Open End Spinning Research Paper

SPINNING:

The process of converting raw cotton into yarn is known as spinning.

The initial stage of denim production starts with spinning process, which start with Opening and Blending. Opening begins with baled cotton fiber being separated into little tufts. A combine of cotton fibres is made on every opening line. These bales are selected using USDA High Volume tool (HVI) data, and PCCA’s unique computer blending software produces most favorable yarn strength.

These cotton bales are delivered by air suction from opening and blending lines, through additional cleaning and blending machine, known as carding machines. The main function of carding is to remove foreign matter and short fibres and form the cotton into a web and convert the web

The drawing procedure produces a single, uniform sliver from seven card slivers. The additional blending, paralleling of fibres and clear out in this process produces a sliver for making yarn.

Cotton fibres are formed into a yarn by centrifugal action in Open-End Spinning. Individual fibers are laid down in the groove of a fast spinning rotor and warped into yarn. after the cotton fibres are spun into yarn, the yarn is wound on the cones.

Lastly the yarn cones are frenzied in the Siger machine which removes the moisture from the yarn so that the yarn does not lose its efficiency.

WARPING:

The wrap yarn is requires to be fed into a sheet form to the weaving machines. At warping, the individual cones are put into the creel (the number of cones depends upon fabric construction) and the yarn form individual cones is pulled together in sheet form, wound on a barrel called warping beams (for Direct warping) or on weaving beams (for Sectional Warping). Normally if warp sheet is with pattern of different coloured yarns it is processed on sectional warping machine.

DYEING & SIZING:

The process of dyeing dictates the technology of Denim manufacturing. Generally there are two methods of dyeing Denim Fabrics. They are:

 Rope Dyeing

 Sheet

This operation is known as Gaiting. This operation is essential because normally beam can carry only certain length of warp sheet on it and when so woven, whole length is converted to the fabric by weaving machine. Further wrap length is required to be fed which can be done by gaiting other beams on weaving machine.

FINISHING:

After weaving, the woven Denim Fabrics goes for various finishing processes consisting of brushing, singeing, washing, impregnation for dressing and drying. Brushing and Singeing should eliminate impurities and help to even the surface of the fabric. Dressing regulates the hand and rigidity of the fabric while compressive shrinkage regulates its dimensional stability.

QUALITY ASSURANCE:

Weaving of fabric on such multi sizes is not economical, hence a standard width fabric is sent to quality assurance section. Fabrics are cut into the desired width as per size required on the machine.

Denim Fabric and Grey Fabric are thoroughly checkedfor various types of defects such as:

 Weaving Defects

 Uneven Dyeing

 Bleaching and Dyeing Defect

 Oil stain

