SYSTEM FOR MANUFACTURING TEXTILE PRODUCTS FROM ROVING WASTE MATERIAL AND METHOD THEREOF
20210262124 · 2021-08-26
Inventors
Cpc classification
Y02W30/66
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
D02G3/02
TEXTILES; PAPER
International classification
Abstract
The present invention relates to textile products and the manufacture of yarns. More particularly, the present invention relates to a system for manufacturing textile products from roving waste material. Further, the present invention relates to the method of manufacturing 100% regenerated ring spun yarn, out of waste generated during spinning and additionally, the present invention relates to the method of manufacturing regenerated ring spun yarn with cotton waste, comber noil and carding flat waste which produces 100% cotton ring spun yarn. Advantageously the present invention relates to a cost effective method for recycling roving waste generated during cotton spinning, and produces yarns of the highest possible quality when compared with the virgin fibers.
Claims
1. A regenerated ring spun yarn, comprising: roving waste 60-100% by weight; comber noil 0-20% by weight; and carding flat waste 0-20% by weight, wherein the regenerated ring spun yarn comprises of 100% by weight of roving waste or a combination of roving waste with comber noil and carding flat waste.
2. A method [100] for manufacturing regenerated ring spun yarn with roving waste material, comprising: collecting [101] the roving waste from a roving frame and a ring frame; collecting [102] the comber noil from a comber and the carding flat waste from a carding machine; opening [103] the roving waste by using roving waste opener; characterized in that, mixing [104] 60-100% by weight of roving waste with 0-20% by weight of comber noil and 0-20% by weight of carding waste material through the blow-room with 2-3 beating points with a flat speed in carding at 280 to 310 MPM; doubling and processing [105] carded sliver with 60-100% by weight of roving waste, 0-20% by weight of comber noil and 0-20% by weight of carding waste material through the drawing frame; feeding [106] the drafted sliver to the roving frame by keeping the Twist Multiplier at 1.4 to 1.54; feeding [107] the roving bobbin in to the ring frame to produce the yarn and wound it on the winding/auto winding machine; and regenerating yarn of 100% cotton/regenerated ring spun yarn made out of 60-100% by weight of roving waste with 0-20% by weight of comber noil and 0-20% by weight of carding waste material, wherein the 100% yarn is produced without any increase in twist multiplier compared to virgin material both in simplex roving frame and ring spinning process, since roving waste comprises of minimum short fibers, and wherein the regenerated ring spun yarn comprises of 100% by weight of roving waste or a combination of roving waste with comber noil and carding flat waste.
3. The method [100] for manufacturing regenerated ring spun yarn with roving waste material as claimed in claim 2, wherein the sliver is spun into yarn of 100% cotton with sheath core effect or with a core made of manmade fiber and the sheath made of 100% Regenerated cotton roving fiber.
4. The method [100] for manufacturing regenerated ring spun yarn with roving waste material as claimed in claim 2, wherein the roving cotton waste materials are taken as source material in a process for making regenerated ring spun yarn.
5. The method [100] for manufacturing regenerated ring spun yarn with roving waste material as claimed in claim 2, wherein the roving waste is selected from Cotton fibers, Natural fibers or natural, Synthetic blend and the like.
6. The method [100] for manufacturing regenerated ring spun yarn with roving waste material as claimed in claim 2, wherein the method is implemented with a system comprising standard manufacturing equipments such as roving waste opener, blow room, carding machine, draw frame, roving frame, ring frame and winding/auto winding machine.
7. The method [100] for manufacturing regenerated ring spun yarn with roving waste material as claimed in claim 2, wherein premium fabrics such as bath towels, bath mats, bed Linen fabrics and the like with green ECO label using regenerated yarn produced from roving waste material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] So that the manner in which the features, advantages and objects of the invention, as well as others which will become apparent, may be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which form a part of this specification. It is to be noted, however, that the drawings illustrate only a preferred embodiment of the invention and is therefore not to be considered limiting of the invention's scope as it may admit to other equally effective embodiments.
[0039]
[0040]
DETAILED DESCRIPTION OF THE INVENTION
[0041] It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
[0042] The present invention relates to textile products and the manufacture of yarns. More particularly, the present invention relates to a system for manufacturing textile products from roving waste material. Further, the present invention relates to the method of manufacturing 100% regenerated ring spun yarn, out of waste generated during spinning and additionally, the present invention relates to the method of manufacturing regenerated ring spun yarn with roving waste, comber noil and carding flat waste which produces 100% cotton ring spun yarn.
[0043] A regenerated ring spun yarn, comprises roving waste 60-100% by weight, comber noil 0-20% by weight and carding flat waste 0-20% by weight. The regenerated ring spun yarn comprises of 100% by weight of roving waste or a combination of roving waste with comber noil and carding flat waste.
[0044] Referring to
[0045] The 100% yarn is produced without any increase in twist multiplier compared to virgin material both in roving frame and ring spinning process, since roving waste comprises of minimum short fibers. The regenerated ring spun yarn comprises of 100% by weight of roving waste or a combination of roving waste with comber noil and carding flat waste. The sliver is spun into yarn of 100% cotton with sheath core effect or with a core made of manmade fiber and the sheath made of 100% Regenerated cotton roving fiber. The roving cotton waste materials are taken as source material in a process for making regenerated ring spun yarn.
[0046] Blow room is the very first process of yarn manufacturing. In blow room the raw cotton is fed as bale form and it converted as tuft by eliminating the trashes through beating. Initially the raw materials laid in the bale blucker zone. After that the material was taken to the first tuff opening machine, in which the first beating and cleaning is taken place. After that It will go to the homogeneous mixer for the better blending. Next to this the material went to the carding machine.
[0047] After this operation the tufts will be converted into the form of sliver in the next process named carding. In carding further cleaning will be done by carding the material. After the card process the silvers are doubled and drafted in the Draw frame which is the process will reduce the thickness and increase the strength of the sliver. (This activity is mainly to give the strength for the sliver to process it subsequently for the next roving stage.)
TABLE-US-00001 TABLE 1 Experimental Setting Comparison (Virgin Spinning Process and regenerated waste Spinning Process) Virgin Spinning Regenerated Waste Process Spinning Process BLOW ROOM VARIO CLEANER SPEED 550 RPM 200 RPM GRID BAR SETTING WIDE CLOSE UNIMIX BOOSTING FAN 450 RPM 220 RPM UNIMIX BEATER SPEED 550 RPM BY PASS FLEXI CLEANER SPEED 550 RPM BY PASS FLEXI CLEANER BOOSTING FAN 450 RPM 150 RPM SPEED IN RPM CARDING CHUTE BEATER SPEED 600 RPM 600 RPM PROD/HR 120 120 CYLINDER SPEED IN RPM 510 510 FLATS SPEED IN MPM 310 310 FLATS SETTING IN mm 0.3, 0.3, 0.2, 0.2, 0.2, 0.3, 0.3, 0.2, 0.2, 0.2, FEED PLATE TO LICKER IN SETTING 0.9 MM 0.9 MM IN MM WASTE PLATE SETTING 0.9 MM 0.9 MM CYLINDER FRONT TOP PLATE 0.7 MM 0.7 MM SETTING BREAKER DRAWING SPEED 325 MPM 325 MPM BREAK DRAFT 1.5 1.5 NO.OF.DOUBLING 3 3 FINISHER DRAWING SPEED 350 MPM 350 MPM BREAK DRAFT 1.16 1.16 SIMPLEX HANK 0.4 0.4 SPEED 1000 RPM 1000 RPM TM 1.54 1.54 RING FRAME SPINDLE SPEED 11000 RPM 11000 RPM TM 3.5 3.5 WINDING SPEED 1400 MPM 1400 MPM
TABLE-US-00002 TABLE 2 Categories of cotton waste fibers Roving Waste Total 100% 100%
TABLE-US-00003 TABLE 3 Categories of cotton waste fibers Combed Noil Carding flat waste Roving Waste Total 10% 10% 80% 100% 15% 15% 70% 100% White or Ring Ring Open End Open natural Combed Spinning Spun spinning end knitt Combed Waste Waste Waste Carding Opening Roving waste waste cutting Virgin Yarn Type Noil yarn fibre Yarn waste waste Waste fibre yarn waste Cotton Polyester Total 100% Cotton - 0 0 100 100 10/1 -1900 CSP 100% Cotton - 0 0 100 100 13/1 -1800 CSP 100% Cotton - 10 10 80 100 10/1 -1850 CSP 100% Cotton - 10 10 80 100 13/1 -1750 CSP 100% Cotton - 15 15 70 100 10/1 -1850 CSP 100% Cotton - 15 15 70 100 13/1 -1750 CSP
[0048] The roving waste is selected from Cotton fibers, Natural fibers or natural, Synthetic blend and the like. The method is implemented with a system comprising standard manufacturing equipments such as roving waste opener, blow room, carding machine, draw frame, roving frame, ring frame and winding/auto winding machine. Premium fabrics such as bath towels, bath mats, bed Linen fabrics and the like with green ECO label using regenerated yarn produced from roving waste material.
[0049] Maximum beating point will be 2-3 when compare the virgin process in which it is from 3 to 4. Because the roving waste is already free from trash. It is essential to align the loose fibers in the fiber strands core area, the minimum 1 beating point is required. Yarn is produced without any increase in TM (Twist Multiplier) Compared to virgin material both in simplex (Roving Frame) and Ring spinning Process. The roving waste is itself having a very minimum short fibers when compare to the other waste. So there is no necessary to increase TM when compare to the virgin while processing in both Roving & ring frame.
[0050] The present invention relates to the formation of yarn from roving waste, and the yarn so obtained is produced at the same TM, with comparable level of feel and aesthetics as that of the virgin yarn. The yarn doesn't need to be consolidated together by means of higher twist and hence doesn't adversely affect the production tonnage. Also the yarn is also comparable in terms of its hairiness and other feel properties. Twist multiplier is a unit which helps to decide their twist per unit length for different counts from the same raw material. This is nothing but the angle of inclination of the helical disposition of the fibre in the yarn.
[0051] Although the invention has been described and illustrated with respect to the exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention.