Spinning Sector

Introduction of  Spinning:

Spinning is a process of making or converting fiber materials into yarns.Since few centuries ago, spinning have been known as a process of converting raw materials(fiber) such as cotton and wool into yarns for making textile fabric or products. There are two classes of spinning process have been developed by people, Hand Spinning and Machine Spinning. In Textile Industry, the size of yarns is determined by unit of Tex, Count, Worsted, Woolen, and Denier.

Hand Spinning:

Before industrial revolution occurs, hand spinning method is widely used by people for making yarns. The principle is by using a tool such called carder or bare hand to align parallel the yarns before twisting.

Machine Spinning:

After industrial revolution, many developments have been done by the industry to ease the process by apply machine to control the process effectively. One of the oldest types of machine used by the industry since nowadays is Ring Spinning Machine

                                                                                    

Types of Yarn Production:

There are two classifications of yarns that will be produced by spinning which are Filament and Staple yarns.

Filament:

These yarns are made from long, and continuous strands of fiber. Most of them from synthetic and only silk represents for natural fibers in filament

Staple:

Staple or spun yarns in other hand are made from short length of fibers. It can be found from natural fibers or can be produced using synthetic as staple filament yarns. As it is short length, staple fibers need to be held together with others in order to get the long and continuous yarns.

Steps in Making Fibers into Yarns

Spinning is the process (or the processes) used in the production of yarns or filaments. Following are different steps/stages of the spinning process.

Blowroom:

The end product of blow room is lap. It is made on Scutcher. It is roll of uniform sheet of cleaned cotton wrapped after calendaring with sufficient pressure.

There is also another system in which partially opened and cleaned cotton is directly fed to the carding section directly from blow room, without lap formation. This system is called chute feed system.

A process where the raw materials packed in bale forms(supplier) will be open and clean the impurities on the surface by using bale opener machine.

Carding:

It is the most important stage of cleaning where in the minutest impurities foreign to the material and all fibers, leaf and broken seed ought to be removed.

Cotton carding is the operation of treating cotton fibers, which thoroughly opens the cotton, frees it of most of the remaining dirt, motes and neps, removes some short fibers and condenses the fibers to a sliver.It’s the heart of spinning process. This is where the flock from bales will be open into individual fiber. Thus, it will ease to remove the excess impurities on the fiber surface. At this point, short fiber which not suitable for production in terms of length requirements will be eliminated.

Combing:

This is a process where the yarn will be straightened again so that they are arranged in parallel manner. While at the same time, the remaining of short fiber will be eliminated completely from the longer staple fiber. By doing this, long-staple will produce stronger and smoother  fabric which are highly demanded in the market. 

Drawing:

At this stage, it will be pulled the sliver lengthwise direction over each other. Thus, it will cause it to be stronger and thinner in production which is very important in evenness of the yarn. If there is any faults occur during process, it will still pass into the yarn. Most of manufacturer will use blending process where two or more different types of fibers will be blended to form a yarn. Common type of blend use is Cotton/Polyester combination, by doing this it will not only reduce the cost but also increase the performance.

                                                                                              

Roving:

The suitable size spinning the purpose of the roving operation is to reduce the sliver to a

This is the final stage where the preparatory steps for insertion of the twist. Enough twist is given to hold the fibers together but still has no tensile strength. The roving in bobbins is placed in spinning frame where it passes several sets of roller which running at high-speed to convert into yarn forms.

Ring Frame:

The end-product of ring department is yarn. Yarn is the continuous strand of fibers, which has received its final shape. It may be finer (wt/yard is less) or coarser (wt/yard is more) as per requirement of customer. However it is many times lighter in wt/yard as compared to that of roving from which it is produced.The machine which produces yarn takes roving and reduces it by roller drawing, twisting as needed and winds the products accurately in a special form of bobbin for further use in auto cone.