Shahid Abdur Rab Serniabat Textile Engineering

College, Barishal
Affiliated by Bangladesh University of Textiles

Project Report
On
“Investigation of Energy Consumption in Yarn Production With Special
Reference to Open-End Rotor Spinning”

Supervised By:
Engr. Md. Ahshanul Hoq
Lecturer (Textile)
Shahid Abdur Rab Serniabat Textile Engineering College, Barishal

Submitted By:
Name Student ID No. Session
Chinmoy Das Mithun B-201611007 2015-2016
Md Anas Imam B-201611009 2015-2016
Rifat Bin Sattar B-201611011 2015-2016
Md Tanvir Rahman B-201511021 2014-2015

Dept. of Yarn Manufacturing Engineering

Shahid Abdur Rab Serniabat Textile Engineering College pg. 1

 ACKNOWLEDGEMENT

Shahid Abdur Rab Serniabat Textile Engineering College, Barisal has given us the
opportunity to perform the project work. We are grateful to Engr Md. Ahshanul Hoq,
Lecturer (Textile) & Supervising Teacher of our college for guiding us to accomplish the
project work. We also take the opportunity to express our sincere gratitude to Engr. Abdul
Kader Bepari, Principal for his kind co-operation.

Above all, we would like to acknowledge our deep debt to all the teachers of our college,
and specially of Yarn Manufacturing Department for their kind inspiration & help. It reminds
us the backdrop of all our effort. Finally, we would like to convey our acknowledgement that
we remain responsible for the inadequacies & errors, which doubtless remain.

ABSTRACT

During the past 40 years, rotor spinning has established itself as an effective and important
yarn manufacturing process. Rotor spinning overcomes all the problems of ring spinning by
separating twisting and winding in the yarn manufacturing process. The aim of this study is
to evaluate the energy consumption, in general, for open-end rotor type yarn
manufacturing systems and to examine the energy consumption in a chosen spinning mill by
considering available data including installed power as well as monthly and yearly energy
usage. A simple theoretical approach for predicting specific energy consumption in a
particular yarn type produced in the spinning mill selected has been developed. The results
obtained by applying this model to a specific yarn have been compared with relevant values
available in literature.

Shahid Abdur Rab Serniabat Textile Engineering College pg. 2

 KEY WORDS

 Rotor yarn
 Open-end Rotor Manufacturing
 Energy Consumption of Rotor Yarn Manufacturing
 Cost of Rotor Yarn Manufacturing
 Advantage of Rotor Yarn
 End uses

Shahid Abdur Rab Serniabat Textile Engineering College pg. 3

 INDEX

SL NO TOPICS PAGE NO
01 Introduction 05-06
02 Source of Energy O7
03 Raw materials 07
04 Flow chart of Rotor spinning process 08-10
05 Types of Rotor yarn 11
06 Energy consumption of Rotor spinning 12-13
07 Prediction of energy consumption 14-21
08 Determination of energy consumption for chosen 22
yarn
09 Total energy consumption including air 23-26
conditioning and illumination
10 Energy cost 27
11 How to save energy 28
12 Summery 29
13 End uses an Advantage 30
14 Conclusion 31

Shahid Abdur Rab Serniabat Textile Engineering College pg. 4

 INTRODUCTION

Rotor Yarn in Spinning:

In textile spinning sector, open ended spinning or break spinning is considered as rotor
spinning. Here, total process flow chart is less than combed yarn as well as carded yarn. One
important point should be pointed out here that, roving formation in simplex machine is not
needed in rotor spinning where drawn slivers are fed to the machine directly.
Medium to low quality yarns are produced here which are used for making dungaree,
denim, chino, and twill as well as any heavy fabric. Production rate of open end spinning
process is higher than ring spinning process where coarse yarns are made within a range of
5 to 40 cotton count. Rotor spinning is too much popular in use because of the higher
production rate and less wastage percentage as well as highly usable in denim to make blue
jeans.

Properties of Rotor Yarn:

 Important properties of rotor yarn have mentioned in the below:
 Imperfection index is lower in case of rotor yarn.
 Less amount of power needed during rotor yarn manufacturing.
 Stiffness is higher in rotor yarn.
 Breaking strength is lower in rotor yarn.
 Mass irregularity is better here.
 Co-efficient of variation (CV %) of strength is higher here.
 It has higher abrasion resistance.
 Possibility of producing rotor yarn count ranges from 3 to 60Ne.
 Energy consumption with productivity is lower in case of rotor yarn production.
Volume is greater here than ring spinning.

Shahid Abdur Rab Serniabat Textile Engineering College pg. 5

Why Rotor is called open end yarn?

Rotor Spinning is a more recent method of yarn formation compared to Ring Spinning. This
is a form of open-end spinning where the twist is introduced into the yarn without the need
for package rotation. The fiber layer is stripped off the rotor groove and the resultant yarn
wound onto a package. This is possible because it combines three manufacturing processes
– Speed frame, Ring frame and Winding – into one single step. So it is called open-end yarn.

Fig: Rotor yarn

Shahid Abdur Rab Serniabat Textile Engineering College pg. 6

 SOURCES OF ENERGY

POWER: (Electricity): Generator.

STEAM: Boiler produces the required steam.
COMPRESSED AIR: The compressed air is supplied from air compressor.
WATER: The water source is deep tube well.
GAS: The source of gas is government agency.

RAW MATERIALS USED IN ROTOR SPINNING

Short staple spinning m/c (up to 60 mm fiber length) require

 Cotton (CO)
 Cotton waste ( secondary m/t recycled m/t)
 Cotton noil
 Blends of two or more of these materials.
 Polyester fibers (PES).
 Poly acrylonitrile fiber ( PAC)
 Poly amide fiber (PA)
 Viscose (CA)
 Blends of man-made fibers ( mostly PES/ CV & PAC/CV)
 Blends of cotton & manmade fibers ( mostly CO/ PES & CO/CV)

Shahid Abdur Rab Serniabat Textile Engineering College pg. 7

 FLOWCHART OF ROTOR SPINNING

Input or Feed product→→→ Manufacturing process →→Output or Delivery product

Fiber/Bale →→→→→→→→ Blow Room →→→→→→→→ Lap/Chute

↓
Lap/Chute →→→→→→→→ Carding →→→→→→→ Sliver (Carded)

↓
Carded Sliver →→→→→→→ 1st Drawing frame →→→→→→→ Drawing Sliver

↓
Drawing Sliver →→→→→→→ 2nd Drawing frame →→→→→→→ Drawing Sliver

↓
Drawing Sliver →→→→→→→→ Rotor Spinning →→→→→→→→→ Rotor Yarn

↓
Rotor Yarn →→→→→→→→ Cone winding →→→→→→→→→ Cone

↓
Cone →→→→→→→→→→ Reeling →→→→→→→→→→ Hank

↓
Hank →→→→→→→→→→ Bundling →→→→→→→→→→ Bundle

↓
Bundle →→→→→→→→→→→ Baling →→→→→→→→→→→→→ Bale

Shahid Abdur Rab Serniabat Textile Engineering College pg. 8

ROTOR SPINNING PROCESS

Rotor Spinning is a more recent method of yarn formation compared to Ring Spinning. This
is a form of open-end spinning where the twist is introduced into the yarn without the need
for package rotation. Allowing for higher twisting speeds with a relatively low power cost.

In rotor spinning a continuous supply of fibers is delivered from delivery rollers off a drafting
system or from an opening unit.

The fibers are sucked down a delivery tube and deposited in the groove of the rotor as a
continuous ring of fiber. The fiber layer is stripped off the rotor groove and the resultant
yarn wound onto a package. The twist in the yarn being determined by the ratio of the
rotational speed of the rotor and the linear speed of the yarn.

Shahid Abdur Rab Serniabat Textile Engineering College pg. 9

Sliver is fed into the machine and combed and individualized by the opening roller. The
fibers are then deposited into the rotor where air current and centrifugal force deposits
them along the groove of the rotor where they are evenly distributed. The fibers are twisted
together by the spinning action of the rotor, and the yarn is continuously drawn from the
center of the rotor. The resultant yarn is cleared of any defects and wound onto packages.

The production rates of rotor spinning are 6-8 times higher than that of ring spinning and as
the machines are fed directly by sliver and yarn is wound onto packages ready for use in
fabric formation the yarn is a lot cheaper to produce.

Rotor spun yarns are more even, somewhat weaker and have a harsher feel than ring spun
yarns. Rotor spun yarns are mainly produced in the medium count (30 Ne, 20 tex) to coarse
count (10 Ne, 60 tex) range. End uses include denim, towels, blankets socks, t-shirts, shirts,
and pants.

The use of this system has two basic advantages. It is fed by a sliver, not as with the ring
frame by roving, and so eliminates the speed frame from the process line. It can also be
modified to remove any remaining trash, thereby improving the yarn quality.

Open-end spinning produces a different type of yarn to ring frame spinning. Open-end yarns
tend to be more uniform, lower in strength, more extensible, bulkier, more abrasion
resistant and more absorbent. It is likely that with all of these differences, only some of
which are beneficial, that open-end spinning will not replace ring spun yarn as originally
thought, but will be a complimentary product.

Open-end spinning operates at a rate up to five times that of ring spinning and can be
effectively used for cotton, polyester-cotton blends, as well as other short and medium
staple systems. Synthetic staple fibers such as polyester alone cannot be effectively open
end spun due to a dusting of oligomer from the fibers that interfere with the spinning action
of the rotor.

Shahid Abdur Rab Serniabat Textile Engineering College pg. 10

 ROTOR YARN TYPES

1. Siro Yarn

2. Fancy Yarn

3. Melange Yarn

4. Chenile Yarn

5. Gimp Yarn

6. Core Yarn

7. Friction Yarn

8. Wrap Yarn

9. Airjet Yarn

Shahid Abdur Rab Serniabat Textile Engineering College pg. 11

 ENERGY CONSUMPTION OF ROTOR SPINNING

General energy usage in open-end rotor spinning Generally, energy is needed for operating
machines, air conditioning and illuminating the place where yarns are manufactured in
spinning mills. Additionally, compressors, which provide compressed air to the spinning line,
use energy. Electrical energy and thermal energy are of the type that can be used in a
specific spinning mill. Machines, air conditioning, lamps used for illumination and
compressors consume electrical energy, while thermal energy is consumed by air
conditioning and processes such as the fixation of yarns. Thermal energy is generally
obtained from coal, diesel oil, fuel oil, natural gas and steam. The specific energy
consumption and energy cost of both 20 tex combed ring-spun yarn and 20 tex open-end
yarn for selected countries are illustrated in Table 2. Specific energy is the unit energy
needed during the production of a unit mass of yarn in kWh/kg. The amount of energy
needed for ring yarn changes between 2 - 4.167 kWh/kg, while the energy needed for open
end yarn is between 1.6 and 1.778 kWh/kg. Electrical energy prices are different in the
countries selected, although the consumption is nearly the same .

Shahid Abdur Rab Serniabat Textile Engineering College pg. 12

Shahid Abdur Rab Serniabat Textile Engineering College pg. 13
 PREDITION OF ENERGY CONSUMPTION

In order to give an example, the energy consumption for 20 tex (Ne 30) open- end rotor
yarn produced in the spinning mill under investigation is calculated by applying the
procedure given above. Here, 3000 kg of 20 tex carded yarn is supposed to be produced in
the open- end rotor spinning system at a speed 0f 107000 rev/min and with a twist factor is
3828.

For unit machine For total

Installe
Share of each in total
Actual d Actual
Equipment Number of Installed power, power,k power,
Type machines power,kW kW W kW actual power, %

Blow Room 1 36.00 22.00 36.00 22.00 8.10

(Cot-Linen
Line)

Blow Room 1 64.00 42.00 64.00 42.00

(Automatic)

Blow Room 6 16.30 8.00 97,75 48.00

(Manuel1)

Blow Room 3 7.15 4.00 21,45 12.00

(Manuel2)

Blow Room 4 26.10 10.75 104,50 43.00

(Poly/vis)

Shahid Abdur Rab Serniabat Textile Engineering College pg. 14

 For unit machine For total

Installe
Share of each in total
Actual d Actual
Equipment Number of Installed power, power,k power,
Type machines power,kW kW W kW actual power, %

Vertical 5 9.40 6.00 47.00 30.00

Opener

SUB – 158.95 92.75 370,70 197.00

TOTAL

Carding M. 5 4.00 3.30 20.00 16.50 9.44

(Saco-
Lowell)

Carding 8 13.25 8.50 106.00 68.00

M.(C10)

Carding 10 20.70 14.50 207.00 145.00

M.(Rieter)

SUB - 37.95 26.30 333.00 229.50

TOTAL

Drawing 14 10.00 7.50 140.00 105.00 4.30

Machines

Combing 4 6.53 5.50 26.12 22.00 0.90

Machines

Shahid Abdur Rab Serniabat Textile Engineering College pg. 15

 For unit machine For total

Installe
Share of each in total
Actual d Actual
Equipment Number of Installed power, power,k power,
Type machines power,kW kW W kW actual power, %

Lap 1 13.00 11.00 13.00 11.00 0.45

Machine

Roving 12 17.30 11.40 207.50 136.80 5.60

Machines

Ring 33 40.00 34.00 1320.00 700.00 28.80

Spinning
Machines

Ring 10 0.497 0.30 4.97 3.00 0.10

Traveler
Robots

Open-end 5 81.60 60.00 408.00 300.00 15.10

Spinning
Machines 1

Open-end 1 100.00 67.50 100.00 67.50

Spinning
Machines 2

Winding 15.50 13.50 155.00 135.00 5.60

Machine 10

SUBTOTAL OF MACHINES 3078.29 1906.80 78.40

Shahid Abdur Rab Serniabat Textile Engineering College pg. 16

 For unit machine For total

Installe
Share of each in total
Actual d Actual
Equipment Number of Installed power, power,k power,
Type machines power,kW kW W kW actual power, %

Compressor 1 58.00 40.00 58.00 40.00 2.63

1

Compressor 1 45.00 24.00 45.00 24.00

2

SUBTOTAL OF 103.00 64.00 103.00 64.00

COMPRESSORS

Air 1 110.00 55.00 110.00 55.00 16.00

Conditionin
g System 1

Air 1 147.10 91.00 147.10 91.00

Conditionin
g System 2

Air 1 147.10 116.00 147.10 116.00

Conditionin
g System 3

Air 1 126.00 73.00 126.00 73.00

Conditionin
g System 4

Air 1 81.50 55.00 81.50 55.00

Conditionin

Shahid Abdur Rab Serniabat Textile Engineering College pg. 17

 For unit machine For total

Installe
Share of each in total
Actual d Actual
Equipment Number of Installed power, power,k power,
Type machines power,kW kW W kW actual power, %

g System 5

SUBTOTAL OF AIR 611.70 390.00 611.70 390.00

CONDITIONING

LAMPS 2555 0.04 – 102.00 72.00 2.98

TOTAL 3894.99 2432.80 100

Fig: unit power consumption for chosen

spinning mill

Monthly
energy
Hourly energy Daily energy consumption,
Equipment Type consumption, kWh consumption, kWh kWh

Blow Room (Cot- 22 528.0 13200

Linen Line)

Blow Room 42 1008.0 25200

(Automatic)

Shahid Abdur Rab Serniabat Textile Engineering College pg. 18

 Monthly
energy
Hourly energy Daily energy consumption,
Equipment Type consumption, kWh consumption, kWh kWh

Blow Room 48 1152.0 28800

(Manuel1)

Blow Room 12 288.0 7200

(Manuel2)

Blow Room 43 1032.0 25800

(Poly/vis)

Vertical Opener 30 720.0 18000

SUB TOTAL 197 4728.0 118200

Carding 16.5 396.0 9900

M.(Sacolowell)

Carding M.(C10) 68 1632.0 40800

Carding M.(Rieter) 145 3480.0 87000

SUB TOTAL 229.5 5508.0 137700

Drawing Machines 105 2520.0 63000

Combing + Lap 33 792.0 19800

Shahid Abdur Rab Serniabat Textile Engineering College pg. 19

 Monthly
energy
Hourly energy Daily energy consumption,
Equipment Type consumption, kWh consumption, kWh kWh

Machines

Roving Machines 136.8 3283.2 82080

Ring Spinning 703 16872.0 421800

Machines + Robots

Open-end Spinning 367.5 8820.0 220500

Machines

Winding Machines 135 3240.0 81000

MACHINE 1906.8 45763.2 1144080

TOTAL

AIR 390 9360.0 234000

CONDITIONING
SYTEMS

ILLUMINATION 72 1728.0 43200

COMPRESSORS 64 1536.0 38400

TOTAL 2432.8 58387.2 1459680

Fig: Energy consumption for chosen spinning mill

Shahid Abdur Rab Serniabat Textile Engineering College pg. 20

Where Ei is the energy consumption of the blow room (E1 - energy for bale opener, E2 -
energy for cleaner, E3 - energy for mixer etc.), ECa - the energy consumption of carding, ED -
the energy consumption of drawing, ES - the energy consumption of spinning, represents
the relevant individual machine, and n is the total number of machines in the blow room.
The energy consumption of compressors for the first machine, EA1, is found using the
following equation: EA1 = t1 × N1 × C1 × n1 where C1 in m3/h is the compressed air needed
per hour , NA in kWh/m3 is the unit power for compressors which can be determined by
dividing the installed power of the compressor by the compressed air capacity. The total
energy consumption

DETERMINATION OF ENERGY CONSUMPTION OF CHOSEN YARN

A simple approach has been developed to obtain the specific energy consumption of any
yarn. Since a production line contains many steps/machines, the approach has been
explained here for the first machine, which is described as a bale opener. The approach
should be repeated for the rest of the machine/step. According to this approach, a raw
material should first be found for each machine, and then the operating time of each
machine must be obtained. Using the operating time and actual power of the manufacturing
machines, the energy consumption of each machine during manufacturing can easily be

Shahid Abdur Rab Serniabat Textile Engineering College pg. 21

calculated. The amount of raw material R1 in kg which will be processed in the first machine
(bale opener) can be found by using the total waste ratio W Tot in% and mass of the specific
yarn M in kg in the following equation R1 = M × (1 + WT ot) The operating time for the first
machine,t1 in hour, can be determined as follows where L1 in kg/h is the manufacturing
rate of the machine, n1 is the number of machines and h1 in % is the mechanical efficiency
of the machine. With the given parameters, the electrical energy, E1 in kWh, used by the
first machine can be obtained from

E1 = t1 × N1 × hE1 × n1

Here, N1 in kW is the installed power of the first machine, and hE1 in % is the energy
efficiency concerned. After calculating the energy consumption of each step, the total
energy consumed for operating the machines, EM in kWh, can easily be calculated by the
following equation

EM = aEi + ECa + ED + ES

ENERGY CONSUMPTION FOR MACHINES AND COMPRESSED AIR

The results obtained by the procedure applied above are demonstrated in Table 6. This table
contains production parameters (type and number of machines, actual production rate, actual
installed power etc.) and calculated data (operating time, energy use for operating machines and
compressed air). For the spinning mill investigated, the unit power needed for compressors to
provide As 0.12 kWh/m. As the machines in the blowing room are interconnected, the compressed
air needed has been calculated cumulatively by taking the operate In time as 5.5 hours. Using the

Shahid Abdur Rab Serniabat Textile Engineering College pg. 22

parameters in the table and related equations, the total energy consumed by the machines was
found to be 6491.323 kWh, 4897.125 kWh of which was used by open-end rotor spinning machines.
In order to see the percentage of energy used for each machine, Figure 4 was constructed. As can be
seen, maximum energy consumption (4897.125 kWh) occurs in open-end rotor spinning machines
(75.4%), followed by carding machines with a share of 16.1%. This figure also provides an
opportunity to compare the corresponding data with data available in literature, as shown in Table
7. The calculated share of each machine type in the total energy.

Consumption has been compared with the results for 49 tex. As 49 tex yarn is coarser than
20 tex, the share of open-end rotor machines for 20 tex yarn seemed to be higher than that
of 49 tex yarn, as expected. Because of the fact that similar data presenting the shares of
machines in the total energy consumption have not been established for 20 tex yarn in
literature, the energy consumption for 49 tex yarn was also calculated using the present
approach with suitable production parameters for 49 tex yarn (αtex = 3828,65000 r.p.m.),
the results of which have been compared with data in literature as shown in Table 8. The
results calculated and data given in literature are nearly the same. The small differences
Occurring between values is attributed to the exclusion of winding step data in literature
and changes faced in production parameters.

Shahid Abdur Rab Serniabat Textile Engineering College pg. 23

TOTAL ENERGY CONSUMPTION INCLUDING AIR
CONDITIONING AND ILLUMINATION

As explained before, the energy consumption of air conditioning and illumination should be
added to the energy consumption of machines and compressors so as to get the total
energy consumption during relevant yarn production. Data for the monthly energy
consumption of air conditioning, the illuminating system and monthly yarn production
should be obtained. As given earlier in Table 5, the monthly energy consumption for air
conditioning and illumination has been calculated as 234000 kWh/month and 43200
kWh/month, respectively. Moreover, the amount of monthly yarn production determined

Shahid Abdur Rab Serniabat Textile Engineering College pg. 24

from the mill records is 401580 kg/month for the month examined (May). Applying the
approach developed, the energy consumption for air conditioning and illumination has been
found, the results of which are shown in Table 9. The specific energy consumption of the
yarn considered was determined as 2.95 kWh/kg (given in the last column of the table) by
dividing the total energy consumption by the amount of yarn produced. The specific energy
consumption for 20 tex carded open-end rotor yarn changes between 1.60 and 3.00 kWh/kg
for the countries selected. This value changes between 1.667 - 2.919 kWh for Turkey in the
given years. The data obtained from the present study (2.95 kWh/kg) represents a relatively
smaller value than that of the selected countries. In addition, this value is within the range
of the limit values given for

Shahid Abdur Rab Serniabat Textile Engineering College pg. 25

 ENERGY COST OF DIFFERENT UTILITIES:

Electricity cost:
REB =3.8 TK / KW-HR
Gas generator = 2.70 TK / KW-HR
Diesel generator = 6.50 TK / KW-HR

Gas cost:
4.94 Tk/m³ for boiler
3.66 Tk/m³ for generator
4.5 Tk/m³ for domestic purpose

Steam cost:
4.30 Tk per kg yarn.

REMARKS:
For smooth running of production main utilities like gas, electricity or steam is very
essential. Sometimes gas pressure is low than required pressure. When the gas pressure is

Shahid Abdur Rab Serniabat Textile Engineering College pg. 26

low, then diesel generator run. Government should have to ensure proper gas supply for
Industrial purpose.

HOW TO SAVE ENERGY

Energy is necessary for each step of spinning processes to drive machines, air conditioning,
and lighting, but the highest energy consumption occurs during the spinning process in
spinning machines. Another study which handled energy conservation in the textile industry
focused on the electricity consumption of each step of ring spinning for the modern and
traditional factory. Electrical energy consumption of 1 kg of yarn changes between 2.7
kWh/kg and 4 kWh/kg. Additionally, it was pointed out that thermal energy alternating
between 1.1 MJ/kg and 4.7 MJ/kg is necessary for processes such as fixation besides
electrical energy needs. General assessment for energy consumption and conservation in
fiber-producing and textile industries was done while determining the power requirement
of a specific ring and open-end spinning machine with chosen machine parameters.

Since the highest power is required in spinning machines, many studies have been carried
out to determine the power demand of spinning machines. It was found that in the coarse
yarn range (tex>60) the open-end rotor machine needed less energy per kg of yarn than the
ring frame for warp yarns, for finer yarns (tex<30), on the other hand, the oe-rotor machine
demanded more energy per kg of yarn than ring frame. It was reported that the factors
affecting the power demand of the ring system were ring diameter, balloon height, spindle
speed and traveler mass.

Shahid Abdur Rab Serniabat Textile Engineering College pg. 27

SUMMERY
As a result of detailed investigations into energy consumption for yarn manufacturing, with
special reference to open-end rotor spinning, the following conclusions can be made:
1. It has been shown that manufacturing machines consume 78.4% of the total monthly
energy consumption (1459680 kWh/month), while air conditioning comprises 16% of
the total energy consumption in the spinning mill selected. Additionally, specific energy
consumed for each month in one-year period has been calculated and it has been
determined that the calculated values change between 3.23 and 3.76 kWh/kg.
2. Applying the simple model developed, the total energy consumed during the
manufacturing of 100% cotton, 20 texcarded open-end rotor spun yarn in the spinning mill
chosen has been calculated as 8874.893 kWh, 73.2% of which is consumed by
manufacturing machines. The highest energy consumption, with a 75.4% share, is
represented by open-end rotor spinning machines alone. The values calculated have been
compared with data available in literature, and it has been shown that there is a close
agreement between the data calculated and those given in literature. The small differences
have been attributed to variations in operation parameters such as the type, mechanical
efficiency, energy loss and waste ratio of machines.
3. The specific energy consumption for 20 tex carded open-end rotor yarn has been
obtained as 2.95 kWh/kg and compared with values outlined by ITMF (changing between
1.60 and 3.00 kWh/kg for the same yarn type and 1.667 - 2.919 kWh/kg for Turkey). The
difference between calculated and reported values is thought to be because of the variation
in production parameters.

Shahid Abdur Rab Serniabat Textile Engineering College pg. 28

 4. It has been demonstrated that the approach presented in this study can be used to
calculate the total and specific energy consumption of a particular yarn type with
reasonable confidence.

END USES OF ROTOR SPINNING YARN

Upholstery
Lace
Net curtains
House hold fabric
Denim or ring frame
Shirting
Knit wear
Sweater
Outer wear fabric
Cortains
Throusers
Blankets etc.

OPEN END SPINNING HAS THE FOLLOWING ADVANTAGES

Shahid Abdur Rab Serniabat Textile Engineering College pg. 29

 1. Lower power consumption per unit quantity of yarn produced
2. Higher speed of twist insertion resulting in very high yarn delivery speed
3. A significant resulting increase in productivity
4. Larger delivered package size
5. Elimination of some processes such as roving and winding more uniform yarns

CONCLUSION

The research project showed that there are many factors by which we can improve
Productivity & Quality, but our emphasis was on one of the most important factor which
yielded very important results. We focused on raw material staple length and machine
efficiency. By using the same raw material with good staple length, we achieved better
results in the form of high production and high profit. The other benefit is that due to
increase in staple length, Short fibers percentage also decreases and results in the form of
less TPI and less yarn breakage. Breakage is one of the big factors due to which efficiency of
department is disturbed. Productivity increases with a variation in a raw material staple
length and machine efficiency is directly dependent on the staple length of a raw material.
In the production of yarn we should keep many things in mind which can control and
enhance the productivity & quality parameters. Productivity can be enhanced by
restructuring each process or using fully automated machine. While producing yarn, quality
of raw material or other parameters have their own importance. On the other hand, we
should realize that without participation of each individual nothing can be done. So,
companies should make the policies which are favourable and helpful to both managers and
workers.
Skilled labour, automated machinery, raw material quality and energy issues have an impact
on production of yarn. If any company has a grip in these issues then, that company can
survive in this competitive market in a better way.

Shahid Abdur Rab Serniabat Textile Engineering College pg. 30

With the growth of production, the company earns more profit and can create more vacant
positions for the new jobs to increase or install new machinery. For this they need more
investment or capital and new labour will help in increasing the productivity & quality.
High profit or high investment in every business is the first preference, but in the textile
sector the high profit with customer satisfaction is the key issue. Customers should be
satisfied by the textile sector in order to retain a long term relationship with them.
Customer’s trust must be kept on top priority by each and every company.

THE END

Shahid Abdur Rab Serniabat Textile Engineering College pg. 31