Rotor spinning

• Rotor spun yarns are well known for their

unique three-part structure:
• wrapper or belt fibres
• sheath fibres
• core fibers
• The core contains densely-packed fibers
similar to ring-spun yarns
• Sheath fibres are loosely packed round the
yarn core at a low angle to yarn axis
• The wrapper or belt fibres are wrapped
around the outside of the yarn at a very large
inclination to the yarn axis.
• Rotor spun yarn is less strong than
comparable ring spun yarn. This is because of
the straight, parallel arrangements of fibers
and denser packing of fibers in ring spun yarn
which contrast with the higher numbers of
disoriented folded fibers in rotor spun yarn,
lower levels of fibre migration, less packing
and the presence of non-load bearing
wrappers and belt fibres.
• Rotor spun yarns are generally more extensible
than ring spun yarns. The higher breaking
extension of rotor yarn is due to presence of a lot
of hooked, looped and disoriented fibers in the
structure. However, the dense, more tangled
structure of fibres in the core offers very little
freedom of movement of fibres in rotor yarns.
Rotor yarns are therefore less flexible than ring
yarns which have a more uniform helical
arrangement of fibres.
• rotor yarn shows higher abrasion resistance
than ring spun yarn
• fibers in rotor yarn are less packed than ring
yarn. Rotor yarns are known to be 5-10% bulkier
than ring yarn. Across the cross-section, the
packing is not uniform. The packing is maximum
at a point approximately one third to one quarter
of yarn radius from the central axis. This has been
attributed to greater buckling if fibres in the core.
As a result, packing of rotor yarn is concentrated
nearer the yarn axis and less towards the outer
surface of the yarn in comparison to ring yarn.
• Unlike a ring frame, the winding and twisting functions
are separate and this permits the building of large yarn
packages. Both these characteristics allow much higher
levels of productivity than ring spinning.
• The second objective has not yet been achieved
because of the structure of rotor yarns, which also
limits the fineness of count that can be spun. Perhaps
the biggest current obstacle facing rotor spinning is the
fact that it is limited to coarse and medium yarn counts
(16 tex to 120 tex) while ring spinning excels in the
medium to fine counts (finer than > 16 tex).
 LIMITATION OF RING SPG
• the major limiting factor in ring spinning is their
low production rate in comparison with all new
spinning technologies.
• ring-spinning can only operate at a production
speed of up to 30 m/min, while other systems
producing comparable yarns (such as rotor
spinning and air-jet spinning) can operate at
production speeds of up to 250 m/min. The low
production rate in ring spinning is primarily
attributed to the use of the ring/traveller system
for twisting and winding.
 TWISTING AND WINDING TOGETHER
IN RING SPG
• The twist insertion mechanism which requires
one full rotation of the yarn bobbin to
introduce one turn of twist into the yarn is
one of the main reasons for limiting the
productivity of ring spinning. Increasing the
spindle speed, and thereby the bobbin speed,
increases productivity but the increase in
spindle speed is itself limited owing to the
heat transfer and wear problems of the
traveller situated on the ring.
Ring spinning
 In rotor spinning, the fibres are added
to the yarn tail continuously almost
one at a time, with the result that the
fibres exhibit individual helix structure.
 rotor
• TWISTING AND WINDING SEPERATELY
• To produce an open end yarn, it is necessary
to use a very high draft so that the fibre flow
is reduced to just a few fibres in the cross
section. This prevents twist from running back
into the fibre to produce a false twist.