Industry Profile

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Spinning is a major part of the textile industry.

It is part of the textile manufacturing process where three types of fiber are converted into yarn, then fabrics, which undergo finishing processes such as bleaching to become textiles. The textiles are then fabricated into clothes or other products. There are three industrial processes available to spin yarn, and a handicraft community who use hand spinning techniques. Spinning is the twisting together of drawn out strands of fibers to form yarn, though it is colloquially used to describe the process of drawing out, inserting the twist, and winding onto bobbins

Types of fibre
Artificial fibres are made by extruding a polymer through a spinneret into a medium where it hardens. Wet spinning (rayon) uses a coagulating medium. In dry spinning (acetate and triacetate), the polymer is contained in a solvent that evaporates in the heated exit chamber. In melt spinning (nylons and polyesters) the extruded polymer is cooled in gas or air and sets. All these fibres will be of great length, often kilometers long. Natural fibres are either from animals (sheep, goat, rabbit, silk-worm), mineral (asbestos), or from plants (cotton, flax, sisal). These vegetable fibres can come from the seed (cotton), the stem (known as bast fibres: flax, hemp, jute) or the leaf (sisal). Without exception, many processes are needed before a clean even staple is obtained each with a specific name. With the exception of silk, each of these fibres is short, being only centimeters in length, and each has a rough surface that enables it to bond with similar staples. Artificial fibres can be processed as long fibres or batched and cut so they can be processed like a natural fibre.

Spinning
Ring-spinning is the most common spinning method in the world. Other systems include air-jet and open-end spinning. Open-end spinning is done using break or open-end spinning. This is a technique where the staple fibre is blown by air into a rotor and attaches to the tail of formed yarn that is continually being drawn out of the chamber. Other methods of break spinning use needles and electrostatic forces. The processes to make yarn short-staple yarn (typically spun from fibres from 0.75 to 2.0") are blending, opening, carding, pin-drafting, roving, spinning, andif desiredplying and dyeing. In long staple spinning, the process may start with stretch-break of tow, a continuous "rope" of synthetic fibre. In open-end and air-jet spinning, the roving operation is eliminated. The spinning frame winds yarn a bobbin. Generally, after this step the yarn is wound to a cone for knitting or weaving. In mule spinning the roving is pulled off a bobbin and fed through rollers, which are feeding at several different speeds. This thins the roving at a consistent rate. If the roving was not a consistent size, then this step could cause a break in the yarn, or could jam the machine. The yarn is twisted through the spinning of the bobbin as the carriage moves out, and is rolled onto a

cop as the carriage returns. Mule spinning produces a finer thread than the less skilled ring spinning. The mule was an intermittent process, as the frame advanced and returned a distance of 5ft.It was the descendant of a 1779 Crompton device. It produces a softer, less twisted thread that was favored for fines and for weft. The ring was a descendant of the Arkwright water frame of 1769. It was a continuous process; the yarn was coarser, had a greater twist and was stronger so was suited to be warp. Ring spinning is slow due to the distance the thread must pass around the ring, and similar methods have improved on this; such as flyer and bobbin and cap spinning. Sewing thread was made of several threads twisted together, or doubled. The pre-industrial techniques of hand spinning with spindle or spinning wheel continue to be practiced as a handicraft or hobby, and enable wool or unusual vegetable and animal staples to be creatively used.

Checking This is the process where each of the bobbins is rewound to give a tighter bobbin. Folding and twisting Plying is done by pulling yarn from two or more bobbins and twisting it together, in the opposite direction from that in which it was spun. Depending on the weight desired, the yarn may or may not be plied, and the number of strands twisted together varies

Mule spinning

Ring spinning

India Spinning Industry has gone from strength to strength since a very long time now as it was the hub of cotton manufacturing. Cotton is not only consumed to the highest extent in India but it has also become one of the most profitable textiles in the export industry

Spinning in India can be classified into 2 categories: medium and long staple. But there was a shortfall in the 'extra-long' category that continued for many years. There was a massive downfall in the cotton spinning in India during 2004-2005. The production rate of cotton was about 4 lakh bales that was less by 5 lakh bales from the required rate which was 9 lakh bales. Mr. P. D. Patodia, the Chairman of the Standing Committee on Cotton, CITI-CDRA said that the manufacturing of cotton will rise to 11-12 lakh bales in 2010.

The present downfall in the cotton production has witnessed a 50% increase in the price of Indian varieties of ELS, which is detrimental for the spinning industry in India. Spinning mills require domestic accessibility of ELS cotton in increased quantity and of better fiber qualities.

To survive this downfall in the cotton trade which is a highly profitable textile in the India Spinning Industry, CITI-CDRA is conducting a conference with various research organizations such as CICR (Nagpur), JNKVV (Khandwa), UAS (Dharwad), and Regional Textile Mills' Association in R&D activities. It conducted a discussion pertaining to the development of new varieties of seeds and adopting the advanced procedure of cultivation which will add to the profit in the cotton textile sector of the spinning industry. The most important and efficient step towards the resurgence of cotton manufacturing would be to develop the ELS varieties with lesser duration crops and yield to cost-effectiveness and consistency in cultivation. This will not only motivate the farmers but will also make them stick to the desired sector of cotton crop.

The yarn spinning industry covers almost 25 percent of the total industrial production of one of the world's 10 largest economies. Trends are reviewed every year in accordance with the need and fashion. An elaborate and detailed assessment is made on various sectors of the yarn spinning such as, production, consumption, and materials. The legislative and the political consequences are also reviewed at the same time. In addition to it, other areas that are being

reviewed in the yarn spinning sector are exports, imports, prices, advertising, and sales promotion patterns.

Some of the popular companies engaged in the India Spinning Industry are listed below:

Bhilwara Spinners Ltd. (LNG Group) - polyester, viscose, wool-blended fabrics and high-end products like lycra and linen. BSL Suitings and Mayur Suitings are the two brands under Bhilwara Spinners Ltd. Nitin Spinners Ltd. - manufactures single and multi-fold yarns in the range from Ne 4 to Ne 40 appropriate for various applications such as Knitted Fabrics, Woven Fabrics, Terry Towels, Denims, Furnishing Fabrics, carpets and other Industrial Fabrics. Sangam (India) Ltd. (Sangam Group of Companies) - Largest producer of dyed yarn in India with a capacity of 64032 spindles in one location. Ajay Group of Industries - Manufacturer and seller of polyester viscose, polyester woolen and uniform fabrics.

The Spinning Industry in India is on set to hit the global market with other fabrics as well like the cotton textiles with its enthusiasm and consistency in work. It has already reached a phenomenal status in India by beating the obstacles that caused a downfall since past few years and is now on its way to cover a wider area in the spinning sector

Cotton Manufacturing Processes (after Murray 1911)


Bale Breaker Blowing Room

Willowing

Breaker Scutcher

Batting

Finishing Scutcher

Lapping

Carding

Carding Room

Silver Lap

Combing

Drawing

Slubbing

Intermediate

Roving

Fine Roving

Mule Spinning

Ring Spinning

Spinning

Reeling

Doubling

Winding

Bundling

Bleaching

Winding

Warping

Cabling

Sizing/Slashing/Dressing

Gassing

Weaving

Spooling

Cloth

Yarn (Cheese)- - Bundle

Sewing Thread

India Spinning Industry has gone from strength to strength since a very long time now as it was the hub of cotton manufacturing. Cotton is not only consumed to the highest extent in India but it has also become one of the most profitable textiles in the export industry.

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