garments---Effect of blent ratio on quality of polyester/cotton yarns

WELCOME TO THE PROJECT
PRESENTATION

Ahsanullah University of Science &
Technology
Department of Textile Engineering

A Project On
“Effect of Blend Ratio on Quality of
Polyester/Cotton Yarns”

Supervised By
Dr. Ahmed Jalal Uddin
Associate Professor
DTE, AUST
Dr. Engr. Md. Rubaiyat Chowdhury
Associate Professor
DTE, AUST

Submitted By
Apurba Adhikary 08.02.06.116
Md. Sazzad Bin Siraj 08.01.06.021
Ahmad Tausif Syed 08.02.06.075
Ayatullah Ruhullah Shishir 08.02.06.068

Acknowledgement
At first we like to express our gratitude to Almighty God for his kindness
to enable us to complete the project.
It was a great opportunity for us to carry out our project work at Yasmin
Spinning Mills Ltd. (YSML) a sister concern of Noman Group. So at this
point we would like to express our gratitude to everyone related to
project work.
At first we express our heartiest thanks to our Prof. Dr. Mustafizur
Rahman, Head of Department of Textile Engineering (DTE) for arranging
our industrial training at YSML where we conducted our project work.
Our heartiest thanks go to our project supervisors Dr. Ahmed Jalal
Uddin, Associate Professor(DTE) and Dr. Engr. Md. Rubaiyat
Chowdhury, Associate Professor(DTE) for their logical guideline,
constant inspiration, necessary instruction and proper supervision that
have led us to complete this project work successfully.

Introduction
Cotton is a cool, soft, comfortable and is the principal clothing fiber of the
world. This fabric absorbs and releases perspiration quickly, thus allowing
the fabric to “breath.” Cotton provides absorbency and consequent
comfort.
The advantages of polyester over cotton fibers are its strength, lustre,
easy-care, price, consistency in quality and ready availability. But, it has
low moisture regain 0.4% as compared to cotton 8%. The polyester fabric
will absorb and wick less water.
There is no perfect fiber that contains all the qualities of cotton and
polyester mentioned above. In this context, blending is the technique to
combine fibers which emphasizes the good qualities and minimizes poor
qualities of the fibers. Blending also makes the fabric manufacturing
process economical. The price of man-made fiber is much more stable. In
blends of polyester/cotton, the fibers provide crease recovery,
dimensional stability, tensile strength, abrasion resistance, moisture
absorption, drape ability, etc.
Our project title is
“Effect of Blend Ratio on Quality of Polyester/Cotton Yarns”.

Here, the properties of P/C blend yarns are compared with the same
of 100% cotton yarn and the results are discussed in terms of the
following quality parameters:
CVm% and Um%: Mass irregularity (CV% and U% ).
Thick, Thin & Neps
IPI: Imperfection Index
CSP and single yarn strength.
Hairiness
To incorporate the advantageous points of both cotton and PET
fibers, different blend ratios of P/C have been tried and the ratio
65/35 is widely used commercially. In this work, we tried to check
the yarn characteristics with several P/C blend ratios.

AIM OF THE PROJECT
To compare different blend ratio of Polyester/Cotton yarn in
terms of yarn quality parameters such as CVm% and Um%, Thick,
Thin, Neps, IPI, CSP, Hairiness, Single yarn strength by which we
can find out the best quality blended yarn of 30/s Ne.

COTTON
FIBER
• Cotton is defined as white fibrous substance
covering seeds harvested from Cotton Plant.
No other fiber comes close to duplicating all
of the desirable characteristics combined in
cotton. Cotton Fiber is having a tubular
structure in twisted form. Now researchers
have developed colored cotton also. No
other material is quite like cotton. It is the
most important of all natural fibers,
accounting for half of all the fibers used by
the world's textile industry. Cotton has
many qualities that make it the best choice
for countless uses:
• Cotton fibers have a natural twist that
makes them so suitable for spinning into a
very strong yarn.
• Cotton fabric is soft and comfortable to
wear close to skin because of its good
moisture absorption qualities.
• Charges of static electricity do not build up
readily on the clothes.

Properties of Cotton Fiber
FIBER LENGTH
STRENGTH
Staple
classification
Length
mm
Length
inches
Spinning Count
Short Less than 24 15/16 -1 Coarse Below 20
Medium 24- 28 1.1/132-1.3/32 Medium Count 20s-
34s
Long 28 -34 1.3/32 -1.3/8 Fine Count 34s - 60s
Extra Long 34- 40 1.3/8 -1.9/16 Superfine Count 80s -
140s
G/tex Classification
Below 23 Weak
24-25 Medium
26-28 Average
29-30 Strong
Above 31 Very Strong

FIBER FINENESS
COTTON GRADE
Micronaire Value(µgm/inch) Fineness
Up to 3.1 Very fine
3.1-3.9 Fine
4.0-4.9 Medium
5.0-5.9 Slightly coarse
Above 6.0 Coarse
S.NO GRADE SYMBOL CODE
1 GOOD MIDDLING GM 11
2 STRICT MIDDLING SM 21
3 MIDDLING M 31
4 STRICT LOW
MIDDLING
SLM 41
5 LOW MIDDLING LM 51
6 STRICT GOOD
ORDINARY
SGO 61
7 GOOD ORDINARY GO 71

FIBER MATURITY
The cotton fiber consists of cell wall &lumen. Schenek suggest that
a fiber is to be considered as ripe when the cell wall of the
moisture –swollen fiber represents 50-80 % of the round x-section,
as unripe when it represents 30-40% &as dead when it represents
less than 25%.
NEPPINESS
Neppiness may be due to entanglement of fibers in ginning
process or immature fibers. Entangled fibers can be sorted out by
careful processing But, Neps due to immature fiber will stay on in
the end product and cause the level of Yarn defects to go higher.

POLYESTER
FIBER
• Polyester is a term often defined as
“long-chain polymers chemically
composed of at least 85% by weight of
an ester and a dihydric alcohol and a
terephthalic acid”. In other words, it
means the linking of several esters
within the fibers. Reaction of alcohol
with carboxylic acid results in the
formation of esters.
• Polyester also refers to the various
polymers in which the backbones are
formed by the “esterification
condensation of polyfunctional alcohols
and acids”.
• Polyester can also be classified as
saturated and unsaturated polyesters.

Properties of Polyester Fiber
Cut Length
Cut lengths available are 32,38,44,51 and 64 mm for cotton type
spinning. The most common length is 38 mm.
Tenacity
Elongation
Tenacity (gpd) High Tenacity Normal Tenacity Staple
Dry 6-7 4.5-5.5 3.5-4
Wet 6-7 4.5-5.5 3.5-4
Elongation (%) High Tenacity Normal Tenacity Staple
Dry 12.5-7.5 25-15 40-25
Wet 12.5-7.5 25-15 40-25
Density 1.38 1.38 1.38

Moisture Regain
At 65% RH and 70 ºF, Polyester moisture regain is less than0.4%.
Because of low moisture regain it develops static charge. Garments of
polyester fibers get soiled easily during wear.
Thermal Properties
Polyester fibers are most thermally stable of all synthetic fibers. As with
all thermoplastic fibers, its tenacity decreases and elongation increases
with rise in temperature. When ignited, polyester fiber burns with
difficulty.
Shrinkage
Polyester shrinks approx 7% when immersed in an unrestrained state in
boiling water. Like other textile fibers, polyester fibers undergo
degradation when exposed to sunlight.
Its biological resistance is good as it is not a nutrient for micro
organisms.

Swelling & Dissolving
The fibers swell in 2% Solution of Benzoic Acid, Salicylic Acid and
phenol.
Alcohols, Ketones, Soaps, Detergents and dry-cleaning solvents have
no chemical action on Polyester fiber.
Chemical Resistance
Polyester fibers have a high resistance to organic and mineral acids.
Weak acids do not harm even at boil. Similarly strong acids including
hydrofluoric acids do not attack the fibers appreciably in the cold.

• Resists abrasion (but can "pill")
• Very resilient (springs back into shape)
• Resist wrinkling
• Very high heat can "melt" the fabric
• The right amount of heat can be used to permanently "heat set".
• Easy to wash and wear
• Does not absorb water (can be uncomfortable when worn next to the skin
in warm weather unless loosely woven)
• Dries quickly
• Attracts static electricity which also attracts dirt and lint
• Although they do not absorb water, they do absorb oil and grease. This
means synthetics.
• Resist soiling, but once oil based stain soaks in, it can be difficult to clean.
• Strong fiber (but nylon is stronger)
• Often blended with cotton or even wool to add crease resistance
• Polyester does not absorb water, but it can be produced in such (as in
polypropylene and microfibers) as to "wick" water away from the skin.
Characteristics of Polyester Fibers and Products

BLENDED
FIBER
• Blending of fibers is usually made with
different fibers having dissimilarity in their
properties, with a view to achieving or
improving certain characters of the yarn or
its processing performances. Fabric produced
from the blended yarn might have better
characteristics than what could be obtained
in a fabric produced from a single fiber. The
blending of cotton is done to develop drape
properties, comfort ability, durability, dye
ability and many other properties of the
fabric products.
• In the cotton/polyester blends, polyester
fiber plays a vital role in the textile
applications in all areas from the lifesaving
medical textiles to the geo-textiles. The
advantages of polyester over other fibers are
strength, lustre, aesthetics, economics,
consistency in quality and ready availability.

OBJECTS OF BLENDING
In the cotton spinning process, blending has the main objective of yarn
manufacture with good quality at a reasonable cost. It also helps in
processing of following stages.
• Carding
• Spinning
• Warping and Weaving
• Dyeing and Finishing
REQUIREMENTS FOR SUCCESSIVE BLENDING
Successful blending depends on obtaining an intimacy of blending.
Theoretically in a blend single fiber units are distributed at random
throughout the x-section of the yarn. Some important requirements are as
follows:
1. Properties of fiber
2. Atmospheric condition
3. Good working conditions of machines

TYPES OF BLENDING
• Bale Blending (6-60 bales)
• Flock Blending
• Lap Blending (4-6 laps)
• Web Blending
• Sliver Blending
• Fiber Blending
• Roving Blending

Cotton Polyester
Blowroom Blowroom
Carding Carding
Drawframe 1
Drawing-2,3 & 4
Simplex
Ring frame
Winding
Heat setting
Packing
PROCESS FLOW CHART FOR BLENDED YARN

PRODUCTION & QUALITY
CONTROL MACHINERY
Part - 3

Machinery Used
Machine/
Process
Model Manufacturer Country of Origin
Blowroom (Cotton)
Uniflock A 1/2 RIETER SWITZERLAND
Uniclean B10 RIETER SWITZERLAND
Unimix B7/3R RIETER SWITZERLAND
ERM-III B 5/5 RIETER SWITZERLAND
Condenser RIETER SWITZERLAND
Loptex OPTOSONIC ITALY
Dustex SP-DX TRUTZSCHLER GERMANY
Blowroom(Polyester)
Bale Opener CS TRUTZSCHLER GERMANY
Tuftomat TO-T1 TRUTZSCHLER GERMANY

Machinery Used(Continued)
Machine/ Process Model Manufacturer Country of
Origin
Carding (Cotton) C-50, C-60. RIETER SWITZERLAND
Carding(Polyester) MK-6D CROSS ROLL CHINA
Draw Frame DX7AH, DX8 &
DX8- LT
CROSS ROLL CHINA
Simplex FL-100 TOYOTA JAPAN
Ring Frame UA33F HOWA JAPAN
Winding 21C MURATEC JAPAN

TESTING EQUIPMENT
• USTER® HVI Spectrum, Zellweger Uster,
Switzerland
 Function: To test and give results on important fiber properties.
• USTER®AFIS Pro, Zellweger Uster,
Switzerland
 Function: To test the number and size of Neps, different fiber lengths, fiber
maturity etc.
• USTER® Evenness Tester 4, Zellweger
Uster, Switzerland.
 Function : To test evenness, imperfection and hairiness of yarns and other
strands such as roving's and slivers.

TESTING EQUIPMENT(Continued)
• USTER® Auto Sorter 4. Zellweger, Uster,
Switzerland
 Function: To weigh certain lengths of skeins and give English Counts (Ne) of
slivers rovings and yarns.
• USTER ® TENSOJET 4
 Measurement of tensile strength and elongation of staple fiber yarns.
• Electronic Wrap Reel
 Function: To wrap leas of yarn into skeins.
• Lea Strength Tester
 The machine is used for determining the Tensile Strength and Elongation of Cotton,
Wool, Jute and other textile materials in form of skein.

(EXPERIMENTAL PART &
TEST RESULT)
Part – 4

Mixing Ratio of Cotton Fiber
Cotton
Origin % MIC Color Grade
Uganda 17% 4.15 33-2
Zambian 20% 4.08 32-1
Togo 4% 4.01 31-3
Cameroon 39% 3.82 11-1
Benin 11% 3.86 31-3
Memphis 9% 4.74 41-1
Ratio of Polyester Fiber
Polyester
Origin % Denier Length
Virgin (China) 100% 1.4 32 mm

SAMPLE PREPERATION
• Fiber Testing: First of all we collected fiber of different region from bale store to get
information with the help of HVI instrument.
• Laydown: According to the HVI Report laydown was made considering the
Micronaire value & color Grade.
• In blow room Cotton & polyester fiber were processed separately for the carding
process.
• In carding process Cotton & Polyester fiber were processed for Draw frame in sliver
form separately.
• Then Polyester sliver went through the Pre-Pass.
• Then Polyester & Cotton fiber were blended in breaker drawing-1.Optimum range
of doubling is given to get better blending. Then blended slivers were passed
through breaker drawing-2 & finally finisher draw frame.
• After completing previous process finisher drawn slivers of different blend ratio
were fed to the Simplex machine accordingly. The slivers were drafted to a
tolerable extent within insertion of slight amount of twist.
• Then Roving was drafted in Ring frame to produce yarn.

LAB TESTING
HVI TEST PROCEDURE:
• First we collected fiber sample from the bale store for the test of Mic, Maturity, Color & Trash, and
Length & Strength of the fiber.
• For mic & maturity test we weighted 10 gm of fiber and then we placed it to the sample box for
determining the mic & maturity value of the fiber.
• Here some amount of cotton sample placed over a color tray to determine the Rd, +b value.
• Then we checked length & Strength of the fiber sample.
• We checked it for each origin fiber.
Cotton Identification
HVI Test
Origin SCI Mic Mat Unf SFI Str +b Rd CG UHML
Uganda 147 4.15 0.84 84.2 2.40 32.7 10.8 69.7 33-2 29.61
Zambian 128 4.08 0.83 83.0 4.80 28.2 9.8 75.2 32-1 27.38
Togo 133 4.01 0.83 81.6 7.7 31.9 9.1 76.7 31-3 27.15
Cameroon 142 3.82 0.83 82.7 5.8 30.4 9.5 80.7 11-1 29.16
Benin 126 3.86 0.83 81.7 7.2 28.9 9.1 76.2 31-3 27.39
Memphis 132 4.74 0.85 82.9 5.8 31.0 8.0 75.2 41-1 29.19

LAB TESTING(Continued)
USTER AUTO SORTER & LEA STRENGTH TESTER PROCEDURE:
• First we took the 120yds length of yarn from each ring cops.
• Then we placed the each 120yds yarn to the auto sorter and got the count
accordingly.
• Then we test the strength of the yarn by Lea strength tester
• After that we multiply the strength with the yarn count for CSP.

USTER TESTER TEST PROCEDURE:
• We collected 10 ring cops for each blend ratio.
• Then we set the yarn through guide to the yarn slot. From every ring cops we took
400m yarn within 1 min for test.
• Here we tested for U%, CVm, DR, Thin -50% /km, Thick +50% /km, Neps +200% /km
& H
Nominal
Count
Actual
CSP
U% CV% DR
1.5m
5%
H Thin-
50%
Thick
+50%
Neps
+200%
IPI
30s/1KW(100
% Cotton)
2457 11.347 14.413 22.76 4.980 4.250 126.00 216.25 346.50
30s/1CVC(60%
+40%)
2902 10.106 12.804 13.96 4.660 1.250 50.25 150.55 202.05
30s/1PC(50%+
50%)
3121 10.100 12.754 13.50 4.410 1.200 49.75 126.75 177.70

SINGLE YARN STRENGTH TESTER TEST PROCEDURE:
• First of all we set the yarn through guide to the yarn slot. From every ring cops we
took 200m yarn within 1 min for test.
• Here we tested for B-force, Elongation, Tenacity and B-work.
Nominal Count B. Force
(cN)
Elong % Tenacity
cN/Tex
B.work
N.cm
30s/1KW (100% Cotton) 324.1 3.98 16.47 379.2
30s/1CVC (60%+40%) 300.5 5.21 19.5 570
30s/1PC (50%+50%) 410.9 6.8 21.2 812

(GRAPHICAL ANALYSIS &
DISCUSSION)
Part – 5

Figure shows the relationship
between the yarn blend ratio and
U% & CV% for various blend ratios
of cotton and polyester. It is
clearly revealed in the graph that
U% & CV% decreases gradually
with the increase in polyester
proportion.
 We hereby infer that increase
in polyester proportion on
Yarns have lower U% and CV%
than lower proportion of
polyester on yarns and that the
increase proportion of
polyester brings down yarn U%
and CV% to an appreciable
extent. An explanation to this
phenomenon may be found in
Introduction and Literature
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON U% & CV%
5
7
9
11
13
15
17
19
21
23
25
27
0% 40% 50%
U%&CV%
Polyester%
U% & CV%
CV%
U%

Figure displays the relationship
between the blend ratio and
number of thick places in the yarn
for the various blend ratios. It is
observed that the number of thick
places in the yarn decreases with
the increase in the polyester
proportion in the blend
Yarns have much lower thick
place than lower proportion of
polyester brings down yarn
thick place to an appreciable
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON THICK
+50%/KM
40
50
60
70
80
90
100
110
120
130
0% 40% 50%
Thick+50%/KM
Polyester %
Thick + 50% / KM
Thick +
50% / KM

Figure displays the relation
between the blend ratio and
number of thin places in the yarn
for the various blend ratios. It is
observed that the number of thin
places in the yarn decreases with
the increase in the polyester
proportion in the blend.
Yarns have much lower thin
place than lower proportion of
polyester brings down yarn thin
place to an appreciable extent.
An explanation to this
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON THIN -50%/KM
1
1.5
2
2.5
3
3.5
4
4.5
0% 40% 50%
Thin-50%/KM
Polyester %
Thin -50%/KM
Thin -
50%/KM

Figure shows the relation between
the blend ratio and the Neps 200%
in the yarn per km. Neps also
shows a decrease nature with the
increase in polyester proportion in
the blend ratio.
Yarns have much lower neps
neps to an appreciable extent.
An explanation to this
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON NEPS
200%/KM
90
110
130
150
170
190
210
230
0% 40% 50%
Neps200%/KM
Polyester %
Neps 200%/KM
Neps 200%/KM

Figure shows the relation
between the blend ratio and the
IPI in the yarn. IPI graph also
shows a decrease nature with the
increase in polyester proportion in
the blend ratio.
 So that increase in polyester
proportion on Yarns have much
lower IPI than lower proportion
of polyester on yarns and that
the increase proportion of
polyester brings down yarn IPI
to an appreciable extent. An
explanation to this
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON IPI
[Thick(+50%)+Thin(-50%)+Neps(+200%)]
0
50
100
150
200
250
300
350
400
0% 40% 50%
IPI
Polyester %
IPI
IPI

Line chart gives the relation
between blend ratio and hairiness
index of the various blended
yarns. The nature of the graph
shows that an increase in
polyester proportion decreases
the hairiness of the yarn.
Yarns have much lower
hairiness than lower proportion
hairiness to an appreciable
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON HAIRINESS
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
5.1
0% 40% 50%
Hairiness
Polyester %
Hairiness
H

Figure shows the strength values
of the various blend ratio yarns.
The graph reveals that increase in
polyester proportion increases the
yarn strength.
Yarns have much higher CSP
polyester brings up yarn CSP to
an appreciable extent. An
explanation to this
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON CSP
2300
2400
2500
2600
2700
2800
2900
3000
3100
3200
0% 40% 50%
CSP
Polyester %
CSP
CSP

Figure shows the tenacity values
of the blended yarns. The graph
shows that the tenacity value
increases with the increase in
polyester proportion.
Yarns have much higher
strength than lower proportion
polyester brings up yarn
strength to an appreciable
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON STRENGTH
14
15
16
17
18
19
20
21
22
0% 40% 50%
cN/Tex
Polyester %
cN/Tex
Cn/Tex

Figure shows the elongation of the
yarn for the various blend
proportions. The graph reveals the
increase in extension with an
increase in the polyester
proportion.
Yarns have much higher
elongation than lower
proportion of polyester on
yarns and that the increase
proportion of polyester brings
up yarn elongation to an
appreciable extent. An
explanation to this
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON
ELONGATION AT BREAK
3.5
4.2
4.9
5.6
6.3
7
0% 40% 50%
Elongation
Polyester %
Elongation
Elongation

Figure shows the Work of Rupture
values of the blended yarns. The
graph shows that the Work of
Rupture value increases with the
increase in polyester proportion.
Yarns have much higher work of
rupture than lower proportion
polyester brings up work of
rupture to an appreciable
Review chapters.
EFFECT OF POLYESTER/COTTON BLEND RATIO ON WORK OF
RUPTURE
75
80
85
90
95
100
105
110
0% 40% 50%
WorkofRupture
Polyester %
Work of Rupture
Rupture

Figure shows the Moisture regain
values of the blended yarns. The
graph shows that the Moisture
regain value decreases with the
increase in polyester proportion.
Yarns have much moisture
regain than lower proportion of
polyester brings down the
moisture regain.
EFFECT OF POLYESTER/COTTON BLEND RATIO MOISTURE
REGAIN
4
5
6
7
8
9
0% 40% 50%
MR%
Polyester%
Moisture Regain
MR%

While doing this project work we have faced various problems.
Those are given below.
 We tried to add various blend ratio (polyester more than 50%) but it was not
possible to spin such yarns during our training period.
 Printer of single yarn strength tester was out-of-order so that we could not
print the test result and could not attach with this report. But we noted the
results.
LIMITATIONS

 In conclusion, we can say that with the increase in polyester% in blend yarn,
the quality parameters of yarns improved. Some of them are U/CV%, IPI,
Hairiness, CSP and single yarn strength. At the same time, moisture
regain% of the yarns decreased; for 100% cotton: 8.4%, 40/60 PC: 5.7% and
50/50: 5.0%. However, depending on the end uses, the optimum percentage
of polyester and cotton may be adjusted.
 This project work has given us insight knowledge for producing blend yarns
by manipulating fibre%.
CONCLUSIONS

garments---Effect of blent ratio on quality of polyester/cotton yarns

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Viewers also liked

Viewers also liked (7)

Similar to garments---Effect of blent ratio on quality of polyester/cotton yarns

Similar to garments---Effect of blent ratio on quality of polyester/cotton yarns (20)

Recently uploaded

Recently uploaded (20)

garments---Effect of blent ratio on quality of polyester/cotton yarns