VORTEX SPINNING SYSTEM

Not all succeeded with the technology of Airjet spinning. But one , who acheived much better success in Airjet spinning system and it seems they successfully convinced many spinners as well as knitters that this yarn can really make some difference.

With the technological machines started from Roller Jet Spinning to Vortex Spinning , the company " Muratec " made an difference with their latest "VORTEX SPINNING MACHINES".

While Ring Spinning remains most successful spinning system yet today , we can not deny unique advantages which 'Vortex' yarns give.

In Ring Spinning improving Hairiness & Production reached almost saturation level , in which 'Vortex' gives excellent results.

Advantages ;

Less hariness & Clear appearance

High resistance to Pilling & abrasion

High moisture absorption

Less shrinkage & High wash resistance

Can be spun with various other materials such as cotton, synthetic fiber, regenerated fiber and blended fiber.

Yarn structure also suitable as core yarn.

MORE TECHNOLOGICAL ADVANTAGES ARE EXPLAINED HERE IN DETAIL.

The above is stated in Muratec website. We cant say everything good about 'vortex' there are some serious issues to be discussed. in which we still need to concentrate.

- THE STRENGTH AND TENACITY

- BY MEANS OF UNIQUE TWISTING PROCESS , YOU GET LESSER HAIRINESS AND VERY UNIFORM YARN STRUCTURE , ALONG WITH YOU GET VERY LESS STRENGTH AND ELONGATION. WHICH RAISES A QUESTION , HOW SUCCESSFUL THIS TECHNOLOGY IN CASE OF WEAVING. WITHOUT SUFFICIENT STRENGTH YOU CANT USE ANY YARN IN WEAVING , WHEREAS IN KNITTING IT CAN BE STILL WORKABLE AND MANAGEABLE.

ACCEPTABLITY FOR ALL MATERIALS.

- AS OF MY UNDERSTANDING , THE VORTEX SYSTEM IS SOME WHAT SUCCESSFUL IN 100% RAYON ( VISCOSE ) COUNTS ESPECIALLY WHEN USED IN KNITTING FASHION FABRICS.

- HAVE BEEN INFORMED BY SOURCES IT CAN BE SUCCESSFULLY USED FOR TR BLENDS TOO.

APART FROM THE ABOVE STILL OTHER MATERIAL YARNS ARE NOT ACCEPTED BY THE END USERS.

EXCESSIVE FIBRE LOSS DURING SPINNING ALSO RAISES A CONCERN ESPECIALLY WHEN SPUN WITH NATURAL FIBRES WHICH HAS IRREGULAR LENGTH OF FIBRES.

BY CONSIDERING THE INITIAL INVESTMENT , HIGH PRODUCTION AND SO ON , VORTEX WILL BE A SERIOUS THREAT TO OPEN END SPINNING SYSTEM

THE REASON WHY STILL WE CAN'T AVOID RING SPINNING SYSTEM

The main reasons why still ring spinning system is dominating the whole textile world.

Long before , say 2 decades are more open end spinning system was launched , everybody predicted that is the end point of ring spinning system. It survived , in fact Open End System was failed.

Why ?

A decade before , Airjet Spinning System developed by Murata , Japan , With the abnormal production increase , with the reduction of cone winding process and simplex(roving) process at any ways this project should become great success. But No. Even with recent update of Vortex Spinning , still the success was just only limited to 100% Viscose Yarn.

Even though with very smooth fabric surface , resistant to pilling still it cant beat fabric made by ring spinning system.

Why?

There are something "nature" made perfect , when you take about cloth quality - nature made ring spinning system as the perfect thing.

- Wide Range of Yarn Counts. From Ne 1 to Ne 300 - you can make with Ring Spinning System ( Eventhough with some practical difficulties.)

- With The natural twist flow , you will be rest assured of getting best strength possible.

- With even controllable drafting , the yarn created with better internal fibre structure , which is uniform and which makes the cloth very good hand feeling.

- Core yarn, Cover yarn, lycra , spandex and the list of special yarns goes for the time. Universally applicable and upgradable technology is Ring Spinning System.

- The raw materials of wide range or say almost all can be spun by using Ring and Traveller System.

- Drafting Speeds Can be Easily Controlled , which makes yarn unevenness better , however fibre length contributes as a major factor.

- When two entirely different fibres such as polyester and cotton blended - open end makes more harm to the yarn than doing good. Whereas Ring Spinning System is more flexible and more suitable for any kind of blending and any percent of blending.

- Yarns with SIRO process is considered one of the best quality because of its hand feeling , improved structure than doubled or single count. Which is not possible with any other spinning systems.

- Any Quantity can do very easily. , Sampling Process is very easy , fast , simple .

- Fine Yarns can be done very easily.

There are some more points to be discussed about this topic and hope time permits me in to do that next couple of weeks....

Catch you soon, please feel free to comment about this topic.

IS MAGNETIC PRINCIPLE HELPS ON RING TRAVELLER SYSTEM???

have u ever came across a new concept instead of present ring & traveller system??? ( forget about orbit / SU rings - all are in same generation.)

THE LIMITATION OF PRESENT RING & TRAVELLER SYSTEM

1. Due to continous contact in between rings & travellers , we are unable to increase the speed of ring frame above certain limit.
2. Many tried to reach 25000 rpm , but very less chance of success noticed due to more end breaks , higher worn-out of ring travellers , improper quality of the yarns etc., etc.,
3. the most important limitation is - FRICTION between RINGS & TRAVELLERS.

How to avoid the friction between ring & traveller.

• as of now , we can't avoid the friction , but we may try to reduce the friction , by using a better coating for both ring & travellers. or different profile of rings & travellers.

Why not we can have a better design - where there is no contact area in between rings & travellers ? If we able to achieve , no need of changing ring flange , no need of changing ring travellers , no limitation of speed , no much damage to the fibre strand , better yarn quality , better efficiency by avoiding traveller chnage & ring change...so many advantagous.........

Is it possible to do the same???//

If u ask me right now , the chance is REMOTE. But quite sometime before , i came across some article - the ring traveler system designed by using a magnetic principle....

We all know - Magnets has a character that opposite sides attract each other & the same sides distract each other.

on this case , If we have two magnets - One is Ring - X SIDE of a magnet & other is Ring travellers - Same X Side of a magnet ...............so it distract each other.............

Yarn is on the travellers and traveller is drived because of yarn pull ( as usual like now...)......

On this case , ring should be a electro magnet and traveller should be a permanent magnet.....

I hope this can be a possible if we have through practical research...............

Time will Say the Answer..! Isn't it?

Factors influencing Yarn Hairiness

Hairiness

The term, Hairiness in a spun yarn means, fibers which are protruding from the outer surface of the yarn. Hairiness Index in a yarn corresponds to the total length of protruding fibers within the measurement field of 1cm length of the yarn.

Major factors influencing Yarn Hairiness

There are number of factors influencing yarn hairiness from Speed Frame to Winding. I like to focus mainly on Ring Spinning Department.

Damaged Rings and Worn –out Ring Travellers.

Replace the damaged rings and match the perfect ring traveller which suits to the rings , materials , spindle speed etc.,

Prolonged usage of Ring Travellers.

Fix the optimum ring traveller life based on ring condition, spindle speed , yarn count & material.

Very light or very heavy Ring Traveller Numbers.

Choose the optimum traveller Number. The optimum traveller no. has to be assessed by Trial & Error method only.

Yarn clearance between ring and ring traveller is lesser than required.

Increase the yarn clearance by trying a high bow traveller. But please ensure that the high bow height ring traveller is not affecting your spindle speed. In general terms , low bow height ring traveller is suitable for high speed and a high bow height traveller reduces the stability of ring travellers while running.

Wire cross section of ring traveller should be used as per the material spun.

Ring Traveller manufactures are offering various wire profiles based on the material spun. In general sharper edges of a wire section reduces the yarn hairiness.

Traveller loading – i.e. Fluff accumulation on ring traveller.

More traveller loading increases the weight of ring travellers – Abnormal weight of ring travellers results in high yarn tension which leads to high hairiness.

Diameter of the full cop touches with the Ring Traveller while running.

Reduce the Cop Diameter with respect to ring diameter. Normally 3mm difference between Ring Diameter and Cop Diameter.

Spacer Size plays an important role in yarn hairiness.

Normally, technicians prefer thinner spacer to reduce the U% & Imperfections. But a thinner spacer may result in higher hairiness. Optimum Spacer can result in average quality and hairiness.

Yarn Twist

Lesser TPI reduces the control of short fibers from the core of the yarn. So, higher twist in the yarn may reduce the yarn hairiness.

Spinning Geometry

A higher lappet height from top of the cop leads to more yarn tension and it results in more yarn hairiness. Reducing the lappet height may result in lesser yarn hairiness, but please ensure that the yarn should not touch the top of the cop.

Using lesser ring dia and lesser lift reduces yarn hairiness significantly. More significance noticed when the spindle speed is constant.

Higher width of spinning triangle gives more time for fibers to get into the yarn strand and which gives lesser hairiness. Spinning Triangle varies based on winding angle and front roller offset.

Damaged suction tubes and snail wires may result in higher hairiness. Some recent study shows that, Ceramic based snail wires gives consistent Hairiness or say hairiness CV% between the spindles.

These are all the major factors which are directly influencing the yarn hairiness in ring spinning department. In addition, Roving Hank, Simplex spacer size, Cone Winding speed, Yarn Tension & Waxing method in winding also has great importance in controlling the yarn hairiness.