The spinning process design is crucial for ensuring stable yarn quality. Poor design can lead to inconsistent results and frequent breakages, wasting materials and time.
Proper spinning process design combines fiber characteristics, machine condition, and equipment configuration to achieve optimal yarn quality with minimal breakage.
Every textile manufacturer knows that yarn quality and breakage rate directly impact production efficiency. A well-designed spinning process minimizes defects and maximizes output.
How Does Drafting Process Configuration Affect Yarn Quality?
Even small changes in drafting settings can dramatically alter yarn strength, evenness, and breakage rates.
Drafting process configuration must match fiber properties—factors like roving hank, twist multiplier, and drafting form determine final yarn quality.
The drafting process plays a critical role in fiber alignment and tension control.
Roving Hank & Twist Multiplier Selection
| Factor | Recommendation (Viscose Compact Spinning 120S) | Adjustment If Issues Occur |
|---|---|---|
| Roving Dry Weight | ~2g/10m | Reduce if breakage rises |
| Twist Multiplier | 72-75 (with high-pressure cradle) | Lower for unstable drafting |
| Top Roller Position | Forward 1.5mm | Adjust based on testing |
Higher twist multipliers increase fiber control but may cause drafting resistance if cradle pressure is insufficient.
Drafting Form Selection
V-drafting works best for pure cotton, while flat drafting suits synthetic fibers. Using the wrong type leads to uneven tension and breakage.
Additional Friction Zones
Adding friction zones improves cotton fiber control but may create excessive drafting force for synthetic fibers, causing intermittent breaks.
What Causes Spinning Breakage During Startup?
Startup periods account for over 30% of total spinning breaks in many mills—a preventable waste.
Breakage at startup occurs due to improper traveler selection, incorrect ring rail position, or tension imbalance during acceleration.
Identifying and correcting startup issues requires systematic observation.
Key Causes & Solutions
-
Ring Rail Positioning
- Problem: Too low causes yarn wrapping; too high increases tension
- Fix: Set 2.5-3cm above tube tip
-
Traveler Selection
- Problem: Light travelers cause balloon collision; heavy ones increase breakage
- Fix: Observe balloon shape and adjust accordingly
-
Tail Yarn Length
- Problem: Short tails detach; long tails form knots
- Fix: Maintain 3-5 wraps at tube base
-
Forming Cam Position
- Problem: Stopping at large radius increases tension
- Fix: Stop at small radius midpoint
Conclusion
Optimal spinning process design balances fiber properties, machine settings, and environmental factors to minimize breakage while maximizing yarn quality. Continuous monitoring and adjustment ensure consistent production efficiency.
