COM-4 AND ELITE YARNS -COMPACT SPINNING

COM-4 CONCEPT:

With the ComforSpin technology a new yarn with perfect yarn structure – the
COM4 yarn - has been established in the market. With the help of a microscope
the structure of the yarns can easily be compared: The conventional ring yarn
shows to be far less perfect than commonly assumed.

The long, protruding fibres cause a number of problems in downstream

processing. COM4 yarn shows a very compact structure with highly parallel
fibres and much less disturbing hairiness.The air current created by the vacuum
generated in the perforated drum condenses the fibres after the main draft. The
fibres are fully controlled all the way from the nipping line after the drafting zone
to the spinning triangle.

An additional nip roller prevents the twist from being propagated into the
condensing zone. The compacting efficiency in the condensing zone is enhanced
by a specially designed and patented air guide element.

Optimal interaction of the compacting ele-ments ensures complete condensation

of all fibres. This results in the typical COM4 ® yarn characteristics.

The ComforSpin ® technology allows aero-dynamic parallelization and

condensation of the fibres after the main draft. The spinning triangle is thus
reduced to a minimum. The heart of ComforSpin machine is the compacting
zone, consisting of the following elements:

• perforated drum
• suction insert

• air guide element

The directly driven perforated drum is hard to wear and resistant to fibre clinging.
Inside each drum there is an exchangeable stationary suction insert with a
specially shaped slot. It is connected to the machine’s suction system.

THE ELITE YARN:

The operating method of the SUESSEN EliTe Spinning System is well-

known.After the fibres leave the drafting system they are condensed by an air-
permeable lattice apron,which slides over an inclined suction slot.The fibres
follow the outer edge of this suction slot and at the same time they perform a
lateral rolling motion.

Above the front bottom roller of the drafting system,the fibre band influenced by
high draft is spreading.In the area of the suction slot,which is covered by the
lattice apron,the fibre band is condensed.Commencing from the semi-dotted
clamping line of the EliTe Q Top Roller,twist is being inserted.There is no
spinning triangle.
The improvement achieved is shown in Fig .The left side displays the fibre
triangle at the exit of a conventional ring frame drafting system.The twist
imparted by the spindle cannot flow up to the clamping line.The outer fibres
spread out and are thus more highly tensioned than those on the inside. The
right side of the picture does not show a spinning triangle.The yarn twist flows
right up to the clamping line.The yarn is round and smooth.

Since the spinning triangle is very very small, the end breaks will be very
less and therefore the fly liberation will also be less.

Condensing of the fibr bundle,which follows the drafting process,can already be

seen as a significant development of the ring spinning technology.Condensed
ring yarn is more than a speciality.In view of its manifold advantages.

It is of technological importance that the suction leve l relevant for the

condensing operation is exactly the same for all spinning positions. To fulfil this
criteria,individual motors combined with suction units for 6 spinning
positions,have been arranged accordingly.This provides short air-flow distances
with identical negativ pressures at all spinning points .

During yarn formation all fibres are perfectly condensed and gathered parallel to
each other in the compacting zone. Consequently all fibres are twisted in and
contributing to the superior fibre utilisation rate compared to conventional ring
yarn. The result is exceptionally low hairiness combined with higher yarn tenacity
and elongation. These are the unique characteristics of these yarns.

ADVANTAGES OF COMPACT YARN:

• higher fibre utilisation

• 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

• greater brilliance of colour

• intensive dye penetration

• no singeing before printing

 Due to better utilization of fibre substance it is possible to reduce yarn

twist of these Yarns,particularly of knitting yarns,by up to 20%,maintaining
the yarn strength of conventional ring yarns.This increases yarn
production. The ends-down rate in spinning these Yarns is reduced by 30
to 60%,which improves machine efficiency.

 Applying the same winding speed as with conventional ring yarns,there

are less raised points in these Yarns and the increase in yarn
imperfections is reduced because they have a better resistance to shifting.
Higher winding speeds are therefore possible with compact yarns Yar ns .

 In accordance with 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.

 Owing to the lower hairiness and higher tenacity of compact Yarns,the

ends-down rate in beaming is reduced by up to 30%.Higher beamer
efficiency,higher produc tion and fewer personnel for repair of ends-down
in beaming are the consequence.
 Compact Warp yarns help to save up to 50%of sizing agent,while the
running behaviour of weaving machi-nes is the same or even better. Cost
can be saved in sizing and desizing processes.

 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 with compact Yarns on air-jet weaving machines.

 Due to reduced Yarn hairiness,singeing can sometimes be dispensed

with,or it can be carried out at a higher cloth advance speed.As a
result,production costs are considerably reduced.

 fibres upto 7% can be saved because singing can be avoided

 Dyeing and Printing Improved structure of compact Yarns and their

reduced twist favours the absorption of colour pigments and chemical
finishing agents.Saving of dyestuff is possible.

 Owing to the improved yarn strength, compact Yarns are well suited for
non-iron treatment of woven fabrics. In the course of such treatment,the
strength of fabrics made from conventional ring yarns can decrease by up
to 25%,with frequent problems in the manufacture of clothes. compcat
Yarns make up for this loss in strength.

 Knitting :Compact Yarns with their 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.
The enormously low hairiness of compact Yarns often permits to dispense
with usual waxing. Considerable cost saving is achieved because of this.

 In knitting fibre abrasion reduced by 40% due to low hairiness. Fewer

defects/ yarn breaks and better quality. Less contamination on all
machines by foreign fibres . Less wear of needles, guide elements and
sinkers due to less dust in the compact Yarn . Low hairiness has positive
impact on loop structure . L Low pilling values get more and more
important . In many cases single compact Yarns substitute conventional
ply yarns. Waxing can be reduced or completely dispensed with .

 Compact Yarns are much more suitable for warp knitting than
conventional ring yarns,because of their higher work capacity and lower
 hairiness. They are predestined to bear the high load due to numerous
deflecting points with high friction in the warp knitting machine.

 Due to better embedding of fibres (including short ones)in compact

Yarn,approx.6%fewer combing noils are possible.

 Cheaper carded qualities instead of combed qualities can be spun with the
Compact Spinning ystem.

 in many cases single EliTe ® Yarns can substitute conventional ply yarns

 new qualities can be developed, opening up a new creative scope for

products

Hairiness Testing of Yarns

Hairiness of yarns has been discussed for many years,but it always remained a
fuzzy subject. With the advent of compact yarns and their low hairiness
compared to conventional yarns,the issue of measuring hairiness and the proper
interpretation of the values has become important again.Generally speaking,long
hairs are undesirable, while short hairs are desirable (see picture ). The picture
shown below just give a visual impression of undesirable and desirable hairiness
at the edge of a cops.

Figure:

RING YARN COMPACT YARN

There are two major manufacturers of hairiness testing equipment on the

market,and both have their advantages and disadvantages. Some detail is given
below.
USTER

USTER is the leading manufacturer of textile testing equipment. The USTER

hairiness H is defined as follows .

H =total length (measured in centimeters) of all the hairs within one centimeter of
yarn .

(The hairiness value given by the tester at the end of the test is the average of all these
values measured, that is,if 400 m have been measured,it is the average of 40,000
individual values) . The hairiness H is an average value,giving no indication of the
distribution of the length of the hairs. Let us see an example

0.1cm 0.2cm 0.3cm 0.4cm 0.5cm 0.6cm 0.7cm 0.8cm 0.9cm 1.0cm total
yarn
100 50 30 10 5 6 0 2 1 0 398
1
yarn
50 10 11 5 10 0 5 10 0 11 398
2

Both yarns would have the same hairiness index H, even though yarn is more
desirable,as it has more short hairs and less long hairs,compared to yarn 2.

This example shows that the hairiness H suppresses information,as all averages
do. Two yarns with a similar value H might have vastly different distributions of
the length of the individual hairs.

The equipment allows to evaluate the variation of the value H along the length of
the yarn. The "sh value "is given, but the correlation to the CV of hairiness is
somehow not obvious.A spectrogram may be obtained.

2.ZWEIGLE

Zweigle is a somewhat less well known manufacturer of yarn testing equipment.

Unlike USTER,the Zweigle does not give averages. The number of hairs of
different lengths are counted separately, and these values are displayed on the
equipment. In addition, the S3 value is given,which is defined as follows:

S3 =Sum (number of hairs 3 mm and longer)

In the above example,the yarns would have different S3 values:

S3yarn 1 =2 .

S3yarn 2 =4 .
A clear indication that yarn 2 is "more hairy "than yarn 1. The CV value of
hairiness is given a histogram (graphical representation of the distribution of the
hairiness) is given.

The USTER H value only gives an average,which is of limited use when

analyzing the hairiness of the yarn.The Zweigle testing equipment gives the
complete distributionof the different lengths of the hairs. The S3 value
distinguishes between long and short hairiness, which is more informative than
the H value.

Ten Fundamental Rules for Successful Operation of EliTe Ring Spinning

Machines:

1.EliTe Q Spinning Machines produce yarn of supreme quality and come up to

the expectations. Installation of the machine in the spinning mill EliTe Q Spinning
Machines have a considerable air flow rate –a machine with .1008 spindles
sucks in about 60 cubic meter of air per minute,i.e. it has the effect of a vacuum
cleaner. The ambient air is sucked into machine and most of the fly and dirt
contained in it is deposited on the EliTe Q Machine. Although EliTe Spinning
Machines generate considerably less fly than standard ring spinning machines,
they are soon covered with dust and fly if they are installed in the same room as
conventional spinning machines. The fly has a negative effect on the yarn in the
condensing zone and the smooth running of the lattice apron. As a result,the
yarn is of substandard quality.

Rule .:EliTe Q Spinning Machines must be separated from conventional spinning

machines.

2.Spinning room conditions: The fibres in the condensing zone are exposed to
the room conditions without any protection. Our recommendations on the room
conditions suitable for processing cotton and man-made fibres should be
followed, therefore. If the air humidity is too high, there will be a higher tendency
towards roller laps. If the air is too dry,t here will be more fly. If the room
temperature is too high, there will be higher friction values and premature wear.

Rule 2:maximum room temperature:33 .C

humidity should be

 max...,5 g water/kg air for cotton

 min.9,0 g water/kg air for cotton
 max..0,0 g water/kg air for synthetics
 min.9,0 g water/kg air for synthetics

3.Position of the Eli Top in relation to the front bottom roller of the drafting
system: If the setting is correct, the top edge of the suction slot in the Eli Tube is
precisely set at the nip line of the delivery top roller. If the nip line cuts the slot,
condensation is impaired. The hairiness of the yarn increases and the tearing
strength is reduced. If the nip line is behind the slot, part of the spinning torsion
may get into the condensation zone, resulting in an increased ends-down rate
and damaged lattice aprons.

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.

4.Traverse mechanism: The roving must run over the slot in such a way, that,
from the operator ’s view, the fibres move from the top right to the bottom left. If
the fibres run over the slot top from the L.H. side,they make an S-shaped
movement causing a certain unsteadiness in the condensing zone. This has a
negative effect on the yarn values.

Rule 4:The traverse mechanism for the sliver 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 sliver is level with the L.H..edge of the top
of the slot.

5.Cleaning the Eli Tubes and lattice aprons :Eli Tubes and lattice aprons are the
most important components of the EliTe Q Condensing System. Careful
maintenance is an important prerequisite for optimum yarn values. In the centre
area, where the suction is active, a permanent air flow keeps the lattice aprons
clean. To the left and right of this area, the lattice apron can be clogged by fine
dust. With the time, this results in a considerable increase of the friction between
the lattice aprons and the EliTube. If this friction is too high, erratic running of the
lattice apron and substandard yarn quality is the result. Therefore,lattice aprons
and Eli Tubes should be removed from the machine from time to time and
cleaned. This can be done when the machine is running. The time needed per
box length is 5 min. The expenditure of time necessary for changing the EliTubes
with lattice aprons is about 90 minutes for a machine with .1008 spindles, which
corresponds to a loss of production of 90 minutes. For yarn count Ne 40, the
production loss involved is less than 370 g. The cleaning frequency varies
depending on the portion of fine dust of the cotton. As an average value, 500
operating hours may be taken into account. The aprons are cleaned in a washing
machine or in an ultrasonic cleaning device.The EliTubes are cleaned using a
damp piece of cloth. Damaged lattice aprons must be replaced. On EliTubes with
considerable traces of wear, the inserts must be replaced.

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

6.Measures to be taken in the case of laps at the front top roller Laps may occur
in the case of unsuitable room conditions or damaged or inappropriately buffed
cuts, or if the fibre material used is prone to the formation of laps. Large laps may
block the delivery and front rollers and damage the cot of the blocked roller. If
spinning is continued with damaged cots,periodic yarn faults will be the result.
Consequently, a blocked Eli Top must be replaced by a new Eli Top and repaired
in the service room. For this purpose,all operators should carry a spare Eli Top
with them.

Rule 6:EliTops with blocked top rollers must be replaced by new top rollers.

7.Buffing the EliTe Q Top Rollers : The cots of the EliTe Q Top Rollers are
subject to wear and should be buffed from time to time.The tension draft in the
condensing zone –6 %as a general rule depends on the difference in diameter
between the front top roller and the delivery top roller. Changed tension drafts
may result in changed yarn parameters.

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.

8.Checking the partial vacuum As a general rule,continuous control of the

vacuum pressure is not necessary. When the whole machine is cleaned, we
recommend, however,to remove also the connecting hoses between the suction
tubes and the fans and to clean them.

Rule 8:Clean the connecting hoses with regular frequency.

9.Maintenance of the fans: Fans may be clogged after a time,which has a

negative effect on the suction.

Rule 9:The fans should be removed from the machine and cleaned once a year.

10.Spinning speed: In the case of EliTe Q Spinning Machines, return on

investment is not based on higher production, but on the production of yarn of
supreme quality. The Suessen recommendations concerning traveller speeds
and running-in speeds for rings and travellers should be followed, therefore. Not
the ultimate increase in speed, but the yarn quality leads to success.