Compact Yarn
S.M. Farhana Iqbal
Associate Prof.
BUTEX
INTRODUCTION
The developments in spinning systems from mule
spinning, cop spinning, flyer spinning and then ring
spinning to the todays latest spinning systems
like rotor spinning, airjet spinning shows an ultimate
ways to produce yarn. However, the versatility of ring
spinning has created its own root in todays spinning
world. The compact spinning is one of the major
development in the history of spinning, as the
improved properties of compact yarn over
conventional ring yarn.
BASIC PROBLEMS ASSOCIATED WITH
CONVENTIONAL RING FRAME
The width of fiber strand fed is always more than width of
spinning triangle. The width of spinning triangle is dependent
upon spinning tension and is directly related with spinning
tension. Basically, the restriction of twist flow to the front
roller nip, because of spinning geometry, causes the formation
of spinning triangle. The fibers at selvedge of fiber strand,
delivered by front roller may not get fully integrated into yarn
body or they may gets lost through pneumafil suction tube (PN
waste), because in the spinning triangle, the selvedge fibers are
always at very high tension than inner ones and due to
improper integration of selvedge fibers into yarn, the hairiness
rises up.
BASIC PROBLEMS ASSOCIATED WITH
CONVENTIONAL RING FRAME
BASIC PROBLEMS ASSOCIATED WITH
CONVENTIONAL RING FRAME
Also the spinning triangle is the major weak place in yarn
formation zone and therefore most of the end breaks in ring
frame are occurring in spinning triangle and which is largely
influencing the machine efficiency. Therefore it needs to have
control over formation of spinning triangle and which is made
possible by compact spinning.
WHAT IS COMPACT SPINNING?
COM4 SPIN SYSTEM OF RIETER
In this system, the condensing is done by aerodynamic force.
The delivery bottom roller of drafting system is replaced by
perforated drum. The fixed suction system under the perforated
drum creates vacuum, which generates air current on drum. The
air guide element plays important role in condensing process,
as air is guided by air guide element & this air current helps to
condense the fiber strand. This condensing of fiber strand
considerably reduces the width of spinning triangle and hence
problems associated with spinning triangle. The yarn produced
on this system is named by Rieter as COM4 yarn.
COM4 SPIN SYSTEM OF RIETER
COM4 SPIN SYSTEM OF RIETER
SUESSEN ELITE COMPACT SPINNING
SYSTEM
In the Elite system of suessen, the condensing zone following
the front drafting roller and it consists of profile tube with
suction slot which is placed at certain angle to the flow of
fibers, perforated lattice apron and delivery top roller. The
lattice apron is driven by delivery top roller and which is driven
by gear drive from front top roller of drafting system. The
suction under the tube creates the air currents through slot and
lattice apron which are responsible for condensing and perfect
parallelization of fiber strand. The suction air pressure, size of
slot, speed of apron, number of holds in the lattice apron has a
influence on condensing action.
COMPACT 3 SYSTEM OF ZINSER
The compACT3 system of zinser works on aerodynamic
compacting principle. The condensing zone following the
conventional 3/3 roller, double apron drafting system and it
consists of perforated apron with special vacuum element for
correct air current and drive for the perforated apron
COMPACT 3 SYSTEM OF ZINSER
The special vacuum element generates the air current
underneath the apron. The special arrangement of circular and
elliptical perforations on apron ensures the better compacting
effect. The fiber properties largely influencing the condensing
process e.g. stiff fibers behaves in diffirent manner than a
flexible ones. The fiber tension in compacting zone has
influence on yarn quality. Therefore for cotton compact
spinning process, 0-4% overfeeding is required as per raw
material.
ROCOS-MAGNETIC COMPACTING SYSTEM
RoCoS stands for 'RotorCraft compact spinning' system which
was developed by Hans Stahlecker of Rotorcraft
Maschinenfabrik Switzerland and is available on ring frames of
Lakshmi Machine Works (LMW). The RoCoS works without
use of air suction. Magnetic mechanical compacting principle is
used in RoCoS system. The RoCoS device consists of front
bottom roller which supports the front top roller and delivery
roller , in between these two rollers the ceramic compactor is
placed.
ROCOS-MAGNETIC COMPACTING SYSTEM
The supra magnets are equipped with ceramic compactor,
which is pressed against front bottom drafting roller by supra
magnet Without clearance. It forms together with the bottom
roller an overall enclosed compression chamber whose bottom
contour, the generated surface of front bottom roller, moves
synchronously with the strand of fibers and transport this safely
through the compactor.
ROCOS-MAGNETIC COMPACTING SYSTEM
According to Stahlecker , RoCoS 1 is suitable for 100 % cotton, cotton
blends and 100% synthetic fibers with maximum staple length of 60 mm.
RoCoS 2 is suitable for 100% wool,100 synthetic and wool/synthetic blends
having minimum staple length of 50 mm. As RoCoS does not requiring air
suction, air piping, perforated drum or apron and therefore there is no extra
power and maintenance is necessary.
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 in spinning department.
2. Yarn twist can be reduced by 10% while maintaining the same strength as
the conventional ring yarn. Therefore, it is possible to increase the machine
speed which ultimately results into increased production.
3. 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.
ADVANTAGES OF COMPACT SPINNING
4. 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.
5. Appreciable reduction in hairiness due to virtually elimination of spinning
triangle.
6. Less expensive raw material can be used to produce good quality yarn.
7. Significant reduction in IPI, results better yarn quality.
8. Singeing can be completely eliminated.
9. Noil % at comber can be reduced as short fibers are better integrated into
yarn body during spinning..
[Link] improved characteristics of compact yarns give higher yarn sales price.
Advantages in Winding
1. Due to less end breaks in spinning, improved winding efficiency
as few clearer cuts.
2. Waxing of yarn can be eliminated.
Advantages in Twisting
1. Lower twist can be employed in doubling, to improve the
strength of yarn.
2. The systems like COM4twist, Elitwist saves the cost of doubling.
ADVANTAGES IN WEAVING PREPARATION &
WEAVING
1. Better packing density of compact yarn gives better abrasion
resistance and which leads to fewer end breaks in weaving. also loom
shed droppings and linting in knitting are reduced.
2. Degree of sizing can be reduced which reduces the sizing cost and the
subsequent desizing cost.
3. Reduced end breaks in warping improves efficiency of warping.
4. Low end breaks in weaving improves weaving machine efficiency.
5. The compact spun yarn gives more clear cut contours in design .
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.
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 spinning technology. However, despite of few
disadvantages the compact spinning system can be a system
of future.
THANK YOU