Open end spinning
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Open end spinning is a technology for creating yarn without using a spindle. It was invented and developed in Czechoslovakia in Výzkumný ústav bavlnářský / Cotton Researching Institute in Ústí nad Orlicí in the year 1963. It is also known as break spinning or rotor spinning. The principal behind open end spinning is similar to that of a clothes dryer spinning full of sheets. If you could open the door and pull out a sheet, it would spin together as you pulled it out. Sliver from the card goes into the rotor, is spun around into yarn and comes out, wrapped up on a package, all ready to go to the next step. There is no roving stage or re-packaging on an auto-coner. This system is much faster than ring spinning with rotor speeds up to 140,000rpm , and less labour intensive. Several design of rotors are used by different manufacturers; designed for different fibres.
The first open end machines in the UK, were placed under great secrecy, in Maple Mill, Oldham in 1967.
The disadvantage is mainly that the open end is limited to coarse counts, cloth made from open-end yarn having a 'fuzzier' feel and poorer wear resistance.
Fibre quantities processed into yarn throughout world is increasing. The nature of conversion from fibre to yarn is a complicated process. Inventive efforts in spinning has led to increase in productivity in many folds which begun from
Hand spinning,
Mule spinning
Ring spinning
Rotor spinning and
Friction spinning.
Though demand in yarn is ever increasing spinning mills are competing for constant reduction in spinning cost and with additional improvement in yarn quality and productivity. The last stage of spinning is referred to as fine spinning where the yarn arrives at its final count and strength. This operation call for highest expenditure of the entire spinning process. Thus many thought process lead us to newer and innovative method of optimization and incremental productivity as under,
A different method of imparting twist Eliminating twist impartation and consequently a different method of yarn of consolidation Process which employ finished yarn, synthetics in addition to staple fibres. Out of all the above mentioned process Open End spinning succeeded for higher output, good quality, ease of automation and high degree of spinning ability.
Development stages of Open End
1937
Berthelsen developed a relatively perfect open end.
1965
Czech KS200 rotor spinning machine was introduced at 30000 rotor rpm.
1967
Improved BD200 with G5/1 Rieter were presented with first mill of OE coming under production
1971-1975
There was a considerable increase in machine manufacturer and newer and improved
version of machines were launched with increased speed at 100000 rpm .
1975
Also witnessed first automated machine from Sussen equipped with Spincat and Cleancat
which opened up the industrial rotor spinning breakthrough.
1977
Witnessed Schlafhorst with Autocoro machines which made a mark in open end market.
Presently the market is heading to very few established OE makers for quality and quantity production.
A good O.E machine look forward to,
a. high content sliver cans ( up to 18”)
b. Larger packages of yarn ( 4 to 5 kgs)
c. Less power consumption
d. Higher productivity
e. Automation involved
f. Flexibility of spinning components
g. Handling count range.
A. Large Sliver Can:- In early days major machines were equipped in less distance between Rotors (Guage of machine) . this led to creeling of very small cans henceforth involving higher can changes and thereby break in yarn, now all major manufacturers allow cans upto 18” diameter leading to less breakage, less joining of yarn, hence better quality and higher productivity. These round cans are now updated by Rectangular can with double capacity of sliver.
B. Large Final Package:- Earlier machines used to offer smaller yarn packages. Although they were bigger than cops of Ring spinning but still led to frequent change of tubes and leading to increase in idle time for creeling. Now in modern stages with higher control on package we can manufacture Yarn package with weight up to 4 to 5 kgs which helps in reducing creeling time at Warping zone and higher productivity owing to low idle time. The maximum possible has now been upto 6 kgs by SAVIO Super Spinner 3000.
C. Less Power Consumption:- Drive control of the machine used to be centralized structure leading to high capacity under utilized motors. Decentralization and futuristic electronic controls to various drives of machine has led to maximize utilization of power with minimum damages to machine. This in turn gives less power cost to manufacturing of yarn.
D. Higher Productivity:- This is a major criteria as the present needs are increasing very fast and the basic thumb rule is more the productivity less the cost of manufacturing. The O.E machines which are now in market boasts of many a basic needs like, longer length of machine, higher speeds, able to process coarser hank, less no. of changes for Count, easy access to parts ( less downtime for cleaning), longer production time between cleaning schedules, logical intelligence for less power consumption and lower downtime for attending rotors, complete report generation giving leads to problem area are some points to discuss.
E. Automation:- All the machines where we are spinning yarn needs process of yarn joining irrespective of ring or open end. This process is largely dependent on human expertise. Presently with an eye on keeping consistency in the product we need to have precise control on joining of yarn. Human tendency does not, which has led to Autopiecing units, where market leaders like Schlafhorst, Rieter, Savio have their machines already incorporated with good quality piecers (Robots). Other manufacturers are also joining the league in same levels to achieve good quality norms of yarn. Auto Piecing, Auto Doffing leads to less material handling and help in reducing contamination at the final package levels.
F. Flexibility of spinning component:- This requires a high degree of optimization from the machine manufacturers as well as buyers for their end use program. Presently a spinning mill should have a range of product which can apply from Denim, Knitting, Towels, Structured fabric, Construction and various other products like Core spun , Multi count etc. , hence these machines should be able to take up challenges at ease. Manufacturers are trying to incorporate major systems on single machine to cater to different units for their demands of yarns.
G. Handling count range:- The machines needs ability to spin yarns from 4sNe to 60sNe which is a demand of spinners. This is looking to the fast changing market where a spinner with single setup has to cater to different end users having different requirements.
