Short Staple Yarn Manufacturing

by McCreight, Dan J.; Feil, Ralph W.; Booterbaugh, James H.; Backe, Everett E.

• ISBN13: 9780890898536
• ISBN10: 0890898537
• Format: Paperback
• Copyright: 1997-10-22
• Publisher: Carolina Academic Press

Table of Contents

Foreword	xiv
Acknowledgments	xvi
Introduction	3	(8)
The Integrated USA Textile Industry	3	(2)
About This Textbook	5	(2)
Yarn Numbering Systems	7	(4)
Indirect or Reciprocal Yarn Numbering Systems	7	(1)
Direct Yarn Numbering Systems	8	(2)
Further Yarn Numbering Information	10	(1)
Fibers Used in Short Staple Spinning	11	(6)
Natural Fibers	11	(2)
Cotton	11	(1)
Flax	12	(1)
Manufactured (Man-Made) Fibers	13	(4)
Polyester	13	(1)
Rayon	14	(1)
Acrylics	15	(2)
Typical Process Steps for Short Staple Yarn Manufacturing	17	(44)
General Processing Functions	17	(36)
Bale Storage and Bale Management	18	(1)
Bale Laydown	19	(1)
The Card Room	19	(1)
Bale Feeding	20	(1)
Opening and Cleaning	21	(12)
Mixing of Fibers from Bales in the Laydown	33	(1)
Blending of Different Fiber Types	33	(1)
Carding	34	(1)
Lap Preparation and Combing	34	(7)
Drawing	41	(1)
Roving	42	(1)
Spinning Room	43	(1)
Ring Spinning	43	(9)
Rotor Spinning	52	(1)
Air Jet Spinning	52	(1)
Winding	53	(1)
Control of Ambient Conditions	53	(8)
The Opening Room	61	(62)
General Functions and Goals of the Opening Room	61	(62)
Bale Laydown	62	(10)
Critical Factors in Virgin Stock Feeding	72	(10)
Opening of Fiber Tufts	82	(9)
Blending and Mixing of a Single Fiber Type	91	(4)
Intimate Blending of Different Fiber Types	95	(3)
Cotton Cleaning	98	(12)
Assessing and Minimizing Fiber Damage in Opening Room Processes	110	(2)
Example Plan for Effectively Analyzing a Modern Cotton Opening Line	112	(3)
Reworkable Fiber Processing	115	(4)
Opening Room Benchmarks	119	(2)
Opening Room Machinery Manufacturers	121	(2)
The Carding Process	123	(56)
The Feeding of Stock to the Card	123	(9)
Introduction	123	(1)
Stock Transport to the Chute	124	(2)
System of Transport Ducts to Chutes	126	(2)
The Feed Chute	128	(4)
The Card and Its Standard and Optional Components	132	(30)
Multiple Lickerins	137	(1)
Revolving Flats and Stationary Flats	138	(3)
Doffer	141	(1)
Web Travel from Stripping Roller to Coiler	142	(4)
Crush Rollers	146	(2)
Webs and Web Condensers	148	(1)
Trumpets and Calender Rolls	149	(1)
Card Drives	150	(1)
Autoleveling	151	(4)
Autodoffing	155	(2)
Metallic Wire Clothing	157	(5)
Fiber Hooks Formed at the Card	162	(1)
Waste Removal and Vacuum Cleaning at the Card	163	(2)
Tendem Carding	165	(2)
Monitoring of the Carding Process	167	(1)
Critical Factors for the Carding Process	168	(9)
Card Mat Openness	168	(1)
Card Mat Weight	169	(2)
Lickerin Zone	171	(1)
Waste Removal Uniformity	172	(1)
Flat Strip Weight	172	(1)
Cylinder and Flat Wire	173	(1)
Doffer Wire Loading	173	(1)
Tension Draft on Web and Sliver	173	(1)
Slub Generation	174	(2)
Production Rate and Sliver Weight	176	(1)
Quality Benchmarks for Card Slivers	177	(1)
Manufacturers of Carding Machines	177	(2)
The Drawing Process	179	(30)
Fiber Alignment in the Drawing Process	179	(3)
Purpose of Drawing	182	(4)
Fiber Straightening	183	(1)
Evenness of Drawing Sliver	184	(2)
Common Draw Frames in USA Industry	186	(1)
Main Parts of the Draw Frame	187	(6)
Creel	188	(2)
Drafting System	190	(1)
Sliver Condensing Section	191	(1)
Coiler Section	192	(1)
Suction System	192	(1)
Critical Factors for Optimal Drawing	193	(13)
Creel Zone Optimization	193	(2)
Draft Zone Optimization	195	(6)
Coiling Zone Optimization	201	(2)
Autoleveling Zone Optimization	203	(3)
Documenting Quality of Drawn Sliver	206	(1)
Benchmarks for Finisher Slivers	207	(2)
Combing	209	(28)
Definition of terms	210	(3)
Brief History of Comber Development	213	(1)
Comber Lap Preparation	213	(8)
Combing Cycle and Comber Mechanisms	221	(4)
High Production Combing Machines	225	(6)
Hollingsworth Model CA Comber	225	(2)
Rieter Model 7/6 and Model E70R Combers	227	(1)
Marzoli Model PX2 and PX80	228	(3)
Other Suppliers of Commercial Combers	231	(1)
Comber Setting and Elements	231	(4)
Half Laps	232	(1)
Self-Cleaning Top Comb	232	(1)
Test Methods at the Comber	233	(2)
Quality Benchmarks for Combed Sliver	235	(2)
Ring Spinning	237	(74)
Introduction	237	(1)
Objectives of the Spinning Process	238	(2)
Productivity and Market Share of Commercial Spinning Systems	240	(1)
The Roving Process	241	(18)
Introduction	241	(1)
Description of the Roving Frame	242	(2)
Creel	244	(1)
Drafting	244	(4)
Wind and Spindle/Flyer Drive	248	(1)
Stop Motions	249	(1)
Grommetts	250	(1)
Doffing	250	(1)
Roving Frame Settings	251	(2)
Determining Critical Draft of Roving Using the ITT Draftometer	253	(2)
Twist and Production Calculations	255	(3)
Critical Factors at Roving	258	(1)
Ambient Conditions	259	(1)
Quality Benchmarks	259	(1)
Machine Suppliers	259	(1)
The Ring Spinning Process	259	(43)
Description of the Ring Spinning Machine	259	(1)
The Creel Zone	260	(3)
The Drafting Zone	263	(7)
Critical Factors in the Drafting Zone	270	(6)
Twisting Zine-Ring Frame Geometry	276	(4)
Ring Spinning Winding Zone	280	(7)
Ring Spinning Production Rate	287	(1)
Ring and Traveler System	288	(3)
Spindle Drives	291	(3)
Automatic Doffing and Link Winding	294	(2)
Automated Ring Spinning	296	(1)
Fly Lint Control at Ring Spinning and Winding	297	(2)
Summary of Critical Factors in Ring Spinning	299	(1)
Checklist for Ring Frame Overhaul	299	(1)
Ring Spun Yarn Quality	300	(1)
Machine Suppliers	301	(1)
The Winding Process	302	(9)
Packages Produced at Winding	304	(1)
Components of the Winder	304	(5)
Winding Benchmarks and Critical Factors	309	(1)
Link Winders	309	(2)
Rotor Spinning	311	(62)
Spinning Mechanism	311	(3)
Fiber Separation	314	(1)
Fiber Transport	315	(1)
Fiber Reassembly	315	(2)
Twist Insertion	317	(2)
Wrapper Fiber Formation	319	(2)
Typical End Uses of Rotor Yarn	321	(1)
Advantages of Rotor Spun Yarn	322	(1)
Disadvantages of Rotor Yarn	323	(1)
Rotor Yarn Structure	323	(1)
Predominant Rotor Spinning Machines in the USA Industry	323	(3)
Raw Material Requirements	326	(7)
Cotton Properties	326	(4)
Synthetic Fiber Properties	330	(3)
Sliver Preparation	333	(4)
Machinery Description	337	(1)
Critical Spinbox Factors for Spinning Performance and Quality	338	(25)
Draft	338	(2)
Rotor Speed	340	(2)
Suction	342	(4)
Combing Roll Zone	346	(4)
Fiber Transport Channel	350	(2)
Rotor Zone	352	(6)
Yarn Withdrawal Zone (Navel and Doff Tube)	358	(5)
Critical Winding and Piecing Factors for Spinning Performance and Quality	363	(7)
Winding Zone	363	(6)
Automatic Piecer Consideration	369	(1)
Rotor Spinning Benchmarks	370	(3)
Air Jet Spinning	373	(52)
Air Jet Spinning Principle	375	(2)
Typical End Uses of Air Jet Yarn	377	(3)
Advantages of MJS Yarns	380	(2)
Disadvantages of MJS Yarns	382	(1)
Air Jet Yarn Structure	383	(3)
Raw Material Requirements for Air Jet Spinning	386	(7)
Synthetic Fiber Properties	386	(5)
Cotton Properties	391	(2)
Sliver Requirements for Air Jet Spinning	393	(3)
Sliver Evenness	394	(1)
Fiber Alignment	394	(1)
Slubs	395	(1)
Neps	395	(1)
Sliver Periodicities	396	(1)
Critical Factors for Yarn Quality	396	(22)
Draft Zone	398	(6)
Nozzle Zone	404	(12)
Winding Zone	416	(2)
Influence of Spinning Speed on Yarn Properties	418	(1)
Automatic Knotting/Splicing	419	(3)
Benchmarks for Air Jet Yarn Performance and Quality	422	(3)
Other Spinning Systems	425	(14)
Coverspun (Wrap Yarn)	425	(3)
Parafil (Wrap Yarn)	428	(2)
Hollingsworth Masterspinner (Friction)	430	(2)
DREF 3 (Friction)	432	(2)
The Bobtex Composite Spinning System	434	(1)
Murata Twin Spinner (Ply Spinning)	435	(1)
Suessen Plyfil (Ply Spinning)	436	(3)
Test Instruments and Quality Assurance Methods	439	(42)
Atmospheric Conditions in the Laboratory	439	(1)
Sampling	440	(1)
Fiber Testing Instrumentation and Methods	440	(16)
Fiber Fineness	440	(1)
Strength and Elongation	441	(2)
Fiber Length	443	(5)
Maturity	448	(2)
Color	450	(1)
Non-Lint Content	451	(4)
Nep Count	455	(1)
Yarn Quality Instrumentation	456	(17)
Linear Density-Sliver Weight, Roving Hank Size, and Yarn Count	456	(2)
Yarn Tenacity and Elongation-at-Break	458	(4)
Yarn Evenness (Mass Variation) and Imperfection Count	462	(4)
Classifying Seldom Occurring Faults	466	(2)
Yarn Twist	468	(1)
Yarn Hairiness	469	(2)
Yarn Appearance Grade	471	(2)
High Volume Instrumentation for Fiber Property Measurement and Establishing Cotton Mix Laydowns	473	(1)
Quality Assurance Practices and Procedures in Short Staple Spinning	474	(7)
Short Staple Spun Yarn Manufacturing Costs	481	(4)
Strategies for Competitiveness in the Manufacturing of Short Staple Yarns	485	(6)
Appendix I Determining Fiber Alignment in Sliver Using the ITT Bulk tester	491	(6)
Appendix II Converting Between Units Commonly Used in Staple Yarn Manufacturing	497	(4)
Appendix III Glossary of Terms	501	(26)
Literature Cited	527	(2)
Index	529