yarn.
 WINDING PROCESS
 WINDING MACHINE

 Coromat machine detects the breakage in yarn and

robot in it joins the yarn with the help of automatic
piecing system.
 The Doffing system is programmed for the
quantity of the material or count and related length
to be winded on the cones.
 The material is then set on trollies and passes on
through the same conditioning and packing process
as involved in spinning of ring- spun yarn.
 PACKING PROCESS
 After getting the material ready from the TFO (two
for one)/ link coner, the material is set on the big
trollies to get it ready for the conditioning process.
 Each trolly has different coloured cone tips
according to the counts and yarn type.
 The cones are then tested in the UV (Ultraviolet)
room to detect any other variation that cannot be
seen with the naked eyes. It is generally done to see
the variation in the cotton type and shade. If yarn is
having variations in it will be detected with high
intensity in the UV- room.
 PACKING PROCESS
CONDITIONING PROCESS

 To maintain the moisture level and strength in the

yarn, the cones are sent to the pre- conditioning
room.
 Moisture is added to the yarn with the help of
steam.
 Later, the yarn is taken to the yarn conditioning
room.
 Xorella machine is used to add moisture in the
yarn.
 PACKING PROCESS
CONDITIONING PROCESS
 XORELLA MACHINE
Cycle/Type Unwaxed Waxed
Temperature 70 60
(Celcius)
Cycle I Vacuum 180 150
Time 5 5
(minutes)

Temperature 75 65
(Celcius)
Cycle II Vacuum 200 170
Time 25 25
(minutes)
 PACKING PROCESS

 After conditioning, the material is then taken out

for segregation process and sent for further
packing. There are different segregation counters
according to the type and count of the yarn.
 The segregation counters have boards mentioning
the lot number, count and cone tip colour. The
material is packed in transparent polythenes and
then sent further for final pallet or carton packing
according to the requirement of the customer.
 PACKING PROCESS
CARTONS DESCRIPTION

 Count
 Gross weight

 Net weight

 Excise no.

 Carton no.-

 Lot No.
 PACKING PROCESS
LOT NUMBER SPECIFICATION

 R- 138211601. Here R stands for RAHON, 1 stands

for unit number, 3 is the last number of the year, 8
is the series for carded slub, 2 is used for weaving
OR 1 for hosiery, 1 denotes single yarn, 16
represents the count and 01 represents the lot
number.