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HOW TO REDUCE THE END BREAKAGE RATE IN SPINNING

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STEPS TO REDUCE THE END BREAKAGE RATE IN SPINNING:-

  • Raw material selection to be done carefully, Not only length and strength of fiber also uniformity ratio. maturity ratio and micronaire value will contribute for end breakages in ring frame. it has to be noted that around 70-80% of yarn characteristics are depend on raw material including end breakages & optimum selection will help to maintain consistency in all aspects.
  • For cotton, the fiber length, strength, micronaire and uniformity, based on count and speed at spinning had very high correlation with end breaks at spinning.

  • Selection of raw material in relation to spinning speed plays a vital role in control of breaks in spinning.

  • There should be appropriate atmospheric conditions like temperature, relative humidity, number of air exchanges etc. Maintain the air humidity and temperature inside the department as per standard requirement because too low RH & temperature may result to static charge that is responsible for lapping & hence increase of the breakage rate. 
  • Every end breakages apart from being potential cause of breaks, in subsequent department results in the yarn defect, lower machine efficiency, higher waste & more work load for the siders. end breaks more than 3 breaks/spindle hour or more than per hour individual spindle shift is unacceptable. 
  • Incorporation of the parabolic speed control system & best suited speed table with minimum 16nos. of steps by conducting trials for checking the stage wise breaks. ensure the speed difference between peak speed & average speed is less than 7% & peak speed running time should be 60% of total doff time. 
  • Good house keeping to be maintained inside department & maintain proper humidity (48-53%) is to be maintained & there should not be any wide variations further flies in the spinning department & to be controlled by running the necessary fresh air fans, water pumps & exhaust fans.
  •  Normally every roving breaks in simplex will cause an end breaks in spinning. hence the roving breakage rate is to be maintained at below 1 in simplex. mainly in simplex roving strech is to be maintained below 0.5 because this has a direct impact on yarn long thin faults which in turn influence spinning breakage rate. 
  • Simplex hank & tpi influence spinning breaks. correct tm & hank to be select in simplex. higher tm roving creates more undrafted ends in spinning & lower tm roving creates higher creel breaks. so, optimum TM shall be select. bobbin content higher bobbin weigh gives more breaks in spinning. correct bobbin weight with free from roving fault to reduce spinning breaks.
  • Simplex empties condition should be good so as it hold in the spinning creel properly. if there is any damage inside the bobbin, then the bobbin becomes tilting while running in the creel caused strech, breaks will occur due to thin place. simplex empties to be good.
  • To reduce the breakage in spinning, performance of delay drafting & its function should be perfect, any uneven air supply should be avoided, plant suction performance should be perfect to avoid any loose flies & air rebounding & both total drafting pressure & individual top arm pressure has to be maintained. 
  • Maintaining proper RH% & temperature in ring frame department, running ohtc with correct position of blowing nozzles to maintain ring frame fluff free, better housekeeping to reduce fluff generation in ring frame department & maintaining the spindle speed in parabolic from for avoiding jerky movement of ring rail will help to reduce the breakage rate.
  • To reduce the breakage rate, clearer rolls, drafting zone cleaning should be 24 hours once, process to be with appropriate spacer, roller setting, breakdraft, pressure & top roll shore hardness & identifying the repeated spindles & correcting then & there.
  • Apron nip opening & settings, top roller pressure, breakdraft, total draft, pneumafil suction pressure, traveller clearer settings, lappet height setting, traverse motion setting, & top roller buffing schedule bobbin dia to should be set optimum to reduce the breakage rate.
  • Controlling roving linear density, proper draft & roller setting, optimizing spindle speed based on material & its spinnable properties changing traveller strictly at ¾ the stage, proper positioning of ohtc nozzles & proper settings of top arm pressure, ABC rings, separators, traveller clearer & height & centering of lappet hooks will minimize the breakage rate.
  • To reduce the breakage rate, the inverter spindle speed one step to another step should not match difference, better 1000 to 1500rpm, in case of the drafting pneumatic the pressure hose & letch condition should be good, timely servicing of jockey pulley & replacement of spindle tapes.
  • To reduce the breakage rate the distance between front bottom rollers to suction tube should be maintained not below to 1mm, top roller pressure to be kept front-18kgs, middle- 14kgs, & back-16kgs, shore hardness of rubber cots should be 60 to 70 degrees & BD. should be optimum.


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