This documents help to us and give advance knowledge of Textile Yarn Manufacturing Technology.

1. AKM Sahedujjaman (SAJU)
Student of Textile Engineering
City University, Dhaka
Email:shahedsaju2015@gmail.com
Cell: 01737-171048
Combing action:
The straightening and paralleling of fibers and the removal of short fiber are neps and impurities by
using a comb or combs assisted brushes and rollers is called combing action.
Objects of combing action:
 Elimination of a precisely, pre-determined amount of short fiber.
 Elimination of remaining impurities.
 Elimination of large proportion of neps from the fiber material.
 Formation of combed sliver with maximum possible evenness.
Sequence of operation of comber:
I. Felling
II. Nipping
III. Rotary combing
IV. Nipper forward
V. Web return
VI. Piecing
VII. Detaching
VIII. Combing by the top comb
IX. Top comb withdrawing
X. Brushing
Noil:
The waste found in comber machine which mainly short fibers or neps.

2. Production calculation of comber:
Lap weight = 750 grain/yards
Nips/min =300
Feed/nips = 5.5 mm
Noil =15%
No of head = 8
Calculate the production hour /shift ?
Solution:
Here,
Lap weight = 750 grain/yards [7000 grain= 1 pound]
Nips/min =300
Feed/nips = 5.5 mm
Noil = 15% = =85/100 =0.85
Prod. / hrs. =
=
=30.31 kg
=30.31 8 (1 shift =8 hours)
= 243 kg (Ans.)
Objectives of lap formation:
I. To produce a suitable lap formation for combing.
II. To wind the lap or bobbin.
III. Facilitate the next subsequent process.
Working principle of super lap former:

3. Fig: super lap former
In this machine, 42 slivers are used to form the lap . Dram sliver are arranged on a creel in three individual vertical columns. The
machine has a three layered feed table. From the 1st
column (on left) sliver are enter to the bottom layer of the table, then from the
mid column to the mid layer and from the 3rd
columns to the layer. The slivers move forward though the pairs of guide rollers
(Leather coated top roller and fluted steel bottom). The table is made of metal, the slivers can slip and move on to it. Then the
three layers of slivers from three layers of feed table entre to the 4 over 4 drafting zone. After drafting the lap is wound on to
bobbin by the help of two lap rollers.
Simplex / roving frame
Objective of simplex / roving frame:
I. To form the required hank of roving by drafting.
II. To insert small amount of twist to give required strength roving.
III. To wind the roving on bobbin.
IV. To build the roving on bobbin in such a form this will facilitate handing and withdrawing.
Necessity of simplex:
I. High draft range cannot be achieve in one frame to form yarn to sliver.
II. Drawn sliver is not in such a form so that it can be feed directly to the ring frame.
Functions of simplex:
Cree ling:
To arrange finisher drawn frame sliver toward creel for further processing.

4. Drafting:
A process of drawing out laps, slivers and roving to decrease the thickness .
Twisting:
Method of on an imparting twist.
Winding:
A process of accumulating roving on bobbin.
Building:
Technique of forming bobbin to a uniform shape.
Doffing:
The removal of textile material or package from a textile machine.
Modern drafting system (Apron draft):
Characteristics of modern drafting system:
1. Roller weighting is spring or pneumatic.
2. Not require to change the roller setting due to slight variation of fiber length.
3. Apron (Endless synthetic or rubber sheet) is used here and fiber moves with its contact.
4. There is a control or fiber while leaving the nip point, so fiber controlling l is better.
5. Apron may be single (Bottom drafting roller) or double both top and bottom drafting system.
6. Helps to maintain fiber alignment.
Roller hardness:
 Hardness of synthetic coating is expressed by shore and denoted by degree.
 Hardness is highest at back gradually decrease to the front.
Example:
Back - (75-80)
Front – 65
Twist insertion on roving/flyer:

5. Function of flyer:
 Helps to insert twist on strands of fiber.
 Holds the roving.
 Helps to wind.
 Helps for building.
Calculation of T.P.I (twist per inch):
T.P.I =
Factors considered for T.P.I in simple machine:
 Staple length of fiber(staple length , strength ,twist ,production )
 Fineness of fiber ( Mic , fineness ,no of fiber in cross section , twist )
 Hank of roving ( count , twist )
 Types of material ( Polyester : twist cotton : twist )
Bobbin loading principle of winding:
I. In order to wind roving on to bobbin, the bobbin speed must be higher than spindle/
flyer speed, at point of winding.
II. With increase in bobbin diameter the bobbin speed must be decreased.
III. The reduction of bobbin speed with in bobbin diameter must be re-corrected.
IV. The variation of bobbin speed with the increases in bobbin diameter must be
synchronized.
Change wheels in simplex:
 DCP – Draft Change Pinion.
 DCCP – Draft Constant Change Pinion.
 TCP – Twist Change Pinion.
 TCCP – Twist Constant Change Pinion.
 RCW – Retched Change Wheel.
 LCP – Lappet Change Pinion.

6.  SSCP – Surface Speed Change pinion.
 PCW – Pigeon Change Wheel.
 SWCP – Spur Wheel Change Pinion.
 BCDCP – Back Constant Draft Change Pinion.
Common faults or problem in simplex machine:
1. Stretch roving:
I. Improper cone drum belt starting position.
II. Improper no. of rat chest wheel teeth.
III. More tension draft.
2. Rigidity bobbin (uneven bobbin surface):
I. Faulty bobbin rail movement.
II. Broken lifter shaft bearing.
3. Soft bobbin :
I. Less no. of teeth in new.
II. Less winding speed with respect to delivery speed.
III. Higher rate of bobbin rail speed (less coil / inch).
4. Unequal tapering :
I. Unequal setting of pucker rod (Imperfect leveling).
II. Unequal pucker rod.
5. Doubles :
I. Double sliver feeding.
II. After breaking if the roving attach with another.
III. Long piecing.
6. Slough off :
I. Improper tapering.
II. Imperfect building motion.
7. Cut- roving:
I. Closer setting of two drafter roller.
II. High top roller weight.
III. Broken gear of drafting zone.
8. Irregular roving :
I. Irregular feed sliver.
II. Roller lapping.
III. Incorrect distribution of draft.
IV. Incorrect tension draft.
V. Worn out drafting roller.
9. Excessive and breaking :
I. Loose cone drugs belt.
II. Insufficient twist.
III. Roller lapping.
IV. Higher tension draft.
V. Higher or lower winding or speed than delivery.
VI. Thick or their or stubby roving.
10 . Slobs :
I. Improper drafting.
II. Irregular feed sliver.
Causes of reducing the efficiency of simple machine:
1. Cree ling

7. 2. Roving breakage
3. Bad sliver
4. Schedule maintain
5. Break down maintain
6. Shortage of sliver
7. Doffing
8. Mechanical problem
9. Electrical problem
10. Power failure
11. Quality change
12. Improper relative humidity%
13. Unskilled worker
14. Lot change
Recent development in modern simplex (roving):
1. Improved drafting system
2. Higher flyer speed
3. Polymer made flyer
4. Auto stop motion
5. Inching motion
6. Data monitoring system
7. Cone drum belt returns automatically
8. Suction unit drafting zone
9. Air blower introduced
10. Auto doffing
Production calculation of simplex machine:
Given data,
Spindle speed=11.50 r .p. m
No of spindle=120
T.P.I =1.2
Roving hank = 0.68 Ne
Efficiency = 85%
Prod. / Hours. =
=
=129.37 kg
Ans. 129.37 kg
Ring frame
Object of ring frame:
I. Drafting to form yarn.

8. II. To impart twist in yarn to hold the fibers.
III. To wind yarn into bobbin.
IV. To build the bobbin in such a way this will facilitate handling as well as the subsequent process.
Causes of using ring frame (why should we go for ring frame):
 It is universally applicable. That means any material can be spun to any required thickness.
 It delivers a yarn with optimal characteristics.
 It is an uncomplicated process.
 Operation of the machine is well as established and accessible to everyone.
Functions of ring frame:
Cree ling: To arrange roving bobbin towards creel for further processing.
Drafting: A process of drawing roving and to from yarn.
Twisting: Method of imparting twist.
Winding: A process of accumulating yarn or package (cone)
Building: Technique of winding yarn onto bobbin in a suitable shape.
Doffing: The removal of yarn or package from a textile machine.
Creel:
A structure of holding supply package in textile processing is called creel.
Fig: creel
Spacer:
Plastic element which maintains space between two aprons are termed as spacer. Finer the count, less the space required
between aprons.

9. Example:
Red spacer 2.5mm
Yellow spacer 3.5mm
Black spacer 2 mm
Green spacer 4 mm
Count wise spacer size:
Up to 20 ne 4.5mm
Up to 20-30 ne 3.5mm
Up to 30-60 ne 3 mm
Up to 50-80 ne 2 mm
Traveller:
The metal or plastic element/component through which yarn passes its way from the ballooning eye to the package
surface in ring spinning is called traveller.
It is mounted on a ring and is dragged round by the yarn. It is the must tiny part in ring frame, but impossible to produce
yarn without its help.
Objective of using traveller:
I. To insert twist to the drafted strands of fiber.
II. To maintain spinning tension.
III. To help to wind the yarn on package.
IV. Act as a thread guide.
Types of traveller:
According to shape:
J shape
SU shape
C shape
Elliptical
According to crossection:
Flat
Round
Semi circular

10. Traveller size/number (conventional system):
1 weight of 10 travellers= 10 grain = traveller no. 1
2 weight of 10 travellers= 11 grain = traveller no. 2
3 weight of 10 travellers= 12 grain = traveller no. 3
4 weight of 10 travellers= 9 grain = traveller no. 1/0
5 weight of 10 travellers= 8 grain = traveller no. 2/0
6 weight of 10 travellers= 7.50 grain = traveller no. 3/0
Factors to be considered for selection of traveller:
Traveller cleaner:
It is a tiny metal part, set from the traveller to a prescribed distance. It helps to keep traveller clean.
Traveller changing schedule:
Travellers are changed due to count change, during schedule maintain and spindle
gauging.
Replacement of all travellers is re commended at the same time, but not partially.
A typically changing schedule of travellers are given below –
1 week for 3 shift running
1/2 week for 2 shift running
1/3 week for 1 shift running
Spindle:

11. Essential characteristics of spindle:
I. It must be perpendicular to the roving rail.
II. Both ring and spindle should be concentric.
III. Spindle blade should never run with defective manner.
IV. Spindle must be well balanced.
V. It must run with minimum friction and less vibration.
Function of spindle:
I. It holds the bobbin.
II. It helps to insert twist with aid of ring and traveller.
III. Helps to wind yarn on to bobbin.
Bobbin:
A cylinder (Simplex use) or slightly tapered (Ring frame use) form with or without flange or flanges for holding roving or yarns.
Bobbin is made of wood metal or plastic. Now a day’s plastic bobbin is mostly used. Lighter the bobbin, better the result.
Problem of wooden bobbin:
 Very heavy.
 High spindle speed can’t be achieved.
 High power required due to high bobbin weight.
 100% unwinding of yarn is not possible.
Features of paper bobbin:
 Long time can’t be used (Less life time)
 Lighter in weight.
 Easy package damage while holding and thus damage the yarn.

12. Features of plastic bobbin:
 Longer life.
 Appropriate weight.
 Slippery.
 Mostly used.
 Less power required.
 Less expensive.
End breakage:
It is measured as no. of break /1000 spindle / hours. Breakage at start position is high, at middle it is low and at and at
last average. For this reason start the machine at low speed and gradually we increase speed step by step. At mid position machine
runs at highest speed, against we reduce the speed at last.
Causes of end breakage:
I. Technology fault.
II. Machine fault.
Technology fault:
1. In correct roving twist.
2. Incorrect yarn twist.
3. Irregular roving.
4. In correct roller setting.
5. In correct break draft.
6. Excessive yarn tension due to high traveller weight.
7. Excessive yarn tension due to high spindle speed.
8. Excessive yarn tension due to bobbin vibration.
9. In correct number of traveller selection.
10. In correct atmospheric condition.
Machine fault:
1. Defective ring.
2. Dirty ring.
3. Worn out roller.
4. Roller lapping due to defective.
5. Worn out traveller.
6. Spindle vibration.
Limitation of ring frame:
1. Traveller speed:
Maximum attainable speed 50m/sec.
2. Delivery speed:
For every high delivery speed problem arisen for piecing.
3. Yarn tension:

13. For higher machine speed size of balloons increases as machine speed as has
positive influence on balloon size. Due to increase in tension, end breakage rate
increases.
4. Roving consumption:
After a certain speed power consumption of the machine increase
in such a way which doesn’t fit commercially.
5. Limitation of drafting system:
For higher speed of the machine drafting
zone can’t control fiber perfectly due to high roller speed.
As a result irregular yarn will to produce.
Types of wastage found in ring frame:
1. Pneumatic wastage
2. Bonda wastage Useable wastage
3. Roving wastage
4. Hard wastage
5. Wood roller Non- useable wastage
6. sweeping
Some yarn faults:
1. Yarn irregular.
2. Thick and thin place.
3. Slubs.
4. Neps.
5. Spiness double.
6. Crackness.
7. Bad piecing.
8. Short length of hard twist.
9. Hairiness.
10. Dirty yarn.
11. Badly shaped bobbin.
12. Slough off.
Faults associated in ring frame:
1. Soft bobbin: due to bigger twist wheel and higher traveller, fault way occur.
2. Fuzzy and uneven yarn: due to uneven surface of drafted roller and worn out draft roller create and uneven yarn.
3. High twisted or brittle yarn: worn out ring heavy traveller, luck of humidity this type of faults will occur.
4. Rough yarn: worn out traveller, rough bobbin and rough separate can create this type fault.
5. Slub: due to piecing fault, fly thick-thin roving faulty drafting zone, this type fault may occur.
6. In elastic yarn: excessive twist, excessive draft can produce in elastic yarn.
7. Neppy yarn: hard cot roller (top drafting roller) processing fault can produce neppy yarn.
8. Cracked yarn: by keeping the top arm pressure at position during stop condition of the machine can create this fault.
Recent development in ring frame:
1. Automation
 Auto Cree ling
 Auto doffing
 Auto piecing nep

14.  Data collection
 Spin wind link system
2. Higher drafting capacity
3. Direct two ply yarn spinning
4. Lubricated balloon control ring
5. Ring traveller with an increased contact area
6. Rotating ring
Twist stabling/heat setting:
Normally heat setting is done after winding in cone form but it can be done with other package. Heat
setting is done by vapor at 95 (degree) c or higher temperature. After passing vapor sometime vacuum is created to ensure the
penetration of vapor to inside the package. It set down the twist.
COMPILED & EDITED & ASSEMBLED BY-
AKM Sahedujjaman (SAJU)
01/03/2018