Yarn realisation

Yarn realisation is one of the important factors that affect the quality of the yarn, profitability, and lead time of a spinning mill.{{Cite book |last=Ratnam |first=Tarakad Vedamurthy |url=https://books.google.com/books?id=7dTbAAAAMAAJ&q=%22Yarn+realisation%22+-wikipedia |title=A Decade of SITRA's Research, 1981-82 to 1990-91 |date=1993 |publisher=South India Textile Research Association |pages=87 |language=en}}{{Cite journal |last1=Anand |first1=K. T. |last2=Rajan |first2=A. John |last3=Narayanan |first3=K. V. |date=2015 |title=Factors Affecting Leadtime in Spinning Mills |url=https://www.scientific.net/AMM.813-814.1154 |journal=Applied Mechanics and Materials |language=en |volume=813-814 |pages=1154–1164 |doi=10.4028/www.scientific.net/AMM.813-814.1154 |s2cid=111591834 |issn=1662-7482|url-access=subscription }} Better realisations make spinning mills more competitive, and greater realisations mean better economics for a spinning business. Even minor changes in yarn realisation, say 1%, translate into a huge impact on spinning production economics. Thus, controlling yarn realisation is as critical to a mill as controlling cotton and mixing costs.{{Cite journal |title=Quality Improvement of Yarn by Automatic Waste Removal |url=https://www.ijeter.everscience.org/Manuscripts/Volume-6/Issue-1/Vol-6-issue-1-M-23.pdf |journal=International Journal of Emerging Technologies in Engineering Research |volume=6 |issue=1}}

$\backslash mathrm\{Yarn\backslash \; realisation\}\; =\; \backslash frac\{\backslash mathrm\{Yarn\backslash \; produced\}\}\{\backslash mathrm\{Consumption\backslash \; of\backslash \; cotton\}\}\backslash times\; 100$

The following components play a significant role in yarn realisation:

In the spinning industry, the cost of raw material is directly influenced by: procurement, methods of mixing, yarn realisation (waste standards), and re-use of waste.{{Cite book |last=Association |first=Bombay Textile Research |url=https://books.google.com/books?id=hN1HAAAAYAAJ&q=%22Yarn+realisation%22+-wikipedia |title=Proceedings of the Annual Technological Conference |date=1966 |pages=27 |language=en}} After picking, the cotton lint in compressed bales is transferred to the yarn spinning mills.{{Cite book |last=Sen |first=Ashish Kumar |url=https://books.google.com/books?id=qHLLBQAAQBAJ&dq=after+ginning+cotton+in+bale+transferred+to+spinning+mill&pg=PA59 |title=Coated Textiles: Principles and Applications |date=2001-05-08 |publisher=CRC Press |isbn=978-1-4200-3192-8 |pages=59 |language=en}}{{Cite web |title=The Story of Cotton- How Cotton is Ginned and Marketed |url=https://www.cotton.org/pubs/cottoncounts/story/gin-and-market.cfm |access-date=2022-04-09 |website=www.cotton.org}}

Cotton lint{{cite web |last1=Weigmann |first1=Hans-Dietrich |title=Cotton - Description, History, Production, Uses, Botanical Name, & Facts |url=https://www.britannica.com/topic/cotton-fibre-and-plant |website=www.britannica.com |publisher=Encyclopædia Britannica, Inc. |access-date=14 February 2025 |language=en |date=8 February 2025}} refers to the fibrous coat that covers the cotton seeds that is left as a byproduct when cotton is ginned.{{cite web |last1=Etherington |first1=Don |last2=Roberts |first2=Matt T. |title=Etherington & Roberts Dictionary |url=https://cool.culturalheritage.org/don/dt/dt0863.html |website=Etherington & Roberts Dictionary |publisher=CoOL |access-date=14 February 2025}} The lint that is delivered to the spinning mill contains a variety of extraneous materials, including seed pieces, dust, and motes, which are collectively referred to as trash. Yarn realisation (YR) is largely influenced by the trash content of cotton, the intended yarn quality, and the type of machinery used.{{Cite web |title=Cotton Lint - an overview {{!}} ScienceDirect Topics |url=https://www.sciencedirect.com/topics/materials-science/cotton-lint |access-date=2022-04-07 |website=www.sciencedirect.com}}

Trash is non-lint material that is present with cotton lint. It is made up of leaf fragments, bark bits, grass, plastic pieces, sand, and dust. The level of contamination is determined by cultivation, harvesting, and ginning conditions.{{Cite web |title=2.2.10-Cotton Value Addition-Trash (non-lint) content |url=https://www.cottonguide.org/cotton-guide/cotton-value-addition/trash-non-lint-content/ |access-date=2022-04-07 |website=www.cottonguide.org}}

=====Short fibers=====

Cotton is a natural plant fiber, and depending upon many conditions, such as geography, seed quality, and cultivation, the length of the fiber varies from lot to lot, as well as different qualities.{{Cite web |title=Natural Plant Fiber - an overview {{!}} ScienceDirect Topics |url=https://www.sciencedirect.com/topics/engineering/natural-plant-fiber |access-date=2022-04-07 |website=www.sciencedirect.com}}{{Cite web |title=Cotton Fibre - an overview {{!}} ScienceDirect Topics |url=https://www.sciencedirect.com/topics/engineering/cotton-fibre |access-date=2022-04-07 |website=www.sciencedirect.com}}{{Cite book |last1=Fang |first1=David D. |url=https://books.google.com/books?id=amDMDwAAQBAJ&q=micronaire+value+of+cotton |title=Cotton |last2=Percy |first2=Richard G. |date=2020-01-22 |publisher=John Wiley & Sons |isbn=978-0-89118-625-0 |language=en}} Increased efficiency in yarn manufacturing and yarn quality are dependent on certain fiber characteristics.{{Cite web |title=Fibre Strength - an overview {{!}} ScienceDirect Topics |url=https://www.sciencedirect.com/topics/engineering/fibre-strength |access-date=2022-04-07 |website=www.sciencedirect.com}} For an example short fiber content (SFC) by number and by weight influences the productivity and quality of the yarn. Cotton lint with more than 25%SFC(n) is a problem in spinning.{{Cite web |date=2020-05-15 |title=Short Fibre Content in Cotton Is It The Next Big Challenge for Spinners? Continued Part 2 |url=https://www.texcoms.com/short-fibre-content-in-cotton-is-it-the-next-big-challenge-for-spinners-continued-part-2 |access-date=2022-04-07 |website=Texcoms Worldwide |language=en-US}}{{Cite journal |last1=Zeidman |first1=Mishu I. |last2=Batra |first2=Subhash K. |last3=Sasser |first3=Preston E. |date=1991 |title=Determining Short Fiber Content in Cotton |url=https://journals.sagepub.com/doi/abs/10.1177/004051759106100103 |journal=Textile Research Journal |volume=61 |issue=1 |pages=21–30 |doi=10.1177/004051759106100103 |s2cid=135638967 |issn=0040-5175|url-access=subscription }} Short fibers also known as "noil" extraction improves the yarn quality, consequently affects yarn realisation.{{Cite book |last=Rutnagur |first=Sorabji M. |url=https://books.google.com/books?id=U8dOAAAAYAAJ&q=yarn+realisation+and+noil |title=The Indian Textile Journal |date=2006 |publisher=Business Press |pages=17 |language=en}}{{Cite book |last=Purushothama |first=B. |url=https://books.google.com/books?id=CWvdCgAAQBAJ&dq=yarn+realisation+and+noil&pg=PA249 |title=Handbook on Cotton Spinning Industry |date=2016-01-05 |publisher=CRC Press |isbn=978-93-85059-55-1 |pages=239 |language=en}} Extra noil extraction is required for superior and fine quality yarn, which affects the yarn realization.

Cotton is a hygroscopic fiber, which means it takes in moisture from the environment and also dries quickly if it is kept in a dry place. A small amount of moisture loss in the lint may also contribute to yarn realisation.{{Cite book |last1=Shaikh |first1=Tasnim N. |url=https://books.google.com/books?id=z7dDDwAAQBAJ&dq=%22Yarn+realisation%22+-wikipedia&pg=PT46 |title=Engineering Cotton Yarns with Artificial Neural Networking (ANN) |last2=Agrawal |first2=Sweety A. |date=2017-12-06 |publisher=CRC Press |isbn=978-1-351-18625-4 |pages=46 |language=en}}

To maintain a specified level of moisture in cotton, the relative humidity must be maintained at 65 percent during mixing, winding, and packing. Moisture helps in reducing fluff generation and decreasing in invisible losses.

Spinning is a process in textile manufacturing in which staple fibers are converted into yarn. Optimizing spinning processes and waste management benefits the yarn realisation and the economics of a spinning mill.{{Cite book |url=https://books.google.com/books?id=k3RQAAAAYAAJ&q=%22Yarn+realisation%22+-wikipedia |title=Textile Trends |date=2003 |publisher=Eastland Publications. |pages=17 |language=en}}

Cotton fibers vary in terms of staple length and other physical qualities; it is an inherent characteristic. Bale mixing, or bale management is the process of testing, sorting, and then mixing fibers from different bales [also include the bales received from different stations] according to their fiber qualities in order to produce a certain quality yarn at the lowest possible cost.{{Cite web |title=Bale Opener - an overview {{!}} ScienceDirect Topics |url=https://www.sciencedirect.com/topics/engineering/bale-opener |access-date=2022-04-07 |website=www.sciencedirect.com}}

The waste in textiles is classified into two types: production waste, which is the raw material for subsequent steps in spinning production (it is cleaning waste left out short fibers in carding or combing, it is a reusable waste). Post-production waste that is not related to spinning, but does happen at the stages of yarn to fabric [manufacturing and processing]. Waste management in spinning contributes to better yarn realisation.

The two types of waste that contribute to yarn realisation are: one is hard waste, which is not reused, and the second type of waste is reusable waste, also called soft waste, which includes sliver bits, lap bits, roving ends, roller waste, and pneumafil.{{Cite book |last=Nayak |first=Rajkishore |url=https://books.google.com/books?id=Z8i2DwAAQBAJ&dq=reusable+wastes+(soft+waste)+such+as+lap+bits,+sliver+bits,+roving+ends+and+pneumafil+and+roller+waste.&pg=PA49 |title=Sustainable Technologies for Fashion and Textiles |date=2019-12-01 |publisher=Woodhead Publishing |isbn=978-0-08-102868-1 |pages=49 |language=en}}

Yarn produced from the waste fibers can reduce the losses and contribute to the mill's profitability. There are many areas where waste fibers can be used, such as blending.{{Cite book |last1=Nayak |first1=Rajkishore |url=https://books.google.com/books?id=YXDhDwAAQBAJ&dq=blow+room+yarn+recovery&pg=PA78 |title=Waste Management in the Fashion and Textile Industries |last2=Patnaik |first2=Asis |date=2021-01-07 |publisher=Woodhead Publishing |isbn=978-0-12-818759-3 |pages=78 |language=en}}

• Staple (textiles)

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Category:Spinning