Effect of Number of Draw Frame Passages on Rotor-Spun Yarn Quality

This study investigates the effects of the number of passages for draw frame machines on the quality of rotor-spun yarn. In the presented study, the goal is to produce more cost-effective yarn with similar physical properties to those obtained with two drawing passages by reducing the number of drawing passages. Additionally, the study aims to achieve a lower carbon footprint and reduce the environmental impacts of production processes through lower energy consumption. Yarn samples of Ne 20/1 and Ne 10/1 with the same cotton fibre were produced by means of both single-passage and double-passage drawing machines. The unevenness and tensile properties of the produced yarns were measured using Uster Tester and Uster Tensorapid testing devices, while abrage control was evaluated in an abrage cabinet under ultraviolet light. Furthermore, the energy consumption of the eliminated drawing machine was measured using an energy analyzer. The yarn samples produced with the single passage drawing machine demonstrated better IPI (imperfections) values than those produced with the two-passage system, and the tensile strength values remained at comparable levels. Under UV light, no abrage differences were observed between the yarns from the two different production processes. Energy and raw material waste savings were achieved by eliminating one of the drawing machines. Additionally, considering a waste ratio of 0.6% for a single passage drafting machine, it is estimated that approximately 100 tons of cotton waste per year can be prevented in a rotor-spun facility producing 50 tons of yarn daily. The study revealed that the reduction in raw material and energy consumption enables the production process to be carried out with a lower carbon footprint, thereby making a significant contribution to sustainability. Furthermore, this approach results in a notable reduction in yarn production costs.