Category: Spinning

A Journey from Mulberry Trees to silk Yarn in China

Spinning, Yarn
A Journey from Mulberry Trees to silk Yarn in China

In ancient China, the production of silk yarn was a closely guarded secret that played a crucial role in the country’s economic prosperity. The intricate process involved several labor-intensive steps, showcasing the ingenuity of the Chinese people in harnessing the potential of silkworms and silk fibers.

The journey of silk production began with the cultivation of mulberry trees, as the leaves served as the primary food source for silkworms. The silkworms, or Bombyx mori, were carefully nurtured in controlled environments, emphasizing the importance of maintaining optimal temperature and humidity. The quality of the silk produced was directly linked to the health and diet of these silkworms.

As the silkworms matured, they spun protective cocoons around themselves using their silk-producing glands. The next step in the process involved carefully harvesting the cocoons without damaging the delicate fibers. This was typically done by placing the cocoons in hot water to soften the sericin, a natural protein in silk that holds the fibers together. The softened silk fibers were then unraveled, revealing long threads that formed the basis of silk yarn.

One notable aspect of ancient Chinese silk production was the use of a device known as a “sericulture reel.” This hand-powered reel facilitated the precise unwinding of silk threads from the cocoon. The process required skill and patience, as the delicate nature of silk demanded careful handling to avoid breakage. Skilled artisans, often women, played a crucial role in this meticulous and time-consuming task.

After obtaining the silk threads, they were dyed using natural pigments sourced from plants and minerals. This step added vibrant colors to the otherwise lustrous but plain silk. The dyed silk threads were then ready for weaving into various textiles, ranging from luxurious garments to intricate tapestries.

The silk industry in ancient China was not just a source of economic prosperity but also a cultural treasure. The secrecy surrounding the silk production process was maintained for centuries, contributing to the mystique of Chinese silk. The knowledge eventually spread along the Silk Road, fostering trade and cultural exchange between East and West.

In conclusion, the ancient Chinese methods of producing silk yarn were a testament to the meticulous care and craftsmanship involved in transforming the humble silkworm into a source of exquisite and coveted fabric. The intricate process, from mulberry cultivation to sericulture and weaving, reflected the rich cultural and economic significance of silk in ancient China. The legacy of these methods endures, as silk continues to be admired globally for its beauty and historical significance.

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Revolution of textile by banana fiber

Fiber, News, Spinning, Testing
Revolution of textile by banana fiber

Banana is a famous well-known fruit specially in yellow color all across the word. Banana has too much natural nutrition fact that makes human body more healthy and strong. Today’s we realize that banana is not only one purpose we cultivate banana tree.  Because banana stalk can be used to extract valuable fiber. That fiber could be used to make products like tea bag, sanitary napkin, floor and wall mat. Recently japan used this fiber to make yen bank notes, car tyres and many more. The multipurpose usage of banana fiber increasing the demanding value recent years. Expert says this banana fiber might brought to light by Japanese and Nepalis on ancient time. When they think about waste the entire banana tree by cut and through into dustbin. They find out the stalk of banana fiber can be produced to make rope that take too much force to get it breaking point.

Revolution of textile by banana fiber

Revolution of textile by banana fiber

The archaeologists say may be three banana trees was first cultivated in Kuk valley of New Guinea around 8,000 BCE but it could be occurred throughout South-East Asia and the South Pacific. In the time of 13th century they use banana stalk as a source of fiber. But when people get a better, strong and smoot fiber like cotton and silk the banana fiber faded away by time.

Todays those ancient thought giving us amazing silk grade banana fiber by Turning a waste into profit.

 

Banana fiber composed

  • cellulose
  • hemicelluloses
  • lignin

It’s like bamboo and ramie fibers. But this fiber’s fineness and spin ability are better than bamboo and ramie fibers.

Properties of banana fiber

  • The chemical composition is cellulose, hemicelluloses and lignin.
  • It has better fineness and spin ability which include ring spinning, open -end spinning, best fiber spinning and semi-worsted spinning.
  • it is strong fiber & it has smaller elongation and
  • its weight is light.
  • It has strong moisture absorb quality.
  • Best fiber of banana extract from bark of banana tree.
  • This fiber is bio-degradable.
  • It is ECO-friendly fiber.
  • Banana fiber comes from wasted banana tree which we thought worthless.
Revolution of textile by banana fiber- waste material

Revolution of textile by banana fiber- waste material

Production of banana fiber

 

  • Banana tree is harvest in field
  • Stems are peeled to extract sheaths
  • Sheaths are fed into machine
  • Extracted fiber in sun dried for a day
  • This fiber is ready for craft
  • Fiber used for handicrafts

Value of this fiber is increasing for its demand and multipurpose usages all over the world. Global textile industries took an important step to turn a waste material into profitable fiber.

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Top ten country by cotton Exporting

Fiber, Spinning
Top ten country by exporting cotton

Cotton is a natural fiber which able to makes most comfortable and beloved of all cloth in efficient budget. This is the most popular natural fiber across the world because of its chemical and natural properties. Cotton takes an important role in textile industry to fill the necessity of natural fiber. All that textile production country does not have the ability to grow cotton in own country because of sufficient land, fertilization, climates and government approval. Pick a country like Bangladesh; it’s able to cultivate cotton in their inland but cotton takes a little long to grow and mature; in that time Bangladeshi farmer can grow more crops than cotton which helps them to survive and feed the nation.

Top ten country by exporting cotton

Top ten country by exporting cotton

In that case some people export their cotton after complete the demand of domestic industry. Various countries grow cotton which not only fulfills domestic needs but also boosting up the overall economical health of the country by exporting cotton across the world.

Global cotton export estimate amount was $54.3billion in 2015. Here are given blew the top ten list of the country which add a fair amount of money on annual growth of economy. This statistic is taken from recent global market export and import statistic report.

List of top ten country by exporting cotton:

S/N Country Worth of shipment in (USD) Percentage of total exports
01 China $15.8 billion 29.1%
02 India $7.5 billion 13.8%
03 United States $5.9 billion 10.8%
04 Pakistan $3.1 billion 5.7%
05 Hong Kong $2.3 billion 4.3%
06 Vietnam $1.8 billion 3.2%
07 Turkey $1.7 billion 3.1%
08 Italy $1.5 billion 2.7%
09 Brazil $1.4 billion 2.7%
10 Germany $998.9 million 1.8%

China is the country who leads the cotton exporting business around the globe. With 9,596,961 km2 and 1,376,049,000 population china produce a huge amount of cotton that fulfill their domestic Demand and makes more than $15.8 billion USD last year. Come to the second country India which 3,287,263 km2 and 1,293,057,000 of population they produce vast amount of cotton that fill domestic demand and export extra cotton; like china and makes $7.5 billion USD last year. In that situation one thing is clear that; to produce huge amount of cotton you need more lands with adept people to cultivate cotton to makes garments and export it in worldwide.

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Distinguish between rotors & ring spinning frame.

Accessories, Machinery, Spinning
Rotor spinning frame

Spinning is a process where yarn makes from cotton or something else by twisting though spinning frame machine. There are a few types of spinning machine are used around the world but we will discuss about most used machine like rotor spinning frame and ring spinning frame. Every modern machine has history which created by conventional machine. Modern machine is an upgrade version of conventional machine. Remove some unusual parts of machine & using some latest mechanical or electrical technology; speed up the machine and finally got the modern machine.

Ring spinning frame

Ring spinning frame

Rotor spinning frame

Rotor spinning frame

No Rotor Spinning frame No Ring Spinning frame
01 Rotor spinning frame is modern spinning system machine 01 Ring spinning frame is conventional spinning system machine
02 This machine makes yarn by high drafting from sliver. 02 This machine makes yarn by lower pressure than rotor spinning frame from roving.
03 The working speed of rotor spinning frame is faster than ring spinning frame. 03 The working speed of ring spinning frame is lower than ring spinning frame.
04 Usually rotor spinning frame produced lower count yarn. 04 This machine can produce from low count yarn to high count yarn.
05 Basically the raw material of this machine is low quality. Means low grade cotton. 05 Relatively this machine used high grade cotton to produce yarn.
06 Temperature and moisture of cotton should be controlled to produce yarn by rotor spinning frame. 06 No need to control temperature and moisture of cotton to produced yarn by ring spinning frame.
07 Room temperature should be controlled in 20 to 28 C on spinning room. 07 Its better if the room temperature controlled in 28 to 35 C.
08 Only one drafting system is available on this machine so there are now break draft in this machine. 08 Darting system is split in two divisions called main draft and break draft.
09 Twisting and winding process work separately in rotor spinning frame. 09 Twisting and winding process work with each other.
10 Production of rotor spinning frame is more than ring spinning frame. 10 Production of ring spinning frame is less than rotor spinning frame
11 Consumption of electricity is less than ring spinning frame. 11 Consumption of electricity is more than rotor spinning frame.
12 The ratio of breakage yarn is less than ring spinning frame. 12 The ratio of breakage yarn more than rotor spinning frame.
13 Production sound or noise is less than ring spinning frame. 13 Production sound or noise of the machine is more than ring rotor spinning frame.
14 The produced yarn package large. 14 The produced yarn package is small.
15 A few labor or technician can produce or maintain rotor spinning machine. 15 Ring spinning machine required more than ring spinning frame machine.
16 Rotor spinning frame produced balanced yarn. 16 Ring spinning frame produced less balanced yarn.
17 Trash less cotton is perfect for make yarn balanced so always used cotton should less trash cotton. 17 Comparability this machine can produce yarn from maximum amount of trash full cotton.

You may Interested to read What is carding and classification of carding machine?

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Technical specification of modern ring frame

Machinery, Spinning
Technical specification of modern ring frame

About Ring spinning frame:

Spinning is the final step of yearn manufacturing process. The working procedure of ring spinning frame is taking the roving comes from simplex and produced yarn by reducing the weight of unit length. Ring is attached around bobbin. The traveler rolling on ring and enfold the yarn on bobbin. Ring spinning frame plays the vital role to spinning the yarn so it is called Ring spinning frame. Ring spinning frame’s production system is conventional.

Technical specification of modern ring frame

Technical specification of modern ring frame

Ring frame is only one machine which can produce yarn by any kind of fiber. Basically the working system of ring spinning frame is easy and the cost of machine is a little cheap. It is easy to separate the bobbin from ring and easy to carry. but a few problem also reduce its popularity like, working speed, conventional system, large amount of electricity consumption.  please follow the link to know more about rotor spinning frame and ring spinning frame. Click here!

Technical specification of modern ring spinning frame:

No Description of parts Specification
01 Roller and angle 45˚
02 The distance between center of lappet hook and center of front roller. 66.50 mm
03 Gage 70.00 mm
04 Tube length (gage -70.00 mm) 201, 220, 230 mm
05 Mechanical speed 25,000 mm
06 Count From 5.5s to 120s
07 Twist/inch From 4 to 55
08 Draft system Double apron 3 roller to arm.
09 Number of spindle From 96 to 1008
10 Main motor Down 15KM, High 37KM (45KW with Inver )
11 Ring lowering motor 0.35KW
12 Suction motor 0.35KW
13 Pantograph drive 2.20 KW
14 Horizontal transport belt 2×0.12 KW (Geared motor)
15 Inclined transport belt 2×0.185 KW (Geared motor)
16 Tube feeding 2.5 Minutes
17 Doffing time 2.5 minutes
18 Bobbin discharge speed 60 (30+30) Minutes
19 Compressed air consumption 1.35 liter/minute

You May interested to read Distinguish between rotors & ring spinning frame.

Function of ring spinning frame

Producing yarn is the main work of ring spinning frame. A few steps required to make yarn by ring spinning frame. The steps are given blew.

  1. Creeling
  2. drafting
  3. twisting
  4. winding
  5. building
  6. doffing

Detail discussing of the steps of ring spinning frame is coming in upcoming article.

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Complete Dyeing process of cotton

Fiber, Spinning, Wet Processing
Complete Dyeing process of cotton

Complete Dyeing process of 100% cotton fabric
Cotton is most popular natural fiber around the world. The original way of wet processing is most important. Follow chart is part and parcel in textile industry. This is ideal follow chart for cotton dyeing which is help somebody to know about cotton fabric or yarn dying.

Complete Dyeing process of cotton

Complete Dyeing process of cotton

I’m describing the complete dyeing process of 100% cotton fabric by the following process flowchart:
Fill water
↓
Load fabric
↓
Temperature control 600 C
↓
Inject detergent + Sequestering agent + Anti-creasing agent
↓
Run time 10 minute
↓
Caustic dosing 600C X 10’
↓
Increase temperature at 700C
↓
H2 O2 dosing
↓
Run time 110 0 C X 40’
↓
Cooling at 800 C
↓
Rinse at 60 0C for 7 minute
↓
Water drain
↓
Fill water and inject PKK
↓
Temperature 980 C and run time 10’
↓
Cooling at 800 C
↓
Rinse at 50 0C for 7 minute
↓
Water drain
↓
Fill water
↓
Inject acetic acid at 550 C X 10’ and check p H
↓
Raise temperature at 800 C X 10’ and destroy enzyme activity
↓
Rinse for 5 minutes
↓
Water drain
↓
Fill water
↓
Check p H
↓
Temperature 600 C
↓
Inject leveling + sequestering agent run time 5’
↓
Inject salt 600 C X 20’
↓
Color dosing 60 0C X 33’
↓
Run time 20 minute
↓
Soda ash dosing for 33’
↓
Check sample after 10, 33.…… during shade matching
↓
Rinse at 50 0C for 15’
↓
Drain
↓
Fill water
↓
For neutralizing, inject A. acid
↓
Run time 10 minute then rinse for 10 minute
↓
Darin
↓
Fill water
↓
Inject
↓
A. Acid 55 0C X 10’
↓
Check PH
↓
Inject softener
↓
Run time 500C X 20’
↓
Rinse
↓
Drain
↓
Fill water
↓
Cold wash
↓
Unload from machine

Acknowledgement for reader who is must be textile student or expert on textile technology. If you missed something on this flowchart and if you have any objection about anything please leave a comment on comment box are given blew.

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