AUTEX 2009 World Textile Conference 26-28 May, 2009 Đzmir, Turkey

A COMPARATIVE STUDY ON EGYPTIAN CARDED, COMBED

COMPACT YARNS AND COMBED RING YARNS
BY

Prof Dr. Magdy El Messiry1, Dr. Naglaa Hosny and Eng. Ghada Esmat
Textile Eng. Department, Faculty of Engineering, Alexandria University, Egypt
mmessiry@yahoo.com

Abstract

The compact spinning has found a wide market in the last decade. Several systems are introduced to produce
such yarns which have better physical and mechanical properties than the ring spinning. All the systems for the
production of compact spun yarns consist of a modification of the drafting system on the ring spinning machine,
so that the spinning triangle dimensions decreases. The properties of compact spinning were thoroughly
investigated by several researchers. The results of their studies indicated that compact spun yarn strength is
higher by about 15% and elongation at break by about 20%. Furthermore, the yarn hairiness becomes 70% less,
and the coefficient of variation of the yarn was lower by 15% than that for the equivalent ring spun yarn. These
advantages can reflect on the downstream processing. In this work a comparative study has been carried out to
investigate if the compact fine ply carded yarn spun from Egyptian cotton G86 will have better quality than
combed ring spun yarns. The results indicate that through the adjusting the production speed of the carding
machine the carded compact yarns for the counts up to Ne 80/2 give better quality in comparison to the combed
ring spun yarns.

Key Words: Compact yarns, carded yarns, combed yarns, ring spun yarns.

1.INTRODUCTION

Quality and quality management are the key words used in our time; cost and quality are the
most important factors for any company. The raw material cost in a spinning mill reaches up
to 60% of the production cost. Several researchers (1-5) show the possibility to use a compact
spinning to improve the quality of the yarns produced from short staple cotton fibers in order
to get use of the improvement in the compact yarn properties (6-9).
The study of results (10-16) indicated that compact spun yarn strength was found to be higher
by about 15% and elongation at break by about 20%. Furthermore, the yarn hairiness becomes
70% less, and the coefficient of variation of the yarn was lower by 15% than that for the
equivalent ring spun yarn. The goal of this work is to make best use of compact spinning
taking the advantage of compact yarn structure in processing of carded compact ply yarns
instead of combed ring ply yarn. A comparative study of the physical and mechanical
properties of ply yarn produced from the Egyptian cotton G86 on the three systems is studied.

2. EXPERIMENTAL

A set of the experimental trials was performed to study the effect of carding production speed
on compact yarn quality. Compact yarns of count Ne 50/1, 60/1, 80/1 using Egyptian cotton
G.86 were spun on K44 RIETER spinning compact machine from slivers processed at
different carding machine production speeds (40, 60, 80 and 100 m/min). The slivers are
combed at 20% noiles and processed into ply compact yarns and ring spun yarn of count 50/2,
60/2 and 80/2. Another set of trials was made to produce similar compact plied yarns from
carded slivers processed at different carding production speed.

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3. RESULTS AND DISCUSSION

3.1 Effect of carding machine production speed

Single carded compact yarns were obtained at different carding machine production speeds
varied from 50 to 100 m/min to produce yarn counts Ne 50/1, 60/1, 80/1. From the analysis
of the results of the different single yarn properties, it can be seen that as the carding machine
production speed increases, the yarn imperfections are reduced and the tenacity and
elongation increased. This may be due to that the design of modern carding machine has a
higher number of wires on the carding cylinder which leads to significantly lower acting
carding forces on the fibers during processing compared to conventional carding systems. The
forces prevailing between the cylinder and the flat wires have a major impact on the
possibility of increasing productivity without the deterioration of the sliver quality. The
analysis of results show that compact spinning made possible the production of carded yarns
up to count Ne 80/1 from G.86. Also the carded compact yarns have significantly lower
hairiness than conventional yarns, while for yarn tensile properties, carded yarns which were
produced at higher carding machine production speed have higher tenacity and elongation
than combed yarn spun on the conventional ring spinning frame. This is most likely because
the fiber extent is increased at high carding production speed, which leads to maximizing the
effect of the reduction of spinning triangle on the compact spinning machine, i.e. enables
more fibers to be embedded to the yarn body. On the other hand, yarn evenness and thin
places of carded compact yarns are of the same level of conventional ring spun yarns up to
yarn count Ne 60/1. Thick places and neps seems to be a problem when producing fine single
carded compact yarn because the combing process, in addition to removing short fibers,
increases the fiber separation, eliminates many impurities remaining in the sliver after the
carding process, thus neps and seed- coat fragments (SCFs) are reduced resulting in more yarn
evenness and less imperfections.

3.2 Effect of plying compact carded yarn

In order to study the reflection of the above results on the ply yarns, a set of trials was carried
out to produce ply yarns from combed and carded slivers at carding speed 100 m/min on
conventional ring spinning machine and compact machine.
Figure (1) shows a comparison between properties of different plied yarns (combed compact
yarn, carded compact yarn and combed conventional yarn). The analysis of the results
indicates that in the case of combed compact ply yarns, cotton G.86 can be processed to
produce ply yarn up to count Ne 80/2 from carded single compact yarn at Uster quality level
5% (combed compact yarn levels).
Carded compact yarns of the counts Ne 50/2, Ne 60/2 have significantly higher tenacity and
elongation than conventional ring combed spun yarns. For their yarn evenness and
imperfections, it is observed that there is a considerable decrease in plied carded compact yarn
than in plied combed conventional yarn. This may be due to the effect of winding process
which removes appreciable percentage of the yarn imperfections. However, for Ne 80/2
carded compact yarn, it has less hairiness and higher tenacity than conventional ring spun
combed yarn. Although the yarn imperfections of Ne 80/2 compact carded yarn are
significantly higher than that of plied combed conventional yarn, but it is still has a quality
level at Uster quality level 5% (combed ring spun yarn levels). It is acceptable to replace the
combed ring ply yarn by a similar carded compact yarn.

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C.V m%
38
C.V m% C.V m% 33
11
16
10 28
9 14
23
8 12
7 18
10
6
13
5 8 ELONGATION% THICK PLACES/ KM
4 8
ELONGATION% THICK PLACES/ KM 6
3 ELONGATION% THICK PLACES/ KM
3
2 4
1 2 -2

0
0

HAIRINESS NEPS/ KM
HAIRINESS NEPS/ KM
HAIRINESS NEPS/ KM

combed combed carded combed combed carded

Ne 50/2 compact conventional compact combed combed carded
Ne 80/2 compact conventional compact
at 100m/min Ne 60/2 compact conventional compact
at 100m/min
at 100m/min

Ne 50 /2 Ne60 /2 Ne 80/2
Fig. 1 Comparison between properties of plied yarns (combed compact yarn, carded compact yarn and combed
conventional yarn)
4. CONCLUSION
The compact spinning enables the possibility of producing single yarns up to 60/1 from
Egyptian cotton G86,for ply carded yarn it is recommended to produce compact count of Ne
60/2 to replace combed ring spun yarns.

5. REFERENCES
1. Staler, H., “New Spinning Process Comfort Spin,” Milliard International 6,No 1-22,2000
2. Thump, R.,” Suisse Elite Spinning System for Long and Short Staple Fiber,” Textile World
150, No 4, 38, 2000
3. Kampen, W., “Advantages of Condensed Spinning,” Milliand International 6, 98-
100(2000.
4. Meyer, U., Compact Yarns: Innovation as a Sector Driving Force. Milliand International 6,
2, (2000) .
5. Staler, H., Compact Spinning – A new Generation of Ring Spun Yarns. Melliand
Textilberichtee 76(3), E29-E31 (1995).
6. Basal, g., and Oxenham, W., “Comparison of Properties and Structure of Compact and
Conventional Spun Yarns,” Textile Res. J. 76(7), 567-575.
7. Klein, W., “A Practical Guide to Ring Spinning,” The Textile Institute Manual of Textile
Technology, MFP Design & Print, Manchester, UK, 1987.
8. El Messiry, M., “New Attachment for Compact Spinning,” 1st International Textile
Conference NRC, 2004.
9. Krause, H., Soliman, H., “Investigation of the Strength of the Spinning Triangle in Ring
Spinning,” Melliand Textilberichte 72 (1991), p. 499.
10. Cheng, K., Yu, C.: A Study of Compact Spun Yarns, Textile Res. J. 73 (2003).
11. Artz, P.: The Special Structure of Compact Yarns-Advantages in Downstream Processing,
ITB Yarn and Fabric Forming (1997) 2, 41-48.
12. Behera, B., Hari, P., Ghosh, S.: Weavability of compact Yarn, Melliand International, 9
(2003) 311-314.
13. Goyal, A., etal, “Comparative Study of Ring and Compact Spun Yarns,” Melliand
International 2 (2007).
14. Goktepa, etal, “A Comparison of Compact Yarn Properties Produced on Different
systems,” Textile Res. J. 76 (3), p. 226.
15. Krifa, Ethridge, “Compact Spinning Effect of Cotton Quality Interaction with Fiber
Characteristics,” Textile Res. J., 76 (5), p. 388.
16. Krifa.m, Ethridge.D, "Compact Ring Yarn: An Examination of Some Production Issues,”
Textile topics volume 2003-2.

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