How to Produce Recycled Fiber Blend Cored Yarn?
In this paper, we successfully developed 36.9 tex recycled antibacterial, moisture-absorbing and abrasion-resistant faux hemp cored yarn using recycled fibers, of which the ratio of the outer short fiber Refibra/recycled cotton/recycled flax/recycled nylon blend is 51/22/15/12 and the core yarn is 44.4 dtex polyester filament. Due to the large proportion of short fibers below 16 mm of recycled cotton and recycled flax, the formation of floating fibers in the drafting process is not easily controlled effectively, and into bundles of variable speed, making the spun yarn has more small bamboo nodes, the woven denim has the effect of imitation hemp particles.
At present, the relevant literature mainly focuses on the source of recycled fibers and recycling methods and other aspects of research and elaboration, the production of various types of recycled fiber pure spinning yarn and blended yarn has been reported, but the environmental protection recycling recycled fiber blended cored yarn is less reported.
This study focuses on the methods to improve the spinnability of various types of recycled fibers, summarizes the effective measures to improve the production efficiency of the whole process, such as reducing the breakage of spun yarn, developing the production process of recycled fiber blended imitation hemp cored yarn and the process parameters of each process, so as to provide reference for the production of such recycled environmental protection fibers.
Table of Contents
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KINGEAGLE is a Top Core Spun Yarn Manufacturer from China.KINGEAGLE is a top brand in the yarn industry and has become the top Top Core Spun Yarn manufacturer in India, Pakistan, Egypt, Peru, Mexico, Argentina, Bangladesh, Thailand, Indonesia and other countries with its high quality yarn products. Many Core Spun Yarn brands from these countries source their yarn products from KINGEAGLE.
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What are the raw material characteristics of cored spinning yarn?
Refibra is a recycled lyocell fiber produced by using post-consumer waste as part of the recycled raw material, which has good permeability and is biochemically degradable. Its main performance index: fineness 1.70 dtex, length 38.0 mm, dry breaking strength 3.50 cN/dtex, wet breaking strength 2.70 cN/dtex, dry breaking elongation 13%, wet breaking elongation 16%, moisture recovery 11.5%. Compared with conventional Lyser fiber, Refibra’s dry and wet breaking strengths are slightly lower, and other performance indicators are not much different, so the spinning process can be referred to Lyser fiber.
Recycled cotton is made from waste cotton, industrial offcuts, textile companies’ cloth and yarn head recycling and reprocessing. Its main performance indicators: the cloning value of 4.6, maturity 0.89, the upper half of the average length of 21.5 mm, neatness 70%, fiber breaking strength of 2.32 cN / dtex, short fiber index 70.1%, elongation 3.5%, reflectivity 77.5%, moisture recovery rate of 8.2%. Regenerated cotton fiber length is short, high staple, poor neatness, poor spinnability.
Regenerated flax is made of various types of linen threads, back to the silk and other processed fibers. Its main performance index: average length 23.5 mm, breaking strength 6.10 cN/dtex, staple rate below 16 mm 37.5%, splitting degree 3 300 Nm, rewinding rate 11.7%, merging rate 3.1%, thread content 69.2 mg/100 g. Regenerated flax has short length, high staple, high merging rate, high thread content and poor spinnability. The recycled nylon is an environmentally friendly recycled nylon developed by Suzhou Youfu Textile Co.
Its main performance index: fineness 1.56 dtex, length 38 mm, breaking strength 5.60 cN/dtex, elongation at break 55%, body length 38.1 mm, volume specific resistance 5.2×108Ω-cm, curl number 8/25 mm, defect content 7.8 mg/100 g, oil content 0.23%, moisture return rate 2.3%. It can be seen that the defect content of recycled nylon is obviously very high, which is 13 times higher than that of ordinary nylon (0.6 mg/100 g), and the curl number is also higher, thus increasing the difficulty of spinning.
What is the ratio of cored yarn blending?
Blending ratio is determined: one is to ensure the spinnability, to ensure the roll, into a smooth; the second is the organic combination of Refibra fiber biodegradable properties, recycled cotton recyclability, recycled linen fiber excellent antibacterial anti-static properties and recycled nylon high strength wear resistance and high elongation properties, making full use of the performance of each component fiber, so as to achieve the goal of regeneration and environmental protection.
Due to the poor spinnability of recycled cotton and recycled linen, into rolls, into a more difficult, the use of disc blending plus strip blending method, can ensure that the composition of the ratio is accurate. Specific production method: first Refi⁃bra fiber and recycled nylon according to 50/50 ratio of package mix, after the combing process to make Refibra recycled nylon blended raw; at the same time, Refibra fiber, recycled cotton and recycled flax according to 50/30/20 ratio of package mix, after the combing process to make Refibra recycled cotton recycled flax blended raw, and then after a Pre-combination; then the above-mentioned blended raw and pre-combined strips are blended through the blending process, and finally made to meet the requirements of the blended ratio of cooked strips.
How to produce recycled cored spun yarn?
Cotton cleaning process
According to the characteristics of the fiber, the raw material is pretreated before production. refibra fiber raw material into the workshop first test the moisture recovery rate, control at 10.5% or more, and then open a small hole in the side of the bale, add 4 kg ~ 8 kg of water in each bale of raw materials, balance 24 h ~ 48 h, test the moisture recovery rate control at 11% ~ 13% before the plate.
Regenerated flax raw materials into the workshop first test moisture recovery rate, control at 14% or less, need to use the steamer to steam raw materials, the specific steam method for the first release of steam for 20 min, stew 2 h and then release steam for 20 min, and then stew 3 h. Regenerated cotton in the grading room moisture absorption balance 24 h ~ 48 h after the plate.
When the volume specific resistance is greater than 1×108Ω-cm, a mixture of 3% water and 5% antistatic agent is used to make a spray humidifying solution, and the mixture is evenly sprayed on the raw material and balanced for 24 h before it is put on the plate.
Refibra fiber and recycled nylon package mix, due to the high content of recycled nylon defects, defects can not be completely removed, after the impurity separator, the rate of removal of defects in about 90%. refibra recycled nylon blended volume moisture rate control at 8.0% ~ 9.0%, moisture rate is too high and too low are not suitable for production. refibra recycled nylon blended volume weight 410 g / m. Weight unevenness is controlled within 1.2%, elongation is controlled at -3.0%~-2.0%.
Refibra fiber and recycled cotton, recycled flax package blend, due to the high thread content of recycled flax raw materials, more thread, cotton cleaning process need to be pre-opening once, pre-opening after the cotton rate control within 3.0%, after treatment of thread content 8.7 mg/100 g.
The quality of opening must be paid attention to when the regenerated flax is pre-opened, and the raw material is easy to cause the increase of yarn defects when it is not opened properly. Pre-opening of recycled flax and recycled cotton, Refibra fiber package mix, because of recycled flax and recycled cotton fiber length is short, making the cotton volume thickness is not uniform, the weight is not uniform rate. Strictly according to the plate chart on the plate, the flat plate must do to cut high filling, the upper and lower left and right raw materials consistent, trolley operation efficiency control at 85% or more. For the problem of uneven weight of cotton rolls, the following measures are mainly taken.
(1) must ensure that the A002 type cotton grasping machine to open the cotton block as small as possible, the blade out of the rib distance is small control, to do less grasping fast run.
(2) FA035 type cotton mixer pressure curtain and corner nail curtain separation distance between 20 mm ~ 30 mm small control, to ensure that the cotton block is small. To improve the operation efficiency of FA106 type cotton opener, the position of the photoelectric tube can be appropriately raised to ensure a certain amount of cotton feast in the cotton box; add frequency converter for the cotton roller, as far as possible to adjust the small cotton, to ensure that the opening and loosening more uniform.
(3) to ensure that the A046 cotton machine to give uniform cotton, one is to ensure that the middle of the cotton box in the upper right corner of the observation window there is no cotton space, so as to ensure that the cotton box in the cotton block turn over evenly, cotton flow more uniform; secondly, the amount of cotton vibration box should not be too much, accounting for 2/3 of the observation window can be; thirdly, to ensure that the A046 cotton machine can better adjust the three cotton boxes and balance leveling mechanism, making a cotton box than a cotton box more (4) ensure the constant amount of fiber by leveling balance Lola; (5) use the leveling instrument reasonably and set the parameters of quality and thickness well.
Ensure the air volume of A076F roll forming machine, no accidental drafting, and increase the roller pressure appropriately. Must drive after the unqualified cotton roll back to the plate. Add 6 cotton roving isolation to prevent sticky rolls when playing rolls. After the roll is sealed with plastic cloth, put it into humidification shed to moisturize. In order to ensure the rate of production, back to the flower, car belly are used back to the plate, and to ensure that between the plate and the plate back to the flower, car belly use a stable proportion of the same.
Carding process
Refibra and recycled nylon blend, in the carding process spinnability is poor, manifested in carding drop net, tangle pressure roller, fiber loose holding force is poor.
Measures for this problem: production in the shed, relative humidity control at 65% ~ 75%, when the relative humidity is small open micro humidifier humidification; the tin Lin speed reduced to 330 r/min, Dawei speed reduced to 18 r/min.
Adjust the card tension gear, the cotton net tension draft bias control, adjusted to 1.085 times; appropriate to increase the raw ration to improve spinnability, raw ration from 21 g/5 m to 23 g/5 m. Through the above measures, carding drop net phenomenon significantly improved.
Increase the car belly drop, can remove most of the cotton roll in the hard silk, and silk, but there are still a small amount into the carding area, the doffer needle cloth has the phenomenon of embedded flowers. Replace the cover pulley diameter from 315 mm to 260 mm, can ensure good combing, minimize the number of cotton knots, the number of cotton knots is not higher than 2 / g, combing degree is high master. Other main process parameters: barbed roller and cotton feed plate separation distance 0.30 mm, sillin and barbed roller separation distance 0.13 mm, sillin and doffer separation distance 0.13 mm, cover plate and sillin separation distance 0.18 mm, 0.18 mm, 0.18 mm, 0.18 mm, 0.18 mm, 0.18 mm, barbed roller speed 770 r / min, cover plate speed 98 r / min.
Refibra and recycled cotton, recycled flax blending, carding process production break more. Measures for this problem: production in the shed, relative humidity control at 55% ~ 65%, relative humidity hours open micro humidifier humidification, cotton rolls now made, not too much storage to prevent moisture dissipation. The raw strip weight is as large as possible, not less than 27 g/5 m.
Main process parameters: Separation distance between stinging roll and cotton feeding board 0.30 mm, separation distance between sillin and stinging roll 0.13 mm, separation distance between sillin and doffer 0.13 mm, dust removal knife height 3, angle 90°, separation distance between dust removal knife and stinging roll 1.45 mm, separation distance from cover to sillin: 0.23 mm, 0.20 mm, 0.18 mm, 0.18 mm, 0.20 mm. main process parameters: sillin Speed 360 r/min, barbed roll speed 1,070 r/min, cover plate speed 82 r/min, raw bar weight 27 g/5 m, daugher speed 18 r/min.
In order to reduce yarn defects, the carding process focuses on checking the size of the bottom of the leakage, dust knife, dawe and other hanging flowers, suction pipe off, plugging, and the problem of short lint can not be taken away in time to be brought into the cotton net. Not timely clean up the doffer flower, needle cloth damage, cotton net fallen net, car belly fallen cotton, etc., will cause insufficient airflow, to the cotton roller winding short lint.
Slitting process
Due to the re-flowering of the rubber rolls in the parallel process, the surface of the rubber rolls is treated with nylon 6 coating, and the production is arranged in the shed to ensure that the temperature is above 23℃ and the relative humidity is 65%~70% in advance, and the micro humidifier is used to humidify when necessary, or the ground is improved by sprinkling hot water; the parallel speed should not be too high, and it is reduced from 320 m/min to 278 m/min to ensure the smooth production of the parallel.
Refibra regenerated cotton regenerated linen blended raw weight uneven rate is large, for this situation, need to go through a pre-combination, so that the carding raw strip mixed evenly, and then according to the proportion after three parallel production. The focus of the parallel process is to check the lint cleanliness, roller roller sticky tangle, pressure bar hanging flower, dust accumulation, flare flower accumulation.
Roving process
For the problem of high short fiber content of regenerated cotton and regenerated flax and poor holding power of roving, the twist factor of roving is grasped by a large margin.
The short fiber content is high and the fiber is not easy to be controlled, so it is easy to form roving defects, so the distance between the front area is tightly controlled. Roving process focus on checking the poor cleaning of the pile, such as the flare, collector flower, pressure palm hanging flower, spindle wing top hole flower, etc. Main process parameters: roving weight 8.0 g/10 m, twist factor 141, twist rate 5.0 twist/10 cm, roller spacing 11 mm×25 mm×25 mm, jaw spacing 6.0 mm, collector 10 mm, front roller speed 190 r/min, roller hardness Shore A 75 degree.
Spinning process
When producing conventional ring-spun Refibra/recycled cotton/recycled linen/nylon 51/22/15/12 36.9 tex, there were problems such as poor dryness, many broken ends of the yarn, broken ends of the flute not absorbing the broken ends and hanging flowers of the wire ring.
So add a 44.4 dtex polyester filament yarn to produce cored yarn. add a hanging spindle type cored yarn device on the ring spinning machine, filament hanging spindle type device modification: fine yarn need to add roving frame, rewind the filament to the roving tube and place it on the roving hanging spindle, the filament of this device is passive rewind way. The tension device is of the double tension disc passive type, with the filament passing through two tension discs. After leading the filament from the barrel, it passes through the upper guide bar, upper tension disc, lower guide bar, lower tension disc, and finally is fed into the front jaw through the guide roller and then placed in the center-left wrapped yarn body of the roving whisker to reduce spinning breakage by the filament strength.
Although cored yarn strength mainly depends on the outer covering fiber, cored yarn with the content of filament increases, the lower the strength of cored yarn, but after adding filament, the dynamic strength of the yarn increases, the strength of the weak ring is less, if there is a sudden change in tension, there is the role of filament elasticity, can avoid the problem of brittle breakage, also to a certain extent to reduce the yarn breakage. In addition, there is a need to further solve the problem of more yarn breakage and yarn defects from the following aspects.
Measures to reduce spinning head breakage
(1) Daily inspection and maintenance by a person responsible for maintaining good equipment condition to ensure smooth tension.
(2) This variety of high staple content, the car file flying flowers, steel collar plate around the accumulation of flowers, the original old wire ring cleaner can not effectively remove the hanging flowers on the wire ring in a timely manner, replaced with a new serrated wire ring cleaner, the hanging flowers on the wire ring easy to clean, lengthening the use of the wire ring cycle at the same time, the yarn driving head breakage is also significantly reduced.
(3) Preferred steel collar, wire ring model, using thin bow type wire ring, wire ring specifications from 6903 1 # to TPJM1EMgc 1 #, wire ring cycle from 4 days to 7 days, steel collar model from PG14554 to PG1 4254, reduce spinning tension, reduce head breakage.
(4) Analyze the distribution of yarn breakage in one drop, optimize the nine-stage variable frequency speed setting to ensure that the variable speed process is as smooth as possible and the speed curve is smooth. If there are many big yarn breaks, make sure the speed of big yarn is reduced, as well as the length of the ninth section speed L9 is equal to the panel set length, so that the spinning yarn will automatically drop when it reaches the set length.
(5) After the yarn drop, most of the spinning sections have twisting, which is easy to break the head after driving. For this reason, the blowing and sucking device is turned off when the yarn is dropped and turned on again after driving. Because the steel collar plate rises first during the raw head period and falls after driving, in order to make the braid yarn at the twist fast, it is necessary to speed up the starting speed, increase the value of low-speed starting frequency, the position of the rising steel collar plate and the speed of the falling steel collar plate when driving, one is to ensure that the air ring is opened, and the twist triangle is twisted in time, and the second is that the instantaneous spindle speed cannot be too high, otherwise the tension is too large and the yarn is easy to break the head.
(6) Do a good job of temperature and humidity management, with temperature control at 25℃~33℃ and relative humidity control at 55%~65%. Otherwise, there will be more flying flowers due to small relative humidity, which will easily produce static electricity and tangle the roller, and then cause head breakage.
(7) After yarn breakage, it is easy to block the flute tube, and the flying flowers are easy to float into the neighboring spindle to cause breakage. It is necessary to remove the flute tube for cleaning, using warm water with detergent, soak it for 1 h first, then brush it inside, and polish it timely with burrs. After reloading the machine, the problem of easy blocking of the tube after the head break is effectively solved. Therefore, the cleaning cycle is set at 3 months.
How to reduce yarn defects?
(1) Reduce yarn defects caused by flying flowers. Focus on checking the flock roll flower, flare mouth flower, flute pipe suction mouth flower and rubber roll tangle flower, increase the number of times the machine is cleaned, especially the drafting area and the steel collar plate, and adjust the position of the blowing and suction air to reduce the fly into the yarn defects. After adding filament, the twisting triangle is smaller than the conventional ring spinning, fiber loss is reduced, the dryness is more uniform, which in turn reduces the number of yarn defects.
(2) Analysis of the yarn defect data using the Lofty Yarn Defects function shows that all of the defects are irregular, poorly dried, with large differences between spindles, the calculated drafting efficiency is 93.5%, which is small, and the elastic jaws do not have enough control over the whiskers, and there is a slippery phenomenon.
There is insufficient control of fibers by individual spindle, or insufficient control of fibers by the same spindle at different times. Solutions: Stop the fluctuation of the pressure of the shaking frame; replace the deformed upper pin frame spring in time; clean the accumulated flowers in the rubber ring in time and make sure the size of the floating area is the same; make sure that the pressure of the upper pin frame is not enough, otherwise it is easy to make the rubber ring run off, so that the upper and lower rubber rings cannot be close to each other and slippage occurs.
(3) for the workshop airflow disorder, can increase the suction air outlet, and adjust the air conditioning outlet, so that its air volume is not too large. The machine blowing wind should be softer, can blow away the machine surface flowers. Can not blow away the accumulated flowers by the cleaners to deal with in a timely manner, and increase the number of times to clean. Adjust the position of the blowing and sucking air to reduce the attachment of dirty flowers and flying flowers.
What is the key process of Core-spun yarn production?
In the spinning process of core yarn, first of all, the control of filament unwinding tension is especially critical. In order to ensure that the core tension value is slightly higher than the tension of the short fibers when the core yarn is twisted with the short fibers in the twisting triangle, the core yarn should have enough tension to keep its position during the yarn formation to ensure the covering effect, but at the same time, in order to reduce the loss of the outer covering fibers, the filament tension should be relatively small to ensure that the filament covering is uniform. Secondly, the yarn twist factor is controlled on the high side to ensure the yarn body is tight. After trial spinning, it is concluded that the tension control is reasonable at 15 cN~35 cN using Y2301 digital yarn tension meter, which is not easy to be pulled off, but also can ensure the tension and yarn structure requirements.
The main spinning parameters: roller spacing 18 mm×34 mm, roller hardness Shore A 65 degrees, jaw spacing 4.5 mm, front roller speed 210 r/min, design twist factor 430.
Testing of fiber content and yarn formation index
The fiber content of each component of the yarn was tested: Refibra fiber 53.0%, regenerated cotton 20.3%, regenerated linen 13.1%, regenerated nylon 12.5%, polyester 1.1%, which basically meet the design requirements. Due to the low content of regenerated linen and regenerated cotton measured in practice, these two fibers were increased by 2% of the input material during re-production. In normal production, the yarn content needs to be tested regularly, and according to the test results, the proportion of various fibers with cotton can be fine-tuned appropriately.
With the implementation of the above measures, yarn quality and head breakage at 1,000 spindles of fine yarn are significantly improved. The main quality indicators of the developed cored yarn are: breaking strength 12.9 cN/tex, strength CV 5.8%, bar length CV 14.7%, bar length CVb 2.8%, details 0/km, rough nodes 286/km, knots 278/km. The head breakage at 1,000 spindles can be controlled within 15.
Winding process
The main task of winding is to select the appropriate twister, twisting process and yarn clearing parameters [7]. According to the user’s requirements on yarn defects, the yarn clearing parameters are preferably selected to keep the required imitation hemp particles and to remove the over-distributed imitation hemp particles and large yarn defects. The electronic yarn clearer is analyzed daily for short and coarse knotted yarn faults, which are mostly caused by the accumulation of short pile, so the focus is on checking the short pile or disordered fiber masses attached to the yarn strips in each process to reduce short pile aggregation faults.
According to the customer’s usage, the number of 9 yarn faults in 100,000 meters is limited to 26. The quality of twist directly affects the number of breaks in the subsequent process, production efficiency and fabric quality, so the user focuses more on the requirements of twist strength.
Reduce the rate of twist failure, eliminate twist slip, low strength, long tail at both ends or long tail at one end. Slightly loose yarn clearing parameters to reduce knots. Control the knot length and tighten the electronic yarn clearer twist control parameters to ensure the knot quality. Pay attention to yarn surface cleanliness before inserting yarns and eliminate silk-free yarns. Strengthen the quality control of fine yarns with weak twist, color difference yarns, cylinder yarns, color difference yarns, etc
Conclusion
The use of four kinds of recycled fibers to develop antibacterial moisture-absorbing wear-resistant imitation hemp cored yarn, in order to improve the spinnability of each component of the recycled fibers, according to the performance characteristics of each fiber, respectively, for its pre-spinning pretreatment.
In order to ensure the blending ratio of blended yarn, the use of packet blending plus strip blending blending method, cotton clearing process of regenerated flax pre-opening once, which is conducive to reducing spun yarn breakage and yarn defects; on Refibra regenerated cotton regenerated flax blended volume of weight unevenness to attack, the effect is obvious.
Imitation hemp cored yarn spinning process, to solve the spinning yarn breakage is the key, through the analysis of the reasons for spinning yarn breakage, reduce the chemical fiber hard wire, regenerated flax thread, preferential steel collar wire ring type, wire ring cleaner, cleaning flute, reasonable control of temperature and humidity, and the spinning process using cored yarn production technology and other measures, so that spinning yarn breakage when a thousand spindles significantly reduced; spinning yarn filament rewinding tension The control of filament rewinding tension is particularly important, and it is reasonable to control it at 15 cN~35 cN, which is not easy to be pulled off, but also can ensure the tension and yarn structure requirements.
At the same time, by optimizing the main process parameters of each process, the yarn quality of Refibra/Recycled cotton/Recycled flax/Recycled nylon 51/22/15/12 36.9 tex (T 44.4 dtex) imitation hemp cored yarn is finally guaranteed to meet the user’s requirements. In the development process of environmental recycling recycled fiber blended cored yarn, all component fibers are made of recycled raw materials, and the measures taken in the production ensure the smooth production of recycled fiber blended cored yarn.