Wrap spinning
Introduction
• A wrap yarn is a composite structure comprising a core of twisted or twists-less
fibers bound by a yarn or continuous filament.
• Wrap spinning, although not new, has become the subject of renewed interest in
recent years. The process is claimed to provide the spinner with a highly efficient
method of producing yarns of high quality for a wide range of applications. High
production speeds are claimed and the resultant yarns possess many desirable
qualities.
• Wrap yarns were produced more than a century ago by the woven horsehair
interlining trade. A horsehair core of virtually untwisted fibers having been wrapped
first with a yarn in "S“ direction and then with one in “Z" direction or vice versa.
This was then wound and used as weft in high quality interlining fabrics.
• Wrap spun yarns are said to be as strong as, more regular and bulkier than
conventional ring spun yarns, effecting good cover and a full handle when
converted into fabric. Wrap yarns have been successfully employed in the
production of a wide range of products including both woven and knitted goods,
tufted carpets and velour fabrics.
Methods of wrap yarn production
• Different types of wrap spinning is available to produce wrap
yarns;
1) Selfil
2) Repco
3) Hollow spindle method
4) Wrap yarns produced on ring frame
5) Differential twist yarns
6) Wrap spun rotor yarns
7) Wrap yarns produced on woolen card
8) Parafil System
Selfil system
• A method of yarn production whereby two continuous filaments
are wrapped around a staple fiber core on a modified Repco self-
twister has been described by Walls.
• These yarns consisted of a core of staple fibers which is
wrapped in alternating directions with a fine filament by a self-
twist unit. A second self-twist unit repeated this action such that
the point of low twist of the second filament coincided with the
point of high twist of the first filament and vice versa.
• The resultant yarns were called SELFIL wrapped yarns.
Selfil Process
• A worsted roving is fed into the drafting system E to B and the
drafted strand is fed through self- twist rollers at A, which, as
well as rotating to move the strand forward, reciprocate
longitudinally to impart alternating twist to the strand.
• A monofilament converges with the strand at C and a second
monofilament converges at D. The final yarn is wound at F.
Selfil wraapped yarns
Repco system
• A method of yarn manufacture which utilizes the self
twist principle, has been developed at SAWTRI. These
yarns are termed Repco Wrapped Core-Spun (RWCS)
yarns and consist of a strand of staple fibers and filament
core, self twisted with a single filament binder yarn.
• The system was initially developed for the production of
fine mohair yarns which were subsequently up-twisted and
used for weaving. RWCS yarns have since been produced
for knitting.
Repco system
Repco RDWCS System
• A further method has been developed, primarily for the
production of wrapped core-spun cotton yarns on a self-twist
spinner, which could be used readily without the necessity of
up-twisting.
• These yarns have been termed Repco Double Wrapped Core-
Spun (RDWCS) yarns and employ two wrapping filaments.
• It was stated that with the exception of yarn tenacity, the
RDWCS system produced yarns as good as up-twisted RWCS
yarns.
Repco RDWCS System:
Wrapped yarns produced on Ring frame
• A continuous filament, drawn off a bobbin situated behind the
drafting mechanism of the spinning frame is threaded through the
delivery rollers so that it will emerge at the front of these rollers
alongside the drafted dubbing.
• Correct positioning of the filament is achieved by means of a
guide at the back of and close to the delivery rollers. Both
filament and dubbing are then twisted into a yam consisting of a
core of staple fibers wrapped with filament at the balloon zone.
• His method has been used both for the production of waste
yams and cotton yams which need not be sized.
Wrap yarn produced on ring frame
Differential twist yarns
• A further method of wrap spinning is that of passing a core of
staple fibers through a hollow spindle, wrapping the fibers with
filament and subsequently ring spinning the yams in one
continuous process.
• This system is used both for the production of fancy yarns and
for the production of straight yams.
• These yarns consisted of a strand of staple fiber which had been first
wrapped with filament and subsequently twisted together with the same
filament, the outstanding character being that the twist of the staple fiber
was lower than that of the filament.
• The direction of twist inserted by the ring spindle was the same as that
of the 'wrapping' twist. In this manner the strand of staple fiber was given
twist and the final twist of the filament in the spun yam was the sum of
the 'wrapping' twist and 'spinning' twist.
• Tensile properties spin ability and regularity, of Differential Twist Yarns
is invariably better than conventional ring spun yarns.
Wrap spun rotor yarns
• A method of producing Wrap-Spun Rotor yams bas been developed in
Czeckoslovakia. The process which was termed 'ROTONA" made its first
international appearance at ATME '82.
• Fundamentally, the system is a modification of the rotor spinning process
which makes it possible in one operation to spin a single rotor yarn and to wrap
it around another continuous textile product such as a staple core or filament
yarn, while it is practically still in the rotor.
• ROTONA yarns were designed primarily to replace traditional ply yarns in a
broad range of textile products.
Hollow spindle method & Prafil system
Hollow Spindle method:
• The hollow spindle system of wrap yarn production, in which no
real twist is inserted during the actual spinning process, has
become generally accepted as the most important method of wrap
yam production.
• The hollow spindle method of wrap yam production involves the
drafting of a sliver produced either on the worsted, semi-worsted
or cotton system of manufacture into a roving of parallel fibers
which is then passed together with a fine filament, through a
hollow spindle onto which the filament package is mounted.
• By rotating the spindle, the core is helically wrapped with
filament. The filament exerts radial pressure on the fiber core
resulting in frictional forces acting between the individual
components, which, together with the wrapping filament, are
responsible for yam strength.
Principle of Hollow spindle method
• A roving or sliver feedstock (1) is drafted in a three-, four-
or five-roller drafting arrangement.
• The fiber strand delivered runs through a hollow spindle (3)
without receiving true twist.
• In order to impart strength to the strand before it falls apart,
a continuous-filament thread (4) is wound around the strand
as it emerges from the drafting arrangement.
• The continuous-filament thread comes from a small,
rapidly rotating bobbin (5) mounted on the hollow spindle.
• Take-off rollers lead the resulting wrap yarn to a winding
device.
Hollow spindle method
Wrap yarns produced on a Woolen card
• A system whereby wrap yams can be produced directly on the
condenser of a woolen carding machine.
• Hollow spindles were fitted between the rubbing apron and the
condenser surface drum of a woolen carding machine, thus
producing a wrap yam from staple fibers in one continuous
process.
• An additional method is described whereby the rubbing aprons
are bypassed so that yarn is produced from fiber ribbons as
presented by the condenser tapes, thus eliminating the rubbing
aprons and eccentric motion of the condenser.
Wrap yarns produced on a Woolen card
Parafil System
• Three, four, or five roller drafting arrangements are used, depending upon the
raw material to be processed.
• The hollow spindle permits rotation speeds of up to 35 000 rpm and is designed
as a false-twist assembly.
• The fiber strand does not pass directly through the spindle vertically; instead,
shortly after entering the spindle, the strand is led out again and back around the
spindle, with a wrap of about one- quarter of the spindle periphery.
• In this way, as the spindle rotates, the strand is provided with twist between the
drafting arrangement and the head of the hollow spindle.
• These turns of twist are canceled out again in the spindle head in accordance
with the false-twist principle. This false twist prevents the strand from falling
apart in the length prior to wrapping with filament.
Features of Parafil system
• Slivers are used as feedstock, the roving frame is eliminated.
• Parafil yarn (called Parallel yarn by Suessen) is usually more
even than ring-spun yarn.
• Its strength is also better because of the filament and because
of the high degree of parallel orientation of the fibers.
• Covering power is high and hairiness low.
Use of Parafil yarns
• The yarns are used primarily for:
• Machine-knitting yarn
• Velours (home and automobile upholstery materials)
• Woven goods (men‘s and ladies‘ wear)
• Carpet yarns (mainly for tufted carpets).
• At present, the process is more suited to the long-staple than
the short-staple field, i.e. for fiber lengths above 60 mm.
• In ParafiL yarns, the filament makes up 2 - 5% of the yarn.
Technological & Economic Inter relationships
• High percentage of filament always has a disturbing effect.
• More often in the coarse-yarn sector, and to some extent in the
coarse-to- medium- yarn range. • The high price of filament
relative to staple fibers exerts a strong influence on costs.
• Economic production of fine yarns using the wrap-spinning
process is therefore not possible, due to higher raw material
costs.
• Fine filaments in the 20 - 110 dTex count range are usually
used.
• Most common are polyamide fiber, polyester fiber, and viscose.
Types of wrap spun yarns
Types of wrap yarns Wrap yarns can be categorized into three
groups;
1) Flat parallel yarns
2) Structured parallel yarns
3) Fancy yarns
Flat parallel yarns
• These yarns are also referred to as straight regular or smooth
yarns, and consist of a core of parallel, untwisted fibers
helically wrapped with a fine filament yarn.
• In addition, wrap yams of this type, which have been
produced on the "LEESONA" range of wrap spinning
machinery, have been termed "Core Spun" yarns.
• In contrast to ring spun yarn, the fiber structure is held
together not by twist, but by the wrapping thread.
Flat parallel yarns wrap spinning assembly
Structured parallel yarns
• Structured or engineered yams can be created to give the
finished product improved performance, enhanced aesthetics,
softer handle, lower unit mass, greater bulk and cover etc.
• An example of such a process is to use a filament yam which
contracts when the wrap yam is dyed or steamed. The contracting
filament exerts pressure on the staple fiber core, thus squeezing
the staple fibers in a bow out of the yam axis.
• A spiral appearance is therefore generated, which grows to a
string of pearls pattern as volume builds up to a maximum.
Structured parallel yarns wrap spinning assembly
Fancy yarns
• Fancy yams can be produced by feeding an effect yam together
with the drafted sliver through the hollow spindle so that both the
sliver and the effect yarn are wrapped by the filament. Fancy
yams are also produced by employing overfeeding and
intermittent feeding of the effect yarn or drafted sliver.
• The fibers are drafted either with or without aprons. The core
yarn is brought through a groove in the front draft roller and
therefore runs at the speed of the delivery roller, permitting
overfeeding at the front roller. The materials then pass through the
hollow spindle, where they are wrapped with the binder.
Fancy yarns wrap spinning assembly
Fancy yarns basic structure
Raw material, Properties, Advantages & Disadvantages
Wrapping filaments The most important filaments used in wrap spinning are;
Filament Linear density (dTex)
Nylon 17 – 228
Polyester 17 – 167
Polypropylene 78 – 330
Acrylic 78
Acetate 220 – 330
Water soluble 62
Glass 110 – 440
Silk 33 – 88
Elastomeric 22 – 156
Staple yarns 50.– 2000
Core fibers
Fiber types:
Virtually all textile raw materials can be successfully converted into wrap yarns including
asbestos and glass. The system is considered suitable for both the long staple, and short
staple sectors of the industry. It is said that any fibers that can be drafted can be wrap
spun.
Range of yarn linear density:
Yams of a very wide range of linear densities can be spun on the hollow spindle system
and it is said that restrictions on linear density range are economical rather than
mechanical.
Physical properties of wrap yarns
• Yarn uniformity is found to be equal to or better than that of conventional ring spun
yarns.
• The wrap yarns are also being smoother and less hairy.
• Wrap yarns were found to be very voluminous and therefore effect a better cover in
fabrics.
• Yam tenacity is reported to be higher than that of conventional yarn. The reason for this
is stated to be as a consequence of the higher level of inter-fiber friction due to the better
contact between the parallel staple fibers bound and compressed by the wrapping
filament.
• Elongation at break is higher in the case of wrap spun yams than in the case of
conventional ring spun yarns.
• A further important property possessed by wrap spun yarns is a lack of torsion. The zero
twist of wrap spun yams reduces problems of spirality.
Economics of wrap spinning
• The costs of package doffing during wrap spinning are lower than
in ring spinning due to the longer running lengths in the former case.
• Due to the lower yam tension and the even distribution of the
wrapping twist, the yam breakages during wrap spinning are lower
than for ring spinning by a factor of 2 to 3.
• During wrap spinning, patrolling and supervision is more
conveniently carried out due to the lower number of spindles
employed. It is therefore, reasonable to assume that wage costs will
be lower for wrap spinning.
• In the production of yams of a high linear density, the ratio of
spindle price to production are more favorable in the case of wrap
spinning.
• In conclusion it Is stated that, when producing yams of a relatively
high linear density, wrap spinning can compete with ring spinning
economically. However, this does not necessarily follow in the case
of fine yams.
Advantages of wrap spinning
Many advantages are claimed for wrap-spun yams when compared to conventional ring
spun yarns the most important of which are the f0llowing:
• Greater bulk
• Improved cover in pile fabrics
• Softer handle
• Higher absorbency
• Greater strength
• Higher elasticity
• Less hairy
• Simplicity of operation
• Higher efficiency
• Ability to "engineer" specific requirements
• Requires fewer fibers per cross-section, therefore, coarse fibers can be spun into finer
linear densities.
• Increased production
• Favorable costs per unit of production
• Lower energy costs • Lower overall investments
• Less floor space required
• Greater scope and versatility
• Less spinning waste
Disadvantages of wrap spinning
• It seems clear that wrap spinning has much to offer in many areas, and has been
receiving much attention in recent years.
• However, not all reports have been positive. There are two purely textile facts
limiting the filament yam spinning technology for articles made of flat yams.
• In the first place it is noted that the filament share of a flat fabric surface
becomes visible to available extent and leads to glazing effects which are
considered unpleasant.
• This weakness could be compensated for by using fancy yams, but they are
very dependent on fashion.
• Secondly it is stated, that according to certain textile labeling acts the type and
content of the filament has to be stated, which is a psychological hindrance with
the result that technically superior fabrics fail to be accepted by the consumer.
• This can be overcome, however, if for example wool or even more precious
fibers are combined with silk as filament yarn, or by employing a water soluble
filament wrapper.
End uses of wrap yarns
•End uses of wrap yarns Knitted ladies
tides
•End uses wrap yarns Knitted ladies shirts
•End uses wrap yarns Knitted fancy cloths
•End uses wrap yarns Knitted Upholstery
End uses of wrap yarns
•End uses of wrap yarns Elastic fabrics
•End uses of wrap yarns Tufted carpets
•End uses of wrap yarns Male Shirting
•End uses of wrap yarns Velour fabrics
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