Yarn Spinning Guidelines for CoolVisions™ Dyeable ... Yarn Spinning... · Yarn Spinning Guidelines for CoolVisions® Dyeable Polypropylene Fibers ... Yarn Count 30 Blend %

CoolVisions® Dyeable Polypropylene Fiber Yarn Spinning Guidelines for CoolVisions® Dyeable Polypropylene Fibers General Comments The CoolVisions® dyeable PP staple fibers are offered as 1.5 dpf X 1.5", 1.5 dpf X 2.5” and 1.2 dpf X 1.5" staple length for ring spinning (T-108) and 1.2 dpf X 1.5" (T-111) for Murata Air Jet Spinning (MJS). Over working the fiber in the card is what causes most of the neps and imperfections. A key factor is the card wire – aggressive wire will damage the fibers. Attention must also be paid in the primary and final opening system to ensure the in feed fiber mat feeding the card is uniform and remains uniform during carding (mat density). Uneven feed mat can cause thick & thin spots in the web. Newer high speed cards with rotary flats are recommended. We suggest start up at low carding speeds. For example, in our trials with Trutschler DK 760 cards we start up at 75 or 80 yards/min (45 to 50 lbs/hr) until the card wire becomes acclimated with the fiber finish. Most phosphate ester finishes are compatible with the finish on our fiber. One must be careful trying to run behind rayon blends, as the rayon finish may be highly incompatible and will cause cards to load quickly and could cause fusion. General Recommendations The subsequent pages show detailed optimized settings developed by the Textile Technology Center at Gaston College (Belmont, NC). Not all the work has been completed. The information in this document shall be updated as additional optimization studies are completed. In general, we recommend the following card settings as a starting point: Feed Roll Clearance = ~ 0.007" Flat Clearance = ~ 0.022" Doffer Roll Clearance = ~ 0.006" We do not recommend mineral oil-based lubricants. These swell polypropylene fibers and are absorbed into the fibers. We recommend paraffin wax lubricants for the spun yarns. A soft wax containing an anti-stat is preferred as polypropylene tends to pick up less wax from a lubricating disc than other fibers. In the US, a source for a wax that has been tested and works well is United Wax - catalog number UW 1500 DPA. Contact Information: United Wax Ellen Kiser 704-786-6716

©FiberVisions, 2007 INTERIM DOCUMENT September 5, 2007

CoolVisions® Dyeable Polypropylene Fiber Trouble Shooting Recommendations If the fiber does not open well: The openness of the fiber is crucial to insure uniform web in carding. The primary and fine opening systems can be adjusted to help with the aforementioned problem. The incline in the primary opener should be adjusted up to slow the flow to the transfer belt, and make the fiber stay in the opener longer. This will help further break up clumps of unopened fibers. The fine opener should be set up to run and maintain the minimal amount of fiber in the hold. This will not allow the fibers to pack while being opened. The transfer air between the fine opener and the even-feed system at the card can be increased to further the openness. Reduction of neps: Speed up the flats and make sure the brushes are set deep enough in the flats to ensure that all fibers are removed from the flats please note that overworking the polypropylene fiber with an aggressive wirewill shred our fiber and result in neps. Reduction of thicks and thins: match as closely as possible the ratio between the main cylinder, doffer roll, crush rolls, and coiler tension settings. Otherwise, holes will be pulled in the web during carding and result in poor yarn quality.

©FiberVisions, 2007

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INTERIM DOCUMENT September 5, 2007

CoolVisions® Dyeable PP Fibers for Ring Spinning Opening using a Truetzschler 760 Card

CUSTOMER: FiberVisionsTYPE FIBER: PolypropyleneBLEND (%) 100%SLIVER DEL. (Grs./yd.) 65.0

WORKING MEMO.Sliver Wt. (grs./yd.) 65High Speed (yds./min.) 100Slow Speed (yds./min.) 20Starting Speed (yds/min.) 15Draft V-4 (min) Draft V-4(max)Draft 90Speed of Flats (M/M) 167Can Filling (yards) 4500DFK Target Pressure (Pa) 310Main Cylinder Speed (%) 69Main Cylinder Speed (RPM) 358Licker-in Speed (%)Licker-in Speed (RPM) 924

ACTUAL VALUESSliver wt. (grs.) 66Web Thickness 1.76Balancing value 5.03Actual Draft 82-88Momentary Draft V-4 1.3Card Wt. C. V. % 1.4Sliver CV% 4.48

Hopper Settings:Hopper # 11 VolumetricHopper # 12 offLift Apron Notch 6Fine Opener Settings:Beater Speed (RPM) 671Fan Speed (RPM) 1900

Electrical Pannel Settings:Fine Opener Feed Rolls 9Pressure Setting (Pa) 825

FBK 533 Settings:Chute Wall (MM) 50Mate Draft Sprocket 30

©FiberVisions, 2007 Page 3 INTERIM DOCUMENT

September 5, 2007

CoolVisions® Dyeable PP Fibers for Ring Spinning TRUETZSCHLER EXACTACARD DK760

CUSTOMER: FiberVisionsTYPE FIBER: PolypropyleneBLEND (%) 100%SLIVER WT. (Grs./Yd.) 65

CARD WIRE (Hollingsworth) WIRE I. D. NO. POINTS/SQ. IN. FRONT ANGLE WIRE HEIGHT (.000) LICKER-IN 3445 JDH 40 +10 CARDING SEGMENT 3881 78 0 0.26700 CYLINDER T20.30.050.0860.05/X 860 +30 0.09840 DOFFER T40.30.100.0295.28.05/X 295 +30 0.1575 REV. FLATS HX33 Progressive 330 STATIONARY FLATS (FEED) 4358 145 +10 0.19700 STARIONARY FLATS (DEL.) 3439 541 +10 0.19700

CARD DRAFTS FBK DEL. ROLL TO CARD FEED ROLL 1.860 34 T. SPROCKET DOFFER TO STRIPPER ROLL 1.040 81 T. GEAR STRIPPER ROLL TO CRUSH ROLLS 1.192 28 T. GRAR WEB TENSION 1.166 17 T. GEAR COILER TENSION 1.013 17 T MW / 31 T. KW TOTAL DRAFT 90

CARD PULLEY DIAMETERS (MM) CYLINDER (MOTOR) 190 LICKER-IN 210 REVOLVING FLATS 220

CARD SPEEDS DELIVERY SPEED (YDS./MIN.) 150 LICKER-IN (RPM) 920 CYLINDER (RPM) 365 REVOLVING FLATS (MM/MIN.) 166

CARD SETTINGS 1/1000 IN. FED TABLE TO LICKER-IN 0.040 CARDING SEGMENT TO LICKER-IN 0.022 LICKER-IN TO CYLINDER 0.007 STATIONARY FLATS (FEED) .022/.020/ .018 REVOLVING FLATS TO CYLINDER 0.022 STATIONARY FLATS (DEL.) 0.022 CYLINDER TO DOFFER 0.007 DOFFER TO TAKE-OFF ROLL 0.005 CYLINDER SCREEN TOP FRONT 0.080


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CoolVisions® Dyeable PP Fibers for Ring Spinning RSB 851 Draft Settings

CUSTOMER: FiberVisions FiberVisionsTYPE FIBER: Polypropylene PolypropyleneDenier 1.5 1.2TOPCOAT FINISH Ring RingBLEND LEVEL (%) 100% 100%SPINNING MACHINE Ring RingSTAPLE LENGTH: (MM) 38 38STAPLE LENGTH: (INCHES) 1.50 1.50Breaker DrawROLL SETTINGS (MM)FRONT TO MIDDLE 43 43MIDDLE TO BACK 46 46 SLIVER FED (GRS.) 66 66 ENDS UP 5 5 SLIVER DEL. (GRS.) 67 67 GEAR RATIO 52/62 52/62 BREAK DRAFT PULLEY 42.2 42.2 BREAK DRAFT 1.41 1.41 FRONT DRAFT 3.58 3.58 TOTAL DRAFT 5.05 5.05 SLIVER TUBE (MM) 12 12 COILER FINISH Matte Matte COILER TUBE DIA. (MM) 41 41 CAN TABLE GEAR 47 47 DELIVERY SPEED (M/M) 300 300 YARDS/CAN 1425 1425 SLIVER C. V. % 3.39 3.36 Webtension 1.00Finish Draw

ROLL SETTINGS (MM)FRONT TO MIDDLE 43MIDDLE TO BACK 46 SLIVER FED (GRS.) 66 ENDS UP 5 SLIVER DEL. (GRS.) 50 GEAR RATIO 52/58 BREAK DRAFT PULLEY 42.2 BREAK DRAFT 1.41 FRONT DRAFT TOTAL DRAFT 6.71 SLIVER TUBE DIA. (MM) 12 COILER FINISH Matte COILER TUBE DIA. (MM) 41 CAN TABLE GEAR 26 DELIVERY SPEED (M/Min) 300 YARDS/CAN 2100 SLIVER C.V. % 2.00


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CoolVisions® Dyeable PP Fibers for Ring Spinning Rovematic FC-12F Roving Settings for 1.5 dpf

Distance108 63 E3 50 gr./yd. Input Wt. inches Area

18 17.81 G & Middle Roll27.38 J & Back Roll

78 72 67.99 H76 17.00 E1,E2,E3

1.125 8.97 D1,D257 29 43.7 rpm 9.66 C

1.294 Back Draft from rpm 4.03 B1,B2165 66 1.0625 58.5 rpm 3.53 A1 & Front Roll108 8457

36 1.125 282.3 rpm

70 35 1.25 Nec Output count 1 Hours22 # Spindles

41 56.28 Lbs./ Above Hrs.3.20 100% Hanks

gr./yd. Input Wt. 50 gr./yd.Nec Output count 1.25 HkActual draft from sliver & Hk. 7.50Predicted Draft Gear from above 3 & K 36.16 t Mechanical

0.918 From K Constants (K)Draft Gear 35 t 5.33 Front Draft K 186.70 Front Draft KBack Draft Gear 66 t 1.452 Back Draft 95.86 Back Draft K

7.75 Total Draft 271.18 Total Draft K

Required Hank 1.25 HkPresent Hank 1.23 HkNew Gear 34.4 t

Predicted Twist Gear from TPI = 53.50 t 0.559 Desired TwistPredicted Twist Gear from TM = 53.501 t 0.500 Desired TM

Twist from TM 0.559 tpi

Mechanical Twist from chg. & K 0.808 tpi 29.91 Twist KTM from chg. & K 0.723 32 Twist Gear

Measured Twist (by tach) = 0.801 tpi 456 Delivery Roll RPMTM from measure twist & Hk 0.716 1291 Flyer RPM

2740

54 6032

21 5419 22

5322

6041 Desired Hank 1.25 Hk

Present Hank 1.25 HkNew Gear 37.0 t

Desired TPI 0.801 Hk35 57 37 Present TPI 0.801 Hk

New Gear 37.0 t

53 19 35 54 40 29.9081 Twist K22 22 1 32 27 6.087 0.808 TPI

TwistChg. Gear

Roving

sliver

inch

inch

inch

Spectrogram Frequency A l i

Production

Rovematic FC-12F

IdlerTwist KChg. Gear

PIV

Front Roll 1.125 inch

=

New Gear

Draft

inch

E1

E2

D1

C

B2

F

G

H

J

A1B1

D2

Twist Change

Weights

New Gear


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CoolVisions® Dyeable PP Fibers for Ring Spinning Rovematic FC-12F Roving Settings for 1.5 dpf

Escapement Shaft A

Chg. gear # 1953

Tension Constant 2640 Present Hk 0.75Layers Per Inch 49.81 Desired Hk 0.6

38 or 30 New Gear 59.338

110 Tension Constant 2640Layers Per Inch 30

116 or 108 New Gear 88.0108

41 60

Lay Gear Ratio 262.69Lay Constant 26.0Coils Per Inch 11.42 27

50 Coil Multiplier 10.123 56

Present Hk 1.23Desired Hk 1.25New Gear 22.8

Lay Gear Ratio 262.7Coils Per Inch 11.42New Gear 23.0

Idler95-110-120

PIVPIV

IdlerTwist KChg. Gear

Dwell Gear

Idler LayChg. Gear

Tension Change

Lay Change

New Gear

New Gear


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Murata C-7 spinning set-ups for 1.5 denier WINDER INFORMATION Type Winder Murata Model No. C-7 Loction Center Winder Speed (meters/min.) 1000 Waxed yes No. of Spinning Bobbins/cone Pounds/Cone 1 Cones Needed 110 Total Pounds Shipped Winder Set-up Information Yarn Count 30 Blend % Package Length (Yards) 50400 Package Weight (Lbs.) 2 Package Mass (Grams) 925 Package Length (M) 46,086 Bobbin Mass (Grams) 131 Speed (M/M) 1000 Yarn Strength (Grams) 222 Hard/Soft Standard (V) 5.0 Tension (cn) 12.0 Clearer Settings N % 350 S % off;2.5 L % cm 45;45 T % cm 45;45 Spl % cm 135;4.0 C+ % M 30;3 C- % cm 30;200 CC+ % 30 CC- % 30;200 Upper Yarn % 80 Head Type MKC 20


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Spinning set-ups for 1.5 denier SPINNING CSM Back to Middle (mm.) 50.8 Middle to Front (mm.) 44.4 Roving Fed (HR) 1.25 Yarn Count 30 Total Draft 24.00 Draft Gears W-5/W-6 50 Draft Gears Used W-5/W6 50 Actual Draft 27.84 Break Draft 1.26 Yarn Count (Actual Lab. Test) 30.2 Twist Multiple 3.25 Calculated TPI from count & TM 17.8 Twist Gears W-1 W-2 W-3 W-4 63-62-84-96 TPM from gear chart 770.8 Spindle rpm from screen 7960 Delivery m./min from screen 11.4 Actual TPI from above 2 speeds 17.74 Actual TM from above 2 speeds 3.24 Traveller speed from above 2 speeds (ft./min.) 4,512.4 Front Roll Dia. (Inches.) 1.063 Front Roll Speed (RPM) 135 Spindle Speed (RPM) 8,000 M/MM Yarn on Bobbin (1) 30 Traveler Size 2 ; G-3 Apron Clip brown Top Roll Weight (SKF) red No. of Spindles 157 Pounds/Bobbin .23 No. Doffs 2+ Total Spinning Bobbins


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Yarns from Polypropylene Blends

Set ups for spinning blends

TYPE FIBER: First Polypropylene Polypropylene Second Cotton PET BLEND LEVEL (%) 70/30 70/30 SPINNING MACHINE Ring Ring STAPLE LENGTH: (MM) 38 38 STAPLE LENGTH: (INCHES) 1.50 1.50 Denier 1.2 1.2

Breaker Draw

ROLL SETTINGS (MM)

FRONT TO MIDDLE

43 41 MIDDLE TO BACK

46 43

SLIVER FED (GRS.)

72 72 ENDS UP

6 6 SLIVER DEL. (GRS.)

63 63 GEAR RATIO

52/62 52/62 BREAK DRAFT PULLEY

42.2 42.2 BREAK DRAFT

1.41 1.41 FRONT DRAFT

3.58 3.58 TOTAL DRAFT

5.05 5.05 SLIVER TUBE (MM)

12 12 COILER FINISH

Matte Matte COILER TUBE DIA. (MM)

41 41 CAN TABLE GEAR

29 29 DELIVERY SPEED (M/M)

300 300 YARDS/CAN

1425 1425 NO. OF CANS

5 5 SLIVER C. V. %

3.39 3.39 Webtension

1.00 1.00


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Finish Draw ROLL SETTINGS (MM) FRONT TO MIDDLE 43 43 MIDDLE TO BACK 46 46 SLIVER FED (GRS.) 66 66 ENDS UP 6 6 SLIVER DEL. (GRS.) 50 50 GEAR RATIO 52/58 52/58 BREAK DRAFT PULLEY 42.2 42.2 BREAK DRAFT 1.41 1.41 FRONT DRAFT TOTAL DRAFT 6.71 6.71 SLIVER TUBE DIA. (MM) 12 12 COLIER FINISH Matte Matte COLIER TUBE DIA. (MM) 41 41 CAN TABLE GEAR 26 26 AMOUNT NEED (LBS.) DELIVERY SPEED (M/Min) 300 300 YARDS/CAN 700 700 NO. OF CANS SLIVER C.V. % 2.29 2.24 Leveller S-93

Roving, Spinning, and Winding steps are the same for blends as for 100% CoolVisions fiber.


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Yarn Spinning Guidelines for CoolVisions™ Dyeable ... Yarn Spinning... · Yarn Spinning Guidelines for CoolVisions® Dyeable Polypropylene Fibers ... Yarn Count 30 Blend %