Wool Fiber

What Is Wool Fiber?
The Wool Fiber is a Fiber from fleece of domestic sheep. It is a natural protein multicelullar staple Fiber.

What Is Fleece ?

The shared wool is a dense made of fibers wholly entangled by crimp, sticky, fat and dirt forming called wool fleece.

Process Flow Chart of Wool Production:

Wool Grading Between United States Of America (U.S.A) and United Kingdom (U.K)

In America wool shorten grades by comparison with pure blood merino. But in England is more specific in several instance .

U.S Grading	U.K Grading
Fine	80’s to 70’s
Half Blood	62’s to 60’s
Three eight Blood	56’s
Quarter Blood	50’s  to 48’s
Low quarter Blood	46’s
Common	44’s
Braid	40’s to 36’s

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Comparative study for Melt Dry & Wet spinning

==	Melt	Dry	Wet
Investment cost	Low	High	Low
Environment of Health hazard	Non toxic	Toxic & risk of accident	Toxic
Heat input	High	Very high	Low
Solvent	Not required	Only organic	Organic
Solidification	Cooling	Evaporating	Coagulating
Spg  Speed	1000-2000 m/min	600-1200 m/min	60-160 m/min

Table of typical Wet Spinning solvent and coagulant

Fiber	Solvent	Coagulant
Viscose	Aqueous of sodium salt & xanthate  ester	Dilute H2SO4+Na2SO4+ZnSO4
Acrylic	Dimethyl-acetamide (DMA)	50% aqueous  Dimethyl-acetamide
PVA	DMF (Dimethyle Formide), Water	30% aqueous DMF
Spandex	DMA	30% aqueous DMA

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Wet Spinning Process

Wet Spinning :
Wet Spinning Process is the oldest process. It is used for fiber forming substances that have been dissolved in a solvent. The process of wet spinning is given bellow.

Wet Spinning Process

Figure : Wet Spinning Process

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Dry Spinning Process

Dry Spinning : In Dry Spinning, Polymer dissolved in a volatile solvent is introduced into a heated drying chambers, where the solvent is evaporate and solid fiber is obtained. This process may be used for the production of Acetate, Tri-acetate, Acrylic, Modacrylic, PBI, Spandax and Vinyan.

What are Synthetic Fibers : The fibers which are obtained by chemical synthesis called synthetic fibers. Polyester, Nylon, Acrylic, PBI etc are the Synthetic Fibers.

Dry Spinning Process : 

Figure : Dry Spinning Process

What Is Spinneret ?

A nozzle or plate provided with fine holes through which a fiber forming solution or melt is extruded in fiber manufacture is called spinneret. This is most important part of a M/C. There are some spinneret given bellow,

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Melt Spinning Process

Melt Spinning : The fiber forming material is melted and subsequently passed through the holes of a spinneret. Example ; Polyester, Nylon, Polypropylene etc.

Requirements for melt Spinning

• The polymer should not be volatile
• The polymer should not decompose in the molten state and the melting point.
• Polymer should be 30 degree centigrade less than its decomposition temp.

Process of Melt Spinning :

Figure : Melt Spinning Process.

Special Feature Of Melt Spinning :

• High production ( SPG. Speed 1000-2000 m/min)
• Hazard , Non Toxic
• No environment pollution.
• No solvent required .
• Heat of spg high.

Melt Spinning Polymer : 

Polymer	Melting Point
Nylon 6.6	264 degree Celsius
Nylon 6	220 degree Celsius
Polypropylene	167 degree Celsius
PET	264 degree Celsius

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Textile Spinning for Man Made fibers.....!

Spinning for Man Made  Fiber : The conversion of polymer into fiber, filament is called the spinning, from the made made fiber view. The fiber forming substance is made temporal fluid extruded through spinneret and then return to solid state (by solidifying) in fiber form.

Spinning type for Man Made Fiber: There are mainly three types of spinning as

1. Melt spinning,
2. Wet spinning,
3. Wet spinning.

Melt Spinning : 

The fiber forming material is melted and subsequently passed through the holes of spinneret. Example, Polyester, Nylon, Polypropylene. etc

Dry Spinning :

In Dry spinning, polymer dissolved in a volatile solvent is introduced into a heated drying chambers, where the solvent is evaporate and solid fiber is obtained. This process may be used for the production of Acetate, Tri-Acetate, Acrylic, Modacrylic, PBI, Spandax and Vinyon. 

Wet Spinning : 

Wet spinning is the oldest process. It is used for fiber forming substances that have been dissolved in a solvent. The spinnerets are submerged in a chemical bath and as the filament emerge, they precipitate from solution and solidify. Because the solution is extruded directly into the precipitating liquid. This process for making fibers is called Wet Spinning. Acrylic, Rayon, Aramid, Modacrylic, Spander and be produced by this process.

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Yarn Count or Yarn Number

Yarn Count:

The count of Yarn is a numerical expression, which defines its fineness. Spun Yarns are only roughly circular in cross-section and irregularity in thickness is unavoidable. Filaments Yarns with only a small amount of twist in them are referred to as a flat yarns with solid bodies.
A definition of Yarn Count is given by the Textile Institute  (UK) : Yarn Count is number indicating the weight per unit length or the length per unit weight of yarn. However, various counting systems using different units of weight and length are in use. 
We use mainly two counting system as :
1. Direct systems of Yarn Count.
2. Indirect systems of Yarn Count.

1. Direct system of Yarn Count :

In this system, Yarn Count is the weight of a unit length of Yarn. The units of weight and length vary from trade to trade, district to district and country to country. However, a general formula which applies to all directs systems can be written as follows:
Let N= the Yarn count,
W= the weight of the sample at the official regain in the units of the system.
L= the length of the sample,

Then, N= W×l/L

Math :  If a skein of 100 m of filament Viscose Yarn weight is 1.67 g, Calculate its Denier.

Solutions: In the Denier system the weight unit is the gram and the unit of length is 9000 m.

Thus, W=1.67g, L=100m, and l = 9000 m. 

We know, N= W×l/L, therefore,

Denier = N= W×l/L = 1.67×9000/100 = 150.3;

So the Yarn Count is 150.3 Denier.

2. Indirect System of Yarn Count

In this system Yarn Count is the number of units length per unit weight of Yarn. Here again there are various units of length and weight and numerous systems. However, a general formula which applies to all indirect systems can be written as follows:

Let, N= The Yarn Count,

W= The weight of the sample at the official regain in the units of the system, w= the unit weight of the system, L= the length of the system, and l= the unit length of the system,

Then N= L×w/l×W

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