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Journal of Engineered Fibers and Fabrics 87 http://www.jeffjournal.orgVolume 7, Issue 1 2012

Comparison of Conventional Ring, MechanicalCompact and Pneumatic Compact Yarn Spinning Systems

Sevda Altas1, Hseyin Kadolu2

1Ege University Emel Akn Vocational School, zmir TURKEY

2Ege University Textile Engineering Department, zmir TURKEY

Correspondence to:Sevda Altas email: [email protected]

ABSTRACT

This research is a comparative study of the physicalproperties of mechanical compact and conventionalspun yarns and fabrics knitted from these yarns. Toexperiment the relational behavior, mechanicalcompact and conventional spun cotton yarns were

produced in three different yarn linear densitieshaving three twist levels. In order to examine theeffect of spinning systems on fabric properties single

jersey fabrics were knitted from these yarns. Resultsshowed that, compact spun yarns have less hairiness,higher strength and higher elongation ratio thanconventional spun yarns. Also, fabrics produced withcompact yarns were found to have less pillingtendency.

In the second part of the study, we compared the yarnproperties produced with conventional ring,mechanical compact and pneumatic compactspinning systems. Analysis showed that, yarns

produced with the pneumatic compact spinningsystem had the highest strength and the lowesthairiness.

Keywords: Mechanical compact spinning,conventional ring spinning, carded cotton, combedcotton, yarn physical properties, fabric physical

properties.

INTRODUCTION

In conventional ring spinning, the zone between thenip line of the delivery rollers and the twisted end ofthe yarn is called the spinning triangle. This is the

most critical part of the ring spinning system. In thiszone, the fiber assembly doesnt have any twist. Theedge fibers play out from this zone, and make little orno contribution to the yarn tenacity. Furthermore,they lead to yarn hairiness [1].

In compact spinning, the spinning triangle iseliminated and almost all fibers are incorporated intothe yarn structure under the same tension. This leads

to significant advantages such as increasing yarntenacity, yarn abrasion resistance and reducing yarnhairiness [2 and 3].

There are different compact spinning systems on the

market from different manufacturers. The maindifference of these systems is the condensing unit.

Most of the pneumatic compacting systems arecomposed of perforated drums or lattice aprons overthe openings of the suction slots. With the air flow,the fibers move sideways and they are consequentlycondensed. Today, pneumatic compact spinningsystem is widely used in compact yarn production.However the adaptation of this system toconventional ring spinning machine is very complexand expensive; also this method cause high additionalenergy consumption during spinning process.

Mechanical compact spinning is an importantalternative for compact yarn production. The systemis cheaper and less complicated than pneumaticcompact yarn spinning systems. Furthermore, there isnot any additional energy consumption during thespinning process [4].

In this study Rotorcraft mechanical compact spinningsystem (RoCoS) was used in the production ofcompact yarns. In RoCoS compact spinning system,the compact yarn is produced by adding positive nipat the end of the drafting unit. The condenser is heldagainst the bottom front drafting roller by means of a

magnet. By the help of the groove in the ceramiccompactor, fibers are brought closer and spinningtriangle is eliminated [5 and 6]. The view of theRoCoS mechanical compact spinning and the backview of magnetic compactor are given in Figure 1.

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FIGURE1. The view of RoCoS mechanical compact spinning andthe back view of the magnetic compactor.

The compacting zone of the compactor is the distancebetween the two nipping points (A and B). The fronttop roller and delivery rollers have the same are

peripheral speed; therefore fibers are not drafted inthis area.

A roving guide is attached to the top roller mill shaft.By the help of it, roving is fed into the center of theceramic compactor. Roving guide movement iscritical, during compacting process for the best

compact yarn production roving guide should bestopped. However in bulk production to increase thelife time of the roller, traversing distance must bereduced.

According to previous research, mechanical compactspinning significantly improves yarn tensile

properties and reduces its hairiness [7 and 8]. Untilnow there are many studies about the comparison ofthe conventional ring and compact yarns properties[9-12].

In the first part of the study, in order to understand

how the effect of spinning system varies on yarnlinear density and twist coefficient, we producedvarious compact and conventional spun yarns. In thesecond part of the study, we compared conventionalring, mechanical compact and pneumatic compactyarn spinning systems.

EXPERIMENTAL

Yarn Samples Production

In the experimental part of the study 100 % cardedcotton and 100 % combed cotton rovings having Ne1.04 and 45 T/m were collected from one spinningmill.

Carded and combed rovings used in the study wereproduced from (ait olmak) one type of cotton (EgeSt.1) raw material. By this way we could compare the

physical properties of mechanical compact spuncarded and conventional spun combed yarns. Thefiber properties measured with High VolumeInstrument (HVI) test machine were given in Table I.

The first part of the study was carried out in EgeUniversitys Textile & Apparel Research andApplication Centre while the second part of the studywas carried out at one of the textile mill in Turkey.For this reason the spinning particulars of two set of

experimental yarns could not be the same as can beseen in Table II for the first part of the study andTable IIIfor the second part of the study.

In the first part of the study, during mechanicalcompact and conventional yarn spinning, the samerovings and the same spindles were used in order toeliminate any possible effect of roving and spindle onyarn quality properties. Yarn linear densities werechosen as; 29.5/1 tex (Ne 20/1), 19.6/1 tex (Ne 30/1)and 14.7/1 tex (Ne 40/1). For each yarn count, threetwist coefficients were chosen as;

tex = 103 (e = 3.4),

tex

= 115 (e = 3.8)

tex

= 127 (e = 4.2).

In the second part of the study, we comparedconventional ring, mechanical compact and

pneumatic compact yarn spinning systems. RieterK44 pneumatic compact spinning system was used inthe production of pneumatic compact yarns. We used100 % combed rovings which were used in the first

part of the study. Yarn linear densities were chosen

as; 13.1/1 tex (Ne 45/1), 9.5/1 tex (Ne 62/1) and 7.8/1tex (Ne 75/1) having the same twist coefficients as;

tex

=120 (e = 4.0).

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TABLE I. Raw Material Physical Properties.

Measured fiber propertiesCarded

cottonCombed cotton

Fiber fineness, micronaire 4.30 4.35

Fiber strength, gr/tex 37.00 39.02

2.5 % span length, mm 28.43 29.57

Uniformity, % 85.40 86.62

Short fiber percentage, % 6.83 5.75

Elongation at break, % 4.40 4.82

TABLE II. Spinning particulars for conventional ring and mechanical compact yarn spinning systems.

Technological/machine set parametersYarn linear density

29.5/1 tex 19.6/1 tex 14.76/1 tex

Ring yarn typeConventional /

Mechanical CompactConventional /

Mechanical CompactConventional /

Mechanical Compact

Theoretical twist coefficient (tex

) 103 115 127 103 115 127 103 115 127

Theoretical twists (turns/m) 602 667 735 735 818 902 838 947 1044

Spindle speed (rpm) 10.000 10.000 10.000Ring diameter (mm) 42 42 42

Traveller type (ISO No) 80 45 35.5

Traveller design and finishing treatment SFB 2.8 pm dr Saphir SFB 2.8 pm dr Saphir SFB 2.8 rl dr Saphir

Cradle spacer thickness (mm) 3.75 3.25 2.75

TABLE III. Spinning particulars for conventional ring, mechanical compact and pneumatic compact yarn spinning systems.

Technological/machine set parametersYarn linear density

13.1/1 tex 9.5/1 tex 7.8/1 tex

Compacting systemRing / RoCoS /

Rieter K44Ring / RoCoS /

Rieter K44Ring / RoCoS /

Rieter K44

Theoretical twist coefficient (

tex

) 121 121 121

Theoretical twists (turns/m) 1056 1239 1363

Spindle speed (rpm) 18.500 17.000 16.000

Ring diameter (mm) 42 42 42

Traveller type (ISO No) 25 25 23.6

Traveller design and finishing treatment c1 el udr Safir c1 el udr Safir c1 el udr Safir

Cradle spacer thickness (mm) 2.75 2.75 2.75

Yarn evenness, faults, hairiness and diameterproperties were tested using an Uster Tester 5(UT5). We tested each type of yarn 10 times with400 m/min test speed. Yarn tenacity and elongation

properties were tested with a Tensojet. We tested

each type of yarn 25 times with 200 m/min testspeed.

For a comprehensive examination of yarn hairiness,the average hairiness of yarns was also measuredwith a Keisokki Laserspot Hairiness DiameterTester. This instrument measures hairiness andyarn diameter at the same time using a laser beam.The instrument counts the number of hairs in

different length classes including 1 mm, 2 mm, 3,mm and calculates the hairiness index. In thisstudy, we tested each type of yarn 5 times with a 50m/min test speed and evaluated the hairiness indexresults.

All tests were performed after the yarns were keptin standard atmospheric conditions for 24 hours(655 % relative humidity, 202C).

In the analysis of test results, Factorial ANOVAand Multiple ANOVA (LSD) methods were usedwith SPPS statistical pocket program at 0.05significance level.

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Fabric Samples Production

Ring and compact yarns were knitted with 48-gauge, 12-inch diameter Mesdan 294 E laboratoryknitting machine with 225 turn/min productionspeed.

The pilling properties were measured with aMartindale Abrasion and Pilling Tester by 2000revolutions. The pilling tendencies due to frictionof 6 different fabric surfaces were determinedaccording to the ISO 12947-1 standard. Later weused an SDL Atlas Automated 3D Pilling and FuzzGrading test machine to assess pilling grade values.

The bursting strength measurements of 5 differenttype of fabric were determined according to ISO13938-2 (7.3 cm2 area; 30.5 mm diameter) withJames Heal Truburst test device.

All tests were performed after the fabrics were kept

in standard atmospheric conditions for 24 hours(655 % relative humidity, 202C).

RESULTS AND DISCUSSION

Evaluating the Yarn Properties

According to experimental results of yarn lineardensities, compact yarns were found to be coarserthan conventional yarns due to elimination of fiberfly in compact yarn spinning system.

We analyzed the main effects which are yarn lineardensity, twist coefficient and spinning system onyarn properties. We also analyzed the interaction

effects of spinning system versus yarn lineardensity and spinning system versus twistcoefficient.

Figures 2-7 shows the main effect plots on bothcarded and combed yarns. The effect of spinningsystem is shown as X1 and X4. The effect of yarnlinear density is shown as X2 and X5. The effect oftwist coefficient is shown as X3 and X6. Mrepresents the mean value for each observed yarn

property. In the graphics R represents the ringspinning system and C represents the compact yarnspinning system.

According to the statistical analysis the effect ofyarn linear density is significant on all observedyarn properties. As the yarn linear density increaseevenness, the number of thin place, the number ofthick place and neps values increase, hairiness,diameter, tenacity and elongation values decrease.

In carded yarns, increase of twist coefficientincreases the evenness, tenacity and elongationvalues and decreases hairiness (Uster and Keisokki)and diameter values significantly. On the otherhand, we couldnt observe any significant relation

between twist coefficient and the number of thinplace, the number of thick place and neps values.

In the combed yarns, the increase of twistcoefficient increase tenacity and elongation anddecreases the number of thick place, neps, Usterhairiness and diameter values significantly. On theother hand, we couldnt observe any significantrelation between twist coefficient and Keisokkihairiness, evenness and the number of thin placevalues. Due to having different measuring

principles, the effect of twist coefficient on Usterand Keisokki hairiness results are not similar in alltype of yarns observed in this study.

Table IV represents the Factorial ANOVAstatistical results of the yarn properties. F valuerepresents whether a significant difference amongtreatment means or interactions exists. Significance(Sig.) value represents the homogeneity ofvariances, if it is less than 0.05 than we can say thatthe effect is statistically significant.

FIGURE 2. The main effect plots for yarn evenness.

FIGURE 3. The main effect plots for yarn hairiness (uster).

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FIGURE 4. The main effect plots for yarn hairiness (keisokki).

FIGURE 5. The main effect plots for yarn diameter.

FIGURE 6. The main effect plots for yarn tenacity.

FIGURE 7. The main effect plots for yarn elongation.

TABLE IV. The F and significance values of factorial ANOVA analysis for conventional ring and mechanical compact spun yarns.

Compared pairs

Spinning

system

Spinning system*

Yarn linear density

Spinning system* Twist

coefficient

Carded cotton Combed cotton Carded cotton Combed cotton

Carded

cotton Combed cotton

F Sig. F Sig. F Sig. F Sig. F Sig. F Sig.

CV (%) 260.40 .000* 44.54 .000* 22.39 .000* 28.78 .000* 0.57 .562 0.915 .403

Thin place (-%50) 16.54 .000* 2.70 .102 3.19 .043* 5.13 .007* 0.006 .994 0.736 .481

Thick place(+%50) 94.34 .000* 4.44 .036* 5.78 .004* 18.94 .000* 0.20 .811 1.01 .364

Neps (+%200) 40.35 .000* 36.87 .000* 53.67 .000* 58.12 .000* 2.74 .067 6.18 .003*

Hairiness (Uster) 1428.3 .000* 4055.2 .000* 7.11 .001* 25.66 .000* 1.01 .366 15.19 .000*

Hairiness (Keisokki) 629.0 .000* 259.58 .000* 4.70 .045* 8.62 .010* 1.47 .284 0.39 .689

Diameter (mm) 1392.7 .000* 2255.9 .000* 31.86 .000* 63.55 .000* 2.61 .076 13.63 .000*

Tenacity (cN/tex) 329.35 000* 219.92 .000* 12.02 .000* 7.44 .001* 0.79 .454 1.16 .317

Elongation (%) 133.94 .000* 137.32 .000* 6.14 .000* 10.82 .000* 0.36 .693 1.55 .217

* Statistically significant.

Based on the analysis results following conclusionscan be drawn:

Yarn Evenness Results

The experimental results of conventional andcompact spun yarns evenness are given in Figure 8.According to statistical analysis, the effect of

spinning system is statistically significant on bothcarded and combed yarn evenness as shown in TableIV.

Carded compact yarns have higher evenness valuesthan carded conventional ring yarns. The interactioneffect of spinning system and yarn linear density is

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statistically significant. The difference between theevenness values of conventional and compact spuncarded yarns increases as the yarn becomes coarser.

Combed compact yarns have higher evenness valuesthan combed conventional ring yarns. The interactioneffect of spinning system and yarn linear density isstatistically significant. While at 29.5 tex and 19.6 texcombed compact yarns have higher evenness thanconventional ring yarns, at 14.7 tex conventional ringyarns have higher evenness values than combedcompact yarns.

The reason behind the higher irregularity of thecompact yarns can be explained by the use of front

bottom roller in mechanical compact spinning system(Figure 1). Rollers cause irregularities in the draftedstrand since there is an incomplete control of themotion of each individual fiber or fiber groupespecially for coarser yarns. Similar result is obtained

with previous study about mechanical compactspinning [8].

In both carded and combed yarns the interactioneffect of spinning system and twist coefficient onyarn evenness isnt statistically significant.

Yarn Imperfection Results

In carded yarns, the effect of spinning system isstatistically significant on the number of thin places,the number thick places and neps values (Table IV).Carded compact yarns have higher thin place, thick

place and neps values than carded conventional ring

yarns. The interaction effect of spinning system andyarn linear density is statistically significant. Thedifference between the number of thin places, thenumber of thick places and neps value of compactand conventional spun carded yarns increases as theyarn becomes coarser.

FIGURE 8. The evenness of compact and conventional spun yarns.

In combed yarns the effect of spinning system isstatistically significant on the number of thick placesand neps values (Table IV). Combed compact yarnshave higher thick place and neps values than combedconventional ring yarns. The interaction effect ofspinning system and yarn linear density is statisticallysignificant. While at 29.5 tex and 19.6 tex combedcompact yarns have higher number of thick placesand neps, at 14.7 tex conventional combed ring yarnshave higher number of thick places than compactyarns. This result can be explained with the weakcontrol of fibers in coarse yarn due to the increasednumber of fibers in the yarn cross section.

The interaction effect of spinning system and twistcoefficient is only statistically significant on nepsvalues of combed yarn. However the effect isirregular and the trend is unclear to accept the

presence of any meaningful relation.

Yarn Hairiness ResultsThe Uster and Keisokki hairiness test results ofconventional and compact spun yarns are given inFigure 9 and Figure 10 respectively. According tostatistical analysis, the effect of spinning system isstatistically significant on both carded and combedyarn hairiness as shown in Table IV.

Carded and combed compact yarns have lowerhairiness (Uster and Keisokki) than carded andcombed conventional ring yarns. This could beexplained by the elimination of spinning triangle incompact yarn spinning system.

With both Uster and Keisokki hairiness test result,the interaction effect of spinning system and yarnlinear density is statistically significant on carded andcombed yarn hairiness (Table IV). However the effectis irregular varying yarn linear density and the trendis unclear to accept the presence of any meaningfulrelation.

The interaction effect of spinning system and twistcoefficient is only statistically significant on Usterhairiness values of combed yarn. The differences

between compact combed and conventional combed

yarn hairiness values increases as the yarn twistcoefficient decreases. This shows that the advantageof the compact spinning system on combed yarnhairiness property is more noticeable at lower twistlevels.

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FIGURE 9. The hairiness (uster) results of compact andconventional spun yarns.

FIGURE 10. The hairiness (Keisokki) results of compact andconventional spun yarns.

Yarn Diameter Results

The diameter measurement results of conventionaland compact spun yarns are given in Figure 11.According to statistical analysis, the effect ofspinning system is statistically significant on bothcarded and combed yarn diameter as shown in TableIV. The diameter values of carded and combedcompact yarns are lower than the carded and combedconventional ring yarns.

Due to elimination of spinning triangle in compactspinning, the migration of fibers in compact yarns isdeeper and as a result of this compact yarns diameteris smaller than conventional spun yarns [8 and 13].

The interaction effect of spinning system and yarnlinear density is statistically significant on bothcarded and combed yarns diameter. The difference

between the diameter values of conventional ring andcompact yarn increases as the yarn becomes coarser.

FIGURE 11. The diameter results of compact and conventionalspun yarns.

The interaction effect of spinning system and twistcoefficient is statistically significant on combed yarndiameter. The difference between the diameter valuesof conventional and compact spun combed yarns

decreases as the twist coefficient increases.

Yarn Tenacity and Elongation Ratio Results

The tenacity measurement results of conventional andcompact spun yarns are given in Figure 12.According to statistical analysis, the effect ofspinning system is statistically significant on bothcarded and combed yarn tenacity and elongation

properties as shown in Table IV. The tenacity andelongation values of carded and combed compactyarns are significantly higher than carded andcombed conventional ring yarns. The diameter valuesof compact yarns were smaller than those ofconventional ring yarns. In other words the density ofthese yarns was higher. The higher density wouldalso infer higher fiber to fiber interaction and thushigher strength [8 and 13].

The interaction effect of spinning system and yarnlinear density is statistically significant on bothcarded and combed yarn tenacity and elongationratio. The difference between the tenacity andelongation values of conventional and compact spunyarns decreases as the yarn becomes coarser.

For both carded and combed yarns, the interactioneffect of spinning system and twist coefficient isnt

statistically significant on yarn tenacity andelongation ratio.

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Evaluating the Knitted Fabric Properties

Table Vshows the thickness and the weight per unitarea of fabrics knitted with conventional and compactyarns. The weight per unit area of fabrics knitted withcompact yarns is higher than the fabrics knitted withconventional ring yarns. The difference in the weight

per unit area of the fabrics is due to the differencebetween the yarn liner densities of conventional ringand compact spun yarns. However we couldntobserve any significant difference between thethicknesses of the knitted fabrics.

FIGURE 12. The tenacity results of compact and conventionalspun yarns.

TABLE V. The thickness and weight per unit area of fabrics knitted with conventional ring and mechanical compact spun yarns.

FIGURE 13. The main effect plots for fabric bursting strength. FIGURE 14. The main effect plots for fabric pilling grade.

Fabric property

Yarnlinear

density(tex)

Twist coefficient (e)

3.4 3.8 4.2

Weightper unit

area(gr/m)

%CVThickness

(mm)%CV

Weightper unit

area(gr/m)

%CVThickness

(mm)%CV

Weightper unit

area(gr/m)

%CVThickness

(mm)%CV

Fabrics knittedwith cardedring yarn

29.5/1 140 4.38 0.73 0.01 149 4.91 0.75 0.02 146 7.93 0.77 0.02

19.6/1 94 5.85 0.69 0.03 95 0.38 0.72 0.02 102 2.09 0.75 0.02

14.7/1 62 1.13 0.57 0.02 66 1.30 0.68 0.01 69 2.98 0.73 0.03

Fabrics knittedwith cardedcompact yarn

29.5/1 151 1.90 0.72 0.01 157 2.00 0.73 0.02 164 2.58 0.78 0.02

19.6/1 100 3.07 0.69 0.02 103 1.72 0.74 0.02 111 1.72 0.79 0.02

14.7/1 66 0.99 0.62 0.03 72 0.99 0.69 0.04 81 0.50 0.73 0.03

Fabrics knittedwith combedring yarn

29.5/1 148 1.30 0.70 0.05 153 2.83 0.76 0.02 153 2.64 0.77 0.02

19.6/1 98 7.64 0.69 0.03 96 1.96 0.67 0.02 103 3.05 0.73 0.02

14.7/1 70 4.42 0.62 0.04 69 0.38 0.67 0.02 70 2.28 0.70 0.02

Fabrics knittedwith combedcompact yarn

29.5/1 152 1.40 0.70 0.03 163 1.26 0.74 0.03 163 1.61 0.77 0.0319.6/1 92 2.07 0.66 0.02 99 5.55 0.73 0.03 110 1.30 0.78 0.02

14.7/1 68 1.35 0.65 0.01 76 3.34 0.75 0.02 81 6.54 0.75 0.01

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Figure 13 and Figure 14 show the main effect plotsof fabric bursting strength and pilling graderespectively. The effect of spinning system is shownas X1 and X4. The effect of yarn linear density isshown as X2 and X5. The effect of twist coefficientis shown as X3 and X6. M represents the mean valuefor each observed fabric property. In the graphics Rrepresents the ring spinning system and C representsthe compact yarn spinning system.

For the fabrics knitted with carded yarns, the effect ofyarn linear density is statistically significant on the

pilling grade and bursting strength propertiesaccording to the statistical analysis. The pilling gradeand bursting strength values of the fabrics increase asthe yarn becomes coarser.

For the fabrics knitted with combed yarns, the effectof yarn linear density is statistically significant on the

bursting strength property. The bursting strength

values of the fabrics increase as the yarn becomescoarser. On the other hand, we couldnt observe anysignificant relation between combed yarn lineardensity and pilling grade of the fabrics.

In both carded and combed yarns, the effect of twistcoefficient on pilling grade and bursting strength

properties of fabrics isnt statistically significant.

As it can be seen in Table VI, fabric produced fromcompact yarn has significantly higher burstingstrength than fabric produced from conventional

ring yarn. The bursting strength results of fabricsproduced with compact and conventional spun yarnsare shown in Figure 15.

The yarn tenacity contributes the bursting strength ofthe fabrics. The increase of yarn tenacity increasesthe bursting strength property of fabrics. Thedifference between the bursting strength values offabrics knitted with conventional ring and compactyarns are less noticeable than the difference betweenthe tenacity values of these yarns.

The difference between bursting strength results ofthe fabrics produced with compact and conventionalspun yarns doesnt change according to yarn lineardensity and twist coefficient used in the knitting.

The pilling results of the fabrics knitted conventionaland compact spun yarns are shown in Figure 16.Fabrics produced from compact yarns significantly

have higher pilling grade than the fabrics producedfrom conventional ring yarns.

Pilling tendency of fabrics is affected by the yarnhairiness. The fabrics knitted with compact yarnshave better pilling performance compared to thefabric knitted from conventional ring yarns.

The interaction effect of spinning system and yarnlinear density effect is significant on fabric pillinggrade. However we couldnt find linear correlation ofthe interaction effect of spinning system and yarnlinear density.

TABLE VI. The F and significance values of factorial ANOVA analysis for knitted fabrics withconventional ring and mechanical compact spun yarns.

Compared pairs

Spinning systemSpinning system*Yarn linear

density

Spinning system*Twist

coefficient

Carded cotton Combed cotton Carded cotton Combed cotton Carded cotton Combed cotton

F Sig. F Sig. F Sig. F Sig. F Sig. F Sig.

Bursting strength (kPa) 24.92 .001* 13.94 .006* 0.92 .434 1.52 .275 0.04 .956 0.51 .617

Pilling grade 104.04 .000* 12.36 .008* 11.08 .005* 2.39 .153 2.52 .142 1.09 .380


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FIGURE 15. The fabric bursting strength of compact andconventional spun yarns.

FIGURE 16. The fabric pilling grade results of compact andconventional spun yarns.

The Comparison of Conventional Combed and

Compact Carded Yarns and Fabrics Produced

with Them

Table VII shows the statistical analysis forconventional combed and compact carded yarns.Compact spun carded yarn has significantly higherevenness, the number of thin places, the number ofthick places and neps values than conventionalspun combed yarn.

Carded cotton has higher short fiber ratio thancombed cotton. Due to the incomplete control ofthe short fibers in compact yarn spinning systemcarded compact yarn has higher evenness andimperfection values than conventional combedyarn.

However, due to elimination of spinning triangle,compact spun carded yarn has lower hairiness,diameter and similar tenacity and elongation values

with conventional combed yarn.

TABLE VII. The F and significance values of factorial ANOVA analysis for conventional combed and compact carded yarns.

Compared pairsSpinning system

Spinning system*

Yarn linear density

Spinning system* Twist

coefficient

F Sig. F Sig. F Sig.

CV (%) 6327.6 .000* 15.60 .000* 1.10 .334

Thin place (-%50) 248.06 .000* 106.02 .000* 0.55 .578

Thick place(+%50) 1528.5 .000* 231.36 .000* 0.77 .465

Neps (+%200) 1026.7 .000* 110.97 .000* 8.20 .000*

Hairiness (Uster) 759.2 .000* 6.97 .001* 2.96 .054

Diameter (mm) 148.3 .000* 7.85 .001* 2.36 .097

Tenacity (cN/tex) 0.70 .404 9.57 .000* 6.36 .003*

Elongation (%) 0.11 .732 3.54 .033* 0.69 .501


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TABLE VIII. The F and significance values of factorial ANOVA analysis fabrics produced with conventional combed and compact cardedyarns.

Compared pairsSpinning system

Spinning system*Yarn linear

density

Spinning system*Twist

coefficient

F Sig. F Sig. F Sig.

Bursting strength (kPa) 23.00 .001* 6.59 .020* 0.34 .719 23.00 .001* 6.59 .020* 0.34 .719

Pilling grade 7.82 .023* 1.08 .384 0.43 .659 7.82 .023* 1.08 .384 0.43 .659


Table VIII shows the statistical analysis for fabricsknitted with conventional combed and compactcarded yarns. Although carded compact andconventional combed yarn has similar tenacityvalues, fabric produced with compact carded yarnshas lower bursting strength than fabric produced withconventional combed yarns. This can be explained bynon-uniform fiber arrangement in carded cotton rawmaterial.

Fabric produced with compact carded yarn has betterpilling properties because carded compact yarn hasless hairiness than conventional combed yarns.

The Comparison of Yarn Properties Produced

with Conventional Ring, Mechanical Compact and

Pneumatic Compact Yarn Spinning Systems

In this part of the study, we compared the propertiesof yarns produced with conventional ring, mechanicalcompact and pneumatic compact spinning systems.

Table IX shows the multiple comparison of

conventional ring, mechanical compact andpneumatic compact yarn spinning systems.According to statistical analysis results, pneumaticcompact spun yarn has the least evenness, the number

of thin place, the number of thick place, hairiness,diameter and the highest tenacity and elongationvalues.

Conventional spun yarn has the highest neps valuecompared to mechanical and pneumatic compactspun yarns. There isnt any statistically significantdifference between the neps values of pneumatic andmechanical compact spun yarns.

Conventional ring yarn has the highest thin place,neps, hairiness, diameter and the lowest tenacity andelongation values. Pneumatic compact spun yarn haslowest number of thick place value compared toconventional ring and mechanical compact spun yarn.There isnt any statistical significant between thenumber of thick places between conventional ringand mechanical compact spun yarns.

While the pneumatic compacting system usesvacuum effect in the compacting zone, mechanicalcompacting system uses the magnetic force. The

force applied to fibers in pneumatic compact spinningsystem is stronger than mechanical compact spinningsystem. As a result of this pneumatic compact spunyarn has less evenness, fewer imperfections, lowerhairiness and has higher tenacity and elongationvalues compared to mechanical compact spun yarn.

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TABLE IX. The multiple comparisons (LSD) of conventional ring, mechanical compact and pneumatic compact yarn spinning systems.

Yarn property Compared pairs Mean Difference Significance

CV (%)

Conventional RingMechanical Compact .1760 .192Pneumatic Compact 1.5353 .000*

Mechanical CompactConventional Ring -.1760 .192Pneumatic Compact 1.3593 .000*

Pneumatic Compact Conventional Ring -1.5353 .000*Mechanical Compact -1.3593 .000*

Thin place (-%50)

Conventional RingMechanical Compact 54.000 .001*Pneumatic Compact 136.833 .000*

Mechanical CompactConventional Ring -54.000 .001*Pneumatic Compact 82.833 .000*

Pneumatic CompactConventional Ring -136.833 .000*Mechanical Compact -82.833 .000*

Thick place (+%50)

Conventional RingMechanical Compact 10.666 .372Pneumatic Compact 101.333 .000*

Mechanical CompactConventional Ring -10.666 .372Pneumatic Compact 90.666 .000*

Pneumatic CompactConventional Ring -101.333 .000*Mechanical Compact -90.666 .000*

Neps (+%200)

Conventional RingMechanical Compact 65.166 .000*

Pneumatic Compact 86.333 .000*Mechanical Compact

Conventional Ring -65.166 .000*Pneumatic Compact 21.166 .072

Pneumatic CompactConventional Ring -86.333 .000*Mechanical Compact -21.166 .072

Hairiness (Uster)


Mechanical CompactConventional Ring -1.770 .000*Pneumatic Compact .1787 .008*

Pneumatic CompactConventional Ring -1.949 .000*Mechanical Compact -.1787 .008*

Hairiness (Keisokki)


Mechanical CompactConventional Ring -12.740 .000*Pneumatic Compact 1.326 .000*

Pneumatic Compact

Conventional Ring -14.066 .000*

Mechanical Compact -1.326 .000*

Diameter (mm)

Conventional RingMechanical Compact .0235 .000*Pneumatic Compact .0299 .000*

Mechanical CompactConventional Ring -.0235 .000*Pneumatic Compact .0064 .000*

Pneumatic CompactConventional Ring -.0299 .000*Mechanical Compact -.0064 .000*

Tenacity (cN/tex)

Conventional RingMechanical Compact -4.033 .000*Pneumatic Compact -6.320 .000*

Mechanical CompactConventional Ring 4.033 .000*Pneumatic Compact -2.286 .000*

Pneumatic CompactConventional Ring 6.320 .000*Mechanical Compact 2.286 .000*

Elongation (%)

Conventional RingMechanical Compact -.2733 .004*Pneumatic Compact -.6067 .000*

Mechanical Compact Conventional Ring .2733 .004*Pneumatic Compact -.3333 .001*

Pneumatic CompactConventional Ring .6067 .000*Mechanical Compact .3333 .001*


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CONCLUSION

In the first part of the study, we compared theproperties of yarns produced with conventional ringand mechanical compact yarn spinning systems.

Compact yarns were found to have lower hairinessthan conventional ring yarns. The reason behind thelower hairiness in compact spun yarn is theelimination of spinning triangle in spinning system.

Compact yarns were found to have smallerdiameter and better tensile properties thanconventional ring yarns. As the yarn diameterdecreases the fiber to fiber interaction increases andthis leads to higher yarn tenacity and elongationratio.

The mechanical compact spinning system slightlyincreases the evenness and imperfection values ofyarns. However, as the yarn becomes finer these

effects gradually disappear.

The superior properties of compact yarns are seenclearly on the fabric quality. Fabrics knitted withcompact yarns were found to have better pilling

properties and higher bursting strength than fabricsknitted with conventional ring yarns.

Compact spun carded yarn was to found to havelower hairiness and similar tensile propertiescompared to conventional combed yarn; however ithas significantly higher evenness, number of thin

places, number of thick places and neps values. If

the evenness property of carded compact yarn canbe improved, it will have a potential for improvingquality and profitability of cotton yarnmanufacturing.

Fabrics knitted with compact carded yarns werefound to have better pilling properties than fabricsknitted with conventional combed yarns. Althoughcarded compact and conventional combed yarnswere found to have similar tenacity values, fabricsknitted with compact carded yarns had lower

bursting strength than fabrics produced withconventional combed yarns. This can be explained

by non-uniform fiber arrangement in carded cottonraw material.

In the second part of the study we compared theproperties of yarns produced with conventionalring, mechanical compact and pneumatic compactyarn spinning systems.

Pneumatic compact spun yarns were found to havebetter yarn properties than mechanical compactspun yarn. They had less evenness, lessimperfections, lower hairiness, higher tenacity andhigher elongation values. The reason behindunsatisfactory test results could be the weakcompacting power of mechanical compactingsystem.

There are different compact spinning systems onthe market from different manufacturers. In thisstudy we compared only the most commonly used

pneumatic compact spinning system. A furtherstudy about the comparison of mechanical compactspinning with other pneumatic compacting systemsshould be a valuable contribution to the decision-makers in the short-staple spinning industry.

REFERENCES

[1] S. merolu, and S. lk, An Investigationabout Tensile Strength, Pilling andAbrasion Properties of Woven FabricsMade from Conventional and CompactRing-Spun Yarns, Fibers & Textiles inEastern Europe, 2007, 15(1), p. 39-42.

[2] Kampen, W., The Advantages of CondensedSpinning,Melliand English, 2000, No.4, p.58-59.

[3] Cheng, K.P.S. Yu, C., A Study of CompactSpun Yarns, Textile Research Journal,2003, No 4, p. 345-349.

[4] Jayavarthanavelu, D., Compact SpinningSystem-Lakshmi RoCoS 1.14, TechnicalNewsletter Textile Machinery Division,

2006, p. 12, 2-4.[5] Stahlecker, H., RoCoS Rotorcraft Compact

Spinning, Rotorcraft Technical Brochure,2005, p. 1-8.

[6] Joseph, K., Easily Mountable RoCoSCompact from Rotorcraft for Ring YarnSpinning System, XI. International IzmirTextile & Apparel Symposium, eme,2007, p. 1-14.

[7] Beceren, Y., Nergis, B., U., Comparison ofthe Effects of Cotton Yarns Produced by

New, Modified and Conventional SpinningSystems on Yarn and Knitted FabricPerformance, Textile Research Journal,2008, 78(4), p. 297 - 303.

[8] S. Ganesan, A. Venkatachalam, V.Subramaniam, Fiber Migration in CompactSpun Yarns: Part II Mechanical CompactYarn, Indian Journal of Fiber & TextileResearch, 2007, 32, p. 169 - 172.

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[9] Dash, J.,R., Ishtiaque, S.,M., andAlagirusamy, R., Properties andProcessibility of Compact Yarns, IndianJournal of Fiber & Textile Research, 2002,Vol. 27 (4), pp. 362-368.

[10] Jackowski, T., Cyniak, D, and Czekalski, J.,Compact Cotton Yarn, Fibers & Textiles inEastern Europe, 2004, Vol. 12(4), pp. 22-26.

[11]Nikolic, M., and et al., Compact Spinning forImproved Quality Of Ring-Spun Yarns,Fibers & Textiles in Eastern Europe, 2003,Vol. 11(4), pp. 30-35.

[12] Mavruz, S. ve Oulata, R. T., StatisticalInvestigation of Properties of Ring andompact Yarns and Knitted Fabrics Made ofThese Kinds of Yarns, Tekstil veKonfeksiyon, 2008, Vol. 3, pp. 197-205.

[13] Baal, G., and Oxenham, W., Comparison ofProperties and Structures of Compact and

Conventional Spun Yarns, Textile ResearchJournal, 2006, 76(7), p.567- 575.

AUTHORS ADDRESSES

Sevda Altas

Ege UniversityEmel Akn Vocational Schoolzmir, Bornova 35500TURKEY

Hseyin Kadolu

Ege UniversityTextile Engineering Department

zmir, Bornova 35500TURKEY

Date post:	05-Apr-2018
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