Global Service 1 31/3/2020

A HANDBOOK ON SPINPACT FINETUNING

-GLOBAL SERVICE

Prepared by Reviewed by Over seen by

T.Selvakumar K.V.Kulkarni A.Balasubramani

TABLE OF CONTENTS
1. Preamble of our compact
2. Compact claim
3. While commissioning
4. For attending quality related issues.- Includes basic setting of ringframe
Global Service 2 31/3/2020

5. For improving gear life

6. For improving apron life
7. Maintenance activities in Spinpact
8. Idler gear removal & fixing procedure
9. Compact roller bearing replacement

1) Preamble on Suction Compact

The spinning triangle width (WS) and the length of the spinning triangle are two key dimensions for
spinning triangle. The spinning triangle width is always smaller than the roving strand width (W).
Due to the difference between WS and W, the edge fibers are not caught by the spinning triangle
when emerging from the front rollers, and therefore not fully incorporated into the yarn.
These fibers are lost by forming fly or they are bound in the yarn already formed only at one end,
thus becoming hairiness.
Note: The greater the difference between WS and W, the higher the loss of fibers, the greater
the hairiness. Therefore, WS is expected to be as close as possible to W.

On the other hand, the length of the spinning triangle depends mainly on the twist. High yarn twist
results in a short length (L1), but low yarn twist results in a long length (L2).It is unfortunate that both
short length and long length of the spinning triangle can lead to an increase in the yarn break rate
and hairiness.
A long spinning triangle length enlarges the spinning triangle, which is a weak point that may break
when tension peaks induced by shocks or uneven running from traveler or balloon act on the
spinning triangle.Hairiness is also increased, since the hairiness of the yarn depends to a great
extent on the area of the spinning triangle.

On the other hand, a short spinning triangle results in an increase in both hairiness and yarn break
rate, due to difficulties in tying the edge fibers into the yarn body, and due to irregular distribution of
fiber tension in the yarn structure.
If reducing the length of spinning triangle is our motive, then our New 1, New 2 geometry must have
yielded the compact yarn results,but has not happened. EBH might have reduced, but the yarn
quality is never been near to compact yarn.In case of New1 & New 2 geometry, length of the
spinning triangle is vastly reduced than regular geometry by reducing overlapping of fibers
Global Service 3 31/3/2020

on bottom roller, but the width of the spinning triangle is not altered.

To overcome the above facts, the compact spinning technique is introduced, eliminating the
spinning triangle by reducing the fiber strand width to the spinning width & length, resulting
in an increase of yarn strength and decrease of hairiness and yarn break rate.

LMW compact systems

Servo Compact- Dual suction nozzle
As there are more number of joints - from middle coupling to compact nozzle, the user friendliness is
not there & more prone to leakage if enough care not taken by customer.
Components involved: Compact suction J pipe under the drafting, rubber coupling, steel bush,
rubber boot & then the nozzle.
Rubber aprons with Suspension rod loading system.

Servo Compact- Four suction nozzle.

Few joints were eliminated - from middle coupling to compact nozzle, the user friendliness is much
improved, but still there are more customers feel that compact apron replacement is difficult.
Components involved: Compact suction J pipe over the drafting, rubber boot & nozzle.
Rubber aprons with Suspension rod loading system.

Spinpact- Mechanical compact - 8 Spindles nozzle

To overcome the above issue of compact apron replacement, Spinpact is introduced with the ease
of replacing compact apron & other user friendliness reaped in top suction systems.

Rubber compact apron Vs Mesh compact apron

In general, rubber apron is having self cleaning effect, hence no choking of compact apron.In
synthetics application, the chances of fiber lapping/sticking in to apron surface is very less in rubber
aprons.Lesser cleaning is required for rubber compact aprons.
When the priority is quality, the mesh aprons have more advantageous than rubber apron,but needs
periodic cleaning.

2) Compact claim
Reduced hairiness ( Uster HI, up to 30%) & S3 value up to 85%
Increased yarn strength RKM (up to 15%)
IPI improvement expected

Other advantages expected

Global Service 4 31/3/2020

Yarn twist reduction (up to 10%) with corresponding production increase

Reduced ends-down rate
Reduced fiber loss
Reduced fiber fly
High downstream processing speed
Low warp breaks during weaving
High fabric strength after finishing process
Eliminates singeing process
Eliminates separate doubling process by means of SIRO compact.

Technology in compact
a. Tension draft
b. Compact slot width
c. Slot angle
d. Compact nipping point

Tension draft
As the number of the fibers handled in the compact zone is almost countable, slight stretch of fibers
in this zone will lead to affect on yarn quality, end breakage & variation in count.
Amount of tension draft depends upon the drive transmit for the compact top roller.In spinpact due to
positively driven compact bottom roller, tension draft is maintained at 0.982.

Lesser the tension draft, greater the amount of time a drafted fleece can in compact zone.
Fiber will orient towards the compact slot by itself without exploiting its properties.

Compact slot width & angle

Ideally a compact slot width should not be more than the drafted fleece width & also we cant reduce
too much.
Lesser the slot width without precision leads to lesser compact suction & frequent choking of nozzle.
Spinpact nozzle slot length -29 mm, width - 1.5 mm & angle of slot - 7 deg.
Assume as we are making finer count, on the compact nozzle having straight slot, the fibers will
move past the nozzle slot without any coherence between the fibers.And the fiber to fiber cohesion
will happen in pure random.

Fiber flow in straight compact nozzle slot

Global Service 5 31/3/2020

Fiber flow in inclined compact nozzle slot

Compact
nozzle slot

As the fibers pass over the nozzle slot, due to the compact suction force under the nozzle slot, the
fibers will be stopped at the RHS edge of Suction slot & creates a cohesion between the fibers by
itself.
Due to the positive forward movement of compact apron, cohesive fiber web is carried forward &
then twisted into the yarn.
Hence in suction compact systems “ It is not only the suction aids in compact the yarn, it’s the
inclined suction slot makes use of the suction & compacting the yarn.

Tension draft calculation

Compact bottom roller diameter on knurling portion 24.3 mm
Front bottom roller diameter on flutes portion 27 mm
No of gear cut in Front roller 24
No of gear cut in compact roller 22

Available/
Variables Standard Remarks
Maximum
DLS Load 2.5 Kg 5 Kg Based on the need
Compact Zone setting- Top
1.5/41 mm 44 mm Based on the staple
/DLS
Compact suction mmWC 180-210 300 Based on material & count
Cradle 39 36 & 43 Based on the quality
Global Service 6 31/3/2020

3) General check points during commissioning

1) Suction pressure (mm WC) in compact slot during initial running will be ranging between
200–SASU end & 170– free end. If the actual pressure is found lesser while checking then the
following points are to be checked.
a) Proper air discharge provision for SASU
b) Air Leakage in compacting zone
c) Rubber boots presence & position as per sequence.
d) Proper seating of the rubber boots fixed in compacting suction pipe.
e) Proper fixing of middle coupling on compact suction pipe & distributor.
f) Choking in middle coupling.
g) Choking in distributor.
h) Nozzle slot choking.
i) All top arms should be pressed.
j) Distance between aluminum guide and fan inside SASU
k) Pressure switch settings

2) During running with material, the drafting fleece should coincide with the compacting slot, if not
then align the roving condenser using roving condenser centering tool to match the drafted
fleece.
3) Verify the compact roller diameter & front roller diameter as front bottom roller
supplied/available in machine.

Quality Parameters to be checked in Compact Spinning after commissioning

a. Hairiness Index / S3
b. Single Yarn Strength / CSP
c. Imperfection
d. Autoconer Cuts
e. No of alarms in Autoconer
f. Warping / weaving performance

4) Guidelines for attending quality issue

Factors which can influence cop hairiness in Ringframe
a. Tension draft - Constant in spinpact
a) 0.982. Lesser the tension draft, lesser the hairiness.
b. Spindle speed
a) Lesser the spindle speed, lesser the hairiness
c. DLS setting ---41 mm
a) Minimum DLS setting ,lesser the hairiness
Global Service 7 31/3/2020

d. Spacer
a) Wider the spacer the lesser the hairiness
e. Front zone setting
a) Wider the front zone setting , lesser the hairiness
f. Traveller bow height traveler
a) Higher the bow height,lesser the hairiness
g. Drafting pressure- 2.1.bar
a) Optimum drafting pressure at 2.1 bar, lesser the hairiness
h. Ring & lappet Centering
a) Perfect ring centering , lesser the hairiness & CV%
i. Draft in ringframe
a) Lesser the total draft, lesser the hairiness

When comparing two different samples for hairiness, always collect the cops & test at same length.
In general there is a difference of up to 1 hairiness index between the initial layers & final layers o
cop due to the difference in balloon length during winding.
Always there is a increase of hairiness index when converting from cop to cone. Depends upon,
a) Winding speed
b) Hairiness in parent yarn
c) SFC in mixing

Factors can influence cop Single Yarn Strength in Ringframe

In a basic Ringframe , strength cant be increased,only because of compact,fiber cohesion is there &
the strength is improved. The strength thus achieved in compact is variable from system to system &
can only be maintained by proper DLS setting, nozzle cleanliness without choking . Thus there is no
scope for increasing the yarn strength in ringframe.
a. DLS setting
a) Minimum DLS setting, yarn strength will be high
b. Condenser centering
a) Proper centering , yarn strength CV% will be good
c. More traverse
a) Minimum the traverse, yarn strength CV% will be good
d. Traveller weight
a) Higher the traveller weight, higher the strength
e. Spindle Speed
a) Higher the spindle speed, higher will be the strength.
f. Top arm pressure
a) Higher the pressure than required, yarn strength will reduce
i. Maintain the drafting pressure in the range of 2.1 to 2.2 bar.
G. Compact suction pressure
Global Service 8 31/3/2020

a) Always go from minimum compact suction pressure 160mm WC to high compact

pressure.up to 280 mm WC. The ratio between the suction pressure to the tension
draft, fiber dwelling period on compact zone is to be predicted by trial & error.

Factors which have cop imperfection in Ringframe

a. DLS load
b) Poor load in compact top roller cots,leads to periodic fault in yarn
b. Compact top roller rotation
a) Struck up of compact top roller leads to periodic fault & CV alarm.
c. Condenser centering
a) Poor condenser centering, higher will be yarn neps
d. Cots hardness
a) Softer the cots, lesser will be yarn IPI
e. More traverse
a) Lesser the traverse, Unevenness CV% will be better
f. Spacer
a) Closer the spacer size, lesser will b yarn IPI
g. Compact suction pressure
a) Lesser the compact suction, lesser will be yarn IPI
h. Front zone setting.
a) Higher front zone setting, higher will be yarn IPI
i. Minimum setting with 39 mm cradle is 51.5 mm & for 43 mm cradle is 55mm
i. Top arm pressure
a) Higher the pressure than required, yarn IPI will be higher.
i. Maintain the drafting pressure in the range of 2.1 to 2.2 bar.
j. Front bottom roller cleanliness
a) Lapping in front bottom roller ,leads to higher yarn IPI, CV & PF alarms in autoconer.
i. Ensure 42.5 mm front bottom zone setting
ii. Ensure compact apron & bottom apron is slightly touching with front bottom roller
iii. Clean the front bottom roller thoroughly with petrol.

In general when the ring frame draft is exceeding 40-50, front zone setting can be maintained as
51.5 mm with 39 mm cradle
Factors can influence cop elongation in Ringframe.
a) Traveller weight
I. Lesser the traveller weight, higher will be yarn elongation
b) Spindle Speed
I. Lesser the spindle speed, higher will be yarn elongation
c) Draft
I. Lesser the total draft, higher the elongation.
Global Service 9 31/3/2020

5) Improving Idler gear life

a) Set the gear play as minimum as possible mentioned in the manual.
b) Never lift all the top arms in a staff during machine running.
c) Don’t interchange the compact roller assembly.
d) During piecing after cleaning, fix the compact roller assembly in roller stand & press at-
least 1 top arm before running.Its better to do offline cleaning
e) Avoid using fluff picker in idler gear while machine is running.
f) Avoid fluff accumulation in idler gear assembly area by properly locking the suction tubes.
g) Avoid lapping of compact roller assembly.

Note:-
a. Life of idler gear is depends upon the delivery speed of front roller,count
processed,material processed & work practise.
b. Maximum life one can expect up to 2 yrs for cotton finer counts & 1.5 yrs for medium
counts & 8 - 1 yr for coarser & synthetics.
c. Above life period does not mean that all the gears will completely fail in that period only.

6) Improving apron life

a) Avoid over piecing of yarn with long tail end
b) Avoid compact apron lapping
c) Maintain the compact apron & tensioner free from fluff accumulation.
d) Maintain proper apron tensioner centering
e) Maintain proper top arm centering.
f) Maintain proper gap between suction tube & compact apron.

7) Maintenance activities in Spinpact

a) For finer count environment compact zone cleaning can be done once in 20- 25 days. For
coarser count 7-10 days.
b) With proper planning, cleaning can be completed in a maximum time of 1 hr.
c) Always do offline cleaning for safety & improving components life
d) Cleaning areas
i. Compact apron
ii. Nozzle slot
iii. Tensioner
iv. Suction tube
v. Idler shaft area
e) Suction tube to be washed thoroughly once in 3 months.
f) Avoid touching of condenser & vertical pipe with petrol or CTC
g) Clean the fluff accumulation in compact roller grooved ring
Global Service 10 31/3/2020

h) Check the condition of compact apron & remove the damaged apron at once.
i) Check the condition of idler gear. If u suspect the gear play is open, check the gear play
with new idler gear. As the gears have worked, gear play seems to be open always.

8) Idler gear removal & fixing procedure

a) Remove the dust cap
b) Loosen the idler gear stud & remove.
c) Remove the idler gear
d) Check the condition of bearings. If needed, replace the bearings
e) Replace the idler gear
f) Fix the gear & check the gear play. If the gear play is OK, tighten the stud at 9 N-m
g) Fix the dust cap.
h) Never loosen the idler shaft bolts (K3-M6X40 & K-M6X25) when there is no need to adjust
gear play.

9) Compact roller bearing replacement

a) Loosen the grooved ring
b) Insert the puller into the grooved ring & pull the grooved ring for certain distance up to 2-
3mm between grooved ring & compact roller
c) Remove the puller & fix the puller onto the bearing
d) Pull the bearing & take it out.
e) After replacing the bearing, butt the grooved ring with compact roller & tighten the grub
screw.