Apparel-Merchandising: Yarn

How we produce Yarn from cotton?

Dear all,

The yarn making process is a very complicated process. So many things are related with this yarn producing process. Moreover, various kinds of yarn are producing everyday all over the world.

These yarn can be divided by the types of raw materials which we used for making the yarn.
Such as-

100% cotton yarn.
CVC yarn (In this type of yarn the combination of cotton of polyester can be varied depending on the buyer requirement. such as - 65% cotton + 35% polyester, 60% cotton + 40% Polyester etc.Also mainly in this type of yarn the cotton part is always remain greater than the Polyester). CVC mean cheap value cotton.
100% polyester yarn.
PC yarn (In this type of yarn the cotton part is always remain less than the Polyester). PC means Polyester cotton.
100% Viscose yarn.
Grey Mélange yarn. In this type yarn we used a mixer of cotton & viscose. The percentage of cotton & viscose may vary depends on the requirement of buyer. Such as - 85% cotton + 15% viscose (Dark Grey Mélange), 90% cotton + 10% viscose (Grey Mélange), 95% cotton + 5% viscose ( Light Grey Mélange), 98% cotton + 2% viscose (Ecru Mélange) etc. Please note that if we increase the percentage of viscose then the yarn shade also will become dark accordingly. The percentage also can be 80% cotton + 20% viscose. So, if your buyer asked you for Grey mélange fabric then you must confirm it from them that, which percentage of viscose actually they looking for. The yarn price of Grey Mélange is higher than normal cotton yarn. Please always be aware about one thing that, the fabric which knitted by grey mélange yarn is not need to dyeing. Also fabric properties of cotton & grey mealange are almost same. So, we can used same care instruction for both (cotton & g.melange) type of fabric.

Other than these, many more kinds of yarn are producing in this textile world. Such as Bamboo yarn, Organic cotton yarn etc.

We can also separate the yarn by their finishing quality:

Combed Yarn
Carded Yarn
Rotor Yarn
Slav yarn

Yarn is also labeled by their thickness. The unit of this is count. The count number of yarn will increase according to the reduce of yarn thickness. Yarn price also increase according to increased of count number. 40 count yarns are thinner than the 36 count yarn. Some common yarn count:

20 count
22 count
24 count
26 count
28 count
30 count
32 count
34 count
36 count
40 count

Normally we used these yarn count for knit fabrics.

Few days ago I visited a spinning factory to let it know that, how the yarn is producing from cotton. This spinning factory only produced 100% cotton carded yarn. Here, I will describe you the yarn producing process step by step with image and video. Thanks!

Please find below a flow chart for 100% cotton carded yarn.

Ø 1st Step: For producing the yarn at first we need to setup a spinning factory. The production capacity of this spinning factory will be depends on our requirement.

Ø 2nd Step: Cotton purchasing by import or from local market. Then store the cotton separately based on its origin, quality & fiber length etc.

Ø 3rd Step: Blow room section – In this section the cotton goes under several treatment or operations. Such as- Fiber opening, Cleaning, Dust Removal, Blending etc.

Ø 4th Step: Carding section – After end of the blow room process the cotton comes in the carding section. The cotton comes automatically in these carding machines by pipe. A spinning factory has several carding machine. Two proverbs of the experts - "the carding is the heart of the spinning mill" and "well carded is half spun"

Ø 5th Step: 1st Drawing – From the carding machine we got Sliver. The breaker drawing (1st drawing) machine makes even the sliver by doubling process.

Ø 6th Step: 2nd Drawing – After finished the process of 1st drawing by the finisher drawing (2nd drawing) machine we make the sliver more even (as much as possible.)