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International Journal of Advance Engineering and Research

Development
Volume 2, Issue 2, February -2015

Classimat Yarn Faults

D.V.Bihola1 , Hiren N. Amin2
1
Textile Manufacturing Technology, R.C. Technical Institute, Ahmedabad-380060,Ahmedabad,Gujarat. Email id
[email protected],
2
Textile Technology Department, Sarvajanik College of Engineering & Technology, Dr. R.K. Desai Marg, Athwalines, Surat-
395001,Gujarat. Email id: [email protected]

Abstract: From whatever research work done until now, very little information is available on the level for the various
classes of faults as per the count. Uster statistics 2001 does not provide any information on faults, while Uster statistics
1997 which does provide some information on faults does not give guideline on the level of various classes of faults for
different counts. Moreover the publication of the last ten years, gives information about the sources of faults, their
causes, remedies and their effect on fabric appearance, there is however no publication available on the categorization
of the various classes of faults under different types and their percent contribution. There is considerable literature
available on the research work done on the effect of various categories of faults, mainly objectionable on the fabric
appearance. Though it is documented in various papers that yarn faults (objectionable) not only affect fabric appearance
but also causes end breakage in subsequent processes resulting to in low production and higher production cost with low
efficiency, but this is not supported by any systematic study or data. No published information is available on the
physical characteristic of the various faults according to type or classes, therefore the assessment of physical properties
of the faults under different classes of faults and various types of faults to understand their effect on the further processes
is necessary.

Keywords- Yarn fault, classimat yarn fault, Classifault, Thick , Thin, Slub, long thick, long thin.
I. INTRODUCTION
Yarn evenness and yarn faults are very important characteristics affecting spun yarn ability process and fabric
appearance. New generation high speed looms and knitting machines place more stringent demands on the quality of the
yarn. The importance of faults lies in the fact that they are a major factor responsible for rejection and down grading of
yarn and fabrics and low productivity due to higher end breakage in further process

All staple spun yarns have certain variation. This variation can generally be grouped in to three categories
Permanently present variation of the cross section which is called “ unevenness” or “irregularity”
Occasionally occurring thin or thick places which are called “imperfections” and
Seldom occurring thick or thin places that are called “yarn faults”

Yarn faults of various shapes and sizes can be introduced at all stages of spinning process, ever how these need to be
controlled or extracted. Normally in most of the mills, since extraction of these faults which is done at winding is a
simple process, control of generation of faults does not get prime importance. It is well known that to control anything
one should know the characteristic, the causes and the effect. The measurement of the seldom occurring faults is essential
but it is rarely done as the length required for testing is more.

II. YARN FAULTS AND THEIR SIGNIFICANCE

The nature of yarn faults is decided by three factors1 viz,

Frequency of occurrence of faults
Type of faults
Size of faults

“Figure 1. Classification of yarn faults”

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Accordingly, the classification of yarn faults is shown in figure 1. From the figure it can be seen that based on the
frequency of occurrence of these faults, they can be classified as frequent, seldom or special faults. Of these, the
frequently occurring faults include thick place, thin place and neps. These frequent faults are detected as imperfection
when carrying out the yarn evenness testing. The seldom-occurring faults include slubs, fly piecing etc. having specific
dimension in terms of diameter and length. Special faults have variable size.

The frequently occurring faults are measured on imperfection testers that count number of the yarn imperfection i.e. thin
places, thick places and neps which occur over certain specific meters of yarn. Determination and control of imperfection
in the yarn is basic and important since it can influence many other properties of the yarn as well as of the fabric made
from it. The most obvious consequence of high imperfection mainly thin and thick places is the variation of strengths
along the length of yarn and production of patchy defective fabric, while higher neps reflect prominently in the fabric as
specks. These imperfections however do not always result in an end breakage during processing of the yarn. Therefore
over past many decades the imperfection indicator has been in extensive use in the Indian textile industry for day to day
control and as an aid to improves the quality of yarn.

Locher and Ernst1 mentioned that faulty places which are most difficult to be kept in control during spinning are the
relatively seldom occurring yarn faults. These include on one hand thickening in the yarn of different length but with a
size which is multiple of the cross-section of the normal yarn and on the other hand long thin place whose cross section
are reduced to less than half of normal yarn cross sections. Measurement of seldom occurring faults is not a very
common phenomenon in the textile industry. This is so because the length of yarn that needs to be tested to count these
types of faults is very large up to a minimum of hundred kilometers. Despite testing of very huge quantity of yarn the
frequency of occurrence of some of the faults is still very less to draw any meaningful conclusion for one to take specific
steps of corrective action. However, studies carried out on this subject show that seldom occurring faults like slubs, spun
in lint, loose lint, piecing, long thick place, long thin place etc, have a significant contribution to end breaks, during
spinning or more so in the subsequent processes. These fault if pass unbroken, are also many times disturbing or
objectionable in the fabric leading to rejection of the fabric. The third category of faults i.e. the special faults having
variable size and no specific pattern of occurrence are the most difficult to measure, analyze and control. There is no
specific instrument for measuring these types of faults and they results into either end breakage or defect in the fabric.
The various faults and their significance can thus be summarized as following

Frequent event – if higher than the tolerable limits affect the structure and appearance of the woven or knitted fabric
Seldom events – mostly results in end break during spinning or subsequent process and if it passes unbroken they tend to
be disturbing or objectionable in the finished fabric
Special faults – may be problematic in subsequent processing but are often detected as defects in the fabric
In this project we have focused our study on the seldom occurring faults and therefore the term faults
mentioned in the thesis after here refer to this category of faults.

III. MEASURMENT OF YARN FAULTS

There are basically two principles by which yarn faults can be measured.
capacitive method
optical method

3.1. Capacitive methods

The principle of measurement of yarn fault using this method is as follows:
The common instrument available using this principle of measurement are the classimat developed by Uster
Technologies A.G. and by Premier Evolvics Pvt. Ltd. They measure the fault and give the output in terms of cross-
sectional size and length. They divide the thick faults into 16 classes from A1 to D4. A typical results sheet appears as
shown in the figure below.

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“Figure 2. Classimat III system”

“Table 1. Horizontally Length wise class”
Length class A 0.1 - 1 cm.
Length class B 1 – 2 cm
Length class C 2 - 4 cm
Length class D 4 cm and longer

“Table 2. Vertically the cross section size classes”

Cross-sectional size class 1 +100% - +150%
Cross-sectional size class 2 +150% - +250%
Cross-sectional size class 3 +250% - +400%
Cross-sectional size class 4 +400% and longer

“Table 3. The long thick faults obtained in classimat model II and III”
Classes Length Cross-sectional size class
E > 8cm. >100 %
F 8 – 32 cm +45 – 100%
G > 32 cm +45 – 100%

“Table 4. Horizontally long thin faults”

Length class H 8 – 32 cm
Length class I > 32 cm

“Table 4. Vertically long thin faults”

Cross-sectional size class 1 -30 % to -45%
Cross-sectional size class 2 -45% to -70%

3.2. Optical Method.

The principal of measurement of yarn fault using this method is as follows.

“Figure 3. Classifault - CFT-2 System”

The very familiar instruments available using this principal of measurement is „classifault‟(CFT- II) developed by
Keisokki Kogyo Co. Ltd., Photo electric sensor is used for measuring faults, they measures the faults and give the output
in terms of cross sectional size and length. The classifault system is shown in the figure. This system gives forty
classification channels for grading yarn faults. In addition it has software flexibility for changing the limit level of
classification and can record the fault in the form of histogram.

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The CFT –II classifies the yarn faults in 40 classes slubs into 20 classes, thick place into 10 classes & thin place into 10
classes & provides the measured results for winding position as well as total number of them via the printer. Obtained
results as well as test condition can be stored in the disk allowing latter analysis for extracting only required data of
particular type of faults.

IV. CLASSIFICATION OF YARN FAULTS

Various literatures have classified yarn faults differently. The classification given by the major manufacturer of the
instrument are already referred in section 2.2 Besides that Thomson2 consolidated the 16 classes of faults obtained from
classimat to sources, and they are:

“Table 5. Type of yarn faults”.

Type of yarn faults Classimat classes
1) Drafting faults C1-C2-C3-C4, D1-D2-D3-D4
2) Waste slubs A1-A2-A3-A4,B1-B2-B3-B4
3) Fly slubs A3-A4, B1-B3-B3-B4, C2-C3-C4, D3, D4.
4) Operating faults B3-B4, C2-C3-C4, D1-D2-D3-D4.
5) Contact faults A1-A2-A3-A4, B1-B2-B3-B4, C2-C3, D3-D4.
6) Fiber or blend faults A1-A2-A3, B1-B2, C1, D1-D2.

Peter Hattenschariffer and bublour3 have classified faults on the basis of their source of generation i.e. whether they are
due to raw material, process or spinning related. Table 2 gives the comprehensive classification and the finding of the
study done in terms of the contribution of each category to the total fault.

“Table 6. Contribution of each category to the total fault”.

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“Figure 4. Contribution of each category to the total fault”.

M1 foreign matter
Due to non-textiles material which is already available in the bales or is collected at some stage during
the spinning process.

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M2 fibre entanglements
These entanglements are found primarily in yarn containing man-made fibers. They consist of fibers
which are bound together and in many cases, are combined with collection of finish material. In groups
they grow to become thick faults.

M3 synthetic undrawn fibres

These are, of coarse, only encountered in man-made fiber yarn and are the results of yarn and are the
results of single fibre stuck together and of particles of synthetic material.

P1- piecing
These piecing are normally produced during the processes prior to spinning.

P3 short slubs
These are due primarily to collection if short of fibre which are not drafted by the roller drafting system
and appear as thick places. They contain little twist and are, accordingly weak in strength. This type of
faults can also be the result of too wide setting of the gauge with apron drafting.

S1 –Spun-in fly
This refers to free fibres which fall in to the drafting elements or on to the roving fed into the drafting
unit, and are then twisted in to the yarn along their entire length

S2-loose fly
This refers to fibres which are collected by the yarn at a position after the front roller and, in one end.

S3- long collection of fly

These are matted fibres which, collect together on aprons or rollers and from time to time are collected
and carried along by the yarn.

S4 fishes (corkscrew type faults)

These faults results due to static charging of are a result of unsuitable drafting aprons or drafting aprons
which have cracked surfaces.

S5-pushed together collections of fly

These are faults resulting from held back fibres, and occur primarily at the ring traveller.

S6-chains of faults
These are combination of the faults S1, S2 and possibly also S3 which occur in short succession, are
after the other, along the length of the yarn.

S7 crackers
These results due to extra long fibers which disturb the drafting process and, for a short instant of time,
stop the passage of the yarn.

V. SOURCES OF YARN FAULTS AND FACTORS CONTRIBUTING TO THEIR GENERATION

5.1. Sources of yarn faults

The information available on this is subdivided in to two categories
a) Class wise
b) Type wise

5.1.1. Class wise

M.N. Vijayshankar and A.K. Gupta7 mentioned in their paper that

'A' faults  80 to 90 % of the 'A' faults contain a nucleus of seed coats fragments with adhering fibers that bind
thefragment to the body of yarn.
„B‟ faults In the case of „B‟ faults seed coats fragments account for 30 to 60 % of the total „B‟ faults. Seed
coats fragments account for most of the 'A' faults but only for about 50% of the „B‟ faults. In other
words, apart from seed coats fragments some other factors contributes significantly to „B‟ faults

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„C‟ &‟D‟ faults  factors like spun in lint, loose lint, bed piecing etc. are known to contribute to „C‟ &‟D‟ faults.
Drafting deficiencies are not likely to have a very significant contribution to the frequency of
„C‟&‟D‟ faults in the yarn, as these faults are recorded at a level of yarn weight per unit length +100
% or more. Unopened fiber Cluster that are present in the sliver and are potential slubs in yarn, have
the largest processing contribution for „C‟ and „D‟ types of faults.

Grade4 in his paper has clearly mentioned that the Indian polyester/cotton yarns have very high incidence of each type of
faults. The faults of „A‟ type are almost six times as numerous, while those of other types are two to four times more than
the Uster statistics. The most disturbing feature is that even the objectionable faults are four times more.

Kumarswamy and Sheriff5 conducted a study with count group from 29s Ne to 40sNe over the assessment of yarn faults
and observed that in Indian mills, 'A' type of faults are 10 to 15 time higher and „B‟ and „C‟ types of faults are 5 to 6
times higher in comparison to international standard of respective type faults.

V.Ramchandran8 mentioned in his paper that A4 and B4 faults come due to fly at ring traveler C3, C4, D3, D4 faults
come due to defective drafting elements at roving, B, C faults due to excessive trash I1 due to roving stretch.

According to R.N. Yadav 6 H1 faults increase in winding after spinning old apron sets cause more H1 and any hindrance
to cause tension in roving fed results more H1, H1 is lower with higher spindle speed, lower break draft, less number of
H1, variation in fibre length cause reduce of H1. Mechanical or pneumatically arm loading has no significant in H1
faults and also higher draft of spinning is prone to higher number of H1 faults.

5.1.2. Type wise

Peter Hattenschwiler and Margrit Bubler10 mentioned in his paper that the shorter and smaller size faults are due to the
raw material, the opening and the carding processes; the longer and larger size faults are introduced in the processes just
prior to spinning and during spinning.

It has been generalized that quarter of all faults are due to the raw material and process prior to spinning and
approximately three quarters are introduced in to the yarn at the spinning machine

5.2. Factor contributing to the high incidence of the classimat fault

K.P.R.pillay, T.V.Ratnam19 in their paper have drawn the following conclusion that,
a) Faults due to raw material are about 8 times greater in cotton than in staple fibres whereas the drafting faults
are only 1.5 times greater. The numbers of objectionable faults are also 1.5 times higher in cotton than in
staple fibre yarn, and staple fibre yarn give these C and D type of faults when compared to cotton.
b) The number of faults systematically increases with increase in count both in carded and combed yarn however
percentage increase is lower for the latter than the former.
c) Use of high production and tandem cards as compared with semi-high production card as well as flexible fillet
carded yarn, significantly reduce yarn faults. Higher percentage of waste removed in carding and combing
lowered the fault level appreciably.
d) According to them19 the total number at faults in combed yarns is about 65 to 85% lower than those in
corresponding carded yarn.
e) As the percentage of noil removed increased, objectionable fault reduced considerably.
f) Conventional drawing gives lowest number of faults per 100km, & semi high production & high production
drawing give substantial increase in the incidence of faults.
g) Overhead clearer generally used by mills to keep the department clean and prevent fly and dust depositing on
the yarns help in reducing the incidence of different type of yarn faults. In general, it is observed that total
faults in cotton yarn are reduced by about 50% & in staple yarn by 50%. The reduction in other types of faults
does not show any specific trend.
h) No firm conclusion could be drawn regarding the effect of drafting system and spindle speeds on yarn faults.

K. Kumarswamy & I. Sharieff20 mentioned in their paper that high production and semi-high production card do not have
any effect of faults. Carding rate affect C and D type of faults which increase marginally with carding rate. Objectionable
faults A4 and B4 faults affected by carding, objectionable faults C3, C4, D3, and D4 are affected by the ring frame only.
Metallic & tandem card reduce A1, A2 & A3 types of faults significantly.

The long faults are affected marginally and objectionable faults remain unchanged. It appears that tandem card reduce
only the short length faults

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They20 also mentioned that in comparison with the A-500 system, the higher pressure new top arm drafting reduced A
type of faults by 8%, B type of by 35%, C and D type by 55% & objectionable faults by 60% also among the
objectionable faults the reduction in C3, C4, D3, D4 is more than in A4, B4 indicating that unlike carding, ring frame
drafting preferentially reduces the longer length faults.

Vishwanath C. S., Jamdar C. R., Gokhaly S. R., Chandra Sekharan21 mentioned in their paper that about 60 – 70% of
objectionable faults are due to ring frame while 30 – 40% of them are due to preparatory. They found that ring frame
equipped with pneumatic loaded drafting system gives all round best results.

According to P. Bhatt, C. D. Kane, S. R. Desmukh, U. R. Patil, G. S. Dixit & P. C. Purendare 22, if the clearing procedure
is not performed satisfactorily by the ring frame top roller clearer than A, B1, B2, C1 & C2 type faults will be higher.

According to them22 piecing share 9 to 16% of the total number of disturbing yarn faults. The consistency of their
number depends mainly on the piecing at pre-spinning process.

Short slubs occur to an extent of 5 to 7% in all yarn the drafting systems at various processes, short fibers & humidity in
the department are important in its formation. The spun-in-fly type faults may be as high as 50% or more of all
objectionable faults in any yarns. Therefore housekeeping and humidity in the department are very important.
Objectionable faults introduced at spinning process account for 70% in case of carded yarn and 50% in case of manmade
staple fibers yarns.

They concluded from their study that the total yarn faults in Indian yarn are 9 to 12 times the international standards
whereas objectionable faults are to an extent of 5 to 7 times. Ring frame is the highest contributor to the objectionable
faults and drafting systems, heart of ring frame, is the culprit of faults generation at the same time.

The overhead blower reduces 12.5% of all faults. The reduction in C, D faults are 27.3% and that for objectionable fault
is 28.3%. That is, such a high number of faults are influenced by the possibility of blowing (cleaning) or picking-up of
fly.

Another observation is that most of the mills are not maintaining controlled atmosphere the department temperature and
humidity changes from time to time in a day or day after day.

S. M. Ishtique, HVS. Murthy & M. M. Tendulkar 23 mentioned in their paper that, the occurrence of faults in polyester
yarn is at much lower level compared to that in viscose yarn. Blended yarns show an intermediate behavior when
compared with polyester and viscose yarn. The blends with lower viscose content shows less occurrence of classimat
faults.

Increase in the fiber length increased the total faults but increase in the fiber denier decreased the total faults. Fiber length
and denier have significant effect on A & B type of faults.

VI. SIGNIFICANCE OF YARN FAULTS AND THEIR INFLUENCE ON FURTHER PROCESS

1. Verma T.M.K., Ramaswamy. S17, mentioned in his paper that yarn for knitting required special characteristics over
weaving yarn.
According to them the types of defect that result in yarn breakage during cone winding and contribution of each
category of faults are summarized as below

“Table 7. Type of defect caused breakage during winding”.

Type of defect %
Spun-in fly 35%
Slub 25%
Bad piecing 13%
Weak places 9%
Others 8%
Entanglements 5%
Slough-off 3%
Foreign matter 2%

“Table 4. Fabric defects as a percentage of total defects”..

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Type of faults %
Thick places 40%
Long thick places 7%
Thin places 3%
Long thin places 3%
Slubs 5%
Holes(due to thick place) 16%
Knots 5%
Partial press off* 1%
Presence of foreign fibers 20%

(* blockage of loose feeder hole by the accumulation of loose fibres)

According to their research works, the defects per kg of fabric varied widely from 2.1 to 22.4 and the average is
8.5. It can be seen from the above table that thick places in the yarn alone contributed 63% to the total defect in
the fabric.
2. Biradr M.M.15 mentioned in his paper the causes of end breaks in the process, from ring spinning to weaving and
knitting and lower winding efficiency. He also analyzed that yarns with higher fault incidence resulted in fabrics of
inferior appearance and therefore value loss was higher of highly priced premium fabrics.
3. Aggarawal and Hari11 have brought out in their work the importance of grey yarn quality. At a constant level of warp
tension, the reduction in the extensibility resulted in an abnormally high warp breakage rate due to gross faults in the
yarn, but very little effect was due to weak places. This is because the reduction in elongation can only increase the
average warp tension.
4. Doleki13 carried out a detailed study on the causes of warp breaks during weaving and analyzed the characteristics of
breaks, he observed that most of the breaks occurred in the shedding zone and in the close proximity to the bodies
such as, knots, slubs and neps, in normal warp only a small percentage of breaks arises from the effect of normal peak
tension in weaving and a majority arise from abnormal tension caused by obstruction in the shedding zone. Knots,
slubs, piecing cause obstruction which creates abnormally high tension which occurs between the obstruction and the
heald eye.
5. Gangopadhyay16 from his studies on 100% cotton and p/c blends concluded the following
6. The faults in the yarn classed objectionable by classimat are important contributory factors to the total weaving breaks
out of these it is further shown that
Of all the objectionable yarn faults, D4 type of faults appears to be the most contributory to the total weaving
breaks in the case of p/c blends.
Objectionable yarn faults along with piecing and knots contribute to a major portion of the causes of blended
yarn it is found that as high as 56% of the total breaks are in weaving.
7. According to research work conducted at SITRA18 in order to asses the influence of classimat faults on weaving
performance a study was carried out and some of its important finding the are given below.
Class 'A' faults do not significantly affect the strength and elongation of yarn; these faults mainly associated
with adhered seed-coat particles surface is not likely to significantly disturb the yarn structure and hence the
strength.
D3 and D4 faults significantly reduce the strength and elongation of yarn, with these faults the yarn structure is
not properly formed because in many cases, the fault length is greater than fiber length itself. There is a
tendency for the realization factor of strength and elongation to decrease with increased faults magnitude. This
can be explained by the fact that unopened fibre clUster, undrafted ends and poor piecing, spun-in fly etc.

Realization factor = Avg. value of the faults yarn / Avg. value of the normal yarn

Yarn with B4, C3, C4 and all D faults, even after sizing, have lower strength, elongation and abrasion
resistance. About 35% of the yarn with these faults have tensile strength less than the minimum of normal
yarn(after sizing); 46% of yarn with B4,C3,C4 and D faults have elongation or abrasion resistance lower than
the minimum of normal yarn.
Presence of B4, C3, C4 and D faults in yarn are predominant sources of warp breaks when subjected to tensile
load, most yarn break at the faults regions or their vicinities.
8. According to P. Bhatt, C. D. Kane, S. R. Desmukh, U. R. Patil, G. S. Dixit & P. C. Purendare22 C3, C4 & all D types
faults have very poor strength even after sizing, therefore they may lead to breaks in further process.

VII. CONCLUSION
Classimat faults are the one of the important yarn characteristics which affects the quality of the yarn, efficiency of the
further process and quality of the fabrics. Classimat faults need to be under control by means optimum machine setting

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and proper housekeeping. Objectionable faults are more responsible for deterioration of yarn quality, breakages in
further process and deteriorate the fabric appearance.

ACKNOWLEDGEMENT

The author extend his sincere thanks to his peers for the cooperation provided by them and other industrial personnel for
their support as well as every individuals who knowingly or unknowingly supported me in my task of writing this
Research paper.
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