Rotor Spinning Systems Research Articles

Investigation of Performance Properties of Denim Fabrics Containing Cotton/Sustans® Blend Rotor Yarn

It is common to use open-end rotor yarn in the production of denim fabric, which is preferred by people of all ages and social status due to its durability and comfort. Recently, the demand for stretch denim fabrics that can take the body's shape due to the elastic fibers in its structure has been increasing. However, producing elastane-containing yarns in the rotor spinning system is not as practical as ring spinning. For this reason, this study aimed to use the staple Sustans® fibers with high elasticity in the rotor spinning system together with cotton fibers and reflect the good elasticity and elongation properties of Sustans® fibers to the rotor yarns and denim fabrics. In the study, the staple Sustans® fibers based on PTT (Polytrimethylene Terephthalate) were spun with cotton fibers in the rotor spinning system. Then denim fabrics were produced using these yarns in the weft. Later, strength (breaking and tear), dimensional stability (dimensional change after washing, fabric elasticity and growth), abrasion resistance and pilling tests were applied to the produced denim fabrics. Thus, the effects of using Sustans® fibers on the strength, dimensional stability, abrasion and pilling properties of denim fabrics were analyzed. As a result of the study, the dimensional change and growth values after washing were developed by using Sustans®. Although good dimensional stability was observed in the samples, the degree of elasticity was lower than expected. The use of Sustans® at rates of 50% and above improved the pilling values of the fabrics. In addition, it has been determined that the use of Sustans® in terms of abrasion resistance has a more positive effect at the end of long wear periods.

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.

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.

Production and characterization of recycled polyester (r-PET) blend vortex and ring spun yarns

Nowadays, many major fashion brands are now producing recycled polyester (r-PET) textile products from PET bottles to contribute to sustainability. Of course, this means that textiles containing r-PET will now be produced at an increasing volume. R-PET fiber nowadays can be produced by optimizing machine settings only in the ring and rotor spinning systems. In this study, it is aimed to investigate the spinnability of r-PET fiber in the vortex spinning system. In this context, recycled r-PET fiber from PET bottle was blended with cotton (Co) and viscose (Cv) fibers in different blending ratios and yarns production were performed in ring and vortex spinning systems. Strength, elongation, unevenness (CVm%), imperfection index (IPI) and hairiness properties were determined and the results were statistically analyzed. In addition, it was determined that yarn production method, yarn composition and blend ratio had a significant effect on investigtated properties of the yarns.

A Comparison of Color Fastness Properties of Mulberry Silk and Tussah Silk Fabrics in Blends with Cellulosic Fibers

ABSTRACT Although it has been used for centuries; silk’s appearance, touch, and other high-quality properties maintain the popularity of the fiber. However, there are different types of silkworms, so different types of silk fibers are available. Other than Mulberry silk there are some others: eri, muga, tasar and tussah, which are generally deemed “wild silk”. In this study, color fastness properties of one of these wild silk fibers: tussah was investigated in comparison with mulberry silk fiber. For comparison, mulberry and tussah silk fibers were blended with cotton, viscose rayon, and modal fibers and spun using open-end rotor spinning system. After yarn productions; single jersey fabrics were knitted, pretreated and dyed. Color fastness tests were made to evaluate the performances. Results indicate that both types of silk fibers are appropriate for spinning and knitting processes and the fastness results revealed that mulberry fibers resulted with better color fastness properties in comparison with tussah silk fibers

An Analysis of Quality Characteristics of Bamboo/Cotton Blended Yarns of Rotor and Ring Spun

Denim fabrics are in general manufactured by using 100% cotton fibers. A novel attempt has been made by using bamboo/cotton yarns in warp and weft directions to produce denim fabrics using ring yarns in warp and rotor yarns in weft directions. In this research work, bamboo/cotton yarns are manufactured in different blend compositions like 100% bamboo, 100% cotton,70:30, 50:50 and 30:70 ratios. Ne 10 and Ne 16 carded yarns are manufactured from both the ring and rotor spinning systems. The yarns manufactured out of these two spinning systems have been critically analyzed for their quality characteristics like Unevenness, Imperfections, Hairiness, friction, abrasion, strength and elongation. The influence of blend ratios on yarn quality characteristics in ring and rotor yarns has been analyzed and the optimum blend proportion which gives the best quality has been investigated.

Effect of low-quality and inexpensive cotton materials on yarn properties using rotor spinning system

The current search aimed to produce medium and coarse yarns using low-quality and inexpensive cotton materials under the rotor spinning at four yarn counts being 10.s, 16.s, 20.s and 24.s with 4.4 twist multiplier. The used cotton materials were the waste from spinning extra long-staple cotton such as combed wastes, Giza 80 lint grade fully good fair, Giza 90 lint grade fully good fair, Giza 80 lint grade good fair, Giza 90 lint grade good fair, imported china variety and carded wastes. The used cotton materials were prepared from the commercial cotton samples of season 2017. The studied yarn mechanical properties were yarn strength, yarn evenness C.V.%, number of neps, number of thin places and number of thick places. However, the average values of five fiber properties being fiber length 2.5 %, short fiber content %, coefficient of variation fiber C.V. %, fiber strength and micronaire reading were measured for all used cotton materials. Results showed significant differences among cotton materials and among yarn counts for all studied yarn properties. The effect of interaction between cotton materials and yarn counts was only significant for yarn strength and yarn evenness C.V. %.Generally, it is obvious that the mean values of yarn strength were in descending order considering cotton materials of combed wastes, Giza 95 lint grade fully good fair, Giza 90 lint grade fully good fair, Giza 95 lint grade good fair, Giza 90 lint grade good fair, china variety and carded wastes, respectively. On the contrary, the mean values of yarn evenness C.V. %, number of neps, number of thin places and number of thin places were in ascending order for the same aforementioned cotton materials. The mean values of yarn strength were gradually decreased when the yarn count was increased while the mean values of yarn evenness C.V. %, number of neps, number of thin places and number of thin places were gradually increased when the yarn count was increased.

Comparing Quality Parameters of Yarn Produced by Ring, Rotor, and Compact Spinning System

The end use of a garment depends on the properties of a fabric. A fabric property depends on the properties of the constituent yarn. With the diversification of the market, spinners are forced to produce quality yarn. For this reason, conventional hand spinning has been converted to modern system gradually. Ring spinning, Rotor spinning, and compact spinning are widely used spinning system. Ring spinning is the universal spinning system covering the largest area of yarn production. The yarn produced by Ring, Compact, and rotor spinning systems belongs to different structures and properties. Yarn produced Ne 22's, 100% cotton yarn from the above systems, and their properties were tested by UT5 and Titan Universal strength tester. However, this paper focuses on comparing the yarn properties (U%, CmV%, Imperfection, Hairiness, Strength, and elongation) of ring, compact, and rotor spun yarn. Also, it has been observed that yarn produced by compact spinning system revealed highest strength and elongation, least hairiness, and mass irregularity than the other two spinning systems. In addition, it has been observed that rotor spun yarn displayed less mass irregularity than ring spun yarn.

Investigation of the concurrent sliver-opening mechanism and unveiling features of the new dual-feed rotor spinning concept

To examine the effectiveness of the new dual-feed rotor spinning system, we performed a set of experiments to assess the influence of the opening roller type, sliver feed method, and direction of fiber feeding into the rotor on the quality of a polyester/cotton blend yarn. Six yarn samples of 58tex consisting of 55/45 polyester/cotton were prepared in this study. Their respective properties, such as tenacity, elongation at break, mass irregularity, hairiness, thick (+35%) and thin (−30%) places were tested and statistically analyzed using Minitab. ANOVA analysis showed that the tested yarn quality properties were statistically significant among groups except for thick places (+35%). Tukey’s post hoc test based on the honest significant difference was performed to determine the implication of results within groups at the value of α = 0.05. The dual-feed blend yarn (PCLR) spun with opening roller type OK37 on the left and OK40 on the right exhibited superior yarn quality characteristics compared to other samples. Dually carded slivers yielded better yarn quality compared to simultaneously carded ones. The combing direction did not produce a clear trend on the quality of yarns. The study provides important insights into the potential of the dual-feed rotor spinning concept.

Development of biodegradable conductive cotton yarns by in-situ polymerisation of pyrrole

Cotton yarns were modified with pyrrole in the presence of ferric chloride following a dip-nip-dry technique. Treatment of cotton with 23.4% aqueous pyrrole followed by treatment with 40.6% aqueous ferric chloride and subsequent drying in atmospheric air produced balanced improvements in the properties of the yarn such as conductivity, tensile strength and extensibility. Among the three types of yarns such as ring spun, rotor spun and friction spun considered for such treatment, ring spun yarn performed best in respect of conductivity and retention of strength. Examination of surface morphology of yarns by scanning electron microscopy revealed a common discontinuity in the growth of polypyrrole along the length of the yarns spun using friction spinning and rotor spinning systems. Such discontinuity was caused by the wrapper fibres. Ring spun yarn, on the other hand, allowed a continuous spiral growth and deposition of polypyrrole in the inter-fibre space and on the surface of the yarn. Study of pyrrole modified ring spun yarn in a typical photoluminescence system indicated photoluminescence property of such pyrrole-treated cotton yarn.

Effect of an increase in opening roller width on fibre configuration within the yarn structure and wrapper fibres of a rotor spinning system

In second part of the study, width of the opening roller (OR) of the rotor spinning system was increased by 25 and 50%, respectively, and its consequential effect on fibre configuration, wrapper fibres and twist efficiency was accordingly investigated. Observations indicated a positive correlation between widened OR and yarn structure (i.e. fibre configuration and wrapper fibre types).

Effect of geometry of end of the fibre transport channel with slotted exit on rotor spun yarn quality

Geometry of end of the fibre transport channel (EFTC) at the entry to the rotor housing of rotor spinning system has an important effect on yarn properties. In this paper, effect of design of fibre exit edge (FEE) of the transport channel on yarn properties in a slotted model similar to R20 of Rieter was studied. Nine designs of FEE were examined for fibre path and the best one was selected for yarn production. Dimension and positioning of FEE were varied and yarn tensile properties, evenness, imperfections and extent were tested. It was concluded from the test results that the new design improves most of the yarn properties and is superior to the original design.

Effects of spinning conditions on convergent point in rotor-spun composite-yarn spinning process

The forces acting on the components in rotor spinning system cannot shift the convergent point, which can be changed, however, by adjusting speeds of the components. Experimental verification is made, and the result is useful for machine users and engineers.

Using a bench-top rotor spinning system to measure variation between individual fleeces for predicting yarn and fabric characteristics

There is limited information available on variation among individual fleeces in yarn and fabric performance. In this study, 45 mid-side fleece samples (~30 g clean wool) with a wide range in fibre diameter, fibre diameter variation, curvature and felt ball diameter were used to determine whether these fleece characteristics significantly affected yarn and fabric shrinkage, and fabric pilling. Mid-side wool samples ranged from 13.5 to 24.0 µm mean fibre diameter, 46–108°/mm curvature and 22.2–30.2 mm felt ball diameter. Yarn felt shrinkage was significantly (P < 0.001) correlated with fibre diameter (r = –0.52), and total yarn shrinkage (r = 0.99). Fabric felt shrinkage was significantly (P < 0.01) correlated with curvature (r = –0.62), standard deviation of curvature (r = –0.60), and felt ball diameter (r = –0.51). Fibre diameter and curvature accounted for 31% of the variation in yarn felt shrinkage. Standard deviation of curvature and felt ball diameter accounted for 33% of the variation in fabric shrinkage. Fabric pilling was significantly (P < 0.001) correlated with fibre diameter (r = 0.65), with fibre diameter and standard deviation of curvature accounting for 48% of the variation in fabric pilling. These results show that it is possible to predict yarn and fabric shrinkage and fabric pilling outcomes of individual fleeces using raw wool parameters. This study indicates that there is considerable phenotypic variation between individual Merino fleeces in the properties of yarn and fabric produced, suggesting that it is possible to quantitatively select individual sheep directly for yarn and fabric outcomes to improve the consumer performance of woollen fabrics.

INFLUENCE OF CORE COMPONENT ON THE PROPERTIES OF FRICTION SPUN YARNS

Abstract Friction (DREF II) spinning system is one of the promising spinning methods to produce yarns for technical textile applications. The core positioned exactly center and the spinning tension will be very less compare to ring and rotor spinning systems. In an experimental study to produce 6's Ne core spun yarns in DREF II spinning machine, the polyester /viscose (70/30%) sliver was used as sheath component and drawn polyester filaments (150 denier/36) were used as core component. Yarns were produced with the different core/sheath components (0/100%, 16/84%, 30/70%, 50/50% and 70/30% respectively).Friction ratio was kept at 3.33 and the feed rate was changed to produce above 6's Ne core spun yarns. Core spun yarns found that more even and high modulus than the parent friction spun yarn. The filament-core in the yarn appeared to have twisted configuration. The direction and level of twist was difficult to ascertain in these yarns. High core component yarns were found less hairy. S3 values of the yarn found minimum with increment in the core proportion in the yarn. Sheath strength contribution was analyzed with respect to the core filaments and found that the less core proportion yarns have high contribution to the tenacity.

Determining an Optimum Opening Roller Speed for Spinning Polyester/ Waste Blend Rotor Yarns

The opening roller, which is one of the three most important items in the OE rotor spinning system, influences yarn quality and spinning performance. In addition to the raw materials, roller speed and type are critical. In this work, seven different polyester/waste (cotton noil, recycled fibers, flat waste, etc.) rotor yams are produced at seven different opening roller speeds on a laboratory-type OE rotor spinning machine (Quickspin), and the influence of opening roller speed on yarn quality is examined. A high opening roller speed is recommended, while spinning waste content does not provide the expected results.

A Method for Estimating the Spinning-potential Yarn Number for Cotton Spun on the Rotor-spinning System

A test for determining the spinning potential of cotton fibers on the rotor-spinning system is proposed. It is based on the minimum twist required to rotor-spin a fixed yarn size. By using known mathematical relationships inherent in the physics of yarn formation, the minimum twist results are transformed into the theoretically finest yarn count that may be spun commercially. Implications of the effects of some key fiber properties un rotor-spinning performance are clarified.

A Study of the Influence of Fibre Properties on the Characteristics of Rotor-spun Yarns by Factor Analysis

The influence of important fibre properties such as the 2.5% span length, Micronaire value and breaking tenacity on the characteristics of 30-tex yarns spun on the rotor-spinning system from 32 different varieties of Indian cotton has been investigated by the technique of factor analysis by using the SPSS package on a DEC 2020 computer. The behaviour of corresponding ring-spun yarns from the same cottons has also been evaluated for comparative interpretation. Factors expressed in terms of variables lead to the development of new expressions for yarn and fibre quality indices. The method of factor analysis used in the present study confirms a lower degree of exploitation of fibre properties into the yarn characteristics of rotor-spun yarns as compared with ring-spun yarns, which is attributed to the difference in structure of these two types of yarn. Factor loadings obtained by the iterative rotation of the correlation matrix indicate a much higher impact of cotton fibre length on the rotor-spun yarns than...

A Comparative Study of the Properties of Cotton Yarns Spun on the DREF-3 and Ring- and Rotor-spinning Systems

An investigation is reported in which equivalent ring-spun, rotor-spun, and DREF-3 yarns in three counts, 6s, 12s, and 18s Ne, were produced from four different cottons by using optimum process parameters appropriate to each system. Yarn-quality characteristics were assessed and compared. The results revealed that, for a given cotton, ring spinning produces the strongest yarn whereas rotor spinning yields the most even yarn, hut the DREF-3 friction-spinning system also results in a very uniform yarn in terms of appearance.

Preparation and Spinning of Wool with the Rotor-Spinning System

When spinning wool on the rotorspinning system, some conditions for the choice of the wool and its preparation must be observed. Also, the spinning elements such as feed roller and plate, opening roller, feed channel, rotor, and doffing tube must be adapted to the specific demands for wool. These considerations have led to a successful industrial applica tion of the rotorspinning system for wool. Rotor spun wool yarns are used for woven fabrics for example, furnishings, upholstery, blankets, outerwear, and knitted fabrics.