How It's Made Cotton yarn
Summary
TLDRThis script narrates the evolution of yarn production from primitive spindles to modern automated machines. It details the process of transforming raw cotton into commercial yarn, involving cleaning, combing, and stretching stages. The script also highlights the use of winding machines for quality control and the transition from manual to automated processes, culminating in the production of a fine yarn used in fabrics like jeans and tops.
Takeaways
- 📚 The process of spinning yarn from plant or animal fibers dates back to ancient times.
- 🌏 The spinning wheel, invented in India around 500 BC, revolutionized yarn production.
- 🏭 Modern factories utilize fully automated spinning machines that operate on the same principle as the spinning wheel.
- 🧶 A two-ply commercial yarn, used for weaving fabric in jeans and tops, is made from raw cotton.
- 🌿 Cotton naturally contains leaves and stems, which are removed in the initial stages of processing.
- 🔍 The first cleaning machine processes 500 kg of cotton per hour to blend and clean the fibers.
- 🔧 A second cleaning machine further refines the cotton to ensure it is clean enough for spinning.
- 📏 The carding machine combs out tangled fibers and aligns them in parallel rows, discarding any too short to process.
- 🔄 The coiler forms the first stage yarn called sliver from the aligned fibers.
- 📌 The drawing machine and roving frame further process the yarn by stretching and thinning it to increase strength.
- 🔗 The final stage of yarn production involves stretching the roving up to 30 times thinner to strengthen it further.
- 🔄 The winding machine transfers the finished yarn from small spools onto large industrial cones for quality control and packaging.
- 👁️🗨️ An optical sensor performs a quality control check, cutting off and reattaching yarn that doesn't meet specifications.
- ⏱️ The entire process of spinning yarn from start to finish takes approximately 48 hours.
Q & A
What is the historical origin of the spinning wheel?
-The spinning wheel originated in India around 500 BC.
What is the purpose of the first cleaning machine in the cotton processing?
-The first cleaning machine removes a 5 mm layer of cotton and processes 500 kg of cotton per hour to blend and clean it, but it is not yet clean enough for further processing.
What does the second cleaning machine do to the cotton?
-The second cleaning machine finishes the job of cleaning the cotton, making it ready for the next stages of processing.
What is the function of the carding machine in the yarn production process?
-The carding machine combs out tangled fibers and lines them up in parallel rows, also discarding any fibers that are too short to process.
What is the first stage yarn called that is formed by the coiler?
-The first stage yarn formed by the coiler is called sliver.
How does the drawing machine contribute to the yarn production?
-The drawing machine lines up six rows of fibers at a time and draws them out, stretching them to form a second stage yarn.
What is the purpose of the roving frame in the yarn-making process?
-The roving frame stretches the second stage yarn, strengthening it by thinning it out until it reaches the desired consistency.
How much thinner is the final yarn compared to the initial sliver?
-The final yarn is 200 times lighter than the initial sliver that came out of the carding machine.
What is the role of the winding machine in transferring yarn onto industrial size cones?
-The winding machine winds the yarn from small spools onto large industrial size cones, automatically attaching and discarding spools as they empty.
How does the optical sensor on the winding machine ensure quality control?
-The optical sensor performs a quality control check, stopping the winding if a portion of yarn doesn't meet specifications, cutting off the offending portion, reconnecting the ends, and resuming winding.
What is airjet spinning and how does it differ from the winding method described?
-Airjet spinning is another method of making yarn from slivers and winding it onto giant spools known as tubes. It uses a suction tube to connect the yarn spools with tiny knots, which is a more automated process than the manual nodding that was done before the invention of fully automated machines.
How long does it take to spin the yarn from start to finish?
-Spinning the yarn from start to finish takes 48 hours.
Outlines
🧶 The Evolution of Spinning
This paragraph discusses the history and modern process of spinning yarn from plant or animal fibers. It starts with the ancient practice of using primitive spindles made from sticks around 500 BC and the invention of the spinning wheel in India. The narrative then transitions to the present day, where fully automated spinning machines operate on the same principle as the spinning wheel. The paragraph details the production of a two-ply commercial yarn used for fabrics like jeans and tops, which are made from raw cotton. It explains the initial cleaning process that removes leaves and stems, the use of blending and cleaning machines that can process 500 kg of cotton per hour, and subsequent cleaning stages. The paragraph also describes the carding machine that combs and aligns the fibers, the coiler that forms the first stage yarn called sliver, and the drawing machine that stretches and aligns fibers to form a second stage yarn. A roving frame then strengthens the yarn by thinning it out, creating a third stage yarn called roving. The final step involves stretching the roving to make it even thinner and stronger, and transferring it from small spools to large industrial cones using either a winding machine or airjet spinning. The winding machine also performs a quality control check, cutting off any yarn that doesn't meet specifications. The paragraph concludes by noting that the thin finished yarn is 200 times lighter than the initial thick yarn and that the entire spinning process takes 48 hours.
Mindmap
Keywords
💡Yarn
💡Spinning Wheel
💡Cotton
💡Blending and Cleaning Machine
💡Carding Machine
💡Sley
💡Drawing Machine
💡Roving Frame
💡Roving
💡Winding Machine
💡Airjet Spinning
Highlights
Twisting plant or animal fibers into yarn dates back to ancient times.
The spinning wheel was born in India around 500 BC.
Today's factories use fully automated spinning machines.
A two-ply commercial yarn is used to weave fabric for jeans and tops.
Cotton comes from a plant and contains leaves and stems.
The first machine removes a 5 mm layer of cotton and cleans it.
The cotton is processed through a blending and cleaning machine that processes 500 kg per hour.
A second cleaning machine is used to finish cleaning the cotton.
A carding machine combs out tangled fibers and lines them up.
The carding machine discards any fibers that are too short to process.
The coiler forms the first stage yarn called sliver.
The drawing machine stretches the sliver to form a second stage yarn.
A roving frame strengthens the second stage yarn by thinning it out.
The roving is stretched up to 30 times thinner to strengthen it further.
The yarn is transferred from small spools onto huge industrial size cones.
A winding machine winds the yarn and attaches it with knots from one spool to the next.
An optical sensor performs a quality control check during winding.
If yarn doesn't meet specifications, the machine cuts off the offending portion and resumes winding.
Airjet spinning is another method of making yarn from slivers and winding it onto giant spools.
Before fully automated machines, the nodding process had to be done by hand.
The thin finished yarn is 200 times lighter than the thick first stage yarn.
Spinning this yarn takes 48 hours from start to finish.
Transcripts
twisting plant or animal fibers into
yarn dates back to ancient times when
people fashion primitive spindles out of
sticks around 500 BC the spinning wheel
was born in India today's factories have
fully automated spinning machines that
work on the same Principle as a spinning
wheel this is a two ply commercial yarn
the kind factories used to weave fabric
for making jeans and tops it's made from
large Vees of raw
cotton cotton comes from a plant so
naturally some leaves and stems are
mixed in with the cotton
fibers to remove them the first machine
passes over the Bales and removes a 5 mm
layer of
cotton then sends it through a duct
system to the blending and cleaning
machine that machine processes 500 kg of
cotton per hour the cotton comes out
evenly Blended and cleaner but still not
clean enough so it goes into a second
cleaning machine which finishes the
job now the cotton goes through what's
called a cting machine it has huge
rollers with with wire teeth they comb
out the Tangled fibers and line them up
in parallel rows the machine also
discards any fibers that are too short
to
process next stop the coiler this device
takes the rows of fibers and forms them
into a thick and loose first stage yarn
called sver
the slers move on to the drawing machine
It lines them up six at a time and draws
them out stretching them to form a
second stage
yarn then a machine called a roving
frame stretches this second stage yarn
strengthening it by thinning it
out until it looks like this
this third stage yarn is called roving
depending on the type of yarn they're
making it's anywhere from 3 and 1/2 to
16 times thinner than
sver they now stretch the roving up to
30 times thinner which strengthens it
even more the yarn is finally
finished now they have to transfer the
yarn from all these small spools onto
huge industrial size cones 20 spools to
a
cone one transfer method uses the
winding machine it winds the yarn from
the first spool onto the
cone then it automatically takes the
back end of that yarn and attaches it
with a knot to the front end of yarn
from the next spool it winds it onto the
cone then attaches the back end to the
front end from the next spool and so on
as each spool empties the machine
automatically discards
it and while all that winding is going
on the machine's Optical sensor that
white object you see crossing the screen
does a quality control check if a
portion of yarn doesn't meet
specifications the winding stops the
machine cuts off the offending portion
then reconnects the ends and resumes
winding
this is airjet spinning another method
of making yarn from sers and winding it
onto giant spools known as
tubes a suction tube grabs the front end
of one spool and connects it to the back
end of the previous one again with a
tiny Knot Before fully automated
machines like this this were invented 50
years ago all that nodding had to be
done by hand the thin finished yarn is
200 times lighter than the thick first
stage yarn that came out of the carding
machine from start to finish spinning
this yarn has taken 48 hours
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