Spinning System Research Articles

THE EFFECT OF ELECTRIC PULSE TREATMENT ON THE PROPERTIES OF HEMP FIBRE

The production of competitive textile products can be ensured by using natural, environmentally friendly fibres, which include hemp fibre, as raw materials. To expand the possibility of its use, an essential operation is the pre-treatment of the fibre. The use of electric pulse processing of hemp fibre will provide the ability to control the depth of cottonization, select optimal parameters that collectively evaluate the spinning ability of the fibre and correspond to the permissible similar indicators of cotton fibre. The purpose of the work done is to study the mechanism of electric pulse processing of hemp fibre by identifying its structural characteristics under various processing modes for further use. The work carried out studies of the process of cottonization of hemp fibre by a physical-mechanical method using an electric pulse discharge from 500 to 2500 cycles. An effective mode of electric pulse processing of fibres has been established, amounting to 2500 pulses of electric discharges, which makes it possible to obtain cottonized hemp fibre with the required spinning ability. The parameters of cottonized hemp fibre have been determined, allowing the use of hemp cottonin to produce mixed yarn using a card spinning system on cotton spinning equipment.

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.

Thermoplastic bicomponent‐fibers for organosheets via inline polymerization

AbstractState‐of‐the‐art organosheets suffer from several shortcomings that limit their applicability in high‐performance materials, mainly due to the imperfect combination of glass fibers and polymer. To overcome these issues, a novel hybrid fiber is presented, in which every single filament consists of a glass core and an individual, thin, thermoplastic polymer coating. Those fibers can immediately be consolidated into organosheets, without the necessity of the critical combination step. Production is realized by an ultra‐rapid inline coating of the filaments, incorporated into a standard spinning system. This solvent‐free process is realized by coating of the fibers with a tailor‐made, monomeric precursor solution, which is radiation‐polymerized immediately after application. Within fractions of a second, the coating layer is thus solidified, before coiling of the hybrid fiber. Due to the very low thickness of the coating and specific formulation of the precursor, tackless layers can be achieved before the coiling, even at industrial spinning speeds.Highlights Glass fibers are coated with a thermoplast via in situ polymerization. A precursor is developed which polymerizes in 100 ms. Glass fibers are coated completely with thermoplast by using a UV tunnel. Spinning velocities of about 600 m/min can be achieved. Hybrid fibers are consolidated into glass fiber‐reinforced plastics (GFRP).

Study of Thermal Comfort Characteristics of Bi-layer Knitted Fabrics Made by Various Types of Spinning System Yarns

Study of Thermal Comfort Characteristics of Bi-layer Knitted Fabrics Made by Various Types of Spinning System Yarns

Compact Spinning with Different Fibre Types: An Experimental Investigation on Yarn Properties in the Condensing Zone with 3D-Printed Guiding Device

Abstract The lattice apron-based compact spinning system is a form of pneumatic compact spinning that employs airflow to condense fibres into a bundle, enhancing the yarn’s attributes. To explore the airflow dynamics in pneumatic compact spinning, researchers primarily employ traditional theoretical approaches, experimental measurement techniques, and computational fluid dynamics (CFD) methods. In our previous research, we utilized CFD to observe the airflow patterns in pneumatic compact spinning. In this study, we implemented experimental measurement techniques to assess the impact of a 3D-printed guiding device (B-type) on yarn properties. We tested different fibre types in the condensing zone of the compact spinning system with a lattice apron. We used three types of roving to spin the yarn: pure cotton, cotton/polyester (80/20), and polyester/viscose (65/35). The findings revealed that yarns spun using the guiding device exhibited superior strength, hairiness, and evenness compared to those spun without the device.

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.

An efficient and scalable melt fiber spinning system to improve enzyme-based PET recycling

Chemical recycling technologies based on hydrolase enzymes that can depolymerize PET thermoplastic are emerging, yet these approaches require the polymer to be low crystallinity to achieve high conversion. To prepare the polymer for enzymatic depolymerization, current processes rely on melting and cryomilling PET at depressed temperatures to reduce crystallinity and prevent annealing during micronization; however, these approaches require large capital investment in costly equipment, and are not easily incorporated into intermediate-scale, distributed systems. Here, we describe a melt fiber spinning system that achieves significant reduction in crystallinity for real-world PET feedstocks without the need for any active cooling, and can easily be scaled up or down as needed. Single-use water bottles and drinking cups are tested, where they are extruded, drawn and spooled as thin fibers that cool by passive heat dissipation rapidly enough to quench the polymer to low crystallinity (<10%). Additionally, we estimate the fiber spinning also increases the feedstock surface-area-to-volume ratio by up to 15-fold, which further benefits heterogenous enzyme biocatalysis. In small scale PET hydrolase enzyme incubation tests, fiber spinning increased monomer released from PET by 4-fold for drinking cups and 10-fold for water bottles compared to shredded-only controls. Finally, we also show that this system can scale to >300 gs, with the potential for much larger scales, and allows for >95% depolymerization in a larger 20 liter bioreactor run.

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.

Effect of SiO2-doped nanoparticle/electrostatic spinning system on the electro-optical properties of polymer dispersed liquid crystals for smart windows

ABSTRACT Polymer Dispersed Liquid Crystal (PDLC) films are attracting increasing attention as versatile and innovative material for use in electrical switching and flexible devices. This paper investigates the effect of a Poly(methyl methacrylate (PMMA) nanospun membrane system doped with SiO2 nanoparticles on the electro-optical properties and transmittance/voltage slopes of thiol- and acrylate-based PDLC films. Experimental samples were prepared for testing by adding mixtures of liquid crystals and crosslinkers in different proportions to liquid crystal cassettes doped with PMMA/SiO2 nanospun membranes. The size of the polymer mesh was found to influence all parameters of PDLC. The phase separation process, which determines the morphology and electro-optical properties of PDLC films, is directly affected by the doping of different components of PMMA/SiO2. The doping of the PMMA/SiO2 system resulted in improved optoelectronic properties of PDLC films, significantly enhanced weathering resistance, and increased the degree of intelligent regulation of the transmittance of PDLC films. Thus, by developing PDLC-doped reticulated nanofibre films with faster response times and better electro-optical properties, the potential for technological applications of PDLC-based devices in optical windows, displays, energy storage and flexible devices can be significantly enhanced.

Ultralong and highly axially aligned nerve guide conduits produced by electro-centrifugal spinning

The fabrication of nerve guide conduits (NGCs) with axially aligned fibers has been realized by electrospinning; however, the reported maximum length of such NGCs is limited to 2 cm which cannot repair a long injured peripheral nerve. In this context, a modified electro-centrifugal spinning (ECS) system is developed to produce ultralong and highly axially aligned NGCs. To this end, medical-grade poly (lactic-co-glycolic acid) PLGA with L-to-G ratios of 8/2, 7/3, and 5/5 loaded with antibiotic ciprofloxacin (CIP) are used to investigate the corresponding spinning mechanisms and drug release behaviors. Specifically speaking, first, the effects of chloroform/trifluoroethanol co-solvents and drug loading on the spinnability and fiber orientation of PLGA are systematically investigated, and tubular conduits are produced with the established method. Second, uniaxial tensile tests and cyclic compressive tests for the conduits with and without drug loading are conducted; PLGA conduits with an L-to-G ratio of 8/2 are further annealed to enhance their mechanical properties. Last, the drug release behavior of the conduits in vitro is studied. As a result, highly fiber-aligned NGCs with a length of over 10 cm, combined with excellent mechanical properties and well-controlled drug release features can be efficiently produced. Therefore, this work provides a practical strategy for producing NGCs with high efficiency.

Investigating the influence of yarn characteristics on microfibre release from knitted fabrics during laundering

Microfibres generated and released during the use and laundering of textiles have been identified as an important source of environmental pollution. The quantity of microfibres released from a fabric can be influenced by several external factors, such as laundering conditions and consumer use, as well as intrinsic factors such as the fibre composition, yarn characteristics, and fabric structure. This study investigates the influence of various yarn characteristics on microfibre release from knitted fabrics as well as exploring the generation of microfibres during the knitting process. Fibre composition and the yarn spinning system has the greatest influence on microfibre release. The greatest quantity of microfibre was released from ring-spun lyocell (1313 ± 140 mg/kg) and the lowest quantity was released from vortex-spun polyester (80 ± 26 mg/kg). The yarn spinning system was also found to have a significant influence, with vortex-spun yarns consistently demonstrating lower microfibre release than corresponding ring-spun yarns, likely due to the reduced hairiness of yarns spun by the vortex system. The importance of fibre damage during the knitting process was also investigated. Several yarns demonstrated significantly greater microfibre release in knitted form compared to loose, hank form, but the scale of difference was found to be dependent on fibre composition.

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.

Numerical simulation and experimental investigation of lattice-apron compact spinning with an air guide

The four-roller compact spinning system is widely used today and is considered an improvement over traditional ring spinning because of its excellent yarn properties. Reducing energy consumption in compact spinning has always been a key issue for the textile industry. This paper proposed a method for installing an air guide on compact spinning to reduce energy consumption. Four types of air guides were designed with different side shapes (Type-N, Type-L, Type-R, and Type-LR), and the airflow characteristics in the converging zone were analyzed using numerical simulation. In addition, high-speed photography technology and image-processing technology were used to study the dynamic state of the fiber bundle in the flow field of the converging zone. The effectiveness of the preferred solution of the air guide was also verified by spinning experiments. The results revealed that the best air guide was Type-LR, achieving a 3.7% reduction in yarn hairiness even after a decrease in negative pressure by 800 Pa and a 58.4% reduction in power of the fan motor, surpassing the yarn quality observed without any air guide.

The ratio of fibroin to sericin in the middle silk gland of Bombyx mori and its correlation with the extensional behavior of the silk dope.

Understanding how native silk spinning occurs is crucial for designing artificial spinning systems. One often overlooked factor in Bombyx mori is the secretion of sericin proteins. Herein, we investigate the variation in amino acid content at different locations in the middle silk gland (MSG) of B. mori. This variation corresponds to an increase in sericin content when moving towards the anterior region of the MSG, while the posterior region predominantly contains fibroin. We estimate the mass ratio of sericin to fibroin to be ~25/75 wt% in the anterior MSG, depending on the fitting method. Then, we demonstrate that the improvement in the extensional behavior of the silk dope in the MSG correlates with the increase in sericin content. The addition of sericin may decrease the viscosity of the silk dope, a factor associated with an increase in the spinnability of silk. We further discuss whether this effect could also result from other known physicochemical changes within the MSG.

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.

Analysis of input angles of fibrous masses of exhaust steam devices

In existing spinning systems when processing natural, artificial and synthetic fibers into yarn, the main task of the technological process is to obtain sliver, roving and yarn that is uniform in structure and properties by folding and drawing. The article proposes a theoretical analysis of the entry angles of the fibrous masses of the exhaust steam of an exhaust device. The entry angles of the fibrous masses of the existing and new design of the pressure roller with reduced diameters were compared.

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.

Nucleotide-based regenerated fiber production using salmon (Oncorhynchus keta) milt waste by solution spinning

The use of nucleic acid-derived fibers has not been developed in contrast to the traditional use of polysaccharide- and protein-based fibers in daily life. Salmon, Oncorhynchus keta, is an abundant fishery resource, and its milt contains a huge amount of DNA. Most of the milt is discarded because it degrades easily and is unsuitable for food consumption. DNA-based fibers are expected to possess functionality and mechanical strength because DNA is a polyanion with a high molecular weight. Here, using DNA extracted from the salmon milt, we produced nucleotide-based fibers. A solution spinning system was applied using ethanol as a coagulant. Adding the salt to the dope solution reduced the solubility of DNA, which was essential for the successful spinning of DNA-based fibers. The obtained fibers became insoluble in water by ultraviolet (UV) exposure. Fibril-like structures were detected on the fracture surface, and humidity influenced the conformational structure. This study focuses on the bulk-scale production of biodegradable DNA-based fibers. Therefore, it can be used not only for clothing and filters but also as a functional material to remove harmful pollutants released into the ocean, such as heavy metal ions and aromatic derivatives.

İplik Teknolojileri ve Makinaları Konularında Türkiye'de Yazılmış Lisansüstü Tezlerin Nicel Olarak Değerlendirilmesi

Yarn and spinning technology is a complex process that is a combination of raw materials, machinery, and automation technology where continuous improvements, researches and innovations run progressively. For the evolution of spinning technology, academic publications, postgraduate theses, and technological contributions of related shareholders must be considered as adherent supplements. Aim of this study is to examine the accomplished 236 postgraduate theses related to conventional and novel textile fibre types, staple spun/filament yarn technology and machinery, yarn types with structural and functional varieties, and modified spinning technologies in Turkish Universities. Moreover, it is aimed to reveal any trend in theses on yarn technology and the regional textile clusters in Türkiye. The methodology of the pursuit is a quantitative assessment where postgraduate level, thesis subject, year of thesis defence, and raw materials used in the theses are concerned. The findings showed that researchers focussed on conventional spinning systems and yarns in parallel with the spinning capacity and import potential of the country. Other extractions of the study are; classical ring system is mostly studied by the researchers, modern spinning technologies are included in many theses, reflections of global circumstances are distinguished in theses with keywords of manmade/recycled fibres, and blended yarns.