Yarn Faults And Clearing

It is still not possible to produce a yarn without faults for various reasons. Stickiness of cotton can
contribute to the formation of thick and thin places. Fly liberation in Ringframe department is one of the
major reasons for short faults in the yarn because of the fly gets spun into the yarn. Hence it is not possible
to have fault free yarn from ringspinning, it is necessary to have yarn monitoring system in the last
production process of the spinning mill. As physical principle for electronic yarn clearing the capacitive and
the optical principle have established. Both principles have their advantages in specific applications.

Depending upon the rawmaterial, the machiery set up, production and process parameters, there are about
20 to 100 faults over a length of 100 km yarn which do not correspond to the deisred appearance of the
yarn. This means that the yarn exhibits a yarn fault every 1 to 5 km. These faults are thick and thin faults,
foregin fibres and diry places in the yarn.

The yarn faults which go into the woven or knitted fabric can be removed at very high costs or can not be
removed at all. Therefore the yarn processing industry demands a fault free yarn

The difference between frequent yarn faults and seldom occuring yarn faults are mainly given by the mass
or diameter deviation and size. These faults are monitored by classimat or clearer installation on winding

Each yarn contains, here and there, places which deviate to quite a considerable extent from the normal
yarn corss-section. These can be short thick places, long thin places , long thick places or even spinners
doubles. Eventhough such events seldom occur, they represent a potential disturbance in the appearance of
the fabric or can negatively influnece subsequent processing of the yarn.

Short thick places are those faults which are not longer than approximately 8 cms, but have a cross-
sectional size approx. twice that of the yarn. These faults are relatively frequent in all spun yarns. To an
extent they are the result of the rawmaterial ( vegetable matter, non-seprated fibres, etc). To a much larger
extent, these faults are produced in the spinning section of the mill and are the result of spun in fly. Short
thick places are easily determinable in the yarn. In many cases, they cause disturbances in subsequent
processing. Once they reach a certain size( cross-section and length) , and in each case accoridng to the
type of yarn and its application, short thick place fults can considerably affect the appearance of the finished
product.

Long thick places are much more seldom-occuring than the short thick places and usually have a length
longer than 40cms. In some cases, their length can even reach many meters. Their cross sectional size
approx. + 40% to +100% and more with respect of the mean cross-section of the yarn. Long thick places will
affect the fabric apperance. Faults like spinners doubles are difficult to determine in the yarn, with the naked
eye. On the other hand, they can produce quite fatal results in the finished product. A spinners double in the
warp or in yarn for circular knitting can downgrade hundreds of meters of woven , or knitted fabric.

Thin places occur in two length groups. Short thin places are known as imperfections, and have a length
approx. three times the mean staple length of the fibre. Their frequency is dependent on the rawmaterial and
the setting of the drafting element. They are too frequent in the yarn to be extracted by means of the
electronic yarn clearing.

Long thin places have lengths of approx. 40cms and longer and a cross-sectional decrease with respect to
the mean yarn cross-section of approx.30 to 70%. They are relatively seldom-occuring in short staple yarns,
but much more frequently-occuring in long staple yarns. Long thin faults are difficult to determine in the yarn
by means of the naked eye. Their effect in the finished product however, can be extremely serious.

The quite extensive application of electronic yarn clearing has set new quality standards with respect to the
number of faults in spun yarns.

It is therefore necessary to evolve a method of yarn fault classification before clearing the faults in winding.
The most important aspect is certainly the determination of the fault dimensions of cross-sectional size and
length. With such a cross-section and length classification and by means of the correct choice of the class
limits, the characteristic dimensions of the various fault types can be taken into consideration, then a
classification system will result which is suitable primarily for satisfying the requirements of yarn clearing and
yet allows, to quite a large extent, for a selection of the various types of faults.

Types of Electronic Yarn Clearers

Electronic Yarn Clearers available in the market are principally of two types -capacitive and optical. Clearers
working on the capacitive principle have ‘ mass'as the reference for performing its functions while optical
clearers function with ‘ diameter' as the reference. Both have their merits and demerits and are equally
popular in the textile industry. Besides the above basic difference in measuring principle, the basis of
functioning of both the types of clearers are similar if not exactly same. Since most of the other textile
measurements like, U% / CV%, thick and thin places etc., in various departments take into account mass as
the reference parameter, the functioning of the capacitive clearer is explained in some detail in the following
sections.

Functioning Principle

The yarn is measured in a measuring field constituted by a set of parallely placed capacitor plates. When the
yarn passes through this measuring field (between the capacitor plates), an electrical signal is produced
which is proportional to the change in mass per unit length of the yarn. This signal is amplified and fed to the
evaluation channels of the yarn clearing installation. The number and type of evaluation channels available
are dependent on the sophistication and features of the model of the clearer in use. Each of the channels
reacts to the signals for the corresponding type of yarn fault. When the mass per unit length of the yarn
exceeds the threshold limit set for the channel, the cutting device of the yarn clearer cuts the yarn.

Yarn Clearer Settings

The yarn clearer has to be provided with certain basic information in order to obtain the expected results in
terms of clearing objectionable faults. The following are some of them -

A. Clearing Limit

The clearing limit defines the threshold level for the yarn faults, beyond which the cutter is activated to
remove the yarn fault. The clearing limit consists of two setting parameters - Sensitivity and Reference
Length.

i. Sensitivity - This determines the activating limit for the fault cross sectional size.

ii. Reference Length - This defines the length of the yarn over which the fault cross - section is to be
measured. Both the above parameters can be set within a wide range of limits depending on specific yarn
clearing requirements. Here, it is worth mentioning that the ‘ reference length' may be lower or higher than
the actual ‘ fault length'. For a yarn fault to be cut, the mean value of the yarn fault cross-section has to
overstep the set sensitivity for the set reference length.

B. Yarn Count

The setting of the yarn count provides a clearer with the basic information on the mean value of the material
being processed to which the clearer compares the instantaneous yarn signals for identifying the
seriousness of a fault.

C. Material Number

Besides the yarn count there are certain other factors which influence the capacitance signal from the
measuring field like type of fibre (Polyester / Cotton / Viscose etc.) and environmental conditions like relative
humidity. These factors are taken into consideration in the ‘ Material Number'
D. Winding Speed

The setting of the winding speed is also very critical for accurate removal of faults. It is recommended that,
instead of the machine speed, the delivery speed be set by actual calculation after running the yarn for 2-3
minutes and checking the length of yarn delivered. Setting a higher speed than the actual is likely to result in
higher number of cuts. Similarly a lower speed setting relative to the actual causes less cuts with some
faults escaping without being cut. In most of the modern day clearers, the count, material number and
speeds are monitored and automatically corrected during actual running of the yarn.

Fault Channels

The various fault channels available in a latest generation yarn clearer are as follows:
1. Short Thick places

2. Long Thick Places

3. Long Thin Places

4. Neps

5. Count

6. Splice

The availability of one or more of the above channels is dependent on the type of the yarn clearer. Most of
the modern clearers have the above channels. Besides detection of the various types of faults, with latest
clearers, it is also possible to detect concentration of faults in a specific length of yarn by means of
alarms(cluster faults).

Contamination Clearing

Detection of contamination in normal yarn has become a requirement in recent times due to the demands by
yarn buyers abroad. Therefore, some of the optical yarn clearers have an additional channel to detect the
contamination in yarn. This is mostly used while clearing cotton yarn. The various facilities available in the
yarn clearers nowadays enable precise setting and removal of all objectionable faults while at the same time
ensure a reasonably high level of productivity

Winding
Ring spinning produces yarn in a package form called cops. Since cops from ringframes are not suitable for
further processing, the winding process serves to achieve additional objectives made necessary by the
requirements of the subsequent processing stages.

Following are the Tasks of Winding Process

• Extraction of all disturbing yarn faults such as the short, long thick ,long thin, spinners doubles, etc

• Manufacture of cones having good drawing - off properties and with as long a length of yarn as
possible

• Paraffin waxing of the yarn during the winding process

• Introduction into the yarn of a minimum number of knots

 • Achievement of a high machine efficiency i.e high produciton level

The winding process therefore has the basic function of obtaining a larger package from several small ring
bobbins. This conversion process provides one with the possibility of cutting out unwanted and problematic
objectionable faults. The process of removing such objectionable faults is called as yarn ‘ clearing'

Practical experience has proven that winding alters the yarn structure.This phenomenon does not affect yarn
evenness, but affect the following yarn properties

• Thick Places

• Thin Places

• Neps

• Hairiness

• Standard Deviation of Hairiness

Winding
Ring spinning produces yarn in a package form called cops. Since cops from ringframes are not suitable for
further processing, the winding process serves to achieve additional objectives made necessary by the
requirements of the subsequent processing stages.

Following are the Tasks of Winding Process

• Extraction of all disturbing yarn faults such as the short, long thick ,long thin, spinners doubles, etc

• Manufacture of cones having good drawing - off properties and with as long a length of yarn as
possible

• Paraffin waxing of the yarn during the winding process

• Introduction into the yarn of a minimum number of knots

• Achievement of a high machine efficiency i.e high produciton level

The winding process therefore has the basic function of obtaining a larger package from several small ring
bobbins. This conversion process provides one with the possibility of cutting out unwanted and problematic
objectionable faults. The process of removing such objectionable faults is called as yarn ‘ clearing'

Practical experience has proven that winding alters the yarn structure.This phenomenon does not affect yarn
evenness, but affect the following yarn properties

• Thick Places

• Thin Places

• Neps
 • Hairiness

• Standard Deviation of Hairiness

1.Drum Winding

2.Precision Winding

Drum Winding

Drum winding machines rotate the forming package through surface contact with a cylindrical drum , and the
yarn is traversed either by an independent traverse, typically by a wing cam or by grooves in the drum.

Precision Winding

Drum winding systems involves a significant contact between the yarn and the package forming
device.Yarns that can be easily damaged by friction in particular filament yarns,are wound into packages
using precision winders.
With precision winders, the package is mounted onto a drive spindle, and a reciprocating yarn guide, driven
by a cylindrical cam copled into the spindle drive, is used to move the yarn along the traverse length.The
reciprocating yarn guide limits the winding speed because of the inertia on reversals.
The term precision refers to the control of positioning each layer of yarn as it is wound on to the bobbin.

Different Packages Wound on Winding Machines

• Cones

• Cheeses

• Cops

• Pirns

Winding Tension, Bobbin Formation, Speed and ProductionTypes

Of WinIf winding tension is selected properly, the following tensile properties are
not affected

• Tenacity

• Elongation

• Work- to- break

But excessive tension in winding will deteriarate the above said tensile properties.

Characterestics Of Bobbin Formation

Stretch Length
It is the length of the yarn deposited on the bobbin tube during each chase (one up and down movement of
ringrail ) of ring rail. The length should be around 3.5 to 5 meters. It should be shorter for coarser yarns and
longer for fine yarns.

Winding Ratio

It is the ratio of the length of yarn wound during the upward movement of the ring rail and the length wound
during the downward movement of the ringrail.

Bobbin Taper

The ratio of the length of the upper taper of the cop (bobbin with yarn) to the diameter of the bobbin must be
1:2 or greater.

Winding Speed
It depends upon the following factors

• Count

• Type of Yarn, (type of fibre, average strength and minimum strength)

• Type and Charactersitics of Bobbin

• Package Taper

• Final Use of Package

The best winding speed is the speed which allows the highest level of production possible for a given type of
yarn and type of package, and with no damage whatsoever to the yarn.(abrasion and breaks due to
excessive tension)

Winding Production
It depends upon the following factors

• Winding speed

• Time required by the machine to carry out one splicing operation

• Bobbin length per bobbin( both bobbin weight and tpi to be considered, because TPI will affect the
bobbin length). This decides the number of bobbin changes

• The number of faults in the yarn and the clearer settings, this decides the clearer cuts

• Count

• The number of doffs. It depends upon the doff weight. Higher the doff weight, lower the number of
doffs

• The time taken for each doff either by the doffer or by an operator
 • Down time due to red light. It depends upon, number of red lights, number of repeaters setting for
red lights, clearer settings like off count channel, cluster setting which will result in red lights and
• Bobbin rejections, it depends on weak yarn, wrong gaiting, double gaiting, bobbin characteritics etc.

Winding Package Defects

Yarn Waste in the Cones

This is due to loose yarn ends that are wound on to the cone

Stitch, Drop Over, Web

Yarn is visible on the small or on the big side of the cone either across the side , around the tube, or going
back in the cone

Damaged Edges or Broken Ends on the Cone

The yarn is broken on the edges or in the middle of the cone.

Ring Formation
The yarn runs in belt formation on to the package, because it is misguided

Without Transfer Tail

The desired transfer tail is missing or too short

Ribbon Formation
Pattern or ring formation are made by the drum when rpm are staying the same

Displaced Yarn Layers

yarn layers are disturbed and are sliding towards the small diameter of the cone

Misguided Yarn
The yarn is not equally guided over the hole package

Cauliflower
On the smaller side of the package, the yarn shows a wrinkle effect

Soft and Hard Yarn Layer

Some layer of yarn are pushed out on the small side of the cone

Soft and Hard Cones

Great difference in package density from one winder head to another

Bobbin Rejections and Quality Checking for Best Winding

A bobbin change occurs when yarn on the bobbin is fully exhausted during winding. But if a bobbin is
changed with yarn still left on it, we call it ‘Rejected Bobbin'. The quantity of yarn on the bobbin may vary
from full bobbin to only few layers of yarn.

The Various Reasons of Bobbin Rejections are as follows:

1. Bobbin Quality

• Long Tail End

• Kirchi/Lapetta

• Deshaped Bobbin

• Overfilled Bobbin

• Bottom Spoiled Bobbin

• Ring Cut Bobbin

• Soft Bobbin

• Sick Bobbin

2. Bobbin Feeding in Magazine

• Presence of under-winding and back-winding while feeding the bobbins in the magazine leads to
rejection

3. Top Bunch Transfer Failure

• Top bunch position is lower with respect to bobbin tip.

• Blowing device does not come down to concentrate blow at the bobbin tip.

• Very few numbers of coils at the bobbin tip.

• Removal of top bunch due to fault in cutter at the bobbin preparatory or any other reason. Very few
numbers of coils at the top bunch.

4. Fault in Winding Unit, Splicing Failure

5. Yarn Quality

• High degree of objectionable fault

 • Count variation

• High Hairiness Bobbin

Bobbin Quality Checking for Best Winding

Whenever there is a count change in ring frame, the cop quality should be checked. Proper quality of cop
ensures higher winding efficiency. The cop quality is checked as per the following parameters:

1. Bobbin Parameters

2. Cop Content : Depending on the spindle lift and ring diameter, the cop content (in gms) should be
checked

3. Diameter of the Cop : The ‘Actual cop diameter' must be checked against ‘Standard cop diameter'. The
standard cop diameter depends on the ring diameter. Standard Cop Diameter = Ring Diameter - 3mm.

4. Back Winding : The number of back winding coils should be around 1.5 to 2.5 and the maximum length
of back winding should not be more than 80cms

5. Under Winding : The number of under winding coils should be around 2 to 3 and the maximum length of
back winding should not be more than 20cm. As the under winding and back winding increases, more time
is wasted to open them up before feeding in the magazine and also hard waste is increased.

6. Top Clearance : The clearance from bobbin tip to yarn body of a full cop should be approx 10 mm. If the
top clearance is too less, it may cause slough off at the start of the bobbin unwinding

7. Bottom Clearance : The clearance from bobbin bottom to yarn body of should be approx. 10mm. If the
bottom clearance is too less, it may cause bottom spoiled bobbin

8. Yarn Length per Chase : The length of yarn per chase should be around 3.5 to 5.5 m. If the length is too
long, it may lead to slough of during high speed unwinding.

9. Bobbin Hardness : The bobbin hardness should be around 50° to 55°. Soft bobbins results slough off.
Besides the above mentioned points, the cops should be also checked for long tail end, deshaped bobbin,
kirchi & lapetta, ring cut, overfilled and bottom spoiled bobbin to ensure high production efficiency in winding.

Due to the ever-increasing emphasis on better quality of yarn for the competitive market and process
performance, the normal parameters of yarn tenacity, unevenness and imperfections are not adequate to
completely define today's quality. Besides the above mentioned traditional parameters, so many factors
influence the performance of the yarn in the subsequent process such as process parameters in ring
spinning & cone winding, work procedures in ring spinning & cone winding and ambient conditions. So to
attain the expected quality for any applications such as weaving or knitting, one should focus mainly on the
fault free feed material preparation because it contributes more than any other factor. Best winding
capabilities can be achieved through best bobbin quality

Splicing
A high degree of yarn quality is impossible through knot, as the knot itself is objectionable due to its physical
dimension, appearance and problems during downstream processes. The knots are responsible for 30 to
60% of stoppages in weaving.

Splicing is the ultimate method to eliminate yarn faults and problems of knots and piecing. It is universally
acceptable and functionally reliable. This is in spite of the fact that the tensile strength of the yarn with knot
is superior to that of yarn with splice. Splicing is a technique of joining two yarn ends by intermingling the
constituent fibres so that the joint is not significantly different in appearance and mechanical properties with
respect to the parent yarn. The effectiveness of splicing is primarily dependent on the tensile strength and
physical appearance.

Splicing satisfies the demand for knot free yarn joining: no thickening of the thread or only slight increase in
its normal diameter, no great mass variation, visibly unobjectionable, no mechanical obstruction, high
breaking strength close to that of the basic yarn under both static and dynamic loading, almost equal
elasticity in the joint and basic yarn. No extraneous material is used and hence the dye affinity is unchanged
at the joint. In addition, splicing enables a higher degree of yarn clearing to be obtained on the electronic
yarn clearer.

Splicing technology has grown so rapidly in the recent past that automatic knotters on modern high speed
winding machine are a thing of the past. Many techniques for splicing have been developed such as
Electrostatic splicing, Mechanical splicing and Pneumatic splicing. Among them, pneumatic splicing is the
most popular. Other methods have inherent drawbacks like limited fields of application, high cost of
manufacturing, maintenance and operations, improper structure and properties of yarn produced.

Pneumatic Splicing

The first generation of splicing systems operated with just one stage without proceeding to trimming. The
yarn ends were fed into the splicing chamber and pieced together in one operation. Short fibres, highly
twisted and fine yarns could not be joined satisfactorily with such method. Latest methods of splicing
process consist of two operations. During the first stage, the ends are untwisted, to achieve a near parallel
arrangement of fibres. In a second operation the prepared ends are laid and twisted together.

Principle of Pneumatic Splicing

The splicing consists of untwisting and later re-twisting two yarn ends using air blast, i.e., first the yarn is
opened, the fibres intermingled and later twisted in the same direction as that of the parent yarn. Splicing
proceeds in two stages with two different air blasts of different intensity. The first air blast untwists and
causes opening of the free ends. The untwisted fibres are then intermingled and twisted in the same
direction as that of parent yarn by another air blast

Structure of Splice
Analysis of the longitudinal and transverse studies revealed that the structure of the splice comprises of
three distinct regions/elements brought by wrapping, twisting and tucking / intermingling.

Wrapping

The tail end of each yarn strand is tapered and terminates with few fibres. The tail end makes a good
wrapping of several turns and thus prevents fraying of the splice. The fibres of the twisting yarn embrace the
body of the yarn and thus acts as a belt. This in turn gives appearance to the splice.

Twisting

The two yarn ends comprising the splice are twisted around the body of the yarn, each yarn strand twists on
the body of the yarn on either side of the middle of the splice. The cross-section of this region distinctly
shows the fibres of the two yarn strands separately without any intermingling of the fibres.

Tucking / Intermingling

The middle portion of the splice is a region (2-5 mm) with no distinct order. The fibres from each yarn end
intermingle in this splice zone just by tucking. The studies on quantitative contribution of splice elements
showed that intermingling/tucking contributes the most to the strength of splice (52%), followed by twisting
(33%) and wrapping (about 15%). The lower strength of the splice is attributed to the lower packing
coefficient of the splice zone. Spliced yarn has a lower breaking elongation than normal yarn. Breaking
elongation is mainly affected by intermingling. Wrapping and twisting provides mainly transverse forces. The
absence of fibre migration gives lower breaking elongation to splice.

Effect of Variables on the Properties of the Spliced yarn

Several studies have been conducted on the effect of various variables on the properties of the spliced yarn.

Effect of Fibre Properties and Blend

Fibre properties such as torsional rigidity, breaking twist angle and coefficient of friction affect splice strength
and appearance. The lower torsional rigidity and higher breaking twist angle permit better fibre intermingling.
Higher coefficient of friction of fibres generates more inter-fibre friction to give a more cohesive yarn. Thus,
these properties of fibre contribute to better retention of splice strength. In blended yarn, usually the addition
of polyester to other fibre blend like P/W, P/C both for ring and rotor spun yarn increases splice strength.

Effect of Yarn Fineness

Several studies on cotton, polyester and wool report that coarser yarns have higher breaking strength but a
moderate extension. The coarse yarn cross section contains more fibres and provides better fibre
intermingling during pre-opening, hence the splice is stronger than that of finer yarns.

Effect of Yarn Twist

An increase in the twist significantly increases the breaking load and elongation, even at higher pneumatic
pressure. This could be due to better opening of the strands at higher pneumatic pressure. Splicing of
twisted ply yarn is more complicated than single yarn due to the yarn structure having opposing twists in the
single and doubled yarns. Twisted yarns also require a relatively longer time for complete opening of the
yarn ends.

Effect of Different Spinning Methods

Yarn produced with different spinning methods exhibit different structure and properties. Therefore, these
yarns show significant differences in splice quality. The ring spun yarn lent best splicing but the potential of
splicing is affected by the spinning conditions. The breaking strength percentage of ring spliced yarns to a
parent yarn is 70% to 85% for cotton yarn. However, the breaking strength and extension of splice vary with
fibre and yarn properties. Rotor spun yarns, due to the presence of wrapper fibres, make it difficult to untwist
and the disordered structure is less ideal for splicing. The breaking strength retention varies from 54% to
71% and is much lower compared to the splice of ring spun yarns. In case of friction spun yarns, the highest
relative tensile strength obtained at the spliced joints can be above 80%, but a number of splicing failures
occurs due to unfavourable yarn structure.
The air-jet-spun (MJS) yarn and the cover spun yarn are virtually impossible to splice. Only very low tensile
strengths and elongation values can be attained due to the inadequate opening of the yarn ends during
preparation of the splicing. The coefficient of variation of these properties is also generally high.

Effect of Opening Pressure

A study on 50/50 polyester cotton, 25 tex ring spun yarn shows a rise in tensile strength up to a certain
opening pressure. However, long opening time deteriorates the strength. An increase in pressure up to 5 bar
caused release of fibre tufts and fibre loss from the yarn ends in P/C blend which is due to intensive
opening, but beyond this pressure, drafting and twisting in the opposite direction may also occur.

Effect of Splicing Duration

With a given splicing length, when the splicing is extended for a long period of time, the breaking strength of
the spliced yarn and also their strength retention over the normal value of the basic yarn increases because
of increased cohesive force resulting from an increased number of wrapping coils in a given length. The
effects are more pronounced at higher splicing lengths. It is desirable however, that splicing duration be as
short as possible. The splicing duration alone has no conclusive effect on elongation properties of splice
yarn. It has also been observed that, for maximum splice strength, different materials require different
durations of blast. These are between 0.5 to 1.8 seconds.

Effect of Splicing Length

Studies on splicing of flyer and wrap spun yarns spun with different materials, showed that regardless of the
splicing material, the breaking strength and strength retention of both yarn types increase with the splicing
length because of the increased binding length of the two yarn ends. Elongation at break and retention of
elongation of both flyer and wrap spun spliced yarns increase with the splice length. Compared to the
splicing duration, the splicing length has more pronounced effect on the load-elongation properties of the
spliced yarn. It can be therefore be stated that the splices made on longer lengths and for longer period of
time have more uniform strength.

Effect of Splicing Chamber

The factors like method and mode of air supply and pressure along with type of prism affect the splicing
quality. It was observed that irregular air pressure has advantages over constant pressure for better
intermingling in the splicing chamber, which varies with different staple fibres, filament yarns, and yarns with
S and Z twists. It is not possible to make a general comment regarding potential of the splicing chamber due
to the multiplicity of factors influencing splicing.

Comparison of Dry and Wet Splicing

The comparative studies on dry and wet splicing with water showed that the breaking load retention for wet
spliced yarns are significantly greater than dry spliced yarns. In fact, wet splicing is more effective for yarn
made from long staple fibres and for coarse yarn. This may be due to higher packing coefficient resulting
from wet splicing.

Assessment of Yarn Splice Quality

The two important characteristics of a splice are appearance and strength. Although quality of splice can be
assessed by methods like load-elongation, work of rupture, % increase in diameter and evaluation of its
performance in down stream process etc., the appearance can be assessed either by simple visual
assessment or by comparing with photograph of standard splice.

Ply Yarns
For sewing threads as well as for some speciality industrial yarns , it is necessary to ply (to double or fold)
the yarns to give them a smoother and less hairy character.

Doubling improves the evenness and plying balances torque if carried out correctly and binds some of the
hairs on the component yarns.

Plying is a process used to create a strong, balanced yarn. It is done by taking two or more strands of yarn
that each have a twist to them and putting them together. The strands are twisted together, in the opposite
direction than that in which they were spun. When just the right amount of twist is added, this creates a
balanced yarn, which is a yarn with no tendency to twist upon itself. Almost all store bought yarns are
balanced, plied yarns.

A two-ply is thus a yarn plied from two strands, a six-ply is one from six strands, and so on. Most commercial
yarns are more than a two ply. Embroidery floss is generally a six ply yarn
Regular Plying

Regular plying consists of taking two or more singles and twisting them together, the opposite way. This can
be done on either a spinning wheel or a spindle. The most important thing to remember though is that the
twist must go the opposite direction. If in spinning the single the wheel was spinning clockwise (which is
called a "Z" twist, as on any given side the fibres appear to cross diagonally in the same direction as the
diagonal of a "Z"), in order to ply it the wheel must spin counter-clockwise (an "S" twist). This is because
otherwise you are not balancing the twist, just twisting it more. The concept is similar to when a heavily
twisted piece of yarn is folded, and it twists up on itself. It is most common for singles to be spun with a "Z"
twist, and then plied with an "S" twist.

Novelty Yarns

Many novelty yarns make use of special plying techniques to gain their special effects. By varying the
tension in the strands, or the relative sizes of the strands, or many other factors different effects can be
achieved. For example, when a soft, thick strand is plied against a tightly twisted thin strand, the resulting
yarn spirals. Another example is bouclé, which is a yarn where one strand is held loosely and allowed to
make loops on the other yarn while plying.