Count Strength Product Research Articles

Prioritising Yarn Quality Via Varying Top Roller Hardness: A Fuzzy Application

In recent years, the spinning or yarn manufacturing sector has seen remarkable technological advancements, emphasizing high-quality yarn production, especially for cotton combed ring spun yarns. In the case of better quality ring spun combed yarn, each part of the ring frame is significant. To fulfil this issue, this study focuses on understanding the impact of the drafting roller hardness on cotton-combed ring-spun yarn quality. It delves into how ten top and bottom roller hardness combinations influence yarn quality parameters. The cotton combed yarns underwent rigorous testing after spinning on ring frames with varying drafting roller hardness. Key quality parameters studied included yarn Imperfection Index (IPI), Unevenness (Ue%), Hairiness (Hi), Elongation at break (Eb%), and Count Strength Product (CSP), and Tenacity (Te). The primary insight was that extreme roller hardness adversely affects all parameters except Elongation at the break value obtained for the shore hardness value of 80/83. Yarns produced using medium-hardness rollers showcased fewer imperfections due to more consistent fibre flow and minimized drafting slippages, resulting in an even twist. These findings are pivotal for the yarn manufacturing industry, hinting at potential refinements in production methods. The usage of the Fuzzy DEMATEL (Decision-Making Trial and Evaluation Laboratory) methodology also determined that Te CSP) and IPI values significantly influence the combed yarn quality when adjusting roller hardness, whereas Hi is the least influential. Therefore, this study offers twofold insights: determining the optimal roller hardness and identifying the most affected quality parameters.

A novel approach to produce neppy yarn in vortex spinning technology

A novel, cost-effective method for producing neppy yarn using the vortex spinning process was presented in this research. The vortex and ring spinning processes were utilized to produce 26/1 Ne neppy yarn from viscose rayon as a host fiber and polyester as a neppy fiber in three different ratios (98/2, 97/3, and 96/4). It was explored that neppy yarn produced by the vortex spinning system is aesthetically more appealing as it has very low hairiness, fewer coefficient of variation (CV%), and minimal thick and thin places compared to ring-spun neppy yarn. However, the count strength product (CSP) of the vortex-spun neppy yarn is comparatively lower than that of the ring-spun neppy yarn. The close engagement of the neppy fibers to the mother yarn in a vortex spinning system increased the neppy yarn’s aesthetic beauty and strengthened its endurance was a significant discovery of this study. The hairiness value of neppy yarns was measured numerically and evaluated statistically with one-way analysis of variance (ANOVA) and found significant differences between the two-spinning system. The adoption of the vortex spinning technique presents novel approaches for manufacturing neppy yarn, with potential advantages for the textile industry such as enhanced yarn quality, greater productivity, fewer machinery requirements, and ultimate cost-effectiveness.

Prioritizing the quality parameters of cotton carded knit yarn by varying tensions of the bottom aprons of the ring frame

The forces exerted on fibres during drafting in the drafting zone with the upper and bottom aprons of the Ring Frame significantly impact the yarn quality. Aprons are crucial in manipulating fibres by facilitating movement and directing them toward the primary drafting area. From these two aprons, the bottom apron's tension is changed by changing tension spring bar groove hole positions. There is no scope for changing such settings in the case of top aprons. This research aims to achieve high-quality cotton carded knit yarn by selecting an appropriate bottom apron tension due to the significant role in proper drafting and twist insertion at the time of the manufacturing process directly affecting produced yarn's strength, evenness, imperfections, and hairiness properties. To fulfil this requirement, six yarn samples are produced each time by using 5 different tensions of the bottom drafting aprons. The samples underwent quality parameter testing, including Unevenness (U)%, Coefficient of Variation (CV)%, Imperfection Index (IPI), Hairiness (H), and Count Strength Product (CSP). The findings indicated that increasing the tension of the bottom apron while maintaining positions 1, 2, and 3 reduces the occurrence of neps, variations in thickness and thinness, and imperfections. In contrast, CSP is increased due to elevated stress on the fibres. In general, maintaining an appropriate tension enhanced the quality of the yarn, and the best quality was obtained for position 3, considering all the quality variables. Moreover, by using Interpretive Structural Modelling (ISM) methodology, the pairwise relationship between the quality variables is shown. Finally, after calculation, those quality variables are arranged in three levels. According to this level, the quality parameters are ranked where the top is the highest. It is observed that Count Strength Product is at the highest level, which indicates that CSP should be given more priority. Moreover, the end use of this yarn is to produce knit items, and for the knitting yarn, CSP is one of the most influential quality variables.

DEVELOPMENT OF CALOTROPIS/COTTON BLENDED YARN AND ITS PROPERTIES

Natural fibres, which are an important part of the human environment, and also valuable raw materials used for textile and non-textile production. The use of natural fibres instead of materials such as glass fibres, carbon, and talc provides several advantages including low density, low cost, good specific mechanical properties, and biodegradability. Blending is the mixing of two or more masses of fibres so that the resulting mixture has the characteristics of the average of the component items. The most important reason for blending is the creation of new and more desirable effects.This study was conducted in Assam in the year 2021. Four different methods were used for the extraction of fibre from the peeled bark of tender stems of Calotropis gigantea plants and among which chemical retting with alkali (NaOH) was selected for the study. The study was carried out by blending Calotropis and cotton in three proportions (25:75, 50:50, and 75:25 ratios) and the properties of blended yarns were investigated. It was observed that the Cotton yarn has given a higher amount of TPI and extension than the blended yarn. Fifty: fifty blended yarn have higher tensile stress, and higher lea strength than the other yarn, and were the finest among the blends.The cotton yarn had a finer count, high lea strength, and more count strength product compared to blended yarns. It was also noticed that 50:50 blended yarn had high count strength product than the other combination.

Assessing the Impact of Speed Change on Energy Consumption and Productivity: Investigating Ring Frame Process Parameters

A concern in the contemporary period is to find balance in the world's ever-increasing demand and its severely constricted output given by the present energy crisis brought on by the post-pandemic and ongoing Russia-Ukraine war. One of the most fundamental human needs is met by the production of textiles. Spinning is the first step in the production of textiles, where the ring frame machine is essential for creating yarn. In this study, a few process parameters were altered in a ring frame machine to boost production while saving time and ensuring financial feasibility. Comparative analysis was performed based on financial aspects as well as quality concerns like yarn count variation, Count Strength Product (CSP), and end yarn breakage rate. The increased machine speed of the spinning ring frame consumes higher energy but yields higher productivity without compromising quality parameters. The findings enable the spinning industry's decision-makers to understand better how process parameters change when machine speed varies, as well as offer policymakers a clear picture of the correlation between energy consumption and profitability. The machine produces roughly 420 kg/day consuming 567 kWh of energy at 14000 rpm, with 2.57% breakages/100 spindles/hour of 18.48 tex count variation and CSP of 1320. However, the production and energy usage of a machine at 15000 rpm, is approximately 449 kg and 630.44 kWh/day. Respectively, with breakages 3.06%/100 spindles/hour of count variation 18.62 tex and CSP of 1325. A potential increase in profit of 112.58 USD/machine/day, or 9682 BDT resulted from the increase in machine speed.

Sustainable yarn production using leftover fabric from apparel industries

A huge amount of waste was generated from the apparel industries. This study aims to develop the process of producing recycled yarn from apparel waste. The apparel leftover fabric was converted to fiber, and the fiber was mixed with virgin cotton in different ratios to produce sustainable 6/1 Ne rotor yarn. The produced yarn qualities viz. count strength product (CSP), elongation percentage, total quality index (TQI) and tenacity were decreased linearly, and opposite scenario observed for thick and thin places, neps, imperfection index (IPI) and hairiness (H) attributes with increasing the amount of waste addition with virgin cotton. The leftover fabric (LOF) can be utilized to develop a sustainable yarn and to zero waste management.

Preparation of yarn by blending of etherified jute fibre with natural and synthetic fibre

Yarns were prepared by blending the etherified jute fibre in different combinations with cotton, rayon, polyester and silk waste. A blend of 50:50 for each fibre component was prepared with 50% of the etherified jute fibre respectively and 30 tex yarns from each blend were produced using the ring spinning fame. The physical properties of these yarns were determined with respect to the same numbered yarns of cotton. The 50% of the etherified jute fibre in the blends produced yarns having tenacities between 10.9 to 11.9 (g/tex) which are very much comparable to tenacity 11.5 (g/tex) of the same numbered cotton yarns. The breaking elongation 6.2 to 6.4%, moduli between  181 to 184 (g/tex) and count strength product 1605 to 1638 of the yarns from etherified jute & cotton and etherified jute and rayon in the ratio of 50:50 were almost similar to the respective properties 6.6 %, 171(g/tex) and 1694 of the same numbered cotton yarn. The breaking elongation of yarns from etherified jute and polyester and etherified jute and silk was much higher between 12.4 to 12.7% which were due to highly extensible polyester and silk fibres in the combination.

Analysis of Cotton Yarn Properties Spun on Aerodynamic Compact and Open-End Rotor Spinning

This article presents a comparative analysis of the properties of cotton yarn spun on aerodynamic compact spinning and open-end rotor spinning systems. Yarn samples with a linear density of 50 Tex, 37 Tex, 30 Tex, 25 Tex, and 20 Tex were spun both on the aerodynamic compact and rotor spinning systems using the same finisher drawn sliver of medium staple cotton which were produced by a specific mixing. The quality parameters such as mass variation, imperfection index, hairiness, and tensile behavior (strength in count strength product, elongation percentage) of the yarn samples were assessed and analyzed. The results revealed that aerodynamic compact spun yarn had a lower unevenness and mass variation, a higher imperfection in case of a finer count, less hairiness, higher tensile strength, and lower elongation% compared to the open-end rotor spun yarn samples. Finally, paired- samples t-test and regression analysis were carried out by using IBM SPSS 25 to check the significance of yarn quality parameters and correlation among them.

Study on Fiber and Yarn Quality of Some Varieties and Egyptian Cotton Promising Crosses

This investigation was carried out during 2020 season on the laboratory at Cotton Technology Research Division, Cotton Research Institute, Agricultural Research Center, Giza, Egypt, to investigate the effect of two Egyptian cotton varieties (Giza 80 and Giza 94), and two promising cotton hybrids, i.e. hybrid cotton No. 1 [(G83xG80)xG89]Austrian and hybrid cotton No. 2 [(G89xK)xG86]xG94 on fiber and yarn technological properties under using the new technique of the ring spinning system at yarn count of 40's with 4.0 twist multiplier. The obvious results of this investigation can be summarized as follows: The differences between the studied Egyptian cotton genotypes in all fiber and yarn technological properties were significant, except micronaire value and fiber maturity were not significantly affected by cotton varieties under study during 2020 season. The promising hybrid 2 significantly recorded the highest upper half mean length (mm), fiber mean length (mm), fiber uniformity index (%), fiber bundle strength (g/tex) and lea count strength product vice versa, it gave lowest short fiber index (%), yarn evenness and No. of neps/100 m. Giza 94 cotton variety recorded maximum fiber stiffness (g/tex) and fiber brightness degree (Rd %), however it gave lowest fiber elongation percentage and fiber yellowness degree (+b). Maximum short fiber index (%), fiber yellowness degree (+b), yarn evenness and No. of neps/100 m as well as, the minimum upper half mean length (mm), fiber mean length (mm), fiber uniformity index (%), fiber bundle strength (g/tex), fiber stiffness (g/tex), fiber toughness (g/tex), fiber brightness degree (%) and lea count strength product which obtained from Giza 80 cotton variety. The fiber which obtained from promising hybrid 1 recorded greatest fiber elongation percentage and fiber toughness (g/tex).

Investigating the effects of some process parameters on the quality of coarse compact yarn produced from carded roving

This project work aimed to investigate the interactive effects of carded roving parameters (i.e., roving hank and twist) and break draft of ring frame on the quality of compact yarn such as evenness, strength and hairiness. However, in this work, compact spun yarns produced from carded roving hanks of 0.70Ne and 0.90Ne while the roving twist per meter inserted at two levels (i.e., 40 and 45) for each of hank. Moreover, the break draft values of ring frame kept at three levels (i.e., 1.15, 1.25 and 1.35) for each type of roving. However, 100% cotton compact yarns of 24Ne and 32Ne produced for this experimental investigation. However, results showed that yarn unevenness (U%) and imperfection index (IPI) values of compact yarn decreased for the finer roving hank (0.90Ne) irrespective of yarn fineness. It was also noticed that low twisted roving improved yarn evenness during coarser yarn (i.e., 24Ne) production. Regarding the count strength product (CSP) value, increasing levels of roving twist deteriorated the CSP results in general. Trend of CSP results also revealed that finer roving produced higher levels of CSP results for comparatively finer yarn production. As far as yarn hairiness is concerned, it was observed that finer roving (0.90Ne) having higher levels of twist reduced yarn hairiness irrespective of yarn fineness without any exception. Finally, it can be said that this study will help the researchers for comprehending the influences of the process parameters during the production of compact yarn from carded roving.

Study on the Effect of Air Suction Pressure on the Quality of Compact Yarn by Changing the Frequency of Inverter

Compact spinning is the modification of existing ring spinning technology. The structure and quality of yarn are improved by using this spinning technique. This experimental work explores the effect of air suction pressure on the quality of compact yarn. Due to this reason, five samples of 52 Ne yarn were produced using different negative suction pressures such as 17 mbar, 19 mbar, 21 mbar, 23 mbar and 25 mbar (1 mbar = 100 Pa) in Suessen Elite@ system by changing the frequency of inverter. Samples were collected and then results were carried out. After that, the quality parameters of the produced yarn such as Mass variation (CVm%), Imperfection index, Hairiness and Count Strength Product (CSP) were analyzed along with calculating the power consumption against different suction pressures using the inverter frequency. Finally, the test results showed that yarn obtained from 23 mbar negative suction pressure was optimum considering the yarn quality and power consumption compared to others. This experimental work will provide an idea for spinners’ to choose optimum suction pressure for producing minimum imperfection and hairiness of compact yarn.

Comparison between Conventional Ring and Compact Spinning of some Egyptian Cotton Varieties

The current experiments was conducted at Plant Production Department, Faculty of Agriculture (Saba-Basha) Alexandria University, during 2019 season to evaluate the fiber and yarn properties of combed yarns by compact and conventional ring spun yarns for three Egyptian cotton varieties (Giza 94, Giza 92 and Giza 86) which belong to long staple category under three yarn count (Ne 80’s, Ne 100’s and Ne 120’s). The fiber properties were measured as well as yarn properties by two spinning system were made at Cotton Research Institute under comparable technological condition on RstI Marzoli ring and compact spinning fitted with Olfil system on one frame. The results showed that the compact spinning surpassed than conventional ring spinning in yarn traits i.e. lea count strength product (LCSP), single yarn strength (cN/tex), elongation (%), CV%, thin and thick places, neps, total imperfections and yarn hairiness. as that the compact spinning recorded the higher desirable values for lea count strength product (LCSP) (2900), single yarn strength (cN/tex) (25.39) and elongation (%) (5.03). as recorded the lower desirable values for CV%, thin (16) and thick places (36), neps (68), total imperfections (120) and yarn hairiness (1.60). As well as cotton variety Giza 92 recorded the desirable values for lea count strength product (LCSP) (3030), single yarn strength (cN/tex) (25.24) and CV% (12.08). On the other side, Giza 86 recorded the better values for thin (11) and thick places (21), neps (67), total imperfections (99) and yarn hairiness (1.80). Yarn count Ne 80’s gave the desirable values for above studied traits. The first order and second order interaction were significant differences for all studied traits. From the previous results it could be say that cotton variety Giza 92 under both compact spinning and Ne 80’s recorded the best values for the studied characters. In general, the properties of combed yarns produced with compact spinning system are better than the those with conventional ring spinning system, compact yarns were having better tensile properties, elongation ratio and lower hairiness than conventional ring yarns, that could be due to the elimination of spinning triangle in spinning system, and the decrease from the flight of fibers of structure yarn increase and this leads to higher yarn tenacity and elongation ratio. Also, Compact spun combed yarn was to found to have higher evenness and lower number of total imperfection values (thin places, thick places and neps). If the evenness property of compact yarn can be improved, it will have a potential for improving quality and profitability of cotton yarn manufacturing.

Modification of Adapter in Auto Cone Winding Machine for Better Performance

The economy of Bangladesh is largely depending on textile and garments industries at this moment. In this industry the overall demand of quality and cost reduction is increasing constantly along with steadily growing production capacities. For these reasons backward linkage industry like spinning plays a vital role for sustainable textile production in Bangladesh. Winding machine plays a significant role in quality of ring spun yarn in a spinning factory. Modification of adapter used in winding machine is accomplished in this work. Two diameter of adapter such as 58 mm and 68 mm was produced from nylon fibre and attached to the Muratec 21C winding machine. By using these two modified and one conventional metallic adapter three different fineness of yarn such as 30’s Ne cotton, 40’s Ne PC, and 50’s Ne cotton was produced by ring spinning machine in the same processing parameters. Those yarns were wound with 900, 1100, 1300, 1400 & 1500 m/min with original and modified adapters. After winding of yarn different quality parameters like unevenness (%), imperfection index (-), hairiness (-), Count Strength Product (CSP) were tested through Uster Evenness Tester 5 and Ele Stretch XT tester accordingly and compared them. Power consumption was measured by TRINITY (NF29) energy meter. It was found from the analysis of all test results that adapter of 58 mm performed the best; 68 mm made from nylon fibre the better among three along with cost savings is also possible in using nylon adapter.

Comparison of the Quality Parameter between Cotton and Melange process

The comparison of the quality parameter between Cotton and melange processes for different count and melange ratios have been studied. Here the yarns are produced from Indian cotton, Australia cotton, US cotton, China Black Viscose, and Indian Black Viscose (Melange). During the project work, different properties for the different machines in the same setting and ratios have been observed. All observations have completed by the latest model LMW (LR 9/AX) Auto Doffer Ring Machine. The quality parameters, for instance, mass irregularity (U%, CVm%,) Imperfection index (IPI), Count Strength Product (CSP), and hairiness were tested and then analyzed. For melange yarn, for different ratios, the best results have been given by 100% cotton yarn, because there is no blending between two different fibers. The quality parameter and characteristics have been presented for different types of fiber (100 % cotton, Black Viscose) and produced yarn (100 % Cotton, 5% Melange, 10% Melange, and 15 % Melange ratio) from the fiber. The productivity of melange yarn base on different condition is increased than 100% cotton yarn.

Development of a Method to Compute the Overall Key Performance Index for a Spinning Mill to Aid Supply Chain Management

This paper aims to provide a convenient measure of evaluating the performance of spinning mills using the overall Key Performance Index. Although many authors have advocated the concept of the key performance index, their studies were confined to departments other than spinning. The methodology followed in this paper is based on providing weightages to machine utilisation, spindle production, end breaks, HOK (number of operative hours required to produce 100 kg of yarn), roving production, yarn realisation, CSP (count strength product), units/kg of Yarn and to compute the overall Key Performance Index in a logical manner. It has come to light that some mills have achieved an overall Key Performance Index (OKPI) of more than 100 and less than 100 in certain other mills. Also the important factors which are significant for supply chain management have been highlighted. A very useful source of information and advice for various spinning mills to develop their own supply chain strategies is provided. Especially with the introduction of technical textiles, supply chain management has become a critical area.

Statistical Analysis of Properties of Compact Yarn Produced from Different Process

Compact spinning system is a great modification of ring spinning system. It brings a revolution over ring spinning system in case of hairiness and strength of yarn. In this paper, three yarn of “34’s Ne” count was produced in three different spinning systems termed as conventional Ring, Suessen Elite compact, and RoCoS (Rotorcraft) compact spinning system. During processing, all the processing parameters and the environment were kept the same in the case of the compact spinning system. Yarn properties are then tested with Uster Evenness Tester 6 and Mesdan strength tester. Statistical analysis like t-test paired two samples for means for all the properties of two compact yarns such as unevenness percentage, imperfection index, hairiness, tenacity, elongation, and count strength product were performed using Microsoft Excel 2013. Suessen Elite compact spinning system shows good results than another compact spinning system. It was found from the statistical analysis that there is no significant difference in the maximum properties of two compact spinning systems, especially in hairiness and tenacity, as these two properties are crucial in the compact spinning system.

Improvement of Carded Yarn Quality by Changing Ring Frame Break Draft for Different Short Fibre Index

Three types of cotton fibers lot having short fiber index (SFI) 8.65, 9.45 and 11.00 were taken to perform the experiment. The break drafts (BD) in ring frame were set to 1.136, 1.174 and 1.211 to produce the sample yarn; 30S /1 carded knit yarn (30KK) and 34S /1 carded knit yarn (34KK). The objective of this study was to find out the impact of short fibers by changing ring frame break draft on yarn quality and spinning process performance. The yarn quality such as CVm%, thin places (-50%)/km (TN), thick places (+50%)/km (TK), neps (+200%)/km (NP), count-strength product (CSP) and yarn hairiness (H) found satisfactory level for both yarn count in case of ring frame break draft 1.174 for low and high short fiber index. In this study, both physical and tensile properties of ring yarn were found better for ring frame break draft 1.174 of the three samples and quality deteriorates as SFI increases from 8.65 to 11.00.

Comparative Study on Card Yarn Properties Produced from Conventional Ring and Compact Spinning

Yarn characteristics extensively influence by spinning process. The aim of this study is to observe the effect of conventional ring and compact spinning processes on properties of yarn. 100% CIS-Turkey cotton was used to produce conventional ring card yarn and card compact yarn. The twist per inch of 16.99 and 19.57 were settled to fabricate 20 Ne and 30 Ne count of yarn respectively both for conventional ring and compact spinning. The positive effect of spinning process on the yarn properties were evaluated by co-efficient of variation (CVm %), imperfection index (IPI), hairiness, tenacity, count strength product (CSP) and elongation (%). The results exposed that yarn qualities of compact spinning were exhibited higher than conventional ring spinning.

Promising Effect of Processing Parameters on Yarn Properties in Rotor Spinning

Fabric characteristics significantly depend on the physical properties of yarn and the qualities of rotor yarn greatly governed by processing parameters. The aim of this study is to observe the effect of processing parameters such as rotor diameter and speed on the physical properties of yarn in rotor spinning process. Mixing of spinning waste with the virgin cotton is a common phenomenon in rotor spinning. 0.11 sliver hank of 100% cotton fibre with 65% virgin cotton and 35% wastage was used to produce 12 Ne yarn. The favorable impact of processing parameters on the yarn characteristics were accessed by co-efficient of variation (CVm %), imperfection index (IPI), hairiness, tenacity, count strength product (CSP) and force at break. The yarn qualities were improved with increasing of rotor speed and rotor diameter.

Spindle Diameter Effects for Cotton Pickers

Abstract. There is concern that changes to the operating speed and size of spindles on cotton picker harvesters over the years have resulted in a general decrease in cotton fiber quality, especially spindle twists, preparation, and neps. Previous research showed that spindle speeds of 3000 and 4000 rpm had more detrimental effects on cotton fiber quality than a spindle speed of 2000 rpm. Field tests were conducted for the 2011, 2012, and 2013 crop years by the USDA, Agricultural Research Service, Southwestern Cotton Ginning Research Laboratory in Mesilla Park, New Mexico. Three cotton varieties were grown each year under irrigated conditions near Las Cruces, New Mexico, and harvested with cotton pickers equipped with spindles having diameters of 1.27, 1.43, and 1.59 cm (1/2, 9/16, and 5/8 in.), using a ground speed of 0.85 m s-1 (1.9 mi h-1). Spindle speeds were 2000 rpm in each case. Pickers with larger spindle diameters had lower stalk loss and sometimes had lower foreign matter levels in the seed cotton as well as in the ginned lint. These foreign matter levels significantly affected HVI foreign matter content and leaf grade. HVI classing data other than foreign matter content and related leaf grade showed no significant differences among spindle diameter treatments. AFIS nep count, short fiber content, trash count, dust count, and seed coat nep count showed no significant differences due to spindle diameter treatments or interactions. Results from ring spinning mini-tests, including skein breaking strength, skein count, skein count-strength product (CSP), yarn strength, yarn elongation, neps, thick places, and thin places also showed no significant differences due to spindle diameter. Based on these results, the picker unit with 1.59 cm (5/8 in.) spindles was optimal, but differences in performance were not large. Keywords: Fiber quality, Harvesting.