Industry Overview
Open-end spinning, also known as rotor, break, or free-fibre spinning, is a commercially established yarn manufacturing technology that separates drafting, twisting, and winding into independently operated processes. This approach enables high production rates and offers particular advantages for short fibres and waste materials, making open-end spinning an important blending and waste-spinning process.
The development of open-end spinning followed the recognized mechanical, technological, and economic limitations of conventional ring spinning. Although the basic concept dates back to 1807, commercial development accelerated during the twentieth century. The KS200 was demonstrated publicly at Brno in 1965, followed by the BD200 commercial machine in 1967. By 1971, numerous free-fibre spinning machines were being exhibited internationally.
In rotor spinning, sliver is opened into individual fibres, pneumatically conveyed to a rotating rotor, collected in the rotor groove, and continuously withdrawn as twisted yarn. The yarn is then wound into a package by a separate winding mechanism. The independent operation of drafting, twisting, and winding allows high productivity compared with ring spinning. However, twist loss and the minimum fibre population required at the yarn formation point restrict rotor spinning mainly to coarse and medium yarn counts. The technology is also characterized by distinctive wrapper fibres and yarn structural properties.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 8 Ton/Day |
| Land & Building (14,000 sq.mt.) | Rs. 6.67 Cr |
| Plant & Machinery | Rs. 10 Cr |
| Working Capital for 2 Months | Rs. 3.27 Cr |
| Total Capital Investment | Rs. 20.64 Cr |
| Rate of Return | 29% |
| Break Even Point | 55% |
Content Index
- INTRODUCTION
- CHARACTERISTICS OF OPEN END SPINNING
- A GOOD OPEN-END MACHINE SHOULD HAVE:
- HIGHER PRODUCTIVITY
- HIGH-CONTENT SLIVER CANS (UP TO 18”)
- LARGER PACKAGES OF YARN (4 TO 5 KG.)
- LESS POWER CONSUMPTION
- AUTOMATION
- FLEXIBILITY OF SPINNING COMPONENTS
- HANDLING COUNT RANGE.
- ADVANTAGES
- PRODUCTS
- BASIC TEXTILE TERMS OF SPINNING
- YARN COUNT/SLIVER HANK:
- YARN COUNT SYSTEM:
- PRINCIPLE
- FIGURE: FORMATION OF AN OPEN-END SPUN YARN
- OPEN END ROTOR YARN CHARACTERISTICS
- ROTOR SPINNING PROCESS
- ROTOR SPINNING SYSTEM:
- OUTER STRUCTURE OF OPEN END (ROTOR SPINNING YARN)
- STRUCTURE AND WORKING OF ROTOR SPINNING MACHINE:
- SCHEMATIC DIAGRAM OF ROTOR SPINNING MACHINE
- SLIVER FEEDING ASSEMBLY:
- FIBRES OPENING ASSEMBLY:
- FIBRES DRAFTING ZONE:
- CLEANING ASSEMBLY:
- FIBRE CONDENSATING SYSTEM:
- TWISTING (TWIST INSERTION)
- MANUFACTURING PROCESS
- SEQUENCE OF OPERATIONS:
- FIGURE: BLOCK DIAGRAM OF PROCESS FLOW IN OPEN END SPINNING
- ESSENTIAL FEATURES OF THE OPEN END SPINNING PROCESS:
- ELEMENTS OF OPEN END SPINNING SYSTEM:
- ROTOR SPINNING:
- OBJECTIVES OF ROTOR SPINNING:
- ROTOR SPINNING WAS INITIALLY DEVELOPED WITH TWO MAIN OBJECTIVES
- OPERATING PRINCIPLES OF ROTOR SPINNING SYSTEMS:
- FIGURE: MAIN FEATURES OF ROTOR SPINNING SYSTEM
- PROCESS DESCRIPTION
- ROTOR SPINNING: -
- ROTOR USED IN ROTOR SPINNING:-
- ROTOR SPEED AND DIAMETER
- THE ROTOR GROOVE:
- THERE ARE THREE DIFFERENT TYPES OF ROTOR GROOVES AVAILABLE:
- FIGURE BELOW SHOWS THE SHAPES OF DIFFERENT TYPES OF ROTOR GROOVE.
- FIGURE: DIFFERENT TYPES OF ROTOR GROOVES.
- THE ROTOR WALL
- THE TAKE-OFF NOZZLE
- SMOOTH TAKE-OFF NOZZLE:
- FLUTED TAKE-OFF NOZZLE:
- SPIRAL TAKE-OFF NOZZLE:
- SWIRL TAKE-OFF NOZZLE:
- SLIVER FEED:-
- PREPARATION OF THE SLIVER
- FIBRE OPENING
- FIGURE: OPENING ROLLER
- FIBRE TRANSFER:
- FIGURE: FEED GUIDE CHANNEL
- DIFFERENCE BETWEEN DIFFERENT ROTOR MACHINES
- THE MAIN DIFFERENCES BETWEEN DIFFERENT ROTOR MACHINE DESIGNS ARE:
- OTHER FEATURES INCLUDE THE FOLLOWING:
- ROTOR SPINNING PERFORMANCE
- YARN BREAKAGE
- CONVENTIONAL & OPEN END SPINNING
- CHARACTERISTICS:-
- THE STRUCTURE OF OPEN END-SPUN YARN
- STRUCTURE AND PROPERTIES OF ROTOR-SPUN YARNS
- FIGURE: - STRUCTURE OF ROTOR SPUN YARN
- (A) SCHEMATIC DRAWING (B) OPTICAL MICROGRAPH
- ADVANTAGES:-
- DISADVANTAGES:-
- YARN TWIST AND TWIST MULTIPLIER
- DIFFERENT DEFINITIONS OF TWIST OF THE YARN
- TYPES OF TWIST
- HIGHER TWIST MULTIPLIERS ARE USED,
- LOWER TWIST MULTIPLIERS ARE SELECTED, PRESUPPOSING ADEQUATE YARN TENACITY,
- TWIST LEVEL:-
- RELATION BETWEEN TWIST AND YARN STRENGTH:-
- EXPRESSION OF TWIST
- AMOUNT OF TWIST EXPRESSED IN –
- FACTORS AFFECTING TWIST
- IN PRACTICE, YARN TWIST IS DESCRIBED USING THREE MAIN PARAMETERS:
- DIRECTION OF S TWIST
- DIRECTION OF Z TWIST
- FUNCTION AND EFFECTS OF TWIST ON YARN & FABRIC PROPERTIES
- FUNCTION OF TWIST IN YARN STRUCTURE
- EFFECTS OF TWIST ON YARN & FABRIC PROPERTIES
- IN THE CASE OF HANDLE:
- IN THE CASE OF MOISTURE ABSORPTION:
- IN THE CASE OF WEARING PROPERTIES:
- IN THE CASE OF AESTHETIC EFFECTS:
- YARN DIAMETER, SPECIFIC VOLUME & PACKING DENSITY
- SPECIFIC VOLUME FROM TWIST
- PACKING DENSITY
- PRODUCT DESCRIPTION AND APPLICATION
- END USES FOR OPEN END SPUN YARNS
- PLANT CAPACITY AND PRODUCTION PROGRAM
- PLANT CAPACITY
- PRODUCT RANGE:
- PRODUCTION PROGRAM
- INDIAN SPINNING INDUSTRY
- GLOBAL AND DOMESTIC COTTON SCENARIO
- GLOBAL POSITION:
- INDIA’S POSITION:
- CHINA’S POSITION:
- COTTON PRICES – TRENDS & OUTLOOK
- INTERNATIONAL PRICES:
- INDIAN PRICES:
- INDIAN YARN PRODUCTION AND EXPORTS
- EXPORTS:
- PRODUCTION:
- DOMESTIC YARN PRICES AND CONTRIBUTION
- YARN PRICES:
- CONTRIBUTION:
- FINANCIAL PERFORMANCE OF COTTON SPUN-YARN MANUFACTURERS
- QUARTERLY PERFORMANCE:
- INDIAN TEXTILE AND APPREAL INDUSTRY
- ADVANTAGE INDIA
- PRODUCTION OF YARN IN INDIA
- PRODUCTION OF YARN IN INDIA FROM FINANCIAL YEAR 2011 TO 2020 (IN MILLION KILOGRAMS)
- SOME SUPPLIER NAME OF SPINNING AND SPINNING MACHINERY
- LIST OF MACHINES
- MACHINERY PHOTOGRAPHS
- BLOW ROOM
- FILTER
- BLOW ROOM FOR VISCOSE/COTTON
- COTTON CARDS
- DRAW FRAME
- TWISTING AND WINDING MACHINERY
- SCHLAFHORST AUTOCONER
- RAW MATERIAL & PODUCT PHOTOGRAPHS
- PROCESS FLOW DIAGRAM OF OPEN END SPINNING FROM WASTE COTTTON
- PROCESS FLOW DIAGRAM
- TECHNICAL SPECIFICATION
- ROTOR SPINNING (SAURER SCHLAFHORST):- BD 448
- DRAWING:-
- CARDING:-
- ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
- COMPLETE MACHINERY SUPPLIERS
- DETAILS OF MACHINERY
- SCHLAFHORST:-
- BD INNOVATIONS
- DELIVERED FROM CHINA
- SHANDONG LINQING SANHE TEXTILE GROUP
- RAW MATERIAL SUPPLIER
- CLEANING OF OPEN END SPINNING MACHINE & WASTE DISPOSAL
- INSTRUCTIONS FOR SHIFT CHANGE
- HANDING OVER THE SHIFT:
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Open-end spinning is a yarn manufacturing process that forms yarn without using a conventional spindle.
It is also called rotor, break, or free-fibre spinning. The process separates fibres from sliver, transports them to a rotating rotor, collects them in the rotor groove, and continuously withdraws the resulting yarn. Drafting, twisting, and winding are performed as separate operations, which allows the system to achieve high productivity and makes it suitable for various fibre materials, including short fibres and waste-derived materials.
A rotor spinning machine works by opening sliver into individual fibres and collecting those fibres in a rotating rotor to form yarn.
The feed roller supplies sliver to an opening roller, which separates the material into individual fibres. An air stream transports the fibres through a feed duct to the rotor groove. The fibres are continuously deposited and assembled into yarn while the yarn is withdrawn and wound by a separate mechanism. This separation of fibre preparation, twisting, and winding is a fundamental feature of the rotor spinning system.
The main advantages of open-end spinning include high productivity, process integration, automation potential, and suitability for shorter fibres.
The technology separates drafting, twisting, and winding so that each operation can function independently. It can also handle fibre materials that may be less suitable for some conventional spinning systems. Other potential advantages include reduced power consumption, larger yarn packages, flexible spinning components, and automated operation, depending on machine design and process conditions.
Rotor spinning is particularly suited to coarse and medium categories of yarn counts.
The report explains that twist loss at the yarn formation point creates a critical limitation on the number of fibres that can be present there during spinning. Consequently, rotor technology is generally associated with yarns in coarse and medium count ranges. The actual product range depends on fibre characteristics, rotor design, machine settings, yarn requirements, and other process conditions.
Ring spinning and open-end spinning differ mainly in their yarn formation mechanism and the way drafting, twisting, and winding are performed.
In ring spinning, drafting, twisting, and winding are carried out simultaneously around the spinning arrangement. In open-end rotor spinning, these operations are separated, with fibres collected in a rotor groove before yarn withdrawal and winding. Rotor spinning therefore offers a different productivity and yarn-structure profile, while ring spinning remains known for its flexibility and broad applicability to high-quality yarn production.
Fibre opening is essential because rotor spinning requires the sliver to be separated into individual fibres before yarn formation.
The opening roller breaks down the incoming sliver and assists in separating and preparing the fibres for pneumatic transfer to the rotor. Effective opening and fibre transfer contribute to consistent fibre assembly in the rotor groove. The quality of opening can therefore influence yarn formation, yarn uniformity, production stability, and the overall performance of the spinning process.
Yarn twist in rotor spinning is influenced by rotor conditions, yarn withdrawal, fibre characteristics, and process settings.
The report discusses twist level, twist multiplier, twist direction, yarn strength, and the effects of twist on handle, moisture absorption, wearing properties, and aesthetic characteristics. Rotor design, rotor speed, yarn withdrawal conditions, fibre assembly, and other machine parameters also affect the resulting yarn structure. Appropriate twist selection is therefore important for achieving the required balance of strength, appearance, handle, and processing performance.
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