A reduced spinning process with the option of …...Yarn count variation [CV 10m %] - Yarn count...
Transcript of A reduced spinning process with the option of …...Yarn count variation [CV 10m %] - Yarn count...
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Armin Leder
A reduced spinning process with the option of handling a higher non-lint content
Cotton Conference, Bremen March 2018
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Yarn manufacturing costs
Brazil China Egypt India Indo Italy Korea Turkey USA Vietnam AverageInterest 0,17 0,05 0,06 0,10 0,07 0,02 0,03 0,06 0,05 0,06 0,07Depreciation 0,14 0,14 0,10 0,12 0,10 0,21 0,15 0,12 0,18 0,08 0,13Auxillary Material 0,06 0,05 0,05 0,05 0,05 0,05 0,05 0,06 0,05 0,05 0,05Power 0,13 0,17 0,08 0,13 0,12 0,23 0,14 0,11 0,08 0,10 0,13Labor 0,02 0,02 0,02 0,01 0,01 0,17 0,09 0,04 0,12 0,01 0,05Waste 0,11 0,04 0,19 0,10 0,11 0,10 0,11 0,11 0,09 0,10 0,11Material 1,47 1,84 2,56 1,33 1,40 1,38 1,43 1,52 1,24 1,40 1,55
$0,00
$0,50
$1,00
$1,50
$2,00
$2,50
$3,00
$3,50
ITMF International Production Cost Comparison for Rotor Ne20 [USD/kg]
Material Waste Labor Power Auxillary Material Depreciation Interest
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Material costs
Cotton 1.55 $/kg
Comber noil 1.00 $/kg
Flat Strips 0.80 $/kg
Lickerin waste 0.60 $/kg
How much waste can be added without
noticeably losing yarn quality?
Problem: Short fibers can not be drafted without causing defects in the yarn.
Challenge for yarn spinner
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Four spinning/yarn processes
classic ring spinning
compact ring spinning
OpenEnd spinning
Airjet spinning
© Rieter
Question: Which yarn process requires the lowest draft?
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(Compact) Ring Spinning process
Yarn fineness is produced by a drafting process carried out in stages. Increase of short fiber content creates more and more defects in the yarn
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OpenEnd spinning process
• OE Spinning process completely opens the sliver structure coming from card or draw frame
• Yarn production with virtually no drafting • In addition, dirt (non-lint) is excreted in this spinning
process very insensitive when using short fibers
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Vortex Spinning process
Yarn fineness is produced by a drafting process carried out in stages. Increase of short fiber content creates more and more defects in the yarn
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Trial setup Virgin cotton Waste/comber noil
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Trial setup
Cotton (Central Asia) 100% 70% 50% 30% Comber noil 30% 50% 70% 100%
Micronaire 3.9 3.7 3.5 3.3 3.1
UHML HVI mm 27.4 24.7 23.0 21.1 18.4
SFC < 12.7mm (w) % 7.7 23.1 33.4 43.7 59.2
Neps AFIS-N 1/g 434 542 614 687 795
Trash Content Shirley % 2.1 1.8 1.6 1.4 1.1
Material cost ($/kg) 1.55 1.39 1.27 1.17 1.00
2 Draw Frame Passages
1 Draw Frame Passage
Short Process
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Drafting system of a Trützschler draw frame
• Draw frames dublicate and parallelize the fiber material (using high draft 6 to 8)
• Clamping distance cannot be reduced to such an extent that fibers of 20mm and shorter can be streched controlled with high draft
• Low draft make no sense due to doubling
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IDF 2, Trützschler
• Material flow from top to bottom
• Measuring funnel instead of measuring rollers short clamping distance
The applied draft in IDF 2 is just so big that the short-wave sliver defects from the card can be corrected. Corresponding to these boundary conditions, it should be possible to produce an optimal sliver for OpenEnd spinning, with which even high short fiber fractions can be processed to a good yarn quality.
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Results Sliver quality
Sliver coefficient of variation (Uster CVm%]:
0,00
1,00
2,00
3,00
4,00
5,00
6,00
100% Cotton 70% Cotton30% Comber noil
50% Cotton50% Comber noil
30% Cotton70% Comber noil
100% Comber noil
Ust
er C
Vm%
IDF 2TD 8 onlyTD 7 + TD 8
Share of Noil
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Results 100% Cotton – Yarn Quality
0
2
4
6
8
10
12
14
16
18
0 10 20 30 40 50
Brea
king
tena
city
[cN
/tex]
OE - Yarn count [Ne]
IDF 2
2 Draw Frame passages
Yarn Strength
0
50
100
150
200
250
300
350
400
0 10 20 30 40 50
Nep
s [1
/100
0m]
OE - Yarn count [Ne]
IDF 2
2 Draw Frame passages
Neps
0
100
200
300
400
500
600
700
800
900
0 10 20 30 40 50
IPI t
otal
[1/1
000m
]
OE - Yarn count [Ne]
IDF 2
2 Draw Frame passages
Total IPI
0
0,4
0,8
1,2
1,6
2
2,4
2,8
3,2
3,6
4
0 10 20 30 40 50
Yarn
cou
nt v
aria
tion
[CV 1
0m%
]
OE - Yarn count [Ne]
IDF 2
2 Draw Frame passages
Yarn count variation
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Results 70% Cotton/30% Comber noil – Yarn Quality
0
2
4
6
8
10
12
14
16
0 10 20 30 40 50
Brea
king
tena
city
[cN
/tex]
OE - Yarn count [Ne]
IDF 2
2 Draw Frame passages
Yarn Strength
0
50
100
150
200
250
300
350
400
0 10 20 30 40 50
Nep
s [1
/100
0m]
OE - Yarn count [Ne]
IDF 2
2 Draw Frame passages
Neps
0
100
200
300
400
500
600
700
800
0 10 20 30 40 50
IPI t
otal
[1/1
000m
]
OE - Yarn count [Ne]
IDF 2
2 Draw Frame passages
Total IPI
0
0,4
0,8
1,2
1,6
2
2,4
2,8
3,2
3,6
4
0 10 20 30 40 50
Yarn
cou
nt v
aria
tion
[CV 1
0m%
]
OE - Yarn count [Ne]
IDF 2
2 Draw Frame passages
Yarn count variation
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Results 50% Cotton/50% Comber noil – Yarn Quality
0
2
4
6
8
10
12
14
0 10 20 30 40 50
Brea
king
tena
city
[cN
/tex]
OE - Yarn count [Ne]
IDF 22 Draw Frame passages1 Draw Frame passage
Yarn Strength
0
50
100
150
200
250
300
0 10 20 30 40 50
Nep
s [1
/100
0m]
OE - Yarn count [Ne]
IDF 22 Draw Frame passages1 Draw Frame passage
Neps
0
100
200
300
400
500
600
0 10 20 30 40 50
IPI t
otal
[1/1
000m
]
OE - Yarn count [Ne]
IDF 22 Draw Frame passages1 Draw Frame passages
Total IPI
0
0,4
0,8
1,2
1,6
2
2,4
2,8
3,2
3,6
4
0 10 20 30 40 50
Yarn
cou
nt v
aria
tion
[CV 1
0m%
]
OE - Yarn count [Ne]
IDF 22 Draw Frame passages1 Draw Frame passage
Yarn count variation
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Results 30% Cotton/70% Comber noil – Yarn Quality
0
2
4
6
8
10
12
14
0 10 20 30 40 50
Brea
king
tena
city
[cN
/tex]
OE - Yarn count [Ne]
IDF 21 Draw Frame passage
Yarn Strength
0
20
40
60
80
100
120
140
160
180
200
0 10 20 30 40 50
Nep
s [1
/100
0m]
OE - Yarn count [Ne]
IDF 21 Draw Frame passage
Neps
0
50
100
150
200
250
300
350
400
0 10 20 30 40
IPI t
otal
[1/1
000m
]
OE - Yarn count [Ne]
IDF 2
1 Draw Frame passages
Total IPI
0
0,4
0,8
1,2
1,6
2
2,4
2,8
3,2
3,6
4
0 10 20 30 40 50
Yarn
cou
nt v
aria
tion
[CV 1
0m%
]
OE - Yarn count [Ne]
IDF 2
1 Draw Frame passage
Yarn count variation
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Results 100% Comber noil – Yarn Quality
0
2
4
6
8
10
12
14
0 10 20 30 40 50
Brea
king
tena
city
[cN
/tex]
OE - Yarn count [Ne]
IDF 2
Yarn Strength
0
2
4
6
8
10
12
14
16
18
20
0 10 20 30 40 50
Nep
s [1
/100
0m]
OE - Yarn count [Ne]
IDF 2
Neps
0
20
40
60
80
100
120
140
160
180
200
0 10 20 30 40
IPI t
otal
[1/1
000m
]
OE - Yarn count [Ne]
IDF 2
Total IPI
0
0,4
0,8
1,2
1,6
2
2,4
2,8
3,2
3,6
4
0 10 20 30 40 50
Yarn
cou
nt v
aria
tion
[CV 1
0m%
]
OE - Yarn count [Ne]
IDF 2
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Conclusion
• For the OpenEnd spinning process there is now a perfect preparation process through an integrated draw frame (IDF 2) into the card (TC 15, TC 10) with minimal draft.
• This process enables very good yarn values to be produced with a high proportion of short-fiber and foreign matter contaminated fiber material.
there is no reason to use conventional draw frames with doubling anymore to produce OpenEnd cotton yarn.
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Questions?