MANUFACTURING PROCESS OF YARN

1. Blow room:
1.1 Introduction
In this room the air use for cleaning and operating of machines to transfer the material
step by step in a sequence from blow room to card, so that’s why it’s known as blow room.
The temperature in blow room is 105-degree F / 40-degree C. In blow room, the waste is
removed like micro dust particles, seeds. Rapid scan is done by passing air suction to
eliminate dust particles from cotton.
1.2 Objective:
a) Opening
b) Cleaning
c) Mixing / blending
d) Micro dust / trash removal
e) Uniform feed to carding machine
1.3 Blendomate
Cotton bales are brought together and fit to blendomate. The blendomate remove layer
after layer and separate the cotton, and these separated cottons are manually loaded to
carding. The blendomate move forward and backward, up and down. Bales are set on both
side of blendomate. Blendomate also rotate right and left to suck material with the help of
biter.

2. Carding
2.1 Objective:
a) To open the flocks in to fiber
b) Cleaning / elimination of impurities
c) Neps removing
d) Fiber blending
e) Sliver formation (A thick thread like)

The cotton flocks are manually loaded / transferred to the carding machines. 6 carding
machines installed at this unit. The main purpose of carding is to check the quality and
thickness of the lank and these lank loaded in drum. One drum can accommodate 9000m of
lank.
2.2 Eveners
Eveners are used to ensure consistent yarn quality by maintaining uniformity in the
production process. Their primary function is to correct irregularities in the feed material and
provide an even and consistent output. The benefits of using eveners reduces waste by
minimizing fiber loss, improves yarn quality, maintain uniform thickness and strength.
Advanced eveners with automation and feedback control system are installed to achieve high
precision and efficiency.

3. Drawing breaker
Drawing is the operation by which slivers are blended, doubled and levelled. In short
staple spinning the term is only applied to process at a draw frame. In drawings slivers are
elongated when passing through a group of pair rollers. Each pair is moving faster than
previous one. This permits combing, drawing and elongating of several slivers to make them
strong and uniform. Where silvers are loaded in breaker which weighs 40 kg. The drawing
breaker to lap former process is a part of the preparation stage in the production of high-
quality yarn. Where the drawing breaker is the first stage of the drawing process and is
responsible for combining multiple slivers in to one while improving fiber alignment.
Key functions:
 Doubling: Multiple carded slivers are fed together usually 6-8 to reduce irregulates
and increase uniformity.
 Drafting: The slivers are drawn through rollers, which elongate and thin them while
aligning the fibers more parallelly.
 Blending: If slivers from different fiber types are used, the drawing breaker blends
them effectively.

4. Lap former
The lap former is the next stage that converts the sliver in to a lap for the combing
process. It is essential for removing short fibers and neps during combing.
Key functions:
 Drafting and layering: The slivers are drafted further and laid down in to a continuous
sheet or lap.
 Compaction: The lap former compacts the fiber sheet in to a roll, ensuring uniform
weight per unit length.
 Feeding to combing machine: The laps are made to specific dimensions and thickness
to match the combing machine requirements.

5. Lap trolley
Lap trolley is a specialized transport system used to move the prepared laps from the
lap former to the combing machines.
nipper
 Design: Trolley are designed to hold securely the lap rolls, ensuring rolls do not get
damaged / loose their uniformity while transporting.
 Capacity: Trolleys can accommodate four laps to other department on the production
setup.
 Ease of handling: Equipped with wheels for smoother and efficient transport across
the mill.

6. Combing machine
The combing machine process is a critical step in yarn production, particularly for
high quality yarns.it improves the uniformity, strength, and smoothness of the yarn by
removing short impurities and aligning the longer fibers in parallel. Production of finer and
smoother yarns suitable for premium fabrics.
Components of a combing machine
 Feed rollers: deliver the lap to the combing machine
 Nipper assembly: holds the slivers tightly during combing
 Top and cylinder comb: perform the actual combing by eliminating short sliver
and impurities
 Detaching rollers: collect the combed sliver
 Coiler: condenses and delivers the combed sliver for the next process.

Outputs of the combing process

 Combed sliver: A highly uniform clean sliver with aligned long fibers
 Noil: The short sliver and waste removed during combing (used in lower grade
products or waste management)
Advantages of combing
Improves yarn strength, smoothness and evenness thus enhances fabric quality this enables
production of fine and high-count yarns for premium textiles.

7. Drawing finisher
It controls the variation and makes uniform density of 80 grains per yard of sliver
Objectives of drawing:
 To straighten the crimped, curled and hooked sliver.
 To make the sliver parallel to their neighbors.
 To improve uniformity of slivers by drafting and doubling.
 To remove dust from slivers.
 To blend raw materials of same hank perfectly.
 To reduce weight per length unit of sliver.
8. Simplex machine
A Simplex machine, also known as roving frame or speed frame, plays a crucial role
in spinning mills by converting sliver in to roving and the twisted roving is wound on to
bobbin. Recent advancement in simplex machine have focused on enhancing fully
automation, efficiency, user friendly.
8.1 Features of modern simplex machine:

 Automation: Contemporary simplex machines incorporate intelligent automation

controls, managing processes such as drafting, twisting, winding and forming through
computerized systems. This automation reduces manual intervention and enhances
precision.
 High efficiency: Latest simplex machines boast production capacities up to 99.9%
ensuring optimal efficiency in yarn production.
 Flexibility: Modern simplex machine can handle a variety of slivers types including
cotton, wool and synthetic fibers making them versatile for different spinning
requirements.
8.2 Objective:
 Drafting
 Twisting
 Winding
 Packaging formation

8.3 Process of simplex machines:

It involves several key steps designed to convert sliver in to roving, which is a thin
strand of fibers with a slight twist. 192 spinned guard
 Feeding of sliver:
o Input: Drawn slivers are fed in to the machine through creel strands, which
hold multiple cans of slivers.
o The sliver is drawn in to the drafting system for further processing.

 Drafting:
o The drafting system reduces the thickness of sliver by drawing it out to the
desired linear density.
o Latest machine uses accurate drafting rollers and electronic controls to ensure
consistent sliver alignment.

 Twisting:
o A slight twist imparted to the drawn sliver to provide strength and coherence
to strand.
 o The amount of twist can be adjusted based on the requirements of the end
product.

 Bobbin formation:
o The twisted roving is wound on to bobbins for easy handling during the
spinning process.
o Automated system control bobbin rotation and ensure uniform winding
without need of manual adjustments.

 Automatic doffing:
o After the bobbins are filled, an automated doffing system removes them and
replaces them with empty bobbins.
o This reduces downtime and increases efficiency.

 Monitoring and quality control:

o Sensors and monitoring systems continuously check for irregularities in the
roving such as thickness variations or breaks in slivers.
o Faults are automatically detected and corrected. This ensures high quality
output.

 Output:
o The finished bobbins of roving are delivered for further processing in the
spinning machine.

9. Spinning
In modern spinning machine the transformation of slivers in to yarn is achieved
through advanced technology in machinery that enhances efficiency, premium quality and
flexibility. The latest spinning machines incorporate cutting edge technologies to meet the
diverse demands of the textile industries. Six spinning machines are installed and being
utilized where 49 drums are converted in to 100 cones at a single time process.
9.1 Key spinning technologies:
 Ring spinning machine
o High speed ring spinning frame: This machine offers high speed operation
with energy efficient components, ensuring high quality yarn production.
 Rotor
o This machine features advanced automation and high-speed capability suitable
for producing coarser yarn counts efficiently.
9.2 Link conner:
 In modern spinning mills the link conner is an advanced automated winding solution
that directly connects the ring spinning frame to the automatic winder. This
integration stream lines the yarn production process by eliminating intermediate
manual handling, there by increases efficiency, productivity which results in premium
 quality yarn production. The process of converting 50gram cops of thread in to larger
packages like 2.5kg using a link conner system.

 Advantages of using link conner for cops to cones:

o Uniform packaging: Ensures consistent yarn density and tension across the
cone.
o Efficiency: High speed winding with minimal manual intervention.
o Reduced waste: Automated systems minimize yarn wastage during transfer
and splicing.
o Labor savings: Automation reduces the need for manual handling for cops and
cones.

 Features and benefits:

 Direct connection: The link conner system establishes a seamless link between the
spinning frame and automatic winder. Bobbins are automatically transferred from the
spinning frame to the winder without manual intervention, reducing labor
requirements.

 Automation and labor reduction: By automating the transfer and winding processes
the link conner system significantly reduces the need for manual labor, leading to cost
savings allowing personnel to focus on other critical task.

 Applications:

The link conner system is versatile and can handle various yarn types and counts,
making it suitable for a wide range of textile products. Its ability to maintain consistent
yarn quality and enhance production efficiency makes it a valuable assest in modern
spinning operations.

10. Yarn conditioning plant

Yarn conditioning plant is a crucial component in modern spinning mills. It is
designed to improve the quality of yarn by adding controlled moisture and reducing internal
stresses developed during spinning. This process enhances the yarn’s performance in
subsequent operations like weaving and knitting.
10.1 Process in a yarn condition plant:
 Loading:
o Yarn packages (cones, hanks, bobbins) are placed on a stand and moved in to
the conditioning chamber.

 Vacuum and preheating:

o The chamber is sealed, air is evacuated to create a vacuum, preheating
removes excess air and prepares the yarn for moisture absorption.
  Steam injection:
o Steam is injected in to the chamber at controlled pressure and temperature to
reach the desired moisture regain level.

 Cooling and drying:

o After conditioning the yarn is cooled to ambient temperature to stabilize the
added moisture.

 Unloading:
o Conditioned yarn is removed from the chamber and sent for UV light quality
check and then packaging.

10.2 Purpose of yarn conditioning:

 Moisture regain:
o Restore moisture lost during the spinning process, bringing the yarn to its
optimal moisture content.
o Prevent breakages and enhances flexibility.

 Relaxation of stresses:
o Reduces tension in yarn leading to improved uniformity and strength.

 Improved yarn properties:

o Enhances elongation, strength, softeners of the yarn.
o Reduces snarling and improves the efficiency of subsequent process

 Weight gain:
o Controlled addition of moisture increases the yarn weight, improving its
market value.