Compact Spining

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

TEAM MEMBERS
KHURAM

SHAHZAD


M.ZAHID

HUSSAIN KHAN

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

WHAT IS INNOVATION ?  THE PROCESS OF TAKING A

CREATIVE IDEA AND TURNING IT INTO USEFUL PRODUCT, SERVICE OR METHOD OF OPERATION.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Contents

• • • •

Introduction Different innovations Compact spinning Types of compact spinning with respect to method • Comparison • Benefits towards forthcoming processes

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Some Recent Innovations

• • • • • • •

Pre cleaner UNIclean B-12,UNIstore A78. C60,TC 03 cards. New double delivery SB 20 draw frame and RSB D40 Autoleveller. OMEGAlap E65/E75 with 450nips/min with production of 66_68 kg/h Rieter has new ring frames G35 and K45(compact) with 1632 spindles. Rotor machine R 40(440 spinning boxes),BT 924(360 spinning boxes). Rotona rotor core yarn.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

OUR PRESENTATION TOPIC

COMPACT SPINNING

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

WHAT IS COMPACT SPINNING?


Compact or condensed spinning is a new concept

of yarn forming.
Fundamental modification of the conventional ring-spinning system that aims at producing a better surface integrity of spun yarns and maximizing strength.
The eliminated spinning triangle is a by-product of this concept. This close and parallel arrangement of fibers immediately before twist is imparted is responsible for the characteristic advantages of compact yarn.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

HISTORY
For several decades, development efforts

in ring spinning were focused on improving the existing technology and incorporating automation and processlinking capabilities.
The first compact spinning machine was put into trial production in 1995 in some spinning mills in Switzerland.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

IMPORTANCE
Compact spinning offered the potential to create a

near-perfect yarn structure by applying air suction or magnetic system to condense the fiber stream in the main drafting zone, thereby virtually eliminating the spinning triangle.
Compact spinning has been shown to significantly improve yarn tensile properties and reduce its hairiness. Both characteristics are crucial for yarn performance in downstream manufacturing operations

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

CONVENTIONAL V/S COMPACT • The difference (DW) between WF and WT increases as the speed of the front roller increase; this is due to less control on fiber draft and spinning.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Working principle 1-Draft arrangement 1a) Condensing element 1b) Perforated apron VZ) Condensing zone 2) Yarn Balloon with new structure 3) Traveler 4) Ring 5) Spindle 6) Ring carriage 7) Cop 8) Balloon limiter 9) Yarn guide 10) Roving E) Triangle of compact spinning

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Properties of compact spinning: • • • •

Better yarn structure. High strength and low hairiness. Benefits and cost savings in the subsequent processing stages. Compact fabrics distinguish themselves by an increased lustre and a clearly enhanced colour contrast. • The wear comfort and handle of the final products are significantly improved.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Factors Affecting Compact Spinning • Condensing zone is heart of •

• • •

compact spinning. Fiber length, fineness and stiffness are factors affecting the fiber transport by airflow this necessitates apron moving to be less than delivery rollers (condensing). Changing the perforation width increases air velocity. Smooth guides give better twist propagation. Hairs of less than 2mm give better cover factor, Hairs> 3 mm are Problematic for processing.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Methods of compacting fiber strand

These methods are: 1. Aerodynamically compacting system: • a) Suction by drum • b) Suction through perforated apron. 2-Mechanical compact system. 3-Magnetic compacting system.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

AERODYNAMIC METHODS

1.Suction by drum • Rieter (Com4) 2.Suction by apron

• Suessen (Elite) • Zinser • Toyota • Olfil system by Marzoli

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Com 4 (K44) Operating Principle

• Vacuum generated in the perforated drum • The fibers are fully controlled all the way from the nipping line after the drafting zone to the spinning triangle. • Nip roller prevents the twist from being propagated into the condensing zone.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

• • •

Perforated drum Suction insert. Air guide element

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN


SUESSEN is a pioneer in the

compact spinning technology


SUESSEN has sold more than 2.3 million EliTe Compact Spindles Over 10% of these compact spindles have been successfully equipped with EliTwist Technology.

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Special features: • Optimum and sustained yarn quality • High consistency of all yarn parameters • Minimal variation between spinning positions • No restrictions in regard to raw material • Easy handling • Universal application • Can be installed on almost all machine types

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Working principle • The slot creates an air current •

•

through the lattice apron inside the profile tube. As the slot, being under negative pressure, reaches right up to the delivery nipping line, the fiber assembly remains totally compacted. This results in a substantial disappearance of the spinning triangle. To fulfill these criteria suction fans are installed driven by a motor. Each suction pump covers 24/30 spinning positions. This provides short airflow distances with identical negative pressure on all spinning positions.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

• Suessen compact system consists of a tubular profile subjected to a negative pressure and closely embraced a lattice apron. • The delivery top roller fitted with rubber cots presses the lattice apron against the hollow profile and drives the apron, at the same time forming the delivery nipping line. • The tubular profile has a small slot in the direction of the fiber flow.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Eli Top The EliTop has a special design. 1. bottom part of housing 2 .top part of housing 3 . screwed joint of both housing parts 4. front top roller = front of drafting system 5. delivery top roller = EliTe Roller 6. axle with intermediate gears to clip on

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• EliTube / Lattice Aprons The EliTube, assigned to one group of spindles, serves to supply the vacuum for the relevant suction slots • This insert can be replaced easily if it is worn.

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1.For coarse count 1

2.For fine count

2

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Demerits • The EliVAC system (suction system) increases the heat emission of a ring spinning frame.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Demerits • Defective lattice apron (operating life exhausted, damaged by lapping, wrong positioning in the recesses of the guide rod). • Ultrasonic cleaning devices with a content of about 20 liters to wash approx. 1000 aprons at a time. Such devices cost about EURO 1,300. • Due to fiber accumulation between lattice apron and EliTube, lattice apron does not run smoothly.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Fundamental Rules for Successful Elite Compact Spinning

• Rule1: EliTe Spinning Machines must be separated from conventional ring spinning machines.

• Rule 2: Maximum room temperature 33 degree Celsius. • Rule 3: The front top roller is precisely 3.5 mm offset towards the operator in relation to the front bottom roller of the drafting system.

• Rule 4: The traverse mechanism for the roving should be adjusted in such a way that the traverse motion at the front of the drafting system does not exceed 4 mm, and that the l.h.limit position of the roving is level with the left hand edge of the top of the slot.

• Rule 5: Lattice aprons and Eli Tubes must be cleaned from time to time.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Fundamental Rules for Successful Elite Compact Spinning

• Rule 6: Eli Tops must be replaced by new top rollers after the recommended time.

• Rule 7: Make sure that the difference in diameter of the front top roller and the delivery roller corresponds precisely to the desired tension draft

• Rule 8: Clean the connecting hoses with regular frequency. • Rule 9: The fans should be removed from the machine and cleaned once a year.

• Rule 10: Yarn quality is more important than quantity

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

60/1

Comparison b/w com4 and Seussen

COUNT

CM WVG COMPACT Lot-Y

60/1CMWVG COMPACTK-44 Lot-Y

Yarn

RX-240 (Seussen)

K-44

COTTON

Lot-Y

Lot-Y

Actual count

61.13

60.95

Count C.V %

1.21

1.19

Strength

51.6

52.1

Strength C.V %

3.94

2.35

CLSP

3154

3175

RKM (UTJ)

21.94

22.46

U%

10.99

10.9

Thin -50 %

17.96

17.82

Thick +50 %

48.06

48.93

Neps +200 %

98.77

96.7

IPI

164.79

163.45

Hairiness

3

2.88

Sh

0.68

0.63

TPI

32.6

31.88

TM

4.17

4.08

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Toyota compact system • The RX240NEW-EST high quality compact yarns. • The "Simple & Rigid" structural design. • In Toyota when the fibers leave the drafting zone they are compacted by condense apron. Condense unit 4-spindle unit + Perforated apron Suction motor

Synchronous motor controlled by Inverter

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Working principle • Condense system is driven by front bottom roller with Toyota’s specially designed driving system. • Individual’s motor combined with suction units for spinning position have been arranged accordingly. This provides short airflow distances with identical negative pressure. • By applying air suction to condense the fibers stream, thereby virtually eliminating the spinning triangle, helps improve yarn characteristics.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Structure 1. Suction duct (One section per 48 spindles)

Locating the suction duct on the upper part of the roller stands simplifies duct design for easy cleaning and shortens piping length for optimum suction efficiency.

2. Condense unit: 3.

Each 4 spindle unit is easily removed and disassembled without using special tools. Delivery roller: Delivery roller is driven by maintenancefree carrier gear and grooved front roller resulting in a simple and dependable structure.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Features of high quality: • Smooth collection of fleece fibers by suction slit and perforated apron. • Precise slip-free rotation of perforated apron due to positive drive by bottom delivery roller.

• Adjustable suction pressure controlled by inverter.

Features of easy maintenance: • Easy access to detachable condense unit. • Less critical top roller maintenance due to bottom delivery roller drive of perforated apron.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Features of flexibility: • Easy conversion between compact and conventional ring spinning. • Available as retrofit for the RX240NEW.

Stable production of high quality yarn: • Quality yarn with low hairiness and high evenness is produced by eliminating the spinning triangle at the delivery section of the front roller.

COMPARISION 60/1 CM COUNT

60/1 CM WVG Toyota COMPACT Lot-Y

60/1 CM WVG COMPACT K-44 Lot-Y

Depart.

Packed

Packed

RX-240

K-44

Yarn

Difference b/w com4 and Toyota

COTTON

Lot-Y

Lot-Y

Actual count

60.75

60.49

Count C.V %

1.33

0.78

Strength

51

50.9

Strength C.V %

4.22

3.22

CLSP

3098

3079

RKM (UTJ)

22.27

22.49

C.V.%

9.6

10.5

Elg.

4.57

4.23

C.V.%

10.4

11.3

U%

11.53

11.25

CVb

2.3

2.6

Thin -50 %

23.5

30.3

Thick +50 %

80.3

75.5

Neps +200 %

167.5

147.3

IPI

271.3

253.1

Hairiness

3.33

3.33

Sh

0.8

0.77

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Zinser: CompACT • With this compact spinning technology, which is based on a perforated apron, all raw materials can be processed to all major yarn counts. • This, however, not only applies to the field of combed cotton ring yarn, but also to carded ring yarn, blends of cotton with manmade fibers (carded and combed) and pure manmade fibers.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Working Principle • The system of Zinser, is characterized by extending the draft system by a double roller. • A perforated apron is moved over the upper roller, where the suction profile element is found. Between the delivery roller and the perforated apron, the condensing zone occurs. • The roller pair is working in a classical way as in ordinary draft system.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Olfil system by Marzoli • Resembles the Suessen system in that it also uses a bottom • •

• •

perforated apron and an extra top front roller. The Olfil system is still under development and not yet commercially available. The major difference between these two systems is that, whereas Suessen utilizes a bottom perforated apron that extends back into the nip of the normal front roller, the Marzoli system uses a bottom roller around which the perforated apron passes. This implies that the Suessen system has greater control of the issuing strand. Indeed. An additional difference between Suessen and Marzoli is that, while they both use slightly different roller sizes to promote the tension in the condensing zone, Marzoli use a timing-belt drive, whereas Suessen uses a gear drive.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

• The bottom section of the

•

•

condensing system has one stainless steel pipe for every 8 spindles with a perforated apron at each spindle. The top section of the condensing system is composed of two pressure rollers driven by the toothed belt. For each 48 spindles section, there is one motorized inverter driven fan that provides suction for the condensing system.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

RoCos ROTORCRAFT COMPACT SPINNING – – – – – – – –

No air suction No air pipes No perforated drums or aprons No ventilators No extra power No erectors for installation but Magnetic Compacting is simple – safe – solid

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Principle • Any ring spinning machine can be converted into RoCos system.

• Bottom roller 1 supports the front roller 2 and delivery roller 3.

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• Condensing zone extends from clamping line A to clamping line B. • Very precise magnetic compactor 4 is pressed by permanent magnets without 2 clearance against cylinder 1. 3 A • Together with the bottom roller 3 B 1 it forms an overall enclosed compression chamber whose bottom contour, the generated surface of cylinder 1, moves A synchronously with the strand of fibers and transports this safely from clamping line A through the compactor to B clamping line B

4

1 bottom roller 2 front roller 3 delivery roller 4 magnetic compactor A/B clamping line

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Types of the RoCos compact spinning system

• RoCoS1 is suitable for

cotton, pure and as blends with synthetic fibers as well as for pure synthetics with a maximum staple length of 60 mm (21/2 ").

• RoCos 2 is suitable for

wool, pure and as blends with synthetic fibers as well as for pure synthetics, having a minimum staple length of 50 mm (2").

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

Comparative benefits towards other compact systems • • • • • • •

Low operating cost. No additional power required. Hence contributes saving of Rs 1.35 to 5.00 per every km of yarn produced. Higher productivity by optimizing twists insertion and low ends down. Less Pneumafil waste by 0.3 to 0.6 per cent. Ergonomic design for efficient and easy handling during maintenance. Benefit from total recurring cost and investment is multi-fold. Further benefit like elimination of waxing during winding and singeing process

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

ADVANTAGES OF COMPACT YARN • Higher fiber utilization. • Higher tenacity with same twist • • • • •

factor, or same tenacity with reduced twist factor for higher production. Lowest hairiness (highest reduction in hairs longer than 3 mm). Fewer weak points Better imperfections (IPI) values Higher abrasion resistance up to 20%twist reduction in spinning compact yarns, the twisting turns can be reduced for certain types of yarn. As a result, production of twisting frame is increased and twisting costs are reduced.

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

ADVANTAGES OF COMPACT YARN • Due to better embedding of fibers (including short ones) in compact Yarn, approx.6% reduction of combing noils are possible. • Cheaper carded qualities instead of combed qualities can be spun with the Compact Spinning system.

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ADVANTAGES IN WEAVING • Higher tenacity of compact Yarns, the ends-down rate in beaming is reduced by up to 30%. Higher beamer efficiency, higher production and fewer personnel for repair of ends-down in beaming are the consequence. • Owing to the better work capacity of compact Yarns, ends down can decreased by up to 50% in the warp and by up to 30%in the weft. Efficiency is consequently increased by 2 to 3%, production is increased and weaving costs are reduced. • In practice, the average ends-down rate is reduced by 33% per 100,000 weft insertions of compact yarns on rapier weaving machines and by 45% on air-jet weaving machines. Instead of a weft insertion of 500 –600 m/min with conventional ring yarn, 700-800 m/min is possible

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ADVANTAGES in PROCESSING • Compact Warp yarns help to save up to 50%of sizing agent, while the running behavior of weaving machines is the same or even better. Cost can be saved in sizing and desizing processes. • Singeing can sometimes be dispensed with, or it can be carried out at a higher cloth advance speed. Fibers up to 7% can be saved because singing can be avoided. • Dyeing and Printing Improved structure of compact Yarns and their reduced twist favors the absorption of color pigments and chemical finishing agents. Saving of dyestuff is possible.

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ADVANTAGES In knitting Yarn • Reduce yarn twist of knitting yarns, by up to 20%, The ends-down rate in spinning these Yarns is reduced by 30 to 60%, which improves machine efficiency. • Increased yarn strength and reduced formation of fluff permit to achieve higher machine efficiency and therefore production on knitting machines at a reduced ends-down rate, less interruptions and less fabric faults. • Production costs therefore decrease. • In knitting fiber abrasion reduced by 40% due to low hairiness. Fewer defects/ yarn breaks and better quality. Less contamination on all machines by foreign fibers.

• Less wear of needles, guide elements and sinkers due to less dust in the compact Yarn. Low hairiness has positive impact on loop structure.

• For warp knitting can be used, because of their higher work capacity.