Basically, there are two types of yarn mainly. One is carded yarn and other is combed yarn. There are marginally different in process of carded yarn and combed yarn. This article is about modern flow chart of yarn manufacturing including carded yarn and combed yarn manufacturing process. Before going to the modern flow chart, let’s come to learn what is carded yarn and combed yarn?
What is Carded Yarn?
Yarn is produced from fibers that have only been carded but not combed. In the spinning factory, fiber materials are first opened and cleaned. If necessary, blend two or more fibers together in the first stage. Then fiber converts into individual fibers on a card and produces a sliver called a card sliver. Card slivers are fed on a draw frame to give drafting. Drafting leads to a reduction of the fiber mass per sliver and produces a draw frame sliver. Compared to the carded sliver, the drawn sliver better show a better fiber alignment towards the longitudinal axis of the sliver. Drawn slivers also show a higher degree of parallelization between the fiber. Finally, a yarn spun out of this sliver is called a carded yarn.
What is Combed Yarn?
In yarn production, both carded and combed fibers are used. In combed yarn, the combing process is used as an additional process besides carding. During this process, fibers are arranged in a highly parallel pattern, and different short fibers, neps, and trash are removed. As a result, the quality of the combed yarn is high, with excellent strength and evenness. On the other hand, combing leads to a higher degree of cleanliness in fiber materials. Compared to carded yarns, the combed yarn has a softer handle.
Modern flow chart of yarn manufacturing system with a modern Blow room line
Modern flow chart of yarn manufacturing
Now, I will Briefly discuss of the modern flow chart of yarn manufacturing for both carded & combed yarn.
1. Automatic Bale Opener:
this is first machine of blow room line. Cotton fibers comes in spinning in bale form. Bale is a standard sized and weighted pack of compressed cotton lint after ginning. Compressed cotton fiber need to open. Automatic bale opener, open the compressed cotton. The first generation automatic bale opener machines were mostly stationary. Only the bales were moved, either forward and backward or in a circle. But now automatic bale opener machines are traveling type. They move past the stationary bales of the layout. The main task of automatic bale opener is open the compressed cotton evenly from bales, mixing and blending, form tufts of equal size.
2. Metal detector:
Magnets are used in blow room lines to remove metal such as iron from the cotton. We know cotton fiber is processed and made bale in ginning factory. From the factory, metal substances may be mixed with cotton fiber. Metal detectors remove this metal from the fiber.
3. Uniclean:
One of the most essential and primary tasks in the blow room is removing dust, trash, leaf, and other waste from natural fibers, especially cotton. Uniclean is used in blow room lines to remove dust, trash, and other impurities from the fiber.
4. Unimix:
Another function of the blow room is to blend the raw material of different qualities to equalize and even the mean quality of delivered materials. Because natural fiber remains variable in quality. Unimix help mix various quality fiber into each other. The latest version Unimix machine has three chambers: a storage section, an intermediate chamber, and a delivery section. 8 chutes are feed behind the machine in a storage section.
5. Uniflex:
A uniflex machine is used for cleaning purposes. A fan draws the tufts by suction from the previous machine, and a distribution element ejects them into a filling chute. The rear wall of the chute consists of individual aluminum lamellae with slot openings through which the air can escape. This is the first de-dusting step.
6. Vision Shield:
An essential quality objective is to produce contamination-free yarn. Vision shield is used to produce contamination-free yarn. Today’s textile markets are highly competitive. Every buyer wants unique products of the right quality and free from contamination. A vision shield is used in the blow room line to fulfill the buyer’s requirement. Here advanced technology is used for clean cotton with minimum loss of valuable fiber.
7. Condenser:
Condenser used in blow room line as a storage device. This is a very important part of the blow room. The main task of the condenser is to take fibers from the previous machine and supply them to the next machine. Condenser ensures regular feeding of the machine. It consists of a fan, a perforated roller, and a stripping roller.
8. Chute feed:
In a conventional system, Scutcher forms a lap to supply material to the cards. But in modern blow room lines, a chute feed system is used. The chute feed system is a continuous process. Chute feed system has the advantages of higher productivity and low variation in the quality of feed materials.
9. Carding:
the process by which the reduction of entangled mass of fibers of filmy web by working them between two closely spaced relatively moving surfaces closed with sharp points is called carding. There two proverbs of the experts-
“The card is the heart of the spinning” and “well carded is half spun”
10. Drawing:
Drawing is a process in which the sliver is blended, doubled, leveled, and drafted by passing the sliver through a series of pairs of rollers, each pair moving faster than the previous one is called drawing. The main object of the drawing frame is to straighten the crimped and hooked fibers in the card slivers. In the drawing process, paralyzation of the fibers along the sliver axis so that when they come to be spun on the spinning frame, they will be evenly drafted and twisted to produce good quality yarn.
11. Lap Former:
For making combed yarn, a former lap machine is used. The former lap machine converts the drawn sliver into the lap. The lap is obtained by doubling a certain number of draw slivers. Usually, 16 to 32-draw sliver is used to make a lap.
12. Comber:
The combing process is used to make combed yarn. This process involves straightening and parallelizing the fibers and removing short fibers impurities by using a comb. The main object of combing is to remove the fiber shorter than a predetermined length, remove remaining impurities in the pre-comber lap, and remove neps. As a result, a uniform sliver is produced.
13. Simplex or roving or speed frame:
Roving frame converted the combed sliver or, in some cases, draw the sliver into roving. In the roving frame, insert a small amount of twist to give the required strength of roving. Transforming the sliver into roving occurs continuously through three stages: drafting, twisting, and winding.
14. Ring Frame:
This is the final stage of spinning. This machine achieves the goal of this manufacturing process to get yarn. The ring frame converts the roving into yarn. There are different types of spinning machine is used. But the ring frame is a conventional spinning machine. The rotor spinning system is a modern spinning system.
Figure 15: Ring Frame
15. Auto coner:
The size of the spinning bobbins is very small. The auto corner is used to transfer yarn to the large package needed for efficiency at weaving and knitting. Auto coner is a modern winding system. With this machine, we can produce a large cone without any knot. All types of faults of yarn, such as thick places, color materials, etc., are cleaned by this machine. This machine can lubricate the knitted yarn.
16. Heat Setting:
Heat setting changes the strength, dye-ability, and softness of the year. It is done in one kind of chamber. The chamber is heated to about 600C by steam. The yarn package is heated for about 40 to 50 min. Heat setting also sets the yarn twist.
17. Packing:
After the heat setting, yarn cones are packed in polythene paper in a cartoon with a certain number, normally 24 cones of 2.08 kg each for knitted yarn. Finally, cartoons are shifted to the weaving section or buyer.
References
- Belal, P. D. (2009). Understanding Textiles for a Merchandiser . Dhaka: L.B graphics and Printing.
- Chowdhury, M. F. (2016). Manual of Short Staple Spinning . Dhaka: Granthanir Prokashoni.
- Hossain, M. S. (2014). Introduction to Textile Engineering. Dhaka: Books Fair Publications.
- Kadolph, S. J. (2009). Textiles. New Delhi: Dorling Kindersley.
- The_Rieter_Manual_of_Spinning_vol._2_1922 v3_83522_Original__English__83522
Awesome article post. Will read on…
thank you.
Thanks again for the article post.Thanks Again. Awesome.
thanks too…..please support us.
I truly appreciate this article post. Really Great.
Keep visit our site..
I really enjoy the article.Thanks Again. Much obliged.
thanks too……please support us….
Really appreciate you sharing this article post.Really thank you! Great.
thanks……….
I really enjoy the article post.Thanks Again.
keep visit our site….
Very neat blog.Thanks Again. Keep writing.
keep visit our site…..
Major thankies for the blog.Thanks Again. Cool.
thanks for your comments.
I am so grateful for your blog post.Really looking forward to read more. Great.
Really informative blog.Really thank you! Really Great.
keep visit our site…thank too…..
Fantastic article post.Much thanks again. Much obliged.
Very good blog article.Really looking forward to read more. Cool.
Thanks
Thank you for your article.Much thanks again. Really Great.
Wow, great blog article.Really thank you! Keep writing.
Thanks too
Appreciate you sharing, great article.Really looking forward to read more.
Thanks
wow, awesome post.Really looking forward to read more.
Very neat article.Really thank you! Awesome.
I loved your post.Really looking forward to read more. Will read on…
Im grateful for the blog article.Really thank you! Great.
Great, thanks for sharing this blog article.Really thank you! Keep writing.
Im obliged for the post.Thanks Again. Fantastic.
Very good blog.Really thank you! Will read on…
Really enjoyed this post.Really looking forward to read more. Much obliged.
Major thanks for the blog post.Really looking forward to read more. Want more.
Very good article. Really Cool.
keep visit our site……..
Thank you for your article post.Really thank you! Keep writing.
keep visit our site.
Thanks-a-mundo for the blog article.Really looking forward to read more. Keep writing.
keep visit our site.
Major thanks for the blog article.Really thank you! Much obliged.
keep visit our site.
Fantastic blog.Much thanks again. Will read on…
Im thankful for the article.Thanks Again. Want more.
I loved your article.Really thank you! Much obliged.
thank you…
Thanks for sharing, this is a fantastic blog article.Much thanks again. Cool.
Really enjoyed this article.Thanks Again. Fantastic.
Thanks too
Enjoyed every bit of your article post.Much thanks again. Awesome.
Thank you
Enjoyed every bit of your article.Thanks Again. Keep writing.
Thanks too
Im grateful for the article.Really looking forward to read more. Much obliged.
This is one awesome article.Really thank you! Really Great.
Really appreciate you sharing this article post. Much obliged.
I think this is a real great blog post.Much thanks again. Will read on…
Im obliged for the blog.Really looking forward to read more. Will read on…
I really liked your blog.Thanks Again. Want more.
Really informative post.Much thanks again.
I think this is a real great post.Thanks Again. Awesome.
Looking forward to reading more. Great blog.Really looking forward to read more. Really Cool.
Major thankies for the blog post.Really looking forward to read more. Will read on…
Great article post.Really looking forward to read more. Really Great.
Really appreciate you sharing this article post.Thanks Again. Cool.
Great, thanks for sharing this article post.Thanks Again. Much obliged.
Fantastic blog article.Really looking forward to read more. Cool.
Very informative blog post.Really looking forward to read more. Really Great.
Really appreciate you sharing this blog post.Thanks Again. Keep writing.
Wow, great post. Really Great.
A round of applause for your article.Really looking forward to read more. Great.
Very good post.Really thank you! Fantastic.
Im grateful for the blog.Really thank you! Really Great.
wow, awesome blog.Thanks Again. Fantastic.
I truly appreciate this post.Thanks Again. Cool.
Very neat post. Keep writing.
Im thankful for the blog post.Thanks Again. Great.
I am so grateful for your article post.Really looking forward to read more. Awesome.
I think this is a real great blog article.Really looking forward to read more. Will read on…
I value the blog post. Cool.
I loved your blog. Will read on…
Enjoyed every bit of your blog article.Thanks Again. Really Cool.
Im grateful for the article post.Much thanks again. Cool.
Thanks a lot for the blog. Much obliged.
Major thankies for the blog. Fantastic.
I really liked your blog post.Really thank you! Awesome.
Thanks for the blog post.Much thanks again. Really Great.
Say, you got a nice post.Really looking forward to read more. Fantastic.
Thanks
Enjoyed every bit of your blog.Really thank you!
This is one awesome post.Really thank you! Will read on…
I cannot thank you enough for the blog.Really thank you! Really Cool.
Great, thanks for sharing this blog.Really thank you! Awesome.
Very good article post.Thanks Again.
I am so grateful for your blog article.Really looking forward to read more. Want more.
Really appreciate you sharing this blog post.Much thanks again. Will read on…
Very neat blog post.Really thank you!
Thank you for your article post.Much thanks again. Cool.
Major thanks for the blog post.Thanks Again. Fantastic.
Say, you got a nice article post. Much obliged.
Great post.Really thank you! Much obliged.
Great, thanks for sharing this blog article.Much thanks again. Awesome.
Thanks a lot for the blog.Really thank you! Will read on…
Major thanks for the article.Much thanks again.
Looking forward to reading more. Great blog article.Really looking forward to read more. Cool.
I cannot thank you enough for the article.Much thanks again.
I am so grateful for your blog article.Much thanks again. Really Great.
Thanks so much for the article. Awesome.
Thanks a lot for the article.Thanks Again. Great.
Great article post.Really looking forward to read more. Awesome.
I cannot thank you enough for the article.Much thanks again. Want more.
I appreciate you sharing this blog post.Thanks Again. Great.
wow, awesome blog post.Much thanks again. Great.
Hey, thanks for the article post.Really looking forward to read more. Really Cool.
Thank you ever so for you blog article. Cool.
Im obliged for the article.Really thank you! Want more.
Thanks again for the post.Really looking forward to read more.
Say, you got a nice post. Much obliged.
I really like and appreciate your blog.Thanks Again.
I value the article post.Really thank you! Much obliged.
Thanks for the blog article.Really looking forward to read more. Will read on…
Im obliged for the article post.Really thank you! Really Great.
I value the post.Thanks Again. Really Great.
Hey, thanks for the article.Really looking forward to read more. Fantastic.
I cannot thank you enough for the blog post.Much thanks again. Much obliged.
Major thankies for the article post.Really looking forward to read more. Will read on…
I appreciate you sharing this blog article.
Im grateful for the blog.Thanks Again. Will read on…
I think this is a real great blog. Fantastic.
Fantastic blog article.Really thank you! Great.
Thank you ever so for you blog. Really Cool.
Great post.Thanks Again. Cool.
I think this is a real great post.Really looking forward to read more. Keep writing.
Very neat article post.Much thanks again. Will read on…
Thanks a lot for the post.Much thanks again. Keep writing.
I truly appreciate this post.Really thank you! Keep writing.
I appreciate you sharing this blog article.Thanks Again. Much obliged.
Appreciate you sharing, great article post.Thanks Again. Fantastic.
Great blog.Thanks Again.
wow, awesome blog article.Thanks Again. Want more.
This is one awesome blog post.Really thank you! Cool.
Great, thanks for sharing this blog article.Really thank you! Awesome.
I really enjoy the post. Want more.
Awesome article.
Say, you got a nice article post.Thanks Again. Keep writing.
Really appreciate you sharing this article post.Really thank you! Great.
Very neat blog.Thanks Again. Much obliged.
I really liked your blog.Much thanks again. Keep writing.
Thank you ever so for you post.Thanks Again. Much obliged.
Thanks for the blog article.Really looking forward to read more.
I value the article post. Want more.
I loved your blog.Thanks Again. Want more.
I really enjoy the post.Really looking forward to read more. Much obliged.
Say, you got a nice blog.Really thank you! Want more.
Plz stay connected
I really like and appreciate your blog.Really looking forward to read more. Cool.
Thanks for the blog post.Really thank you!
Very good post.Thanks Again. Great.
I really like and appreciate your blog article.Really thank you! Want more.
Thanks
Thanks a lot for the blog article.Really thank you! Really Great.
Thank you ever so for you article post. Really Cool.
Appreciate you sharing, great blog post.Thanks Again. Really Great.
Wow, great blog article. Great.
Awesome article post.
I truly appreciate this post.Much thanks again. Much obliged.
I really liked your blog.Really looking forward to read more. Keep writing.
Im grateful for the blog article.Really looking forward to read more. Much obliged.
Awesome blog article.Much thanks again. Keep writing.
Really enjoyed this post.Really looking forward to read more. Much obliged.
Thanks so much for the blog.Really thank you! Really Cool.
Thanks a lot for the article post.Much thanks again. Cool.
Very neat post. Keep writing.
I think this is a real great article post. Really Great.
Thank you for your blog article.Really thank you! Cool.
I really enjoy the blog article.Really thank you! Want more.
Thank you for your blog post.Much thanks again. Want more.
Thanks for sharing, this is a fantastic blog.Thanks Again. Will read on…
Thanks for sharing, this is a fantastic blog article.Much thanks again. Cool.
Hey, thanks for the blog article.Really thank you! Will read on…
Thanks for sharing, this is a fantastic post. Keep writing.
A big thank you for your article post.Thanks Again. Fantastic.
Im thankful for the post.Really looking forward to read more. Cool.
I appreciate you sharing this blog.Really looking forward to read more. Awesome.
wow, awesome article. Awesome.
Very good blog.Thanks Again. Really Cool.
Very informative blog.Really looking forward to read more. Cool.
Im obliged for the blog article.Much thanks again. Want more.