Yarn Quality Analyses Services with Itru Fibre Testers and Yarn Processing Engineering Software
Fibre Yarn and Yarn/Fibre Conversion Algorithms
Itru has developed a system in UAK-1 + to predict
-Blowroom + Card Waste-Total Imperfections in yarn (thin,thick and neps ) and Mass CV % of yarn : Yarn Evenness Index-Yarn Strength Index
-Optimum twist factor that could be applied for the yarn
-Categorising the fibre mix for selection for carded,combed and rotor spinning from Raw Cotton Fibre Properties.
In order to avoid Dye take up problems and white specks in the fabrics there are special techniques that could also be applied by making use of several UAK-1 + parameters depending upon the type of Process and type of fibres.
The above predictions could only be realised if raw cotton fibre properties are at least reserved. But in real mill practice Fibre properties could be improved according to raw cotton but could also be deteriorated .The yarn is finally made from fibres that come out from the front roller delivery of ring frame. Within this in mind Itru has also developed a system Yarn Process Engineering Pc-Program to determine the fibre properties from Mass Spectrograph curve of yarn and also Yarn Quality criteria from Fibre Properties of ring frame front roller delivery. Fibre Properties at the ring frame delivery pretty well projects all the yarn quality parameters very well. Since Mass Spectrograph of any type of yarn depends mainly upon the Fibre properties.
Itru has developed a new terms called “Processing and Spinning Ability of Fibres “ this can be indexed by the performance of the fibres and processing quality.Hence Processing and Spinning Ability Index (PSAI) = Fibre Properties at the ring frame delivery multiplied by 100 divided by Fibre Properties at the raw stock . Therefore, PSAI is the key parameter to determine the quality of fibres and quality of processing engineering.
According to our research work PSAI is mainly influenced by the changes in the surface structure of the fibres during ginning to ring frame delivery and UAK-1 + is the only information system in the world that can provide information about the surface damage on Fibres.Itru has developed a new algorithm to compute the fibre properties from Mass Spectrograph of any yarn such as Fibre length values and Fibre Fineness .Yarn Mass Spectrograph is drawn after complicated Fourier integrals . Itru Fibre Tester UAK-1 draws Mass Spectrograph from Fibre Properties at any stage of processing in spinning and YPE (Yarn Processing Engineering) reverses this process and obtains the Fibre Properties from Spectrograph. This is a reverse process .
This prove that yarn quality parameters are determined mainly by :
-Fibre Properties at the ring frame delivery
-Yarn Mass /Diameter Spectrograph Curve
The table shows the Fibre Properties at Raw Stock and Ring Frame Delivery. It has been observed that changes in Fibre Length from raw stock to ring frame differs from cotton mix to mix
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Blend |
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Testno |
SLY1 |
SLY2 |
SLF1 |
SLF2 |
URF% |
LMS |
CVN% |
LEF |
SFN% |
SFNK% |
%1SL |
ColA |
YSI |
HS-Mtex |
FM1% |
Neps/100 |
BN% |
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1 |
30,96 |
17,88 |
33,15 |
12,07 |
36,4 |
25,48 |
33,88 |
30,99 |
10,08 |
1,01 |
42,93 |
230 |
22,87 |
174,14 |
79,28 |
6 |
2,42 |
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2 |
30,95 |
18,85 |
32,39 |
12,19 |
37,65 |
25,62 |
32,56 |
30,61 |
9,27 |
0,99 |
42,29 |
228 |
22,65 |
177,14 |
80,22 |
14 |
3,04 |
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Ave |
30,95 |
18,36 |
32,77 |
12,14 |
37,03 |
25,55 |
33,22 |
30,8 |
9,68 |
1 |
42,61 |
229 |
22,76 |
175,64 |
79,75 |
9,5 |
2,73 |
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Min |
30,95 |
17,88 |
32,39 |
12,07 |
36,4 |
25,48 |
32,56 |
30,61 |
9,27 |
0,99 |
42,29 |
228 |
22,65 |
174,14 |
79,28 |
6 |
2,42 |
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Max |
30,96 |
18,85 |
33,15 |
12,19 |
37,65 |
25,62 |
33,88 |
30,99 |
10,08 |
1,01 |
42,93 |
230 |
22,87 |
177,14 |
80,22 |
14 |
3,04 |
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Std |
0,01 |
0,69 |
0,54 |
0,08 |
0,88 |
0,1 |
0,93 |
0,27 |
0,57 |
0,01 |
0,45 |
1,41 |
0,16 |
2,11 |
0,66 |
4,95 |
0,44 |
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CV% |
0,02 |
3,73 |
1,64 |
0,7 |
2,39 |
0,39 |
2,81 |
0,87 |
5,92 |
1,41 |
1,06 |
0,62 |
0,68 |
1,2 |
0,83 |
52,1 |
16,06 |
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LP% |
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98,77 |
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Test No |
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Ring |
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Testno |
SLY1 |
SLY2 |
SLF1 |
SLF2 |
URF% |
LMS |
CVN% |
LEF |
SFN% |
SFNK% |
%1SL |
ColA |
YSI |
HS-Mtex |
FM1% |
Neps/100 |
BN% |
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1 |
29,11 |
17,82 |
29,85 |
11,43 |
38,3 |
24,11 |
32,02 |
28,7 |
11,02 |
1,11 |
39,24 |
228 |
21,65 |
178,72 |
80,72 |
6 |
2,76 |
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2 |
29,27 |
17,6 |
30,35 |
11,43 |
37,66 |
24,19 |
32,19 |
28,96 |
10,67 |
1 |
39,37 |
228 |
21,65 |
178,72 |
80,72 |
1 |
2,4 |
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Ave |
29,19 |
17,71 |
30,1 |
11,43 |
37,98 |
24,15 |
32,1 |
28,83 |
10,85 |
1,06 |
39,31 |
228 |
21,65 |
178,72 |
80,72 |
3,5 |
2,58 |
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Min |
29,11 |
17,6 |
29,85 |
11,43 |
37,66 |
24,11 |
32,02 |
28,7 |
10,67 |
1 |
39,24 |
228 |
21,65 |
178,72 |
80,72 |
1 |
2,4 |
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Max |
29,27 |
17,82 |
30,35 |
11,43 |
38,3 |
24,19 |
32,19 |
28,96 |
11,02 |
1,11 |
39,37 |
228 |
21,65 |
178,72 |
80,72 |
6 |
2,76 |
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Std |
0,11 |
0,16 |
0,35 |
0 |
0,45 |
0,06 |
0,12 |
0,18 |
0,25 |
0,08 |
0,09 |
0 |
0 |
0 |
0 |
3,54 |
0,25 |
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CV% |
0,39 |
0,88 |
1,17 |
0 |
1,19 |
0,23 |
0,37 |
0,64 |
2,28 |
7,37 |
0,23 |
0 |
0 |
0 |
0 |
101,02 |
9,87 |
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LP% |
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99,1 |
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Therefore, it is useless to check the fibre properties at the raw stock if you do not check at the ring frame. Yarn Quality is determined by the fibre properties at the ring frame delivery and must be measured regularly in any spinning mill. However, it is really hard work to measure fibre properties of ring frame delivery . In order to avoid this problem Itru has developed UAK-1 and YPE to measure the Fibre Properties at the ring frame delivery for X-checking. According to our research work in different spinning mills we have developed an completely new algorithm to estimate the Yarn Quality Parameters for any type of raw material according to Fibre Properties at the ring frame delivery which actually forms the yarn. This system brings many advantages to spinning mills. So one can get information about following main points
Yarn Quality of any type of yarn manufactured from any type of raw material (cotton, cotton with blends and man-made fibres ) depends on following parameters:
-Fibre length distribution at the ring frame delivery
-Fibre Fineness in mtex at the ring frame delivery
-Mass CV % of yarn that is actually made.
Mass CV % of yarn is influenced by Fibre Length distribution, Fibre Fineness and Processing /Machine Data.
For any given Mass CV % of yarn there is an upper and lower limit of thin and thick places. We have produced a visual yarn having 100,000 readings long according to Mass CV % measured and computed the thin places (-%50%) and thick places(+50%) from the mass diagram plotted from 100,000 readings.
Itru Yarn Quality Standardization System bases upon the actual measured values of Fibre Properties at the Ring Frame Delivery and Yarn Mass CV % measured on evenness tester or determined by image analyses by Itru Yarn Surface Engineering System. According to this one can compare Yarn Quality with Itru Standards Values.
This system brings many advantages to spinning mills.
-Comparing the fibre properties at the raw stock and at the ring frame delivery
-Comparing Mass CV % achieved and targeted according to given fibre type
-Comparing total imperfections ,Yarn Strength and variation of strength with actual measured values
These are summarized at the table below
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Yarn Quality Data |
Measured |
Itru Standards |
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Mass CV % |
12,8 |
14,5 |
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Thin /1km |
2 |
5 |
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Thick /1 km |
35 |
5 |
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Total Imperfections (thin+thick+neps) |
140 |
85 |
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RKM |
19,2 |
22 |
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RKM CV% |
16,5 |
5,5 |
Results :
-Thin places are better than expected
-Thick places are higher than expected
-Total imperfections are higher than expected
-RKM CV % is higher than expected.
Check Points :
1-Ring ,Roving , Draw Frame Technical Data/Machine Setting
2-Comber Machine Technical Data/Machine Settings
3-Carding Machine Fibre Transfer Ratio and related technical Data/Machine Settings
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Fibre Parameters
Uak-1 Test
YPE-Test
SLY1(mm
29,19
30,40
SLY2(mm)
17,71
16,79
HS(mtex)
178
178
Fibre Graph Mean Fibre Length(mm)
24,15
25,4
CVN%
32,1
32
Yarn Process Engineering Fibre Length Properties of the Yarn
SL1Y: SL2Y: LM: CVN%
-----------: -----------: -----------: -----------
Ave 30,40: 16,79: 25,40 0,32
Std 2,33: 1,72: 1,62 0,10
CV% 7,66: 10,23: 6,36 30,55
---- -----------: -----------: -----------: -----------
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Yarn Process Parameters |
YPE |
UAK-1 |
Result |
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Number of fibres from Spectrograph |
83,049 |
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Fibre Tex |
0,18 |
0,178 |
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Yarn Mass Limit CV% |
10,973 |
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Index of evenness |
1,166 |
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Fibre Strength in grams from Spectrograph |
3,417 |
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Amplitude of Spectrograph Calculated. |
20,000 |
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Short Fibre Index % |
0,198 |
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Projected RKM |
22,898 |
19,2 |
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Actual RKM |
19,200 |
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Projected Fibre Strength g/tex |
19,200 |
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Projected Fibre Tex for Cotton |
0,152 |
0,148 |
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Targeted Yarn Mass CV% |
14,169 |
12,8 |
Very Good |
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Projected End Breaks/1000-spindle-Hour |
16,082 |
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Projected Total Imperfections per km |
84,076 |
130 |
Too high |
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CVL 50cm |
4,620 |
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RKM CV % Actual |
16,600 |
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RKM CV % Projected |
5,521 |
16,5 |
Too high |
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Spinning Angle in degrees |
14,297 |
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Spinning Slope |
-0,261 |
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CV100-m projected |
0,007 |
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Average Yarn Count in Tex |
14,783 |
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Minimum Yarn Count in tex |
14,780 |
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Maximum Yarn Count in Tex |
14,786 |
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Yarn Specific Tenacity g/tex |
21,391 |
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Projected Yarn Strength in gram |
316,154 |
283,27 |
insufficient |
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Projected Yarn Count from actual RKM CV% |
14,780 |
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Minimum Yarn count From X-Section Variation |
14,127 |
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Yarn Mass CV% /Fibre length |
10,147 |
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Thin Places/1 km projected . Normal Distribution |
5 |
2 |
Very Good |
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Thick Places/1 km projected . Normal Distribution |
5 |
35 |
Too high |
Yarn Quality Data has depend upon Fibre Properties of ring frame delivery and Yarn Mass CV %. Yarn Process Engineering ver .1.0 determines Fibre Properties and Yarn Quality Parameters.
This systems also determines the Yarn Count range and Strength range for 100,000 tests so that more information could be gathered for the yarn produced. The system also serves to determine the targeted yarn quality parameters.
RKM
CV %
Gram
Force Minimum
GramForce
Maximum Gram
Force Average 16,5 75 480 278 5,5
220 348 278 8 186
390 278 The above table shows that in this mill main
problem is with RKM CV%
3-Testing Yarn Quality and Spining Performance According to Fibre Properties at Ring Frame Delivery
Input Parameters/Samples /Technical Data
-A sample of 100 gram Raw Cotton
-A sample of 100 gram Ring Frame Delivery Waste
-One Yarn Mass Spectrograph for 2km of yarn tested as spectrograph (chart) (testing time 5 mins testing speed 400 m/min)
-Single values of Thin, thicks ,neps values for 20 spinning cops per 400 meters of yarn (testing time 1 mins testing speed 400 m/min)
-Single values of gram force and elongation of 20 single values
Output Parameters
-Fibre Graph Curve of Fibres of the yarn formed
-Fibre Properties of Ring Frame Delivery
-Yarn Quality Standards according to Fibre Properties at Raw Stock
-Yarn Quality Standard according to Fibre Properties at Ring Frame Delivery
Benefits of Testing and Analyzing your Yarn Quality
-Comparison of Fibre Properties of Raw Cotton and Ring Frame Delivery shows the actual spinning performance . Hence necessary measures can be taken to improve over all yarn quality.
-Comparing yarn quality with Itru Fibre Standards could give suggestions on the potential areas of quality improvement according to your actual fibre properties . What has been achieved and what can be achieved.? If you break the fibres in spinning process then you need to change settings in at each processing stage . Hence this testing leads you
-Improved quality
-Reduced manufacturing costs and increasing productivity.
Click Here to Test Your Yarn Quality and Spinning Performance According to Fibre Properties at Ring Frame Delivery
ITRU GROUP LTD -International Textile Research Unit
Serving to textile industry ,science and technology since 1992