GVS TEX

Yarn Realization

WE ASSURE YOU OF A PROFIT OF 1 % NOILS ON COMBER MACHINE SETTING. WE USE MINIMUM SPARES AS PER YOUR MACHINE STUDY.

WE ASSURE YOU OF A PROFIT OF 2 % NOILS ON COMBER MACHINE SERVICING. WE USE MEDIUM LIST OF SPARES AS PER YOUR MACHINE STUDY.

A Technologist's Guide to Yarn Realization

A Few months before, The cotton spinning industry faced turmoil due to skyrocketing cotton prices, which peaked at ₹1,00,000 per candy, creating a significant price disparity of over ₹20 per kilogram with yarn. In medium-count cotton spinning mills, raw material costs account for approximately 75% of total sales revenue, making it crucial for technicians to optimize yarn realization without compromising quality, thereby enhancing profitability.

Yarn realization norms vary across spinning mills due to differences in raw material properties, such as fiber characteristics and trash percentage, which are influenced by regional variations in raw material sourcing.

Enhanced yarn realization boosts a spinning mill's competitiveness and profitability by optimizing raw material conversion into finished yarn. Key factors influencing yarn realization include Raw material usage, Blow room, cards, and combers efficiency, Waste management (sweeping, hard, overhead cleaner, gutter, top roll clearer, filter, micro dust, and invisible loss).

The value of waste generated during yarn production is significantly lower than the initial cost of cotton, highlighting the importance of efficient yarn realization. Currently, spinning mills achieve 85-95% yarn realization for carded quality, 68-70% yarn realization for comber quality.

Yarn realization norms vary across spinning mills due to differences in raw material properties, such as fiber characteristics and trash percentage, which are influenced by regional variations in raw material sourcing.
For instance, regional variations in raw materials include Shankar 6 (Gujarat), Mech (Maharashtra, Karnataka), J34 (Punjab, Haryana), Additionally, yarn realization is influenced by the type of machinery used including, Brand and manufacturer, Model and technology, Configuration from Blow Room to Auto Coners.
Additional factors influencing yarn realization include Machine technology (year of manufacture and prevailing technology), Process parameters and machine settings, Worker practices and effectiveness, Invisible loss management, Customer-specific yarn quality requirements, Accounting systems.
To recap, the key factors influencing yarn realization include Fiber properties of raw materials, where each property has its unique advantages.

2.5% Span Length influences spinnability, productivity, yarn unevenness, strength, imperfections, and hairiness.
Mic Value affects hairiness, strength, machinery performance, and fabric feel.
Fiber Strength impacts yarn strength and ring frame performance.
Short Fiber Content affects waste extraction, imperfections, and CV percentage.

Short Fiber Content: < 23% in mixing
Neps/Gram: < 100 for minimized waste extraction and yarn quality
RD and B Values: influence fiber brightness and yellowness after dyeing
Trash Content: affects waste extraction from Blow Room and cards, impacting yarn realization

Maintain high nep removal efficiency to minimize waste extraction in combers
Ensure breaker and finish draw frames eliminate good fibers in filter waste

Short fiber content
Neps in feed material
Required yarn quality (buyer specifications)

80% short fiber content in noils
No visible good fibers.

Blow Room

Cleaning efficiency: 50-55%
Beater droppings: ≤20% lint
Nep generation: ≤80%

Card

Lint loss
Licker-in stablings: ≤35%
Flat strips and stationary flats waste: ≤ 50%

Maintain hard waste below 0.4% through
Auto Coners and Link Coners from various manufacturers
Clear cuts below 65%
Control top rejection in Auto Winding below 4%
Leverage latest machine technology for improved yarn realization
Combed yarn: 70-73% realization (up from 70% in older machines)
Regular modernization essential for market sustainability

Minimize link loss in Blow Room
Optimize card licker-in and stationary flat waste
Blow Room: < 80% neps generation
Cards: 70% neps removal efficiency (no additional waste)
Combers: 65% short fiber content removal efficiency
Auto Coners: ≤0.4% hard waste

Higher invisible loss
Increased top roller waste
Higher overhead traveling clearer waste
Higher gutter waste
Lower productivity
Disturbed yarn quality
Higher end breakage rates

Contribution difference: ₹239 (₹2,801 - ₹2,562)
Daily savings: ₹58,931
Annual savings (355 days): ₹209.2 lakhs

To achieve consistent yarn quality, a robust Bale Management System is essential, complemented by:

Strategic machine selection from Blow Room to Link Coner
Partnering with renowned manufacturers: Lakshmi Machine Works, Rieter, and Truetzschler
Optimal beaters selection, tailored to specific mixing requirements, ensures
Enhanced cleaning efficiency
The Global fabrics distributor
Minimized nep generation

Financial Analysis of 30s Combed Compact Hosiery Yarn

Assumptions

Yarn price: ₹270/kg
Raw material cost: ₹63,000/kandy
Waste realization: ₹31/kg
Grams/spindle/shift: 240 (moderate)
Invisible loss: 1%

72% Yarn Realization

Yarn cost: ₹19,440
Waste realization: ₹837
Total revenue: ₹20,277
Contribution: ₹2,562

73% Yarn Realization

Yarn cost: ₹19,710
Waste realization: ₹806
Total revenue: ₹20,516
Contribution: ₹2,801

Yarn Realization

WE ASSURE YOU OF A PROFIT OF 1 % NOILS ON COMBER MACHINE SETTING. WE USE MINIMUM SPARES AS PER YOUR MACHINE STUDY.

WE ASSURE YOU OF A PROFIT OF 2 % NOILS ON COMBER MACHINE SERVICING. WE USE MEDIUM LIST OF SPARES AS PER YOUR MACHINE STUDY.

A Technologist's Guide to Yarn Realization

Specific fiber properties significantly impact yarn quality

Optimal Fiber Parameters for Better Yarn Realization:

Optimization Goals for Nep Removal and Fiber Quality

Comber noil extraction based on:

Target

Optimal Blow Room and Card Performance Parameters

Blow Room

Card

Optimizing Auto Coners and Link Coners for Minimal Waste

Optimizing Machine Parameters for Maximum Yarn Realization