Page 53 - November-December-2020

draft of 1.15, then only a draft of 1.13 remains for the
be manifold and may be related to cotton cultivation
main draft (1.15*1.13 = 1.3). This means that the
and harvesting methods. However, a crucial aspect
is that the economic pressure on spinning mills and
levelling dynamic is limited to 13 percent. This is
their production costs is increasing, leading to the
much too low to respond to short-wave fluctuations.
use of ever shorter fibers.
For comparison: With the autoleveller draw frame,
the main draft and thus the levelling range often
exceeds 400 percent.
Development history of the IDF at Truetzschler
It takes time for optimised processes to establish
themselves on the market. This is because process
shortening initially presents a challenge in the
spinning mill. It must be ensured that the same yarn
quality is achieved in terms of processing
parameters such as strength, elasticity or
appearance. In the mid-nineties, at the beginning of
the IDF development, it was unimaginable that yarn
could be produced from 100 percent noils, but today
this is certainly the case. This is also a way for large
combing mills to include their own waste in the value
By eliminating the break draft in the IDF 2, the entire
chain and selling it with added value. Truetzschler
has significantly advanced this development and
drafting takes place in one drafting zone. Thus the
implemented the IDF system in 1999, based on
levelling range is fully utilised. Fluctuations are ideally
Spanish market requirements for the card TC 11. In
compensated this way. If two parameters must be
the following years, it was continuously developed
optimised simultaneously, it is much more difficult to
and improved.
find the technologically better setting. This is
because break draft and main draft must be varied
In 2013 Truetzschler presented a fundamental
and constantly adapted to material changes. The IDF
2 is thus not only the better technological solution,
revision: The Integrated Draw Frame IDF 2. The
but also simplifies handling. This is a particular
special feature was the reduction of two drafting
advantage, since nowadays many spinning mills
zones to one. Thus, the IDF 2 responds to the
have to deal with the problem of having hardly any
increasingly urgent demands of our customers for
qualified personnel available to technologically
production cost reduction on the one hand and a
evaluate settings of this kind.
high quality standard despite poor raw material
qualities on the other. This is because only the
1-zone drafting system allows particularly low drafts,
When using a normal-width drafting system, larger
which are the decisive guarantee of success for the
the shortening of processes means lower staff
dependent on the presence and experience of
masses are accelerated and decelerated again
processing of particularly short fibers.
during levelling, which can lead to increased energy
numbers are possible, whilst the IDF also provides a
employees in a spinning mill. Nowadays, it is
solution for tackling the increasing demand for
significantly influenced by futuristic plant solutions
consumption. For this reason the width of the bottom
The main difference between IDF 1 and IDF 2 lies in
and intelligent machine systems. In the world of
and top rollers of the IDF 2 has been reduced to the
spinning high-grade yarns from inferior raw material.
the drafting system itself. Experience has shown that
width of a sliver. This also allowed the introduction of
spinning, options for shortening processes, and thus
low total drafts are the key to success – especially
For years, Truetzschler has been watching the trend
the clever solution of rotating top rollers, which has
reducing outlay in production, are becoming more
and more relevant. One example is the IDF
with short-staple cotton, which is usually used in
led to a doubling of the service life before grinding.
that fiber lengths used in the rotor yarn sector in
integrated draw frame from Truetzschler which so far
rotor spinning. However, dividing this small draft into
particular are becoming shorter and shorter. In 2003,
break draft and main draft results in more
the average fiber length for our customers’ rotor yarn
The IDF 2 also introduced the sliver loop storage.
is superior to all competitor solutions. It can be used
disadvantages than advantages. For instance, if the
to combine two important aspects which currently
This driven deflection roller levels the sliver loop by
installations was 28.5 mm, today it is only 26 mm.
Italian Review the rotor spinning process allows a faster production polyester multifilament as T-400® and a cotton fiber. C.A.T. Computer Aided Tension
52 53 High yarn quality is becoming less and less heavily occupy the minds of our customers. For one, This is a remarkable decline. The reasons for this can goal is to achieve a 1.3-fold total draft using a break
cycle and greater output, saving in floor space and This special yarn offers improved recovery and Available on Eco PulsarS Plus, Polar Evolution
capital investment. The process was developed in strength compared to traditional core spun The winding tension is detected continuously by the
means of an integrated light barrier, resulting in actual tension being applied. (IDF 1 break draft 1.0). the ‘60-70 since it was more economical and technology. Tensor, which interacts
perfect synchronisation between card and IDF. The The second diagram illustrates that IDF 2 and IDF 1 resulted in a more consistent yarn thickness. The with the yarn tensioner
levelled loop permits high change speeds. This both have the same trend, i.e. that the yarn strength rotor design is the key to the operation of the Moistair® Splicer device, through the
ensures a higher efficiency at the card, especially decreases with increasing total draft. Compared to open-ended spinners. This system is much less Avalaible on Eco PulsarS Plus, Polar Evolution machine PC, in order to
when using small rotor cans. IDF 1, IDF 2 shows overall strength at a higher level. labor-intensive and faster than ring spinning. A common problem faced by the stretch fabric adjust the load on the
This confirms the statement that the use of only one Solutions for Denim Features of Open End Yarn: yarn as required. The
drafting zone has a positive effect on the yarn • Abbreviated production cycle, optimized cost Tensor, being positioned
properties. production just before the drum,
detects online the real
• More uniform surface
Development of the IDF 2 • Yarn can absorb indigo dye deeper into the core winding tension. The
The IDF 2 has been established on the market for Yarn Processing sensor does not have
seven years. The advantages of the system are now Denim & Winding spun technology. Savio winding machine can easily Single Core Spun Yarn on compact yarns, besides offering the strength, any movable part and
recognised by the entire professional community, Available on Eco PulsarS Plus, Polar Evolution process special and challenging yarns. Savio Core spun yarn is created by twisting staple fibers needs to provide an extremely good appearance not performs as “anti-wrap
competitors and customers. Initially, the shortened winding unit is equipped with splicing and tension to create a visible defect on the finest fabrics. The system”.
process was only used with 100 percent cotton – Savio automatic winders can easily process special and control devices for ensuring perfect joints and Twinsplicer for core yarns preserves the elastomeric
preferably from the recycling sector – but today it is perfect package shape. A common problem faced filament entirely inside the splices. Tensorflex: In presence
challenging yarns; now the most demanding product is by the stretch fabric manufacturers is the breakage Main application range: of elastomeric yarn
blended with
core spun yarns of the yarns during downstream process. • Cotton 100% wool/cotton, the tension
values must be
• Cotton 100% Effect yarns
The well-known Savio Twinsplicer® still represents manufacturers is the breakage of the yarns during • Compact Yarns diversified during the
The combination of Truetzschler cards with IDF 2 The Savio winding unit is equipped with clearing, the solution to achieve the best performance of a production. Savio offers a new splicing technology, • Elastomeric yarns package formation to
“perfect joint” on Core Yarns, mainly “single core”
gives customers an advantage, because they with cotton, but also positive results have been combining air and water, which has given perfect • Cotton and blends ensure a perfect shape.
produce a thin, stable web which is perfectly suited splicing and tension control devices for ensuring perfect achieved with Dual Core Yarns. In this field, Savio Italian Review results in this area. MOISTAIR® splicer gives the
to be drawn directly to the desired sliver count – at can also offer the new splicing technology combining best performance with elastic core yarns. Clearing of Core Yarns C.A.D. Density Control
highest production rates and lowest drafts. If cards splices and perfect package shape air and water, Moistair®, which represents the most MOISTAIR® is an innovative air splicer using a very The structure of core yarns is a special challenge (Optional)
Available on Eco PulsarS Plus, Polar Evolution
produce a heavier web, the use of low drafts is not flexible solution of any kind of yarn. small quantity of water (spray). during quality control. One of the typical faults is the Beyond the winding tension control, the package
possible at all, as, for example, from 12 ktex to 5 ktex density and formation depend on the contact
a draft of 2.4 is applied. Denim is integrated into our lifestyle. Denim is always requested, especially for womenswear. Keeping up Denim & Rotor Spinning around a central elastomeric filament core, usually It is endowed with a water valve with a dosage pressure of the package on the drum. The load of
setting to moisture the splice. Suitable for almost all
made of LYCRA® fiber. Different basic fibers (short
popular and its market is expanding. As lifestyle with this trend of stretch denim, many yarn & fabric To allows the warping process to be best achieved, Available on Helios kind of short and long spun yarns, with the exclusion
One versus two drafting zones – technological no longer limited to this. The system is successfully changes, so does denim – with new weights, fibers, manufacturers are offering core yarns with improved and long staple) are commonly used: cotton,
advantages applied in the processing of 100 percent raw cotton finishing techniques, application treatments and recovery and strength, while retaining the comfort of winding machines produce big cylindrical packages, viscose, siro, woolen blends. of plied cotton, high twisted wool yarns and linen.
In order to show the influence of the distribution of and other materials. It thus offers an answer to the end-uses. Denim today it is worn everywhere: add cotton next to the skin. usually 300mm in diameter and over, with high The MOISTAIR® has delivered superior
drafts on main draft and break draft as opposed to requirements of our customers with regard to spandex for fitand comfort, Tencel® for luster, density. The peculiar robustness and strength of Dual Core Spun Yarn performances on TENCEL® and fine counts fabrics.
only one draft zone, a yarn of 100 percent raw cotton increasing and necessary flexibility in the production polyester for wear, wool for warmth, flax for looks. Dual-core spun yarns are a combination of two denim is given by the thickness of the yarn. Dual core spun yarns are made of three
(Mato Grosso) with Ne27 was spun in the direct process. different stretch products such as LYCRA® fiber and components: a core filament - mainly Lycra®, a Main application range:
spinning process with a card production of 170kg/h. Dye it into bright colors, or print or embellish it. Along LYCRA® T400® fiber; this yarn increases stretch The demand for yarns with elastomeric core is • Short and long spun yarns
With IDF 1, break drafts of 1.0, 1.05 and 1.16 with The handling of the IDF has also been improved. For with pants, denim is now available in coats, jackets, power and provides great shape conformity for expanding and plays an important role because of • TENCEL®
different main drafts were combined. The IDF 2 was example, there is now a retention lock that prevents skirts, dresses, eveningwear, accessories and advanced comfort. This stretch technology hidden fashion versatility and flexibility. Stretch garments are • Elastic core yarns
run with drafts of 1.2 to 1.95. The tests showed the the cover of the IDF from always having to be footwear. It is worn everywhere by men, women and within the yarn eliminates the “bagging knee playing an important role inside this scenario, denim • Very fine cotton yarns
trend across all parameters that IDF 2 with its 1-zone opened completely during the piecing process. children. Denim is the fabric of choice and its syndrome” and creates a new standard for superior jeans and leggings are highly requested, especially • Coarse and slub yarns
drafting system has clear advantages over IDF 1. Similarly, the use of maintenance-free deep groove popularity is growing. Tencel® has taken off in denim shape retention and recovery performance, providing for womenswear. Keeping up this trend of stretch • Dual core yarns
denim, many yarn & fabric manufacturers are
ball bearings entirely eliminates the need for at the high end of denim market. It offers softness, a soft cotton hand and natural appearance. offering duo core yarns with improved recovery and
The first diagram shows the influence on yarn relubrication at the delivery rollers: The number of strength and sustainability. The softness of Tencel® Twinsplicer
evenness for a total draft of 1.7. There is clear lubrication points is thus reduced to four. The is especially popular in womenswear with skinny The technology has relevance not only for jeans and strength, while retaining the comfort of cotton next to Avalaible on Eco PulsarS Plus, Polar Evolution so-called strip-back. Due to a slippage between the
evidence that the break draft in the IDF has a jeans. trousers, but also for denim leggings that lately have the skin. Rotor spinning (commonly called “Open End The Twinsplicer, the unique selling proposition of inner elastomeric filament and the staple fiber, the the package on the drum is controlled by an
negative influence on yarn parameters. It is self-adjusting lap monitoring of the top rollers, become popular. The added strength provided by spinning”) is a process that incorporates spinning Savio, provides top quality splice. The way the splice core is not completely covered with the cotton fibers. “electronic/pneumatic” system, which adjusts the
noteworthy that for all quality parameters, the already known from the draw frames, has now also The trend toward body-fitting yet comfortable fashion polyester helps these fabrics withstand bleaching Dual core spun yarns are consisting of three and winding operations. With the Open End system, is prepared and made, ranks the Twinsplicer at the As elastane and cotton have different characteristics pressure of the counterweight piston, in accordance
presence of the first drafting zone in the IDF 1 alone found its way to the IDF. There is no need to readjust apparel is very demanding and challenging. Stretch and washing techniques, even on denim with components: a core filament - mainly Lycra®, a the sliver coming from the draw frame is directly top among all other splicing devices. The splicer during dyeing, these faults can become visible in the with the density value required for the package.
has a negative effect on the results, without any after grinding intervals and changed settings. polyester multifilament as T-400® and astaple fiber- strength is close to parent yarn, keeping the final product. The yarn clearer can identify faults Special yarns (elastomeric and very fine yarns),
garments are playing an important role inside this treatments such as antique finishes, whisker washing mainly cotton. This special yarn offers improved converted into yarn, wound onto package cones. In appearance the same as the parent yarn. The splicer during winding; also faults in core yarns can be especially for dyeing packages, may require a very
scenario, denim jeans and leggings are highly and sandblasting. recovery and strength compared to traditional core the count range in which it can be used, the use of identified. severe control of package density.
November/December 2020 November/December 2020