Yarn Production Flow Chart with Input and Output Materials

Last Updated on 16/06/2021

Input and Output Materials in Yarn Manufacturing Process

Shareful Islam Palash
Lecturer, Institute of Textile Engineering & Information Technology
Email: palash313@gmail.com

Yarn Manufacturing:
An assemblage of fibers that is twisted or laid together so as to form a continuous strand that can be made into a textile fabric. So a yarn is a strand of natural or man made fibers or filaments that have been twisted or grouped together for use in weaving, knitting, or other methods of constructing textile fabrics. The types of yarn to be manufactured will depend on the fibers selected; the texture, or hand, of the fabric to be made; and qualities such as warmth, resiliency, softness, and durability required in the fabric’s end uses.

Yarn production is a process of converting fibers into yarn. It consists of different processes. Flow charts of cotton carded ring spun, cotton combed ring spun, open end rotor spun and air jet spun yarns with input and output materials are given in below respectively.

Flow chart of cotton carded ring spun yarn production along with input and output.

Input materials	Process machines	Output materials
Raw cotton	Blow room	Lap/ Tufts
Lap	Card	Carded Sliver
Carded Sliver	Drawing 1	Breaker Drawn Sliver
Breaker Sliver	Drawing 2	Finisher Drawn Sliver
Finisher Drawn Sliver	Simplex	Roving
Roving	Ring frame	Yarn
Yarn	Auto winding	Yarn Cones

Flow chart of cotton combed ring spun yarn manufacturing along with input and output.    

Input material	Process machines	Output materials
Raw cotton	Blow room	Lap/ Tufts
Lap	Card	Carded Sliver
Carded Sliver	Drawing	Drawn Sliver
Drawn Sliver	Lap former	Mini Lap
Mini Lap	Comber	Combed Sliver
Combed Sliver	Drawing	Combed Drawn Sliver
Combed Drawn Sliver	Simplex	Roving
Roving	Ring frame	Yarn
Yarn	Auto winding	Yarn Cones

Flowchart of cotton carded rotor spun yarn production along with input and output.  

Input material	Process machines	Output materials
Raw cotton	Blow room	Lap/ Tufts
Lap	Card	Carded Sliver
Carded Sliver	Drawing	Drawn Sliver
Drawn Sliver	Open End Rotor Machine	Yarn Cone

Flow chart of air jet spun yarn production along with input and output.

Input material	Process machines	Output materials
Raw cotton	Blow room	Lap/Tufts
Lap	Card	Carded Sliver
Carded Sliver	Drawing 1	Drawn Sliver
Drawn Sliver	Drawing 2	Finisher Drawn Sliver
Finisher Drawn Sliver	Air jet machine	Yarn Cone

Input and output materials and objects of individual section of yarn manufacturing (for cotton):
Input and output materials in yarn manufacturing process and its objectives (for Cotton) is given below step by step-

1. Section: Mixing of raw cotton

Input:
Bale of raw cotton.

Objects:

• To mix different staple fibers properly.
• To minimize cost.
• To produce better quality of yarn at last stage(ring).

Output:
Mixed raw cotton.

2. Section: Blow room

Input:
Mixed raw cotton.

Objects:

• To open the fibers.
• To remove the trush.
• To mix the fibers.
• To make uniform lap sheet.

Output:
Lap.

3. Section: Carding

Input:
Lap.

Objects:

• To remove fine trash.
• To remove short fibers, neps, motes and foreign materials too.
• To produce regular sliver.

Output:
Carded Sliver.

4. Section: Draw frame

Input:
Sliver.

Objects:

• To parallel the fibers.
• To blend and mix the fibers.
• To reduce weight per unit length.
• To make uniform sliver.

Output:
Regular sliver.

5. Section: Lap former

Input:
Regular sliver.

Objects:

• Forming the interfacing or lap, which is employed to feed the combing machine.

Output:
Lap.

6. Section: Combing

Input:
Lap.

Objects:

• To remove short fibers.
• To remove fine trash and dirt.
• To parallel and straight the fibers.
• To make uniform sliver.

Output:
Regular/combed sliver.

7. Section: Drawing (Finisher)

Input:
Regular/combed sliver.

Objects:

• To parallelize the fibers.
• To make uniform sliver.

Output:
Uniform sliver/drawn sliver.

8. Section: Simplex

Input:
Uniform sliver/drawn sliver.

Objects:

• Draft the material.
• Insert a small amount of twist.
• To make bobbin with roving of conical shape.

Output:
Roving.

9. Section: Ring Frame

Input:
Roving.

Objects:

• Drafting (attenuation).
• Insertion of twist for strengthen the yarn.
• To wind the yarn on to the ring tube/bobbin.

Output:
Yarn.

10. Section: Cone winding

Input:
Yarn.

Objects:

• To transfer the yarn from ring cop/tube. To a large package (weight: 2-2.5 lbs)
• To remove the faults present in the yarn.
• To get better quality of yarn.

Output:
Yarn on cone.

11. Section: Reeling

Input:
Yarn on cone.

Objects:

• To clean the slubs.
• To make hanks (1680) each.

Output:
Hanks.

12. Section: Bundling

Input:
Hanks.

Objects:

• To make Bundle.

Output:
Bundle of 10 lbs.

13. Section: Baling

Input:
Bundle.

Object:

• To make a bale for marketing.

Output:
Bale of 400 lbs.

Conclusion:
Completing this process we can, get yarn and use it different work. This process only use for cotton yarn (carded/combed) manufacturing.

References:

1. Textile Engineering – An Introduction Edited by Yasir Nawab
2. Process management in spinning by R Senthilkumar

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