Yarn Spinning
Yarn Spinning is the process of converting fibers into yarn. From raw cotton bale to finished yarn cone. Includes opening, carding, drawing, roving, and spinning. Different spinning systems create different yarn qualities for different end uses.
Spinning Process Overview
- Opening: Bale opening, cleaning trash, mixing fibers
- Carding: Card machine aligns fibers, removes short fibers, forms sliver
- Drawing: 6-8 slivers drafted into one, improves evenness, parallel fibers
- Roving: Slight twist, reduces sliver to roving for spinning
- Spinning: Final twist converts roving to yarn on industrial cones
- Winding: Yarn wound on cardboard cone, cleared of faults, ready for weaving
Types of Spinning Systems
- Ring Spinning: Classic, strongest, most even, fine to coarse Ne 6 to 80, slow but premium quality for shirting and fine jersey. 90 percent of cotton yarn.
- Open End Rotor: Fast, economical, coarse to medium Ne 6 to 30, hairy, less even, for denim, towels, workwear. High production speed.
- Air Jet Vortex: Fastest, Ne 20 to 60, low hairiness, smooth, for shirting, less pilling. Air wraps fibers without mechanical twist.
- Compact Spinning: Improved ring, less hairiness, stronger, Ne 30 to 80, for premium shirts and combed jersey. Fibers compacted before twist.
- Siro Spinning: Two rovings spun together, Ne 16 to 40, strong, low hairiness, for worsted suiting and gabardine.
- Core Spun: Elastane core with cotton sheath, Ne 20 to 40, stretch yarn for stretch denim and ponte pants.
Sliver Cans vs Finished Cones
Left side of image shows sliver cans - large cans with loose rope of fibers after carding and drawing, organized sliver ready for roving. Right side shows finished yarn cones - cardboard industrial cones with twisted yarn ready for weaving and knitting machines. Thin white elegant divider separates raw stage and finished stage.
Which System For Which Fabric
- Fine shirting poplin and dobby: Compact ring or air jet Ne 60 to 80
- Denim and canvas: Open end rotor Ne 8 to 16 - hairy and strong
- T-shirts jersey: Ring carded Ne 30/1 standard
- Gabardine and twill suiting: Siro compact Ne 40 to 60
- Stretch fabrics: Core spun with elastane center
Quality Control
- Uster Tester: Measures evenness, thin thick places, neps
- Yarn clearer: Removes faults automatically during winding
- Count CV: Low CV means consistent count - premium
- Twist and strength tested every lot