End Breakage in Spinning - A Major Performance Indicator of Spinning Mill

One basic way to increase the profit and quality in ring spinning process is to keep the end breakage rate to a minimum level. The end breakage is a critical spinning parameter that not only affects the maximum spindle speed but may also indicate the quality of yarn, the mechanical condition of the machines and the quality of raw material. Therefore it is an important parameter which determines the overall working of a spinning mill. Any attempt to explain the end breakage mechanism in terms of qualitative approach will provide an aid to understanding the problem and to tackling it to any possible degree.

To reduce end breaks, the following few aspects should be taken into consideration.

1.    The width of the drafted ribbon at the front roller nip should be reduced.

2.    Measures to be taken to reduce mass irregularity of yarn straight after carding.

3.    A reduction in friction between ring and traveler could reduce the peak tension during the rotation of the traveler.

4.     Since the end breakage in ring spinning is related to slippage of fibers at the spinning triangle as a result of peaks occurring in the spinning tension fiber, the grip at the front drafting rollers should be increased by having a higher top roller pressure. The use of softer cots also enhances the grip at the front roller. If the total pressure on the rollers can not be increased, the grip at the front rollers nip can be improved by reducing the width of cots.

5.    The permutation and combination of speeds at different stages of cop build in ring frames can help a lot in reduction of breaks.

6.    In case of spring loading top arms in ring frames, when you restart the ring frame after a mill holiday, the breakages are very high. The practice of inching at interval of 8 to 10 hrs on holiday without releasing the top arm pressure, reduce the end breaks to a great extent.

7.   In case of pneumatic loading top arms ring frames, when you restart the ring frame after a mill holiday, the breakages are very high. The practice of tightening the material in drafting zone by reversing the back & middle rollers with the help of back roller wheel before starting the machine helps in reduction of end breaks during starting of the ring frames.

1.    The lowering of spindle speed by 5 to 6% just after putting new travelers for 2 hours for running-in of travelers helps in reduction of end breaks to large extent.

2.    The use higher twist multipliers will reduce breaks even at higher spindle speeds than at lower spindle speeds with low twist multipliers.

3.   The higher twist than required in roving reduces the creel breaks in ring frames.

4.   The delay in change of travelers will increase end breaks in spinning. Hence timely change of travelers is a must.

5.   The use of common tube suction system improves suction of pneumafil system further without increasing power consumption compared to individual suction tube system in ring frame and reduces end breakages to a large extent.

6.   Any compromise in right selection of fibre properties may lead to higher end breakages in spinning ring frames.

7.   The frequent stoppage of Over Head Travelling Cleaners accumulates fly and results into higher breaks due to loading of traveler with fly.

The end breakage in spinning not only increases physical exercise of workmen, but also increases waste. Hence ultimate effect is on productivity of spinning mill.

There are many such points, but uncommon points are mentioned to share with fellow technicians of other organizations, academic institutions, research associations and machinery manufacturers etc.