Process Management in Spinning: 1st Edition (Hardback) book cover

Process Management in Spinning

1st Edition

By R. Senthil Kumar

CRC Press

416 pages | 182 B/W Illus.

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Hardback: 9781482208368
pub: 2014-09-23
eBook (VitalSource) : 9780429076022
pub: 2014-09-23
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A Straightforward Text Summarizing All Aspects of Process Control

Textile manufacturing is one of the largest industries in the world, second only to agriculture. Spinning covers a prominent segment in textile manufacturing, and this budding industry continues to thrive and grow. Process Management in Spinning considers aspect of process management, and offers insight into the process control procedures and methods of spinning. Focusing on the technology as well as the management of the process, it examines both the economic and technological advancements currently taking place in the spinning industry. This text takes a close look at the advancing technology in manufacturing and process, and product quality control. It provides a basic overview of the subject, and also presents applications of this technology for practicing engineers.

Incorporates Industry-Based, Real-World Examples

The book contains 15 chapters that specifically address the stages of process control, energy management methods, humidification and ventilation systems basics, pollution management, process management tools, productivity, waste control, material handling, and other aspects of spinning mills. It also includes real-time case studies involving typical problems that arise in spinning processes and strategies used to contain them. The author provides a broad outlook on various topics including mixing, winding, raw material and optimizing raw material properties, bale management, yarn engineering systems, processing, and process management systems. He also details the defects associated with each and every process with causes, effects, and control measures. The book addresses process management as it relates to productivity, quality, and costs, as well as process control as it relates to man, machine, and material.

  • Provides the scientific method for optimization/optimizing the properties of the fibers
  • Familiarizes the reader with remedial measures to enhance the quality of the product
  • Addresses productivity measurement and its role in controlling the cost of the manufacturing process
  • Contains detailed examples, as well as linear programming and optimization techniques, and statistical applications
  • Covers the areas of process control methods in spinning, defect analysis and rectification, improving productivity and quality, and using statistical tools

Process Management in Spinning establishes the various process management measures required to help improve the process efficiency in spinning mills and the textile industry overall. Aimed at professionals in the textile industry, this text is a perfect resource for textile engineers/technologists/manufacturers, spin quality control engineers, spin quality assurance personnel, and other industry professionals.


"This is a comprehensive and authoritative guide to textile process enhancement and development, especially in regard to cotton yarn manufacturing. The book allows technologists, quality control and assurance personnel, engineers, and readers at various levels to digest and understand cotton yarn production and quality at different stages of manufacturing. The book is standard scientific material for manufacturers, research workers, and those studying this vital area of the textile industry."

—Prof. Dr. Eng. Ibrahim A. Elhwary, Textile Engineering Department, Faculty of Engineering, Alexandria University, Egypt

"This book provides a detailed and structured manuscript where learners can explore the technological challenges and innovations around yarn manufacturing. [The book also provides] teachers with a consolidated tool for structuring their teaching materials. The key attraction, in my opinion, is the case studies section, where the audience is acquainted with a series of real-life problems in yarn manufacturing. I am looking forward to having this book in my collection."

—Dr. Saniyat Islam, RMIT University, Melbourne, Australia

Table of Contents

Process Control in Mixing

Significance of Process Control in Mixing

Fiber Quality Index

Essential Properties of Fiber

Properties of Cotton: Global Scenario

Process Sequence: Short Staple Spinning

Bale Packing and Dimensions

Bale Management

Bale Lay Down Planning

Linear Programming Technique (LPT) for Cotton Mixing

Cotton Property Evaluation Using HVI and AFIS

Cotton Stickiness

Contamination and Its Impact

Soft Waste Addition in Mixing


Process Control in Blow Room

Significance of Blow Room Process

Intensity of Fiber Opening

Cleaning Efficiency

Neps in Blow Room

Lint Loss

Blending Homogeneity

Fiber Rupture and Its Measurement


Lap Uniformity

Technological Developments in Blow Room Machinery

Chute Feed System and Its Control Mechanism

Process Parameters in Blow Room

Defects Associated with the Blow Room Process

Work Practices in Blow Room

General Considerations in Blow Room Process


Process Control in Carding

Significance of the Carding Process

Neps in Carding

Influence of Licker-In Zone on the Carding Process

Influence of the Carding Zone on the Carding Process

Doffer Zone

Sliver Formation

Wire Geometry in Licker-In, Cylinder, Flats, and Doffer

Autoleveler in Carding

Process Parameters in Carding

Defects Associated with the Carding Process

Ambient Conditions

Cleaning Efficiency and Lint Loss%

Control of Waste

Productivity and Quality for Different End Uses

Technological Developments in Carding


Process Control in Drawing

Significance of the Drawing Process

Fundamentals of Drafting System

Fiber Control in Roller Drafting


Influence of Draw Frame Machine Elements on Process

Roller Setting

Top Roller Maintenance

Draw Frame: Speeds and Draft Distribution

Count C.V% and Irregularity U%

Defects Associated with Draw Frame Process

Process Parameters in Draw Frame

Work Practices

Technological Developments in Draw Frame


Process Control in Comber and Its Preparatory

Significance of Combing Process

Lap Preparation

Factors Influencing the Combing Process

Setting Points in Comber Machine


Noil Removal

Nep Removal in Combing

Hook Straightening in Comber

Sliver Uniformity

Control of Feed Lap Variation

Defects and Remedies

Technological Developments in Comber and Its Preparatory

Work Practices


Process Control in Speed Frame

Significance of Speed Frame

Tasks of Speed Frame

Importance of Machine Components in Speed Frame

Draft Distribution


Bobbin Formation

Quality Control of Roving

Defects in Roving

Technological Developments in Speed Frame


Process Control in Ring Spinning

Significance of Ring Spinning Process

Influence of Ring Spinning Machine Components on Spinning Process

End Breakage Rate

Draft Distribution


Nonconformities in the Ring Spinning Process

Package Size or Cop Content

Count C.V% and Evenness

Tenacity and Tenacity C.V%

Roller Lapping

Yarn Quality Requirements for Different Applications

Technological Developments in Ring Spinning


Process Control in Winding

Significance of the Winding Process

Demands of Cone Winding Process

Factors Influencing Process Efficiency of Automatic Winding Machine

Winding Speed

Yarn Tension

Package Density of Cone

Yarn Clearing


Knotting and Splicing

Package Defects in Winding

Determination of Shade Variation in Yarn Package

Control of Hard Waste

Wrong Work Practices in the Winding Department

Yarn Conditioning

Technological Developments in Winding Machine


Process Control in Rotor Spinning

Significance of Rotor Spinning

Raw Material Selection

Sliver Preparation

Influence of Machine Components on Rotor Spinning Process



Doubling Effect

Winding Angle


End Breakage in Rotor Spinning

Relative Humidity in Rotor Spinning Process

Defects Associated with Rotor Spinning Process


Energy Management in the Spinning Mill

Significance of Energy Management in the Spinning Mill

Manufacturing Cost of Yarn in Spinning Mill

Energy Distribution in Ring Spinning Process

Calculation of Energy Consumption of Ring Frame Machines

Energy Management Programs

Energy Conservation in the Spinning Mill


Compressed Air System

Energy Demand Control

Motor Management Plan

Motor Maintenance

Energy-Efficient Motors

Rewinding of Motors

Motor Burnouts

Power Factor Correction

Minimizing Voltage Unbalances


Humidification and Ventilation Management

Importance of Maintaining Humidity in Spinning Process

Humidity and Working Conditions

Humidity and Yarn Properties

Humidity and Static Electricity

Humidity and Hygiene

Humidity and Human Comfort

Humidity and Electronic Components

Humidity and Dust Control

Moisture Management in Ginning

Humidification Systems in Spinning Mill

Conventional Humidification System

Modern Humidification System


Pollution Management in Spinning Mill

Significance of Pollution in Spinning Mill

Cotton Dust

Pollution in Cotton Cultivation and Processing

Significance of Noise Pollution


Process Management Tools

Significance of Process Management

Process Management Tools

Total Productive Maintenance

Lean Manufacturing Concepts


Productivity, Waste Management, and Material Handling

Productivity in the Spinning Process

Yarn Realization

Material Handling


Case Studies

Mixing-Related Problems

Blow Room–Related Problems

Carding-Related Problems

Draw Frame–Related Problems


Speed Frame

Ring Frame



About the Author

R. Senthil Kumar completed his post-graduation in textile engineering from the Indian Institute of Technology (IIT), Delhi, India. He has been an assistant professor in the Department of Textile Technology, Kumaraguru College of Technology, India, since 2009. Kumar has published more than 30 technical and management-related review papers in various international and national journals and has prepared manuals on "non-woven technologies" for international and local textile industries. He has published nearly 200 technical and management-related textile study materials on the online portal (, and has also authored Textiles for Industrial Applications, which was published by CRC Press in August 2013.

Subject Categories

BISAC Subject Codes/Headings:
TECHNOLOGY & ENGINEERING / Textiles & Polymers