3 .

M E A S U R E ST O R E D U C EL O N GT H I NP L A C E S
Long thin placeswhich havelengthsof approximately8cm and longerand a cross- sectionof about30
to l5Vo of averageyarn diameteris relatively seldom occurring in short-stapleyarn and much more
frequentlyoccurring in long-stapleyarn. The long thin placescould resultin seriouscloth defectslike
streaks,variationin dye pick up etc.,andprocessingproblemslike higherbreaksin air-jetweavingetc.
Thus control of long thin placesneedsno further emphasis. This type of fault is producedmainly by
separationof sliversor rovingsin the processprior to spinning. This paperdealswith variouscontrol
measuresthatarerequiredin differentdepartmentsof the mill andraw materialmanagementto minimize
long thin places.

3.1 CARDING

Web falling in cardsis a sourceof long thin places. The major causefor this is loadingof
cylinderundercasing. Frequentair cleanin-q
of undercasingandpetrolwashingduringfull setting
for cotton and tinted syntheticmaterialcould help avoidingloading. A look into the actual
quantityof tint usedwould alsohelp astint tendsto depositoverundercasings. The othermajor
causesfor cylinderloadingwould be the conditionof rvire points,too high or too low tension
draft, staticgenerationin PV and PC counts,etc.

3.2 DRAWFRAMES

Missing sliversin drawingprocesscan alsobe the reasonfor very long thin placesin the yarn.
The effectivenessof sliverstopmotionsshouldbe lookedinto regularly.The piecingpracticeof
tentersalso need attention.

Crammingof sliversin drawingcan alsobe a source.The mills can increasethe gap between
cansand sliversso asto avoid incidenceof sliversrubbingagainstthe inner surfaceof cansby
suitablychangingcoiler speedchangewheel/canbottomchangewheel.

Reducingcreel tensiondraft and web tensiondraft in draw frames, maintainingthe surfaceof

feedtablein smoothconditionandsmoothrotationof creelrollerswould alsohelp in the control.

The conditionof trumpetsshouldbe good.

Too lou,top roller pressurewould alsocauselong thin andthick faults.

3.3 FLY FRAMES

Excessiveroving stretchdue to improperfunction of builder mechanismand use of empty

bobbinswith wide variationin diameterarecausefor long thin places.
rovin_e

Sliver stretchin the creelin speedframesdueto too high a creeldraft hasto be avoided.Creel
tensiondraft shouldbe asminimum aspossible,at the sametime ensuringno saggingof drawing
slivers.

t9
 ohighabreakdraftinspeedframesandinappropriateselectionofcondensefsaleothervital
causesfor long thin Places'
place. The various
draftingis a serioussoufcefor long thin
sliver splittingin speedframeswhile
are given below:
,"uron, ,hu, could be attributedto this
frame trumpets'
- Wiqgr bore diameterof finisher draw

in suchu.*uy that the sliversrun into the drafting

- Sliver guidesat feed shouldbe adjusted
eachother'
systemsideby sidebut not crossingover

T h e m e t h o d o f f e e d i n g s l i v e r s i n f l y f r a m e s a n d c o n d i t i o n o f c adisturb
n s a r ethe
i m pfree
o r twithdrawal
ant'Sliverscriss
edges of drawing sliver cans damaged' etc' would
crossingeach other,
of sliversfrom cans'

rr long thin places'Especially'while processlng

avoid
with chemicalslike carbontetrachlorideto
thus
t pressure,would lead to roller lapping and

3.4 RINGFRAMES
of
in freerotationof bobbin holders' vibration
creel stretchin ring framesdueto the obstruction points to be
rails, brokenroving guides'etc' are a few
bobbinsin creel,jerky movementof ring
of iong thin places'
looked into in ring framesfor the control
yarnswith lessnumberof
Wider back-zonesettings with a reducedbreakdraft helpsto produce
-Ho,u"u"r, for the long thick
thick placesand slubs. studieshave showntrratthereis a tendency
is madewider' Hence' it is suggestedto conduct
and thin placesto increasewhen the setting
controlledtrials to arrive at optimum settings'

3.5 CASESTUDIES
Study:1
variation
warp export yarn cones-The natureof colour
A mill had colour variation rnl scombed
is of small bandwidthand sPeckY'
in
,the yarn, for various characllri;tics, processparametersemployed
on analysisof 9u.di,v
management, it was observedthat the colour variation
variousdepartmentsandthe raw material
places'
was mainly due to presenceof long thin

from the study:

The following are the findings concluded

and t
The mill has the practice6f testingeach
Bale Managementsystemto decideproportiona
overallf
balesaccordingto the growth areaand
Howt
to maintainthe yarn quality consistency'
fin
long thin placeformation in yarn, i'e'' fibre
the selectionof bales.
20
A closelook at the control systemshowedthat the rangeemployedby the mill for micronaire
value variedvery high within a day for a mix. The total variationwas as high as 57Vo (from a
minimum of 2.8 pglinch to a maximum of 4.4 trt"glinchvaluedbaleswere usedin a single day).

It was suggestedto fix limit valuesfor Micronairepropertywhich would ensureand eliminate

the extremevalues. It was also suggestedto keep Micronaire variation within lOVoto ensure
eliminationof bands.

The mill was abie to successfullycontrol the colour variationusing aboveguidelines.

Study:2

A mill complainedof poor qualityof knittedfabricproducedfrom 20s combedhosieryyarn. A

careful analysisofthe yarn extractedfrom the defectivefabrics showedrandomoccurrencesof
long thin places.

The individual departmentswere analysedfor the various machineryprocessparameters,

machinerycondition and work practicesadopted. Someof the observationsare

- Direct blowing of overheadcleanerair onto the roving in the region betweenthe roving
bobbin and the drafting systemresultingin stretch.

- Wider back zone settingof 60mm in ring frame drafting

- High draft of about30 in ring frames

- Indication of the presenceof roving stretchin fly frames

- Improperpiecing of the by draw frame tenter. t

On taking correctiveactionon the aboveobservations,

the mill was ableto eliminatethe presence
of long thin placesin yarn and consequentlyensuregood fabric quality.

Study:3

A mill faced the problem of presenceof long thin and thick placesin knitted fabric produced
from 30s combedhosieryyarn.

An analysisof the raw materialusedby the mill and processparametersemployedrevealedthe

followin-ecauses.

Raw Material:

- High fibre finenessrangeemployed;It is to be controlledwithin 10%.

- Use of cottonswith excessiveshortfibre content;this would affect the drafting behaviour.

21
 Blow Room

rejectionfor the toleranceset was very

- High full lap cYTo and yard to yard cYTo. Lap
hifh upto 207o;this is to be controlledwithrn 5Vo'

in very high nep generationand material

- Pre-openlngof cottonby bale-openerstesulted
of cotton which would ensurelower
irregularity. It was sugjestedto do manualopening
tuftsize(aslowas50grams)andconsequentlybetteropening.

Combing

-Themillusedlessnumberofends(18)indoubling,lowbreakdraftandtotaldraftin
comberpreparatory;itwassuggestedtotry24ends,l'30breakdraftandatotaldraft
exceeding1'50.

were found disturbedand unsuitable'

- Condition of Unicombsand variouscritical settings

Drawing
to go for either 6 or 8 ends
- The mill uses7 endsdoubling in draw frames;it is suggested
doubling.

wasnoticed;this needsto be corrected'

- Sliver-splittingdueto improperselectionof trumpet

FIy Frames

- Back zone settingwas found varying betweenframes

Rovins stretchVowashtgh (upto ZVo)

Ring Frames
in higher incidenceof Classimat
- Negligencewith respectto machinecleaningresulted
once in 3 days and full cleaning once in
faults. It was ,.rgg"*"0 to do draft zone cleaning
a week.

top roller cots were suggestedfor better

- Tloshorehardnessfor front top rollers and 3omm
performance.

the mill and the results are given in Table 3'1

The various suggestionsoffered were tried out by
for comParison.

22
Table3.1 : Results- Before& After the Study

Sl.No. Details Before* After *

1 Total thin places 300 150
2 Clearer cuts/100Km (in Automatic winding 200 80
machines)
-
J Windin g eflrciency(Vo) 4t - 50 16-18
4 End breaks/l00 spindlehrs in ring spinning l2 7
5 (grams)
Production/spindle/8hrs 160 r65
-
6 Long thin places/roll of 30Kg of fabric (Manual nil
inspection)

for the samesettingof S(shortthick place)- I60Vo, 1.5cm

L( long thick place)- 30Vo, 40cm
T( Long thin place)- 20Vo,30cm

z1