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April ,
2012

Recent Developments in Ring Spinning

Tushar Kumar Paul

Technical Sales Executive, Apptex Sourcing

[email protected]

ABSTRACT
The textile industry has developed rapidly here in Bangladesh. In course of time newer technologies are being introduced
and the only way for survival is encapsulating those innovations into

This article will be published into subsequent issues. This issue contains Developments on Blowroom and Carding. the
following issue will cover Drawframe, Speedframe, Ring and Others.

Abstract:
The textile industry has developed rapidly here in Bangladesh. In course of time newer technologies are being introduced and the
only way for survival is encapsulating those innovations into the manufacturing process and making the best use of them for
increasing the productivity and quality. Spinning sector is termed as one of the Primary Textile sectors in the country which has
got a big enough size over the years to cater almost whole demand of yarn for the local industry and more the 60% demand of
yarn for export oriented RMG. As there have been a lot of developments in the various sectors of the textile industry, and the
following would throw light on the latest developments that have taken place in the major segment of textile industry, namely
spinning.

Demography of Spinning Technology:

The ring spinning machine was invented in 1828. In 1830, the traveler rotating on the ring was being contributed. After more
than 150 years that have passed since that time, the machine has experienced considerable modification in detail, but the basic
concept has remained unchanged. Further developments on a large scale appear unlikely because the traveler is a restrictive
element. The amount of heat developed in traveler at high speeds is considerable, and it is extremely difficult to conduct this
heat away in the short time available. The traveler speed thus limited.

In cotton yarn production there are two main spinning systems which are used for the production of these two types of cotton
yarns: Ring spinning systems and Open end spinning systems. Apart from these systems, there are new yarn spinning
systems like friction and air jet spinning systems. The ring spinning system is the most flexible system from the viewpoints of
fibers which can be used and the extent of the yarn counts which can be produced. So this article focuses mainly on the recent
developments in ring spinning technologies.

Recent Developments in Blowroom:

The trend in spinning mills is now to replace manual bale opener to automatic bale opener. The automatic bale opener gives
smaller tuft size, thus results in better opening and cleaning efficiency of the subsequent machines. The manual bale opening
process relies more on the sincerity and efficiency of the worker, and has more variation in the tuft size fed to the bale opener.

1. Rieter UNIfloc A11 uses single plucking roller, called as take-off roller. The automatic bale opener regularly measures the
profile of the lay down material for gradual level out the bales.
2. Trützschler BLENDOMAT BO-A is fitted with two plucking rollers rotating in opposite direction. It can process three different
cotton/blend lots simultaneously that can be fed into three separate cleaning lines.
3. Marzoli automatic bale opening Super Blender B12SB has two plucking rollers with 254 blades on each roller, which
ensures small flock size. Automatic bale opener can process four different mixings. The production, with a working width of
2,250 mm, is stated to be 1,600 kg/hr.
4. Lakshmi Automatic Bale Plucker LA 17/LA 28 is fitted with twin plucking rollers. The grills of the plucking rollers are

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selectable according to the required tuft size.

Compact Blowroom Line:

The use of 3 to 4 beaters in series (CVT-4 Cleaner of Trützschler) in the same machine rather than 2 or 4 machines in tandem in
line gives same cleaning. Thus, the modern blow room line becomes shorter without any compromise on the quality of the
material.
Trützschler compact blowroom line (Figure: B2) consists of BLEN DOMAT BO-A, Multi Function Separator along with waste
re-feeding, Pre-Cleaner (CL-P), Integrated Mixer (MX-I with 10 trunks) along with CLEANOMAT Cleaner (CL-C 4), and Foreign Part
Separator. The compact blowroom requires less space and lower energy consumption in transporting the fiber tufts to the next
machine. The installation size comparison of normal blowroom line (1,000 kg/h of blowroom production) against Trützschler
compact blowroom (1600 kg/h production) (Figure: B1).

Mordern Blowroom Line of Rieter:

Now a day’s Rieter consider their blow room u pto carding machine. So they designed their modern blow room as follows: 1.
Bale opener UNIfloc A11; 2. Pre-cleaner UNIclean B12; 3. Homogenous mixer UNImix B75; 4. Storage and feeding machine
UNIstore A78; 5. Condenser A21; 6. Card C60; 7. Sliver Coiler CBA4 (As shown in Figure: B3)

Mote knife with suction in place of grid bars: The trend of using mote knife with an open slot along suction was initially
incorporated on carding in the pre-carding and post-carding zones. Recently, the same principle was adopted by Trützschler on
cleaning machines in blowroom.

Better mixing/blending of raw material: Blending of dissimilar fibers should also be done properly at blowroom stage. Mix
homogeneity depends on the methods of mixing and type of mixing/blending machine used. When mixing the different bales in
tuft form, smaller the tuft size better would be the homogeneity.

1. Rieter UNImix blending machine claims to have random distribution of the tufts to the 8 mixing chambers and then the
fiber blending takes place at three different points within the UNImix. This technology has been termed as a '3-point
mixing process'.
2. Rieter 'UNIblend A 81' can be used for multi-component blending. It can precisely measure deviation in fiber percentage
less than 1%, and, thus avoid color non-uniformity in the end product. It can even mix/blend 98% white with 2% black
fibers.
3. Trützschler mixer can have 6 or 10 trunks depending upon the application.

Difference between continuous dosage and weighing System:

In continuous dosage system, different components are filled into each chute accordingly. Each chute has an individually,
continuously working dosage system. A conveyer belt transports the evenly sandwich layered material to the
compressing/opening take-off unit. Thus, the each tuft contains all components in right proportion. The blend ratio, in case of
continuous dosage system is maintained, which otherwise varies with weighing pan method.

On-line parameter settings:

One of the most significant modernizations, which has been brought in the blowroom line, is the online setting of
opening/cleaning machine parameters like beater speed, distance between grid bars, distance between grid bars and beater,
distance between beater and feed roller, etc. The cleaning intensity and amount of waste extracted can be programmed and
adjusted while the machine is in production.

1. The opening and cleaning intensity depends, apart from other parameters, on distance between beater and feed roller,
speed of beater and grid bars setting. The Rieter VarioSet System adjusts these parameters while the machine is in
running state.
2. The Trützschler’s waste sensor WASTECONTROL BR-WCT is attached to a Cleaner CLEANOMAT and optically measures good
fibers in the waste and amount of suction for fibers.

Recent Developments in card

The card is the heart of the spinning mill because if we see the card sliver, it is just the magnified replica of the yarn. Quality of
yarn is directly related to the quality of card sliver. Thus the modern developments, in the carding machine, are carried out to
produce better sliver. The following sections discuss some of the modern developments in the carding machine.

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Unidirectional feed: Unidirectional feed results in gentle fiber treatment because fiber feed and licker-in rotation is in the same
direction.

Multiple Licker-in: The concept of using three licker-in place of one is basically for better cleaning of the feed material. Here the
concept of clamped and unclamped feeding is used. The modular design of Rieter C 60 card makes it possible to convert from 3
licker-in units to 1 unit.

Increase in the carding zone/width of card: The modern machines achieve production rates of 60 - 220 kg/h, compared
with output of 5 - 15 kg/h in 1970. One of the many factors behind increase in the production, without deteriorating quality, is
increase in the carding zone area, particularly width of the card and/or long carding section.

1. The production performance of the Rieter C 70 (Figure: C1) card with 1.5m wide card, compared to that of the C 60, can
be increased by up to 40% with equal or better sliver quality. It has a 15% lower energy requirement than that of the C
60.
2. High production card from Trützschler named TC 11 is said to be providing 40% higher productivity. This Carding machine
evolves with a 300mm wider carding zone. What used to be 98 cm on the predecessor machines is now 128 cm. Since the
large cylinder diameter has been maintained, the carding area is now approximately 5.3 sqm.

Pre and Post-carding segments: The opening/individualization of fibers achieved by the carding action between the cylinder
and the flats is expressed by the number of wire points per fiber. Higher production rate decreases wire points per fiber and thus
deteriorate carding action. So pre and post-carding elements are used to achieve better carding action.

1. Pre-carding zone of Rieter C 70 Card has 6 carding units along with guiding elements and mote knife.
2. Pre-carding zone of Trützschler TC11 card has higher the pre-opening. The large post-carding area takes care of the rest,
thus ensuring even cleaner sliver and higher fibre parallelism.
3. The pre-carding zone of Marzoli C601 N Card has nine carding segments and a knife to eliminate the waste. The total
length of the pre-carding zone is stated to be 720 mm whereas that of post-carding zone is 550 mm. The post-carding
zone has six carding segments with two suction and knives to eliminate remaining trash.

Integrated grinding system: Card wire grinding is not only a troublesome job but also time consuming. The machine
manufacturers are now coming out with a unique idea of wire grinding on the machine itself while the machine is in production.
Rieter IGS-System comes in two versions; IGS-Classic for cylinder wire grinding and IGS-Top for flat wire grinding.

Use of Auto-leveler: To control card sliver count variations, count CV% and unevenness, modern cards are equipped with
auto-leveler. Medium-term leveler of Rieter C 60 card measures the feed mat thickness at the feed trough and, as required, the
feed roller speed is adjusted through the control system. Similarly, long-term leveler measures the sliver thickness by the step
roller pair and adjusts the chute system accordingly.

Online flats setting and Licker-in waste setting: All the major machine manufacturers are improving the card with manual
or motorized reproducible setting of licker-in mote knife and fats. The setting can be optimized while the machine is in running
conditions. Precision Knife Setting (PMS) System of Trützschler Card adjusts the distance of the knife to the needle points and
clamping point between feed roll and needle roll to alter the degree of cleaning. The Flat Measuring System (FLATCONTROL
TC-FCT) is used to measure the distance between cylinder and flat. For measurements, three regular flats are removed with
measuring flat as shown in Figure 40 c.

Online neps monitoring: Trützschler NEP CONTROL TC-NCT monitors the card web during production and provides information
regarding neps in card sliver. An optical electronic camera films the web under the take-off roll approximately 20 times per
second. The camera moves about the whole working width of the card in a special, fully closed profile. The computer attached to
the profile, evaluates the pictures with special analysis software, and indicates neps, trash particles and seed coat fragments in
the card web.

Integrated draw frames: Now-a-days, the cards are available with integrated 3-over-3 drafting. Such cards are able to reduce
one draw frame passage, particularly for low demand yarn or for OE spinning. Rieter C 60 card can either be fitted with RSB
series of coiler or SB series of coiler. The RSB coiler is essentially a complete auto leveler draw frame for sliver weight > 6.6 k.tex
at 120 kg/h whereas non-leveling SB series coiler is for a lighter sliver (3.5 - 6 k.tex) at high production rates. The auto-leveler
version is used for the OE direct process application. Similarly, Trützschler can also supply Integrated Draw Frame IDF with Card
TC 07 and claims to eliminate one draw frame passage, particularly for rotor spinning.

Magnotop system: Trützschler MAGNOTOP (Figure: C2) System uses high energy 'Super strong neodymium magnets' to hold
the clothing strips on the flat bars.

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Carding setting measurement system T-Con: T-Con calculates the distance of the carding elements objectively, based on
various measuring values under production conditions. The various settings displayed on the card monitor include the
flat-cylinder gauge, fixed carding segments, cylinder gauge, etc, and hence these settings can be optimized. T-Con also registers
even slightest contacts of the clothing and shuts down the card long before damage can occur and protects against clothing
damages.

1000mm Cans from the Card to the Comber

Large 1000 mm Cans can now be utilized in the Rieter fiber and spinning preparation from the card to the comber. The number of
different cans in the spinning mill can thereby be reduced which keeps the investment costs low. Thanks to larger can sizes, the
operator time is reduced and the yarn quality improved as a result of the lower number of sliver piecing.

to be continued...

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