Denim Spinning

 

The production process of denim given in the following link gives the general idea of the process, the series of blogs like this give the brief explanation of the process and machines. Here in this blog we will go forward to second step, which is spinning:

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html 

The manufacturing of yarn starts with the transfer of the cotton bales chosen by a special software from the warehouse to the feeder of the blowing room which is the starting point of the yarn spinning halt.

From this point onwards the cotton undergoes many processes such as

cleaning opening and blending with the contents of other bales it is during this process that fibers which are too short are extracted. Process are briefly describe here:

https://bindaprocess.blogspot.com/2022/02/blow-room-process.html

CARDING

The cotton fibers are then subjected to a carding operation that ensures that the fibers are parallel to each other at the same time a vigorous and detailed cleaning of the material to be used in the yarn production is carried out in order to radiate to the next phase of manufacturing as a result of these operations the cotton fibers are transformed from the compressed randomly mixed material containing impurities to the sliver which have been neatly stacked into cans ready to the following processes.

Drawing

In the drawing frame process the sliver from different carding machines are joined to form a homogeneous mix and the parallelism of the fibers is further enhanced the bookends that are a part of the fibers nature are straightened out and the fibers are further lengthened. In order to monitor the weight per unit length of the produced sliver. Control highly developed electronic regulation systems are utilized. Sliver from the drawing frame operation with uniform mass per unit length are further drawn out by the roving frame.

Roving 

In this operation single twisted yarn  then wound onto tubes that can be used on the yarn machines. The roving is the final step before yarn is produced, after this operation the rovings are subjected to a further drawing out operation on the ring machines.

Ring Machine 

Ring machines further thinned out the yarn to the final required yarn thickness. During this operation the yarn gravity is subjected to a twist in order to give it the required durability. The ring machine determines the circuit structure and the physical attributes of the yarn being produced. 

Winding Process 

Last phase of yarn production is the winding process here the cops produced by the ring machines are spliced to each other and transformed into a bobbin format of specific lengths,  this splicing process is very important from the point of view of the productivity of subsequent phases. Where the bobbins will be used and the final appearance of the fabric developed. During the winding process the yarns are monitored every millimeter of the way by high technology sensors on the bobbin machines and faulty areas that may affect the texture of the fabric are eliminated.

Finally, color quality and authentic appearance is preliminary for  preparing the yarn for  Rope dyeing system which is the preferred system of denim production. The yarns that will be used in the warping  are stacked in the ball warping machines creel section and are all brought to the front of the machine to be transformed into Rope. The Rope does produced is then wound on two cylindrical shafts ready to be dyed in the indigo machine. following blog help in the understanding of process , how substantial dyeing range can be produced:

https://bindaprocess.blogspot.com/2022/02/textile-sustainable-denim-dyeing.html

 

BLOW ROOM PROCESS

The production process of denim given in the following link gives the general idea of the process, the series of blogs like this give the brief explanation of the process and machines. here in this blog we will get the idea of Blow room Process:

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html 

Overview

Department blow room is the first apartment inside the spinning mill. The m ain objective of blow room is opening, cleaning, Dust removal, Blending (even feed) for the material to the card blower machineries.

Operations

The operations involves loader, it all begins with lay down arrangements, where Bales are collected from Bale go downs based on the properties they possess, length strength micronized reflective

index which is checked through ketch VI instrument, improper lay down which caused variation in yarn.

Pluckers or blend or mat is the first machine in the department. where fibers are opened from bale with opening rollers which acts on bales and opens into fiber flocks. The height of bale pluckers advances during each transfers so that there will be constant opening of fibers. open fibers are transferred for  further fine opening and cleaning, and are  transported with the help of pipeline. condenser plays a vital role in transporting material to next machine. lean opened fibers from bale plucker reach to the unit precisely called Pre cleaner , through duct line. 

This  line eliminate heavy trash like seed particles, stones trash etc. These heavy particles drop down on the grid bar through gravity and suction generated by waste collection chamber these wastes will be collected through waste pipelines and will be stored in waste collection lines. 

Multi Mix pre-cleaned material reaches the multi mixer contains several chambers to collect the material. material will be filled in sequence in all chambers uniformly and it is controlled by a pressure switch. Material from all chambers mix uniformly inside the chamber before they exit, so the property will not very much different in the output fiber this is to avoid variation in yarn properties and this will be reflective in fabric appearance after dyeing.

flexi clean material from multi mixer is then transferred into fine

cleaning flexi clean material. Which  is subjected to fine beating achieved with the help of pin beta or sawtooth beta.

waste particles adhere to fibers will be removed during this

fine beating precisely called controlled beating. So it is very important to maintain the feed from uniform beating.

waste particles are eliminated through suction generated by waste collection chamber. Contamination cleaner particles which cannot be removed by Uni-clean of flexi clean machines like colored contaminations and polypropylene materials, should be transported and are removed through contaminated cleaners. These machines  particularly act upon colored particles and polypropylene materials. Presence of these materials in yarn should cause bad effect on fabric after dyeing.

Material rejected to these machines are later subjected to sorting where waste particles are separated from good fibers. This should reduce the overall fiber loss and improve yarn realization.