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Fiber To Yarn Spinning Process of Polyester Fiber

This document summarizes the key steps in the spinning process for polyester fiber into yarn, including: 1) Selection of polyester fiber length and count based on the intended machinery and application. 2) The process flow from blowroom through carding, drawing, roving and ring spinning. 3) Quality control parameters and specifications for each process step to produce quality polyester yarn.

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Vinod Kumar
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943 views12 pages

Fiber To Yarn Spinning Process of Polyester Fiber

This document summarizes the key steps in the spinning process for polyester fiber into yarn, including: 1) Selection of polyester fiber length and count based on the intended machinery and application. 2) The process flow from blowroom through carding, drawing, roving and ring spinning. 3) Quality control parameters and specifications for each process step to produce quality polyester yarn.

Uploaded by

Vinod Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Fiber to yarn

Spinning process
of
Polyester fiber
What is count ?
• Count (Ne): No of 840 yards (hank) in one
pound (1lb)
• Denier : weight(grams) of 9000 mts
Selection of fiber – Based on count
• Spinning limit : No of fibers in yarn cross
section should be greater than 100
– No of fiber = Yarn Denier/fiber Denier
• Yarn Denier = 5315/count Ne

• Selection of Cut length is based on Machinery


– Short cradle : 38mm
– Medium cradle: 44 or 51mm
– PC Blends : 32mm
Fiber properties –Based on Application

• Weaving :
– Fiber strength for better yarn strength

• Knitting
– Fiber dyeability for uniform fabric dyeing
– Less yarn Hairiness so normally spinner prefer 38/44mm
Spinning process flow chart

Combed yarn Carded & Poly yarn

Double or
Multi-fold yarn
Mixing

• Keep fiber stock based on lot /creel • Better Mixing


wise is storage avoids most of UV
• Use Min 4 creels/lots equally for
ring / dyeing
better homogenous mixing
problems
• Maximum bales possible in mixing is
better for working

Number of bales per mixing is important


Blow room

• Blow room object is opening of fiber • Nep Generation


• 2 beating points with 550-600 rpm should below 20%
speeds for disc beaters
• For Pin type slightly more speeds are
allowed

Material transfer from BR to carding should be smooth, avoid more bends in


transport line
Carding

 Feed plate to Licker-in  Neps/gram : Below 2


 44mm : 1.0mm (40thou)  Fused fibers numbers
 38mm -0.75mm (30thou) Fused fibers per 10 gram of flat
strips Below 10
 Cylinder to flats
 RH% : 55-60%
 12,12,10,10 thou or 0.3,0.3,0.25,0,25mm
 Sliver U% : 2%
 Flat speed : 220 – 260 mm/min
 Card breaks below one
break /8hrs

 Static at Card should be below +/- 1.0


Drawing

 Drawing I  Sliver U% - Below 2.5%


 BR Sett. : CL + 4-6mm / CL +8-10mm  1mt cv% - below 0.5%
 BD :1.71  Acid treatment (H2SO4) or
 courser hank like 0.09 keep 5 ends or 6 liquimix coting will reduce top
 Drawing II roller lappings
 BR Sett. : CL + 4mm / CL+8 mm
 BD :1.41
 6 & for finer – 8 ends up

 Coiler tube size should be more for Polyester process


Simplex

 Speed – 900 rpm (For polyester  Top roller SH – 83 deg


speeds should be less due to slippage  Brakes – 0.5/100 spl hrs
tendency)  Quality:
 Flyer groves false twister– more than  Roving stretch – Below
cotton (10-12) for better twist 0.5-0.7% and between
spindles should be +/-0.5

 Stretch is performance parameter for simplex


 4 over 4 Drafting is better doer polyester process
Ring frame

 Setting for short cradle : 42.5 -44 / 60-  Top roller & Aprons SH –
65mm 83 deg
 For medium cradle : 54.5/70 -75mm  Brakes – below 2 BPHSH
 Quality: Thin ZERO
 BD -1.14 to 1.2
 RH % : 50-55% & 320C
 Tm = 3.1-3.3 for 38mm, 2.9-3.0 for 44mm
 Total Draft : 35 to 40
& 2.7-2.8 for 51mm
 Spacer for 30s – 3.5, 40s 3.0mm,20s
-4.0mm
 Traveler speed – below 40m/sec is ideal

 Traveler should have grater gap between ring & traveler for poly
 Loose spindle tapes may cause tpi variation in yarn
Auto coner

 Drum speed – max. 1250-1300 (Lesser  Analysis the faults with


than cotton) cut mode
 Cuts - max 35-40/100k  Monthly once check for
rewinding study
 Wax for Knitting and no wax for weaving
 Settings
 N – 4.5 to 5.0
 DS – 2.0
 LS – 1.8 to 2.0
 DL – 1.25
 LL – 30
 D-18
 LL -25

 Splice quality to be taken for polyester

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