This project studied the effect of different yarn clearer settings on yarn quality and winding productivity. Three yarn clearer settings were tested: close, moderate, and wide. The close setting resulted in the highest number of yarn fault cuts but best yarn quality metrics. The wide setting had the lowest number of cuts but worst quality. The moderate setting produced intermediate quality and productivity results. Productivity was highest for the wide setting and lowest for the close setting, while waste generation followed the opposite trend. In conclusion, the appropriate yarn clearer setting balances yarn quality and productivity, and must be determined through experimentation.

1. Welcome to the
project
presentation

2. Project Title

3. Conducted by
NASIF MAHMOOD
11.02.06.019
FAHAD HALIM
11.02.06.041

4. Introduction

5. Introduction
Yarn clearing is a part of the yarn winding. The device which is used
to remove faults (thick places, thin places, foreign matter etc.) from
the yarn is known as yarn clearer.

6. Objectives
This project represents the comparative
study of yarn quality and productivity due
to different yarn clearer settings of winding
machine

7.  Studied different yarn clearer settings
 Analyzed various types of yarn faults
 Observed number of yarn cuts due to different yarn clearer
settings
 Compared yarn quality and characteristics before and after
winding
 Studied the effect of different yarn clearer settings on winding
productivity and wastage generation
What we did in the project

8. Literature review

9. Why is yarn clearer used?

10. Types of yarn clearer
Mechanical type
1. Conventional blunt type
2. Serrated blade type
Electronic type
1. Capacitance type
2. Optical type

11. The capacitive measuring principle
1. Electrode
2. Electric field
3. Alternating voltage
4. Yarn
5. Electrical signal

12. The optical measuring principle
1. Infrared light source
2. Diffuser
3. Photocell
4. Yarn
5. Electric signal

13. Types of faults removed by yarn clearer
1. Thick places
2. Thin places
3. Count variations
4. Foreign fibers
5. Periodic yarn faults

14. Seldom occurring faults and frequently
occurring faults

15. Definition of the yarn body
Yarn body defines the nominal yarn with its tolerable,
frequent yarn faults. The green shaded area represents
the yarn body.

16. Clearing limit
The clearing limit defines the threshold level for the yarn
faults, beyond which the cutter is activated to remove the
yarn fault.
i. Sensitivity – This determines the activating limit for the
fault cross sectional size.
ii. Reference length – This defines the length of the yarn
over which the fault cross-section is
to be measured.
REFERENCE LENGTH
SENSITIVITY

17. Classification Matrix

18. Winding
• Extraction of all
disturbing yarn faults.
• Manufacture of cones.
• Waxing of the yarn.
• Production of yarn with
minimum number of
splice.

19. Different parts of winding unit

20. Winding
process
Winding
speed
Rate of
yarn
breakage
Number
of yarn
splicing
Ring cop
mass
Waiting
time
Timing
for
manual
doffing
Factors influencing winding
productivity

21. Splicing
The process of piecing of two yarn
ends—resulting from yarn breaks,
removal of a yarn defect, or due
to the end of the supply package
is called splicing.
Parameters
Splicing length
Untwisting time
Twisting time
Air pressure
Value
20 mm
0.71 sec
0.08 sec
0.6 MPa
Pneumatic splicer

22. Splicing operation

25. Material and Method

26. Fibre used :
The property of the raw cotton determines the processing parameters of
the spinning machinery and the quality of final yarn. For the current
experiment, we have used 100% Mali cotton.
Properties
Length (mm)
Strength (g/tex)
Micronaire
Nep (Cnt/g)
SCN (Cnt/g)
SFC% (n)
Value
28.65
33.3
4.39
239
28
20.5

27. Flow chart of the experimental
process:

28. Machine used
Manufacturer :
Muratec, Japan
Model: 21C

29. Process parameters
Windingmachine
Winding Speed - 1480 m/min
Yarn type - Cotton
Yarn Count - 36 Ne
Yarn tension - 280 cN
Cop yarn weight – 48 g

30. Uster Quantum 2
Model: SE 617
Manufacturer: Zellweger Uster,
Switzerland

31. USTER HVI SPECTRUM
Manufacturer : Zellweger Uster,
Switzerland
Function: To test and give results
on important fibre properties.

32. USTER AFIS PRO
Manufacturer : Zellweger Uster,
Switzerland
Function: To test the number and
size of neps, different fibre
lengths, fibre maturity etc.

33. USTER TESTER-5
Manufacturer : Zellweger
Uster, Switzerland
Function: To test evenness
and imperfection of yarns and
other strands such as roving
and slivers.

34. Bundle yarn strength tester
Manufacturer: Mesdan, Italy
Function: To measure bundle
yarn strength

35. Tecloch
Model: SLW
Manufacturer: Japan
Function: To measure strength of
splice

36.  300 ring cops were selected
 They were divided into 3 groups each containing 100 cops
 3 drums of winding machine were selected
 3 different yarn clearer settings were chosen for Uster Quantum 2
 Cut data were collected for each settings
 Production and wastage of winding machine were calculated
 Strengths of splice were measured with Tecloch
 Then yarn samples were taken to Quality Control Department for
offline testing
Working procedure

37. Uster Quantum 2
Manufacturer
Model No.
IMK type
: Zellweger Uster, Switzerland
: SE 617
: IMK-C15-F23
Sample 1 Close setting
Sample 2 Moderate setting
Sample 3 Wide setting

38. Thick place
% cm
N
S
L
H1
H2
H3
H4
H5
H6
200
120
20
100
90
80
60
45
0.0
0.0
1.2
20.0
1.5
2.5
5.0
15
30
0.0
Sample 1 (close setting)

39. Thin place
-% cm
T
H1
H2
H3
H4
H5
H6
30
42
38
35
28
26
0.0
12
3
5
7
20
30
0.0
Continued….

40. Scatter plot for sample 1

41. Thick place
% cm
N
S
L
H1
H2
H3
H4
H5
H6
250
180
40
140
100
75
35
0.0
0.0
0.0
1.5
20
3
4.2
6.5
32
0.0
0.0
Sample 2 (moderate setting)

42. Thin places
-% cm
T
H1
H2
H3
H4
H5
H6
30
42
36
33
26
0
0
16.0
3.0
6.0
11.0
32.0
0.0
0.0
Continued….

43. Scatter plot for sample 2

44. Thick place
% cm
N
S
L
H1
H2
H3
H4
H5
H6
500
300
90
0
0
0
0
0
0
0
10
90
0.0
0.0
0.0
0.0
0.0
0.0
Sample 3 (wide setting)

45. Thin places
% cm
T
H1
H2
H3
H4
H5
H6
45
70
60
40
30
0
0
45
10
18
28
10
0.0
0.0
Continued….

46. Scatter plot for sample 3

47. Graphical Representation

48. Comparison of number of yarn fault cuts per 100 km
(N, S, L, T) of samples for different yarn clearer
settings:
Sample-1
Sample-2
Sample-3
0
50
100
150
200
250
219.1
64.6 53.4
Numberofyarncuts

49. Comparison of mass variation (CVm%) of ring yarn
and cone yarn of different yarn clearer settings:
Ring yarn
Sample-1
Sample-2
Sample-3
13.7
13.8
13.9
14
14.1
14.2
14.3
14.4
14.17
14.37
13.93
14.29
CVm%

50. Comparison of thick place(+50%) of ring yarn and
cone yarn of different yarn clearer settings:
148
143
122
144
0
20
40
60
80
100
120
140
160
Thickplace(+50%)
Ring yarn Sample -1 Sample -2 Sample -3

51. Comparison of thin place (-50%) of ring yarn and cone
yarn of different yarn clearer settings:
0
0.5
1
1.5
2
2.5
3
3.5
4
4
3.5
1.3
3.3
Thinplace(-50%)

52. Comparison of neps of ring yarn and cone yarn of
different yarn clearer settings:
281
351
310
355
0
50
100
150
200
250
300
350
400Neps

53. 380
400
420
440
460
480
500
520
433
502
432
498
Comparison of IPI of ring yarn and cone yarn of
different yarn clearer settings:IPI

54. Retained splice strength (RSS %)
The ratio of breaking strength of spliced yarn and parent yarn is
known as Retained spliced strength.
𝑹𝑺𝑺% =
𝑩𝒓𝒆𝒂𝒌𝒊𝒏𝒈 𝒔𝒕𝒓𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒔𝒑𝒍𝒊𝒄𝒆𝒅 𝒚𝒂𝒓𝒏
𝑩𝒓𝒆𝒂𝒌𝒊𝒏𝒈 𝒔𝒕𝒓𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒑𝒂𝒓𝒆𝒏𝒕 𝒚𝒂𝒓𝒏
× 𝟏𝟎𝟎%
=
𝟏. 𝟔
𝟏. 𝟕𝟒
× 𝟏𝟎𝟎%
Retained splice strength, RSS% =
𝟗𝟏. 𝟗𝟓%

55. 1.5
1.55
1.6
1.65
1.7
1.75
1.6
1.74
Strength(N)
Spliced yarn Parent yarn
Comparison between spliced yarn strength and
parent yarn strength

56. Comparison of CSP of ring yarn and cone yarn of
different yarn clearer settings:
2200
2250
2300
2350
2400
2450
2424
2277
2346
2368
CSP

57. Comparison of SEF% of cone yarn of different yarn
clearer settings:
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
60.20%
80.00% 83.30%
Spindleefficiency%

58. Comparison of productivity of cone yarn of different
yarn clearer settings:
383.61
511.48
530.66
0
100
200
300
400
500
600
Sample-1
Sample-2
Sample-3
Production(kg/shift)

59. Comparison of wastage% of autoconer due to
different yarn clearer settings:
0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
3.00%
3.50%
3.12%
0.92%
0.76%
Wastage%

60. Key findings
 It was observed that sample-1 has the highest number of yarn fault cuts
than sample-2 and sample-3 where sample-3 showed lowest number of
yarn fault cuts. On the other hand number of yarn fault cuts for sample-
2 was found in between sample-1 and sample-3.
 Both sample-1 and sample-3 showed higher CVm% than ring yarn where
sample-1 was the highest. On the other hand sample-2 had lower CVm%
than that from sample-1, sample-3 and ring yarn.
 It was observed that both sample-1 and sample-3 had higher IPI value
than ring yarn where sample-2 showed no significant change of IPI value
than that from ring yarn.
 CSP values for all samples was observed lower than that from ring yarn
where sample-1 was lowest, sample-2 had higher value than sample-1
but sample-3 had highest CSP value among all these samples.

61. Continued…
 Spindle efficiency% for sample-3 was observed highest and for
sample-1 it was lowest where spindle efficiency% for sample-2 was
in between sample-1 and sample-3.
 In case of production it was observed that sample-3 had the
highest productivity and for sample-1 it was lowest. Alternatively
productivity for sample-2 was found in between sample-1 and
sample-3.
 In case of waste generation it was observed that sample-1 had the
highest waste generation% and for sample-3 it was lowest where
waste generation% for sample-2 was in between sample-1 and
sample-3.

62. Limitations
 The hairiness module of Uster Tester-5 was disabled. Therefore, we
could not observe hairiness properties of yarn before and after
winding.
 There was no single yarn strength tester as a result we could not
observe tenacity, breaking elongation of yarn before and after winding.
 The method used for calculating waste% was not accurate enough
since it was not possible to collect waste data individually from three
drums. Thus waste% data was calculated based on data of winding
waste produced per shift due to cuts.
 Only three yarn clearer settings were used in this project due to
unwillingness of factory authority to spare more time, material and
machine. So, it was not possible to observe intermediate yarn clearer
settings which would have helped to understand more effectively
about the consequence of clearing limits on different yarn properties
and productivity.

63. Conclusion
Based on experiments and observations conducted in this project work, it
can be concluded that clearing limit of yarn clearer has a significant impact
on yarn quality and productivity.
- Yarn clearer setting, too close or too wide, had adverse effect on yarn
quality. If the yarn clearer setting is too close, the clearing limit will cut
across the yarn body causing excessive cuts than normal. Again if
clearing limit is too wide it will allow faults in ring yarn to pass freely to
cone.
- The number of cuts during winding operation was directly affected by
sensitivity of yarn clearer. Higher number of cuts caused drop in spindle
efficiency and productivity with increase in waste generation.
It can be concluded that the appropriate clearer setting is crucial for
optimum yarn quality and productivity level and is needed to be
determined by trial and error method.

64. THANK YOU