This document discusses various yarn faults that occur during the warping process in weaving, including slubs, neps, thick and thin places, soft yarn, oily stained yarn, kitty yarn, hairiness, and foreign matters. It provides definitions of each fault and recommends remedies to improve yarn quality and warping efficiency such as maintaining clean machinery, optimizing machine settings, improving fiber blending, and ensuring proper material handling procedures. The objectives of the project are also listed as researching yarn faults, analyzing faults in warping, selecting raw materials, improving product quality and reducing wastage.
1. Warping involves winding warp yarns from multiple packages onto a common beam. There are different types of warping including direct/beam warping and pattern/sectional warping.
2. Direct warping is used to produce warp beams for solid color fabrics directly from packages to the beam. Sectional warping is slower but used for short runs or complex patterns by making sections sequentially.
3. A warping machine has a creel to hold packages, a headstock to guide and tension yarns, and a control device. It measures and winds yarns uniformly to produce a warp beam meeting quality requirements.
This document discusses common faults that can occur in knitted fabrics and their potential causes and remedies. It outlines 15 specific faults including needle marks, count mix, slubs, lycra out, sinker marks, yarn mix, broken needles, black oil stripes, thick and thin fabrics, pin holes, patta/barry marks, fly contamination, holes, improper setup, and star marks. For each fault, it describes possible causes such as damaged needles, improper yarn feeding, tension issues, or problems with machine parts. It then provides recommendations for remedies like replacing broken components, improving cleaning procedures, adjusting tensions, or ensuring quality of incoming yarn.
The document discusses the process of preparing warp yarns for weaving. It describes how yarns are wound onto packages through several steps: unwinding from the cop, tensioning to maintain uniform winding, and clearing slubs and faults. It then explains the key components of an autoconer winding machine used for this process, including the cop holder, tension devices, yarn clearer, grooved drum, and stop motion that halts winding if the yarn breaks. Finally, it outlines the basic mechanisms of winding, including unwinding the yarn, applying tension, clearing faults, and forming packages ready for warping.
Filament-core yarns are produced to take advantage of both filament and staple fibre properties. They offer good strength and uniformity without sacrificing the staple fibre yarn-like surface characteristics. Core-spun yarns containing spandex provide fabric designers with broad possibilities, because such stretchable yarns can be constructed with a wide range of properties using virtually any type of hard fibres as the cover yarn. However, a disadvantage of the core yarns is that the staple fibre sheath may slip along the filament when being pulled to pass over or when being rubbed by machine parts during further mechanical processes. But it is very easy to produce core-spun yarn containing spandex in a conventional ring frame after doing some modification of the machine.
This document discusses various types of defects that can occur in knitted fabrics, including yarn-related defects, knitting element defects, machine setting defects, dyeing defects, and finishing defects. Specific defects are defined such as drop stitches, barriness, imperfections, and spirality. The causes and remedies are provided for each defect. In conclusion, detecting faults during knitted fabric production is important for quality and productivity, and identifying the source and solutions for defects can help knitters overcome faults.
The document discusses the key processes that take place in the blowroom of a yarn production facility. These include opening bales of fiber, cleaning the fiber through pre-cleaning and fine cleaning, removing dust, blending different fiber types, and evenly feeding the prepared fiber to the carding process. The goal of blowroom processes is to prepare fibers for subsequent processing while minimizing fiber loss and maintaining fiber quality.
This document discusses advanced weaving technology, including different types of looms. It compares shuttle looms with shuttleless modern looms. Shuttle looms are cheaper but have disadvantages like requiring pirn winding, uncontrolled shuttle speed, and limited width. Modern looms have higher costs but allow for higher speeds, wider fabrics, and better quality control. Key components of modern looms discussed include weft accumulators, which help regulate weft tension, and different types of selvedges along the fabric edges.
1. Warping involves winding warp yarns from multiple packages onto a common beam. There are different types of warping including direct/beam warping and pattern/sectional warping.
2. Direct warping is used to produce warp beams for solid color fabrics directly from packages to the beam. Sectional warping is slower but used for short runs or complex patterns by making sections sequentially.
3. A warping machine has a creel to hold packages, a headstock to guide and tension yarns, and a control device. It measures and winds yarns uniformly to produce a warp beam meeting quality requirements.
This document discusses common faults that can occur in knitted fabrics and their potential causes and remedies. It outlines 15 specific faults including needle marks, count mix, slubs, lycra out, sinker marks, yarn mix, broken needles, black oil stripes, thick and thin fabrics, pin holes, patta/barry marks, fly contamination, holes, improper setup, and star marks. For each fault, it describes possible causes such as damaged needles, improper yarn feeding, tension issues, or problems with machine parts. It then provides recommendations for remedies like replacing broken components, improving cleaning procedures, adjusting tensions, or ensuring quality of incoming yarn.
The document discusses the process of preparing warp yarns for weaving. It describes how yarns are wound onto packages through several steps: unwinding from the cop, tensioning to maintain uniform winding, and clearing slubs and faults. It then explains the key components of an autoconer winding machine used for this process, including the cop holder, tension devices, yarn clearer, grooved drum, and stop motion that halts winding if the yarn breaks. Finally, it outlines the basic mechanisms of winding, including unwinding the yarn, applying tension, clearing faults, and forming packages ready for warping.
Filament-core yarns are produced to take advantage of both filament and staple fibre properties. They offer good strength and uniformity without sacrificing the staple fibre yarn-like surface characteristics. Core-spun yarns containing spandex provide fabric designers with broad possibilities, because such stretchable yarns can be constructed with a wide range of properties using virtually any type of hard fibres as the cover yarn. However, a disadvantage of the core yarns is that the staple fibre sheath may slip along the filament when being pulled to pass over or when being rubbed by machine parts during further mechanical processes. But it is very easy to produce core-spun yarn containing spandex in a conventional ring frame after doing some modification of the machine.
This document discusses various types of defects that can occur in knitted fabrics, including yarn-related defects, knitting element defects, machine setting defects, dyeing defects, and finishing defects. Specific defects are defined such as drop stitches, barriness, imperfections, and spirality. The causes and remedies are provided for each defect. In conclusion, detecting faults during knitted fabric production is important for quality and productivity, and identifying the source and solutions for defects can help knitters overcome faults.
The document discusses the key processes that take place in the blowroom of a yarn production facility. These include opening bales of fiber, cleaning the fiber through pre-cleaning and fine cleaning, removing dust, blending different fiber types, and evenly feeding the prepared fiber to the carding process. The goal of blowroom processes is to prepare fibers for subsequent processing while minimizing fiber loss and maintaining fiber quality.
This document discusses advanced weaving technology, including different types of looms. It compares shuttle looms with shuttleless modern looms. Shuttle looms are cheaper but have disadvantages like requiring pirn winding, uncontrolled shuttle speed, and limited width. Modern looms have higher costs but allow for higher speeds, wider fabrics, and better quality control. Key components of modern looms discussed include weft accumulators, which help regulate weft tension, and different types of selvedges along the fabric edges.
The document discusses various aspects of warping, which is the process of winding yarn onto beams to create a warp. It describes the objectives of warping as uniformly spacing individual yarn ends across the full width to create a warp of specified length and width. The types of warping discussed are beam warping, pattern band or drum warping, and ball warping. Key components of warping machines like the creel, headstock, and pressure roller are also outlined. The document provides details on various creel types, requirements for good warping, potential defects in warped beams, and importance of warping for weaving.
This document discusses winding, which is an important operation in the spinning section that creates large yarn packages. It describes the three zones of winding and the two types of winding: spindle drive and friction drive. It also provides details on the components of an autoconer winding machine, including the cradle, drum, magazine, tension assembly, yarn clearer, and others. The working principle and requirements of the winding process are explained.
An investigation on the inspection of grey & finished knit fabric in wet proc...Md. Mazadul Hasan Shishir
This document discusses fabric inspection processes at Aman Tex Ltd, a knit fabric dyeing and garment manufacturing company in Bangladesh. It outlines the company's operations and describes their grey fabric and finished fabric inspection procedures. For grey fabric, common defects like needle marks, holes, and dropped stitches are defined. For finished fabric, defects from dyeing and finishing like uneven dyeing, dye spots, and crease marks are explained. The aims of inspection are to ensure quality, reduce costs from defects, and improve production efficiency. Inspection standards like the four point system used by Aman Tex are presented.
The document provides information about the ball warping process used to prepare yarn for denim production. It discusses:
1) Ball warping involves creeling multiple ends of yarn and collecting them into an untwisted rope for dyeing. The rope is wound onto a long cylinder called a log.
2) Key steps include passing yarn through a reed to separate ends, inserting lease strings, and condensing the yarn into a rope using a trumpet.
3) After indigo dyeing the rope, it undergoes long chain beaming to change the alignment from rope to sheet form before sizing and weaving. Tension rollers help further separate the yarns.
Yarn unevenness and its empact on qualityArNesto WaHid
This document discusses yarn unevenness, its causes, measurement, and impact on quality. Yarn unevenness refers to variations in yarn thickness along its length. It is influenced by raw material variations and spinning process irregularities. Unevenness is measured using the irregularity percentage and coefficient of variation. Higher unevenness can reduce yarn strength, impact fabric appearance with defects, and lower productivity. Careful control of the spinning process is needed to minimize unevenness and maximize quality.
In the last two decades, spectacular progress has been made in the field of weaving technology and the most significant being the replacement of convectional looms by shuttleless looms for increasing productivity and quality of the end product. New developments in weaving have taken place in such a direction, which ensures reduced time, energy and cost involved. Heavy mechanical parts are now being replaced with electronic or microprocessor controlled alternatives.
This document describes an experiment conducted on a Tricot warp knitting machine. It includes:
1) An overview of the machine, its parts, and yarn path diagram. The main parts described are the compound needle, pattern chain, needle bar, and more.
2) Details of the specific machine used, including its brand, origin, specifications.
3) Explanations of how each part functions and their roles in the knitting process.
4) A conclusion that the experiment provided an introductory understanding of tricot knitting machines to help with future industrial applications.
This document discusses jet weaving processes. In jet weaving, a fluid such as air or water is used to insert the weft yarn through the shed. For air jet weaving, compressed air is accelerated through a nozzle to provide the force to insert the weft. For water jet weaving, water is pressurized using pumps. Key factors that influence the tractive force on the weft include the velocity and viscosity of the fluid, the roughness of the weft yarn, and temperature. Modern jet looms can operate at high speeds up to 1500 picks per minute for water jet and even higher for air jet looms.
VDQ pulley (Variable Dia for Quality Pulley): It is a very important part of the machine. It controls the quality of the product. Altering the position of the tension pulley changes the G.S.M. of the fabric.
This document provides information on various yarn defects, their causes, effects, and methods for rectification. It discusses 18 different yarn defects including slubs, neps, thin places, kinks, uneven yarn, stained yarn, and more. For each defect, it outlines the potential effects on subsequent processes, common causes such as poor machine maintenance or improper process settings, and recommended actions for rectification. The goal is to identify ways to minimize yarn defects and their impacts further down the textile manufacturing line.
1. The winch dyeing machine dyes fabric pieces that are sewn end to end into a rope-like form.
2. The fabric rope is circulated in the dyeing machine by a horizontal rotor called a winch, which gives the machine its name.
3. The winch dyeing machine is commonly used to dye knitted, woolen, and worsted fabrics due to its ability to apply low tension on the fabric.
Study on Different Types of Knitting Faults, Causes and Remedies of Knit FabricsMd. Ariful Islam
This document discusses various types of knitting faults that can occur in knit fabrics, their causes, and potential remedies. It outlines 20 different types of common knitting defects such as drop stitches, barriness, pin holes, and broken needles. For each defect type, the document explains the likely causes such as yarn tension issues, machine problems, or material quality issues. It then provides recommendations for remedies such as ensuring uniform yarn tension, properly maintaining machine parts, and using quality materials. The goal is to help knitting mills identify and address defects in order to improve fabric quality and avoid rejections.
The document discusses the rapier loom, a type of shuttleless weaving loom. A rapier loom uses finger-like carriers called rapiers to pull the weft yarn across the loom between the warp yarns. There are two main types - single rigid rapier looms, which use one long rapier across the full width, and double rigid rapier looms, which use two rapiers entering from opposite sides to transfer the weft yarn. Rapier looms can operate at high speeds up to 1300 meters of weft per minute. They are flexible and can weave a wide range of fabrics from light to heavy weights.
The document discusses the Advanced Fiber Information System (AFIS), which was developed to more accurately and precisely measure properties of raw textile materials like cotton. AFIS uses aeromechanical and electro-optical techniques to separate fibers and analyze them individually, providing distributions of properties rather than just average values. This gives more detailed information about factors like fiber length and imperfections. Specifically, AFIS can classify neps (entanglements) into fiber neps and seed coat neps, providing a more comprehensive quality assessment of ginning cotton and processed fibers.
The document describes an autoconer machinery used for winding yarn into cones. The autoconer is a Savio Orion model from 2005 with 60 cones. It has a drum speed of 1300 rpm, cone weights of 2-3 kg full and 30-35 g empty, and a magazine creel capacity of 6 ring tubes. The autoconer has features like a pneumatic disc tensioner, splicer, and electronic yarn clearer. It can produce 800-1200 kg of cones per shift with up to 95% efficiency.
This presentation discusses yarn evenness testing using an Uster Evenness Tester machine. It covers what yarn evenness testing is, the various methods of measuring yarn evenness including visual examination, cutting and weighing, and electronic testers. It then discusses the usage of the Uster Evenness Tester for testing yarns, rovings and slivers and measuring irregularities and hairiness. The working principle of the Uster Evenness Tester is also explained along with its advantages of high speed testing and measuring coefficient of variation, and its disadvantages related to moisture content and material thickness.
You can find the diffences between mechanical and electronical dobby mechanisms in principle in this presentation.
Also , you can reach the details of dobby mechanisms type like as of single , double and negative dobby systems.
This document discusses positive yarn feeding systems and how they affect fabric quality. It provides information on different types of positive yarn feeding systems including tape feed mechanisms and storage feeders. Positive yarn feeding helps control fabric properties and quality by providing uniform yarn tension and detecting faults before knitting. Modern systems use microprocessors and pre-calculated yarn requirements to precisely control yarn delivery. While positive feeding improves quality, it can also cause yarn breakage issues which manufacturers work to overcome through innovations like ceramic coated feed wheels.
Winding is an important process in fabric manufacturing that involves transferring yarns from one package to another suitable package for weaving. There are several types of winding packages depending on factors like density, package type, and how the package is built. Parallel winding involves winding yarns parallel to each other on packages with flanges. Near parallel winding lays yarns nearly parallel with one another on packages that may or may not have flanges. Cross winding winds a single yarn at an angle across layers for stability without needing flanges. Proper tensioning devices are also important to apply the required tension during winding to reduce breaks and complete weaving successfully.
This document provides information about various yarn defects seen in ring spinning, their causes, effects, and methods for rectification. It describes 18 different types of defects like slubs, neps, thin places, kinks, thick places, etc. For each defect, it mentions the potential effects on subsequent processes and the fabric, likely causes related to machine settings or raw material issues, and recommended actions to address the problem. The goal is to help spinning mill staff properly identify and troubleshoot quality issues.
The document provides information about warping processes. It discusses different types of warping machines including beam warping machines and sectional warping machines. It describes the components and functions of the creel and headstock. The creel holds supply packages in position for warping while the headstock contains mechanisms to control yarn speed and tension, and to wind the yarn onto the beam. Sectional warping is preferred for multi-colored warps as it develops the warp width in sections rather than all at once like beam warping. Control devices and stop motions are used to monitor for yarn breaks during warping.
The document discusses various aspects of warping, which is the process of winding yarn onto beams to create a warp. It describes the objectives of warping as uniformly spacing individual yarn ends across the full width to create a warp of specified length and width. The types of warping discussed are beam warping, pattern band or drum warping, and ball warping. Key components of warping machines like the creel, headstock, and pressure roller are also outlined. The document provides details on various creel types, requirements for good warping, potential defects in warped beams, and importance of warping for weaving.
This document discusses winding, which is an important operation in the spinning section that creates large yarn packages. It describes the three zones of winding and the two types of winding: spindle drive and friction drive. It also provides details on the components of an autoconer winding machine, including the cradle, drum, magazine, tension assembly, yarn clearer, and others. The working principle and requirements of the winding process are explained.
An investigation on the inspection of grey & finished knit fabric in wet proc...Md. Mazadul Hasan Shishir
This document discusses fabric inspection processes at Aman Tex Ltd, a knit fabric dyeing and garment manufacturing company in Bangladesh. It outlines the company's operations and describes their grey fabric and finished fabric inspection procedures. For grey fabric, common defects like needle marks, holes, and dropped stitches are defined. For finished fabric, defects from dyeing and finishing like uneven dyeing, dye spots, and crease marks are explained. The aims of inspection are to ensure quality, reduce costs from defects, and improve production efficiency. Inspection standards like the four point system used by Aman Tex are presented.
The document provides information about the ball warping process used to prepare yarn for denim production. It discusses:
1) Ball warping involves creeling multiple ends of yarn and collecting them into an untwisted rope for dyeing. The rope is wound onto a long cylinder called a log.
2) Key steps include passing yarn through a reed to separate ends, inserting lease strings, and condensing the yarn into a rope using a trumpet.
3) After indigo dyeing the rope, it undergoes long chain beaming to change the alignment from rope to sheet form before sizing and weaving. Tension rollers help further separate the yarns.
Yarn unevenness and its empact on qualityArNesto WaHid
This document discusses yarn unevenness, its causes, measurement, and impact on quality. Yarn unevenness refers to variations in yarn thickness along its length. It is influenced by raw material variations and spinning process irregularities. Unevenness is measured using the irregularity percentage and coefficient of variation. Higher unevenness can reduce yarn strength, impact fabric appearance with defects, and lower productivity. Careful control of the spinning process is needed to minimize unevenness and maximize quality.
In the last two decades, spectacular progress has been made in the field of weaving technology and the most significant being the replacement of convectional looms by shuttleless looms for increasing productivity and quality of the end product. New developments in weaving have taken place in such a direction, which ensures reduced time, energy and cost involved. Heavy mechanical parts are now being replaced with electronic or microprocessor controlled alternatives.
This document describes an experiment conducted on a Tricot warp knitting machine. It includes:
1) An overview of the machine, its parts, and yarn path diagram. The main parts described are the compound needle, pattern chain, needle bar, and more.
2) Details of the specific machine used, including its brand, origin, specifications.
3) Explanations of how each part functions and their roles in the knitting process.
4) A conclusion that the experiment provided an introductory understanding of tricot knitting machines to help with future industrial applications.
This document discusses jet weaving processes. In jet weaving, a fluid such as air or water is used to insert the weft yarn through the shed. For air jet weaving, compressed air is accelerated through a nozzle to provide the force to insert the weft. For water jet weaving, water is pressurized using pumps. Key factors that influence the tractive force on the weft include the velocity and viscosity of the fluid, the roughness of the weft yarn, and temperature. Modern jet looms can operate at high speeds up to 1500 picks per minute for water jet and even higher for air jet looms.
VDQ pulley (Variable Dia for Quality Pulley): It is a very important part of the machine. It controls the quality of the product. Altering the position of the tension pulley changes the G.S.M. of the fabric.
This document provides information on various yarn defects, their causes, effects, and methods for rectification. It discusses 18 different yarn defects including slubs, neps, thin places, kinks, uneven yarn, stained yarn, and more. For each defect, it outlines the potential effects on subsequent processes, common causes such as poor machine maintenance or improper process settings, and recommended actions for rectification. The goal is to identify ways to minimize yarn defects and their impacts further down the textile manufacturing line.
1. The winch dyeing machine dyes fabric pieces that are sewn end to end into a rope-like form.
2. The fabric rope is circulated in the dyeing machine by a horizontal rotor called a winch, which gives the machine its name.
3. The winch dyeing machine is commonly used to dye knitted, woolen, and worsted fabrics due to its ability to apply low tension on the fabric.
Study on Different Types of Knitting Faults, Causes and Remedies of Knit FabricsMd. Ariful Islam
This document discusses various types of knitting faults that can occur in knit fabrics, their causes, and potential remedies. It outlines 20 different types of common knitting defects such as drop stitches, barriness, pin holes, and broken needles. For each defect type, the document explains the likely causes such as yarn tension issues, machine problems, or material quality issues. It then provides recommendations for remedies such as ensuring uniform yarn tension, properly maintaining machine parts, and using quality materials. The goal is to help knitting mills identify and address defects in order to improve fabric quality and avoid rejections.
The document discusses the rapier loom, a type of shuttleless weaving loom. A rapier loom uses finger-like carriers called rapiers to pull the weft yarn across the loom between the warp yarns. There are two main types - single rigid rapier looms, which use one long rapier across the full width, and double rigid rapier looms, which use two rapiers entering from opposite sides to transfer the weft yarn. Rapier looms can operate at high speeds up to 1300 meters of weft per minute. They are flexible and can weave a wide range of fabrics from light to heavy weights.
The document discusses the Advanced Fiber Information System (AFIS), which was developed to more accurately and precisely measure properties of raw textile materials like cotton. AFIS uses aeromechanical and electro-optical techniques to separate fibers and analyze them individually, providing distributions of properties rather than just average values. This gives more detailed information about factors like fiber length and imperfections. Specifically, AFIS can classify neps (entanglements) into fiber neps and seed coat neps, providing a more comprehensive quality assessment of ginning cotton and processed fibers.
The document describes an autoconer machinery used for winding yarn into cones. The autoconer is a Savio Orion model from 2005 with 60 cones. It has a drum speed of 1300 rpm, cone weights of 2-3 kg full and 30-35 g empty, and a magazine creel capacity of 6 ring tubes. The autoconer has features like a pneumatic disc tensioner, splicer, and electronic yarn clearer. It can produce 800-1200 kg of cones per shift with up to 95% efficiency.
This presentation discusses yarn evenness testing using an Uster Evenness Tester machine. It covers what yarn evenness testing is, the various methods of measuring yarn evenness including visual examination, cutting and weighing, and electronic testers. It then discusses the usage of the Uster Evenness Tester for testing yarns, rovings and slivers and measuring irregularities and hairiness. The working principle of the Uster Evenness Tester is also explained along with its advantages of high speed testing and measuring coefficient of variation, and its disadvantages related to moisture content and material thickness.
You can find the diffences between mechanical and electronical dobby mechanisms in principle in this presentation.
Also , you can reach the details of dobby mechanisms type like as of single , double and negative dobby systems.
This document discusses positive yarn feeding systems and how they affect fabric quality. It provides information on different types of positive yarn feeding systems including tape feed mechanisms and storage feeders. Positive yarn feeding helps control fabric properties and quality by providing uniform yarn tension and detecting faults before knitting. Modern systems use microprocessors and pre-calculated yarn requirements to precisely control yarn delivery. While positive feeding improves quality, it can also cause yarn breakage issues which manufacturers work to overcome through innovations like ceramic coated feed wheels.
Winding is an important process in fabric manufacturing that involves transferring yarns from one package to another suitable package for weaving. There are several types of winding packages depending on factors like density, package type, and how the package is built. Parallel winding involves winding yarns parallel to each other on packages with flanges. Near parallel winding lays yarns nearly parallel with one another on packages that may or may not have flanges. Cross winding winds a single yarn at an angle across layers for stability without needing flanges. Proper tensioning devices are also important to apply the required tension during winding to reduce breaks and complete weaving successfully.
This document provides information about various yarn defects seen in ring spinning, their causes, effects, and methods for rectification. It describes 18 different types of defects like slubs, neps, thin places, kinks, thick places, etc. For each defect, it mentions the potential effects on subsequent processes and the fabric, likely causes related to machine settings or raw material issues, and recommended actions to address the problem. The goal is to help spinning mill staff properly identify and troubleshoot quality issues.
The document provides information about warping processes. It discusses different types of warping machines including beam warping machines and sectional warping machines. It describes the components and functions of the creel and headstock. The creel holds supply packages in position for warping while the headstock contains mechanisms to control yarn speed and tension, and to wind the yarn onto the beam. Sectional warping is preferred for multi-colored warps as it develops the warp width in sections rather than all at once like beam warping. Control devices and stop motions are used to monitor for yarn breaks during warping.
Textile fabric may be define as an assembly of fiber, yarn or combination of these. There are several ways to manufacture a fabric.To produce woven fabric yarn preparation is essential.Good preparation means good weaving,Good weaving =Quality fabric.
This document provides information about measuring moisture in textile materials and various related calculations. It lists the standard moisture regain for different materials like cotton, wool, viscose, silk, and jute. It also defines terms like absolute humidity, relative humidity, original weight, dry weight, oven dry weight, correct invoice weight, regain, and moisture content. The document includes examples of calculations for moisture content, regain, conditioned count weight, blending and mixing of materials, and piping diameters.
Sizing is the process of giving a protective coating on the warp yarn to minimize yarn breakage during weaving.
Sizing is the most important operation in preparing warp yarn for weaving especially with cotton yarn. The smallest error in sizing process may be very harmful. This may increase warp breakage rate on the looms and consequently reduce weaving production and quality. Therefore sizing is termed as the “Heart of Weaving”.
1.5 kg/kg of sized yarn
This document provides information on textile calculations related to fibre fineness, yarn counts, conversions, and production calculations for various textile processes. Some key points include:
- Micronaire value, denier, and micron are units used to measure fibre fineness for cotton, man-made fibers, and wool respectively.
- There are indirect and direct systems for classifying yarn counts including English, French, metric, worsted, and tex/denier systems.
- Formulas are provided for calculating production rates for processes like blowroom, carding, drawframe, speedframe, ringframe, winding, and s
The document provides an overview of the process sequence for weaving. It begins with yarn from the spinning department which then undergoes processes like cone winding, warping, sizing, tying-in, drafting, and denting to prepare the warp threads. The warp is then mounted on the loom and undergoes weaving to produce grey fabric. Key steps in weaving include shedding, picking, and beating-up. The woven fabric then undergoes inspection, folding, and baling before delivery. The document outlines the various motions and essential parts of a loom needed to carry out this weaving process.
This document provides information about different types of warping processes and warping machines. It discusses beam warping, patterned band warping, and ball warping. It describes the components and functions of direct and sectional warping machines. Direct warping machines wind yarn directly onto beams while sectional warping machines produce beams in two stages by first winding yarn onto a drum and then rewinding onto a beam. Maintaining uniform tension and spacing of yarn ends is important for producing quality warps. Common faults like broken ends, uneven beams, and snarl formations are also summarized along with their causes and remedies.
This document provides calculations and formulas related to yarn count, twist, winding, warping, sizing, weaving, and yarn quality parameters. It discusses three systems for calculating yarn count: indirect, direct, and universal. It also covers formulas for twist per inch, multi-filament yarns, winding calculations, warping calculations, sizing calculations, weaving calculations, and parameters for assessing yarn appearance, unevenness, linear density, and single thread strength.
This document discusses various aspects of ring spun yarn measurement and production. It begins by explaining that yarn size is typically measured through linear density or count systems. It then provides details on direct and indirect count calculation methods as well as conversions between different systems. The document also covers topics like folded and plied yarn calculations, the formation of different fabrics like weaving and knitting, and requirements for high quality yarn production. Key steps in the production process like winding, warping, sizing, drawing-in and weaving are outlined. Different weaving machine types based on the weft insertion method are also summarized.
Achieving Manufacturing Excellence in Spinning mills through Productivity benchmarking is explained through reference standards and case studies by WINSYS SMC.
The document discusses the manufacturing process of staple or spun yarn, describing the various processes involved from blow room to ring spinning that transform raw cotton fibers into yarn. It provides an overview of each processing stage including blow room, carding, combing, drawing, roving, and ring spinning. The goal is to produce clean, strong, and uniform yarns through these continuous operations of opening, blending, mixing, cleaning, carding, drawing, roving and spinning.
Analysis of rejected ring cops in autoconer winding machineTaukir Kabir Tusar
This document discusses the analysis of rejected ring cops in an autoconer winding machine. It begins with an introduction that describes ring cops, rejected ring cops, and the aim of analyzing the causes of cop rejections. The document then covers literature related to winding, common faults in winding, and reasons for faulty ring cops being rejected. It describes the experimental work, including collecting sample cops, quality tests performed, and identified causes of rejection such as count variation, product type variation, low cop content, and excessive neps. The goal is to understand the sources of rejections in order to reduce rejection rates.
Knowing the basics of raw material, yarn production process and the other factors influencing quality will put the sourcing manager at the same eye level as a spinner /supplier when negotiating quality issues.
As a consequence this puts the sourcing manager in the position to pay the right price for the corresponding quality level.
This kind of know-how supports a retailer enormously in his efforts to establish a reliable supply chain which is based on mutual understanding.
This document discusses root causes of faults in knitted fabrics and their remedies. It begins by introducing the aims of analyzing fabric faults. It then covers causes and remedies for faults originating from yarns, such as barriness, spirality, shrinkage, and thick/thin places. Knitting-related faults like cracks, pin holes, contamination, and broken needles are also examined. Finally, dyeing and finishing faults such as shade variation, pin holes, creases, spots, and dust are analyzed. The conclusion restates that identifying fault sources allows knitters to take steps to prevent defects and improve quality and productivity.
The document discusses textile spinning and quality control processes. It describes the key steps in textile spinning which include: yarn production from staple fibers using drawing and twisting; filament yarn production by forcing fiber-forming substances through spinnerets. The main processes are: blowroom preparation, carding, drawing, roving and ring spinning. Quality is ensured through testing of raw materials and processes. Fiber properties like length, strength and uniformity are evaluated. Machines are also tested to minimize count variations and improve yarn evenness and strength in the final product.
The document discusses weaving technology and processes. It describes how weaving involves interlacing two sets of threads, the warp and weft. It then summarizes the key steps in preparing yarn for weaving: warping to transfer yarn to a beam, sizing to reduce hairiness and increase strength, and drawing-in yarns into the loom. The basic mechanisms of warp and weft control in weaving are also outlined.
The document discusses weaving processes and loom types. It begins by defining weaving as the interlacing of two sets of yarns. Several preparatory processes for weaving are described, including warping, sizing, and drawing the yarns through the loom. Different types of looms are outlined, from hand looms to power looms to shuttleless looms. Woven fabric structures like plain weave, twill weave, and satin/sateen weaves are also summarized. Finally, common weaving faults and how to mend them are briefly covered.
Woven fabric is produced by interlacing warp threads that run lengthwise with weft threads that run across. The appearance and properties of woven fabric depend on yarn structure and fabric structure. There are four basic fabric parameters: thread count, yarn diameter, yarn bending, and weaving order. Weaving involves repeatedly raising warp yarns with harnesses to make a shed, inserting the weft through with a shuttle or rapier, and firmly beating it into place with a reed. Modern looms use rapier or projectile picking for higher speeds.
This document discusses quality control in fabric manufacturing. It outlines several factors that affect quality at different stages of production, including winding, warping, sizing, knitting, and weaving. Specifically, it notes that winding tension, knot strength, and machine functioning impact quality. In warping, beam and drum conditions, stop motions, and length measurements are important. For sizing, factors like viscosity, pressure, tension, and speed influence size pickup. Drying is impacted by speed, density, pickup, and temperature. Common fabric defects from knitting and weaving like loops, bars, holes, and stains are also described. Maintaining quality at all stages of production is essential to avoiding defects and customer rejections.
This document discusses different types of yarn faults, including:
1. Yarn content in the cop being less, causing efficiency loss and more knots. This can be caused by underutilization of bobbin height or improper ratchet settings.
2. Slubs, which are thick lumps showing less twist. This can damage fabrics and cause shade variations. Poor carding, machine dirtiness, and drafting issues can cause slubs.
3. Neps, which are rolled fiber masses visible on black boards. This also damages fabrics. Machine cleaning, carding, and drafting are important to prevent neps.
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This document provides an overview of common knit fabric faults, their causes, and remedies. It discusses various types of defects that can occur during knitting, dyeing, finishing or due to issues with the yarn, machine settings, or knitting elements. Specific faults covered include drop stitches, streakiness, barriness, imperfections, snarls, spirality, contaminations, needle lines, horizontal lines, broken needles/laddering, sinker lines, oil lines, fabric press off, and broken ends. For each fault, the document explains the definition, potential causes, and recommended remedies to address the issue and prevent reoccurrence. The goal is to identify how and why different knitting defects arise so they can
This document discusses various types of fabric defects in woven and knitted fabrics. It begins by defining a fabric defect and explaining its importance. For woven fabrics, 13 common defects are described including loose warp, double ends, broken warp, and oil spots. Causes and remedies are provided for each defect type. For knitted fabrics, 11 defects are covered such as needle lines, holes, thick and thin places, and missing yarn. The document concludes by stating that fabric defects can result in significant value loss, so manufacturers should aim to minimize defects through appropriate remedies.
This document discusses common yarn faults like slubs, neps, snarls, thick and thin places, soft yarn, and oil stained yarn. It describes the effects and causes of each fault as well as methods for rectifying the issues. Some ways to prevent yarn faults include maintaining clean machinery, ensuring proper drafting and piecing, and avoiding mixing cotton with widely varying properties. Overall, the document provides information on identifying, understanding, and addressing different types of defects that can occur in yarns during spinning.
The document discusses various types of faults that can occur in textile manufacturing and woven fabrics. It describes 18 common faults including starting mark, loose warp, double end, broken warp, tight end, float of warp, wrong end color, broken pick, miss pick, double pick, snarl or loose weft, weft bar, ball, holes, oil spot, temple mark, temple pierced hole, and cut/torn selvedge. For each fault, it provides the reasons they may occur and recommendations for remedies. It also discusses faults related to yarn production and garment defects.
This document defines fabric defects and lists common defects found in woven and knitted fabrics. It provides examples of 13 common woven fabric defects such as loose warp, double ends, broken warp, and their causes and remedies. For knitted fabrics, it lists 11 defects including needle lines, holes, oil marks, and their typical causes. The conclusion states that fabric defects can result in lower sales prices and value loss, so manufacturers should aim to minimize defects through appropriate remedies.
IRJET- Study of Reed on High Speed Weaving MachinesIRJET Journal
This document discusses reeds used in high-speed weaving machines and how to increase the life of reeds. It begins by explaining what a reed is and how it is constructed. It then discusses the problem of groove formation in reeds, where the dent wires are cut, which decreases reed life. Groove formation commonly occurs within 500 hours and is caused by high tension and abrasion on selvedge ends from the contraction between the reed and woven cloth. Several factors can influence groove formation, including fabric construction, yarn type, loom settings, sizing recipe, and reed construction. The document provides solutions to prevent groove formation, such as selecting the proper reed specifications, temple,
Fabric defects in woven and knitted fabric - hitesh choudharyHitesh Choudhary
This document provides information about various types of fabric defects, their causes, and methods for inspection and grading. It begins with definitions of a fabric defect and examples of common defects seen in woven, knitted, terry, and velvet fabrics. Specific defects are then described in more detail such as knots, holes, missing threads, oil stains, and more. Grading systems for inspecting and assigning penalty points to defects are also outlined, including the 4-point and 10-point systems. The document aims to help identify, mend, and minimize fabric defects.
1. Singeing is the process of burning off protruding fiber ends from fabric surfaces to obtain a smooth finish and reduce pilling. It is done by passing fabric over an open flame or heated plates.
2. There are three main types of singeing machines: gas, plate, and rotary cylinder. Parameters like flame intensity, fabric speed, and distance between flame and fabric must be optimized.
3. Singeing removes loose fibers and improves fabric appearance, allowing for clearer printing and reducing soiling and pilling. Precautions must be taken to avoid over-singeing or damaging heat-sensitive fibers.
This document defines and describes various types of defects that can occur in woven, terry, velvet, and knitted fabrics. It lists specific defects such as slubs, knots, holes, and broken patterns. For each defect type, it discusses the potential causes and methods for mending or correcting the defects. The main types of defects covered are fabric construction errors, foreign particles, oil or other stains, and distortions in the fabric structure. Maintaining quality at each stage of production is important to avoid defects that can lower the price and reputation of fabrics.
"Warping method in a Textile Weaving Technology"Md Abul Hossain
This document provides information about the warping process. It discusses direct warping, beam warping, pattern band or drum warping, and ball warping. It also describes the key elements of a warping machine including the creel, builder motion, guide reed, measuring motion, and knocking off motion. Overall, the document outlines the different types of warping and key components and procedures for setting up and operating a warping machine.
This document lists various finishing faults that can occur in fabrics and their potential causes and remedies. Some common faults include wet squeezer marks from excessive pressure, GSM variation from inconsistent process parameters, bowing from uneven tension, skewing from improper feeding, shrinkage from high tension, overcompaction from excessive shoe pressure or overfeeding, unwanted marks from contact with dirty machinery, decolorized patches from chemical spills, pinholes from pins holding fabric, pilling from short fibers separating from yarns, water spots from wet fabric not drying quickly enough, and torn selvages from excessive tension. The remedies suggested aim to correct the specific causes, such as using a hydroextractor instead of squeezer rolls, ensuring consistent processing
The document discusses various types of defects that can occur in knit fabrics, including skewing, bowing or twisting, knots, needle lines, holes, oil marks, slubs, ladders, barres or shade bars, fly yarn contamination, fabric weight issues, dye marks, stains, pin marks, spirality, facing up, and cockling or loop distortion. Potential causes and remedies are provided for each defect type.
The document discusses different types of warping processes and machines. It describes beam warping, sectional or patterned warping, and ball warping. Beam warping is direct warping that produces beams with up to 1000 ends, while sectional warping is indirect and produces narrow tapes that are later rewound onto a beam, allowing for complex patterns. High-speed warping machines directly wind ends onto a beam from many packages at once. Sectional warping machines first wind yarns onto a drum before rewinding them onto a beam, enabling fancy multi-colored fabrics. Both processes aim to produce a warp beam with uniformly spaced, tensioned ends of a predetermined length.
This document discusses the requirements for fabric spreading in garment manufacturing. It begins by introducing the author and their background. The document then covers 10 key requirements for proper fabric spreading: 1) the fabric must be flat, 2) have correct ply tension, 3) ply alignment, 4) correct ply direction and stability, 5) elimination of static electricity, 6) elimination of fabric flaws, 7) easy separation of cut layers, 8) avoidance of ply fusion during cutting, 9) avoidance of spread distortion, and 10) matching of checks and stripes. It also briefly discusses pattern making, marker making, and cutting methods. The author provides links to related textile technology Facebook pages and their blog.
Defects of garment(print, fabric & sewing)Rupak Barua,
This document discusses various types of defects that can occur in fabric, printing, dyeing, sewing, and other stages of apparel production. It begins by defining defects and classifying them based on their severity. Section 1 then lists and describes common fabric defects such as loose warp, double ends, broken warp, and oil spots. Section 2 covers dyeing, printing and finishing faults. Section 3 examines sewing problems like slipped stitches, seam pucker, and variable stitch density. Section 4 lists other defects from sizing, ironing, trims and accessories. The document emphasizes that defects can lead to lower prices or seconds goods, creating significant value loss. It stresses the importance of quality control and remedial measures to minimize defects
Similar to Yarn breakage practically found in warping and its remedy (20)
This document provides definitions and background information on various textile terms. It begins with an introduction to textiles and defines key terms like fiber, filament, yarn and fabric. It then discusses the history of natural fibers like cotton, wool and silk. The document also summarizes the development of various man-made fibers like rayon, nylon, acrylic and polyester. It provides timelines of when these fibers were first invented and commercialized. The document is intended to serve as a reference for textile engineering students.
This document provides information about garment manufacturing and exporting processes. It was prepared by Md. Kamrul Hasan, a Textile Engineering graduate from Southeast University in Bangladesh. The document contains several sections that discuss key topics like buyers and buying houses, major garment exporting countries, GSP status, garment export procedures, costing, purchase orders, letters of credit, and timelines. It aims to serve as a reference for students and professionals in the garments sector.
This document provides information about carbon fiber, including:
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The document discusses acrylic fiber, including its definition, chemical composition, properties, characteristics, advantages, uses, and commercial applications. Acrylic fiber is a synthetic fiber made from polymers containing acrylonitrile. It is often used as an artificial replacement for wool in applications like sweaters, socks, and blankets due to its softness and insulating properties. Major uses of acrylic fiber include knit apparel, carpets, and home furnishings due to its ability to wick moisture, durability, and resistance to moths and chemicals.
Elastomeric fibers are fibers that can stretch to very high elongations (400-800%) and rapidly recover their original length. They include fibers made from natural and synthetic rubbers as well as spandex and polyacrylates. Elastomeric fibers are produced via a spinning process where polymers are mixed and reacted to form long chains, then extruded through spinnerets into a water bath or air to solidify. The fibers have excellent elasticity and strength even at high elongations. Common applications include clothing, automotive and industrial parts, coatings and more where elasticity is required.
This document provides a project report on applying disperse and reactive dyes to a 65/35 polyester/cotton blended fabric using a two bath system. It acknowledges those who helped with the project and thanks the textile college and company for the opportunity. The abstract discusses challenges in dyeing poly/cotton blends and how dye selection can help control color value, strength, and other properties. Laboratory trials tested compatibility of reactive dyes and analyzed dye fixation using spectrophotometry. The introduction discusses the importance of practical experience and outlines the project goals of studying dye application in different textile industries in Bangladesh.
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This document provides information about Interstoff Apparels Ltd., a garment manufacturing company in Bangladesh. It discusses the company profile, including its name, business type, employees, and address. It also describes the knitting, quality control, dyeing, and project work sections of the company. The knitting section details the types of yarns, knitting machines, production calculations, and common knitting faults. The quality control section lists inspection equipment. The dyeing section outlines the dyeing process and possible faults. The project work section explains common knitting defects and their causes and remedies.
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The document provides information about GTA Sports Ltd., a knitwear factory in Bangladesh. It includes an organogram of the company's management structure and sections. The knitting section is described in detail, outlining the knitting process, types of knitting machines and their parts. It also discusses increasing production quantity and common knitting faults. The dyeing and finishing sections are briefly introduced, including raw materials, machinery and quality control processes.
The document provides information about reactive dyes, including:
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This document discusses the development of looms from primitive hand looms to modern automated looms. It outlines the key stages of development including the fly shuttle loom, power looms, semi-automatic looms, and modern shuttle-less looms. The basic mechanisms and motions of weaving are described, including primary, secondary, and tertiary motions. Different parts of a loom and their functions are also summarized.
This document provides information about Urmi Group and one of its concerns, Fakhruddin Textile Mills Ltd. It details the company profile, factory information, manpower and organizational structure, raw materials used, and production process of the textile mill. Fakhruddin Textile Mills Ltd is a leading Bangladeshi manufacturer and exporter of knit garments established in 2004. It has over 1200 employees and uses various natural and synthetic yarns, chemicals, and dyes to produce knitted fabrics and garments for the export market.
This document provides an overview of Sadma Fashion Wear Ltd., a garment manufacturing company in Bangladesh. It details the company's profile, facilities, production capacity, certifications, buyers, and organizational structure. Key points include that it has over 200 employees, a production capacity of 20,000 pieces per day, and major buyers such as Walmart, C&A, and Sears. The company operates departments for knitting, dyeing, finishing, garments production and quality assurance.
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The document provides information about an industrial training internship at Olio Apparels Ltd, which is part of the Envoy Group. The objectives of the internship are to learn about the different departments of the company and gain practical knowledge about garment manufacturing. It also aims to compare theoretical knowledge learned in class to real-world practices and identify strengths, weaknesses, opportunities, and threats of the company. Olio Apparels Ltd is described as a large garment manufacturing facility that produces high quality products for European and American customers using modern machinery and technologies.
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This document provides information about garment merchandising and industrial engineering. It defines merchandising and outlines the key steps in the merchandising process from developing buyers to shipment. It also describes the work of merchandisers, including sourcing, pricing, order follow up, and ensuring on-time shipment. Additionally, it discusses industrial engineering and its focus on improving productivity through methods like time studies, layout optimization, and training. It provides details on cost analysis, production planning, and the different techniques used to set work standards.
Leveraging Generative AI to Drive Nonprofit InnovationTechSoup
In this webinar, participants learned how to utilize Generative AI to streamline operations and elevate member engagement. Amazon Web Service experts provided a customer specific use cases and dived into low/no-code tools that are quick and easy to deploy through Amazon Web Service (AWS.)
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Walmart Business+ and Spark Good for Nonprofits.pdfTechSoup
"Learn about all the ways Walmart supports nonprofit organizations.
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ISO/IEC 27001, ISO/IEC 42001, and GDPR: Best Practices for Implementation and...PECB
Denis is a dynamic and results-driven Chief Information Officer (CIO) with a distinguished career spanning information systems analysis and technical project management. With a proven track record of spearheading the design and delivery of cutting-edge Information Management solutions, he has consistently elevated business operations, streamlined reporting functions, and maximized process efficiency.
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Tags: Information Security, ISO/IEC 27001, ISO/IEC 42001, Artificial Intelligence, GDPR
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Yarn breakage practically found in warping and its remedy
1.
2.
3. Prepared By : Mazadul Hasan sheshir
ID: 2010000400008
13th Batch (session 2009-2013)
Department : Wet Processing Technology
Email: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)
Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh
Prepared By :
4. MR. MUZAHIDUR RAHMAN CHOWDHURY
LECTURER
SOUTHEAST UNIVERSITY
DEPARTMENT OF TEXTILE
SOUTHEAST UNIVERSITY
DEPARTMENT OF TEXTILE ENGINEERING
5. PROJECT OBJECTIVE
Research.
Analysis various yarn Fault in Warping process of weaving
Remedies of these faults.
Selection of raw materials.
Product testing.
Product Quality improvement
Reduce wastage
To improve warping efficiency
To improve yarn quality in spinning
6. During processing, textile materials are subjected to various stresses
not only during the machine operation but also during its stoppage. If these
stresses exceeded a given limits it will adversely affect the quality of the
produced yarns, fabrics and the efficiency of the machines .
In weaving process, the strains on warp ends can lead to thread breaks, loss of
quality and shutdowns. Warp breaks still represent major problem especially
for today's high-speed weaving machines .Generally, warp yarn break occurs
due to excessive tension greater than the strength of the yarn.
8. SLUBS
An abnormally thick place or lump in yarn showing less twist at that place.
1. Machine surfaces to be maintained clean.
2. Rotors are properly maintained.
3. Better fiber individualization at cards to be achieved.
4. Optimum top roller pressure &back zone
5. Setting at rotor to be maintained.
1. More end breaks in warping process.
2. Damaged fabric appearance.
3. Shade variation in dyed fabrics.
1. Accumulation of fly and fluff on the machine parts.
2. Poor carding.
3. Defective rotor drafting and bad piecing
1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21
1
9. NEPS
Yarn containing rolled fibre mass, which can be clearly seen on black board at close
distance; measurable on USTER imperfection Indicator
1. Machine surfaces to be maintained clean.
2. Damaged rotor to be avoided and proper maintained.
3. Better fiber individualization at cards to be achieved.
1. Damaged fabric appearance
2. Shade variation in the dyed fabrics
3. An abnormally thick place or lump in yarn showing less twist at that
place is called slubs
1. Accumulation of fly and fluff on the machine parts
2. Poor carding.
3. Defective rotor and bad piecing of robot
2
1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21
10. SNARL
Yarn with kinks (twisted onto itself) due to insufficient tension after twisting
1. Optimum twist to be used for the type of cotton processed
2. Drafting parameters to minimize thin places in the yarn to be
adopted
3. Correct tension weights and slub catcher settings to be employed
at winding
1. Entanglement with adjacent ends causing a break
2. Damaged fabric appearance
3. Shade variation in dyed fabrics
4. Mixing of cottons varying widely in fiber lengths and use of
immature cottons
1. Higher than normal twist in the yarn
2. Presence of too many long thin places in the yarn
3
1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21
11. THICK AND THIN PLACES
Measurable by USTER Imperfection Indicator and observable on appearance
1. Defective rotor to be avoided
2. Right the card setting
3. Wide variation in the properties of cottons used in the mixing to be
avoided
4. Better fiber individualization at cards to be achieved. Correct
spacers to be utilized
1. Damaged fabric appearance
2. Shade variation in dyed fabrics
3. Mixing of cottons varying widely in fiber lengths and use of
immature cottons
4. More breakage in warping
1. Non-uniform sliver
2. Problem in mixing
3. Defect rotor surface
4. Mixing of cottons varying widely in fiber lengths and use of
immature cottons
4
1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21
12. SOFT YARN
Yarn which is weak indicating lesser twist
1. Proper yarn clearing to be ensured
2. Periodic replacement of rotor to be effected
1. More end breaks in subsequent processes such as warping, winding
etc.
2. Shade variation in dyed fabrics
1. Improper feed in rotor
2. Less twist in the yarn
3. Bad rotor
5
1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21
13. OIL STAINED YARN
Yarn stained with oil
1. Appropriate material handling procedures to be followed
2. Oilers to trained in proper method of lubrication
3. Clean containers to be utilized for material transportation
1. Damaged fabric appearance
2. Occurrence of black spot in fabric
1. Careless oil in the moving parts, over head pulleys etc
2. Piecing made with oily or dirty fingers
3. Careless material handlings
6
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14. CRACKERS
Very small snarl-like places in the yarn which disappear when pulled with enough tension or
Yarn with spring -likeshape
1. Feed roller to be maintained
2. Mixing of cottons varying widely in fiber length to be avoided
3. Use of optimum roller settings
4. Use of properly buffed rollers free from eccentricity to be ensured
1. More breaks in winding
2. More noticable in polyester and cotton blended yarns
2. Mixing of cottons of widely differing staple length
3. Closer roller settings
4. Eccentric top feed roller
5. Non optimum temperature and relative humidity in the spinning
shed
6. Over spinning of cottons
7
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15. BAD PIECING
Unduly thick piecing in yarn caused by over End piecing
1. Correctly robot setting and proper repier
2. Separators to be provided
3. Excessive end breaks in spinning to be avoided
1. More end breaks in subsequent process
2. Increase in hard waste
1. Wrong method of piecing and over end piecing of robot.
2. Twisting the ends instead of knotting
8
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16. OILY SLUB
Slub in the yarn stained with oil
1. Yarn contact surfaces to be kept clean
2. Proper segregation of oily waste from process waste
3. Oilers to be trained in correct procedures of lubrication
1. More end breaks in the warping process
2. Damaged fabric appearance
3. Shade variation in dyed fabrics
1. Accumulation of oily fluff on machinery parts
2. Poor methods of lubrication in preparatory processes
3. Negligence in segregating the oily waste from process waste
9
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17. KITTY YARN
Presence of black specks of broken seeds, leaf bits and trash in yar
1. Cleaning efficiency of blow room and cards to be improved
2. Optimum humidity in the departments to be ensured
1. Damaged fabric appearance
2. Production of specks during dyeing
3. Poor performance during winding
1. ineffective cleaning in Blow room and cards
2. Use of cottons with high trash and too many seed coat fragments
10
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18. HAIRINESS
Protrusion of fiber ends from the main yarn structure
1. Proper mixing or blending
2. Periodic maintenance of different parts
3. Roller settings to be maintained
4. Optimum relative humidity to be maintained in the spinning room
5. Wide variation in the properties of cottons used in the mixing to be
avoided
1. More breaks in winding and warping
2. Formation of holes and stains in cloth
1. Use of cottons differing widely in the properties in the same mixing
2. Improper mixing
3. Maintaining low relative humidity, closer roller settings and very
high spindle speeds
11
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HAIRINESS
19. FOREIGN MATTERS
Metallic parts, jute flannel and other similar foreign matters spun along with yarn
1. Improper setting of cleaning zone.
2. Removal of foreign matters(such as jute fibres, colour cloth bits) to
be ensured during preparation of mixing
3. Installation of permanent magnets at proper Places in blow room
lines to be ensured
1. reaks during winding and warping
2. Formation of holes and stains in cloth
1. Damaged fabric appearance
2. Improper preparation of mixings
3. Improper setting of foreign material separator in blow room.
12
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20. SPUN IN FLY
Fly fluff either spun along with the yarn or loosely embedded on the yarn
1. Malfunctioning of humidification plant
2. Machinery surfaces to be kept clean by using roller pickers
3. Fanning by workers to be avoided
4. Performance of over head cleaners and humidification plants to be
closely monitored
1. More breaks in winding and warping
1. Accumulation of fluff over machine parts
2. Fanning by workers
3. Failure of over head cleaners
13
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21. CORK SCREW YARN
It is a double yarn which one yarn is straight and other is coiled over it
1. proper maintenance of robot
2. proper mixing
1. Breaks during winding and warping
2. Causes streaks in the fabric
1. Bad piecing by robot
2. Improper mixing
3. Improper feeding
14
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22. STITCHING ON CONE
Ends not laid properly on the cone at reversal of yarn path
1. Maintenance cone winders to be good
2. Cone holder settings and alignment of tension
3. Brackets with drum to be carried out as frequently as possible
1. More end breaks in the subsequent process
2. Excessive yarn waste
1. Vibrating and wrongly set cone holder
2. Yarn coils wrapped round the base of cone holder
3. Traverse restrictors fixed at incorrect position
4. Improper alignment of tension brackets with the drum
15
1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21
23. RIBBON WOUND CONE
Formation of ribbon like structure on the circumference of the cone
1. Over hauling of cone winders to be periodically carried out
2. Anti ribboning mechanism to be checked at frequent interval
3. Free movement of the cone holders to be ensured by proper
lubrication
1. Overall density of package is lower
2. Soft packing either at the base or at the nose of cones
1. Winding spindle not revolving freely
2. Cone holders incorrectly set
3. Defective settings of cam switch
4. Improper traverse motion
5. Vibration of cone and traverse
16
1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21
24. SOFT BUILD CONES
Unduly soft structure of cone
1. Unwinding tension to be maintained at 6 to 8% of single yarn
strength
1. Overall density of package is lower
2. Soft packing either at the base or at the nose of cones
1. Improper alignment of cone holder and traverse
2. Insufficient unwinding tension
17
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25. BELL SHAPED CONE
Cones which are tightly built at centre, presents a shape of bell
1. Quality of cones to be checked at that time of procurement
2. Optimum unwinding tension to be maintained
1. Excessive breaks during warping and winding processes
1. High yarn tension during winding
2. Cone holders incorrectly set to the winding drum
3. Damages in paper cone centre
18
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26. NOSE BULGING
Bulging of bunches of the yarn at the nose of the cones
1. Periodical inspection of settings in winding machines
2. Tenters to be instructed to adopt correct work practices
3. Avoiding usage of damaged paper cones
1. Slough during warping/unwinding
2. Excessive yarn waste in next process
1. Improper setting of cone holders to the winding drum
2. Damaged nose of the paper cones
19
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27. COLLAPSED CONE
Collapse of the structure of the cone(paper cone)itself
1. Using of poor quality/damaged paper cones should be avoided
2. Winding tenters should be trained by proper work methods
3. Proper material handling devices such as cone transport trolleys to
be used
4. Cone inserts to be used for paper cones
1. Yarn breaks in warping process
2. Wastage increase in yarn preparation
1. Use of poor quality/damaged paper cones
2. Poor system of material handling
3. Maintaining non optimum unwinding tension
20
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28. Formation of ring shaped bulge across the cross section of the cone
1. Due to replacement of defective drums and stop motion
wires to be ensured ,
2. Periodic inspection of cone holder settings and tension
assembly to be carried out ,
1. More end breaks in the subsequent processes
2. Slough off during unwinding
1. Incorrect setting of the cone holder
2. Wrong placement tensioners in the tensioning assembly
3. Traverse of yarn affected due to defects in the grooves of the
drum
21
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32. From Table-1: Data for 20 Ne
0
10
20
30
40
50
60
70
80
90
Fig: Effect of different types of yarn faults in
warping for 20/1 count carded yarn
DATA ANALYSISNoofbreakage
WEAK YARN
44%
SLOUGHING
OFF
0%
OVER
LAPPING
6%
KNOTS/BAD
SPLICE
3%
SLUBS
13%
LOOSE YARN
2%
PIGTAIL
24%
CUT YARN
4%
BAD TIP CONE
4%
33. From Table-2: Data for 10 Ne
0
5
10
15
20
25
30
35
40
45
50
Fig: Effect of different types of yarn faults
in warping for 10/1 count carded yarn
DATA ANALYSISNoofbreakage
WEAK YARN
31%
SLOUGHING
OFF
0%
OVER
LAPPING
11%
KNOTS/BAD
SPLICE
6%
SLUBS
14%
LOOSE YARN
3%
PIGTAIL
23%
CUT YARN
9%
BAD TIP CONE
3%
34. From Table-2: Data for 16 Ne
0
10
20
30
40
50
60
70
Fig: Effect of different types of yarn faults in warping
for 16/1 count carded yarn
WEAK YARN
39%
SLOUGHING
OFF
0%
OVER
LAPPING
5%
KNOTS/BAD
SPLICE
3%
SLUBS
14%
LOOSE YARN
3%
PIGTAIL
24%
CUT YARN
5%
BAD TIP CONE
7%
Noofbreakage
DATA ANALYSIS
35. 1. Found different types of yarn and package faults from warping.
the main cases of warp yarn breakage is improper raw material
mixing and cleaning in spinning because majority percentage of
yarn faults is weak yarn.
2. The number of breaks varied directly with the yarn count.
3. Improper maintenance of spinning.
KEY FINDINGS
36. 1. We had a very limited time. In spite of my willing to study
more details it was not possible to do so.
2. This while process is not possible to bind such a small frame
as this report, hence our effort spent on summarizing them
3. We cannot manage data perfectly. Some fault cannot
recovery such as parallel winding which is occur from
robotic miss action in rotor spinning ,mixing ratio is not
perfectly, large amount of wastage uses as for the rate of
beating action is high and create more amount of neps
which neps carding cannot remove perfectly. If Feed
material is quality full then produce goods also be good.
LIMITATION
37. Considering the objective of the work, a systematic investigation on ‘Yarn
Faults in warping and its Remedies’ were performed in the training period. All
the activities had been done maintaining in sequence of the machinery of the
production. From the thorough investigation it is seen that the following faults
are yarn faults, yarn package faults, mechanical faults in spinning. Reducing
warp breaks on warping machines
uplift the efficiency of this process and the efficiency of weaving machines,
and finally enhances the quality of yarns and produced fabrics.
Yarn faults tend to not fulfill the target of production of a industry. As a result
the production capacity of these industries falls significantly. These are the
common faults which I have tried to find out the causes & their Remedies
against them.
CONCLUSION
38. 1. Yarn Manufacturing Technology
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2. Fabric Manufacturing Technology
Link : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605
3. Garments Manufacturing Technology
Link : http://www.facebook.com/pages/Garments-Manufacturing-
Technology/472364799463126
3. Wet processing Technology
Link : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404
4. Fashion-Design-and-Technology
Link : http://www.facebook.com/pages/Fashion-Design-and-
Technology/587655294583875?ref=ts&fref=ts
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