a trial taken on polyester fibre spun yarn on Rotor Spinning technology, now consistently spinning yarn for IKEA products.

1. EFFECT ON PROCESS OF POLYESTER STAPLE FIBRE ON ROTOR SPINNING WITH RESPECT TO POLYESTER
FIBRE AND SPINFINISH
SatyakamSrivastava1,D K Sharma1,Satpal Singh1,Neeraj Dwivedi1,RKShrimali1,SanjayGupta2
1Unit 7,RSWM Limited, Lodha, Banswara, Rajashthan, India
2Reliance Industries Ltd
Abstract
Rotor spinningsystemsprovideyarnwithdifferentstructuresandpropertiesascomparedtoring
spinning.Eachsystemhasitslimitationsandadvantagesintermsof technical feasibilityandeconomic
viability. Variouscountswere producedfromthe above systemswithdifferenttypesof polyesterfibre
at commercial level withspecificspinfinishandtested.The polyesterfibreexhibitedvarious levelsof
imperfectioninrotoryarntestedonUster tester4. Tensile,evennessandhairinessof the yarnswere
studied. Impactof variousconditionswithrespecttoRotorspeed,Environmentalcondition,fibre finish,
fibre length,fibredenierwas observed.Objective wastocreate a lowestimperfectionyarnat Rotor
Spinningwhichinturnisto be usedto produce awningsandcoatedfabricswithzerodefectsonsurface.
Processinvolvedmaterial processingonstandardTrutzschler Blowroomline,equippedwithTrutzschler
Card TC – 05 (3),TrutzschlerDrawframesTD – 03, and SchlafhorstACO-8latestRotorspinningmachine.
INTRODUCTION
Polyesterwasone of the greatman-made fibre discoveriesof the fortiesandhasbeenmanufacturedon
an industrial scale since 1947. Polyesterfibresare the firstchoice forapparel andare usedin trousers,
skirts,dresses,suits,jackets,blousesandoutdoorclothing
Polyesterfibresare particularlyresistanttolightandweatherandcanwithstandclimaticeffects. They
can be usedwhere lightnessandfinenessare primaryrequirements. Polyesterfibresare verywell suited
to blendswithnatural fibres. Fabricsin100% polyester,orblendswithanappropriatelyhighproportion,
are verycrease-resistantandretainshape evenwhenaffectedbymoisture. Polyesterfibreshave good
moisture transportanddry quickly. Theyare easycare. High tenacityensuresabove-averagewear
qualities.
Polyesterfibres are available inCutlengthsof 32,38, 44, 51 and 64mm forcotton type spinninganda
blendof 76, 88 and102 mm - average cutlengthof 88m for worstedspinning.The mostcommoncut
lengthis38 mm.
For OE spinning, 32 mmfibre ispreferredasitenablessmallerdia rotor(of 33mm) to be usedwhichcan
be run at 80000 to 100000 rpm.
Polyesterfibers are available in4tenacitylevels.
1. Lowpill fibres- usuallyin2.0/ 3.0 D for suitingend use withtenacitiesof 3.0to3.5 gpd(gramsper
denier). These fibres are generally used on worsted system and 1.4D for knitting
2. Medium Tenacity - 4.8 to 5.0 gpd
3. High Tenacity - 6.0 to 6.4 gpd range and
4. Super high tenacity - 7.0 gpd and above

2. Both mediumandhightenacityfibresare usedforapparel end use.
The superhightenacityfibresare usedessentiallyforspinning100% polyestersewingthreadsandother
industrial yarns.The highertenacitiesare obtainedbyusinghigherdraw ratiosandhigherannealer
temperaturesupto225 to 230 degree Cand a slightadditional pull of 2% or so at the last zone in
annealing.
SPIN FINISH
Several typesof spinfinishesare available.Itisonlybya mill trial thatthe effectivenessof aspinfinish
can be established.
A spinfinishissupposedto give highfibre tofibre frictionof 0.4to 0.45, so as to control fibre movement
particularlyatselvedges,lowfibre-metalfrictionof 0.2to 0.15 to enable lowertensionsandprovide
adequate staticprotectionatwhateverspeedthe textile machineare runningandprovide enough
cohesiontocontrol flyandlappingtendenciesandlubricationtoenable smootherdrafting.
Spinfinishasusednormallyconsistsof 2components - one that giveslubrication/cohesionandother
that givesstaticprotection.Eachof these componentshave upto18 differentcomponentstogive
desiredpropertiesplusanti fungus,antibacterial anti foamingandstabilisers.
A mill withnewOEspinningmachineshavingrotorsrunning more than 80000 rpm, thena totally
differentspinfinishwhichhasasignificantlylowerfibre - fibre andfibre - metal frictiongave verygood
results.
For staple processingandhighproductionthoughlatestmachinerywithhigherrotorspeedsandfiner
countsplace greaterimpact onspinfinish, Daefler[1], hasmentionedthatthe processingcapabilityof
fibre dependsonfibre tofibre frictionandfibre tometal frictionandhighrotorspeedgeneratingheat.
Rapidheatgenerationdestroysthe lubricationandfinishbecome ineffective. The highspeedopening
rollerspeedremovesthe polymerfilmfromfibreontorotor where itisdepositedinformof powder.
It has alsobeenobservedthatbrightfibre causesmore troubleinrotorsspinningascomparedto
semidull(TiO2) fibresbecause of the frictional forcesare fourtimeshigherthanbrightfibre.
It has alsobeenclaimedthatTiO2affectsthe surface geometry,ie brightfibreshave asmoothsurface ,
wherasdull fibreshave aroughsurface.It alsoimportanttonote that spinfinishesandcomponentsfor
shearresistance improvementare differentfromthose neededtoreduce dynamicfriction.Alsoforhigh
speedproductionamuchbetterantistaticprotectionisrequired.
LUSTRE:
Polyesterfibresare available in
Bright: 0.05 to 0.10 % TiO2
Semi dull :0.2 to 0.3 % TiO2
Dull : 0.5 % TiO2
Extra dull : 0.7% TiO2 and
Manufacturingtextilesputsextreme pressuresonprocessstability,the qualityconsistencyof textiles
and the life spanof machine components.Withoperatingtimesgraduallyreachingthe maximum
numbersof hoursavailable inayear,a highlevel of long-termconsistencyinall three factorsis
expected.Inspinningpractice,there are constantattemptstoworkagainstthe gradual deteriorationof
these points.Processstabilityisinfluencedmainlybyunsteadyyarntension.A consistentqualitycan

3. onlybe guaranteedthroughthe stabilization of the relevantparameters.Bothcriteriamustassume
primarilydefinedandtemporal constantfrictionbetweentextile andcontactingmachine element.
Study of spin finish:-
SpinfinishwasappliedonPolyesterFibreswithconditioningandresultsare comparedwiththe material
produced without Cirrasol HSL 40
Mixing Blend 100% polyester 1.2 X 32 mm
OE Count 12 Ne
Rotor RPM 88000
With Finish Cirrasol HSL 40 With out Finish
Yarn Breaks / 1000 Rotor Hours 40 114
Yarn Cuts / 1000 Rotor Hours 181 698
Uster 8.48 8.68
-50% 0 2
+50% 2.2 12
+280% 1.8 5
Powder Deposition Very low Very high
Mixing Blend Polyester cotton 65% polyester 1.2 X 32 mm, 35% Cotton
OE Count 10 Ne
With Finish Cirrasol HSL 40 With out Finish
Yarn Breaks / 1000 Rotor Hours 12 156
Yarn Cuts / 1000 Rotor Hours 13 205
Uster 9.99 10.69
-50% 0 0.4
+50% 10.5 30.2
+280% 5 9.8
Total IPI 11 40.4
Condition of Rotor Spin Box
Before Spin Finish
Powder depositioninrotor Spin box with powder deposition Debris collectedfrom rotor
After SpinFinish
no deposition observed in Rotor as well as Spin box even after 48 hrs of process.

4. Study conducted with SHT fibre:-
Comparative running result of Semi Dull verses SHT polyester fibre, the study was conducted with Fibre
supplied from Reliance Industries Limited, at RSWM Lodha unit, processing done at 32oC and 58% RH.
FIBRE - 1
Semi
Dull
1.2D X
32 mm
SHT
1.2D X
32 MM
Semi
Dull
1.2D X
32 mm
SHT
1.2D X
32 MM
Count 7.0 12.0
CSP 3226 4097 3883 4113
RKM 21 24 23 24
USTER 12 8 10 9
THIN/KM [-50 %] 14 0 2 0
THICK/KM [+50%] 474 7 100 13
NEPS/KM [+280%] 144 1 17 2
TOTAL IMP./ KM (-50,+50,+280) 632 7 119 14
HAIRINESS 8 7 179 40
CLASSIMAT Short 2249 8 8 0
Long 62 2 44 0
Thin 0 0 230 40
TOTAL S+L+T 2311 10 8 0
TOTAL OBJ.FAULTS/100KM 68 2 1 0
Result and discussion:-
The total study was conducted with Polyester fibres supplied by Reliance industries, the results reflected
the high temperature environmental condition (32oC , 58% RH),
As presumed the surface structure of semi dull polyester fibre is rough in nature which is a regular fibre to
spin yarns at Rotor Spinning. The fibre blended with cotton provides high strength, and long life to yarn
for high speed weaving and crease free finish to fabric. Polyester fibre is used at 65% to 40% in blend
with cotton to cater to various fabric structures.
During the summer season in India the atmospheric temperature rises to 45oC which increases the
temperature of processing at Rotor. This results in ineffectiveness of fibre finish to the fibre for consistent
processing. The specific deposit of powder in rotor and spin box region is very evident which leads to high
breakage rate and inconsistent quality cuts. Application of external finish of antistatic fails to support
which converts into powder deposition. This leads to higher imperfection in yarn and lower production of
machine.
Croda supported to produce a finish based on Silicon Ethoxyates which is typically a lubricant and
reduces interfibre frictional forces and helps in reducing the impact of friction due to metal processing the
fibre. The treatment of spin finish provided by Croda for treating polyester fibre takes some time to adhere
to the fibre which finally helps in spinning the yarn at Rotor Spinning stage.
There was clear reduction of deposition of powder at rotor and Spin Box region even after 48 hours of
working as displayed in pictures.
The results indicate that there is significant impact of spin finish on yarn breaks per 1000 rotor hours,
Yarn cuts per 1000 rotor hours and also the IPI levels of yarn was been reduced significantly.