How It's Made Cotton yarn

Summary

This 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

00:00

🧶 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.

Keywords

💡Yarn

Yarn refers to a long continuous length of interlocked fibers, suitable for use in the production of textiles, sewing, crocheting, knitting, weaving, and ropemaking. In the context of the video, yarn is twisted from plant or animal fibers and is essential in the textile industry for making fabrics like those used in jeans and tops. The script describes the process of yarn production from raw cotton through various stages of cleaning, combing, and stretching.

💡Spinning Wheel

A spinning wheel is a device used to spin threads or yarn from various纤维. It was invented in India around 500 BC and revolutionized the textile industry. The script mentions the spinning wheel as the precursor to modern automated spinning machines, which operate on the same principle of twisting fibers into yarn.

💡Cotton

Cotton is a soft, fluffy staple fiber that grows in a boll around the seeds of the cotton plant. It is one of the most important natural commodities in the world. In the video script, cotton is the raw material used to create yarn. It undergoes a series of processes to remove leaves, stems, and impurities before being turned into usable yarn.

💡Blending and Cleaning Machine

This machine is part of the yarn production process and is responsible for blending and cleaning the cotton. It processes 500 kg of cotton per hour, ensuring that the fibers are evenly blended and cleaner, although not yet clean enough for the next stages. The script highlights the importance of this machine in preparing the cotton for further processing.

💡Carding Machine

A carding machine is used in the preparation of textile fibers for spinning and is used to disentangle, clean, and intermix fibers. In the script, the carding machine combs out tangled fibers and lines them up in parallel rows, discarding any fibers that are too short to process, which is crucial for the quality of the final yarn.

💡Sley

Sley, also known as sliver, is a thick and loose first stage yarn formed from rows of fibers. In the video script, the coiler device forms the fibers into sley, which is then further processed through drawing and other stages to create finer and stronger yarn.

💡Drawing Machine

A drawing machine in textile manufacturing is used to align and stretch fibers to form a second stage yarn. The script describes how six slivers are lined up and drawn out to form a second stage yarn, which is a step towards creating the final product.

💡Roving Frame

A roving frame is a machine used in the textile industry to stretch and thin out the second stage yarn, called roving, to strengthen it. The script mentions that this machine stretches the roving to make it thinner, which is a critical step in preparing the yarn for the final spinning process.

💡Roving

Roving is a semi-finished product in the spinning process, which is a third stage yarn that is stronger and thinner than the previous stages. The script explains that roving is anywhere from 3.5 to 16 times thinner than sley, indicating the progress in the yarn-making process.

💡Winding Machine

A winding machine is used to transfer yarn from small spools onto larger ones, such as industrial size cones. The script describes a winding machine that winds yarn from one spool onto a cone and attaches it to the next spool with a knot, automating the process and ensuring continuity in the yarn.

💡Airjet Spinning

Airjet spinning is a modern yarn spinning method that uses a suction tube to grab the front end of one spool and connect it to the back end of the previous one, with a tiny knot. The script contrasts this method with older, manual processes, highlighting the advancements in automation and efficiency in yarn production over the past 50 years.

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