DIFFERENT TYPES OF YARN PACKAGE FAULTS, CAUSES, AND REMEDIES

DIFFERENT TPYES OF YARN PACKAGE FAULTS IN DRUM WINDING, CAUSES, AND REMEDIES:

Various types of winding faults occurring during winding are given below:

EXCESS YARN BREAKAGE: 

When the excessive yarn breakages get occurred during  drum winding process, the productivity of the machine gets affected. The poor yarn quality also gets resulted, if there is excessive end breakages during winding. The some common and important reasons creating excessive end breakages are given below:

• The winding tension is selected according to yarn count to be wound. If the winder don't maintain enough and proper yarn tension during winding, excessive end breakages result.  Excessive yarn tension always results in the form of unnecessary end breakages during winding. The winder should take proper care of the yarn winding tension.

Improper winding speed:

The winding speed greatly influences end breakage rate during winding process. The speed of winding machine is selected according to the yarn tensile strength, count, and thick and thin places present in the yarn to be wound.  The winding tension gets increased when the winding speed is increased. This increase in  tension causes end breakage. The yarn having poor tensile strength gets wound on lower winding speed. The thin and thick places present in the yarn always increase the chances of end breakages, so that the yarn having poor tensile strength and high imperfection should get wound at low winding speed.

Setting of slub catcher:

The improper slub catcher setting also causes excessive end breakage during winding process. The clearance between top and bottom blades of slub catcher is selected according to the yarn count. The low clearance causes end breakage. If clearance is more than required, the extra thick places can be passed into the yarn being wound on the package.

STITCHES IN THE YARN PACKAGE:

Some times, the yarn coils get laid outside the edges of the package. These outside laid coils are known as stitches in the package. These stitches causes very big trouble during unwinding of yarn. The end breakage rate gets increased due to stitches in the package. The bottom stitches are very serious problem in yarn unwinding. The nose stitches also create snarling and bunches formation during unwinding. 

 The main possible causes of stitch formation in winding package are given below:

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• The excessive traverse drum speed may result in the form of stitch formation in winding package.

• Worn out cone holder causes stitch formation.

• Huge variation in winding tension creates stitch formation in winding.

• If operator releases the yarn on incorrect position at the time of restarting after knotting of yarn, the stitch formation takes place.

• Improper mounting of package in the cone holder may result stitch formation in winding.

• Worn out traverse drum causes stitch formation in winding.

RIBBON FORMATION OR PATTERNING:

 The main possible reasons of ribbon formation are given below:

• If anti-patterning device is not functioning properly, it may cause patterning or ribbon formation in the resulting yarn package.

• In correct setting or programming of anti-patterning device causes patterning in the package.

• Improper grip of package on the package holder results in the form of ribbon formation.

ENTANGLEMENT OF YARN:

main possible reasons of yarn entanglement  of in the  package are given below:

• Repeated knotter fibres produces yarn entanglement.

• The yarn entanglement may be occurred due to strong suction pressure.

• Faulty release of yarn by operator after knotting

• Improper working of yarn break stop motion causes yarn entanglement.

Wild Yarn:

Yarn waste wrapped on hands of machine operator results wild yarn in the package.

Snarling in the yarn:

possible causes of snarling are given below:

• Improper release of yarn after knotting or at the time of restarting.

• Strong suction pressure in the slack tube

• Inadequate setting of twist.

YARN RUPTURE:

Sometimes, ruptured yarn comes out from the package during unwinding. This ruptured yarn cause big trouble during weaving. The main causes of yarn rupture in the package are given below:

• If stop motion is out of order or not working correctly, the package gets rotated continuously without yarn. The surface of the yarn gets ruptured due to abrasion between drum and package surface.

• The rough or damaged surface of groves of traverse drum also causes rupture in yarn.

• If the yarn path gets ruptured at any place, the ruptured yarn results in the package during unwinding.

• Soft package:

It is very serious package defect. This defect causes yarn coils slippage during unwinding. The whole package gets rejected many times. This problem create due to low winding tension.

• Soft nose package:

If the nose of the package gets much soft, there may be serious problem during yarn unwinding.  Almost half of the package may be rejected.  This defect causes when the operator increases the yarn tension in the middle of the package.  When the winding re starts with increased yarn tension, the winding density gets increased. The top layer of package put pressure on bottom layer. Thus the nose of the package comes out of the package. Winder should not increase tension after starting the winding machine. We should adjust the yarn tension at starting time only.

Related articles:

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Air-jet/ vortex spinning ( an open end spinning process )

Rotor spinning ( an open end spinning process)

Objectives of winding process

Testing of yarn count, tensile strength, and CSP calculation

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