TT 2023 PRINCIPLES OF YARN MANUFACTURE

DEPARTMENT OF TEXTILE AND CLOTHING

TECHNOLOGY
UNIVERSITY OF MORATUWA

ISIN Lanka (Pvt)

NAME : Napagoda N.A.A.M.T.

INDEX NO : 121045T
 INTRODUCTION

ISIN Lanka Pvt Ltd a BOI registered company was established in 1992 in Andiambalama,
Katunayake (Western Province). This is the largest spinning plant in Sri Lanka. Mother company of
ISIN Lanka is INDORAMA and situated in Indonesia. It has 18 factories in Indonesia and Singapore with
this in Sri Lanka. ISIN Lanka produces premium quality spun yarn, both cotton and synthetic for high-
end textile market.
The products are sold to its buyers in Europe, North America, South America, Middle East and
Asia. This is the only one company survived spinning mill in Sri Lanka as company has created their
name in higher place in textile market.
Plant produced 100% reyon yarn, 100% cotton yarn, 100% polyester yarns and poly cotton and
poly rayon blending with count range of Ne 10 to Ne 40. But currently they produce only 100% reyon
and 100% cotton.
100 % rayon staple spun yarn with rayon count of 20tex / 30tex / 36tex
100 % cotton staple spun yarn with cotton count of 16S / 24S / 30S / 34S / 40S

Raw materials they used for spinning are Thai Rayon (Viscose), Australian Cotton, Greek cotton
and USA Cotton. Raw materials suppliers are USA, Australia, Thailand, Greece, Indonesia and Turkey.

Earlier ring spinning had been the only method used for their production. But with the laps of
time they have replaced air jet machines in place of ring spinning machines as air jet machines product
at a higher production rate and save the labor cost and the time.

Location of ISIN Lanka has benefits as only 13 shipment days to Europe and 21 shipment days
to the USA .And benefits from the quota-free access for spun and blended yarn to the E.U. and the US
market. ISIN Lanka can reach for the customers which Indorama cant easily accessible from Indonesia.

THEIR VISION

ISIN Lanka strives to achieve excellence in product quality, to have satisfied customers, to maintain
the position of leadership through innovative ideas and dynamic marketing strategies, to remain cost
effective and competitive and to enforce an effective quality management system.

ISIN
Lanka
PROCESS

BLOW LAP
CARDING DRAWING COMBING DRAWING
ROOM FORMING

2 for 1 DUBLER SPLISER RING FLIRE

TWISTER WINDER WINDING FRAME FRAME

BLOW ROOM

At present 50% of the yarn production is done by the ring spinning process while the other 50%
are produced by the modern Air jet machine.
First of all bales are kept 8 hours exposed to the air for absorbing moisture (65%-60%) to have
some strength.
It leads to reduce breakages in twisting and twists easily.
From 4 lines 3 lines are used for reyon and 1 machine is used for cotton.
After putting into convey belts it is inserted in to opening machine and large particles of
impurities are removed there. Just opening happening there and there is no mixing takes place
here.
Then opened cotton comes to the multi mixer. It contains 6 chambers.(Mixing is not necessary
for reyon as it has uniform color. But here cotton is imported from 3 places and color, quality
and level of impurities are changed to each other. So mixing is essential to have uniform color.
)
In multi mixer color variations and impurities are detected. Mainly the impurities are detected
by two cameras.
Standard weight of cotton bale 350kg and standard weight of rayon bale 300kg.
CARDING

Opening fibres into individual level is done by carding machine.

Chute feeding is the feeding system available here and chutes (output of the blow room) use as
the input for carding.
Chute feeding speed changes according to the delivery speed of carding machine.
There are four lines in carding section and only on line has been allocated for cotton and rest
for reyon.
There are both old and new machine available in carding department.

Features of the machine(new)

Can capacity - 5000 m
Speed of Cylinder - 420 rpm
Speed of Flats - 320 mm / min
Speed of Licker-in roller - 959 rpm
Delivery speed - 135 m/min
Cotton count - 0.11 Ne
DRAW FRAME

Objective of fiber uniformity is to increase the fiber uniformity.

There are two equal drafting systems (4/5drfting system) available in one draw frame machine.
Six carded slivers are fed at one time (12 for two systems).
Auto levelers present in the machine to control the output.

As I have mentioned in the process, draw frame is used again after combing process. So
combed slivers undergo in draw frame machine again to eliminate hook fibers.

COMBING

Objective of combing is to increase fiber orientation and removing short fibers.

For combing slivers cant be used because combing action cant be performed with a sliver. So
lap must be created.
A lap called super lap is formed by using 24 draw frame slivers before combing process.
Linear density of the lap is 76 g/m and then insert for combing.
Gauge of the comb is changed according the short fibre length.
Output of the combing is a sliver.
As I mentioned earlier this slivers are again subjected to drawing by draw frame
machine. For that 8 combed slivers are used.
ROVING FRAME

Objective of this machine is to reduce the linear density and wound onto suitable package.
Again sliver is subjected to a draft of 8.6.
Linear density of roving is 0.78 Ne.

RING FRAME

Then roving takes to the ring frame.

Objective of ring frame is to reduce the linear density to the final count.
For that twist is applied here.
Here also roving is subjected to a draft of 48.
Spindle speed of the machine is 19500 rpm.
Spindle capacity 672 spindles. ( as well as 576 & 912 also present )

SPLISER WINDER

Objective of this machine is to removing defects on the yarn and wound on to a bigger package.
Not like in our laboratory, there is a special robot attached to this machine for unloading filled
packages, loading empty bobbins and insert the yarn end to the empty bobbin.
Standard weight of cotton cone is 2.65 kg and average weight of rayon cone is 2.85 kg.
Different bobbin colors are used for different yarn counts and materials.

DOUBLER WINDER

Plied yarns are also prepared according to the buyers requirement.

From 25000 bobbins prepared per day 1000 bobbins are plied and others are exported as single
yarns.
If needed more than 2 yarns can be plied.
Generally the final package of the plied yarn is 2.65 kg
Output (cheese package) is sent to two for one twister.
TWO FOR ONE TWISTER

Insertion of remaining twist is done here.

AIR JET SPINING

This is the latest method of spinning.

5 air jet machines have been implemented in place of 19 ring spinning machines. It shows how
much efficiency it provides.
Not like in ring spinning no twist is applied to form the yarn, only outer layer fibers are wrapped
around the yarn body.
Thickness of input sliver for air jet spinning machine is less than ring spinning.
By implementing air jet machine both roving and ring frames can be eliminated as it can achieve
all functions in both machines.
Machine delivery speed is 18714 rpm and has 4/3 drafting system.
Here 120 spindles are there and they can be controlled separately.
Like in splicer winder a robot always does the same thing done in ring frame and instead of that
if there is any breakage robot takes the two free ends and wrap by a yarn which is included
inside the robot.
PACKING SECTION
Finally packages are carried to this section and check whether there are defects, color changes,
grease marks and etc. under UV rays.

Then they are packed according to the material type and the yarn count.
There are two packing types:
1) Cartoons- with 16 Packages.
2) Pallets - with 325 Packages