Necessities of alternative spinning
• Cost (related to production speed, automation, package size, number of
machine: Ring, Roving frame and Autoconer)
• Quality
Cost:
• Yarn tension directly proportional to the square of traveller speed or spindle speed. Its occurs
end breakage.
• Higher speed led to friction between traveller and ring cup as third power of spindle rpm.
• So creates more heat generation and fly formation. It leads to end breakage and impede process
control.
• Higher speed also leads thermal damage of traveller.
• Higher speed increases power consumption disproportionately
• Smaller size package also a problem relating to lower production. Ring cup diameter is limited by
many factors like yarn tension, power consumption, speed etc. Spindle speed is inversely
proportional to the square root of ring diameter but linearly proportional to the square root of
traveller speed.
• Higher number of machine (more space, more labour). Moreover roving frame is required
because of draft capacity of roller drafting system.
• Automation can reduce labour cost but it also reached a plateau.
Necessities of alternative spinning
• The textile industry has witnessed many exciting technological innovations
in spinning machines since the late 1960s.
• Ring spinning offered little scope for further development and impeded all
efforts directed towards automation of the whole spinning process.
• The power consumption was also seen to be disproportionately high at
faster spindle speeds.
• Machinery manufacturers looked for alternatives to ring spinning which
seemed to have reached a plateau in regard to maximum production
speeds.
• These disadvantages laid the foundation for the development of alternative
methods of spinning, particularly for higher production speeds.
Necessities of alternative spinning: Quality
• Strength
• IPI
• Periodic fault
• Hairiness
• Twist variation
• Count variation
Count: 22 Ne
Ring frame speed: 14,500
Rotor speed: 125,000
What are the alternative technologies
❑ Super Economic: Rotor, Airjet, Vortex, Wrap, Friction
❑ Premium quality: Compact spinning
Compact Spinning: Technology
.
Compact Spinning: Technology
# L = Width of the fiber band
Twist flows from the # Twisting tringle
ring/traveller to front roller
nip point. The spinning
tension also acts along the
full length from ring/traveller L
to nip point. Jut after the nip
point fibres still not get
twisted and the spinning
tension causes frequent end
breakage at the spinning
triangle. Breakage occurs
because of presence of weak
points in the zone.
Compact Spinning: Technology
Too short triangle (a):
- More number of fibres can
not bend to such an extent
to attend in the twist. So
fuzzy/hairy fibers protruded L
from the yarn body. It also
cause more fly because of
having unbound free fibers.
But this condition offer
limited weak points
(because short length fibers
as well can reach to twisting
point). (In summary: Fiber
bending difficult but short
fibers can attain)
Compact Spinning: Technology
Too long spinning triangle
(b):
- More number of fiber can
bend into twisting point. L
Less fly. Less hairiness.
Smoother yarn. But offer
more weak point hence
more end breakage. (In
summary: Fiber bending
easy but less chance for
short fibers to reach twist
point)
Compact Spinning: Technology
.
https://www.cotton.org/beltwide/proceedings/getPDF.cfm?year=2000&paper=383.pdf
Compact Spinning: Technology
.
https://www.cotton.org/beltwide/proceedings/getPDF.cfm?year=2000&paper=383.pdf
Compact Spinning: Technology
.
Compacting systems
• Following methods are used by machine manufacturers to condense the
fiber strand:
1.Aerodynamic condensing (COM 4 by Rieter, Suessen Elite by Suessen,
CompACT3 by Zinser)
2.Mechanical condensing (COMPACTeasy by Rieter)
3.Magnetic condensing (RoCoS: ‘RotorCraft compact spinning’ by Hans
Stahlecker of Rotorcraft Maschinenfabrik Switzerland)
The most important requirement for perfect compact yarn is complete
parallel arrangement of fibers and close position before twist is imparted.
Compacting systems: Pneumatic
.
Compacting systems: Pneumatic
.
X y
P Q
Z R
Compacting systems: Pneumatic
Com4 Air guide
.
L3T1_
Mechanical: COMPACTeasy by Rieter
• The compacting device COMPACTeasy is a mechanical
compacting system which allows real compacting
without additional energy consumption thanks to the y-
channel in the Compactor. All standard raw materials
such as cotton, man-made fibers and their blends can
be processed with COMPACTeasy.
• The device consists of the retainer holding the front top
roller and the smaller COMPACTeasy Roller. The spring
easy-Spring presses the COMPACTeasy Roller onto the
bottom roller. Between the two top rollers there is the
Compactor with the y-channel and the preceding Pin.
• The Compactor is pressed against the bottom roller by
the Compactor spring with a low spring force. This
causes considerably less wear on the Compactor than
magnetically loaded compacting elements. (May be this
is one difference between mechanical and magnetic https://www.rieter.com/fileadmin/user_uploa
devices). d/products/documents/systems/end-
spinning/rieter-compacteasy-brochure-3340-
v2-94819-en.pdf
Mechanical: COMPACTeasy by Rieter
• The compacting device COMPACTeasy is a mechanical
compacting system which allows real compacting
without additional energy consumption thanks to the y-
channel in the Compactor. All standard raw materials
such as cotton, man-made fibers and their blends can
be processed with COMPACTeasy.
• The device consists of the retainer holding the front top
roller and the smaller COMPACTeasy Roller. The spring
easy-Spring presses the COMPACTeasy Roller onto the
bottom roller. Between the two top rollers there is the
Compactor with the y-channel and the preceding Pin.
• The Compactor is pressed against the bottom roller by
the Compactor spring with a low spring force. This
causes considerably less wear on the Compactor than
magnetically loaded compacting elements. (May be this
is one difference between mechanical and magnetic https://www.rieter.com/fileadmin/user_uploa
devices). d/products/documents/systems/end-
spinning/rieter-compacteasy-brochure-3340-
v2-94819-en.pdf
Mechanical: COMPACTeasy by Rieter
https://www.rieter.com/fileadmin/user_uploa
d/products/documents/systems/end-
spinning/rieter-compacteasy-brochure-3340-
v2-94819-en.pdf
Magnetic compacting system
Comparison of Conventional Ring, Mechanical Compact and Pneumatic Compact Yarn Spinning Systems
Magnetic compacting system
.
Comparison of Conventional Ring, Mechanical Compact and Pneumatic Compact Yarn Spinning Systems
Magnetic compacting system
.
Comparison of Conventional Ring, Mechanical Compact and Pneumatic Compact Yarn Spinning Systems
