European Scientific Journal January 2015 edition vol.11, No.

3 ISSN: 1857 7881 (Print) e - ISSN 1857- 7431

RETROFITTING OF SIMPLE MECHANICAL

COMPACTING DEVICE (ROCOS) ON
CONVENTIONAL RING SPINNING MACHINE
FOR IMPROVING YARN QUALITY

Md. Nasir Uddin

Farhana Afroz
Lecturer, Northern University Bangladesh, Bangladesh

Mohammad Abdul Jalil, PhD

Associate Professor, Mawlana Bhasani Science And Technology University,
Bangladesh

Abstract
Ring spinning is the most popular and universal spinning system due
to its significant advantages in comparison with the new spinning systems.
But the yarn properties are hampered in ring spinning system with the
increase of spindle speed and spinning triangle. Overall yarn properties can
be improved by retrofitting of simple mechanical device (rocos) on
conventional ring spinning machine. In this study we try to show, how rocos
overcome the negative influences of spinning triangle on yarn quality. It also
ensures outstanding yarn properties such as hairiness, strength,
imperfections, elongation etc. Inspite of higher spindle speed as compared to
the yarns which are produced in conventional ring spinning machine by
using same raw materials.
Keywords: Retrofit, spinning triangle, rocos, imperfections, hairiness
Introduction
There are different spinning systems are available to convert the
different textile fibers into yarn such as ring, rotor, siro, compact, friction,
air-jet etc.among them ring spinning is the most useable and popular. The
spinning triangle is the most troublesome and weakest zone in the yarn
formation process in ring spinning as it increases end breakage, fiber loss
and yarn hairiness (Murugan, R. & Vigneswaran. 2011, 211). In order to
obtain fundamental improvements in ring spinning, the modification of the
ring machine is necessary. Compact spinning aims at eliminating the
spinning triangle and the problems associated with it (jaswant

68

European Scientific Journal January 2015 edition vol.11, No.3 ISSN: 1857 7881 (Print) e - ISSN 1857- 7431

rajaney,2008,8).the introduction of compact spinning has minimized the

negative influence of the spinning triangle in ring spinning (Murugan, R &
Vigneswaran 2011, 211). The compaction of the fibers can be accomplished
either by using mechanical condenser or pneumatic condenser (Rocosmagnetic). The condensing of the strand of fibers is brought about by air
suction. The power required to produce this suction is substantial, the
pneumatic compacting devices are expensive, and may require elaborate
maintenance. Rocos, the rotorcraft compact spinning system, works without
air suction and uses magnetic mechanical principles only. Besides the
adaption of pneumatic compacting system in the conventional ring spinning
machine is not easy and expensive. In this study we use mechanical
condenser of rocos mechanical compact spinning of rotorcraft company
because rocos device can be easily retrofitted with the conventional ring
spinning machine.

Figure 1: Yarn structure of compact yarn and conventional ring spun yarn (microscopic
view) ( Lawrence, 2010, 240).

Spinning triangle
In the ring spinning frame the fiber bundle follows a path between the
drafting system and yarn take-up on the cop. This path involves the drafting
arrangement, thread guide, balloon control ring, and traveler. These elements
are arranged at various angles and distances relative to each other. All these
distances, inclinations and angles are referred to as the spinning geometry.
The spinning geometry has a significant effect on the end breaks, tension
conditions, and generation of fly, yarn hairiness and yarn structure.
Twist is imparted by the traveler and goes up as close as possible to
the nip line of the front rollers. However, twist never penetrates completely
to the nip line. Since the width of the fiber bundle emerging from the
drafting system is many times the diameter of the yarn to be spun, fibers in
the bundle have to be diverted inwards and wrapped around each other.
Consequently, at the exit from the front rollers there is always a triangular
bundle of the fibers without twist which is called spinning triangle.

69

European Scientific Journal January 2015 edition vol.11, No.3 ISSN: 1857 7881 (Print) e - ISSN 1857- 7431

Figure 2: comparison of spinning triangles at conventional ring and compact spinning

systems (jaswant rajaney,2008,10).

In rocos compact spinning, compact yarn is produced by adding

positive nip at the end of the drafting unit. The condenser is held against the
bottom front drafting roller by means of a magnet. The operation brings the
fibers closer and eliminates the spinning triangle. The view of the rocos
mechanical compact spinning principle is given in figure 3. According to the
previous research, mechanical compact spinning significantly improves the
imperfections and reduces its hairiness (Sevda & Kadoglu, 2009, 307).

Figure 3: The view of rocos mechanical compact spinning and back view of magnetic
compactor (Atlas & Kadoglu)

70

European Scientific Journal January 2015 edition vol.11, No.3 ISSN: 1857 7881 (Print) e - ISSN 1857- 7431

Experimental design
Material
Cis cotton was used to spin 40 ne combed yarn in conventional ring
spinning machine (reiter) without compacting device and with mechanical
compacting device (rocos) of rotorcraft company .the raw cotton was tested
under standard testing atmospheric conditions at 20 2 c and 65% rh
(Booth, 2012) on hvi (high volume instrument) machine of premier art- 2
(Indian).
Method
To perform this experiment a reputed spinning mill of bangladesh
was selected named as sinha rotor spinning ltd. (a concern of sinha spinning
group). Various types of yarn are produced in this spinning mill such as
combed yarn, carded yarn, compact yarn, rotor yarn (oe yarn), slub yarn,
core yarn etc. The back process machineries of this mill are reiter brand but
simplex machinery is toyota. The ring frame machine is reiter brand and
rocos mechanical compacting device is used in this machine to produce
compact yarn. In this study the raw cotton was processed from blow room to
simplex at same process parameters. But to produce 40 ne combed yarn,
conventional ring frame was used and to produce 40 ne combed compact
yarn, conventional ring frame was used which are modified by simple
mechanical compacting device (rocos) of rotorcraft company. Finally the
quality parameters of yarn such as cv%, ipi (imperfection index) were tested
on premier tester iq2 lx (evenness tester) and single yarn strength (rkm),
elongation % were tested on premier tensomaxx (single yarn strength and
elongation tester) under testing atmospheric conditions.
Experimental
Experimental results of raw cotton, finished yarn which were tested
in different testing machineries are shown below:Table1: Properties of raw cotton fibers (hvi test results)
Cotton fibers test parameters
Mean value
Upper half mean length (mm)
28.66
Uniformity index (%)
82.6

71

Elongation (%)

6.7

Strength (g/tex)

34.10

Micronaire value (/inch)

5.01

Maturity ratio (m.r)

0.92

Rd

72.9

+b

10.7

Sfi (short fibre index)

8.6

European Scientific Journal January 2015 edition vol.11, No.3 ISSN: 1857 7881 (Print) e - ISSN 1857- 7431

Table 2: Setting parameters of ring frame machine for 40/1 ne combed yarn
Types of yarn
Machine parameters
Conventional ring
Compact yarn
spun yarn
Twist per inch (tpi)
28.00
27.25
Ring traveler size
4/0
4/0
Spacer (mm)
2.50
2.50
Spindle speed (r.p.m)
16000
16500
Ring diameter (mm)
38
38
Table 3: Comparison of conventional ring spun yarn and mechanical compact yarn (40/1 ne
combed yarn)
Conventional ring
Quality parameters
Mechanical compact yarn
spun yarn
Um %
9.65
9.20
Cvm %
12.22
11.63
Thin -50%/km
1.00
1.3
Thick +50%/km
21.5
17.3
Neps +200%/km
111
67.7
Ipi (imperfection index)
133.5
86.3
Hairiness
3.32
2.34
Cv% of hairiness
5.12
3.48
Rkm (single yarn
18.19
21.5
strength)
Cv% of rkm
9.21
8.12
Elongation %
5.11
5.93
Cv % of elongation %
11.06
9.5

Results and discussion:

150

15
10

Conventi
onal Yarn

100

Conventi
onal Yarn

Compact
yarn

50

Compact
yarn

0
Um % CVm %

Figure 3: comparison of yarn um %

And cvm %

0
IPI
Figure 4: comparison of ipi
(imperfection index)

72

European Scientific Journal January 2015 edition vol.11, No.3 ISSN: 1857 7881 (Print) e - ISSN 1857- 7431

6
5
4
3
2
1
0

25
20
Conventio
nal Yarn

15

Compact
yarn

Conventi
onal Yarn

10

Compact
yarn

0
RKm CV % of
Rkm

Figure 5: comparison of yarn hairiness

12
10
8
6
4
2
0

Figure 6: comparison of yarn rkm

(single yarn strength)

Conventiona
l Yarn
Compact
yarn
Elg. %

CV % of
Elg.

figure 7: comparison of elongation %

From figure-3, we see both um% and cvm% are less in compact spun
yarn. So its clear to us irregularity of compact spun yarn is reduced by using
rocos in conventional ring frame machine.
From figure-4, we also see that ipi value of compact spun yarn is 86.3
where 133.5 in conventional ring spun yarn.so imperfections are reduced by
using rocos.
From figure-5, we see that both hairiness and cv% of hairiness are
less in compact spun yarn. So rocos improves the hairiness value of
compact spun yarn.
From figure-6, we see that rkm (single yarn strength) value of
compact spun yarn and conventional ring spun yarn are 21.5 and 18.19
repectively. So it reveals that rocos improves the strength of compact yarn as
well.
From figure-7, we also see that the elongation% of compact yarn is
higher than conventional ring spun yarn. So we can say elongation properties
are improved by using rocos in conventional ring frame.

73

European Scientific Journal January 2015 edition vol.11, No.3 ISSN: 1857 7881 (Print) e - ISSN 1857- 7431

Conclusion
This study reveals that the positive effect of retrofitting of simple
mechanical compacting device (rocos) on conventional ring spinning
machine. The evenness and imperfection (ipi) values of compact yarns were
found lower than conventional ring spun yarns. Compact yarn shows lower
hairiness as compared to the yarn which is produced in conventional ring
spinning machine. Increased yarn strength (rkm) and higher elongation
properties also found in compact yarn. It also reveals that inspite of higher
spindle speed and lower twist, compact yarn shows better yarn quality. To
overcome the effect of spinning triangle and limited spindle speed of
conventional ring spinning on yarn quality, it is necessary to modify
conventional ring spinning machine by simple mechanical compacting
device (rocos).
References:
Murugan,R & Vigneswaran.(2011) Novel Technique for improving yarn
quality and reducing hairiness in conventional ring frame. Indian journal of
Fiber & textile Research, 36, 211-214.
Jaswant Rajaney, Pooja.(2008) Comparative Analysis of compact spun yarns
and ring spun yarns, page-08. North Carolina State University, Raleigh.
Retrieved from http.//repiratory.lib.ncsu.edu/ir/bitstream/1840.16/1641/1
etd.pdf
RoCoS- Magnetic Compact Spinning System. Pakistan Textile journal.
Retrieved from http//www.ptj.com.pk/.../rotorcraft.ht.//
Atlas Sevda & Kadoglu Huseyin.Comparison of conventional Ring,
Mechanical Compact and Pneumatic Compact Yarn Spinning
Systems.Journal of Engineered Fibers and Fabrics,volume 7,issue I2012,88.
Lawrence, C.A. (2010), Advanced in yarn spinning technology,Woodhead
Publishing Series in Textiles,238-239.
Jaswant Rajaney, Pooja.(2008). Comparative analysis of compact spun yarns
and ring spun yarns,page-10. North Carolina State University, Raleigh.
Retrieved from http.//repiratory.lib.ncsu.edu/ir/bitstream/1840.16/1641/1
etd.pdf
Lawrence ,C.A. (2010), Advanced in yarn spinning technology,Woodhead
Publishing Series in Textiles, 240.
Booth J.E.(2012), B.Sc. Principles of textile testing. Bristol, England: J.W.
Arrow Smith.101.
Altas Sevda & Hoseyin Kadoglu.Compact spinning research for
regenerated cellulose and synthetic yarns. Tekstilec, 2009, letn. 52, t . 10
12, str. 306311.

74