Yarn Recovery – The He(art) of Spinning
01 Textile Market Scenario
02 Demystifying Yarn Realisation
03 Dissecting Yarn Realisation: Exploring its Components
The 04 Decoding Loss: Examining the Contributing Factors
Presentation 05 Invisible loss - Unravelling the Factors Behind Losses
Unboxed: A 06 Permissible levels of lint in process waste
Look at its
Contents 07 Striking the Balance: The Quality Vs Noil Curve
08 Our approach for Re- Engineering
09 Case study – Operation Reengineering in Spinning Unit
10 Learning Organisation
11 Sealing the Presentation: Concluding Thoughts and Reflections
01 Textile Market Scenario
02 Demystifying Yarn Realisation
Yarn Realization (YR): It's the vital COST IMPACT
measure of raw material conversion to finished
yarn, crucial for assessing spinning mills' 0%
technical performance and profitability. 8%
4% Raw Material
3%
Power
5%
Cost Impact: Raw material costs, Salaries & Wages
constituting 55-65% of sales turnover,
emphasize the need to optimize YR for Stores and Packing
12% Materials
profitability.
Administrative Overheads
Interest and Depreciation
68%
Net Profit Margin
Improvement Potential: Even slight YR
enhancements can yield significant operational
efficiency and financial gains, pivotal for the
survival of spinning mills in a fiercely competitive
global market.
03 Dissecting Yarn Realisation: Exploring its Components
Vital components for cotton yarn realization are
a. Cotton quality specifications & customer
quality requirements
f. Relative humidity %
b. Lot management and mixing issue system g. Invisible loss / gain
c. Machine Working Performance h. Tare weights
d. Process parameters i. Stock accounting system
e. Spinning limits – Under spinning or Over spinning
04 Decoding Loss: Examining the Contributing Factors
Cotton Quality Specifications:
Short Fiber Content Cotton Trash%
Ø In cotton fibres, fiber length whose Ø Trash content removed in blow room &
length is shorter than 12.5 mm are carding processes along with some amount
usually considered as short fiber of good cotton fibers ultimately reduce the
content % (i.e. SFC(n) & SFC(w) %) yarn realisation.
as determined by AFIS instrument.
Ø Heavy particles are extracted easily due to
Ø It is eliminated as waste in blow room, their denser in nature but elimination of
carding and also in comber noils. lighter leaf particles pose a big challenge
and lead to higher waste extraction.
Ø However, SFC(n) is ignored by
majority of the mills being a critical Ø In addition to that, other fibre properties such
factor driving the Yarn Realisation% as Micronaire, immature fiber content (IFC)
(YR%). and fiber strength also influences YR%.
Trash % broadly ranging from 1 to 10%
Ø SFC(n) broadly ranging from 15 to
35%
04 Decoding Loss: Examining the Contributing Factors
Lot Management and Mixing Issue System
Ø As cotton is a natural fiber, within bale and between bale fiber quality variations is also an inherent characteristic. Hence,
it is essential to ensure homogeneity in the mixing lay down. Mixing lay down charts are prepared in novel way to
maintain mixing quality consistency, to minimize quality variations. For example, mixing lay down chart based on
Micronaire is given in Figure 1 can be designed manually or by using software.
Ø Ginners have a practice of spraying excess water, bypassing pre/post cleaners and even supplying false packing by
adding comber noil before dispatching to the spinner. In those bales, variation in Micronaire CV %, Trash %, SFC(n) CV%
and high moisture % which indicates the quality of ginning and exposes false packing.
Ø Mixing specification standards shall be fixed and maintain the same parameters as much as possible for all the lay
downs.
04 Decoding Loss: Examining the Contributing Factors
Customer Quality requirements
Yarn realisation is also widely affected by end use of the product or for specific quality requirement. For high
quality and sensitive end use applications such as shirting’s, suiting’s & garments etc., higher waste has to be
extracted by the mills to meet the requirements.
Process Parameters
Improper selection of process parameters lead to poor quality & working performance of the spinning process,
which ultimately forces the spinner to generate high amount of waste.
Spinning Limits
Under or over limit of spinning also impacts on yarn realisation%. Mills should use the optimum cotton quality
parameters suitable for each count based on yarn quality requirements to minimize the mixing cost.
04 Decoding Loss: Examining the Contributing Factors
Relative Humidity %
To retain the moisture in cotton to specific level, the relative humidity shall have to be maintained around 65%
in mixing, winding and packing. Cotton yarn absorbs adequate moisture which in turn with less fluff liberation.
This will lead to lower invisible losses by maintaining commercially acceptable moisture range in the finished
products.
Invisible Loss or Gain
Moisture in cotton bales shall be within commercially acceptable moisture range (8.5 to 9) to minimize invisible loss.
Tare Weights
The tare weight of cotton bales, carton boxes and waste bales shall be maintained precisely. The weighing
balance used for weighment shall be periodically calibrated for its accuracy.
05 Invisible Loss - Unravelling the Factors Behind Losses
It refers to the amount of material that is lost during various
stages of production without being quantifiable.
Key factors influencing invisible loss are
Moisture content in cotton bales. Lower the moisture, better gain
and vice versa. Imported cotton are supplied with < 6 % moisture
too. However, Indian spinners are accepting cotton moisture up to
9%
Relative humidity for proper working which reduces fly
liberation.
Moisture of cotton waste such as blow room waste, card
waste & comber noil have to be ensured
Moisture gain on finished packages after yarn
conditioning system have to be ensured periodically
Carton box weight tolerance shall be minimized and tare
shall be checked on regular basis.
Finished yarn weight tolerance
06 Permissible Levels of Lint in Process Waste
Acceptable quantities of lint within process waste
Lint in blow room Waste <25%
Lint in Licker in waste <25%
Lint in Flat tops <55%
Lint in Stationary flats <65%
Short fibres (SFC(n)) in Comber >85%
noil
07 Striking the Balance: The Quality Vs Noil Curve
The curve flattens after 20% noil elimination which is an
indicator for the mills to fix their noil level
Dependence of Various Quality Parameters on noil
elimination (Source Rieter)
A – Improvement of yarn Quality in %:
B – Noil elimination in %:
a – Yarn strength: b – Yarn evenness: c – yarn
imperfections
08 Our Approach for Re- Engineering
Devise required
Undertake Finetune and
process
diagnostic study Replicate on
interventions /
digital tool complete set-up
Define areas of
implementation –
Productivity, Undertake a pilot
Realisation, run
Power Saving,
SOPS etc
We can help you to achieve your goal by assisting in making your unit at par with international benchmarks.
Putting Knowledge into Action –
09 Case Study 1 : Operations Re-engineering - Spinning Unit
Client Composite unit having 65,000 state of the art latest spindles
Objective Re-engineering spinning unit for increasing the yarn realisation and reducing the usable waste
Approach
Result
• Comprehensive assessment of plant • Various new systems designed specific to unit from
Gap Analysis
and Action Plan • Identifying issues of various losses selection of raw material to packing of finished goods
• Implementation of developed plan of
action to achieve the desired yarn
Implementation
realisation and reduced Useable waste Improvement Percentage
Yarn
• Sustaining the achievement Realisation 7.1%
Monitoring
• Conducting training and knowledge
Training sharing session for complete staff
Putting Knowledge into Action –
09 Case Study 2 : Operations Re-engineering - Spinning Unit
Client Composite unit having 50,000 spindles of 15 years old unit
Objective Re-engineering spinning unit for increasing the yarn realisation and reducing the usable waste
Approach
Result
• Comprehensive assessment of plant • Various new systems designed specific to unit from
Gap Analysis
and Action Plan • Identifying issues of various losses selection of raw material to packing of finished goods
• Implementation of developed plan of
action to achieve the desired yarn
Implementation
realisation and reduced Useable waste Improvement Percentage
Yarn
• Sustaining the achievement Realisation 8.2%
Monitoring
• Conducting training and knowledge
Training sharing session for complete staff
10 Learning Organisation
10 Learning Organisation
11 Sealing the Presentation: Concluding Thoughts and Reflections
Ø To maintain competitiveness in the market, mills should prioritize operational excellence through regular
comparisons of their performance against other top-performing mills, focusing on key technical parameters.
Ø Additionally, benchmarking against industry leaders should be conducted regularly. Periodic reviews, along with
corrective and preventive actions, will consistently enhance the mill's competitiveness and optimize manufacturing
costs.
Ø Our case studies demonstrate a return on investment within 6 to 9 months when investing in a knowledge partner.
About Texcoms
Transferring know-how to
Consulting operate textile mills efficiently
in spinning, knitting, weaving
and processing
Sourcing and supplying
of specialty and value- Yarn &
Fabric
added yarn and fabric in
Asian market
Sourcing and supplying of
MACHINERY Machinery machines in Spinning, Knitting,
weaving and processing. The
DIVISION only company to have end to
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