Yarn Manufacturing 2

Spinning of man made fibers and their

blends
By
Md. Abu Sayed
 Blending

• In spinning when various fibers of different or same grades are kept together that
is termed as blending . It normally mixes fibers of different physical properties to
ensure a consistent finished products.
• Two or more fibers are combined in one fabric to bring out best qualities of each.
Example: In a cotton/ polyester blend cotton supplies softness and breathability ;
polyester supplies strengths and easy care advantages.

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 Types of blending
1) Intimate blending:
Mixing of fibers of two different types or of different characteristics before carding is
called intimate blending. In this types of blending fibers are mixed more vigorously.

2) Draw frame blending:

When blending is done in draw frame it is called draw frame blending. This is
most famous blending technique used for the production of blended yarn of two
different fibers. The most part blending of the natural and the synthetic fibers is
still carried out in sliver form on the draw frame. This provides best blends in the
longitudinal direction. Up to the draw frame each materials can be processed
separately on the machine best suited for it . For this blending the material is
processed three times on the draw frame by suitable arrangement of the sliver
cans of the both types of fibers.

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 Objects of blending
Improvement of functional properties:
A 100% single yarn cannot impart all the desired properties to a fabric. For example 100% viscose
rayon suffer from low tensile strength, crease resistance, low abrasion resistance.
Similarly 100% polyester fabric are not desirable as they are prone to static accumulation ,melting
and pilling . It is moisture resistant, difficult and expensive to dye and Have poor handle
.These attribute of polyester and viscose can be reasonably Neutralize by addition of certain
percentage of each fibre.

Improve process performance:

Some fibres like polyester are quite troublesome to work specially at cards. Addition of
fibre like cotton or viscose rayon in previous process has been seen to facilitate the
smooth carding of such fibres .
The blending of of man made fibre which are longer And Finer to cotton which is
shorter influences the spin ability as well as productivity.

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Economy :
The price of man-made fibre is much more stable than that of natural fibres like
cotton. Blending could also used for reducing cost. For example a fibre like polyester
which can be blended with cotton for producing specific yarns with reduced raw
material costs.

Fancy Effect:
Fibre with a variety of colour mixture or Shades can be produced by blending different
dyed fibres at the blow room, draw frame or roving frame.

Aesthetics:
The aesthetics of a fabric can be developed by selecting special blend components and
their properties .

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 Objects of P/C or T/C blending
Certainly cotton fiber posses some important properties like
-Comfort ability
-Softness and smoothness
-Breathability
But it suffers from some disadvantages like
- Low strength
-Low crease resistance
-Much time required to dry after washing.
-Ironing is required before use
-shrinkage problem
-Costly
On the other hand , polyester fiber is having
-High crease resistance
-Higher strength
-Easy washing property
-Less shrinkage
-Less cost
So, it is obvious that if the two fibers are blended and processed together a fabric of desirable quality will be
produced and this is the main objective for which polyester and cotton fibers are blended with each other .
Abu sayed
 Polyester-cotton blending in draw frame

Although blending at blow room gives more homogeneity cotton polyester blending is
done most commonly in D/F stage. Because –
1) Polyester fiber does not contain trash like cotton fiber. So polyester fiber needs no
cleaning operation . Only opening operation is required. Sometimes it is required
to remove short fibers and neps from cotton by combing operation. This is why
cotton-polyester blending is done at D/F stage in order to avoid unnecessary
beating and cleaning.
2) Again overbeating of polyester causes strength loss and neps generation.
3) As polyester has fluffy property, excessive pressure is required for polyester
processing. Cotton lap is used directly at carding, but polyester polyester cotton
lap have to give more pressure at time of lap preparation.
4) Cylinder setting of carding for cotton = 5/100’’ . If polyester is processed in this
setting , it increases very high fire hazard risk.
5) Spin finish of polyester fiber may damage wire of different component.

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 Polyester and cotton blend spinning
flow chart
B/R blending flow chart:
SdsPolyester bale nCotton bale

SdsStock mixing
(As per ratio)
SdsBlow Room
SdsCarding
SdsDraw frame
1,2,3
xSimplex

SdsRing frame

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Draw frame blending flow chart:
cotton
Blow Room Polyester
Blow Room
carding

Pre comb draw frame Carding

Draw frame 1,2
Lap former

comber

D/f 1,2,3

Simplex

Ring frame

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 Important properties of fiber to be considered for proper
blending

Important properties of fiber to be considered for blending are-

1) Staple length
2) Fineness
3) Strength
4) Crimp
5) Spin finish
6) MR%

1) Staple Length:
It is an important factor for blending. In case of cotton-polyester blend the different
between the staple length of two fibers should be minimum. Normally polyester
filament is cut to 32-51 mm length, but during blending with cotton 28-38 mm
polyester fiber is most commonly used.

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2) Fiber fineness:
Fiber fineness is the most important fiber property influencing the spinning limit
,which is largely determined by the no of fibers in the yarn cross section . Fiber
fineness affects the following factors:
1) Spinning limit( No of fiber/ X section).
2) Yarn evenness.
3) Yarn tenacity.
4) Yarn performance.
1.2-1.5 denier polyester is ideal for light weight fabric.
2-3 denier polyester is ideal for medium and heavy weight fabric.
The ratio of the fiber length & fiber denier should be unity
Fiber length in inch(L)/ Fiber denier(D) = may be≥ 1
If the ratio is >> 1 , fibers are liable to get damage in opening and carding.
If the ratio be <1 , tends to increase the frequency of end breakage and required high
tension.
3) Fiber strength:
Minimum fiber strength should be 6-7 gpd(grams per denier). In case of blend
compatibility of the blend constituents it is important to derive the minimum fiber
strength utilization.
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4) Crimp:
natural fiber contain little amount of crimp, but MMF has no crimp. So MMF is crimped
to get wavy nature for spinning to ensure better blending properties. Crimp in MMF
therefore helps in their satisfactory processing through the different spinning operation.

5) Spin finish:
Due to spin Application of various types spin finish , the luster of polyester fibers may be
bright or semi-dull or dull. So Adjust color with cotton semi-dull polyester is used during
cotton polyester blending.

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 Changes required to process 100% polyester and
acrylic in cotton processing machinery
Polyester
1) Mixing section:
A large no of bales to be used for mixing
2) Blow room:
a)No of beating points- As less as possible, normally one beating point.
b) Calender roller pressure: 20% higher than cotton system.
c) Setting: Beater to grid bar - wider
Grid bar to grid bar – closer
d) Beating speed: Lower than cotton system
cotton: 300-800 rpm
Polyester : 500-600 rpm
e) Pressure per side: 20% higher than that of cotton system
Cotton: 2200-2500 lbs/side
polyester: 3000 lbs /side
f) scutcher: single cage scutcher is preferred
g) Lap wt: less than cotton( normally 9-11 oz /yds)
h) Lap length : less than cotton.
I)Lap should be wrapped by polythene sheet or paper for long time storage.
J)4-6 lower twisted roving to round up lap.
k) CV% of lap: should be lower (1-1.5%)
l) Room condition to be maintained - Temp: 27 ◦c
RH: 60-65%
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 Acrylic
1) Mixing section:
A large no of bales are taken and tuft size must be as small as possible.
2) Blow room:
a)No of beating points- As less as possible, normally one beater is used.
b) Calender roller pressure: Must be more than 4000 lbs.
c) Setting: Beater to grid bar - wider
Grid bar to grid bar – closer
d) Beating speed: Lower than cotton system
e) Anti lap licking device must be used because of low density , swelling of lap and excess lap
licking occur.
f) Lap length and lap wt/yds must be less than cotton and polyester.
g)Lap should be wrapped by polythene sheet or paper for long time storage.
h)4-6 lower twisted roving to round up lap.
I) Lap weight variation should be 1-1.35%
J) Room condition to be maintained - Temp: 27 ◦c
RH: 60-65%

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 Polyester
Carding:
1. Metallic wire clothing is preferred.
2. Angle of wire: More than cotton system.(≥90 ̊)
3. Taker in speed : less than cotton. For cotton: 600-900 rpm
polyester : 500-600 rpm
4. Wire density: less density, less wire height.
5) When tinting agent is used , frequent washing of taker in is necessary.
6) Sliver wt: 250-300 gr/ 6yds[ 40-50 gr/ yds]
[ for cotton 70-80 gr/yds]
7) Mote knife setting: Wider
Grid bar setting: closer
8) Card setting: ( Unit thou)
Mote Front Taker in to Cylinder to Cylinder
fiber knife to roller to cylinder flat to doffer
taker in taker in
1 12,15 10 7 10,10,9,8 5
Cotton(14 ")
Polyester 15,15 15 7 30,30,30,30 4
(32-38mm) Abu sayed
9) Flat speed: 1-2 inch/min
10) Doffer speed: 12-15 rpm
Acrylic
Carding:
1) Metallic wire clothing is preferred.
2) Angle of wire: More than cotton system.(≥90 ̊)
3) Taker in speed : less than cotton. For cotton: 600-900 rpm
Acrylic : 500-600 rpm
4) Wire density: less density, less wire height.
5) When tinting agent is used , frequent washing of taker in is necessary.
6) Sliver weight: less( 40-45 grains/yds)
7)Card setting:
Mote knife to Feed plate to Taker in to Cylinder to flat Cylinder to
taker in taker in cylinder doffer

15,15 15 7 30,30,30,30

9) Larger coiler tube is used. Abu sayed

 Polyester
4) Draw frame 5) simplex 6) Ring frame
1) D/f passage: normally 3 passages 1. Drafting system: 4 over 4 double 1) Drafting system: Double apron
apron drafting system is preferable. drafting system is preferable.

2) Roller weighting: 20% higher 2) Roller weighting: 20% higher 2) ) Roller weighting: 20% higher
than cotton system than cotton system. than cotton system.
Front: 12.15 kg Front: 14kg
2nd: 15 kg Middle: 10kg
3rd: 18 kg Back: 10-14 kg
Back: 20kg
3) Roller setting: Slightly wider 3) R/r setting: slightly wider 3) ) R/r setting: slightly wider

4) Cot roller hardness : 83-85 ̊ 4) 80-85 ̊ shore 4) 80-85 ̊ shore

shore( Slightly less)

5)Sliver wt: lower than cotton 5) a) Roving count= 120-180 5) TM= 3.4-4
system grain/30yds) ( 4-6 grain/yds)
b) TM= 0.65-0.8

6. Antistatic treatment is necessary 6) Antistatic treatment is necessary 6) Antistatic treatment is necessary

7. Production speed 20% less than 7) Spindle speed = 600-800 rpm 7) Speed less than cotton system
Abu sayed
cotton system
 Acrylic
4) Draw frame 5) simplex 6) Ring frame
1) D/f passage: normally 3 passages 1. Drafting system: 4 over 4 apron 1) Drafting system: Double apron
drafting system is preferable. drafting system is preferable.

2) Roller weighting: 20% higher 2) Roller weighting: 20% higher 2) ) Roller weighting: 20% higher
than cotton system than cotton system. than cotton system.
Front: 14kg
Middle: 10kg
Back: 10-14 kg

3) Roller setting: Slightly wider 3) R/r setting: slightly wider 3) ) R/r setting: slightly wider

4) Top roller hardness : 83-85 ̊ 4) 80-85 ̊ shore 4) 80-85 ̊ shore

shore( Slightly less)

5)Sliver wt: lower than cotton 5) a) Roving count= 120-180 5) TM= 3.4-4
system grain/30yds) ( 4-6 grain/yds)
b) TM= 0.65-0.8
6. Antistatic treatment is necessary 6) Antistatic treatment is necessary 6) Antistatic treatment is necessary

7. Production speed 20% less than 7) Spindle speed = 600-800 rpm 7) Speed less than cotton system
cotton system
8) a) RH : 60% 8) a) RH : 60% 8) a) RH :50- 60%
b) Temp: 27 ̊ c b) Temp: 27 ̊ c b) Temp: 27 ̊ c
Abu sayed
 Polyester and Acrylic
Winding section:
1) Can be wound on usual winding m/c.
2) Tension of tensioner should be kept more to compact the bobbin.

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 Problems of processing of man made fiber

In blow room:
The main problems arising in processing of man made fibers in blow rooms are:
- Static electricity : can be reduced by keeping lower speed and using anti static agent.
- Deposit of spin finish or marking color on machine components. Have to choose
good spin finish for proper processing of yarn.
- Overlong passage that lead to bundling of flocks and finally to neps.
In carding:
-The wrong spin finish can create chocking of the clothing.
-If processing is carried out while moisture content of the room is too low, the fibers
become dry and static charge accumulate.
- Higher roller and cylinder revolution usually give a cleaner web but also lead to
greater shortening of fibers and possibility also to thermal damage.

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The draw frame:
- Accumulation of static charge where air is too dry.
- Laps can be caused by smearing of poor spin finish and also by splitting out of edge fibers
by badly maintained top roller.
- Blockage of guide passage are caused partly by static electricity , but mainly through the
deposit of spin finish.
- Thermal damages is caused by heating of top rollers. This primarily affects dyeing
behavior and defects mainly visible after dyeing. E.g PES begins to change structure at
temperature of 80 ̊ c and top roller temp reach 80 ̊ c even at speed of 400 m/min.

The following are advisable to minimize the problems of processing at draw frames:
- top rollers coating treated with anti-static and avoidance of damage of the coating.
- Keeping roller hardness 75-83 ̊ shore. As softer coating tend to lap more easily.
- By periodic washing of the coating and smoothing of the coating by an acid treatment or
UV- light irradiation.
- By reducing delivery speed specially for processing of fine fibers.
- Blockage problems can be dealt with only by periodic cleaning.

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The speed frame/simplex:
-once again the problems arise mainly from spin finish. Long subjection of the top roller coating
and aprons to spin finish can be lead to swelling of those elements and to formation and
deposits.
- The apron often become smeared with spin finish and become sticky. So it should be
washed from time to time.
- Flyer crowns with sharp edges lead to roughening of the roving. For this plastic or rubber
crowns with 5 or 8 ribs are advantageous.
- Flyer with highly polished chromed surfaces give a high generation of fly . Unpolished
surfaces are suitable.
- The roving will have too many thick and thin places or even slubs due to
 Exit opening of drafting arrangement too narrow.
 Condenser too narrow
 Top roller loading inadequate.
 Feed stock sliver too coarse.
 Damaged apron.

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The ring frame:
Problems arising in the spinning of synthetic fibers on the ring frame can be caused by fibers,
the machine , the roving or the air conditioning.
1) In relation to the fibers , the relevant factors are
 Poor spin finish.
 Low plasticizing point which leads rapidly to thermal damage
2) On the machine side the factors to be considered are:
 Incorrect setting
 Wrong break draft
 Top roller loading too low
 incorrect or damaged top rollers and guide aprons.
 Incorrect or damaged ring or traveller.
 Inadequate centering of ring , spindle and thread guide.
 Excessive speed.
3) The problems in roving are :
 Hairiness level too high.
 Excessive unevenness
 Twist level too high

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4) In air conditioning system the moisture level may be:
 -Too low and help to form static electricity, roller lapping, hairiness
 Too high and this cause smearing of spin finish , stickiness of spinning elements and lap
formation.
5) In processing of synthetic fibers is the risk of thermal fiber damage on the balloon control
ring and in the region of ring and traveller. The results are:
 Reduction of yarn strength.
 Lowering of yarn elongation.
 A rise in ends down and dust level.
 Slub formation when rubbed over thread guide.

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