Indian Journal of Fibre & Textile Research

Vol. 34, September 2009, pp. 225-230

Mechanical properties and fault analysis of D-slot carded compact yarn

R Loganathan & C B Lakshmikantha
Department of Textile Technology, K S R College of Technology, Tiruchengode 637 215, India
and
T Ramachandrana
Department of Textile Technology, P S G College of Technology, Coimbatore 641 004, India
Received 1 September 2008; revised received and accepted 21 November 2008

An attempt has been made to analyze the imperfections, hairiness, tensile properties and classimat faults of D-slot
carded compact yarn (DCY) of the Shankar 6 cotton variety. Three different twist factors have been selected and the results
are compared with regular carded compact yarn (RCY) and regular carded ring yarn (RRY). The results show that the
mechanical properties of D-slot carded compact yarn are far better than those of the regular carded compact and ring yarns.
Thin places and hairiness of the D-slot carded compact yarn are found to be lower than those of other two yarns. The
elongation percentage and tenacity of DCY are higher than those of RRY and RCY at all the twist levels. Short thick faults
of DCY are lower than those of RRY and RCY at all twist levels. However, there is no significant difference in long thick
faults and long thin faults at all twist levels.

Keywords: D-slot carded compact yarn, Elongation, Long thick faults, Long thin faults, Regular carded compact yarn,
Regular carded ring yarn, Short thick faults, Tenacity, Yarn hairiness, Yarn imperfections

1 Introduction combed roving without spinning triangle, is one of the

Compact spinning is a modification in regular ring
spinning process which has special advantages, and
can be used for short, medium and long-staple fibre
spinning. Many research works have been carried out
in this area. The compact yarn has better fibre
arrangements in the yarn structure with minimum pe-
ripheral fibres and a better twist distribution1-6. In an
interesting finding7, the author has critically analyzed
the yarn similarities, structural differences and
mechanical properties of both regular ring and
compact yarns produced using medium staple fibres.
Compact spinning technique has been used for the
long fibres also. The study by Çelik and Kadoglu8 on
100% wool, 45:55 wool/polyester, 50:50 wool/acrylic
and 100% acrylic yarns shows in detail their
properties and applications. Many attempts have been
made to study short, medium and long fibres. 100%
cotton short staple fibres have been used in combed
compact spinning system, whereas little R&D work
has been carried out on carded compact yarn9, 10.
Normally, combed roving is used in regular
compacting technique, whereas compacting of carded
roving, which has more short fibres as compared to
_______________________
a
To whom all the correspondence should be adderssed.
E-mail: trampsgtech@gmail.com
interesting phenomena. In carded compact yarn
formation, fibres are uniformly oriented and
compacted into the yarn axis at the delivery point of
the drafting system, and hence the carded compact
yarn can ensure better tenacity, elongation and
hairiness properties than regular ring carded yarns.
These are the essential characteristics for the better
working performance in the subsequent process.
Classimat faults analysis is one of the important
aspects not only to assess the yarn faults but also to
identify the places where faults are produced. Hence,
all the spinners are utilizing this fault analysis to run
the machineries of the plant at better performance
level.
In compact spinning system, the improved fibre
integration, lower end breakage and reduced fluff are
some of the factors to produce high quality yarn in
respect of hairiness, evenness and tensile properties.
So far, no attempt has been made to analyze the
classimat faults even in combed compact yarns. To
identify the fault introducing spot either in compact
yarn or in regular yarn, classimat fault analysis gives
better solution.
In Suessen conventional compacting system, the
compact is achieved by fibre transport through the
perforated lattice and air drawn through inclined slots
226 INDIAN J. FIBRE TEXT. RES., SEPTEMBER 2009

of the suction tube11. Recently, Suessen introduced a compact system12 has been used (Fig. 2). Figures 1
novel concept of D-slot, which is specially designed and 2 clearly indicate that the Suessen D-slot has
for the carded compact yarn12. An attempt has been more slot length than conventional slot. In addition to
made in this study to analyze and compare the that, Suessen D-slot has delta shape at the entry point
mechanical properties and the classimat faults of which helps the shorter fibres to compact in a better
regular ring yarn, regular compact yarns and D-slot manner, which results in better utilization of short
compact yarns at three different twist levels. fibre.
The yarn testing equipments, such as Uster
2 Materials and Methods evenness tester 4 with hairiness module, Uster
Carded 40s Ne yarn was produced using three tensorapid 3 and classimat tester II, were used for
different spinning systems, viz. conventional ring testing the various properties of yarn samples
spinning system, Suessen conventional compact produced from three different spinning systems. Prior
spinning system and Suessen D-slot compact spinning to testing, samples were conditioned for 48 h under
system. Three different twist levels (3.8, 4.2 and 4.6) standard atmospheric conditions of 27o±2oC and
were selected and yarns of the Shankar 6 Indian 65±2% relative humidity. The yarn characteristics,
cotton variety were prepared. The properties of cotton such as yarn mass CV%, thin places, thick places,
fibres (Table 1) were measured using high volume neps, yarn hairiness, breaking tenacity, breaking
instruments (HVI) and advanced fibre information elongation and work-to-break, have been measured
system (AFIS). It is a well-known fact that the fibre using the standard testing procedures. Figure 3 shows
characteristics are having direct influences on that the yarn faults, measured using Uster classimat
mechanical properties and faults of the yarn. Hence,
the same raw materials with the mentioned
characteristics were used to produce yarns in all the
three different spinning systems.
2.1 Yarn Production Methods
Shankar 6 cotton was processed in blow room
followed by carding. The sliver hank of 0.14 Ne was
produced in carding and processed in breaker and
finisher draw frames. The roving hank of 1.61 Ne
bobbins was produced in simplex machine. Regular
ring yarn, regular compact yarn and D-slot compact
yarns of 40s Ne count have been produced at three
different twist levels (3.8, 4.2 and 4.6). To produce
regular compact yarns, Suessen conventional slot
compact system11 has been used (Fig. 1) and to
produce D-slot compact yarns Suessen D-slot Fig. 1—Suessen’s conventional slot

Table 1–Main fibre properties

Fibre properties Min. Max. Avg
AFIS system
Short fibre content by number, % 19.2 35.4 25.8
Mean length by weight, mm 20.5 26.5 23.5
Upper quartile length weighing, mm 24.2 31.2 27.5
Maturity ratio 0.81 0.93 0.84
Seed coat neps/g 65 95 72
HVI system
Micronaire 3.4 4.2 3.8
Upper half mean length, mm 24.2 31.0 26.8
Length uniformity, % 72.1 82.1 75.2
Strength, g/tex 25.2 28.9 26.7
Elongation, % 4.5 8.2 6.5 Fig. 2—Suessen’s D-Slot
 LOGANATHAN et al.: D-SLOT CARDED COMPACT YARN 227

tester II, can be classified into 23 types based on their combinations, viz RRY vs RCY, RRY vs DCY and
fault length and size. Yarn faults are grouped into RCY vs DCY.
short thick fault (A, B, C, D), long thick faults (E, F,
3.1 Yarn Imperfections
G) and long thin fault (H, I).
From Table 2, it can be observed that there is no
3 Results and Discussion significant difference in yarn mass CV% for the RCY
Three different types of yarns, viz. regular ring and RRY, whereas DCY has significant difference in
yarn (RRY), regular compact yarn (RCY) and D-slot the value at 4.2 and 4.6 twist levels and thus shows
compact yarn (DCY), were produced at different twist improvement of 7% and 10% respectively when
levels of 3.8, 4.2 and 4.6. The yarn characteristics and compared to RRY. Similarly, there is a significant
yarn faults along with their significant test results are improvement of 4 - 6 % in the mass CV% at all twist
given in Tables 2-4. The statistical analysis using F levels of DCY in comparison to RCY. As compared
and T test has been carried out for three different to RRY, RCY has significant difference in thin places
at 4.6 twist level, showing about 12% reduction in
thin place. As compared to RRY, DCY also has
significant difference in thin places, showing about
30% and 37% reduction at 4.2 and 4.6 twist levels
respectively. Similarly, as compared to RCY, DCY
shows a significant reduction of 27 % and 28% in thin
places at 4.2 and 4.6 twist levels respectively. The
major reduction in yarn thin places and yarn mass
CV% of DCY is due to the effective short fibre
control using larger slot area and delta shape at entry
point to the end point of the D-slot compact system.
In addition to the above, the short fibres are forced
towards the center of the yarn axis. As compared to
RRY, RCY has no significant difference in yarn thick
places, whereas DCY has significant reduction of 5%
and 4% in thick places at 4.2 and 4.6 twist levels
respectively when compared to RRY. As compared to
RCY, DCY has no significant differences as far as
Fig. 3—Classimat - II yarn fault classification thick places are concerned. As far as nep level is
Table 2–Yarn mass CV%, thin places, thick places and neps and their significant test results
Quality RRY RCY DCY
parameter 3.8a 4.2a 4.6a 3.8a 4.2a 4.6a 3.8a 4.2a 4.6a
CV% of yarn mass 17.8 17.4 17.9 17.2 16.8 17.1 16.4 16.2 16.1
F – test (RRY vs RCY & RRY vs DCY) ns ns ns ns s s
F –test (RCY vs DCY) s s s
Thin places / 1000m 425 410 402 415 394 352 345 287 254
(-50%)
T – test (RRY vs RCY & RRY vs DCY) ns ns s ns s s
T – test (RCY vs DCY) ns s s
Thick places / 1000m 951 925 906 915 915 910 894 876 874
(+50%)
T – test (RRY vs RCY & RRY vs DCY) ns ns ns ns s s
T – test (RCY vs DCY) ns ns ns
Neps / 1000m 1212 1098 1154 1024 1078 1098 1024 1041 1087
(+200%)
T – test (RRY vs RCY & RRY vs DCY) s ns ns ns ns ns
T – test (RCY vs DCY) ns ns ns
a
Twist factor.
ns— not significant, s—significant.
228 INDIAN J. FIBRE TEXT. RES., SEPTEMBER 2009

concerned, there is no specific trend noticed in three is a significant improvement of 4% in work-to-break

spinning systems at all twist levels.
3.2 Hairiness
It can be observed from the Table 3 that there is
significant reductions (7-9%) of hairiness in DCY at
all twist levels, whereas in RCY 6% and 5%
significant reduction is observed at 3.8 and 4.2 twist
levels respectively when compared to RRY. As far as
DCY is concerned, there is a significant reduction of
2% and 3% in yarn hairiness at 4.2 and 4.6 twist
levels respectively when compared to RCY. It is also
observed that there is a reduction in hairiness at
higher twist levels.
3.3 Tensile Properties
Table 3 shows that there are significant
improvements (11-14%) in elongation of DCY at all
twist levels, whereas in RCY a significant
improvement (9%) in elongation is observed at 4.2
twist level when compared to RRY. As far as DCY is
concerned, there is a significant improvement of 6 %
in yarn elongation at 4.2 and 4.6 twist levels as
compared to RCY. As far as yarn breaking tenacity is
concerned, there is significant increase (8%) in
tenacity for DCY at all twist levels when compared to
RRY. Similarly in RCY, 5 - 6% increase in tenacity is
observed at all twist levels when compared to RRY.
As far as DCY is concerned, there is a significant
increase of 3% in yarn tenacity at 4.6 twist level when
compared to RCY. Further, it can be observed that
there is a significant improvement of 20-30% at all
twist levels in work- to-break in DCY when compared
to RRY. In RCY there is no significant improvement
in the work-to-break value at all twist levels when
compared to RRY. As far as DCY is concerned, there
at 4.6 twist level when compared to RCY.
3.4 Classimat Faults
Table 4 shows that there is a significant reduction
in short thick faults of DCY when compared to RRY.
However, in comparison to RRY, RCY shows no
significant difference as far as short thick faults are
concerned. It is also observed that DCY and RCY
have no significant reduction in long thin and long
thick faults when compared to RRY. Further, it is also
observed that in case of A - Fault, DCY shows 9 -13
% reduction at all twist levels when compared to
RRY, whereas RCY shows a significant reduction of
11% at 4.2 twist level when compared to RRY. As far
as DCY is concerned, there is a significant reduction
of 3% at 4.6 twist level when compared to RCY.
As far as B Fault is concerned, DCY shows 28-32
% reduction at all twist levels, whereas in RCY there
is no significant reduction at all twist levels when
compared to RRY. As far as DCY is concerned, there
is a significant reduction of 14–23 % at all twist levels
when compared to RCY.
It is also observed that in case of C - Fault, DCY
has 37-40% reduction at all twist levels when
compared to RRY, whereas in RCY a significant
reduction of 12% is observed at 4.6 twist level when
compared to RRY. As far as DCY is concerned, there
is a significant reduction of 28% and 24% at 4.2 and
4.6 twist levels respectively when compared to RCY.
It is also observed that D-slot DCY has 28 - 34%
reduction at all twist levels when compared to RRY,
whereas in RCY, a significant reduction of 22% and
20% is observed at 4.2 and 4.6 twist levels respectively
when compared to RRY. As far as DCY is concerned,

Table 3–Hairiness, elongation, tenacity and work-to-break, and their significant test results
Quality RRY RCY DCY
parameter 3.8 4.2 4.6 3.8 4.2 4.6 3.8 4.2 4.6
Hairiness 6.04 5.82 5.66 5.69 5.53 5.41 5.47 5.4 5.26
(Uster), H T – test (RRY vs RCY & RRY vs DCY) s s ns s s s
T – test (RCY vs DCY) ns s s
Breaking 14.5 14.9 15.2 15.2 15.7 15.9 15.7 16.1 16.4
tenacity, cN/tex T – test (RRY vs RCY & RRY vs DCY) s s s s s s
T – test (RCY vs DCY) ns ns s
Breaking 5.62 5.76 5.95 6.05 6.27 6.38 6.24 6.58 6.78
elongation, % T – test (RRY vs RCY & RRY vs DCY) ns s ns s s s
T – test (RCY vs DCY) ns s s
Work-to-break 405.4 415.8 452.9 478.5 495.2 521.2 527.6 538.2 541.9
cNcm T – test (RRY vs RCY & RRY vs DCY) ns ns ns s s s
T – test (RCY vs DCY) ns ns s
 LOGANATHAN et al.: D-SLOT CARDED COMPACT YARN 229

Table 4–Classimat faults (non-cleared) and their significant test results (each class per 100 km)

Fault type RRY RCY DCY

3.8 4.2 4.6 3.8 4.2 4.6 3.8 4.2 4.6
A1+A2+ 5782.5 5798.2 5482.1 5155.4 5172.5 5150.7 5010.5 5039.2 5003.2
A3+A4 T – test (RRY vs RCY & RRY vs DCY) ns s ns s s s
T – test (RCY vs DCY) ns ns s
B1+B2+ 778.48 782.2 767.62 643.88 648.62 674.02 554.04 539.4 520.4
B3+B4 T – test (RRY vs RCY & RRY vs DCY) s ns ns s s s
T – test (RCY vs DCY) s s s
C1+C2+ 130.98 118.26 120.6 97.98 98.39 96.38 78.86 74.02 73.58
C3+C4 T – test (RRY vs RCY & RRY vs DCY) ns ns s s s s
T – test (RCY vs DCY) ns s s
D1+D2+ 8.18 9.02 8.14 6.78 7.04 6.32 5.86 5.92 5.46
D3+D4 T – test (RRY vs RCY & RRY vs DCY) ns s s s s s
T – test (RCY vs DCY) s s s
E 5.42 5.72 6.32 5.74 5.82 6.9 5.86 5.92 6.22
T – test (RRY vs RCY & RRY vs DCY) ns ns ns ns ns ns
T – test (RCY vs DCY) ns ns ns
F 45.44 46.22 45.7 45.76 46.8 46.12 47.58 47.7 46.28
T – test (RRY vs RCY & RRY vs DCY) ns ns ns ns ns ns
T – test (RCY vs DCY) ns ns ns
G 6.12 5.68 5.82 6.38 6.14 5.82 6.16 6.44 6.46
T – test (RRY vs RCY & RRY vs DCY) ns ns ns ns ns ns
T – test (RCY vs DCY) ns ns ns
H1 + H2 228.8 229.7 216.6 229.2 215.9 216.2 195.4 192.5 187.9
T – test (RRY vs RCY & RRY vs DCY) ns ns ns ns ns ns
T – test (RCY vs DCY) ns ns ns
I1 + I2 3.64 3.9 3.42 3.58 3.6 3.82 3.72 3.8 3.8
T – test (RRY vs RCY & RRY vs DCY) ns ns ns ns ns ns
T – test (RCY vs DCY) ns ns ns

there is a significant reduction of 14 – 16 % at all twist
levels when compared to RCY. However, DCY shows
an improvement in yarn characteristics, such as
hairiness, tensile properties and short thick fault, which
are due to the following technical reasons:
• All the short fibres in fibre strand are condensed
properly and bundled effectively at the condensing
zone without any fly in the case of D-slot compact
system.
• Another important reason is that the delta shaped
entry in D-slot ensures better compactness when
compared to other two systems.
• Moreover, D-slot angle and slot width ensure better
suction and compactness.
• The D-slot has better control on edge fibres due to
higher suction slit area and delta shape at entry level
of the compacting zone.
• The bundling effect in D-slot compact system is
better due to diagonal positioning of the guiding
edge.
4 Conclusions
There is an improvement in D-slot compact yarn
with respect to yarn mass CV%, thin places, hairiness,
tensile properties and short thick faults as compared
to regular ring yarn and regular compact yarn for 40s
Ne carded cotton yarn only. No significant difference
is observed in long thick and long thin faults in DCY
when compared to RRY and RCY. These findings are
applicable only for 40s carded cotton yarns. Further
work needs to be done for more counts of yarn at 3
different twist levels on the ring, regular compact and
D-compact systems.
Industrial Importance: This research work is useful
for the 40s Ne carded compact yarn manufactures.
Using the D-slot compacting system, improved
quality parameters such as short thick faults, yarn
230 INDIAN J. FIBRE TEXT. RES., SEPTEMBER 2009
mass CV%, thin places, hairiness and tensile
properties can be achieved.
Acknowledgement
The authors are thankful to the General Manager of
Arun Textile Mills, Gobi-Chetipalayam and to the
Chief Technical Officer of Lakshmi Mills,
Coimbatore, India for their valuable help in the
production of regular carded ring-spun and regular
carded compact-spun yarns and D-slot carded
compact yarns.
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