Compact Spining

UNIVERSITY COLLEGE OF TEXTILE ENGINEERING
BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

TEAM MEMBERS
KHURAM SHAHZAD
M.ZAHID HUSSAIN KHAN

WHAT IS INNOVATION ?
THE PROCESS OF TAKING A
CREATIVE IDEA AND TURNING IT
INTO USEFUL PRODUCT, SERVICE
OR METHOD OF OPERATION.
Contents
• Introduction
• Different innovations
• Compact spinning
• Types of compact spinning with respect
to method
• Comparison
• Benefits towards forthcoming processes
Some Recent Innovations
• Pre cleaner UNIclean B-12,UNIstore A78.

• C60,TC 03 cards.
• New double delivery SB 20 draw frame and RSB
D40 Autoleveller.
• OMEGAlap E65/E75 with 450nips/min with
production of 66_68 kg/h
• Rieter has new ring frames G35 and
K45(compact) with 1632 spindles.
• Rotor machine R 40(440 spinning boxes),BT
924(360 spinning boxes).
• Rotona rotor core yarn.
OUR PRESENTATION TOPIC
COMPACT SPINNING
WHAT IS COMPACT SPINNING?
Compact or condensed spinning is a new concept

of yarn forming.
Fundamental modification of the conventional
ring-spinning system that aims at producing a
better surface integrity of spun yarns and
maximizing strength.
The eliminated spinning triangle is a by-product of
this concept. This close and parallel arrangement
of fibers immediately before twist is imparted is
responsible for the characteristic advantages of
compact yarn.
HISTORY
For several decades, development efforts
in ring spinning were focused on
improving the existing technology and
incorporating automation and process-
linking capabilities.
The first compact spinning machine was
put into trial production in 1995 in some
spinning mills in Switzerland.
IMPORTANCE
Compact spinning offered the potential to create a
near-perfect yarn structure by applying air
suction or magnetic system to condense the fiber
stream in the main drafting zone, thereby
virtually eliminating the spinning triangle.
Compact spinning has been shown to
significantly improve yarn tensile properties and
reduce its hairiness. Both characteristics are
crucial for yarn performance in downstream
manufacturing operations
CONVENTIONAL V/S COMPACT
• The difference (DW)

between WF and WT
increases as the speed of
the front roller increase;
this is due to less control
on fiber draft and
spinning.
Working principle
1-Draft arrangement
1a) Condensing element
1b) Perforated apron
VZ) Condensing zone
2) Yarn Balloon with new
structure
3) Traveler
4) Ring
5) Spindle
6) Ring carriage
7) Cop
8) Balloon limiter
9) Yarn guide
10) Roving
E) Triangle of compact
spinning
Properties of compact spinning:
• Better yarn structure.

• High strength and low hairiness.
• Benefits and cost savings in the subsequent processing stages.
• Compact fabrics distinguish themselves by an increased lustre and a
clearly enhanced colour contrast.
• The wear comfort and handle of the final products are significantly
improved.
Factors Affecting Compact Spinning

• Condensing zone is heart of
compact spinning.
• Fiber length, fineness and
stiffness are factors affecting
the fiber transport by airflow
this necessitates apron moving
to be less than delivery rollers
(condensing).
• Changing the perforation
width increases air velocity.
• Smooth guides give better twist
propagation.
• Hairs of less than 2mm give
better cover factor, Hairs> 3
mm are Problematic for
processing.
Methods of compacting fiber strand
These methods are:

1. Aerodynamically compacting system:
• a) Suction by drum
• b) Suction through perforated apron.
2-Mechanical compact system.
3-Magnetic compacting system.
AERODYNAMIC METHODS
1.Suction by drum
• Rieter (Com4)
2.Suction by apron
• Suessen (Elite)
• Zinser
• Toyota
• Olfil system by Marzoli
Com 4 (K44) Operating Principle

• Vacuum generated in the
perforated drum
• The fibers are fully
controlled all the way
from the nipping line after
the drafting zone to the
spinning triangle.
• Nip roller prevents the
twist from being
propagated into the
condensing zone.
• Perforated drum
• Suction insert.
• Air guide element
SUESSEN is a pioneer in the

compact spinning technology
SUESSEN has sold more than

2.3 million EliTe Compact
Spindles Over 10% of these
compact spindles have been
successfully equipped with
EliTwist Technology.
Special features:
• Optimum and sustained yarn quality
• High consistency of all yarn parameters
• Minimal variation between spinning positions
• No restrictions in regard to raw material
• Easy handling
• Universal application
• Can be installed on almost all machine types
Working principle
• The slot creates an air current
through the lattice apron inside the
profile tube.
• As the slot, being under negative
pressure, reaches right up to the
delivery nipping line, the fiber
assembly remains totally
compacted. This results in a
substantial disappearance of the
spinning triangle.
• To fulfill these criteria suction fans
are installed driven by a motor.
Each suction pump covers 24/30
spinning positions. This provides
short airflow distances with
identical negative pressure on all
spinning positions.
• Suessen compact system

consists of a tubular profile
subjected to a negative pressure
and closely embraced a lattice
apron.
• The delivery top roller fitted
with rubber cots presses the
lattice apron against the hollow
profile and drives the apron, at
the same time forming the
delivery nipping line.
• The tubular profile has a small
slot in the direction of the fiber
flow.
Eli Top
The EliTop has a special design.
1. bottom part of housing
2 .top part of housing
3 . screwed joint of both
housing parts
4. front top roller =
front of drafting system
5. delivery top roller = EliTe Roller
6. axle with intermediate
gears to clip on
• EliTube / Lattice
Aprons
The EliTube, assigned to one
group of spindles, serves to supply
the vacuum for the relevant
suction slots
• This insert can be replaced easily
if it is worn.
1.For coarse count
2.For fine count

2
Demerits
• The EliVAC system

(suction system) increases
the heat emission of a ring
spinning frame.
Demerits
• Defective lattice apron
(operating life exhausted,
damaged by lapping, wrong
positioning in the recesses of the
guide rod).
• Ultrasonic cleaning devices with
a content of about 20 liters to
wash approx. 1000 aprons at a
time. Such devices cost about
EURO 1,300.
• Due to fiber accumulation
between lattice apron and
EliTube, lattice apron does not
run smoothly.
Fundamental Rules for Successful Elite Compact Spinning
• Rule1: EliTe Spinning Machines must be separated from

conventional ring spinning machines.
• Rule 2: Maximum room temperature 33 degree Celsius.
• Rule 3: The front top roller is precisely 3.5 mm offset towards the
operator in relation to the front bottom roller of the drafting system.
• Rule 4: The traverse mechanism for the roving should be adjusted
in such a way that the traverse motion at the front of the drafting
system does not exceed 4 mm, and that the l.h.limit position of the
roving is level with the left hand edge of the top of the slot.
• Rule 5: Lattice aprons and Eli Tubes must be cleaned from time to
time.
Fundamental Rules for Successful Elite

Compact Spinning
• Rule 6: Eli Tops must be replaced by new top rollers after

the recommended time.
• Rule 7: Make sure that the difference in diameter of the
front top roller and the delivery roller corresponds precisely to
the desired tension draft
• Rule 8: Clean the connecting hoses with regular frequency.
• Rule 9: The fans should be removed from the machine and
cleaned once a year.
• Rule 10: Yarn quality is more important than quantity
60/1 CM WVG 60/1CMWVG

COUNT COMPACT COMPACTK-44
Comparison Lot-Y Lot-Y
Yarn RX-240 (Seussen) K-44
b/w com4 and COTTON Lot-Y Lot-Y
Seussen Actual count

Count C.V %
61.13
1.21
60.95
1.19
Strength 51.6 52.1
Strength C.V % 3.94 2.35
CLSP 3154 3175
RKM (UTJ) 21.94 22.46

U% 10.99 10.9
Thin -50 % 17.96 17.82
Thick +50 % 48.06 48.93

Neps +200 % 98.77 96.7
IPI 164.79 163.45
Hairiness 3 2.88
Sh 0.68 0.63
TPI 32.6 31.88
TM 4.17 4.08
Toyota compact system

• The RX240NEW-EST high quality
compact yarns.
• The "Simple & Rigid" structural
design.
• In Toyota when the fibers leave the
drafting zone they are compacted by
condense apron.
Condense unit 4-spindle unit +

Perforated apron
Suction motor Synchronous motor
controlled by Inverter
Working principle
• Condense system is driven by front bottom
roller with Toyota’s specially designed driving
system.
• Individual’s motor combined with suction units
for spinning position have been arranged
accordingly. This provides short airflow
distances with identical negative pressure.
• By applying air suction to condense the fibers
stream, thereby virtually eliminating the
spinning triangle, helps improve yarn
characteristics.
Structure
1. Suction duct (One section per 48 spindles)
Locating the suction duct on the upper
part of the roller stands simplifies duct
design for easy cleaning and shortens
piping length for optimum suction
efficiency.
2. Condense unit:
Each 4 spindle unit is easily removed and
disassembled without using special tools.
3. Delivery roller:
Delivery roller is driven by maintenance-
free carrier gear and grooved front roller
resulting in a simple and dependable
structure.
Features of high quality:

• Smooth collection of fleece fibers by suction slit and
perforated apron.
• Precise slip-free rotation of perforated apron due to positive
drive by bottom delivery roller.
• Adjustable suction pressure controlled by inverter.

Features of easy maintenance:
• Easy access to detachable condense unit.
• Less critical top roller maintenance due to bottom delivery
roller drive of perforated apron.
Features of flexibility:
• Easy conversion between
compact and conventional ring
spinning.
• Available as retrofit for the
RX240NEW.
Stable production of high

quality yarn:
• Quality yarn with low hairiness
and high evenness is produced
by eliminating the spinning
triangle at the delivery section
of the front roller.
COMPARISION 60/1 CM
60/1 CM WVG Toyota 60/1 CM WVG COMPACT
COUNT
COMPACT Lot-Y K-44 Lot-Y
Depart. Packed Packed
Yarn RX-240 K-44
COTTON Lot-Y Lot-Y
Actual count 60.75 60.49

Count C.V % 1.33 0.78
Difference Strength
Strength C.V
51 50.9
b/w com4 CLSP

% 4.22
3098
3.22
3079
and Toyota RKM (UTJ)

C.V.%
22.27
9.6
22.49
10.5
Elg. 4.57 4.23
C.V.% 10.4 11.3
U% 11.53 11.25
CVb 2.3 2.6
Thin -50 % 23.5 30.3
Thick +50 % 80.3 75.5
Neps +200 % 167.5 147.3
IPI 271.3 253.1
Hairiness 3.33 3.33
Sh 0.8 0.77
Zinser: CompACT
• With this compact spinning
technology, which is based on a
perforated apron, all raw materials
can be processed to all major yarn
counts.
• This, however, not only applies to the
field of combed cotton ring yarn, but
also to carded ring yarn, blends of
cotton with manmade fibers (carded
and combed) and pure manmade
fibers.
Working Principle
• The system of Zinser, is characterized by
extending the draft system by a double
roller.
• A perforated apron is moved over the
upper roller, where the suction profile
element is found. Between the delivery
roller and the perforated apron, the
condensing zone occurs.
• The roller pair is working in a classical
way as in ordinary draft system.
Olfil system by Marzoli

• Resembles the Suessen system in that it also uses a bottom
perforated apron and an extra top front roller.
• The Olfil system is still under development and not yet
commercially available.
• The major difference between these two systems is that,
whereas Suessen utilizes a bottom perforated apron that
extends back into the nip of the normal front roller, the Marzoli
system uses a bottom roller around which the perforated apron
passes.
• This implies that the Suessen system has greater control of the
issuing strand. Indeed.
• An additional difference between Suessen and Marzoli is that,
while they both use slightly different roller sizes to promote the
tension in the condensing zone, Marzoli use a timing-belt drive,
whereas Suessen uses a gear drive.
• The bottom section of the

condensing system has one
stainless steel pipe for every 8
spindles with a perforated apron
at each spindle.
• The top section of the condensing
system is composed of two
pressure rollers driven by the
toothed belt.
• For each 48 spindles section,
there is one motorized inverter
driven fan that provides suction
for the condensing system.
RoCos ROTORCRAFT
COMPACT SPINNING
– No air suction
– No air pipes
– No perforated drums or aprons
– No ventilators
– No extra power
– No erectors for installation
– but
– Magnetic Compacting is
simple – safe – solid
Principle
• Any ring spinning
machine can be
converted into RoCos
system.
• Bottom roller 1
supports the front roller
2 and delivery roller 3.
• Condensing zone extends from

clamping line A to clamping line
B.
• Very precise magnetic
compactor 4 is pressed by
permanent magnets without
clearance against cylinder 1. 2
3 1 bottom
• Together with the bottom roller A
roller
it forms an overall enclosed 3 B 1
2 front roller
compression chamber whose
3 delivery
bottom contour, the generated
surface of cylinder 1, moves roller
A
synchronously with the strand 4 magnetic
of fibers and transports this 4 compactor
safely from clamping line A A/B clamping
through the compactor to B line
clamping line B
Types of the RoCos compact spinning

system
• RoCoS1 is suitable for
cotton, pure and as blends
with synthetic fibers as
well as for pure synthetics
with a maximum staple
length of 60 mm (21/2 ").
• RoCos 2 is suitable for

wool, pure and as blends
with synthetic fibers as
well as for pure synthetics,
having a minimum staple
length of 50 mm (2").
Comparative benefits towards other compact

systems
• Low operating cost.
• No additional power required. Hence contributes
saving of Rs 1.35 to 5.00 per every km of yarn
produced.
• Higher productivity by optimizing twists insertion
and low ends down.
• Less Pneumafil waste by 0.3 to 0.6 per cent.
• Ergonomic design for efficient and easy handling
during maintenance.
• Benefit from total recurring cost and investment
is multi-fold.
• Further benefit like elimination of waxing during
winding and singeing process
ADVANTAGES OF COMPACT YARN

• Higher fiber utilization.
• Higher tenacity with same twist
factor, or same tenacity with
reduced twist factor for higher
production.
• Lowest hairiness (highest
reduction in hairs longer than 3
mm).
• Fewer weak points
• Better imperfections (IPI) values
• Higher abrasion resistance
• up to 20%twist reduction in
spinning compact yarns, the
twisting turns can be reduced for
certain types of yarn. As a result,
production of twisting frame is
increased and twisting costs are
reduced.
ADVANTAGES OF COMPACT YARN

• Due to better embedding of fibers
(including short ones) in compact Yarn,
approx.6% reduction of combing noils
are possible.
• Cheaper carded qualities instead of
combed qualities can be spun with the
Compact Spinning system.
ADVANTAGES IN WEAVING
• Higher tenacity of compact Yarns, the ends-down rate in beaming

is reduced by up to 30%. Higher beamer efficiency, higher
production and fewer personnel for repair of ends-down in
beaming are the consequence.
• Owing to the better work capacity of compact Yarns, ends down
can decreased by up to 50% in the warp and by up to 30%in the
weft. Efficiency is consequently increased by 2 to 3%, production
is increased and weaving costs are reduced.
• In practice, the average ends-down rate is reduced by 33% per
100,000 weft insertions of compact yarns on rapier
weaving machines and by 45% on air-jet weaving
machines. Instead of a weft insertion of 500 –600 m/min with
conventional ring yarn, 700-800 m/min is possible
ADVANTAGES in PROCESSING
• Compact Warp yarns help to save up to 50%of sizing agent, while

the running behavior of weaving machines is the same or even
better. Cost can be saved in sizing and desizing processes.
• Singeing can sometimes be dispensed with, or it can be carried out at
a higher cloth advance speed. Fibers up to 7% can be saved because
singing can be avoided.
• Dyeing and Printing Improved structure of compact Yarns and
their reduced twist favors the absorption of color pigments and
chemical finishing agents. Saving of dyestuff is possible.

ADVANTAGES In knitting Yarn

• Reduce yarn twist of knitting yarns, by up to 20%, The ends-down rate in
spinning these Yarns is reduced by 30 to 60%, which improves machine
efficiency.
• Increased yarn strength and reduced formation of fluff permit to achieve
higher machine efficiency and therefore production on knitting machines at
a reduced ends-down rate, less interruptions and less fabric faults.
• Production costs therefore decrease.
• In knitting fiber abrasion reduced by 40% due to low hairiness. Fewer
defects/ yarn breaks and better quality. Less contamination on all machines
by foreign fibers.
• Less wear of needles, guide elements and sinkers due to less dust in the
compact Yarn. Low hairiness has positive impact on loop structure.
• For warp knitting can be used, because of their higher work capacity.

Compact Spining

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UNIVERSITY COLLEGE OF TEXTILE ENGINEERING

BAHAUDDIN ZAKARIYA UNIVERSITY , MULTAN

M.ZAHID HUSSAIN KHAN

Some Recent Innovations

• Pre cleaner UNIclean B-12,UNIstore A78.

OUR PRESENTATION TOPIC

WHAT IS COMPACT SPINNING?

Compact or condensed spinning is a new concept

CONVENTIONAL V/S COMPACT

• The difference (DW)

Properties of compact spinning:

• Better yarn structure.

Factors Affecting Compact Spinning

Methods of compacting fiber strand

These methods are:

Com 4 (K44) Operating Principle

SUESSEN is a pioneer in the

SUESSEN has sold more than

• Suessen compact system

1.For coarse count

2.For fine count

• The EliVAC system

Fundamental Rules for Successful Elite Compact Spinning

• Rule1: EliTe Spinning Machines must be separated from

Fundamental Rules for Successful Elite

• Rule 6: Eli Tops must be replaced by new top rollers after

60/1 CM WVG 60/1CMWVG

Seussen Actual count

Strength C.V % 3.94 2.35

CLSP 3154 3175

RKM (UTJ) 21.94 22.46

Thin -50 % 17.96 17.82

Thick +50 % 48.06 48.93

Toyota compact system

Condense unit 4-spindle unit +

Features of high quality:

• Adjustable suction pressure controlled by inverter.

Stable production of high

COTTON Lot-Y Lot-Y

Actual count 60.75 60.49

b/w com4 CLSP

and Toyota RKM (UTJ)

Olfil system by Marzoli

• The bottom section of the

• Condensing zone extends from

Types of the RoCos compact spinning

• RoCos 2 is suitable for

Comparative benefits towards other compact

ADVANTAGES OF COMPACT YARN

ADVANTAGES OF COMPACT YARN

• Higher tenacity of compact Yarns, the ends-down rate in beaming

• Compact Warp yarns help to save up to 50%of sizing agent, while

chemical finishing agents. Saving of dyestuff is possible.

ADVANTAGES In knitting Yarn

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