Ring Spinning System Research Articles

Effect of the blending between upland and combing waste on cotton fiber and yarn quality

Blending of cotton wastes with raw materials to produce different textile products has economically and environmentally beneficial. This study was carried out in Cotton Research Institute, Agricultural Research Center. This investigation aimed to study the impact of blending ratio on fiber, mechanical and physical yarn quality properties to find out the optimum blending ratio that achieves the optimum yarn quality properties. For this purpose, fiber properties, mechanical and physical yarn quality properties of ring spun yarns produced from cotton variety Giza95, Delta pine245 cotton variety (upland cotton) combed cotton waste of Extra Fine Giza93 and six different binary blend ratios were studied. Blended samples were spun into 36s, and 40s, carded yarns at constant twist multiplier 4 on ring spinning system. the results showed that fiber properties, Physical and mechanical properties of yarns produced from Giza95 were better than 100% upland cotton, 100% combed cotton waste and the other blended yarns.65% Giza95-35% combed waste of blended samples recorded higher fiber properties(maturity ratio, fiber length, uniformity index, fiber strength and fiber elongation) than all blended samples.Also,the same blended ratio at 36s, yarn count give better lea count product strength, yarn strength, yarn elongation, evenness, imperfections and yarn hairiness compared with all blended yarns followed by 65% combed waste - 35% Giza95.While, the lowest yarn quality properties recorded by The blended yarn of 35% Giza95-65% Delta pine245. Also, it observed that increasing proportion of G95 cotton variety in blended samples led to improve fiber, mechanical and physical yarn properties

New feeding mechanism to enhance the properties of wrapped elastic composite yarn and denim fabrics thereof

In light of the recent technological advancements in composite yarns with multicomponent cores, also known as dual core spun yarns, their utilisation in the textile industry has become widespread. A V-grooved roller is employed to enhance the feeding of multicomponent cores. In this context, diverse composite yarn designs with varying feeding mechanisms can be employed to optimise yarn performance. This study presents an alternative feeding mechanism utilising a W-grooved roller for commercial use in composite yarn production. To achieve this, dual core yarns and wound elastic composite yarns (filament feeding varies with the sheath cotton fibre with elastane in the centre wrapped on the right and left side) were produced using a modified ring spinning system with different parameters. Denim fabrics were then produced using these composite yarns as weft yarns. The results demonstrated that the wrapped elastic composite yarns with left and right filament core positioning exhibited superior yarn properties in terms of strength, elongation at break, evenness and hairiness. Furthermore, denim fabrics made with wrapped elastic composite yarns exhibited superior breaking load and tearing force results on weft basis. These fabrics also exhibited lower growth, defined as the percentage of the fabric returning to its original length after tensile stress removal.

Mechanically-enhanced structural composites yarns with multifilament-spreading technique using a modified ring spinning system and predicting modelling

To advance spinning technology for multifilament covered cotton fibers, a spreading apparatus was introduced to ring spinning. This innovation allowed the manufacturing of a composite yarn with a wrapped structure. However, an effective strategy for predicting the mechanical properties of multifilament spread composite structural yarns (FS-CSY) was urgently needed. In this study, researchers compared FS-CSY with bi-component composite yarn (b-CY) to determine if the addition of a spreading apparatus and twisting in the manufacturing process resulted in any improvements or enhancements. The FS-CSY structure was found to be novel and exhibited significant mechanical properties, including a 4.7% increase in tensile strength compared to b-CY. A strategy was developed to predict FS-CSY by considering the transfer impact of fiber enhancement within the yarn and by incorporating two-component interaction forces in the yarn-wrapped structure. Meanwhile, a modified three-element tensile constitutive model was established to effectively simulate the stress characteristics under different twist levels, which proved the composite yarn prediction theoretical model. Finally, the fracture morphology analysis shown the b-CY fracture surface was irregular, while FS-CSY exhibited a uniform fracture surface, and the 750TPM showed a more uniform and stable structure. By developing this predictive strategy, enhance existing structural composite yarn by maximizing the efficiency and quality of multi-filament covered cotton fibers. Ultimately, this research contributes to advancements in textile manufacturing processes and lays a foundation for future innovations.

Tuning drafting zone parameters for polyester yarn within a ring spinning system: modeling and optimization

Yarn is a fundamental element in most textile products. Among various yarn manufacturing methods, the ring spinning system is particularly important due to its benefits, such as high yarn quality, evenness, low hairiness, and ease of handling. The parameters of the drafting zone in this system greatly impact yarn quality. Typically, adjusting these parameters in the drafting zone is time-consuming and costly using trial-and-error method. This study introduces an algorithmic approach using response surface methodology (RSM), experimental modeling, and multi-objective optimization to decrease unevenness percentage (U%) and imperfection index (IPI). Input parameters optimized include cots hardness of front and back top rollers, spacer size, and break draft. Results showed that the artificial neural network (ANN) predicts response parameters superiorly with determination coefficient close to 1, compared to RSM, which has a determination coefficient of about 0.72. Therefore, ANN was chosen for optimization. Additionally, combining the genetic algorithm (GA) with two ANN-based models reduced IPI from 39 to 33.67 and a decreased from 9.73% to 9.67% occurred in terms of U%. The final Input settings were the cots hardness of the front roller of 70 shores and the cots hardness of the back roller of 76 shores, spacer size 2.8 mm, and break draft of 1.26. This method efficiently optimizes the drafting zone parameter, thus enhancing yarn quality.

Transforming melange fabric waste into mélange yarn employing compact, Siro, and compact-Siro spinning: A cleaner and sustainable strategy

The concept of sustainable and eco-friendly production of textiles has gained significant traction in recent years. Utilizing sustainable raw materials, processes, and recycling methods are fundamental strategies in the development of cleaner and more eco-conscious textile manufacturing. The current work reports a sustainable approach to manufacturing melange yarn from recycled fibers shredded from pre-consumer cotton/viscose mélange fabric waste. The recycled fibers obtained by the shredding method are short and lumpy, necessitating the blending with virgin fibers which serve as carriers throughout the spinning process. In the traditional ring spinning system, the poor inter-fiber cohesion, especially shorter recycled fibers, inhibits achieving the optimum yarn quality. With a view to their better control during spinning, advanced spinning systems such as Siro, compact and compact-Siro spinning were adopted. Experimental results revealed that all these spinning systems led to superior yarn qualities. Among them, yarn produced with compact-Siro spinning demonstrated the most significant improvements in yarn structure (reduced hairiness, unevenness & imperfections) and properties (increased strength & elongation). Through adept engineering and precise process control, 30-Ne (19.68 Tex) melange yarns containing up to 60% recycled mélange fiber were successfully produced. These melange yarns proved to be suitable for manufacturing knit fabrics with aesthetics similar to commercial mélange fabrics. The innovation of producing melange yarn, incorporating 60% recycled fibers, introduces a revolutionary concept aimed at supporting the Sustainable Development Goal (SDG) 12. This initiative aims to reduce the reliance on production of viscose, and cultivating and processing cotton, thereby making significant contributions to environmental conservation in various dimensions. Moreover, embracing this approach offers the potential for cost savings in the production of melange clothing.

Escalating the use of jute (Robi-1)-cotton blended yarn rather than entirely made of cotton yarn

The process of blending involves the mixing of two different fibers to achieve the desired percentage. Various compositions, lengths, diameters, or colors may be intermingling to produce a blended yarn in a ring spinning system. This system entails the combination of different fibers lots into a homogeneous mass before spinning the mass into a staple fiber yarn. Typically, BJRI Tossa Pat-8 (Robi-1) and cotton fibers are combined to create jute-cotton blended yarn. Jute can be utilized in various ways, which is one approach to blending yarn. The jute-cotton blended yarn was produced in a ratio of 30% and 70%. Both jute-cotton blended yarn and totally cotton yarn were produced on a cotton spinning line using a ring frame. The physical characteristics of both yarns, such as count, yarn Lea strength, and CSP were measured. The average count of fully cotton yarn and jute-cotton blended yarn was found to be roughly equal at 12.16 and 11.82, respectively. However, the yarn lea strength and CSP of both samples, which are significantly different from one another, were 232 lb, 140 lb, and 2835, 1670, respectively. Along with entirely made of yarn, blended yarn also exhibits consistency in terms of CV%, SD, and PMD. This study compared the physical characteristics of both yarns after Robi-1 was first introduced for the blending process with cotton to produce a jute-cotton blended yarn.

Influence of Blending Method and Blending Ratio on Ring-spun Yarn Quality – a MANOVA Approach

Cotton-polyester is a common and popular fibre blend in the textile industry nowadays. Its main advantage is that it improves the functional properties of clothing and textile products. In this study, fibre-blended, sliver-blended and roving-blended yarns with a fineness of 23 tex were manufactured using a ring spinning system, with blend ratios of cotton and polyester fibres of 50:50, 60:40 and 70:30. The quality parameters of the produced yarn, such as mass variations, imperfections, hairiness and bundle yarn strength, were studied. The end breakage rate of the ring frame machine was also studied during the manufacturing of the yarns. The results were analysed using multivariate analysis of variance (MANOVA) to determine the significance of the impact of the blending method and blending ratio on yarn quality and the end breakage rate of the ring frame machine. The profile plots were analysed from statistical and technical points of view. Among the three blended yarns, fibre-blended yarn demonstrated the best results in terms of mass variations and imperfections due to better blending homogeneity, while roving-blended yarn demonstrated better results in terms of hairiness. Among the blended yarn, fibre-blended yarn demonstrated the highest bundle yarn strength value, while the corresponding end breakage rate of the ring frame machine recorded the lowest value. The yarn quality was improved in terms of mass variations, imperfections, hairiness and bundle yarn strength by increasing the polyester fibre percentage in the blend ratio.

Investigation on the Flammability and Washing Durability of Trevira CS and Its Blends with Cotton, Modal, and Acrylic Fabrics

The aim of this study was to develop flame-retardant textile materials and study their aspects to durability against several washing cycles. Since the conventional textile substrates are flammable and combustible, the development of flame-retardant apparel from pure Trevira CS fabrics as well as its blends with cotton, modal, and acrylic in certain proportion was carried out in this study. Furthermore, in addition to demonstrating necessary flame-retardancy characteristics, flame-retardant garments must provide a minimum degree of comfort to the wearer, and it is thought of as blending. The productions of yarn were made with ring spinning systems, and knitted fabrics also were produced from this pure Trevira CS and its blends yarn. Flammability test was carried out for the spun yarn and for the fabrics manufactured separately. Limiting oxygen index (LOI) tests were carried out for the sample fabrics. The result indicates that most of the fabrics are flame resistant except the T/C (80 : 20) fabric which show low LOI values, but by treatment with finishing agents, it can be improved. In order to study the durability against washing cycles, LOI values of all sample fabrics were determined. LOI values of all the four types of knitted fabrics in gray, finished, and washed states were evaluated and compared. The pure Trevira-spun knitted fabric exhibits very good flame retardancy in gray state and hence may not require any flame-retardant finishing treatment. Upon imparting the wash resistant, flame-retardant finish Pekoflam DPN, it was observed that the LOI of all the treated samples showed a significant increase. It was revealed also that upon washing (after 10 washes), the LOI values of the fabrics have been considerably reduced; however, no appreciable reduction in flame retardancy is noticed upon further washing of fabrics, after 20 and 30 washes, respectively. Even after 30 washes, the flame retardancy of most of fabrics are very good and one sample showed good result. Finally, the knitted fabrics from pure Trevira-spun yarns and the FR-treated T/C (80 : 20), T/M (80 : 20), and T/A (80 : 20) ones qualify very well for the production of flame-retardant garments for various applications in different forms.

EVALUATION OF NOISE ON RING SPINNING MACHINES

The ring spinning system is a system that continuously spins yarn and winds bobbins. This yarn, after leaving the delivery rollers, takes the twist of the rotating spindle and traveler, and is wound onto the bobbin, which goes as overlapping on the spindle. The degree of weight in the spinning mills increases. On top of that, one of the reasons is working at its higher speeds to improve the production rates in the production process in a competitive environment of development. The evaluation and evaluation of speed balance almost as a whole is increasing, and in the evaluation of more energy in sound. assessment does not qualify as a problem of poor human health and condition in many countries. It is at a level to serve people. “Production rather than production consists of elements freed from the emergence of high-level indicators. Fuzzy logic can be developed by tool from tool pilots with predictive and general applicability to the planning of aircraft by human being difficult to craft. In this model, the appropriate gear wheel on the appropriate type gear wheels.

INVESTIGATION OF THE USAGE OF ALTERNATIVE NEW GENERATION ECO-FRIENDLY FIBER BLENDS IN SYNTHETIC BASED DENIM FABRICS

Polyester yarn is made from post-consumer waste such as bottles, fabrics, etc., in the composition of polyester ethylene terephthalate (PET). Polyester (mainly polyethylene terephthalate, PET) is the most commonly employed textile fibre with over 50% share in total production of textile fibres. Pla is a biobased and biodegradable polymer produced from renewable resources. PLA is also a thermoplastic aliphatic compostable polyester. In this study, 75% Cotton - 25% PLA, 75% Lyocell - 25% PLA and 75% Cotton - 25% PET blended yarns were produced as rigid, corespun and dualcore in the ring spinning system .The fabrics were weaved with produced yarn. In the finishing processes, some of the fabrics were treated with caustic and some of the fabrics were only washed. Fabrics containing PLA and PET were compared with each other. Fabrics containing PLA and PET fiber were evaluated in terms of strength, elasticity, abrasion and pilling performances. Although the weft tensile and tear properties of Cotton-PLA blended fabrics are lower than Lyocell-PLA and Cotton-PET blends, it has been indicated that PLA blended yarns can be used as an alternative to PET based yarns and fabrics.

The Influence of Elimination of Roving Frame on Ring Spun Cotton Yarn Characteristics

Generally, ring spun yarns are manufactured from roving which is produced by roving frame. In this paper, an experiment has been done producing ring spun cotton yarn directly from finisher drawn sliver eliminating the roving frame. Total 3 types of yarn with the various linear density of 8 Ne, 10 Ne & 12 Ne were produced using a roving frame and without using a roving frame. In the next step, physical and mechanical properties of those yarns including unevenness, imperfections, hairiness & tenacity were investigated. The result showed that ring spun cotton yarns produced from sliver exhibited inferior physical and mechanical properties compared with samples from the conventional ring spinning system.

Thermal, mechanical and comfort performance of various modacrylic fibre blended fabric

In this study, various blended fabrics of modacrylic fibre with flame retardant (FR) viscose, and Nylon 66 have been manufactured and studied for their thermal, mechanical and comfort properties for workers of oil & gas industry. The ring spinning system is used to manufacture three sets of yarns. In the first set, three yarns are produced using only modacrylic, only FR viscose, and only Nylon 66 fibres. The second set of yarns is made using blends of FR viscose and modacrylic. These fibres are blended in three different ratios of 30:70, 50:50 and 70:30 for making yarns. The third set is made out of tertiary blends of FR viscose, nylon 66 and modacrylic. These are blended in two different ratios of 30:20:50 and 50:20:30 respectively. Fabric samples have been produced out of these yarns and evaluated for their flame, thermal and mechanical properties after 5 and 50 washes. The radiant heat transfer index and convective heat transfer index of blends of modacrylic fibre are found in the range 12 - 13.5 s and 5.0 - 5.7 s respectively. Multivariate test analysis has been applied to find out the effect of different fibre blends on various flame and thermal properties. The study shows that flame and thermal resistant properties are influenced by fibre blending ratio.

An improved dynamic model and numerical simulation of yarn in the ring spinning system

The nonlinear dynamic behavior of ballooning yarn in the ring spinning system is investigated. An improved dynamic model of ballooning yarn with axial conveying speed is established. Based on Hamilton’s law of variation principle, the three-dimensional dynamic differential equations are derived. Then, the shooting method is employed to solve the two-point boundary value problem of ordinary differential equations. The numerical results of balloon profiles and distribution tension curves of ballooning yarns are discussed. The numerical results imply that with the increase of Ω, the yarn conveying speed increases, the minimum tension at the guide eye increases, and the helical loops of the balloon profile decrease. It is also found that as Ω increases, the spatial area of the guide eye tension [Formula: see text] that forms the dynamic balloon decreases. When the yarn conveying speed is medium or high, under different tensions at the guide eye, the yarn tensions along the height direction of the balloon change in the same trend, and the tensions of the ballooning yarn at the same height are very close. In addition, with the increase of Ω, the distribution tension of the ballooning yarn changes significantly under the same guide eye tension.

Recycled fibers from pre- and post-consumer textile waste as blend constituents in manufacturing 100% cotton yarns in ring spinning: A sustainable and eco-friendly approach

The usage of recycled fibers has achieved enormous importance in the textile sector due to growing environmental awareness, legal requirements for more sustainability and the cost of raw materials. Recycled cotton fibers derived from mechanical shredding of textile waste possess lower quality values and therefore they are spun through blending with other fibers in rotor spinning system for the production of coarse yarns (10–20 Ne) to make denim, towel and home furnishing. Owing to low fiber migration, rotor yarns require high twist during spinning which makes them stiffer and poorly moisture absorbent. Rotor yarns also feel harsh in skin contact due to the presence of wrapper fibers in the yarn surface. Intending to make knit top garments like T-shirts and polo shirts, apparel manufacturers nowadays demand recycled fiber-contained soft and high moisture absorbent yarn that can be produced in ring spinning system. In the current endeavor, cotton fibers reclaimed from pre- and post-consumer textile waste were blended with virgin cotton and soft-twisted 30 Ne yarns were manufactured in ring spinning frame on an industrial scale in a spinning mill. A thorough analysis of the structure and properties of the yarns revealed that up to 25% recycled cotton fibers can be used as an alternative to virgin cotton to manufacture medium count (30 Ne) yarn in ring spinning suitable to produce knit top garments.

Enhancing the quality of elastane-cotton core yarn by compact spinning

The quest for highly stretchable fabrics with good aesthetic and functional properties has led researchers to constantly involve in mingling of natural and synthetic fibers. Elastane-cotton core yarns have an increasing demand due to their wear comfort and stretch-to-fit properties; therefore, efforts are still going on to optimize the yarn properties to meet the requirements for diversified applications. With a view to enhancing the appearance and performance characteristics of elastane-cotton core yarns, the present work was undertaken to manufacture them by exploiting the most modern and versatile pneumatic compacting mechanism, namely Suessen's EliTe compact spinning system. Elastane-cotton core yarns of different counts (20 tex, 30 tex and 60 tex) were produced with compact and conventional ring spinning system. The difference in morphology and physical properties of two types of yarns were compared after a thorough investigation by scanning electron microscope, evenness tester and strength tester. The results exhibited a noticeable decrease in hairiness, hairiness variation and neps values, especially seed-coat neps, for elastane-cotton compact core yarn. Unevenness & imperfection of compact core yarns were also found to be decreased that were reflected to the proportional enhancements in tenacity & elongation values. The overall observation reveals the potential of pneumatic compacting mechanism in obtaining elastane-cotton core yarn with superior structure and improved mechanical properties.

Fabrication and characterization of braided auxetic yarns based on a high-speed braiding machine

In recent years, three kinds of auxetic yarns have mainly been developed, namely helical auxetic yarns based on the ring spinning system and the hollow spindle system and braided auxetic yarns based on the braiding system. However, these auxetic yarns have some drawbacks, such as an unstable structure or no obvious auxetic effect. In this paper, auxetic yarns were successfully braided by wrap filaments and a core filament based on a braiding system, which overcame the slippage problem in the traditional helical yarn structure. Yarns were spun by different structural parameters of the core filament, the wrap filaments and braiding filament, including the diameter ratio, braiding speed and different numbers of wrap filaments. The results showed that all parameters have an impact on the Poisson’s ratio of auxetic yarns and, in addition, the braided auxetic yarns can cause the yarns to be in the pre-stretching state; once the stretching effect occurs, the Poisson's ratio will directly change from a negative value. Since the new auxetic yarns were produced using a high-speed braiding machine and filaments, this would pave the way for their mass production. This provides a certain research basis for mass production of the stable auxetic yarn structure, and based on the realization of the pre-stretching state, it also provides more possibilities for future research.

Investigation of the performance of okra fiber in woven fabric

There has been an increase interest in natural plant fibers over the last decades with the intension to identify the ecologically acceptable alternatives to reduce the dependency on synthetic fibers. Naturally extracted okra fiber (Abelmoschus esculentus) was used in this study. Since okra is a stiff fiber, yarns with 100% Okra fiber was not possible to produce and tried to blend with polyester. The maximal ratio of okra was 20% with polyester to spin yarns in traditional ring spinning system. This study explores, for the first time, the possibility of manufacturing woven fabric with polyester-okra (80/20) yarns at weft direction with 100% cotton yarn at warp direction in order to prominent blend effect at weft direction. The properties of produced fabrics were compared with the same produced widely-used polyester-linen (PL) (80/20) counterpart. The both PO and PL woven fabrics were characterized in terms of fabric weight, thickness, abrasion, pilling, fuzzing, air permeability, tensile strength and tear strength. In addition, the morphological aspects of the fiber alignment in the woven fabric structure were observed using optical microscopic images. The performance of PO woven fabric was in acceptable ranges and can be considered as a sustainable blended woven fabric to meet the actual demand in the textile weaving industries.

Comparison of solo and conventional ring yarns: effects on the compression characteristics of cut-pile carpets

Carpet manufacturers are continuously looking for new approach to improve the characteristics of their produced carpets in terms of appearance and durability. Material and structural parameters have a significant effect on the carpet compression properties. This study deals with characterization of the cut-pile carpets produced with Solospun pile yarns in comparison to Ring spun yarns. To this end, the acrylic pile yarns were produced in same linear density using a semi-worsted Solo- and Ring spinning systems. Both prepared pile yarns were used to produce machine-woven carpets in two different weft densities (1500 and 2000 yarns/m). Compression characteristics of the manufactured carpet samples under compression loading were evaluated. The findings revealed that the hairiness of Solospun yarn decreased by 24% and 41% for 3 and 6 mm hairs, respectively; while the yarn abrasion resistance increased by 39%. The results also revealed that the thickness loss (TL) under long-term static loading was vividly lower for the carpets produced from Solospun yarns, in comparison to Ring spun yarns. The compression characteristics such as compressibility, permanent deformation, compression energy and residual energy of the carpet samples made of the Solospun yarns were less than those made of conventional Ring spun yarns. Finally, using the Solospun yarns as carpet pile leads to higher useful life and pile recovery of the cut-pile carpets. Accordingly, these yarns are recommended to be applied in the carpet industry, instead of the Ring spun pile yarns.

Construction and analysis of a three-channel numerical control ring-spinning system for segment colored yarn

At present, there have been a significant number of studies of segment colored yarn, and the majority of these studies have made considerable progress, which has made the types and styles of segment colored yarn more abundant. However, the problem that exists in the segment colored yarn is its relatively few kinds of color, which greatly limits its flexibility and diversity in commercial applications. To address the above problems, a multi-channel computer numerical control (CNC) ring-spinning machine was developed, and a digital spinning mechanism with online regulation of the forming linear density and blending ratio was constructed through the developed three-channel drafting mechanism and its driving and controlling system; the spinning mechanism of segment colored yarn using the time-varying three-channel drafting ratio to the spinning time-varying three-colored fiber blending ratio was established by implementing a coupling algorithm for co-drafting of multi-channel roving; the forming process and algorithm of segment colored yarn, which is used to solve the blending ratio of three colored fibers and the drafting ratio of three-channel roving based on segment color, was constructed through the digital color mixing model and the design of segment color of yarn. According to the above mechanism, three rovings with two color combinations of cyan, magenta, yellow and cyan, magenta, black were used to design and spin segment colored yarns with three, five and seven colors, respectively. By testing and analyzing the linear density, twist, unevenness, surface hairiness and tensile properties of the segment colored yarn, it is proved that the timing control of the three-channel drafting ratio based on CNC ring spinning can achieve the timing control of the blending ratio of the three colored fibers, which is beneficial to the spinning of segment colored yarn with color segment distribution.

Development of hemp-blended cotton fabrics and analysis on handle behavior, low-stress mechanical and aesthetic properties

Cotton is the most popular natural fiber used in apparel industry world over. Although cotton is cultivated in approximately 2.4% of the world’s arable land, it accounts for 24% of the world’s insecticide market. Industrial hemp is considered as the most sustainable raw material as substitute of cotton in textile industry. However, there are several challenges associated with hemp processing as the fiber is coarse, stiff and it has comparatively poor spinnability particularly when 100% hemp is processed in ring spinning system. The purpose of this paper is to investigate the aesthetic and low-stress mechanical properties, and handle value of the plain woven hemp-blended cotton fabrics. The 16Ne and 30Ne linear density compact and ring yarns were produced and were used to manufacture plain woven suiting and shirting fabrics, respectively. Crease recovery angle, pilling, tear and tensile strength, and handle value of the fabrics were determined.