Itru-Information-Fibre Mix Selection ver 1.0 Pc-Program

Fibre Mix Selection ver 1.0 for Cotton Fibres for UAK-1

Introduction

Itru Fibre Tester UAK-1 also includes Fibre Mix Selection Pc-Program .

Fibre Mix Selection Pc-Program makes use of following input values from Itru Fibre Tester UAK-1

2,5% SLY1-Fibre Graph.Weighted........mm:

50,0%SLY2-Fibre Graph Weighhted.. ....mm:

Fibre Fineness.U.....micronaire.........:

Presley-1/8in-Fibre Strength cn/tex.....:

More Information about Itru Fibre Tester UAK-1 and Portable UAK-1A

This program "FIBRE MIX SEARCH & SELECTION CONTROL by ITRU GROUP LTD" has been developed by ITRU GROUP LTD -International Textile Consulting & Management. FMSSC PC-PROGRAM could be used on all IBM compatible PCs to optimize spinning process. This program has been prepared for cotton fibres and cotton spinning. A part of the program could also be used for other short staple fibres spinning processes. PROGRAM has consists of following sub-PC-programs :

a)Fibre Mix Samples Search and Selection Data Bank

b)Fibre Samples Selection and Pareto Analyses and also supported by Bale Management and Yarn ENGINEERING PC-PROGRAMS as well.

1.2.1 Fibre-Mix Search and Selection Data Bank

Cotton fibre is commercially judged bye its main properties; staple length,color,micronaire,presley at zero gauge etc. To purchase the cotton fibre as it seems to an eye,without using any testing instruments is rather a risky attempt. In order to obtain optimum quality with minimum cost,one should purchase the right raw materially for the required yarn properties. Therefore,the selection of the raw material would depend the required quality of yarn and its end-use. After supplying the appropriate material,measurements should go on during the processes as the fibre parameters are not constant and modify in each process.

This program has been developed through extensive research work carried out on carded,combed and rotor spinning mills,and measurements are conducted on cotton samples taken all round the world. Many cotton fibres were tested by fibrogram,HVI ,Steolometre and Fibre Tester UAK-1 the relevant correlation were developed and tested in actual mill running conditions.

The intention of the program is to select the most proper type of cotton according to the spinning data:

• Count of yarn in tex

• Turns per cm

• Type of process (Carded Ring-Combed Ring-Rotor Spinning)

and present most important fibre parameters of the cotton fibres tested.

Fibre Mix Selection Data Bank consists of fibre data values and fed by the FIBRE SAMPLES PARETO ANALYSES PC-PROGRAM. Therefore,any sample testing carried out in the mill could be used in future purposes for selecting the most optimum cotton type. Therefore, DATABANK grows at each fibre testing. In the DATA BANK more than 400 cotton samples from all round the world has been included. And this Data Bank could be used any time for any type fibre mix selection. Therefore,it is possible to compare the different types of cotton from any part of the world and choose the most appropriate type of cotton for processing.

Table 1.1 shows the recommended various types of cotton. From this table one could compare the projected yarn strength values of different types and choose the most optimum one for the end use such as weaving warp yarn , weaving weft yarn and hosiery.

From projected blowroom+card waste loss and short fibre content one could also estimate the end break rate and yield performance of the each cotton type. It is clear that this PC-PROGRAM gives many information on cotton spinning. But it also requires excellent knowledge of textile technologist if one needs to get maximum efficiency from the PC-PROGRAM.

It is clear that CIM systems has been developed by many companies on a worldwide basis i.e. on-line quality and production control systems now
exits in many spinning and weaving mills. But CIM systems do not eliminate the existing problems. The data gathered from the systems should be collected and analyzed. Therefore CIM systems require very qualified textile technologists to achieve better running efficiencies in spinning and weaving mills. On the other hand PC-PROGRAMS could analyze these collected data. PC-PROGRAMS could be designed on three basis

a)Statistical calculations

b)Technological conceptions and Knowledge based

c)Both

Therefore PC-PROGRAMS also act as a tool to help the textile technologists to achieve better running performance in the spinning mills. The result of the PC-PROGRAMS should also be analyzed and worked on very carefully. However,both CIM AND PC-PROGRAMS bring new management techniques to the mills. Now,the mills should be directed not by the managers but through knowledge. We call this new system Knowledge Based Management . FIBRE MIX SELECTION DATA BANK PC-PROGRAM is such a part of this complete CIM systems. We can not guess exactly what will the future will bring but we are sure that most of the existing conceptions inn spinning and weaving technology would definitely change and are changing.5 years ago most of the spinners would emphasize the importance of linear irregularity CV% value of yarn for weaving. But now,people have started to talk about elastic modulus of yarn more than evenness. Therefore,we have taken the key parameter as a single end projected yarn strength for optimum selection of the raw material rather than evenness.

Table 1.0 shows a print out a <Data Entry From Fibre Selection Data Bank> From this result one could choose the most optimum cotton type for the required spinning process.

FIBRE MIX SEARCH & SELECTION DATA BANK

   SL1 =2.5% Span length in mm (weighted from UAK-1 Fibre Tester) -Input
   SL2 =50% Span length in mm (weighted from UAK-1 Fibre Tester)-Input
   LM   =Mean fibre length by number in mm
   CVN =CV % of fibre length distribution by number divided by 10
   LG   =Mean fibre length by fibre weight in mm
   LUHM =Upper half mean length in mm
   LS   =Staple length in 1/16 inch
   SFC =Short fibre content by fibre number
   U    =Micronaire (From UAK-1 Fibre Tester)-Input
   FM3 =Maturity ratio
   HS   =Standart fibre fineness mtex
   CN   =Fibre strength in cN/tex for 1/8 inch gauge (From UAK-1 Fibre Tester)-Input
   NLC =Non-lint content of cotton
   RKM =Single end projected yarn strength in cN/tex

Input:

TURNS PER CM..................11.53
COUNT OF YARN IN TEX.......... 9.66
SPINNING PROCESS :COMBED RING SPINNING

Output:
Cotton Type
      SL1   SL2    LM   CVN LG   LUHM LS    SFC   U FM3   HS    CN NLC RKM
-------------------------------------------------------------------------------
Nazilli Delsore
      33.81 14.54 24.19 4.0 29.3 34.22 20.9 5.5 3.50 0.88 161.8 26.6 3.3 20.31
LONG STAPLE-LONG- CARDED&COMBED
KoycegizM
      30.16 15.38 23.25 3.8 26.4 30.47 18.9 3.5 3.50 0.91 148.4 25.6 3.6 22.40
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
Bergama S
      30.13 14.28 22.47 3.9 26.2 30.46 18.8 5.4 3.60 0.89 161.0 24.2 4.2 18.75
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
Manisa S
      30.31 14.01 22.36 3.9 26.3 30.65 18.9 5.9 3.40 0.83 174.6 22.9 4.7 16.90
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
TurgutluS
      30.30 14.20 22.49 3.9 26.3 30.64 18.9 5.5 3.80 0.90 171.5 23.2 4.6 17.60
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
Milas   E
      30.41 14.40 22.67 3.9 26.4 30.75 19.0 5.2 3.40 0.87 156.0 25.0 3.9 19.62
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
Salihli E
      30.23 14.72 22.82 3.8 26.3 30.56 18.9 4.6 4.00 0.97 156.6 24.7 4.0 20.17
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
Milas   E
      30.41 14.40 22.67 3.9 26.4 30.75 19.0 5.2 3.40 0.87 156.0 25.0 3.9 19.62
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
Salihli E
      30.23 14.72 22.82 3.8 26.3 30.56 18.9 4.6 4.00 0.97 156.6 24.7 4.0 20.17
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
Rahad ShambBSG
      33.34 14.50 23.97 3.9 28.9 33.74 20.6 5.5 4.30 0.92 192.5 23.0 4.7 17.08
LONG STAPLE-LONG- CARDED&COMBED
Sudan Barakat
      33.58 14.31 23.94 4.0 29.1 33.99 20.7 5.9 3.60 0.95 141.2 29.5 2.3 22.46
LONG STAPLE-LONG- CARDED&COMBED
IsraelPima Maori/s
      31.82 15.04 23.71 3.9 27.7 32.17 19.8 4.4 3.40 0.96 130.9 29.8 2.2 24.60
MEDIUM STAPLE-MEDIUM TO LONG CARDED/COMBED
Giza 70 G
      33.06 15.12 24.28 3.9 28.7 33.44 20.5 4.6 4.10 0.98 159.1 26.3 3.4 21.40
LONG STAPLE-LONG- CARDED&COMBED
Russ.Varna/87
      33.44 15.83 24.93 3.9 29.1 33.81 20.7 3.6 3.60 0.97 136.9 29.9 2.2 25.62
LONG STAPLE-LONG- CARDED&COMBED
Russ.Petro/86
      33.49 15.85 24.97 3.9 29.1 33.86 20.7 3.6 3.20 0.90 137.3 29.9 2.2 25.60
LONG STAPLE-LONG- CARDED&COMBED
Peruvian Tanguis
      31.03 15.97 24.02 3.8 27.2 31.35 19.4 2.8 4.90 0.96 210.1 20.1 6.0 18.08
LONG STAPLE-LONG- CARDED&COMBED

Optimum selection of fibre type would depend upon the yarn end use which will depend upon following factors:

Projected single end yarn strength

Short fibre content % which is related to the end break rate and hairiness

Non-lint content % which is a key for blowroom+card loss

Cost price and yield performance

Required mean yarn strength in cN/tex

It becomes very clear that best cotton is not the one which gives highest yarn strength but most compatible one with the yarn quality. Therefore,one should carefully analyses these results and choose the optimum cotton type for the selection. So PC-PROGRAMS certainly bring new conceptions to the spinners.

1.2.2 Fibre Samples Selection and Pareto Analyses

1.2.2.1 Sample Selection

The cotton samples were tested for comparison purposes before purchase actually take place. For testing there are many testing instruments available. Theseare fibre-length,strength,micronaire and sometimes non-lint content percentage. However,these values do not correlate very well with the yarn performance in weaving or knitting if one consider them separately . All the fibre parameters should be considered as a whole to distinguish the cotton samples from one another. Therefore,selection of a most appropriate cotton sample for the spinning should be compatible with the actual mill running conditions and spinning data. The usual procedure is to have one blend for each type of process i.e. carded,combed and rotor.

In order to achieve optimum spinning conditions following plan should be drawn for each type of spinning process.

• Count range to be spun

• Twist range

• Yarn end-use i.e. warp,weft or hosiery

• Yield ratio i.e. raw material/yarn performance

• End-break rate at each stage of processing

• Type of weaving or knitting machine

• Cost of raw material

It is possible to achieve optimum quality if these points are taken into consideration. We do not intend to get higher quality but optimum quality of yarn from the raw material selection to optimize the manufacturing costs and to get optimum results. In actual spinning conditions mills organize their blend according to count range.

Cotton fibres could be classified into five classes according to the count,twist multiplier and processing organization as shown below.

`2.5% SL`	`COUNT OF YARN TEX`	`FIBRE CLASS`
`25.40`	`32>`	Short
`27.18`	20	Medium
`30.98`	15	Medium to long
`34.00`	12	Long
`38.80`	7	Extra long

However,there is a large variation within each class and between classes. Nowadays,spinners try to spin finer counts medium to long type of cottons such as 12 tex combed yarn . Therefore,the trend is to get finest count for a given fibre class group with optimum weaving and knitting performance.

We would like to spin 19.68 tex carded yarn and there are ten samples to be tested. We have Fibre Tester UAK-1 testing instruments in our lab. FIBRE SAMPLE SELECTION PC-PROGRAM here analyses these ten samples and gives the projected single end yarn strength. From these projected single end yarn strength one could select the optimum cotton type to spin in mill. The following list gives an example of ten cotton samples result.

++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
       Carded Ring Spinning : Turns per cm............: 9.05
                               Count of yarn in tex....:19.68
------------------------------------------------------------------------------
Type of Fibre...........................:AUSTRALIAN ANDY
2.5 % Span length value in mm.......................................:29.25
50 % Span length value in mm........................................:13.11
Mean Fibre Length by number in mm...................................:21.30
Mean Fibre Length by Fibre Weight in mm.............................:25.47
% of Coefficient of Fibre Length Variation by fibre number..........:44.23
Short Fibre Content by Fibre Number.................................: 7.43
Effective Length in mm..............................................:33.50
Upper Half Mean Length in mm........................................:29.59
% of Causticaire Maturity ..........................................:75.97
Fibre Fineness in mtex..............................................:183.49
Percentage of Mature fibres.........................................: 75.90
Fibre Strength in cN/tex at 1/8 in gauge............................:21.53
Classer length in 16 th of an inch..................................:18.30
% of Calculated non-lint content....................................: 5.32
Projected Neps/gram in card sliver..................................:56.58
% of Projected Waste lost total(blowroom+plus cards)................: 7.11
------------------------------------------------------------------------------
Projected single end yarn strength in cN/tex........................:14.03
------------------------------------------------------------------------------
MEDIUM STAPLE-MEDIUM TO LONG-CARDED/COMBED
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
       Carded Ring Spinning : Turns per cm............: 9.05
                               Count of yarn in tex....:19.68
------------------------------------------------------------------------------
Type of Fibre...........................:AUSTRALIAN NICE
2.5 % Span length value in mm.......................................:29.56
50 % Span length value in mm........................................:13.78
Mean Fibre Length by number in mm...................................:21.89
Mean Fibre Length by Fibre Weight in mm.............................:25.77
% of Coefficient of Fibre Length Variation by fibre number..........:42.07
Short Fibre Content by Fibre Number.................................: 6.19
Effective Length in mm..............................................:33.70
Upper Half Mean Length in mm........................................:29.89
% of Causticaire Maturity ..........................................:77.73
Fibre Fineness in mtex..............................................:177.32
Percentage of Mature fibres.........................................: 78.42
Fibre Strength in cN/tex at 1/8 in gauge............................:22.19
Classer length in 16 th of an inch..................................:18.51
% of Calculated non-lint content....................................: 5.03
Projected Neps/gram in card sliver..................................:45.06
% of Projected Waste lost total(blowroom+plus cards)................: 6.85
------------------------------------------------------------------------------
Projected single end yarn strength in cN/tex........................:16.42
------------------------------------------------------------------------------
MEDIUM STAPLE-MEDIUM TO LONG-CARDED/COMBED

++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
       Carded Ring Spinning : Turns per cm............: 9.05
                               Count of yarn in tex....:19.68
------------------------------------------------------------------------------

Type of Fibre...........................:GREECE MABAL
2.5 % Span length value in mm.......................................:27.07
50 % Span length value in mm........................................:12.04
Mean Fibre Length by number in mm...................................:19.65
Mean Fibre Length by Fibre Weight in mm.............................:23.57
% of Coefficient of Fibre Length Variation by fibre number..........:44.65
Short Fibre Content by Fibre Number.................................: 9.62
Effective Length in mm..............................................:31.03
Upper Half Mean Length in mm........................................:27.39
% of Causticaire Maturity ..........................................:74.46
Fibre Fineness in mtex..............................................:168.56
Percentage of Mature fibres.........................................: 73.67
Fibre Strength in cN/tex at 1/8 in gauge............................:21.67
Classer length in 16 th of an inch..................................:17.03
% of Calculated non-lint content....................................: 5.26
Projected Neps/gram in card sliver..................................:94.11
% of Projected Waste lost total(blowroom+plus cards)................: 7.05
------------------------------------------------------------------------------
Projected single end yarn strength in cN/tex........................:11.23
------------------------------------------------------------------------------
MEDIUM STAPLE-MEDIUM-CARDED/COMBED/ROTOR
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
       Carded Ring Spinning : Turns per cm............: 9.05
                               Count of yarn in tex....:19.68
------------------------------------------------------------------------------
Type of Fibre...........................:AFRICAN SPINLAC
2.5 % Span length value in mm.......................................:31.07
50 % Span length value in mm........................................:15.33
Mean Fibre Length by number in mm...................................:23.60
Mean Fibre Length by Fibre Weight in mm.............................:27.17
% of Coefficient of Fibre Length Variation by fibre number..........:38.94
Short Fibre Content by Fibre Number.................................: 3.79
Effective Length in mm..............................................:35.18
Upper Half Mean Length in mm........................................:31.40
% of Causticaire Maturity ..........................................:79.18
Fibre Fineness in mtex..............................................:156.39
Percentage of Mature fibres.........................................: 80.44
Fibre Strength in cN/tex at 1/8 in gauge............................:25.24
Classer length in 16 th of an inch..................................:19.45
% of Calculated non-lint content....................................: 3.79
Projected Neps/gram in card sliver..................................:25.15
% of Projected Waste lost total(blowroom+plus cards)................: 5.67
------------------------------------------------------------------------------
Projected single end yarn strength in cN/tex........................:22.54
------------------------------------------------------------------------------
MEDIUM STAPLE-MEDIUM TO LONG-CARDED/COMBED