STAPLE / FILAMENT

YARN SPINNING SYSTEMS

STAPLE YARNS:

Yarns can be made of staple fibres by any one of several

techniques

The method used is depended upon factors such as:

8. Manufacturers preference of equipment

9. Economic implications
10. Fibres to be used
11. Desired properties of the yarn
The value and character of yarn are determined by

3. Kind and quality of fibre

4. Amount of processing necessary to produce fineness
5. Amount of twist which increases strength in the final yarn

Staple spinning Processes:

• Conventional ring spinning
• Open end spinning or rotor spinning
• Friction spinning
• Self twist spinning
• Electrostatic spinning
• Vortex spinning
• Air-jet spinning
• Twist less spinning (Twilo)
1. Conventional ring spinning:

The roved sliver passes through several sets of rollers

running at successively higher rates of speed and is finally
drawn out to yarn of the size desired

Ring spinning is more suitable for the cotton yarn mass

production. The highest rpm and constant spinning action
provides fast operation.

It completes yarn formation through 3 steps.

Drawing out the roving
Inserting twist
Winding the yarn on bobbins
2. Open end spinning (O-E) or rotor or break spinning

A relatively recent devpt. in the production of spun yarn

This technique is widely accepted as a satisfactory process

for spinning coarser yarns of counts of upto about 40

The open end spinning begins with the carded sliver, which
Passes through a set of rollers revolving at progressive speeds
there by completely opening the sliver.
The fibres are fed individually by a stream of air
in to the inner groove of funnel shaped rotor
rotating at a very high speed.

The centrifugal force of the rotor builds up a multi

layer of fibres which is peeled away from the
collecting groove as it is simultaneously twisted by
the rotation of the rotor and withdrawn continuously,
thus being formed in to a yarn.
RING SPINNING OPEN END SPINNING

Bobbin rotates constantly for Spool does not need to be

insertion of twist rotated to insert twist

Cannot handle spools of Much larger spools

bigger size can be wound

Can spin finer yarns Can spin coarser/ carded yarns

Faster production 3-5 times faster than ring

spinning

Uniform and strong yarn Uniform but flexible yarn

with better dye ability
RING SPINNING OPEN END SPINNING

Combed yarns (finer) Carded yarns (coarser)

Yarns for varied Yarns for heavier fabrics

applications such as denims, towels and
poplins

Stronger 20% more twisted but 15-20%

weaker as the yarn is coarser

Suitable for all staple Not suitable for man-made

fibres staple fibre spinning except rayon
as the fibre finish clogs the rotor
• Friction spinning

Commercialized under the trade mark DREF

It is a variation of the Open end spinning system

The principle of the technique is that passing along the

longitudinal drum axis a stream of carded fibres
in the roll nip of perforated drums, both of which are
rotated in the same direction.

This action forces the fibres to be wedged along the nip

there by becoming compressed; The friction of the rollers
cause the fibres to twist around each other
1. Self twist spinning:

A process developed for wool and wool like fibres

Pairs of rovings are drawn out on a succession of

drafting rollers, the last set of which moves sideways
causing a rolling action of the strands to wraparound
each other

Some times additives are used for the cohesion

The self twist process can spin worsted yarn of good quality
upto 10 times faster than conventional spinning
1. Electrostatic spinning

The technique utilises a non uniform electrostatic field

which can efficiently separate short staple fibres from
the long staples to produce a yarn of more strength and
uniformity

Twilo: A twist less spinning process, which forms a yarn

by temporarily binding the fibres together with an adhesive
(water soluble agent) and subsequently removing the
adhesive after the yarn has been made in to a fabric
Filament yarn spinning systems:

3. Wet spinning
4. Dry spinning
5. Melt spinning
6. Bicomponent spinning
7. Biconstituent spinning
8. Film splitting
9. Integrated multicomponent yarns
10. Coverspun yarns
11. Selfil tyarns
12. Aerodynamic spinning
Bi component spinning:

The technique involves extrusion through a spinneret

of two different types of the same polymer

There are three methods of bicomponent yarn production

7. Side by side extrusion
8. Extrusion through one spinneret enclosed in an other
9. Distribution of drops of molten polymers
Bicomponent fiber
/yarn
Biconstituent spinning:

This technique utilizes two different polymers that

are combined and extruded in the same manner

Film Splitting:

Melt extrusion of polymer through a wide die but with

a very narrow slit to form a sheet of film which is later
broken /cracked by mechanical means in to a mat of fibres
Or embossed with a roller having patterned indentations
to fibrillate the film
Integrated multi component yarns:

1. Integrated composite spinning(ICS)

The process entails passing a monofilament or
a multifilament strand (Carrier) through a poly propylene
Polymer (binder resin) and then immediately embedding part of the
length of staple fibres in to the polymeric resin

Different types of staples of different sizes and colours

can be used to incorporate desirable properties, effects and
appearances.
2. Cover spun:

The technique wraps fine continuous filament man made fibre

around a core of untwisted natural or man made staple fibre
to produce yarns in a wide range of counts.

Selfil: The self twisted staple core is initially wrapped with a

filament yarn in alternating S and Z phases; a second filament yarn
is then wrapped around these in alternating opposite Z and S twists.

Aerodynamic Spinning: This system passes a continuous

Multi filament yarn together with staple fibre through a
Pneumatic device which causes the filaments to twist and curl
entrapping the staple fibres in the snarls.
Types and characteristics of yarns:

• Single yarns
• Ply or folded yarns
• Doubled yarns or compound yarns
• Cabled yarns or cords
• Textured yarns: Stretch yarns, Bulk yarns
• Novelty yarns:
• Slub yarns
• Flake yarns
• Spiral yarns
• Ratine yarns
• Boucle, Loop or Curl yarns
• Nub, Knop, Knot or Spot yarns
• Chinelle yarns
Varieties
Boucle
Loop
Gimp
Nep
Chenille
Corkscrew
Core spun
Metallic
Novelty yarns / Fancy yarns / Complex Yarns
ASTM defines fancy yarn as:

A yarn that differs significantly from the normal appearance

of single or plied yarn due to the presence of irregularities
deliberately produced during its formation.

In single yarns the irregularities may be due to the inclusion of

knots, loops, curls, slubs and the like.

In plied yarns, the irregularities may be due to a variable

delivery of one or more of its components or twisting together
dissimilar single yarns.
Slub yarns:

Slub yarns have soft untwisted areas at frequent intervals

throughout their length.

They are coarse with slight twist, having varying d

diameters that show irregularities typical of an
incomplete spinning operation

Features: simulates linen yarn

not durable
used in shantung and tweeds
Flake yarns:

Variation of slub yarn

The flake or slub effect is made by inserting

soft, thick tufts of roving between binder yarns at
intervals.

Spiral yarns or Cork Screw yarns:

The general appearance of spiral yarn is that of a coarse yarn

wound around a fine yarn giving the effect of a spiral.
The thicker yarn is given a slack twist and wound
spirally around a finer yarn which is given a hard twist.
Ratine yarns:

A variation of spiral yarn : The outer yarn (effect) and

the core yarn are twisted in a spiral manner, but
at intervals a longer loop is thrown out by the effect yarn
which kinks back on itself and is held in place
by a third (binder) yarn.

Boucle, Loop or Curl yarns:

These yarns are comparable to the ratine yarns but in this type,
the yarns are more softer with more pronounced
novelty effect or loops
Nub, Knop, Knot or Spot yarns:

The effect ply is twisted around the core ply

many times within a very short space, causing bumps or nubs
that may be spaced at intervals along the yarn.

‘Chenille’ yarns: the name derived from French Caterpillar

It is a yarn with a velvet like or pile surface.

The effect is achieved by a core of two yarns plied together
and firmly holding short tufts of soft-twisted yarns
between the twists along the core’s length.

A leno weave fabric with soft filling yarns held within the
twists of the warp is split in to strips between the warps