Yarn breakage practically found in warping and its remedy

Prepared By : Mazadul Hasan sheshir
ID: 2010000400008
13th Batch (session 2009-2013)
Department : Wet Processing Technology
Email: mazadulhasan@yahoo.com
Blog : www. Textilelab.blogspot.com (visit)
Southeast University
Department Of Textile Engineering
I/A 251,252 Tejgaon Dhaka Bangladesh
Prepared By :

MR. MUZAHIDUR RAHMAN CHOWDHURY
LECTURER
SOUTHEAST UNIVERSITY
DEPARTMENT OF TEXTILE
SOUTHEAST UNIVERSITY
DEPARTMENT OF TEXTILE ENGINEERING

PROJECT OBJECTIVE
Research.
Analysis various yarn Fault in Warping process of weaving
Remedies of these faults.
Selection of raw materials.
Product testing.
Product Quality improvement
Reduce wastage
To improve warping efficiency
To improve yarn quality in spinning

During processing, textile materials are subjected to various stresses
not only during the machine operation but also during its stoppage. If these
stresses exceeded a given limits it will adversely affect the quality of the
produced yarns, fabrics and the efficiency of the machines .
In weaving process, the strains on warp ends can lead to thread breaks, loss of
quality and shutdowns. Warp breaks still represent major problem especially
for today's high-speed weaving machines .Generally, warp yarn break occurs
due to excessive tension greater than the strength of the yarn.

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9 OILY SLUB
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2110 KITTY YARN

SLUBS
An abnormally thick place or lump in yarn showing less twist at that place.
1. Machine surfaces to be maintained clean.
2. Rotors are properly maintained.
3. Better fiber individualization at cards to be achieved.
4. Optimum top roller pressure &back zone
5. Setting at rotor to be maintained.
1. More end breaks in warping process.
2. Damaged fabric appearance.
3. Shade variation in dyed fabrics.
1. Accumulation of fly and fluff on the machine parts.
2. Poor carding.
3. Defective rotor drafting and bad piecing
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NEPS
Yarn containing rolled fibre mass, which can be clearly seen on black board at close
distance; measurable on USTER imperfection Indicator
1. Machine surfaces to be maintained clean.
2. Damaged rotor to be avoided and proper maintained.
3. Better fiber individualization at cards to be achieved.
1. Damaged fabric appearance
2. Shade variation in the dyed fabrics
3. An abnormally thick place or lump in yarn showing less twist at that
place is called slubs
1. Accumulation of fly and fluff on the machine parts
2. Poor carding.
3. Defective rotor and bad piecing of robot
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SNARL
Yarn with kinks (twisted onto itself) due to insufficient tension after twisting
1. Optimum twist to be used for the type of cotton processed
2. Drafting parameters to minimize thin places in the yarn to be
adopted
3. Correct tension weights and slub catcher settings to be employed
at winding
1. Entanglement with adjacent ends causing a break
3. Shade variation in dyed fabrics
4. Mixing of cottons varying widely in fiber lengths and use of
immature cottons
1. Higher than normal twist in the yarn
2. Presence of too many long thin places in the yarn
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THICK AND THIN PLACES
Measurable by USTER Imperfection Indicator and observable on appearance
1. Defective rotor to be avoided
2. Right the card setting
3. Wide variation in the properties of cottons used in the mixing to be
avoided
4. Better fiber individualization at cards to be achieved. Correct
spacers to be utilized
immature cottons
4. More breakage in warping
1. Non-uniform sliver
2. Problem in mixing
3. Defect rotor surface
immature cottons
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SOFT YARN
Yarn which is weak indicating lesser twist
1. Proper yarn clearing to be ensured
2. Periodic replacement of rotor to be effected
1. More end breaks in subsequent processes such as warping, winding
etc.
1. Improper feed in rotor
2. Less twist in the yarn
3. Bad rotor
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OIL STAINED YARN
Yarn stained with oil
1. Appropriate material handling procedures to be followed
2. Oilers to trained in proper method of lubrication
3. Clean containers to be utilized for material transportation
2. Occurrence of black spot in fabric
1. Careless oil in the moving parts, over head pulleys etc
2. Piecing made with oily or dirty fingers
3. Careless material handlings
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CRACKERS
Very small snarl-like places in the yarn which disappear when pulled with enough tension or
Yarn with spring -likeshape
1. Feed roller to be maintained
2. Mixing of cottons varying widely in fiber length to be avoided
3. Use of optimum roller settings
4. Use of properly buffed rollers free from eccentricity to be ensured
1. More breaks in winding
2. More noticable in polyester and cotton blended yarns
2. Mixing of cottons of widely differing staple length
3. Closer roller settings
4. Eccentric top feed roller
5. Non optimum temperature and relative humidity in the spinning
shed
6. Over spinning of cottons
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BAD PIECING
Unduly thick piecing in yarn caused by over End piecing
1. Correctly robot setting and proper repier
2. Separators to be provided
3. Excessive end breaks in spinning to be avoided
1. More end breaks in subsequent process
2. Increase in hard waste
1. Wrong method of piecing and over end piecing of robot.
2. Twisting the ends instead of knotting
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OILY SLUB
Slub in the yarn stained with oil
1. Yarn contact surfaces to be kept clean
2. Proper segregation of oily waste from process waste
3. Oilers to be trained in correct procedures of lubrication
1. More end breaks in the warping process
1. Accumulation of oily fluff on machinery parts
2. Poor methods of lubrication in preparatory processes
3. Negligence in segregating the oily waste from process waste
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KITTY YARN
Presence of black specks of broken seeds, leaf bits and trash in yar
1. Cleaning efficiency of blow room and cards to be improved
2. Optimum humidity in the departments to be ensured
2. Production of specks during dyeing
3. Poor performance during winding
1. ineffective cleaning in Blow room and cards
2. Use of cottons with high trash and too many seed coat fragments
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HAIRINESS
Protrusion of fiber ends from the main yarn structure
1. Proper mixing or blending
2. Periodic maintenance of different parts
3. Roller settings to be maintained
4. Optimum relative humidity to be maintained in the spinning room
5. Wide variation in the properties of cottons used in the mixing to be
avoided
1. More breaks in winding and warping
2. Formation of holes and stains in cloth
1. Use of cottons differing widely in the properties in the same mixing
2. Improper mixing
3. Maintaining low relative humidity, closer roller settings and very
high spindle speeds
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HAIRINESS

FOREIGN MATTERS
Metallic parts, jute flannel and other similar foreign matters spun along with yarn
1. Improper setting of cleaning zone.
2. Removal of foreign matters(such as jute fibres, colour cloth bits) to
be ensured during preparation of mixing
3. Installation of permanent magnets at proper Places in blow room
lines to be ensured
1. reaks during winding and warping
2. Formation of holes and stains in cloth
2. Improper preparation of mixings
3. Improper setting of foreign material separator in blow room.
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SPUN IN FLY
Fly fluff either spun along with the yarn or loosely embedded on the yarn
1. Malfunctioning of humidification plant
2. Machinery surfaces to be kept clean by using roller pickers
3. Fanning by workers to be avoided
4. Performance of over head cleaners and humidification plants to be
closely monitored
1. More breaks in winding and warping
1. Accumulation of fluff over machine parts
2. Fanning by workers
3. Failure of over head cleaners
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CORK SCREW YARN
It is a double yarn which one yarn is straight and other is coiled over it
1. proper maintenance of robot
2. proper mixing
1. Breaks during winding and warping
2. Causes streaks in the fabric
1. Bad piecing by robot
2. Improper mixing
3. Improper feeding
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STITCHING ON CONE
Ends not laid properly on the cone at reversal of yarn path
1. Maintenance cone winders to be good
2. Cone holder settings and alignment of tension
3. Brackets with drum to be carried out as frequently as possible
1. More end breaks in the subsequent process
2. Excessive yarn waste
1. Vibrating and wrongly set cone holder
2. Yarn coils wrapped round the base of cone holder
3. Traverse restrictors fixed at incorrect position
4. Improper alignment of tension brackets with the drum
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RIBBON WOUND CONE
Formation of ribbon like structure on the circumference of the cone
1. Over hauling of cone winders to be periodically carried out
2. Anti ribboning mechanism to be checked at frequent interval
3. Free movement of the cone holders to be ensured by proper
lubrication
1. Overall density of package is lower
2. Soft packing either at the base or at the nose of cones
1. Winding spindle not revolving freely
2. Cone holders incorrectly set
3. Defective settings of cam switch
4. Improper traverse motion
5. Vibration of cone and traverse
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SOFT BUILD CONES
Unduly soft structure of cone
1. Unwinding tension to be maintained at 6 to 8% of single yarn
strength
1. Overall density of package is lower
2. Soft packing either at the base or at the nose of cones
1. Improper alignment of cone holder and traverse
2. Insufficient unwinding tension
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BELL SHAPED CONE
Cones which are tightly built at centre, presents a shape of bell
1. Quality of cones to be checked at that time of procurement
2. Optimum unwinding tension to be maintained
1. Excessive breaks during warping and winding processes
1. High yarn tension during winding
2. Cone holders incorrectly set to the winding drum
3. Damages in paper cone centre
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NOSE BULGING
Bulging of bunches of the yarn at the nose of the cones
1. Periodical inspection of settings in winding machines
2. Tenters to be instructed to adopt correct work practices
3. Avoiding usage of damaged paper cones
1. Slough during warping/unwinding
2. Excessive yarn waste in next process
1. Improper setting of cone holders to the winding drum
2. Damaged nose of the paper cones
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COLLAPSED CONE
Collapse of the structure of the cone(paper cone)itself
1. Using of poor quality/damaged paper cones should be avoided
2. Winding tenters should be trained by proper work methods
3. Proper material handling devices such as cone transport trolleys to
be used
4. Cone inserts to be used for paper cones
1. Yarn breaks in warping process
2. Wastage increase in yarn preparation
1. Use of poor quality/damaged paper cones
2. Poor system of material handling
3. Maintaining non optimum unwinding tension
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Formation of ring shaped bulge across the cross section of the cone
1. Due to replacement of defective drums and stop motion
wires to be ensured ,
2. Periodic inspection of cone holder settings and tension
assembly to be carried out ,
1. More end breaks in the subsequent processes
2. Slough off during unwinding
1. Incorrect setting of the cone holder
2. Wrong placement tensioners in the tensioning assembly
3. Traverse of yarn affected due to defects in the grooves of the
drum
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SL # BEAM
LENGTH
WEAK YARN SLOUGHING OFF OVER LAPPING KNOTS/BAD SPLICE SLUBS LOOSE YARN PIGTAIL CUT YARN BAD TIP CONE
1 12400 7 0 0 0 1 0 0 3 0
2 12400 5 0 0 1 2 0 6 0 0
3 12400 6 0 0 1 4 0 3 0 0
4 12400 4 0 0 0 1 2 6 2 3
5 12400 5 0 3 0 2 0 4 0 0
6 6500 2 0 0 1 1 0 2 0 0
7 6500 1 0 1 0 1 0 0 0 0
8 12400 4 0 2 0 1 0 3 1 0
9 6550 3 0 0 0 1 0 0 1 0
10 6550 3 0 0 1 1 0 0 0 0
11 6550 5 0 1 0 1 1 4 0 0
12 5150 2 0 0 0 0 0 0 0 0
13 6550 3 0 2 0 0 0 0 0 0
14 6550 5 0 0 0 1 0 0 0 0
15 12400 5 0 0 1 2 0 0 0 3
16 12400 6 0 0 0 3 0 5 0 0
17 12400 4 0 2 0 0 0 4 0 0
18 12400 4 0 0 0 2 1 4 1 1
19 12400 5 0 1 0 0 0 3 0 0
20 12400 5 0 0 0 1 0 2 0 0
Total 199700 84 0 12 5 25 4 46 8 7
Table-1: Data for 20/1 Ne Yarn breakage in Warping
EXPERIMANTAL DATA

SL # BEAM LENGTH WEAK YARN SLOUGHING
OFF
OVER LAPPING KNOTS/BAD
SPLICE
SLUBS LOOSE YARN PIGTAIL CUT YARN BAD TIP CONE
1 12400 4 0 1 0 1 0 2 3 0
2 12400 2 0 0 0 2 1 1 0 0
3 12400 1 0 1 1 1 0 3 0 1
4 12400 2 0 0 0 1 2 1 2 0
5 12400 3 0 1 2 2 0 4 0 0
6 6500 2 0 0 0 1 0 2 2 0
7 6500 1 0 1 2 1 0 1 0 1
8 12400 3 0 2 0 1 0 1 1 1
9 6550 3 0 0 1 2 0 2 1 0
10 6550 1 0 2 0 0 0 0 0 1
11 6550 4 0 1 0 1 1 2 0 0
12 6550 1 0 0 0 0 0 1 4 0
13 6550 1 0 1 0 2 0 0 0 0
14 6550 1 0 0 1 1 0 2 0 0
15 6550 1 0 3 0 2 0 0 0 0
16 6550 1 0 0 0 0 0 2 0 0
17 6550 3 0 1 0 1 0 1 0 0
18 6550 4 0 0 1 0 0 4 0 1
19 6550 1 0 1 0 0 0 1 0 0
20 6550 5 0 0 1 1 0 2 0 0
Total 166000 44 0 15 9 20 4 32 13 5
Table-2: Data for 10/1 Ne Yarn breakages in Warping
EXPERIMANTAL DATA

SL # BEAM LENGTH WEAK YARN SLOUGHING
OFF
OVER LAPPING KNOTS/BAD
SPLICE
SLUBS LOOSE YARN PIGTAIL CUT YARN BAD TIP CONE
1 12400 5 0 1 0 0 0 2 2 0
2 12400 4 0 0 0 1 0 3 0 0
3 12400 4 0 1 1 4 0 2 0 0
4 12400 3 0 1 0 1 1 2 1 2
5 12400 4 0 0 0 0 0 4 0 0
6 12400 1 0 1 0 1 1 2 0 2
7 12400 1 0 0 1 1 0 0 0 0
8 12400 3 0 0 0 2 0 1 1 1
9 12400 2 0 1 0 1 2 2 1 0
10 12400 2 0 0 0 1 0 0 0 1
11 12400 4 0 1 0 1 0 3 1 0
12 12400 2 0 0 1 0 0 0 0 1
13 12400 1 0 0 0 0 0 0 0 1
14 12400 2 0 1 0 1 0 1 1 0
15 12400 3 0 0 0 2 0 0 0 1
16 12400 4 0 0 0 2 0 4 0 0
17 12400 4 0 0 1 0 0 3 0 0
18 12400 5 0 0 0 1 0 3 1 1
19 12400 1 0 1 0 0 0 3 0 0
20 12400 3 0 0 0 1 0 1 0 0
248000 58 0 8 4 20 4 36 8 10
Table-3: Data for 16/1 Ne Yarn breakages in Warping
EXPERIMANTAL DATA

From Table-1: Data for 20 Ne
0
10
20
30
40
50
60
70
80
90
Fig: Effect of different types of yarn faults in
warping for 20/1 count carded yarn
DATA ANALYSISNoofbreakage
WEAK YARN
44%
SLOUGHING
OFF
0%
OVER
LAPPING
6%
KNOTS/BAD
SPLICE
3%
SLUBS
13%
LOOSE YARN
2%
PIGTAIL
24%
CUT YARN
4%
BAD TIP CONE
4%

0
5
10
15
20
25
30
35
40
45
50
Fig: Effect of different types of yarn faults
in warping for 10/1 count carded yarn
DATA ANALYSISNoofbreakage
WEAK YARN
31%
SLOUGHING
OFF
0%
OVER
LAPPING
11%
KNOTS/BAD
SPLICE
6%
SLUBS
14%
LOOSE YARN
3%
PIGTAIL
23%
CUT YARN
9%
BAD TIP CONE
3%

0
10
20
30
40
50
60
70
Fig: Effect of different types of yarn faults in warping
for 16/1 count carded yarn
WEAK YARN
39%
SLOUGHING
OFF
0%
OVER
LAPPING
5%
KNOTS/BAD
SPLICE
3%
SLUBS
14%
LOOSE YARN
3%
PIGTAIL
24%
CUT YARN
5%
BAD TIP CONE
7%
Noofbreakage
DATA ANALYSIS

1. Found different types of yarn and package faults from warping.
the main cases of warp yarn breakage is improper raw material
mixing and cleaning in spinning because majority percentage of
yarn faults is weak yarn.
2. The number of breaks varied directly with the yarn count.
3. Improper maintenance of spinning.
KEY FINDINGS

1. We had a very limited time. In spite of my willing to study
more details it was not possible to do so.
2. This while process is not possible to bind such a small frame
as this report, hence our effort spent on summarizing them
3. We cannot manage data perfectly. Some fault cannot
recovery such as parallel winding which is occur from
robotic miss action in rotor spinning ,mixing ratio is not
perfectly, large amount of wastage uses as for the rate of
beating action is high and create more amount of neps
which neps carding cannot remove perfectly. If Feed
material is quality full then produce goods also be good.
LIMITATION

Considering the objective of the work, a systematic investigation on ‘Yarn
Faults in warping and its Remedies’ were performed in the training period. All
the activities had been done maintaining in sequence of the machinery of the
production. From the thorough investigation it is seen that the following faults
are yarn faults, yarn package faults, mechanical faults in spinning. Reducing
warp breaks on warping machines
uplift the efficiency of this process and the efficiency of weaving machines,
and finally enhances the quality of yarns and produced fabrics.
Yarn faults tend to not fulfill the target of production of a industry. As a result
the production capacity of these industries falls significantly. These are the
common faults which I have tried to find out the causes & their Remedies
against them.
CONCLUSION

1. Yarn Manufacturing Technology
Link : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808
2. Fabric Manufacturing Technology
Link : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605
3. Garments Manufacturing Technology
Link : http://www.facebook.com/pages/Garments-Manufacturing-
Technology/472364799463126
3. Wet processing Technology
Link : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404
4. Fashion-Design-and-Technology
Link : http://www.facebook.com/pages/Fashion-Design-and-
Technology/587655294583875?ref=ts&fref=ts
My Facebook Textile related Pages
http://www.textilelab.blogspot.com (Visit )

Yarn breakage practically found in warping and its remedy

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