Ring Spinning Machine

3.9 Compact Spinning

Why compact spinning?
In conventional ring spinning, fibres in the selvedge of strand emerging from front roller nip do not get fully integrated
into the yarn because of the restriction to twist flow by the spinning triangle. These fibres show up partly as protruding
hairs or as wild fibres.

The spinning triangle exists because of higher width of the strand as compared to final yarn diameter. Further the fibres
are tensioned to varying extent depending upon their position in the spinning triangle. As a result full realization of fibre
strength is not achieved in the yarn.

The hairiness gives a rough feel to the yarn. Variation in hairiness is a source of weft bars and warp way streaks in the
fabric. Long protruding hairs from the yarn contribute to multiple breaks in weaving and fabric faults like stitches and
floats.

This problem is solved by applying the compact spinning systems that increases yarn quality. It is carried out by means
of narrowing and decreasing the width of the band of fibres which come out from the drawing apparatus before it is
twisted into yarn, and by the elimination of the spinning triangle. It can be used for spinning both short and long staple
yarns.

The compact spinning process produces a new yarn structure, which approaches the ideal staple fibre yarn construction
even more closely. This has positive effects on raw material use, productivity, downstream processing, and on the
product appearance.

Factors Affecting The Spinning Triangle

The twist that is transmitted to the yarn in the ring spinning process originates along the curve between the traveler and front
drafting rollers. Transmission of twists is opposite to the yarn movement in this area. The traveler transmits twists to already
drafted fibres as close as possible to the clamping point after the front rollers. However, the twists never reach the clampi ng
point, because after leaving the front rollers the fibres tend to direct towards yarn axis. The different lengths of the path of
the inner and outer fibres that form the yarn cause a spinning triangle in ring spinning.

If the spinning triangle is too short (a), then the fibres on the edge must be strongly deflected to bind them in. This is no t
possible with all fibres, and lost as fly. Thus with shorter triangle, smaller weak point resulting into fewer end breaks but
makes the yarn hairy. On the other hand, a long spinning triangle (b) implies a long weak point and hence more end breaks
giving smoother yarn and less fly.

The length of the spinning triangle depends on spinning geometry and twisting intensity. The form and dimensions of the
spinning triangle significantly influence the structure, surface characteristics, physical and mechanical characteristics of spun
yarn. Not all fibres that are placed at the external edges of the triangle can be spun into the yarn structure, and can leave the
drafting equipment without having been spun into the yarn. Such fibres also increase yarn hairiness.
 Figure 1: Spinning triangles (a) Short (b) Long and (c) Side View
The spinning triangle is the critical weak spot of the spinning process. The spinning triangle prevents the edge fibres from
being completely incorporated into the yarn body. However, in compact spinning, the drafted fibres emerging from the nip
line of the front roller of the drafting arrangement are condensed in a line.

Conventional Ring Spinning vs. Compact Ring Spinning

Ring-spun yarn is not perfect. If the enlarged view of ring spun yarn is examined, it is easy to see that the integration of
many fibres is poor, and they therefore make no contribution to yarn strength as shown in Figure 2. In other words, if all
fibres could be completely integrated in the yarn, both strength and elongation could in turn be further enhanced. It is thus
obvious that even ring-spun yarns are not yet ideal as regards yarn structure
 Figure 2 : Spinning triangles in ring and compact spinning.
The development of the compact spinning process began with the desire to achieve a significant improvement in yarn quality
by influencing the spinning triangle (Figure 3). The process is focused on achieving higher yarn strength and a reduction of
yarn hairiness, especially on eliminating the longer hairs, which have a particularly bad influence on the further process.

The improvement achieved is shown in the Figure 3. The Fig 3(a) displays the fibre triangle at the exit of a conventional ring
frame drafting system. The twist imparted by the spindle cannot flow up to the clamping line. The outer fibres spread out and
are thus more highly tensioned than those on the inside. The Fig 3(b) does not show a spinning triangle. The yarn twist flows
right up to the clamping line. The yarn is round and smooth.
 Figure 3 : Conventional (a) and compact (b) ring spun yarns
Minimization or even elimination of the spinning triangle, enables almost all fibres to be incorporated into the yarn structure
with maximum possible length and pre-tension of the fibres, irrespective of their position in the spinning triangle. The uniform
pre-tension of the majority of fibres enables more synchronic breakage of the majority of the fibres, which contributes to
higher yarn strength and better utilization of the fibre tenacity.
All compact yarns, whether produced of short-staple fibres (cotton, cotton-type chemical fibres and their mixtures) or long-
staple fibres (wool, wool-type chemical fibres and their mixtures) represent a whole new range of yarns as regards their
quality and appearance. When compared with conventional ring-spun yarns, compact yarns have significantly higher tenacity
and elongation, work to break, and abrasion resistance. In addition, their surface smoothness, elasticity and softness are
much better thanks to the almost ideal structure of compact yarns. To achieve tenacity comparable with conventiona l ring-
spun yarns, a lower number of turns per meter can be used, which enables higher productivity of the spinning machine, as
well as better elasticity and softer hand of different flat textile products.

Methods of compacting fiber strand

In compact spinning the mass of fibres is condensed before twist is imparted. This condensation happens in so called
'Condensing Zone' following the main drafting zone. Different machine manufactures are using different methods to condense
the fibres emerging out from the front roller. These methods are:
1) Aerodynamic compacting system: a) Suction by drum and b) Suction through perforated apron.

2) Mechanical compact system.

 3) Magnetic compacting system.

Aerodynamical compacting system

In this methods the condensation of the fibres strand take place with help of perforated drum or apron. The examples of
aerodynamical compacting system are Com4Spin® of Rieter, Elite® Compact Spinning by Suessen, CompACT3 by Zinser,
Com4®wool by Cognetex, Olfil system by Marzoli, Toyota's compact spinning, etc.

The Rieter Com4 Technology

The Rieter compact spinning solution is based on aerodynamic parallelization and condensation after the main draft zone. At
the heart of this technology is the perforated drum through which suction is obtained to create air currents to condense the
fibres coming out of the main draft zone. The main features of this technology are the perforated drum, the suction system,
and the air guide element. The setup of the system is shown in Figure 4.

Figure 4 : Cross section drafting unit in Rieter Compact Spinning

The drafting system is 3/3, with the third bottom roller being replaced by the perforated drum (1). The suction is created in
the perforated drum with the help of the suction system (2). The drum is directly driven, and is made of materials which have
high wear resistance and also resistant to fibre clinging. The drum helps in condensing the fibres. For guiding the fibres from
the nip of the drafting cylinder to the spinning triangle, a guided lateral stream of air is used. For this the air guide element
(6) is used. The air guide element also helps in the further condensation of the fibres in the compacting zone. The profile of
the perforated drum and the arrangement of the 3rd top roller with the nip roller and the perforated drum are shown
in Figure 5.
 Figure 5 : Profile of top roller and perforated drum
After the compacting has been done, the fibre strand needs to be twisted. Hence the spinning triangle is formed, which
results in deterioration of the orientation of the fibres leading to hairiness, loss of fibres due to fly generation, etc. Therefore,
another nip is given between the Nip roller (5) and the perforated drum, which doesn’t allow the twist to travel up to the
compacting zone reducing the length of the spinning triangle, and thus leading to reduction in the above-mentioned
occurrences. Also due to compacting and condensation the base of the spinning triangle b(Figure 6) reduces when compared
to normal ring spinning. This technology is also expensive, due to the fact that suction has to be provided to each individual
drum.

Figure 6 : Operating principle of Rieter Com4 Technology

The SUESSEN EliTe System
The Suessen EliTe system comprises of a normal 3/3 roller drafting system (Figure 7), with a pair of aprons on the middle
rollers (2). The condensation zone consists of a Profile tube (9), a lattice apron (3), and the top delivery roller (6). The top
delivery roller drives the lattice apron. The air permeable lattice slides over the suction tube (9) having an inclined slot in the
region (7-8). The profile tube is stationary. The drafted roving comes into the condensation zone, where with the help of the
inclined slot and the apron they are condensed up to the point 6 – 8.
 Figure 7 Drafting arrangements in SUESSEN EliTe System
The inclined slot in the profile tube as shown in Figure 8 helps in the inclusion of outer fibres into the yarn because of the
tranverse force being applied on the condensed fibres. The air being drawn in through the suction slot helps in the rotation of
the fibres about their axis which results in better orientation of the fibres and as a result majority of the fibres are aligned and
compacted leading to reduced hairiness, more strength and elongation, etc.

Figure 8 : Profile tube having inclined slots

The lattice apron is an essential part, and has to be designed appropriately. The lattice has small perforations, which doesn ’t
allow the fibres to be sucked in. The lattice fabric is made, in case of cotton spinning, of a cotton fabric of simple weave
having around 3000-holes/ square cm. Also the lattice moves slightly faster than the delivery giving a small drafting leading
to optimal fibre orientation and axial tension. The lattice moves faster, due to greater diameter of roller 6 than top roller 4a.
Also the spinning triangle formed here is very small as the twist given travels right up to the clamping line 6-8. Thereby the
end breakages and the fly generation are now reduced as the weak point i.e. the spinning triangle, has nearly been
eliminated.
Advantages of Elite® Compact Yarn
 1) Higher work capacity by 30% (max).

2) Higher yarn strength by 20% (max).

3) Better elongation by 20%.

4) Lower hairiness by 85% (max) Zweigle S3.

5) Better yarn evenness.

6) Lower imperfection value (IPI).

The Zinser CompAct Technology

The drafting system (Figure 9) consists of the normal 3/3-roller system, with aprons on the middle rollers for better fibre
control, and thus allowing processing of a larger variety of raw materials. The condensing zone starts from 4 till 4-4a. The top
roller 4 is covered by the endless apron with a set of holes in the middle. This apron runs over a profile tube having a suct ion
slot in the region H1-H2. The fibre bundle is condensed under suction on the perforated surface of the apron in the zone H1-
H2. In between the zone H1-H2 and 4-4a, the fibre bundle is not under any suction effect, and thereby loses some of its
condensed form and orientation. Therefore at the nip line 4-4a, the spinning triangle is not reduced to the minimum as in the
case of EliTe, thereby negatively influencing the quality of the spun yarn. This effect is observed more prominently while
handling shorter staple fibres.
 Figure 9 : Drafting and condensing zone
Also the suction slot here is not inclined as in EliTe, and is directed in the fibre bundle axis. A small axial tension draft is given
here also between the zones 4 and 6, which improve the adhesion and the compacting of the fibre bundle. .
Advantages of CompACT3 yarn

1) The UT4 hairiness for carded cotton CompACT3 yarn is 20% lower as compared to conventional ring spinning. The S3
hairiness value according to Zweigle reduced by 93% (max).

2) Yarn irregularities (Zellweger Uster) show improvements of 6% (max).

3) 25% (max) lower IPI values (Zellweger Uster).

4) 20% higher tenacity values compared to the values of conventionally spun yarns.

5) Productivity increase at the spinning machine is 10% (max) through increasing the spinning speed and/or reducing
the yarn twist.

6) Extension of the spinning limit by 15% (max).

Mechanical Compacting System

Mechanical Compacting Spinning (MCS) is given by Officine Gaudino for long staple. This compact system makes the compact
yarn without the use of air. The compacting of the fibre strand is carried out with smooth bottom front roller and an angled
top roller. Officine Gaudino offers long staple spinning machine (Model FP 03) with mechanical compacting system. This
compacting system does not require the additional suction system. The MCS consists of an additional smooth bottom front
roller and an angled top roller. These rollers run at a slightly slower speed than the front drafting rollers and this 'negative
draft', coupled with offset top roller, creates false twist which compacts the drafting strand as it comes out from the
compacting zone. This system can be incorporated into the new machines and is claimed to be easily added or taken off the
spinning frame.
The LMW Magnetic Compacting or The Rotorcraft Compacting

This technology from Lakshmi Machine Works is based on the RoCoS principle of magnetic compacting. The need of any
perforated drums, endless aprons, suction tubes, etc are removed by this system.

The RoCoS device (Figure 10) consists of a cylinder (1), front roller (2), delivery roller (3), the precision ground and with
supra-magnets equipped ceramic compactors (4), the supporting bridge (5), the yarn guides (6), and the top roller holders
with the weighting springs (8).

The bottom roller has very precise flutes and radius exactly corresponding to the compactor radius. The bottom roller (1)
supports the front roller (2) and the delivery roller (3). The precise magnetic compactor (4) is pressed against the cylinder. A
and B are the two nips between which the compacting takes place.

Figure 10 : Components of RoCoS device

The magnetic compactor (4) as shown in Figure 11 is pressed against the cylinder without any clearance against cylinder
(1), thereby forming with the bottom roller an enclosed compression chamber where the bottom contour, i.e. the generated
surface of the cylinder (1) moves synchronously with the strand of fibres and transports these fibres safely through the
compactor. Therefore in the chamber formed, the compacting of the fibre bundle takes place, due to magnetic forces. The
condensation of the fibres takes place to such a degree so that the formation of the spinning triangle is prevented while
twisting of the fibres takes place.
 Figure 11 : Schematic diagram of Magnetic compactor
As a result the power required for this compacting is very small as compared to the previously mentioned technologies. The
only problem with this technology is that the size of the front and the delivery roller is considerably smaller, which leads to
increased fiber lapping and problems in serviceability. Also the cost of this technology is very high.
Sources :

• W. Klein, “Technology of Short Staple Spinning”, The Textile Institute, Manual of Textile Technology, All volumes.
• Carl A. Lawrence , “ Fundamentals of Spun Yarn Technology”, CRC Publications, 2003.
• P.R. Lord, Hand Book of Yarn Production : Science, Technology and Economics, Tailor and Francis, 2003.
• Eric Oxtoby, “Spun Yarn Technology”, Butterworths, 1987.
• NCUTE publications on Yarn Manufacturing, Indian Institute of Technology, Delhi.