Yarn breakage practically found in warping and its remedy Yarn breakage practically found in warping and its remedy TOPIC Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh Prepared By : SUBMITTED TO MR. MUZAHIDUR RAHMAN CHOWDHURY LECTURER SOUTHEAST UNIVERSITY DEPARTMENT OF TEXTILE SOUTHEAST UNIVERSITY DEPARTMENT OF TEXTILE ENGINEERING Project Objective  Research.  Analysis various yarn Fault in Warping process of weaving  Remedies of these faults.  Selection of raw materials.  Product testing.  Product Quality improvement  Reduce wastage  To improve warping efficiency  To improve yarn quality in spinning During processing, textile materials are subjected to various stresses not only during the machine operation but also during its stoppage. If these stresses exceeded a given limits it will adversely affect the quality of the produced yarns, fabrics and the efficiency of the machines . In weaving process, the strains on warp ends can lead to thread breaks, loss of quality and shutdowns. Warp breaks still represent major problem especially for today's high-speed weaving machines .Generally, warp yarn break occurs due to excessive tension greater than the strength of the yarn. INTRODUCTION YARN FAULTS FOR WARP YARN BREAKAGE 1 SLUBS 2 NEPS 3 SNARL 4 THICK AND THIN PLACES 5 SOFT YARN 6 OIL STAINED YARN 7 CRACKERS 8 BAD PIECING 9 OILY SLUB 11 HAIRINESS 12 FOREIGN MATTERS 13 SPUN IN FLY 14 CORK SCREW YARN 15 STITCHING ON CONE 16 RIBBON WOUND CONE 17 SOFT BUILD CONES 18 BELL SHAPED CONE 19 NOSE BULGINGG 20 COLLAPSED CONE 21 RING SHAPED CONE 10 KITTY YARN SLUBS An abnormally thick place or lump in yarn showing less twist at that place. RECTIFICATION 1. Machine surfaces to be maintained clean. 2. Rotors are properly maintained. 3. Better fiber individualization at cards to be achieved. 4. Optimum top roller pressure &back zone 5. Setting at rotor to be maintained. EFFECT 1. More end breaks in warping process. 2. Damaged fabric appearance. 3. Shade variation in dyed fabrics. CAUSES 1. Accumulation of fly and fluff on the machine parts. 2. Poor carding. 3. Defective rotor drafting and bad piecing 1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21 1 NEPS Yarn containing rolled fibre mass, which can be clearly seen on black board at close distance; measurable on USTER imperfection Indicator RECTIFICATION 1. Machine surfaces to be maintained clean. 2. Damaged rotor to be avoided and proper maintained. 3. Better fiber individualization at cards to be achieved. EFFECT 1. Damaged fabric appearance 2. Shade variation in the dyed fabrics 3. An abnormally thick place or lump in yarn showing less twist at that place is called slubs CAUSES 1. Accumulation of fly and fluff on the machine parts 2. Poor carding. 3. Defective rotor and bad piecing of robot 2 1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21 SNARL Yarn with kinks (twisted onto itself) due to insufficient tension after twisting RECTIFICATION 1. Optimum twist to be used for the type of cotton processed 2. Drafting parameters to minimize thin places in the yarn to be adopted 3. Correct tension weights and slub catcher settings to be employed at winding EFFECT 1. Entanglement with adjacent ends causing a break 2. Damaged fabric appearance 3. Shade variation in dyed fabrics 4. Mixing of cottons varying widely in fiber lengths and use of immature cottons CAUSES 1. Higher than normal twist in the yarn 2. Presence of too many long thin places in the yarn 3 1 32 4 5 6 87 9 10 11 12 13 14 15 16 17 18 19 20 21 [...]... types of yarn faults in warping for 16/1 count carded yarn OVER LAPPING; 5% KEY FINDINGS 1 Found different types of yarn and package faults from warping the main cases of warp yarn breakage is improper raw material mixing and cleaning in spinning because majority percentage of yarn faults is weak yarn 2 The number of breaks varied directly with the yarn count 3 Improper maintenance of spinning LIMITATION... the main yarn structure EFFECT 1 More breaks in winding and warping 2 Formation of holes and stains in cloth CAUSES 1 Use of cottons differing widely in the properties in the same mixing 2 Improper mixing 3 Maintaining low relative humidity, closer roller settings and very high spindle speeds RECTIFICATION 1 2 3 4 5 1 Proper mixing or blending Periodic maintenance of different parts Roller settings... cone(paper cone)itself EFFECT 1 Yarn breaks in warping process 2 Wastage increase in yarn preparation CAUSES 1 Use of poor quality/damaged paper cones 2 Poor system of material handling 3 Maintaining non optimum unwinding tension RECTIFICATION 1 Using of poor quality/damaged paper cones should be avoided 2 Winding tenters should be trained by proper work methods 3 Proper material handling devices such... settings to be maintained Optimum relative humidity to be maintained in the spinning room Wide variation in the properties of cottons used in the mixing to be avoided 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 12 FOREIGN MATTERS Metallic parts, jute flannel and other similar foreign matters spun along with yarn EFFECT 1 reaks during winding and warping 2 Formation of holes and stains in cloth CAUSES... EFFECT 1 More breaks in winding 2 More noticable in polyester and cotton blended yarns 1 2 3 4 5 CAUSES Mixing of cottons of widely differing staple length Closer roller settings Eccentric top feed roller Non optimum temperature and relative humidity in the spinning shed 6 Over spinning of cottons RECTIFICATION 1 2 3 4 1 Feed roller to be maintained Mixing of cottons varying widely in fiber length to...4 THICK AND THIN PLACES Measurable by USTER Imperfection Indicator and observable on appearance EFFECT 1 Damaged fabric appearance 2 Shade variation in dyed fabrics 3 Mixing of cottons varying widely in fiber lengths and use of immature cottons 4 More breakage in warping CAUSES 1 2 3 4 Non-uniform sliver Problem in mixing Defect rotor surface Mixing of cottons varying widely in fiber lengths and use... breaks during warping and winding processes CAUSES 1 High yarn tension during winding 2 Cone holders incorrectly set to the winding drum 3 Damages in paper cone centre RECTIFICATION 1 Quality of cones to be checked at that time of procurement 2 Optimum unwinding tension to be maintained 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 19 NOSE BULGING Bulging of bunches of the yarn at the nose of... of the yarn at the nose of the cones EFFECT 1 Slough during warping/ unwinding 2 Excessive yarn waste in next process CAUSES 1 Improper setting of cone holders to the winding drum 2 Damaged nose of the paper cones RECTIFICATION 1 Periodical inspection of settings in winding machines 2 Tenters to be instructed to adopt correct work practices 3 Avoiding usage of damaged paper cones 1 2 3 4 5 6 7 8 9 10... 17 18 19 20 21 14 CORK SCREW YARN It is a double yarn which one yarn is straight and other is coiled over it EFFECT 1 Breaks during winding and warping 2 Causes streaks in the fabric CAUSES 1 Bad piecing by robot 2 Improper mixing 3 Improper feeding RECTIFICATION 1 proper maintenance of robot 2 proper mixing 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 15 STITCHING ON CONE Ends not laid properly... the card setting 3 Wide variation in the properties of cottons used in the mixing to be avoided 4 Better fiber individualization at cards to be achieved Correct spacers to be utilized 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 5 SOFT YARN Yarn which is weak indicating lesser twist EFFECT 1 More end breaks in subsequent processes such as warping, winding etc 2 Shade variation in dyed fabrics . Yarn breakage practically found in warping and its remedy Yarn breakage practically found in warping and its remedy TOPIC Prepared By : Mazadul Hasan. maintained in the spinning room 5. Wide variation in the properties of cottons used in the mixing to be avoided EFFECT 1. More breaks in winding and warping 2. Formation of holes and stains in. of the yarn. INTRODUCTION YARN FAULTS FOR WARP YARN BREAKAGE 1 SLUBS 2 NEPS 3 SNARL 4 THICK AND THIN PLACES 5 SOFT YARN 6 OIL STAINED YARN 7 CRACKERS 8 BAD PIECING 9 OILY SLUB 11 HAIRINESS 12 FOREIGN