Difference between Rotor and Ring Spinning

Rotor Spinning Process

Rotor spinning process is fundamentally different from the ring spinning process in both mechanism and outcomes. Rotor spinning is also called open-end spinning. In rotor spinning process the preparatory processes include the operation of the blow room, card and draw frame passage. For the spinning of coarser yarn counts with shorter fiber length, card sliver can directly be fed to the rotor machine. However the need of right quality of sliver determines the requirement of one or two draw frame passage after carding process. Instead of classical roller drafting technique, the dispersion drafting is used in rotor machine. Twist is also inserted due to rotation of rotor.

The production rate of rotor spinning is 6–8 times higher than that of ring spinning. Open end rotor machines are fed directly by sliver and yarn is wound onto packages ready for use in fabric formation so in open end rotor spinning, only one machine is used instead of three machines (Roving frame, Ring frame and Autowinding) in ring spinning. Rotor spun yarns are more even but somewhat weaker and have a harsher feel than ring spun yarns.

Rotor yarn is coarser than ring spun yarn. The count of rotor yarn is very low. Most of rotor yarn count is below 20’s but highest yarn count may be 40’s. Coarser fabric is formed by rotor yarn. Most of the jeans or pant is made by rotor yarn. Denim is fully depends on rotor yarn. The price of rotor yarn fabric is very low than combed and carded yarn fabric.

The first functioning rotor spinning machine was presented at ITMA 1967. Yarn formation according to the rotor spinning principle predominates for all nonconventional spinning methods. Worldwide, more than 8 million spindles are in operation.

Jeans products are mainly made of OE-rotor cotton yarns because production is less expensive and a special yarn quality is obtained. The yarn fineness is between 70 (medium) and 120 tex (coarse). Warp yarns usually have a metric twist factor of 140, and weft yarns have a metric twist factor of 130. The average rotor diameter is about 35 mm and the rotary speed about 70,000 rpm. Delivery speeds are up to 160 m/min.

Ring Spinning Process

The ring spinning system is the most flexible yarn production system in terms of both raw material handling and the range of yarns produced. Currently, the most popular spinning method is the ring spinning process with a market share of about 80% of overall yarn production. The first ring spinning frame was built in 1828 in the United States. Ring spinning soon dominated because of its high production speed and is practiced worldwide with about 250 million spindles. In recent years other nonconventional spinning methods have gained importance.

Ring spinning consists of three subsequent processing steps: slubbing, ring spinning, and winding. With non-conventional spinning methods, these three steps are combined in one processing step. In general, in ring spinning, it can be assumed that the twist propagation speed is much larger than the delivery speed of the yarn.

Difference between Rotor and Ring Spinning

Here’s a table summarizing the differences between rotor spinning and ring spinning:

Comparison between Ring Spun Yarn and Rotor Spun Yarn

1. Breaking strength lower than ring spun Yarn
2. CV% of strength better than ring spun yarn
3. Elongation at break higher than ring spun yarn
4. Mass irregularity (over short lengths) better than ring spun yarn
5. Imperfection index lower than ring spun yarn
6. Volume greater than ring spun yarn
7. Abrasion resistance higher than ring spun yarn
8. Stiffness higher than ring spun yarn
9. Handle harder
10. Power consumption less than ring spun yarn
11. Possible yarn counts rotor Ne 3 – 60 and Ring Ne 6 – 200
12. Energy consumption with productivity lower as compared to ring m/c.

Aesthetic Properties of Rotor and Ring Spun Yarn

• Surface rougher than ring yarn
• Hairiness higher than ring yarn
• Lusture on the dull side

More capital costs & more maintenance cost as compared to ring machine. In modern rotor spinning line; blow room and carding machine are use at a time. This technique is called “Chute to feed card” or “Chute to feed drawing”. Rotor spinning number is less than combed or carded spinning. Low graded fiber spin in rotor spinning.

Conclusion
Rotor spinning and ring spinning are two widely used yarn production techniques, each suited for specific needs. Rotor spinning is faster, energy-efficient, and ideal for producing coarser yarns from short fibers or recycled materials, commonly used in denim, towels, and home furnishings. On the other hand, ring spinning delivers finer, stronger, and more uniform yarn, making it perfect for high-quality textiles and apparel, though it operates at a slower speed and consumes more energy. The choice between the two depends on the desired yarn quality, production efficiency, and end-use applications.

References:

1. Gries, T., Veit, D., & Wulfhorst, B. (2015b). Textile Technology: An Introduction. Hanser Pub Incorporated.
2. Textile and Clothing Design Technology. (2017). In CRC Press eBooks. https://doi.org/10.1201/9781315156163
3. Nawab, Y. (2016). Textile Engineering: An introduction. Walter de Gruyter GmbH & Co KG.

4. Kiron, M. I. (2021, November 2). Ring spun and rotor spun yarn: Properties, factors and comparison. Textile Learner. https://textilelearner.net/ring-spun-yarn-and-rotor-spun-yarn/

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