SPENNING

SUESSEN
Compact spinning and advantages of EliTe®Yarns

by
Muhammad Mushtaq Ahmad
MTS Consultant, Lahore

With the market introduction of "Compact Ring Yarns", the situation in ring spinning has changed fundamentally. In all relevant quality criteria, genuine condensed or compact yarns are substantially superior to conventional ring yarns to such a degree that it is no longer possible to speak of a standard market value. In the best sense of the word, this is a revolution in ring spinning and, even at this point in time, one can categorically say that the future belongs to compact yarns. Suessen has developed the new EliTe®CompactSet, the modernization of ring spinning machines with the SUESSEN EliTe®Compact Spinning System. It is a compact spinning technique that can be used universally for all raw materials and raw material blends, as well as for the complete count range without restriction.

In compact spinning, the spinning triangle associated with conventional ring spinning is eliminated by pneumatic compaction. This happens by suction and compaction on a perforated revolving apron in front zone of the drafting system.

The process is characterized by the introduction of a fourth nip point down stream of the exit from the conventional 3/3 drafting system, which takes the form of the perforated drum in Rieter Comforspin® process between the third and fourth top rollers, which acts as an aerodynamic condenser.

The Aerodynamic condensing of the fibers through suction results in narrower spinning zone with individual fibers more effectively bound into the yarn assembly.

In conventional spinning a spinning triangle is formed immediately after the drafting mechanism in the Ring Frame. The spinning triangle is a weak zone due to less twist in this region. Under normal working conditions most of the breaks occur near-vicinity of the spinning triangle. The strength of the fibrous mass in the spinning triangle determines the attainable spindle speed. Hence, if the spinning triangle is avoided or its length reduced, the achievable spindle speed could be increased. It is with this objective in mind that compact spinning is being tried.

Properties of compact yarn, compared with that of conventional yarn
With compact spinning yarn strength is higher by about 15% and elongation at break by about 20%. Compact Spun yarns also have better abrasion resistance of about 25%. Fabric properties in terms of breaking strength, breaking elongation and tear strength are also better with compact yarn.

Advantages:
Knitting
· Due to low hairiness, low pilling tendency ensure good wear behaviour.
· Due to low twist, absorbency of dye also increases which means less dye consumption. Body twist is also minimized, which is a common problem in ring spun yarn.
· The abrasion of yarn is also about 25% lower. This results in better

running properties and improved quality. Since fiber fly and oil cannot combine to form clumps of fly, which are occasionally knitted into the fabric and can cause thread & needle breaks, the wear on guide elements, needles and sinkers is reduced as a result of the lower residual dust content of compact yarn.

Sizing
Clinging tendency of compact yarn display considerably fewer & less pronounced clinging phenomena. Due to lower clinging tendency of yarn, resulting improvement in separability of the warp. This reduces the cost of sizing and subsequent desizing, at the same time, resulting in lesser environment pollution.

Weaving
Despite the lower degree of sizing, thread break rates are lower, which significantly improves efficiency, fabric appearance and a more brilliant luster.

Finishing
The higher stretch recovery is also retained in the finished fabric. This is a great advantage, especially in shirting fabrics with non-iron finish since losses in strength of upto 50% can be caused by this finishing process.

In printed fabrics due to special yarn structure of Compact Yarn, results in better dye take-up, therefore retain their attractive appearance even after frequent washing. The smoother surface structure of the yarn has a generally positive impact on the optical final appearance of the fabric. The higher color brilliance of piece- dyed articles more than Ring Spun Yarn result in an attractive final fabric appearance. The above advantages are observed practically in bulk production in Air jet weaving applications.

Twisting
The advantage in spinning also has an impact when it comes to twisting. In Compact yarn less twist is possible without any loss of strength. This results in lower manufacturing cost and the opportunity to manufacture new & softer twist yarns. Yarn in fine ply yarns offers a further advantage.

Singeing
The customary addition of weight to the yarn count, which is burned off in singeing, is no longer necessary. This amounts to raw material saving of 6 to 10%.
The rewinding process which is usually necessary to remove the singeing dust from the ply / single yarn can also be dispensed with.

Compact Yarn
Other than yarn hairiness, other yarn parameters such as Strength, Elongation, IPI and Uniformity are also better than Ring Spun Yarn and these advantages can also be exploited in down stream processing.

· Strength 15 ~ 20 % better
· Uniformity 10 ~ 15 % better
· IPI 60 ~ 70 % better
· Hairiness 15 ~ 20 % better
· OPS 20 ~ 25 % better

Conclusion
The advantages EliTe® Yarns can be economically utilized in a variety of ways: It is often possible to replace classical two-ply yarns by single EliTe® Yarns or conventional combed yarns by carded EliTe® Yarns.

Sizing can be completely or partially dispensed with. The same can be said about singeing.
If the strength of the conventional yarn is sufficient for the intended application, using the EliTe® technology will allow a reduction of twist by approximately 20%. This means a softer yarn, increased production and reduced energy consumption.

Not only in yarn manufacture and in further processing does EliTe®Yarn provide decisive advantages. Also the end product profits by the use of EliTe®Yarns.

Fabric handle becomes softer, print definition more brilliant due to better dye uptake, pilling resistance, lustre and strength increase. And, last but not least: Whenever the properties of conventional ring yarn are fully sufficient for the desired use, EliTe®Yarn can be spun from a less expensive raw material.

Of paramount importance for the practical mill operation is that compact spinning can be realized without any adverse effect on the operational safety standard expected of ring spinning frames. Also this stipulation is fully met with the SUESSEN-EliTe® Compact Spinning System.

The idea of Compact Spinning has been realized in an ideal manner in the SUESSEN EliTe® CompactSet. Easy handling and operational reliability are the key features for producing ring yarns in a quality not obtainable up to now. The resulting economic benefits for Yarn Producers and Yarn Users provide a quick return on investment. (The advantages EliTe® Yarns are reproduced from Spinnovation Suessen in-house magazine).