Nowadays, spinning industry is conscious about cost optimization which has diverted the industry policy from mass production to mass customization. So, it is necessary to invent modern production technique for superior yarn quality [1]. Yarn manufacturing is a long and difficult technological process that is thus expensive. Newspinning systems tend to curtail this process by combining machines in processing line or by eliminating some of the machines (Idzik [2]). The final scutcher is removed during the preliminary fiber processing step and the number of machines is decreased from several to a few. Currently, just 3 to 4 machines open and clean fiber prior to being constructed to transfer loose fiber mass from a container in a processing line with a carding machine. There are options that connect the carding machine directly to the drawing frame.

In fact, producing yarns directly from the sliver, there is nothing new in this concept. This concept has been around for well over a century. According to documents, a guy called Day patented a continuous technique in 1836 that amounted to producing yarn directly from sliver. Since then, various single-process techniques for generating high-quality yarns have been created [3]. Cotton yarns made straight from sliver have long been a dream of spinners all over the world [4]. Many countries’ researchers, as well as numerous industrial makers, have done this on occasion. The majority of the time, the advancements were set aside either the quality of yarn was not up to par or the procedure was not feasible or cost-effective. However, after World War II, there has been a resurgence in this thought and Japan has produced the first true practical use of this method for the yarn spinning. Specifically, super high draft spinning is an invention perfected by the O-M spinning machine firm in Osaka, Japan, around seven years ago. It essentially comprises two Casablanca systems working together [5]. Other than, the deletion of all roving frames result in cost savings, the process of spinning yarns directly from drawn sliver offers significant theoretical benefits such as floor space, power, maintenance, depreciation, work in progress inventory to consider [6]. Finisher drawn sliver denotes the most uniform strand in terms of quality (for both short-term and long-term variation) in the factory [5]. The roving frame doubles the short-term variation and indicates a change in drafting direction [8]. In reality, multiple recent pieces of research have demonstrated that while drafting is done in a similar direction, there is lower chance of generating variation. Although there were various pieces of research on the manufacturing process of ring spun yarn from roving, a few were performed on the effect of simplex machine’s absence on the yarn properties. In this study, an attempt has been made to produce ring spun cotton yarn directly from finisher drawn sliver. Therefore, the influence of the elimination of roving frame on yarn characteristics such as unevenness, imperfections, hairiness, tenacity was investigated & then compared to the traditional ring spun yarn which is usually made from roving mentioned in Table 1.

Investigation into the potential of directly feeding a ring frame machine with the drawn sliver and removing the roving frame in the technological process having already been carried out at the Faculty of Material Technologies and Textile Design’s Department of Spinning Technology and Yarn Construction. Quality parameters were found in the yarn that was obtained significantly comparable to those produced by a standard spinning method.

In summary, we see that yarn irregularity increases while producing yarn without using the roving frame. For example, unevenness value increased from 7.76% to 8.65% for 8 Ne. Similarly, U% increased from 8.52 to 9.00 for 10 Ne and 9.07 to 9.93 for 12 Ne. As high draft is required to produce yarn directly from the sliver, this irregularity causes. Moreover, more thin places, thick places & neps are also noticed in the produced yarn. Yarn hairiness also increased. For instance, hairiness increased from 7.1 to 7.5 for 8 Ne. Moreover, with the elimination of roving frame and greater assignments in the spinning, there are significant labor cost savings. Hence research can be carried out in the future on the influence of simplex machine’s absence on production cost of ring spun yarn.

This work was supported by Centre for Research & Industrial Relations-NITER.

This research did not receive any specific grant from funding agencies in the public, commercial or not for profit sectors.

The authors declare no conflicts of interest regarding the publication of this paper.

Islam, Md.I. Rahman, S. and Hoque, M.M.U. (2023) The Influence of Elimination of Roving Frame on Ring Spun Cotton Yarn Characteristics. World Journal of Engineering and Technology, 11, 10-19. https://doi.org/10.4236/wjet.2023.111002