Yarn Manufacturing-II Lecture 1-12 Prof. DR Farooq Ahmed and Dr. Pardeep Kumar Online

Yarn Manufacturing -II
Prof. Dr. Farooq Ahmed

Dr. Pardeep Kumar Gianchandani
Textile Mechanics 1
Class Time Table
Time Monday Tuesday Wednesday Thursday Friday
8:00-9:00
9:00-10:00 YM-II YM-II YM-II

YM-II
10:00-11:00
Q&A
11:00-12:00
12:00-13:00 YM-II
13:00-14:00
15:00-15:00

Yarn Manufacturing -II 2
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Course learning outcomes
Taxonomy Linking to
CLO No. Description
Level PLOs
Demonstrate the preparatory processes for yarn
manufacturing (combed sliver and roving), machines
CLO-1 C1 PLO-1
and methods related to Combed sliver formation and
Roving.
Analyse and investigate problem and parameters related
CLO-2 C4 PLO-2
to yarn preparatory process
Manufacture and control the processes of combed sliver

CLO-3 P3 PLO-4
and roving on production scale.

MARKS DISTRIBUTION, METHOD OF STUDY AND ASSESSMENT
https://exam.muet.edu.pk/website/regulations-for-fall-to-18-undergraduate/

Recommended Books:
1. Grosberg, P. and Iype C., “Yarn Production: Theoretical Aspects”, The Textile Institute, Manchester, latest edition.
2. Charnley, F., “Draw frames, Combers and Speed frames”, Vol. IV, The Textile Institute, Manchester, UK, latest edition.
3. Merril G. R., “Cotton Combing”, GibertMerril, England, latest edition.
4. Booth, J,E , “Textile Mathematics” ,Vol.II , The Textile Institute, Manchester, UK,latest edition.

Departments of a Textile Industry
Textile Industry
Yarn manufacturing Fabric manufacturing Wet-processing Garments
Knitting Weaving Cutting

Blow room Drawing Ring pre-treatment Finishing
Carding Roving Auto cone Dyeing/ printing Embroidery
Combing Two for one twister Sewing

Introduction to Various Departments of a Textile Industry
Textile Industry
Yarn manufacturing
Blow room Drawing Ring
Carding Roving Auto cone
Combing Two for one twister

Introduction to Various Departments of a Textile Industry
Textile Industry
Yarn manufacturing
Roving
Yarn manufacturing-II
Combing

The short-staple spinning process for combed yarns
Yarn manufacturing-II

The short-staple spinning process for combed yarns

Combing
The process of straightening and parallelisings of fibers and the removal of short
fibers and impurities by using a comb on combs assisted by brushes and rollers is
called combing. The combing process is carried out in order to improve the quality
of the sliver coming out of the card.
Within the overall spinning process, the combing operation serves to improve the
raw material.
Its use in production of medium, medium-fine and fine yarns enables a positive
influence to be exerted primarily on the following yarn characteristics:
Yarn evenness Strength Cleanness
Smoothness Visual appearance

Why it is called a Combing?
It is actually a modern combing

process because of its process
and objectives.

Objectives of Combing
Following are the objectives of combing process:
•To remove naps in the carded sliver.
•To make the fiber more parallel and straight.
•To produce a uniform sliver of required length.
•To remove the fiber shorter than a predetermined length.
•To remove remaining impurities in the comber lap.

➢ In addition, a yarn made of combed cotton needs less twist than a carded yarn. However, these quality
improvements are obtained at the cost of additional expenditure on machines. Floor-space and personnel,
together with a loss of raw material.
➢ Yarn production cost is increased by 1 dollar per kilo of yarn (depending upon the intensity of combing).
That’s why it is a Optional and Costly Process

➢ Elimination of short fibres produces an improvement mainly in staple length, but it also affects the fineness of
the raw material.
➢ Since noil (short fibers removed during combing) is on average finer than the original raw material, the
micronaire value of combed silver is slightly higher than that of the feedstock.
➢ It should also be noted that combing increases the parallelization might reduce inter-fibre adhesion in the silver
to such an extent that the fibres slide apart while being pulled out of the can - i.e, silver breaks of false drafts
might be caused.
➢ The amount of material combed out varies within the range 5-25% of the infeed stock.

Types of application
The amount of material combed out varies within the range 5-25% of the infeed stock.
It follows that, where the raw material is concerned, quality improvement can exhibit large variations.
Correspondingly, basic distinctions are drawn between three major groups of spinning mills using
combing.
a) Long Staple Combing Mills
b) Medium Staple Combing Mills
c) Short – (to medium) staple combing mills.

a) Long Staple Combing Mills
▪ These organizations spin first class, expensive cotton of high strength, containing a low
proportion of short fibres and little dirt.
▪ The product is a fine-to-very-fine yarn of top quality.
▪ The demands placed, on the know-how and skill of operating personnel are correspondingly
high, as they are on the design and maintenance of the machines.
▪ Yarn production is low, while generation of noil is high.

b) Medium Staple Combing Mills
▪ Here, medium cotton qualities with a wide spread of quality parameters are spun into
medium (to fine) yarns of good quality at economic production costs.
▪ The proportion of noil lies in the region of the average and production is usually high.
▪ The process is problematic in that it has to achieve a high standard of quality and at the
same time give high production at low cost: requirements that are difficult to bring into
harmony.
▪ The spinner has particular problems in relation to isolated “patches” of poor quality. The
maximum demands placed on medium-staple combing can only be fulfilled by optimally
trained personnel.

c) Short – (to medium) staple combing mills.
▪ Raw Material used here is the same as that for production of carded yarns.
▪ Often the same cotton blend is spun to both carded and combed yarn, sometimes even of
the same fineness (in the coarser to medium fine region).
▪ In comparison with a carded yarn, the combed yarn should chiefly exhibit better
smoothness and strength.
▪ In this type of process, high production is usually sought in combination with low noil levels
(6-14%).
▪ This process is the most widely used in practice; it is technologically undemanding and can
be operated without problems when good machines are available

Types of Comber
Many different types of comber are available, including;
• Rectilinear combers (with stationary or oscillating nippers).

• Circular combers (English worsted process).
• Rotary comber (production of Schappe-spun yarns), and
• Hackling machines (bast fibres)
➢ The short staple spinning mill uses only the rectilinear comber with swinging nippers and stationary detaching rollers, as
originally conceived in 1845 by J. Heilmann in Alsace and further developed in 1902 by the Englishman Nasmith and in
1948 by the Whitin company.
➢ Machine layouts used in practice comprise single-sided machines with eight heads (almost all manufacturers) and
double-sided machines with six-plus-six heads (Platt Saco Lowell).
➢ Improvements in machine design since 1948 have enabled a doubling in production rate.

Sequence of operations in a rectilinear comber
(a) The feed rollers S move the sheet W 4 – 6.5 mm forward, while the nippers Z0/Zu are held
open (feed).

(b) The upper nipper plate Z0 is lowered onto the cushion plate Zu so that the fibers are
clamped between them (nipping).

(c) The combing segment (K), mounted on rotating cylinder (Z), sweeps its needles or saw-
teeth through the fibre fringe (B) and carries away anything not held by the nippers (rotary
combing).

(d) The nippers open again and move towards the detaching rollers A (nippers forward)

(e) Meanwhile, the detaching rollers A have returned part of the previously drawn off
stock (web V) by means of a reverse rotation, so that the web protrudes from the back-of
the detaching device (web return)

(f)In the course of the forward movement of the nippers, the projecting fibre fringe B is placed
upon the returned web V (piecing).

(g) The detaching rollers begin to rotate in the forward direction again and draw the clamped fibres out of
the sheet W held fast by the feed rollers S (detaching).

(h) Before the start of the detaching operation, the top comb F has thrust its single row of needles into
the fibre fringe. As the fibres are pulled through the needles of the top comb during detaching, the
trailing part of the fringe is combed, thus making up for the inability of the cylinder combs to reach this
part of the fringe (combing by the top comb).

(i) As the nipper assembly is retracted, the nippers open for the next feeding step. The
top comb is withdrawn a new combing cycle begins.

(j) The combing cylinder rotates continuously and the combing segment is therefore brought
into the vicinity of a rapidly revolving brush mounted below the combing cylinder. This strips
the combing segment of fibre impurities, etc., and ejects them into an aspirator that carries the
noil away to a collecting filter drum.
All of this is carried out up to 300 times per minute


Preparation of stock for combing
➢ The raw material delivered by the card is unsuitable for combing as regards form the fiber
arrangement.
➢ If card sliver were fed to the comber, then true nipping by the nipping plates (Fig) would
occur only on the high points, with the risk that the nippers could retain the less strongly
compressed edge zones of the slivers.
➢ These could then be pulled out as clumps by the cylinders combs. A sheet with the least
possible degree of unevenness is therefore required as infeed to the comber.
➢ A random disposition of the fibres within the sheet is a further prerequisite.
➢ If the fibres lie across the strand even short fibres are presented to the cylinder combs as if
they were short fibres and they are eliminated as such. This represents unnecessary loss of
good fibres.

Preparation of stock for combing
➢ Appropriate preparatory machines are needed to prepare the material so that it meets the requirements.
➢ The fibre arrangement must also be taken into account i.e. in this case the disposition of the hooks. As explained
earlier, over 50% of fibres in card sliver have trailing hooks.
➢ If the comber is to straighten these hooks, as it is intended to, then the fibres must be presented to it with leading
hooks.
➢ Because of the repeated reversal of the hook disposition during coiling and subsequent removal from cans, an
even number of machines passages must be provided between the card and the comber, e.g. sliver lap and
ribbon lap machines.
o As demonstrated in Fig. 5 two types of process are currently used most widely in practice:
• the lap doubling process (classical method); and
• the sliver doubling process (e.g. the superlap of whitin, unilap 3 of Rieter, SR 34 of Marzoli).
Lap Former Machine
The lap former has, furthermore, the task of forming the interfacing or lap , which is employed
to feed the combing machine. The lap is obtained by doubling a certain number of slivers
(from16 to 32)previously subject to a drawing passage.
The slivers are fed side by side, passing , through rollers and stop motion. The slivers enter the
drafting section and then calendar ' section to produce a compact lap. Finally the lap is wound
on to bobbin. In the lap former, the material under goes a light draft of around 1.5 to 2 times
one drawing passage aggregate of 2 by 3 top cylinders (rollers)

Features of Lap Former Machine:
•Delivery speed up to 120 mts/min •Modular construction
•Complete belt drive

•Batt weight up to 80 gms/mt
•Auto spool changer
•Pro-In control for lap build-up
•Positively driven creel
•4/4 spring loaded drafting system •Lap transport through lap trolley
•Integral top roller release
•Variable top roller loading

Necessity of lap former:
1.To reduce the strain to delicate comber reduce.

2.To reduce fiber damage.
3.To reduce chance of good fibers waste.
4.To reduce short fibers.
5.To reduce thick and thin places in the sliver.
6.To control wastage.
7.To parallel and straight of fiber in carded sliver by pushing fibers.
8. freely opening of fiber from sliver.

Classification of lap former machine
A. Conventional system
1. Sliver lap machine Ribbon lap machine
B. Modern system
1. Super lap former (unilap)

In general two systems are still in use
The earlier web doubling process (conventional The sliver doubling process, in which a normal
method) employing a sliver lap machine drawframe (without leveling) provides the first
followed by a ribbon lap machine; passage and a sliver doubling machine follows
as the second passage

Conventional system
In this process the sliver lap machine is the
first step. 24 slivers from the card are usually
fed together, and side by side over a table
into a drafting arrangement. A loose form of

Top view of a sliver lap machine
web is created with a small draft of around
1.5. After pressing and smoothing, this web Rieter E 2/4A sliver lap machine
is rolled up to a lap by calender rollers.

Six such laps are simultaneously forwarded to the ribbon lap
machine (Fig). These webs pass individually through separate
drafting systems arranged side by side.
Elements of a ribbon lap machine

The 6 webs thus formed run over 6 deflecting plates (Fig)
and then over a collecting table into a pair of calender
rollers. The 6 webs, now overlapping, are pressed together
to form a compact web and rolled up to a lap on the

Rieter E 4/1 ribbon lap machine
subsequent lap rollers. An inherent feature of this classical
system is very low productivity, i.e. it is therefore
unsuitable for modern combing preparation.

Conventional System
Conventional (Lap Doubling) method
In the conventional (sliver lap/ribbon lap) method a number of card
slivers 16 to 32 are fed to a sliver lap machine, which consists of
three pairs of drafting rolls followed by two pairs of calender rolls.
A pair of lap varying in weight from 50 to 70 g/m, the lap width of
about 230 to 300 mm (9.5 to 12 inch) and diameter of 500mm and
weight of to 27Kg. Draft ratio commonly is 1.5 to 2.5

Ribbon Lap Machine
In this process the sliver lap machine is the first step. 24 slivers from the card are
usually fed together and side by side over a table into a drafting arrangement. A
loose form of web is created with a small draft of around 1.5. After pressing and
smoothing, this web is rolled up to a lap by calendar rollers.
Laps from the sliver lap machine are taken to the ribbon lap machine. Most ribbon
lappers are four heads (earlier 6 heads), four independent sections, each of which
process a single sliver lap.

Ribbon Lap Machine
Accordingly four thin sheets of from the various heads are led down over a curved
plate, which turns at a right angles, inverts them and superimpose one upon the
others. The drafts used in the ribbon lapper are about four, so the weight per
meter of the ribbon lap is about the same as that of the sliver lap

Modern Preparation System (sliver doubling system)
The idea of creating a comber feeding lap by a single web forming
process directly in front of the comber, with a single passage
drawn slivers as feed of lap forming machine, can be traced back
to a development in 1948 by the former Whitin Company, called
the super lap machine (unilap machine) Basic design of the former Rieter UNiLap
E5/3 (lap forming machine)
Although all later machines are of different designs they all are based on this idea.

The web former (e.g. UNIlap) always follows a normal drawframe.
On the UNIlap machine the material flow starts with the creel
consisting of two feed rails.
In normal operation 12 cans are laid out under each roller-

assisted feed table. Altogether, this gives a total of 24
Basic design of the former Rieter UNiLap
doublings. E5/3 (lap forming machine)
The pre-drawframe slivers run over a guide bridge above the

service alley and also over several guide rollers to the drafting
system at 2

The web created by the draft of 1.3 to 2.5 passes
over two deflecting plates onto the web table on
which the webs are superimposed. Calendar rollers
draw these superimposed webs from the table to
the lap winding assembly
E 32 UNIlap
The strong compression created between the calender rollers forms a new web, which is rolled into a
lap in the lap forming assembly. Empty tubes are automatically exchanged for full laps. Transport of the
laps to the combing machine is semi-automatic or fully automatic. he following detailed description
refers to the latest generation of lap formers using the sliver doubling system:

Description of UNIlap E32

Working Principle of Lap former UNIlap E32
The drawframe slivers are drafted and wound into a lap Fig.5.10. The
drawing sliver (5) is conveyed to the drafting systems (9) and (10) via
the sliver-feed units (4). The drawframe slivers are drafted in the
drafting systems to produce fleeces (8). These are then drawn into
the lap head (2) by the calender rolls (3) which compress it strongly
to form a lap sheet (batt). This is then wound onto a tube by the lap
rolls (1) and lap roller flanges (7). When the tube is full (lap) it is
automatically ex-changed for an empty one (6)

Parts of Lap Former and their Function

1. Sliver Feed System (Sliver Creel and Sliver Guides )
The first part of the machine is a creel on each side feeding two drafting
arrangements from max. 28 cans from the drawframe. The slivers are also
guided over a service pathway (one on each side) to the drafting
arrangement. Static and dynamic sliver sensors detect missing or stationary
slivers. Clear fault signals allow the operator to rectify the fault quickly.
This results in improved efficiency.

2. Drafting System
The UNIlap machine features a 3-over-3 roller, two-zone drafting
arrangement. The 2-zone drafting system enables the correct application of
splitting pre- and main drafting in both zones. Only optimal drafting
distribution can ensure the best drafting conditions and the resulting fiber
parallelization.
The pneumatically loaded top rollers can be continuously adjusted from minimum to maximum per top roller. Draft
distances are individually variable, as are the draft levels in each of the break and main draft zones. Upper and lower
clearer aprons in combination with a suction system keep the rollers clean. The easily accessible drive for the drafting
arrangement is in an enclosed housing and is fitted with appropriate change gears and oil spray lubrication.

3. Guide rails and guide plates in the lap head
The guide rails (10) and guide plates (11) and (12) act as guides for the edges of
the batt . The width of the lap can only be corrected slightly with them. The lap
width is considerably affected by the setting of the sliver guides and the fleece
guides.
4. Drafting unit Drive System
The drive system features state-of-the-art flate belt technology. Improved
accessibility and handling are the result. Fast and easy draft change is possible
without change gears.

5. Calendar Rollers – Large Lap Rollers
4 calendar rollers and large lap rollers allow for faultless batt structure and ensure
secure and optimal lap construction
6. Main valve
The main valve (2) is used to turn the compressed air supply for the machine on and off
• Slide (2) up, air supply on
• Slide (2) down, air supply interrupted
• Operating pressure of the machine is 6 bar

7. Regulated Lap Loading Mechanism
Regulated automatic lap loading ensures ideal pressure of the lap on the
lap rollers during the complete build-up cycle.

General Specification

Infeed
The first part of the machine is a creel on each side feeding
two drafting arrangements from max. 28 cans from the
draw frame. Here also the slivers are guided over a service
alley (one on each side) to the drafting arrangement.
The drafting arrangement of the UNIlap system

Infeed
The UNIlap machine features a 3-over-3 roller, two-zone drafting

arrangement. The pneumatically weighted top rollers can be
continuously adjusted from minimum to maximum per top roller.
Draft distances are individually variable, as are the draft levels in
each of the break and main draft zones. Upper and lower clearer
aprons in combination with a suction system keep the rollers clean.
The easily accessible drive for the drafting arrangement is in an
enclosed housing and is fitted with appropriate change gears and
oil spray lubrication.
The drafting arrangement of the UNIlap system


The lap winding assembly – conventional system
After passing the web table, the web runs through four
calender rollers (1). The pressure generated by two
membrane cylinders can be adjusted up to 16 000 N. The
calender rollers are followed by two winding rolls (2) and a
lap tube holding device (3) with a lap weighting device;

The lap winding device of the UNIlap machine
these have to cooperate to form the lap.
The required weighting pressure (up to 10 000 N), derived from a piston, is transferred via a pivoting
lever to the weighting frame and thus to the lap tube.

The lap winding assembly – conventional system
The UNIlap has an automatic lap pressure control which
adapts the pressure according to the lap diameter. An
increase in diameter of the lap raises the weighting frame,
in the course of which the pressure increases. The size of
the increase can be set by adjustment using setting screws. The lap winding device of the UNIlap machine
The machine stops when a preset lap length is reached,
whereupon an automatic device replaces the full lap by an
empty tube.
Former VARIO speed arrangement on the UNIlap
On this former system the UNIlap machine did not run at
constant speed, since this would mean choosing the speed
according to the most critical phase of lap winding, i.e. when
lap winding was close to completion. However, this meant
losing productivity. That is why Rieter adapted the speed of the
machine to the buildup of the lap by means of the VARIOspeed
set. So, for example, if a final speed of about 70 m/min was
required, the machine started with a speed of 140 m/min

System incorporating the latest technology
Since production speeds using the winding system based on calender rollers have reached their
limit due to the system itself, Rieter developed a new lap winding system. The new lap winding
system makes use of a unique belt tension and pressure arrangement. The winding belt (1), with a
width similar to that of the laps
Belt surrounds the lap to form a
circumferential pressure area
(omega-shaped) ranging from
180° to 270° from start to full lap.


Fiber guidance and pressure distribution applied by the OMEGA principle allow constant
production (i.e. constant speed during winding of the lap) at speeds of up to 180 m/min over the
entire lap build up.
Comparison between two different winding systems of Rieter‘s

combing preparation machines
Calculation Basics
Yarn count:
Yarn count is a system of expressing the fineness of yarn in terms of thickness.
It is the relationship between the weight and length of yarn
1. Indirect count system 2. Direct count system
In this system the count of yarn expresses the In this system the count of yarn expresses the
number of length units in one weight unit. number of weight units in one length unit.
𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑢𝑛𝑡 = 𝐿𝑒𝑛𝑔𝑡ℎ 𝑖𝑛 𝑎𝑝𝑝𝑟𝑜𝑝𝑟𝑖𝑎𝑡𝑒 𝑢𝑛𝑖𝑡 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑢𝑛𝑡 = 𝑊𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝑎𝑝𝑝𝑟𝑜𝑝𝑟𝑖𝑎𝑡𝑒 𝑢𝑛𝑖𝑡
𝑊𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝑎𝑝𝑝𝑟𝑜𝑝𝑟𝑖𝑎𝑡𝑒 𝑢𝑛𝑖𝑡 𝐿𝑒𝑛𝑔𝑡ℎ 𝑖𝑛 𝑎𝑝𝑝𝑟𝑜𝑝𝑟𝑖𝑎𝑡𝑒 𝑢𝑛𝑖𝑡
finer or less bulky the yarn, higher is its count number finer or less bulky the yarn, lower is its count number

Yarn Count system

Yarn Count system

Yarn Count system

Basic Conversions

Yarn Count system 1. Indirect count system

Yarn Count system 2. Direct count system

calculations
Production
The output of a machine per unit time is called its production. The production is usually
calculated in the units of weight/time or length/time.
e.g, oz/hr, lb/shift, yd/hr, Hk/day etc. The most commonly used unit of time for production
calculation is hour. So if the unit is not mentioned, it is understood to be a production/hr
Efficiency
It is the ability of a material to perform its task. In other words, it is the ratio of the output of a
machine to the input of that machine.
Mathematically,
Efficiency = output/ Input Its value ranges from 0→1. it has no units.

Calculations
Efficiency Percentage
It is the %age performance of a machine.

Mathematically,
Efficiency = output × 100/Input
Its value ranges from 0→100.
If the efficiency of a machine is 0.8, its percentage efficiency 80. The word ‘percent’ means ‘per
100’ which suggests that the efficiency is 80/100.
Cleaning Efficiency (%)
It is the ratio of the trash extracted to the total trash content in a material. For any machine,
mathematically

Production of card machine

Since the efficiency of a machine is always less than 1 and 1lb = 7000 gr so,

Example 1: What will be the production of a carding engine in 8 hours at 84%efficiency and 5% waste, if the speed
of 2 in. coiler calendar rollers is 125 rpm with the carded sliver weighing 58 gr/yd ?

Use the formula of tax system and
calculate the production for Example 1

Production of Draw frame

Since a drawing frame may have more than one delivery ends or heads and also we may use one
or more machines at a time for drawing the same kinds of slivers, so to calculate the total
production,

Example 2: The 3 in. diameter calendar rollers of a 6 delivery drawing frame revolves 125 rpm.
Calculate the production in pounds if the drawn sliver is 60 gr/yd and the machine works for 8
hrs at 70% efficiency.


calculate the production example 2

Production of Lap former
Sliver Lap Former

English count system
Tax count system

Example 3: The speed and dia. of the fluted lap drum of a sliver lap machine are 30 rpm and 16
in. respectively. If 24 card cans having 0.15 Hk sliver are fed to the machine, what will be the
production in one shift at 70% efficiency?

No. of pounds of each sliver delivered in 1 shift at 70% efficiency
No. of pounds/yard of each sliver delivered





Production of Ribbon Lap Machine
Example 4: Calculate the production of a ribbon lap m/c in 8 hours at 70% efficiency if the
speed of 16” dia. lap drum is 48 rpm and hank of ribbon lap is 0.0119.

Draft Calculation

Draft Calculation

Drafting system (total draft)
The optimum draft depends on various factors such as the proportion of short fibres, fibre
fineness, friction behavior of the fibres, fibre parallelism, and fibre mass. These are very
important factors which affect the lap build-up.
The drafting system total draft is the product
of the drafts when multiplied and should be
between 1.3 and 1.8.

Factors Affecting the Draft
The optimum draft depends on various factors such as
➢ the proportion of short fibres,

➢ fibre fineness,
➢ friction behaviour of the fibres,
➢ fibre parallelism, and fibre mass.
These are very important factors which affect the lap build-up.

Factors Affecting the Draft
Drafting System Gear
The same drafts must be set on all the drafting systems
Main draft:
Use the gears (a), (b), (i), (j) to set the draft between cylinders
(1) and (2).
Break draft:
Use the gears (l), (m), (r), (s) to set the draft between the cylinders
(2) and (3)
From the prescribed drafts HV and VV read off the change gears
from the appropriate tables and insert.

Draft Tables

Calculating the required total draft 𝑽𝒕𝒐𝒕
Example 5: calculate the total draft having doubling of 24 with sliver weight 4.9 (g/m) with
nominal batt weight is 70 (g/m)?

Example 6 : If actual batt weight is 71 g/m (ktex) and actual main draft (HV) is 1.53 whereas
required batt weight is 75 g/m (ktex) then correction of main draft will be? Find the gears from
given table
Round up to the nearest figure e.g., 1.443 see Table Main Draft

Tension Draft and Delivery Draft Calculation
Lap Roll Change Gear A / B

The change gears A / B affect the draft, between the fluted lap roll (4) and
the smooth one (2). Keep this tension as low as possible.

Tension draft (3) too low
Visible transverse creases on the surface of the lap sheet
(batt) when unwinding on the combing machine. The lap
tension is too low at (1). The smooth lap roller (2) is turning
too slowly.
Tension draft (3) too high

Visible lengthwise creases on the surface of the lap sheet
when unwinding on the combing machine. The lap tension
is too low before winding on at (5). The smooth lap roller
(2) is turning too fast

Calendar-lap roll change gears C / D

Effect of change gears A / B, C / D

Delivery draft


Yarn Manufacturing-II Lecture 1-12 Prof. DR Farooq Ahmed and Dr. Pardeep Kumar Online

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Yarn Manufacturing-II Lecture 1-12 Prof. DR Farooq Ahmed and Dr. Pardeep Kumar Online

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Yarn Manufacturing -II

Prof. Dr. Farooq Ahmed

Time Monday Tuesday Wednesday Thursday Friday

9:00-10:00 YM-II YM-II YM-II

Prof. Dr. Farooq Ahmed

The material used in this presentation i.e., pictures/graphs/text, etc. is solely

Manufacture and control the processes of combed sliver

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

3. Merril G. R., “Cotton Combing”, GibertMerril, England, latest edition.

Prof. Dr. Farooq Ahmed

Yarn manufacturing Fabric manufacturing Wet-processing Garments

Knitting Weaving Cutting

Carding Roving Auto cone Dyeing/ printing Embroidery

Combing Two for one twister Sewing

Blow room Drawing Ring

Carding Roving Auto cone

Combing Two for one twister

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Yarn evenness Strength Cleanness

Smoothness Visual appearance

Prof. Dr. Farooq Ahmed

It is actually a modern combing

Prof. Dr. Farooq Ahmed

Following are the objectives of combing process:

•To remove naps in the carded sliver.

•To make the fiber more parallel and straight.

•To produce a uniform sliver of required length.

•To remove the fiber shorter than a predetermined length.

•To remove remaining impurities in the comber lap.

Prof. Dr. Farooq Ahmed

That’s why it is a Optional and Costly Process

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

a) Long Staple Combing Mills

b) Medium Staple Combing Mills

c) Short – (to medium) staple combing mills.

Prof. Dr. Farooq Ahmed

▪ The product is a fine-to-very-fine yarn of top quality.

▪ Yarn production is low, while generation of noil is high.

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Many different types of comber are available, including;

• Rectilinear combers (with stationary or oscillating nippers).

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

All of this is carried out up to 300 times per minute

Prof. Dr. Farooq Ahmed

Prof. Dr. Farooq Ahmed

➢ A random disposition of the fibres within the sheet is a further prerequisite.

Prof. Dr. Farooq Ahmed