Process flow chart of Spinning
Process flow chart of spinning-
Cotton Bale Blowroom
↓
Carding
↓
Drawing
↓
Combing
↓
Drawing
↓
Roving/ Speed/ Simplex Frame
↓
Ring Spinning
↓
Yarn
Blowroom
The section where the supplied compressed bale is turned into a uniform lap by opening, cleaning, blending or mixing.
Functions of Blowroom:-
Opening: Open the cotton bales.
Cleaning: Eliminate dust, dirt, broken leaf, seed particles, grass.
Blending / Mixing: By blending/mixing different types of cotton produce a comparatively good quality cotton.
Lap Forming: Convert the opened and cleaned fiber into a sheet form.
Flow Chart of Blowroom (Modern):
Bale plucker
↓
Metal detector
↓
Uniclean
↓
Unimix
↓
Uni flex
↓
↓
Vision shield
↓
Condenser
Chute feed
↓
Carding
Carding
Carding is the reduction of entangled mass of fibers to filmy web by working them between two closely spaced relatively moving surfaces closed with sharp points.
To remove the small trash particles.
To give some degree of blending.
To eliminate the remaining impurities.
To produce a thick untwisted rope of fibers called sliver.
Reduction of naps.
Fiber orientation.
Elimination of short fibers.
Main Parts:
Taker-in: The region from lap roller up to cylinder is known as taker-in.
Cylinder: The cylinder get opened with sharp teeth and then pass over to doffer.
Doffer: The doffer take the cleaned cotton.
Combing
The process of straightening or parallelizing of fibers and removing of short fibers and impurities by using brushes and rollers is called combing.
Objectives of Combing
To remove naps in the carded sliver.
To make the fiber more parallel and straight.
To produce a uniform sliver of required per unit length.
To remove the fiber shorter than a predetermined length.
To remove remaining impurities in the comber lap.
Formation of sliver having maximum possible evenness.
Drawing
Drawing is the process in which the slivers are blended, doubled, leveled and drafted by passing the slivers through a series of pairs of rollers.
Function Of Draw frame Machine
To straighten the crimped and hooked fibers.
To achieve a fairly through parallelization of the fibers.
To improve the short, medium and long term unevenness of the slivers by doubling.
To produce a more uniform sliver.
To reduce the weight/unit length of the card sliver.
Roving/Speed/Simplex Frame
Simplex is an intermediate process in which fibers are converted into low twist lea called roving.
Operations Involved in Simplex Machine:
i. Creeling
ii. Drafting
iii. Twisting
iv. Winding
v. Building
vi. Doffing
Functions Roving/Speed/Simplex Frame:
To prepare the package for the R/F.
To draft the sliver to reduce weight per unit length.
Insert small amount of twist to give required strength of roving.
Wind the twisted roving on to the bobbin.
Build the roving in bobbin such a form which will facilitate handling, withdrawing & transfer to the next process.
Ring Frame
Spinning process is done by the Ring frame machine. Ring frame converts the bobbin into yarn.
Functions of ring frame:
Draft the roving until the required fineness is achieved.
Twist the drafted strand to form yarn of required count and strength.
Winding the twisted yarn on to the bobbin for suitable storage, transportation and further processing.
Advantage of Ring Spinning System:
i. Any type of material (fiber) can be spun.
ii. Wide range of count can be processed.
iii. It delivers a yarn with optimum characteristics.
iv. Idealized twisting system.
v. It is uncomplicated and easy to operate.
vi. Higher yarn strength can be achieved
Disadvantages of Ring Spinning System:
i. Low production.
ii. Machine generates more heat .
Structure
Spun yarn is made by twisting staple fibers together to make a cohesive thread, or "single. "Twisting fibers into yarn in the process called spinning can be dated back to the Upper Paleolithic, and yarn spinning was one of the very first processes to be industrialized. Spun yarns may contain a single type of fiber, or be a blend of various types. Combining synthetic fibers (which can have high strength, luster, and fire retardant qualities) with natural fibers (which have good water absorbency and skin comforting qualities) is very common. The most widely used blends are cotton-polyester and wool-acrylic fiber blends. Blends of different natural fibers are common too, especially with more expensive fibers such as alpaca, angora and cashmere.
Yarn is selected for different textiles based on the characteristics of the yarn fibers, such as warmth (wool), light weight (cotton or rayon), durability (nylon is added to sock yarn, for example), or softness (cashmere, alpaca).
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