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SPINNING & YARN

FAULTS

Prepared By :

Prepared By : Mazadul
Hasan sheshir
ID: 2010000400008
13th Batch
Wet Processing Technology
Email:
mazadulhasan@yahoo.com
Southeast University

Southeast University

Department Of Textile Engineering


I/A 251,252 Tejgaon Dhaka Bangladesh

YA
FA R
U N
LT

LOW COP CONTENT


Yarn content in the cop is less

EFFECT
Efficiency loss in ring frame
Drop in winding efficiency
More knots for a given length of wound yarn
CAUSES
Under utilisation of bobbin height
Lower number of coils /inch
Higher chase length
Cop bottom bracket properly not set
Improper selection of ratchet
Ratchet pawl pushing number of teeths/movment in the
ratchet wheel
Spinning empties wall thickness is high
RECTIFICATION
Optimum chase length, coil spacing and wall thickness of empy
cops tobe ensured
1. Ratchet/pawl movement to be properly set
2. Free space of only 7.5mm to be maintained at the top
and bottom of the cop

SLUBS
An abnormally thick place or lump in yarn showing less twist at that
place.

EFFECT
More end breaks in the next process.
Damaged fabric appearance.
Shade variation in dyed fabrics.
CAUSES
Accumulation of fly and fluff on the machine parts.
Poor carding.
Defective ring frame drafting and bad piecing
Improperly clothed top roller clearers.
RECTIFICATION
1. Machine surfaces to be maintained clean.
2. Proper functioning of pnemafil/roller clearers to be
ensured.
3. Broken teeth gear wheel to be avoided and proper
meshing to be ensured.
4. Better fiber individualisation at cards to be achieved.
5. Optimum top roller pressure &back zone
6. Setting at ring frame to be maintained.

NEPS
Yarn containing rolled fibre mass, which can be
clearly seen on black board at close distance;
measurable on Uster imperfection Indicator.

EFFECT
Damaged fabric appearance
Shade variation in the dyed fabrics
An abnormally thick place or lump in yarn showing less
twist at that place is called slubs
CAUSES
Accumalation of fly and fluff on the machine parts
Poor carding.
Defective ring frame drafting and bad piecing
Improperly clothed top roller clearers.
RECTIFICATION
Machine surfaces to be maintained clean.
1. Proper functioning of pnemafil/roller clearers to be
ensured.
2. Broken teeth gear wheel to be avoided and proper
meshing to be ensured.

SNARL
Yarn with kinks(twisted onto itself)due to insufficient
tension after twisting

EFFECT
Entanglement with adjacent ends causing a break
Damaged fabric appearance
Shade variation in dyed fabrics
Improper meshing of gear wheels
Mixing of cottons varying widely in fiber lengths and use of
immature cottons
CAUSES Higher than normal twist in the yarn
Presence of too many long thin places in the yarn
RECTIFICATION
Optimum twist to be used for the type of cotton processed
1. Drafting parameters to minimise thin places in the yarn
to be adopted
2. The yarn to be conditioned
3. Correct tension weights and slub catcher settings to be

THICK AND THIN PLACES


Measurable by Uster Imperfection Indicator and
observable on appearance

EFFECT
Eccentric top and bottom rollers
Insufficient pressure on top rollers
Worn and old aprons and improper apron spacing
Improper meshing of gear wheels
Mixing of cottons varying widely in fiber lengths and use of
immature cottons
CAUSES Eccentric top and bottom rollers
Insufficient pressure on top rollers
Worn and old aprons and improper apron spacing
Improper meshing of gear wheels
Mixing of cottons varying widely in fibre lengths and use of
immature cottons
RECTIFICATION
Eccentric top and bottom rollers to be avoided
1. Top arm pressure checking schedules to be Maintained
strictly
2. Wide variation in the properties of cottons used in the
mixing to be avoided

SOFT YARN
Yarn which is weak indicating lesser twist

EFFECT:
More end breaks in subsequent processes
Shade variation in dyed fabrics
CAUSES:
Slack tapes dirty jockey pulleys
Improper bobbin feed on the spls
Less twist in the yarn
Bad clearing at the travellar
RECTIFICATION:
Vibration of bobbins on the spindles to be avoided
1. Proper yarn clearing to be ensured
2. Periodic replacement of worn rings and travellars to

OIL STAINED YARN


Yarn stained with oil

EFFECT
Damaged fabric appearance
Occurrence of black spot in fabric
CAUSES
Careless oil in the moving parts,over head pulleys etc
Piecings made with oily or dirty fingers
Careless material handlings
RECTIFICATION
Appropriate material handling procedures to be followed
1. Oilers to trained in proper method of lubrication
2. Clean containers to be utilised for material
transportation

CRACKERS

Very small snarl-like places in the yarn which disappear when


pulled with enough tension or Yarn with spring like shape

EFFECT
More breaks in winding
More noticable in polyester and cotton blended yarns
CAUSES Mixing of cottons of widely differing staple length
Closer roller settings
Eccentric top and bottom rollers
Non optimum temperature and relative humidity in
the spinning shed
Over spinning of cottons
RECTIFICATION
Optimum top roller pressure to be maintained
1. Mixing of cottons varying widely in fibre length to
be avoided
2. Use of optimum roller settings
3. Use of properly buffed rollers free from eccentricity
to be ensured

BAD PIECING
Unduly thick piecing in yarn caused by over End piecing

EFFECT
More end breaks in subsequent process
Increase in hard waste
CAUSES Wrong method of piecing and over end piecing
Twisting the ends instead of knotting
RECTIFICATION
Tenters to be trained in proper methods of piecing
1. Separators to be provided
2. Excessive end breaks in spinning to be avoided

OILY SLUB

Slub in the yarn stained with oil

1
0

EFFECT
More end breaks in the ensuring process
Damaged fabric appearance
Shade variation in dyed fabrics
CAUSES Accumulation of oily fluff on machinery parts
Poor methods of lubrication in preparatory processes
Negligence in segregating the oily waste from process
waste
RECTIFICATION
Yarn contact surfaces to be kept clean
1. Oilers to be trained in correct procedures of
lubrication

KITTY YARN

Presence of black specks of broken seeds, leaf bits and trash in y

1
1

EFFECT
Damaged fabric appearance
Production of specks during dyeing
Needle breaks during knitting
Poor performance during winding

CAUSES Ineffective cleaning in Blow room and cards


Use of cottons with high trash and too many seed coat
fragments

RECTIFICATION
Cleaning efficiency of blow room and cards to be improved
1. Optimum humidity in the departments to be
ensured

HAIRINESS
Protrusion of fibre ends from the main yarn
structure

1
2

EFFECT
More end breaks in winding
Uneven fabric surface
Beads formation in the fabric in the case of polyester/cotton
blends
CAUSES Use of cottons differing widely in the properties in the
same mixing
Use of worn rings and lighter travellars
Maintaining low relative humidity, closer roller settings and
very high spindle speeds
RECTIFICATION
Use of travellars of correct size and shape and rings in good
condition to be ensured
1. Periodic replacement of travellars and suitable
2. Roller settings to be maintained
3. Optimum relative humidity to be maintained in the spinning

FOREIGN MATTERS
Metallic parts, jute flannel and other similar foreign
matters spun along with yarn

1
3

EFFECT
Breaks during winding
Formation of holes and stains in cloth
Damaged fabric appearance
CAUSES Improper handling of travellers
Improper preparation of mixings
RECTIFICATION
Removal of foreign matters(such as jute fibres,colour cloth
bits) to be ensured during preparation of mixing
1. Installation of permanent magnets at proper
2. Places in blow room lines to be ensured

SPUN IN FLY

Fly or fluff either spun along with the yarn or loosely embedde
on the yarn

1
4

EFFECT
More breaks in winding
CAUSES Accumulation of fluff over machine parts
Fanning by workers
Failure of over head cleaners
Malfunctioning of humidification plant
RECTIFICATION
Machinery surfaces to be kept clean by using roller pickers
1. Fanning by workers to be avoided
2. Performance of over head cleaners and
humidification plants to be closely monitored

CORK SCREW YARN


It is a double yarn which one yarn is straight and other is
coiled over it

1
5

EFFECT
Breaks during winding
Causes streaks in the fabric
CAUSES

Feeding of two ends (instead of one ) in ring

frame
Lashing -in ends in ring frame
RECTIFICATION
Tenters are to be trained in piecing methods(or) practices
1. Pneumafil ducts to be kept clean and properly set

SLOUGH OFF

of yarn coming out of the ring cops in bunches at the time of unw

1
6

EFFECT
Increase in end breaks
Higher yarn waste
CAUSES Improper ring rail movement
Worn builder cam
Loose package and excessive coils in the package
Soft build of cops
Improper empties fit on the spindles and slack tapes
RECTIFICATION
Ring rail movement to be set right
Optimum ratio of winding: bindings coils and
optimum chase length to be maintained

RING CUTS
Damaged layers on the surface of the ring cops

1
7

EFFECT
Excessive breaks during winding

More hard waste at winding

CAUSES Spindle or empty cops wobbling


Use of lighter travellers snd incorrect ratchet wheel
Movement of spindles to the rings not concentric
RECTIFICATION
Worn spindles to be replaced
1. Improper fit of empty cops with spindles to be
avoided
2. Gauging of spindles with rings to be properly carried
out

IMPROPER BOBBIN BUILD


Step-like appearance of
the cop

1
8

EFFECT
Slough-off during doffing/winding
More breaks during unwinding(due to slough off)
Higher hard waste in winding
CAUSES

Improper combination of ratchet and pawl

Jerky ring rail movement(pocker rod movement to


check)
RECTIFICATION
Ratchet and Ratchet/pawl movement to be accurately arrived
at taking into consideration
1. Count of yarn, ring dia and chase length
2. Lubrication of pocker rods at appropriate interavels
to be carried out

STITCHING ON CONE
Ends not laid properly on the cone at reversal
of yarn path

1
9

EFFECT
More end breaks in the subsequent process
Excessive yarn waste
CAUSES

Vibrating and wrongly set cone holder

Yarn coils wrapped round the base of cone holder


Traverse restrictors fixed at incorrect position
Improper alignment of tension brackets with the
drum
RECTIFICATION
Maintenance cone winders to be good
1. Cone holder settings and alignment of tension
2. Brackets with drum to be carried out as

RIBBON WOUND CONE

Formation of ribbon like structure on the circumference of the con

2
0

EFFECT
High level of slough off during unwinding
Excessive yarn waste
Uneven dye pick up in the case of dye packages
CAUSES Winding spindle not revolving freely
Cone holders incorrectly set
Defective settings of cam switch
Lint accumulation in builder cam groove
RECTIFICATION
Over hauling of cone winders to be periodically carried out
1. Anti ribboning mechanism to be checked at frequent
interval
2. Free movement of the cone holders to be ensured by

SOFT BUILD CONE


Unduly soft structure of cone

2
1

EFFECT
Overall density of package is lower
Soft packing either at the base or at the nose of cones
CAUSES Improper alignment of winding spindle to the
winding drum
Insufficient unwinding tension
Inadequate cradle loading

RECTIFICATION
Unwinding tension to be maintained at 6 to 8% of single yarn
strength
1. Cradle pressure to be maintained to the optimum level

BELL SHAPED CONE


Cones which are tightly built at centre, presents a shape of bell

2
2

EFFECT
Excessive breaks during subsequent processes
CAUSES

High yarn tension during winding

Cone holders incorrectly set to the winding drum


Damages in paper cone centre

RECTIFICATION
Quality of cones to be checked at that time of procurement
1. Optimum unwinding tension to be maintained

NOSE BULGING
Bulging of bunches of the yarn at the nose of the cones

2
3

EFFECT
Slough during warping/unwinding
Excessive yarn waste in next process
CAUSES Improper setting of cone holders to the winding
drum
Damaged nose of the paper cones
RECTIFICATION
Periodical inspection of settings in winding machines
1. Tenters to be instructed to adopt correct work
practices
2. Avoiding usage of damaged paper cones

COLLAPSED CONE
Collapse of the structure of the cone(paper cone)itself

2
4

EFFECT
Use of poor quality /damaged paper cones
Poor system of material handling
Maintaining non optimum unwinding tension
CAUSES

Use of poor quality/damaged cones

RECTIFICATION
Using of poor quality/damaged paper cones should be avoided
1. Winding tenters should be trained by proper work
methods
2. Proper material handling devices such as cone
transport trolleys to be used
3. Cone inserts to be used for paper cones

BLOW ROOM FAULT

Faults: miss-shaped laps.


Remedy:
If the censity of cotton across the width of the laps is
constant ,wedge

shaped laps can still occur due to

unequal pressure on side of the calendar r/r.


Pressure should be equal on both sides.

Faults: split laps.


Remedy:
If lap licking at the card persists, it can be prevented by
feeding roving into the lap sheet as it is formed at the lap
end or by use of lap r/r.

Faults: Poor cleaning efficiency.


Remedy:
In the m/c cleaning efficiency is affected by grid bar to
beater settings, better speeds, condition of beater blade
edges and beater bars, fan speed and m/c cleanliness.
Appropriate stapes have to be taken.

Faults: Neps Formation


Remedy:
The paddle regulator mechanism and cone drum drive
should be kept in good working order.

CARDING FAULT

Faults: neppy web.


Remedy:
The m/c made neps may be due to an excessive number of
immature fibres in the cotton or to poor settings and
maintenance. Which should be properly maintained.
Raw materials:
Checking that the belts are correctly mixed according to
micronaire value and fibre bundle strength.
Percentage of wastage should be maintained accordingly.

Faults: cloudy web.


Remedy:
Correct settings of back sheet.
Poor condition of wire with patches missing, damaged or
rubbed

will

maintained.

have

the

same

results

which

should

be

Faults: Irregular sliver.


Remedy:
Any eccentric r/r, incorrect undergrid settings, rubber wire
across the eccentric r/r settings should be on the points.

DRAWFRAMES FAULT

Faults: fine sliver.


Remedy:
All drawframe stop mechanism should be regularly
tested.

Faults: irregular sliver.


Remedy:
Checking top and bottom r/r, top spinning pressure
and r/r settings and taking suitable action.
Also checking that sliver is not being reserved.

COMBERS FAULT :

Remedy:
Top combs and cylinders should be examined daily
because damaged cylinder wire/needles and top com
needles can cause flocking.

Faults: Long fibers in waste.


Remedy:
There are a number of comber settings and timings which
will cause long fibre to be found in the wastage. They
include insufficient of the nippers during feeding, late
closing

of

the

nippers,

wide

detaching

r/r

settings

detaching r/r turning back too late which should be

Faults: Irregular sliver.


Remedy:
R/R, r/r settings and drafts should be checked.

Faults: Curls.
Remedy:
Correct timing of nippers and detaching r/r, correct
penetration of the top combs and r/r covering.

SIMPLEX FAULT

Faults: Slippings coils.


Remedy:
Attention to finding the correct taper wheel, resetting
poker bar and the builder will cure this faults.

Faults: Soft bobbins.


Remedy:
This faults can be prevented by using suitable change
wheels. If an odd bobbin is affected this could be due
to fine a fine roving or incorrect tensioning.

Faults : Irregular roving.


Remedy:
Simplex m/c are susceptible to this faults and source
of the vibration is usually in the gearing or grafting r/r.

Faults: Count and hank variation


Variation in hank and count should be monitored and
controlled as previously specified by:
Regular daily inspection and maintained strict control lap
weights, weekly meter/metre wrappings of scutcher laps,
calculating variation and graphing results.
Wrapping finisher drawframe sliver every 4 hours and
taking immediate action if results exceed tolerance quality
control graphs to be used.
Daily wrappings of yarn for count, regularity of count,
strength and twist. Assessment of yarn on blackboards.
Faults have adequately death with earlier in this section
under regularity.

RINGFRAME FAULT

Faults: Foreign fibers:


Remedy:
Operatives working in the mixing chamber must be
instructed to take out any foreign fibers, string, cloth
contaminated with dye or oil.
Care have to be taken when taking the tare from the
bale.

Faults: Twist variation:


Remedy:
Too much twist reduces yarn strength and also makes
the yarn brittle and liable to from snarls. Spindle to
spindle variation also occurs due to differences in
spindle speed as a result of driving tape slippage,
misalignment of tapes and spindle bearings or
inadequate lubrication which should be maintained
properly.

CONCLUSION:
The quality control in spinning has a vital consequences
on the production. In the aspect of textile it is a must to
make sure

to fulfill the general requirement of the

quality in different stages in spinning.

REFERENCE :
vijayakumhark.tripod.com

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