A Research on the Compact Spinning for Long Staple Yarns
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Pinar Çelik, Hüseyin Kadoğlu A Research on the Compact Spinning for Long Staple Yarns Ege University, Department of Textile Engineering 35100 Bornova, Izmir, Turkey Abstract E-mail: [email protected] Compact spinning produces a new yarn structure, as the edge fibres are incorporated into the [email protected] yarn due to the elimination of the spinning triangle, so that the harmful effects of the spinning triangle on yarn characteristics are eliminated. The compact yarns possess less hairiness, better strength, better uniformity and lower values of thick & thin places and neps compared to the conventional ring-spun yarns. In this article, some quality parameters of long-staple compact yarns are compared to those of long-staple conventional ring yarns. Key words: compact spinning, conventional ring spinning, spinning triangle, worsted spin- ning, yarn hairiness, yarn tenacity. n Introduction yarn hairiness, especially on eliminating with lower twist coefficients, resulting in the longer hairs which have a particularly an increase in production rate, and also Compact spinning technology has been bad influence on the further process[ 4]. better handling properties of the end- gaining much more interest since its first product. commercial introduction at ITMA-Paris Many researchers have described the tech- in 1999. These spinning machines have nical principles of compact spinning and Another advantage of the compact spun been installed in several spinning facto- the more organised structure without pe- system is the fly and dust reduction as an ries all over the world. Compact spinning ripheral fibres and with a better twist dis- effect of condensation. The cleaning re- is a modified ring spinning process which tribution. The compact yarn shows higher quirement is reduced when compared to has special advantages, and can be used strength, reduced hairiness, and improved conventional ring spinning frames. in both short- and long-staple yarn spin- evenness. (Artzt, 1997 [5]; Olbrich, 2000 ning areas. [4]; Stalder, 2000 [3]). M. Nicolic et al. Compact spun worsted yarns also have [10,11]are among those researchers who the advantages of better quality proper- The zone between the line of contact investigated the similarities and differenc- ties and different surface specifications, of the pair of delivery rollers and the es in the structural, mechanical/physical which will help to improve further twisted end of the yarn is called the and texturing properties of ring-spun yarns processing and increase their production spinning triangle. In this zone, the fibre of 20 tex, manufactured from various yarn rate [7]. assembly contains no twist. Edge fibres blends (combed cotton, PET, CV, PA) splay out from this zone, and make little When using compact yarns, and allow- or no contribution to the yarn strength. from the same sliver, employing compact spinning on the Fiomax 1000 and Fiomax ing for the same level of warp breaks, The spinning triangle is the critical the consumption of sizing agents can weak spot of the spinning process [1]. E1 ring-spinning machines from Suessen. According to their test results, the qualities be reduced. This provides considerable cost savings in sizing and de-sizing. The The spinning triangle prevents the edge of compact yarns are better than those of same is true for warp breaks in weaving. fibres from being completely incorporat- ring-spun yarns [10,11]. ed into the yarn body. However, in com- Compact yarns permit better yarn regu- pact spinning, the drafted fibres emerging The compact spinning process produces larity and the formation of a smoother from the nip line of the front roller of the a new yarn structure which approaches yarn surface. This reduces the number drafting arrangement are condensed in a the ideal staple fibre yarn construction of end-breaks by 30-50%, and leads to line [2]. even more closely. This has positive savings in the weaving department with effects on raw material use, productiv- significant improvements in efficiency, in Ring-spun yarn is not perfect. If the ity, downstream processing, and on the the range of 3-5% [6]. enlarged view of ring spun yarn is exam- product appearance [5]. ined, it is easy to see that the integration Industrial trials of compact yarns have of many fibres is poor, and they therefore The end breaks in spinning are approx. revealed a fly reduction of 1/3 on the make no contribution to yarn strength. 50% fewer, which permits the reduction In other words, if all fibres could be of the number of fibres in the cross-sec- completely integrated in the yarn, both tion, or to spin a finer yarn count. Reduc- strength and elongation could in turn ing the possibility of the number of fibres be further enhanced. It is thus obvi- in the cross-section allows for the use of ous that even ring-spun yarns are not lower-priced tops with coarser fibres [6]. yet ideal as regards yarn structure [3]. In compact yarns, fibres are uniformly The development of the compact spin- oriented and joined into the yarn right ning process began with the desire to after the end of the drafting arrangement. achieve a significant step for yarn quality Therefore, better tenacity, elongation, by influencing the spinning triangle (Fig- and hairiness properties can be ensured. ure 1). This work is focused on achieving The better tenacity properties of compact Figure 1. Conventional and compact ring higher yarn strength and a reduction of spun yarn provide opportunities to work spinning yarns (Spinnovation 7/2000) [9]. FIBRES & TEXTILES in Eastern Europe October / December 2004, Vol. 12, No. 4 (48) 27 knitting machine. If one considers the compact spinning equipments (Suessen the test results, statistical results and F number of faults due to knitted-in fly EliTe) was available. It was thus pos- values are found in Çelik [12]). lumps as a percentage of the total fault sible to compare both the systems under count in knitting, there is distinct cost- identical machine conditions. Table 1 Yarn evenness reducing potential here with the use of shows the experiment plan. After the these yarns. [5] With their increased yarn spinning trials, the physical properties of When we examined the yarn evenness of strength and reduced formation of fluff, each yarn sample were measured, and the 100%-wool yarns, the Uster CV% and compact yarns permit higher machine measurement results of conventional ring the thin place values of both compact and efficiency to be achieved, and therefore yarns and compact yarns were compared conventional yarns were found to have production on knitting machines can to each other. a statistically significant difference for a achieve a reduced ends-down rate, fewer significance level of α=0.05 for both 19 interruptions and fewer fabric faults [8]. Yarn evenness (CV%), thick & thin tex and 25 tex yarn counts (Figure 2). On places, nep values and yarn hairiness the other hand, the differences of the two values were measured with an Uster spinning systems in terms of the mean n Experimental Tester 3 (the measurement length was numbers of thick places and neps of Materials and methods 400 m/bobbin). Yarn tenacity (cN/Tex) 100% wool yarns were found to be sta- tistically significant for only the fine yarn In this study, we compared the yarn and elongation at break (%) were meas- count, 19 tex. The Uster CV%, the thin properties of compact yarns and the ured with a Statimat M. In addition, yarn and thick place values of compact and conventional ring spun yarns in terms of hairiness was also measured with a Zwei- yarn hairiness (the number of protruding gle G565 yarn hairiness tester (the meas- conventional 45% wool/55% PET yarns fibres on the yarn’s surface), yarn even- urement length was 100 m/bobbin). were found to have a statistically signifi- ness, tenacity and elongation (%). cant difference for 19 tex (Figure 3). n Results and Discussion The experimental work of this study was When we examined the yarn irregular- conducted on a Long Staple Tester PR The compact spun yarns had better yarn ity CV%, there was a statistically sig- 135 ring spinning machine by using four property values - irregularity, thinand nificant difference between the compact different raw materials. Compact spin- thick places, nep values, yarn hairiness, and conventional ring yarns which was ning has some advantages for both weav- tenacity and elongation at break (%) produced with 50% wool/50% PAN for ing and knitting. The 100% wool and - than the conventional ring spun yarns both two yarn counts, 25 tex and 36 tex, 45% wool/55% PET materials were spun for all material types. The 100% wool and all twist factor levels; but the differ- with weaving twist factors, and the 50% yarn hairiness test results were given in ences of two systems were found to be wool/50% PAN and 100% PAN materials Table 2 as an example. statistically significant in terms of thin were spun with knitting twist factors. In and thick places for fine yarn count only, the market, acrylic yarns and their blends The results obtained from the laboratory 25 tex (Table 3). with wool are usually preferred for knit- testing of yarn samples were statistically ting products; on the other hand, wool evaluated by using SPSS software. Vari- The differences of compact-spun and and wool/PET worsted yarns are usually ance analysis was applied, and by using conventionally-spun yarns which were preferred for woven products. F values we tried to find out if there was produced with 100% PAC, in terms of any statistically significant difference the Uster CV% and I.P.I. values (thin & On the ring spinning machine, the op- between the yarn quality data of conven- thick places and neps) were not found to tion of spinning compact yarn by adding tional and compact yarns.