1.
Yarn Formation
TEXT-201
Lecture No 3 and 4
By
Muhammad Siddique

2.
VARIABLES IN YARN PRODUCTION
Most generally yarns can be classified into
continuous filament yarns made out of manmade
raw material and short staple yarns produced
from natural fibers. However within these two
categories endless varieties of yarns can be
produced because there are so many variables
involved in yarn production. Some of the
variables are listed below:
• Type of Fiber (s) and / or filament(s) used in an
individual yarn

3.
VARIABLES IN YARN PRODUCTION
• Dimensional and physical characteristics of the
Fiber Or filament used in a yarn e.g. fineness,
cross sectional shape, crimp, density, etc
• The mechanical properties of a Fibre or filament
e.g. tensile strength, tenacity, extensibility, elastic
properties, etc
• The general properties of a Fiber or filament e.g.
frictional properties, moisture regain, thermal
properties, dimensional stability, resistance to
micro organisms, static properties, electrical
properties, Colour ageing etc

4.
VARIABLES IN YARN PRODUCTION
• Chemical properties of a Fibre or filament e.g.
resistance to acids, alkalis, dry cleaning agents
and other chemicals.
• The method of yarn production e.g. carded
system, combed system, Woollen system,
worsted system, etc
• Method of final yarn formation e.g. ring, rotor,
wrap, core, air jet & friction spinning, etc.

5.
VARIABLES IN YARN PRODUCTION
• Component of the yarn e.g. 100% natural
fibers, 100% manmade fibers, blend of natural
fibers with manmade fibers, blend of natural
fibers with filaments, etc
• The linear density i.e. the count of the yarn
and the level of twist (twist multiplier)
• Cross section of the yarn e.g. circular,
elliptical, flat, textured, etc.

6.
VARIABLES IN YARN PRODUCTION
• Ply of the yarn whether the yarn is single plied or multi
plied
• As far as natural fibres are concerned, they have typical
properties depending upon the group to which they
belong. For example cotton, flax, jute, etc all are cellulosic
fibers on the other hand wool, silk, mohair, etc all belong to
Proteinic fibres.There is nothing much can be done to alter
the basic properties of these fibres.These properties also
vary from lot to lot within the same category
• On the other hand in manmade fibers, most of the
properties can be controlled to a great extent and
precision. They can both occur in filament and short staple
form of desired length

7.
VARIABLES IN YARN PRODUCTION
• Consequently the yarn properties made of
natural fibres are dependent on the basic
natural properties of the Fibre However in
case of man made yarns properties of the
fibers can be modified to meet the
requirements of the end use of the yarn.

8.
Topics to be covered
• Cotton impurities
• Blow room opening
• Blow room cleaning
• Blow room Mixing /Blending

9.
What is cotton Impurities ?

10.
COTTON IMPURITIES
The impurities in cotton fibers can be
classified into:
• (1)Seed
• (2) Chaff
• (3) Dirt
• (4) Micro Dust
• (5) Abnormal Impurities

11.
Seed
Seed impurity is the
largest type of impurity
present in raw cotton
and it includes un
ginned seeds with fibers
attached to it, ginned
seeds and parts of
seeds

12.
Chaff
The chaff is the
vegetable fragments
consisting of leaf
particles, bract, shale
and stalk of the cotton
plant. Bract is a small
type of a leaf that grows
beneath the cotton boll
and shale is the silvery
interior lining of the
cotton boll

13.
Dirt
The dirt impurity includes soil and sand
particles that may be added from the cotton
fields due to mishandling of the fibres and
also the cotton fibers pick up dust and sand if
they are transported by open trucks

14.
Micro dust
The micro dust includes very fine particles of
chaff, dirt, Small Fiber fragments and spores of
mildew. These particles are extremely small
and are often a fraction of the Fiber diameter.
They generally gets embedded around the
natural wax of the cotton fiber

15.
Abnormal Impurities
The abnormal impurities are very rare however when found
in the cotton fibers, they can cause serious problems. These
• impurities include
• Pieces of stones,
• Pieces of iron,
• Cloth fragments
• Foreign fibers such as jute, polypropylene, etc (that may be
included due to the bagging of cotton fibers made up of
these fibers)
• Grease and oil (from machine harvesting or ginning),
• Small pieces of wood, etc

16.
Trash
The term trash is applied to all of these
impurities present in the raw cotton. The total
trash content of cotton fibers ranges from 1%
to 10% of the total weight of the cotton
fibres.The amount of trash content directly
determines the amount of cleaning required.

17.
What is Blow room ?

18.
Blow room
The blow room is the first stage or the first
process in the short staple spinning. The name
‘Blow Room’ is given to this stage because of
the air currents that are commonly used
during the processing of fibers.

19.
Flow Chart of Blow Room
• Bale plucker
↓
• Metal detector
↓
• Uniclean
↓
• multimix
↓
• Condenser
↓
• Chute feed
↓
• Carding

20.
Blow room Department

21.
BLOW ROOM
The objectives of blow room are :
• Opening
• Cleaning
• Blending / Mixing
• Even feed of Material to Card
• Lap formation

22.
Why opening ?

23.
Why OPENING
The tightly packed fiber bales
received from the ginning mills
have to be opened by converting
the larger fiber tufts into smaller
ones and ultimately converting
the smaller tufts into individual
fiber form .

24.
BLOW ROOM OPENING
• Opening is also related to cleaning as where is
opening there is also cleaning.
• There are two different level of opening:
• Opening into Small fiber tufts(bunch of fibers)
(performed in blow room)
• Opening into individual fibers (performed in
carding and rotor spinning)

25.
BLOW ROOM
OPENING

26.
BLOW ROOM
OPENING

27.
BLOW ROOM
OPENING Machines
Bale Opening machines are of Three types
• Hopper Feeder
• Reciprocating Bale Plucker (Top Feeder )
• Rotary Bale Plucker

28.
BLOW ROOM
OPENING , HOPPER FEEDER

29.
Working of Bale breaker
• Open the material gently.
• Open up to smallest tufts.
• Process as many bales as possible in a single
charge.
• Blend fibers at the start of the process.

30.
BLOW ROOM
RECIPROCATING TYPE(Top Feeder)
• Move over and past the
bale layout and extract
fibers from top to
bottom

31.
2-Cleaning
Why cleaning ?

32.
Why cleaning ?
All the natural fibers including cotton have
considerable amount of impurities in them
which have to be removed to produce a clean
yarn.

33.
BLOW ROOM
CLEANING
• The Cleaning machines directly gets it feed from
the hopper feeders or bale opener
• Different machine manufacturers have developed
various types of cleaning machines. The most
commonly used ones are:
• Step cleaner
• Dual Roller cleaner
• Three roller cleaner

34.
STEP CLEANER

35.
DUAL ROLLER CLEANER

36.
DUAL ROLLER CLEANER

37.
THREE ROLLER CLEANER

38.
Why Mixing /Blending

39.
Why Mixing /Blending
The properties of the cotton fibres differ from
each other from bale to bale and from fibre to
fiber so in order to obtain a homogenous and
consistent quality yarn, they need to be
thoroughly mixed together. Sometimes in order
to have a desired quality at the right price high
quality cotton fibers are mixed with low quality
fibers
• Fibers can be blended at various stages of the
process Blow room, carding and drawing
• To give required characteristics to end product

40.
BLOW ROOM
BLENDING / MIXING Machines
• Types of Blending / Mixing
• Bale mixing
• Flock blending
• Sliver blending

41.
Multi mixer

42.
Thanks