Various Yarn Manufacturing Process

Core Spun Yarn Spinning Process

In our core-spun yarn factory, the production of core-spun yarn is divided into the following processes:

opening and cleaning→ carding→ drawing→ roving→ spinning→ post processing.

After this series of processes, the selected staple fiber will eventually become the finished core-spun yarn.

1 Opening and Cleaning Process

Opening and cleaning is the first process after the staple fiber enters the core spun yarn factory. In this process, the short fiber is made into a uniform fiber roll to create conditions for carding process. 

The main tasks of this process are:
(1) Opening: Through the tearing and blowing action of the brad nails, beaters in each individual machine of the cleaning and cleaning machine, the compressed block fibers in the fiber package are loosened into small fiber bundles weighing 0.3-0.5g, which are used for impurity removal and cleaning. Blending creates the conditions for separation into single fibers. Minimize debris fragmentation and fiber damage during opening.
(2) Impurity removal: at the same time of opening, removing 50% to 60% of impurities in raw cotton should reduce the fall of spinnable fibers and save fibers.
(3) Mixing: Mix all kinds of raw materials in proportion, the fibrils will be loosened well, and the mixing will be more uniform.
(4) Uniform roll: make a certain weight, a certain length and a uniform fiber roll for the next process.

2 Carding Process

After the opening and cleaning combined machine processing, the fibers in the fiber roll are mostly in the state of loose fiber blocks and fiber bundles, and contain 40% to 50% impurities, most of which are small and highly adhesive fibrous impurities. It is necessary to completely decompose the fiber bundle into single fibers, remove the small impurities remaining in it, make each component fiber fully mixed in the single fiber state, and make a uniform sliver to meet the requirements of the subsequent process of core spun yarn manufacturing.

The tasks of the carding process are:
(1) Carding: Under the premise of as little fiber damage as possible, the feeding fiber layer is carefully and thoroughly carded to separate the bundle fibers into single fibers.
(2) Impurity removal: On the basis of sufficient separation of fibers, thoroughly remove residual impurities and defects.
(3) Uniform mixing: the fibers are fully mixed and evenly distributed in the single fiber state.
(4) Card Sliver: Make the uniform card sliver of certain specifications and quality requirements and place it in the card sliver can regularly.

We use flat cards for this process in our core spun yarn factory, and some core yarn factories also use roller cards.

3 Drawing Process

The fiber material has been opened and carded before the process, and has been made into a continuous strip of semi-finished products, that is, sliver, but it cannot be directly spun into spun yarn, because the quality and structural state of the sliver are far from the final. There is still a big gap in the requirements for yarn formation, and the straightness and separation of the fibers are poor. For example, most of the fibers in the green sliver are still in a buckling or hooked state, and some small fiber bundles exist; while the combed sliver has better straightness of the fibers, but the evenness of the evenness is poor. If these slivers are directly spun through the roving, it will inevitably affect the quality of the final core spun yarn, so they must be processed by the drawing process first. This is an essential process for producing high-quality core spun yarns.

The tasks of the drawing process are:
(1) Merging: 6-8 fiber slivers are combined and fed into the drawing frame to make a fiber sliver. Since the thick and thin sections of each fiber sliver have the opportunity to overlap each other, the unevenness of the long segments of the sliver is improved. Rate. The weight unevenness of the raw sliver is about 4.0%, and the weight unevenness of the cooked sliver should be reduced to less than 1% after combining.
(2) Drafting: The sliver is stretched and thinned to the original level, and the state of the fibers is improved by drafting, so that the hooks and crimped fibers can be further straightened and paralleled, so that the small fiber bundles are further separated into single fibers. By changing the draft ratio, the ration of the sliver can be effectively controlled to ensure that the weight deviation and weight unevenness of the spun yarn meet the standards.
(3) Mixing: The mixing of single fibers is further realized by the method of repeated merging to ensure that the composition of the sliver is uniform and the yarn quality is stable. Due to the different dyeing properties of various fibers, the sliver made of different fibers can be combined on the drawing frame, so that various fibers can be fully mixed. An effective means of producing color difference, especially when chemical fiber and cotton are blended.
(4) Sliver formation: The fiber sliver made by the drawing frame is placed in a regular circle in the fiber sliver can for transportation and storage for the next process.

4 Roving Process

In the core-spun yarn factory, roving is the fourth process, and the sliver can be processed into rovings of different counts and twists for the spinning process.

The tasks of the roving process are:
(1) Drafting: The cooked slivers are evenly stretched and thinned, and the fibers are further straightened and paralleled.
(2) Twisting: appropriate twisting of the drafted sliver, so that the sliver has a certain strength, which is convenient for roving winding and unwinding on the spinning frame.

5 Spinning Process

Spinning is a very important process in spinning. It is to spin roving into spun yarn with certain properties, quality standards or customer requirements for twisting, weaving or knitting. The quality of the spun yarn reflects the production technology and management level of a core spun yarn factory.
The spinning process mainly completes the following tasks:
(1) Drafting: The fed roving is evenly stretched and thinned to the required number of spun yarns.
(2) Twisting: adding an appropriate twist to the drafted whiskers, so that the yarn has certain physical and mechanical properties such as strength, elasticity, luster and feel.
(3) Winding and forming: The spun yarn is wound on the bobbin according to certain forming requirements, so as to facilitate transportation, storage and subsequent processing.

After this process, the single-strand core-spun yarn is completed. However, in order to be used in the production of textiles, post-processing is also required.

6 Post Processing

Although the spinning of spinning machine has basically completed the spinning task, it does not mean the completion of the whole spinning project. In addition to the filling yarn directly from the spinning workshop to the weaving workshop, other varieties according to the processing requirements need to undergo appropriate post-processing. The yarn processing process after the spinning process is collectively referred to as the post-processing process, which mainly has the following four purposes:
(1) Improve the internal performance of products
(2) Improve the appearance quality of products
(3) Stabilize the structural state of the product
(4) Make the appropriate roll form

Content Source: https://www.saludstyle.com/yarn-factory/core-spun-yarn-factory/

Core Spun Yarn Dyeing Process

High quality core spun yarn requires that the manufacturer strictly follows color accuracy, moisture content and color fastness as key indicators of yarn quality. Color accuracy is the accuracy with which colors are reproduced on fabric. Moisture content is the amount of water present in the yarn, and color fastness is how well the colors stay on fabric after being washed.

Salud Style is a leading core spun yarn manufacturer, and all the core spun yarn products are carefully screened for these three quality indicators before they’re released to the market. This ensures that every single strand of yarn is of the highest quality possible and provides customers with products that are sure to look brilliant no matter what environment they’re used in.

Well, please follow us to visit our core spun yarn dyeing factory and see how we manufacture core spun yarn in high quality.

One-Pass Color Samples

At our yarn dyeing laboratory, we pride ourselves on having a team of highly experienced technicians who are able to provide you with the highest quality dyeing services possible. All of our technicians have more than ten years of experience, which means that they are well-equipped to handle any dyeing project that you may have.

We believe that time is of the essence. That’s why we provide up to 4 color swatches, so that you can be sure that the color samples pass at one time. This way, you won’t have to wait around for the second, or third sample to arrive to delay your textile manufacturing project. Plus, it gives you more options and flexibility in terms of choosing the right colors of the core spun yarn for your project.

Besides, we strictly follow the requirements of customers and use D65, CWF, TL84, U30 and other standard light sources for color matching.

We Use High Quality Dyes

We use disperse dyes. Even bright colors core spun yarn can achieve high color fastness and no color difference. 

Disperse dyes are unique in that they have a wide range of colors, and they can be made to achieve high color fastness and no color difference. This is a significant advantage over other types of dyes, like acid dyes, which tend to fade quickly over time. 

We Have Our Own Dyeing Factory

In our core spun yarn dyeing factory, there are 50 dye tanks of various specifications, which can meet any dyeing needs.

To ensure fast delivery, the MOQ is from 200 kg to 1000 kg per color.

During the dyeing process, the most suitable dyeing temperature is 100 degrees, dyeing time is 8-10 hours and auxiliaries will be configured to ensure the color-fastness and quality of the yarn.

We Strictly Control The Moisture Regain

The dyed core spun yarn needs to be dehydrated for 20 minutes to remove most of the water. Then, the yarn will be taken to be dried for 2 hours. The core spun yarn will pass through the drying equipment three times to dry the excess moisture and achieve the set moisture regain. This step is crucial to the moisture regain control of the core spun yarn.

Finally, the moisture regains of the dyed core spun yarn will be 2% to 3% lower than the official moisture regain.

We Use Stable Quality Embryo Yarn

Quality is our goal. We use the 2029 batch of embryo yarn with stable quality, which can be dyed into a melange color. The 2029 batch of embryonic core spun yarn has been tested for five years and has won unanimous praise from all customers.

Finished Product Moisture Regain Test

Then, we can carry out the constant weight winding process for the dried yarn according to the customer’s requirements.

After winding, we store the finished core spun yarn in the warehouse. We will ensure that the moisture regain of the yarn is lower than the official moisture regain.

Content Source: https://www.saludstyle.com/news/core-spun-yarn-dyeing-and-moisture-control/

Core Spun Yarn Manufacturing Process

Welcome to Salud Sytle core spun yarn spinning factory. Today I’m going to show you how the core spun yarn is made in our factory.

In our core-spun yarn factory, the production of core-spun yarn is divided into the following processes: 

opening and cleaning→ carding→ drawing→ roving→ spinning→ post processing.

After this series of processes, the selected staple fiber will eventually become the finished core-spun yarn.

Opening and cleaning process

The first process is opening and cleaning, which can mix the different fibers and make them into a uniform fiber bundle, as well as remove the impurities. This process will last 3 times to ensure core spun yarn purity. We control the workshop moisture and temperature in all the processes to ensure the yarn strength and quality.

In this process, the short fiber is made into a uniform fiber roll to create conditions for the carding process. This process can ensure the whole batch of short fiber will have the same strength and color when it’s spun into thread.

Carding process

Next, the fiber bundles will go through the carding machine, to make themselves completely decompose into single fibers. The product after this process is card sliver.

After opening and cleaning process, the fibers were loose and contained from 40% to 50% impurities. Carding process can mix the fibers evenly and be bundled with a single fiber that is parallel to normal, while also removing impurities with strong adhesion.

Drawing process

The quality of the card sliver is not good enough, and it needs to be processed into the drawn sliver. We will operate the drawing process for 2 times to ensure the yarn is of great evenness.

In the drawing process, after the fiber strip is mechanically processed, the distance between the fiber and the fiber becomes closer, and the mixed composition and color of the fiber are more uniform. The treated fiber strips are wound into appropriate packages for use in subsequent processes.

Roving process

Next is the roving process, where the drawn sliver is processed into roving yarn, preparing for the spinning process.

The main task of the roving process is to stretch and draw the fiber strips according to certain technical parameters, improve the parallel elongation of the fiber, and at the same time, the fiber gets the appropriate twist and is wound into shape, so as to facilitate the storage and use of the next process.

Spinning process

The spinning process is to spin the roving yarn into the spun yarn with certain specifications and quality standards. This process will determine the direction of the twist. We have 50 sets of spinning machines, and our daily capacity is about 20 tons.

During the process, a proper twist is added to make the spinning yarn have a certain strength, elasticity, gloss, feel and other physical and mechanical properties. After this, the spun yarn would be ready for the subsequent process.

Post processing

The spun yarn is not big and convenient enough for textile manufacturing. Therefore, we will wind them into the bigger cone yarn. If the yarn is used for the industries like fabric manufacturing, then the cone yarn is the final product after this process.

Although the spinning of the spinning machine has basically completed the spinning task, it does not mean the completion of the whole spinning project. The post-processing process mainly has the following four purposes:

(1) Improve the internal performance of products

(2) Improve the appearance quality of products

(3) Stabilize the structural state of the product

(4) Make the appropriate roll form

Winding Process

The spun yarn is not big and convenient enough for textile manufacturing. Therefore, we will wind them into the bigger cone yarn. If the yarn is used for the industries like fabric manufacturing, then the cone yarn is the final product after this process.

Plying Process

If the yarn is used for the industries like sweater manufacturing, then the plying process is necessary. This process will make 2 of the single yarn into 1 double plied yarn, and make sure all of them are at the same weight.

Twisting Process

Next is the twisting process, which is to make the yarn have higher strength and elasticity. It can also make the fabric and sweaters achieve the anti-pilling effect.

Packaging

Finally, the high-quality core spun yarn will be automatically packaged up by the machine. That’s all about core yarn spinning. Welcome to visit our factory. If you have any questions, please do not hesitate to contact us.

Content source: https://www.saludstyle.com/news/core-spun-yarn-manufacturing-process/

Blended Yarn Manufacturing Process

Blended yarn is a popular option in the fabric market as it provides different advantages, consisting of boosted resilience, versatility, and special colors. It is a mix of 2 or more various fibers, spun together to produce a brand-new yarn with enhanced homes. In this short article, we’ll take a better take a look at the procedure of how combined yarn is made, action by action.

Picking the Fibers

The very first action in making mixed yarn is to pick the fibers that will be mixed. Cotton and polyester are combined to develop a yarn that is soft, light-weight, and simple to care for, while wool and silk are mixed to develop a warm and elegant yarn.

Carding the Fibers

The next action is to card the fibers. This guarantees that the fibers are consistent in length and density, making it much easier to spin them into yarn.

Mixing the Fibers

As soon as the fibers have actually been carded, they are mixed together in a particular ratio. The mixing procedure can be done by hand or by utilizing a mixing device. A mixing device is chosen as it makes sure that the fibers are equally dispersed, and the ratio is precise.

Spinning the Yarn

Spinning is the procedure of twisting the fibers together to develop a constant hair of yarn. The spinning device takes the mixed fibers and twists them together, producing a resilient and strong yarn.

Ply the Yarn

Plying is the procedure of twisting 2 or more hairs of yarn together to develop a more powerful, thicker yarn. The variety of plies utilized depends upon the preferred density of the last yarn. A single-ply yarn is thinner than a three-ply or two-ply yarn.

Finishing the Yarn

After the yarn has actually been plied, it is all set for finishing. Finishing includes a series of procedures such as cleaning, steaming, and dealing with the yarn with chemicals to boost its homes. The finishing procedure likewise assists to get rid of any pollutants or oils that might have collected throughout the spinning procedure.

The very first action in making mixed yarn is to choose the fibers that will be mixed. Cotton and polyester are mixed to produce a yarn that is soft, light-weight, and simple to care for, while wool and silk are mixed to develop a warm and elegant yarn. The spinning device takes the mixed fibers and twists them together, developing a long lasting and strong yarn.

Content source: https://www.saludstyle.com/yarn-factory/blended-yarn-factory/

Feather Yarn Manufacturing Process

The production procedure of plume yarn can differ depending upon the products utilized, however in basic, it includes the following actions:

Fiber preparation: The fibers utilized to make plume yarn are very first prepared by cleansing and carding. This includes getting rid of any pollutants or particles from the fibers, and after that aligning them into long, thin hairs.

Spinning: The ready fibers are then spun into yarn utilizing a spinning maker. This maker twists the fibers together to develop a constant hair of yarn.

Feathering: The yarn is then fed through a device that includes a series of little tufts or fluffs of fiber at routine periods along the length of the yarn. This is what provides plume yarn its particular feather-like look.

Setting: After the feathering procedure, the yarn is heat-treated or usually steamed to set the tufts of fiber in location and offer the yarn its last texture.

Finishing: Once the yarn has actually been steamed and set, it might go through extra finishing procedures, such as cleaning, drying, or brushing, to even more improve its texture and look.

The particular production procedure for plume yarn might differ depending upon the producer and the products utilized. The basic actions included are comparable and objective to produce a soft, fluffy yarn with a feather-like look.

Covered Yarn Manufacturing Process

Covered yarn is a type of fabric yarn that consists of 2 or more various fibers or yarns twisted together. The production procedure of covered yarn generally includes the following actions:

Preparation of the core yarn: The initial step in the production procedure is to prepare the core yarn. The core yarn can be made from a range of products, such as cotton, wool, polyester, or nylon. The core yarn should be strong and have excellent tensile strength to offer an excellent base for the covering yarn.

Preparation of the covering yarn: The covering yarn is prepared by spinning 2 or more yarns together. The covering yarn can be made from numerous fibers such as polyester, wool, cotton, or nylon.

Twisting the core and covering yarns together: The next action is to twist the core yarn and the covering yarn together. The quantity of twist depends upon the preferred homes of the covered yarn, such as strength, texture, and flexibility.

Heat setting: After the twisting procedure, the covered yarn is generally heat set to decrease and support the structure shrinking throughout subsequent production procedures.

Examination: The covered yarn is checked for problems such as knots, abnormalities, and snarls.

Winding: The last action is to wind the covered yarn onto a spindle or cone. The yarn is all set for usage in numerous fabric applications such as knitting, weaving, and embroidery.

In summary, the production procedure of covered yarn includes preparing the core yarn and covering yarn, twisting them together, heat setting, evaluation, and winding. The resulting covered yarn has actually enhanced residential or commercial properties and is utilized in numerous fabric applications.

Covered yarn is a type of fabric yarn that consists of 2 or more various fibers or yarns twisted together. Preparation of the core yarn: The very first action in the production procedure is to prepare the core yarn. The core yarn should be strong and have excellent tensile strength to offer an excellent base for the covering yarn.

Polyester Yarn Manufacturing Process

As a yarn manufacturer, we want to show you how polyester yarn is made in our polyester yarn factory.

Polyester yarn is currently an important yarn type among synthetic fiber yarns, because of the fastest development speed and the highest output.

The production of polyester yarn can be roughly divided into two steps: melt spinning and post-processing.

The manufacturing process of polyester yarn is shewn as below.

Melt Spinning Process

Melt spinning is a method in which the fiber-forming polymer melt flows out of a thin stream of melt through a spinning spinneret, and is cooled and solidified in ambient air (or water). Polyester filament yarn and polyester staple fiber are produced by melt spinning method. This method has short process, high spinning speed, spinning speed is generally 900 to 1200 meter/min, high-speed spinning can reach more than 3600 meter/min, low cost, but the number of spinneret holes is small, making polyester filament yarn The number of holes is 1 to 150, generally 300 to 800 holes when making polyester staple fibers, and the highest can reach 1000 to 2600 holes, or even more. If the conventional circular spinneret holes are used, the cross-section of the spun fibers is mostly circular; if the special-shaped spinneret holes are used, the spun fiber cross-sections are special-shaped. This method is suitable for polyester fibers and other polymers that can melt, flow easily, and are not easily decomposed.

According to the spinning speed, the melt spinning process of polyester yarn can be divided into conventional spinning process, medium-speed spinning process, high-speed spinning process and ultra-high-speed spinning process.

Generally speaking, the product after the conventional spinning process is polyester undrawn yarn (UDY), the product after the medium-speed spinning process is polyester medium-oriented yarn (MOY), the product after the high-speed spinning process is polyester pre-oriented yarn (POY), and the product after the ultra-high-speed spinning process is polyester high-oriented yarn (HOY) or polyester fully drawn yarn (FDY).

The table below is for your better understanding.

We will use high-speed spinning, the most commonly used process route for the production of textured yarns, to illustrate the melt spinning process of polyester yarn. 

The spinning speed of high-speed spinning is 3000 to 3600 meter/min, and the product after this process is pre-oriented yarn (POY). 

The principle of the process is to feed polyester chips into the chips hopper, then melt them, and ensure that the melt flows stably in the screw extruder. 

In the screw extruder, the melt is filtered and pressed into the spinneret to spray out a thin stream of melt, and then quickly condensed by cold air to form a solidified tow fiber. 

During this process, pre-stretching of the polyester yarn is generated due to the function of the yarn guide, and it also makes the fiber thinner. 

The nascent fiber is wound into a roll with a certain shape by the winding system. 

Post-processing

The post-processing of polyester yarn refers to the processing that can make the spun nascent  polyester fiber suitable for textile production. After a series of post-processing, the structure and properties of the polyester yarn are improved. 

Post-processing can be roughly divided into the following five steps: POY to DTY, twisting, hanking, dyeing, and winding. 

POY to DTY

Combining the drawing and twisting process on the same machine, the produced yarn is called drawn textured yarn – DTY.

Drawn textured yarn (DTY), generally using POY as raw material, is a low-elasticity yarn obtained by one-step stretching and deformation; it has a certain elasticity, and the hand feel is not as soft as conventional textured yarn, but the quality is stable, and the strength and elongation have met the requirements of taking.

The processing technology of polyester DTY is slightly complicated, which is not discussed here, but roughly includes the following steps:

A. Polyester POY raw material feeding;

B. Stretching; stretch the polyester POY raw material to obtain a product; the stretching ratio is generally 1-1.1 times;

C. Heat deformation of product a to obtain product b; the temperature of heating deformation is 160-180 °C;

D. Cooling the product b to obtain the product c;

E. Perform false twisting treatment on product c to obtain product d;

The products F and d are processed by the network nozzle to obtain the product e; the network pressure of the network nozzle is 1.4-1.6 kg;

G. Heat and shape product e to obtain product f;

H. Perform oiling and winding treatment on the f product in turn to obtain the finished polyester DTY.

The polyester DTY obtained through the above steps has basically met the requirements of textile yarns, but in order to obtain better properties such as elasticity and wear resistance, and to dye different colors, subsequent processes are required.

Twisting Process

Twisting process of polyester yarn refers to combining two or several single yarns together and twisting them through a machine to produce strong, elastic strands, with the properties of uniform thickness, smooth surface, and wear-resistance,  to meet the requirements of the subsequent process.

In fact, in the previous step “POY to DTY”, some twist was also imparted to the polyester yarn. But for some textiles that require high-twist yarns as raw materials, these twists are not enough.

Hanking Process

The purpose of hanking is to loosen the twisted polyester yarn so that the dye can penetrate into the yarn completely during the dyeing process.

During the process of hanking, workers will add some water appropriately to tighten the yarn a little bit.

After hanking, the product becomes “bread yarn”. Then it will be packed, bagged, and then transported to our dyeing factory for dyeing.

Dyeing Process

In the existing dyeing process, the dyeing of high-elastic polyester yarn usually adopts the hank dyeing process of bread yarn. The hank dyeing of polyester yarn is to stack the fiber yarn in the dyeing machine in a hank shape, and use a pump or mechanical device to circulate or agitate the dye liquor, so that the polyester yarn can be dyed uniformly.

Before the mass dyeing, professional color staff will prepare the color formula according to the customer’s sample and dye it with a dyeing machine. Then, they compare the dyed sample with the customer’s sample under the specified lighting environment. After confirming that there is no color difference, mass dyeing will be carried out.

Dyeing is a link that tests experience and technology the most, because this process requires not only precise dye ratios, but also temperature control. At the same time, workers must add additives at appropriate times based on experience for the corresponding functions, such as waterproof, heat preservation, antibacterial, etc. 

Winding Process

Winding is the last process of yarn post-processing.  Its task is to process the hanked and dyed polyester yarn into the tube yarn, which is the polyester yarn product that our customer can directly use to produce the textile products, such as socks and medical bandages. 

Before winding, workers will place the dyed bread polyester yarn in a cool place and dry it with the wind.  This process generally lasts 2 to 3 days. 

Then the workers put the dried bread yarn on a shelf, spread it out evenly, and cut off the surface yarn that has been exposed to air for a long time. 

When it’s all done, workers will place it on the machine to wind it to the final polyester yarn product. 

After winding, the tube polyester yarn will be placed on a shelf, and after passing the inspection by the workers, it will be packed, stored and sent out to our customers. 

Content source: https://www.saludstyle.com/news/polyester-yarn-manufacturing-process-from-chips-to-yarn/

Wool Yarn Manufacturing Process

In the wool yarn market, the level of quality, completely depends on raw materials. In order to ensure the ultimate quality, Salud Style, with unprecedented courage, starts from the origin of the wool yarn industry by raising sheep. After varieties selection, scientific feeding, timely wool, screening and classification, washing and combing, bleaching and dyeing drying, spinning yarn, do a complete industrial chain.

When the quality of a product is beyond the control of standardized production, it needs a way to control the entire production process to ensure the quality of the final product. Therefore, we choose the whole chain production model that can be monitored to produce wool yarn.

In order to realize the monitoring of the whole process, we have found a model of companies plus farmers plus bases. In order to enable the sheep raised by farmers to have wool of the same quality standard, the company cooperates with the China Sheep Raising Association and hires experts to provide professional help for farmers to carry out scientific sheep raising. At the same time, an ear tag with an information chip is placed for each sheep, so as to comprehensively monitor the quality control, so that each sheep is under the technical management of the company from the lamb to the final wool.

Sorting Process

The first step after wool enters the industrialization process is screening and classification, sorting according to different colors and different wool qualities, and sorting the raw wool according to the three colors of white, blue and purple.

Combing Process

After sorting, enter the second step of washing and carding, which is a key step to determine the quality of wool yarn. According to the traditional thinning method, in order to obtain the best wool, it is necessary to go through twelve combs. However, if you comb too much wool, the length will be lost, and if you comb less wool, the fineness will not be enough. In response to this problem, Salud Style has carried out technological innovation in the carding process of wool, using continuous secondary carding technology, which has made a revolutionary breakthrough in the entire wool carding.

Spinning Process

Here are the steps from wool to wool yarn. Salud Style’s wool yarn factory strictly implements the industry standards promulgated by the state, and its purpose is to strive to control product quality in every link.

Content Source: https://www.saludstyle.com/yarn-factory/wool-yarn-factory/

Nylon Yarn Manufacturing Process

Nylon was the first synthetic fiber to appear in the world. Its appearance brought a new look to textiles. Its synthesis is a major breakthrough in the synthetic fiber industry and a very important milestone in polymer chemistry.

Take Nylon Stretch Yarn as an example, its production process is simpler than other natural fibers. The production of nylon stretch yarn can be roughly divided into two steps: spinning and post-processing.

Spinning Process

According to the spinning speed, the spinning process can be divided into conventional spinning process, medium-speed spinning process, high-speed spinning process and ultra-high-speed spinning process.

We will use high-speed spinning, the most commonly used process route for the production of nylon yarns, to illustrate the spinning process.

The spinning speed of high-speed spinning is 3000-3600m/min, and the product after this process is pre-oriented yarn (POY).

The principle of the process is to feed nylon chips into the chips hopper, then melt them, and ensure that the melt flows stably in the screw extruder. 

In the screw extruder, the melt is filtered and pressed into the spinneret to spray out a thin stream of melt, and then quickly condensed by cold air to form a solidified tow fiber. 

During this process, pre-stretching is also generated due to the function of the yarn guide, and it also makes the nylon fiber thinner. Then the pre-oriented nylon yarn is wound into a roll with a certain shape by the winding system.

Post-processing

The post-processing can make the pre-oriented nylon yarn suitable for textile production. After a series of post-processing, the structure and properties of the nylon fiber are improved.

Post-processing can be roughly divided into the following five steps: POY to DTY, twisting, hanking, dyeing, and winding.

POY to DTY

Combining the drawing and twisting process on the same machine, the produced yarn is called draw texturing yarn – DTY.  

Twisting Process

Twisting refers to combining two or several single yarns together and twisting them through a machine to produce strong, elastic strands, with the properties of uniform thickness, smooth surface, and wear-resistance,  to meet the needs of the subsequent process.

The workers will set the twist on the machine according to the customer’s requirements, and wind one end of the nylon DTY on the machine and the machine will operate the twisting process. When the required weight of twisted nylon DTY  is reached, it will stop and give a red light signal to remind workers.

Hanking Process

The purpose of hanking is to loosen the twisted nylon yarn so that the dye can penetrate into the yarn completely during the dyeing process.

Workers will place the twisted product next to the machine, connect one end of the yarn to the machine, and turn on the machine.

During the process of hanking, workers will add some water appropriately to tighten the nylon yarn a little bit.

After hanking, the product becomes “bread yarn”. Then it will be packed, bagged, and then transported to our dyeing factory for dyeing.

Dyeing Process

Before the mass dyeing, professional color staff will prepare the color formula according to the customer’s sample and dye it with a dyeing machine. Then, they compare the dyed sample with the customer’s sample under the specified lighting environment. After confirming that there is no color difference, mass dyeing will be carried out.

Hank dyeing, dope dyeing, and cone dyeing are the three most commonly used dyeing methods.

The dyeing method used in our nylon yarn factory is hank dyeing. Compared with other dyeing methods, hank dyeing has the characteristics of high color fastness and uniform dyeing. Our dyeing factory is equipped with dyeing tanks of different specifications, and the yarn dyeing weight ranges from 1.5kg to 800kg. Small dyeing tanks are generally used to dye sample yarns for customers.

Dyeing is a link that tests experience and technology the most, because this process requires not only precise dye ratios, but also temperature control. At the same time, workers must add additives at appropriate times based on experience for the corresponding functions, such as waterproof, heat preservation, antibacterial, etc.

Winding Process

Winding is the last process of yarn post-processing.  Its task is to process the hank yarn into the cone nylon yarn, which is the product that our customer can directly use to produce the textile products, such as socks and medical bandages.

Before winding, workers will place the dyed nylon “bread yarn” in a cool place and dry it with the wind.  This process generally lasts 2 to 3 days.

Then the workers put the dried dyed nylon “bread yarn” on a shelf, spread it out evenly, and cut off the surface yarn that has been exposed to air for a long time.

When it’s all done, workers will place it on the machine, and turn on the machine to wind it.

After winding, the cone nylon yarn will be placed on a shelf, and after passing the inspection by the workers, it will be packed, stored and sent out to our customers. 

Content source: https://www.saludstyle.com/yarn-factory/nylon-yarn-factory/