Chapter 3 (Lecture 7-11) - Quality Control in Yarn Manufacturing
Chapter 3 (Lecture 7-11) - Quality Control in Yarn Manufacturing
in
Yarn Manufacturing
1
Quality Assurance Steps in Spinning
Setting of Norms
Quality of incoming raw material
Process Monitoring and Control
Inspection of final product
2
Quality of incoming raw material
Test of raw cotton in terms of physical parameters
and accept if comparable with norms
3
Critical difference (CD)
Critical difference is a measure of the difference between two values that occur due to normal or
unavoidable causes.
When the difference between two values exceed that of the critical difference, the two values are said
to be statistically different.
i) CV%
ii) No of test.
Calculation of CD%
CD%(New)=CD% (table)√(N1/N2)
Table-1: No. of test and critical difference (%) for various fibre properties:
Fibre Property No. of tests CD(%)
2.5% span length 4combs/sample 4
Uniformity ratio 4combs/sample 5
Microniare value 4plugs/sample 6
Fibre strength 10breaks/sample 5
Trash content 8 test/sample 7
Calculation of CD%
Table-2: No. of test and critical difference (%) for various yarn properties:
Problem-2. Mill C received 5 cotton samples from A & B. Their strength value were
found to be 22 g/tex and 24 g/tex respectively (based on 5 tests). Which decision was
taken by the mill?
Problem-3. Mill Z received yarn sample from gulshan spinning mill and karim spinning
mill. Their strength was found 20 g/tex and 22 g/tex (Based on five tests). Which
dicision will be taken by the mill?
SOLUTION
Quality of Fiber: Staple Length
2.5% spun length: 2.5% spun length is defined as the distance of 2.5% of the
fibers extended from the clamp where they are caught at random along their
length.
50% spun length: 50% spun length is defined as the distance of 50% of the
fibers extended from the clamp where they are caught at random along their
length.
Quality of Fiber: Uniformity Ratio
Definition Rating
Uniformity ratio is defined as the Uniformity Ratio Grade
ratio of 50% spun length to the
47 Good
2.5% spun length expressed as a
percentage 45 Average
43 Poor
50% spun length
UR=-----------------------------------x100
2.5% spun length
This ratio is a measure of the
length variability of the cotton.
Quality of Fiber: Fiber Fineness
Mc = (N + 0.6H + 0.4I)/100
where N - percentage of mature fibers.
H - Percentage half mature fibers
I - Percentage of immature fibers
Quality of fiber: Maturity coefficient (Mc)
Based on the maturity coefficient, the cottons are classed into different
groups as shown below:
Different fiber characteristics are synthesized into a single index called Fiber
quality index (FQI)
FQI = L * U *S / F
The undesirable and sometimes unavoidable defects that are found in yarn are
known as yarn fault. It is impossible to produce fault-free yarn. So the
spinners try to produce yarn with considerable limit of fault.
Faults found in yarn are:
Count variation
Unevenness & irregularity
Thick thin place and neps (Imperfection Index – IPI of yarn)
Hairiness
Lot mixing
Dead Fiber
Types of Yarn Fault
Count variation: According to the textile institute, “ Count is the mathematical
expression of fineness which expresses the length per unit weight of weight per unit
length”. Practically ± 3 count variation is acceptable. Count can be measured by wrap reel
and balance or using count measuring software (CMS).
Unevenness or irregularity: It is the mass variation per unit length. Cut length is taken
generally 1cm. This fault is expressed as U% or CV%. Evenness tester is used to measure
unevenness.
Types of Yarn Faults
Thick-thin paces and neps (IPI): These faults occur in yarn 10-5000 times per 1000m
of yarn. Yarn spun from staple fibres contains ‘imperfection’ which can be subdivided
into three groups. These three faults are normally measured in no. of faults per 1 km.
These types of faults are determined during evenness testing with imperfection
indicator.
Lot mixing: Sometimes two lots can be mixed at the stage of sliver, roving, bobbin,
cone and cartoon in spinning mill, as well as in the preparatory section weaving and
knitting mill. This type of mixing causes several problems in subsequent process.
Types of Yarn Faults
Dead Fiber: Presence of dead fiber is a great problem for end users as
dead fibers are not capable to absorb dyes, So they remain undyed/white
after dyeing.
Causes of imperfection
Causes of thick & thin places:
1. Short fibre content
2. Improper draft
3. Poor efficiency of carding & combing
4. Twist variation
Causes of Neps:
Immature fibre
Improper ginning
Improper carding speed & card setting
Less efficiency of card
Improper drafting speed
25
Factors Affecting Yarn Strength
1) Quality of Mixing:
Fibre Properties: Better length, strength & fineness of fibre gives better
yarn strength.
Mixing Ratio: Proper mixing leads to higher & uniform yarn strength.
2) Quality of carding:
Mechanical condition of all carding surface
Waste control in carding action
Proper maintenance
26
Factors Affecting Yarn Strength
3) Quality of comber:
Level of comber waste.
Mechanical condition of comber.
27
Factors Affecting Yarn Strength
5) Quality of twisting at ring frame:
Amount of appropriate twist.
Level of twist
Uniformity of twist
28
Fibre testing equipment
Quality of the fibre is maintained through different lab test in the spinning. These are-
AFIS (Advanced Fiber Information System): Sample weight taken for this test is 5 gm. Then
this sample cotton is rolled up to 31 cm then it is inserted to the machine.
For neps, size of neps, fibre length, short fibre content, fineness, immature fibre content,
no. and size of trash measurement.
Evenness tester.
Yarn testing equipment
Wrap reel and balance: Yarn count testing
Auto sorter: For count & CV% analysis
Evenness tester: Yarn imperfection, U%, hairiness etc.
Uster classimate: Yarn fault analysis.
Yarn tension meter
Twist tester
Yarn strength tester
Software: