a comparative study on egyptian carded c

8/18/2019 A Comparative Study on Egyptian Carded c

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A COMPARATIVE STUDY ON EGYPTIAN CARDED, COMBEDCOMPACT YARNS AND COMBED RING YARNS

BY

Prof Dr. Magdy El Messiry1, Dr. Naglaa Hosny and Eng. Ghada EsmatTextile Eng. Department, Faculty of Engineering, Alexandria University, Egypt

[email protected]

AbstractThe compact spinning has found a wide market in the last decade. Several systems are

introduced to produce such yarns which have better physical and mechanical properties

than the ring spinning. All the systems for the production of compact spun yarns consist

of a modification of the drafting system on the ring spinning machine, so that the

spinning triangle dimensions decreases. The properties of compact spinning were

thoroughly investigated by several researchers. The results of their studies indicated that

compact spun yarn strength is higher by about 15% and elongation at break by about

20%. Furthermore, the yarn hairiness becomes 70% less, and the coefficient of variation

of the yarn was lower by 15% than that for the equivalent ring spun yarn. Compact spun

yarns had better abrasion resistance. These advantages can reflect on the downstream

processing. Fabric properties in terms of breaking strength, breaking elongation and tear

strength are also better with the compact spun yarns. Clinging tendency of compact yarn

shows considerably fewer and less pronounced clinging phenomena. Lower clingingtendency of the yarn results in the improvement of the warp yarn separation. This reduces

the cost of sizing and subsequent desizing, and at the same time, resulting in less

environmental pollution. Despite the lower degree of sizing, thread break rates are lower,

which significantly improves loom efficiency, and fabric appearance. In this work a

comparative study has been carried out to investigate if the compact fine ply carded yarn

spun from Egyptian cotton G86 will have better quality than combed ring spun yarns.

The results indicate that through the adjusting the production speed of the carding

machine the carded compact yarns for the counts up to Ne 80/2 give better quality in

comparison to the combed ring spun yarns.

Key words: Compact yarns, carded yarns, combed yarns, ring spun yarns.


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Introduction

Quality and quality management are the key words used in our time; cost and quality are

the most important factors for any company. The raw material cost in a spinning mill

reaches up to 60% of the production cost. Several researchers (1-5) show the possibility

to use a compact spinning to improve the quality of the yarns produced from short staple

cotton fibers in order to get use of the improvement in the compact yarn properties (6-9).

The study of results (10-16) indicated that compact spun yarn strength was found to be

higher by about 15% and elongation at break by about 20%. Furthermore, the yarn

hairiness becomes 70% less, and the coefficient of variation of the yarn was lower by

15% than that for the equivalent ring spun yarn

The goal of this work is to make best use of compact spinning in order to taking theadvantage of compact yarn structure in processing of carded compact ply yarns instead of

comber ring ply yarn. A comparative study of the physical and mechanical properties of

ply yarn produced from the Egyptian cotton G86 on the three systems is studied.

Experimental

A set of the experimental trials was performed to study the effect of carding production

speed on compact yarn quality . Compact yarns of count Ne 50/1, 60/1, 80/1 using

Egyptian cotton G.86 were spun on K44 RIETER spinning compact machine from

slivers processed at different carding machine production speeds (40, 60, 80 and 100

m/min). The slivers are combed at 20% noiles and processed into ply compact yarns and

ring spun yarn of count 50/2, 60/2 and 80/2. Another set of trials was made to produce

similar compact plied yarns from carded slivers processed at different carding production

speed.

Results and discussion

Effect of carding machine production speed

Figures from (1) to (21) show the properties of single carded compact yarns obtained at

different carding machine production speeds varied from 50 to 100 m/min for yarn

counts Ne 50/1, 60/1, 80/1.


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From the analysis of the results of the different single yarn properties, it can be seen that

as the carding machine production speed increases, the yarn imperfections are reduced

and the tenacity and elongation increased. This may be due to that the design of modern

carding machine has a higher number of wires on the carding cylinder which leads to

significantly lower acting carding forces on the fibers during processing compared to

conventional carding systems. The forces prevailing between the cylinder and the flat

wires have a major impact on the possibility of increasing productivity without the

deterioration of the sliver quality. The analysis of results show that compact spinning

made possible the production of carded yarns up to count Ne 80/1 from G.86.

Also the carded compact yarns have significantly lower hairiness than conventional

yarns, while for yarn tensile properties, carded yarns which were produced at higher

carding machine production speed have higher tenacity and elongation than combed yarnspun on the conventional ring spinning frame. This is most likely because that the fiber

extent is increased at high carding production speed, which leads to maximizing the

effect reduction of spinning triangle on the compact spinning machine, i.e. enables more

fibers to be embedded to the yarn body. On the other hand yarn evenness and thin places

of carded compact yarns are of the same level of conventional ring spun yarns up to yarn

count Ne 60/1. Thick places and neps seems to be a problem when producing fine single

carded compact yarn because the combing processes in addition to removing short fibers,

the combing operation increases the fiber separation, eliminates many impurities

remaining in the sliver after the carding process, thus neps and seed- coat fragments

(SCFs) are reduced resulting in more yarn evenness and less imperfections.

Effect of plying compact carded yarn In order to study the reflection of the above results on the ply yarns, a set of trials was

carried out to produce ply yarns from combed and carded slivers at carding speed 100

m/min on conventional ring spinning machine and compact machine. The results of

testing of the produced different ply yarns properties are given in Tables [1], [2], and [3]

.


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Table [1] Comparison between properties of different plied yarn (combed compactyarn, carded compact yarn and combed conventional yarn of count Ne 50/2)


SPINNING SYSTEM

YARNPROPERTIES

Compact

SystemK44 RIETER

ConventionalRing

spinningsystem

CompactSystem

K44RIETER

CompactSystem

K44RIETER

CompactSystem

K44RIETER

CompactSystem

K44RIETER

COTTON TYPE GIZA 86 GIZA 86 GIZA 86 GIZA 86 GIZA 86 GIZA 86

YARN TYPE COMBED COMBED CARDED CARDED CARDED CARDED

CARDINGSPEED(m/min) 100 100 40 60 80 100TWIST FACTOR 3.6 3.6 3.6 3.6 3.6 3.6TENACITY(g/tex) 29.00 21.94 24.69 25.86 25.86 25.16ELONGATION% 5.40 4.88 5.16 5.22 5.45 5.36C.V m% 8.25 10.49 10.38 10.43 10.33 9.92THIN PLACES/ KM 0 0 0 0 0 0THICK PLACES/ KM 2.5 5 8 8.5 7 6.5

NEPS/ KM 1 9.5 9 5.5 3 3HAIRINESS 3.75 6.4 4.88 4.76 4.38 4.51YARN COUNT(Ne) 50/2 50/2 50/2 50/2 50/2 50/2

SPINNING SYSTEM

YARNPROPERTIES

CompactSystem

K44RIETER

ConventionalRing

spinningsystem

CompactSystem

K44RIETER

CompactSystem

K44RIETER

CompactSystem

K44RIETER

CompactSystem

K44RIETER

COTTON TYPE GIZA 86 GIZA 86 GIZA 86 GIZA 86 GIZA 86 GIZA 86YARN TYPE COMBED COMBED CARDED CARDED CARDED CARDED

CARDINGSPEED(m/min) 100 100 40 60 80 100TWIST FACTOR 4.747 4.747 4.747 4.747 4.747 4.747TENACITY(g/tex) 28.52 24.33 23.07 25.74 26.78 27.40ELONGATION% 5.67 5.06 4.82 5.06 5.10 5.24C.V m% 8.50 11.15 11.22 10.69 10.64 10.47THIN PLACES/ KM 0 3 0 0 0 0THICK PLACES/ KM 1 8.5 7.5 9 8 7.5

NEPS/ KM 1 15.3 10.8 10 13.5 12.5HAIRINESS 4.22 6.68 4.77 4.64 4.48 4.53YARN COUNT(Ne) 60/2 60/2 60/2 60/2 60/2 60/2


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Figures (22) to (25) shows a comparison between properties of different plied yarns

(combed compact yarn, carded compact yarn and combed conventional yarn). The

analysis of the results indicates that in the case of combed compact ply yarns, cotton G.86

can be processed to produce ply yarn up to count Ne 80/2 from carded single compact

yarn at Uster quality level 5% (combed compact yarn levels).

Carded compact yarns of the counts Ne 50/2, Ne 60/2 have significantly higher tenacity

and elongation than conventional ring combed spun yarns. For their yarn evenness and

imperfections, it is observed that there is a considerable decrease in plied carded compact

yarn than in plied combed conventional yarn. This may be due to the effect of winding

process which removes appreciable percentage of the yarn imperfections. However, for

Ne 80/2 carded compact yarn it has less hairiness and higher tenacity than conventionalring spun combed yarn. Although the yarn imperfections of Ne 80/2 compact carded yarn

are significantly higher than that of plied combed conventional yarn, but it is still has a

quality level at Uster quality level 5% (combed ring spun yarn levels). It is acceptable to

replace the combed ring ply yarn by a similar carded compact yarn.

SPINNING SYSTEM

YARNPROPERTIES

CompactSystem

K44RIETER

ConventionalRing

spinningsystem

CompactSystem

K44RIETER

CompactSystem

K44RIETER

CompactSystem

K44RIETER

CompactSystem

K44RIETER

COTTON TYPE GIZA 86 GIZA 86 GIZA 86 GIZA 86 GIZA 86 GIZA 86

YARN TYPE COMBED COMBED CARDED CARDED CARDED CARDED

CARDINGSPEED(m/min) 100 100 40 60 80 100TWIST FACTOR 4.217 4.217 4.217 4.217 4.217 4.217TENACITY(g/tex) 27.92 23.64 23.47 23.79 23.93 24.34ELONGATION% 4.81 4.75 4.30 4.23 4.52 4.31C.V m% 9.66 10.70 12.15 12.01 11.75 11.67THIN PLACES/ KM 0 0 0 0 0 0THICK PLACES/ KM 1.5 5 29 26 21 16

NEPS/ KM 3 8 32 32 32 37HAIRINESS 3.74 4.96 4.74 4.65 4.51 4.46YARN COUNT(Ne) 80/2 80/2 80/2 80/2 80/2 80/2


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CONCLUSION 1-The compact spinning enables the possibility of producing yarn count up to Ne 80/1

carded yarn from G.86, when the carding production speed reaches 100 m/min.

2-Comparison between different plied yarns :( carded compact, combed compact and

combed conventional yarn) indicated that carded ply yarn up to Ne 60/2 produced by

compact spinning gives a quality better or equal to that of conventional combed ring spun

yarn according to 5%Uster Statistics quality level.

3-It is recommended to use carded compact ply yarns up to count 60/2 instead of ply ring

spun yarns.


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Fig. 1 Effect of card speed Fig. 2 Effect of card speedon thin places on yarn evenness

Fig. 3 Effect of card speed on thick Fig. 4 Effect of card speed onneps places

Fig. 5 Effect of card speed on Fig. 6 Effect of card speed ontenacity hairiness

Ne 50/1

R2 = 0.9594

050

100150200250300

40 60 80 100Carding machine production

speed(m/min)

N e p s

/ k m

Ne 50/1

R2 = 0.9201

50

100150

200

250

300


speed(m/min)

T h i c k p l a c e s

/ k m

Ne 50/1

R2 = 0.5

3

3.05

3.1

3.15

3.2


speed(m/min)

H a

i r i n e s s

Ne 50/1

R2 = 0.9905

20

22

24

26

28

40 60 80 100Carding machine pr oduction

speed(m/min)

T e n a c

i t y

( g / t e x

)

Ne 50/1

R2 = 0.96

01

23456

40 60 80 100Carding machine pr oduction

speed(m/min)

T h i n p

l a c e s /

k m

Ne 50/1

R2 = 0.9383

13.0%13.5%

14.0%

14.5%

15.0%

15.5%

40 60 80 100carding machine production

speed(m/min)

C . V

m %


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Fig. 7 Effect of card speed on yarn elongation

Fig. 9 Effect of card speed on yarn evenness Fig.8 Effect of card speed on thinplaces

Fig.10 Effect of card speed on thick Fig. 11 Effect of card speedon neps places

Ne 60/1

R2 = 0.9383

13.5%14.0%14.5%15.0%

15.5%16.0%16.5%

40 60 80 100carding m achine production

speed(m/min)

C . V

m %

Ne 60/1

R2

= 0.684

0

10

20

30


speed(m/min)

T h i n p l a c e s /

k m

Ne 60/1

R2

= 0.8394

0

50

100

150

200

250

40 60 80 100carding machine pr oduction

speed(m/min)

T h i c k p

l a c e s

/ k m

Ne 60/1

R2 = 0.684

180190200210220230240

250


speed(m/min)

N e p s /

k m

Ne 60/1

R2 = 0.9092

2.72.82.9

33.13.23.3

40 60 80 100carding m achine production spee d

(m/min)

H a i r i n e s s

Ne 60/1

R2 = 0.9706

05

1015202530

40 60 80 100

carding machine productionspeed(m/min)

T e n a c i t y

g / t e x

Ne 50/1

R2 = 0.8897

3

4

5

6


speed(m/min)

E l o n g a t

i o n

%


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Fig. 12 Effect of card speed on Fig. 13 Effect of card speed ontenacity hairiness

Fig.

14Effect

ofcardspeed

onyarn elongation

Fig. 15 Effect of card speed Fig. 16 Effect of card speedOn yarn evenness on thin places

Fig. 17 Effect of card speed

Ne 60/1

R2 = 0.9142

0

2

4

6


speed(m/min)

E l o n g a t

i o n

%

Ne 80/1

R2 = 0.9031

16.0%

16.5%17.0%

17.5%18.0%

18.5%


speed(m/min)

C . V

m %

Ne 80/1

R2 = 0.875

0

50

100

150


speed(m/min)

T h i n p

l a c e s

/ k m

Ne 80/1

R2 = 0.7049

520530

540550560570580590


speed(m/min)

T h i c k p

l a c e s

/ k m

Ne 80/1

R2 = 0.9231

0

200

400

600

800


speed(m/min)

N e p s /

k m

Ne 80/1

R2 = 0.9821

0

5

1015

20

25


speed(m/min)

T e n a c i t y

( g / t e x

)


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Fig. 18 Effect of card speed on nepson thick places

Fig. 19 Effect of card speed Fig. 20 Effect of card speedon tenacityhairinesson

Fig. 21 Effect of card speed on yarn elongation

Ne 80/1

R2 = 0.9846

3

3.05

3.1

3.15

3.2

3.25


speed(m/min)

H a i r i n e s s

Ne 80/1

R2 = 0.7448

0

1

2

3

4

5


speed(m/min)

E l o n g a t

i o n

%

Ne 50/2

0

1

2

3

4

5

6

7

8

9

10

11

C.V m%

THICK PLACES/ KM

NEPS/ KMHAIRINESS

ELONGATION%

combed compact

combed conventional

cardedcompactat 100m/min


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Fig. 22 Comparison between properties of 50/2 plied yarns (combed compact yarn,carded compact yarn and combed conventional yarn)


Ne 60/2

0

2

4

6

8

10

12

1416

C.V m%

THICK PLACES/ KM

NEPS/ KMHAIRINESS

ELONGATION%

combed compact

combed conventional


Ne 80/2

-2

3

8

13

18

23

28

33

38

C.V m%

THICK PLACES/ KM

NEPS/ KMHAIRINESS

ELONGATION%

combed compact

combed conventional



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Fig. 25 Comparison between tenacities of different plied yarns (combed compactyarn, carded compact yarn and combed conventional yarn)

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2000

2. Thump, R., ” Suisse Elite Spinning System for Long and Short Staple Fiber ,” TextileWorld 150, No 4, 38, 20003. Kampen, W., “Advantages of Condensed Spinning,” Milliand International 6, 98 -100(2000.4. Meyer, U., Compact Yarns: Innovation as a Sector Driving Force. MilliandInternational 6, 2, (2000) .5. Staler, H., Compact Spinning – A new Generation of Ring Spun Yarns. MelliandTextilberichtee 76(3), E29-E31 (1995).6. Basal, g., and Oxenham, W., “Comparison of Properties and Structure of Compact andConventional Spun Yarns,” Textil e Res. J. 76(7), 567-575.7. Klein, W., “A Practical Guide to Ring Spinning,” The Textile Institute Manual ofTextile Technology, MFP Design & Print, Manchester, UK, 1987.8. El Messiry, M., “New Attachment for Compact Spinning,” 1st International Textile Conference NRC, 2004.

15

18

21

24

27

30TENACITY(g/tex) Ne 50/2

TENACITY(g/tex) Ne 60/2TENACITY(g/tex)Ne 80/2

combed compact

combed conventional



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12. Behera, B., Hari, P., Ghosh, S.: Weavability of compact Yarn, Melliand International,9 (2003) 311-314.13. Goyal, A., etal , “Comparative Study of Ring and Compact Spun Yarns,” MelliandInternational 2 (2007).14. Goktepa, etal, “A Comparison of Compact Yarn Properties Produced on Differentsystems,” Textile Res. J. 76 (3), p. 226. 15. Krifa, Ethridge, “Compact Spinning Effec t of Cotton Quality Interaction with FiberCharacteristics,” Textile Res. J., 76 (5), p. 388. 16. Krifa.m, Ethridge.D, "Compact Ring Yarn: An Examination of Some ProductionIssues,” Textile topics volume 2003 -2.

a comparative study on egyptian carded c

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