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Low Residual Torque Singles Ring Yarn Technology

Technology Overview

Ring-spinning has been the most common technology in producing yarns because of the excellent softness and structure of its end products and its applicability on different materials. However, a residual torque (or twist liveliness) tends to build up in the yarn as the twist is inserted. Such torque results in spirality and distortion of single jersey knitted fabrics, and surface unevenness of denim fabric after stone-wash finishing. For instance, some T-shirts would have crooked seams that curl towards the front or the back after a few washes. This is a result of the residual torque built up in the yarn during the spinning process.

This is a new technology that produces ring-spun yarn with no torque and low hairiness. Fabrics weaved with the yarns produced from this technology exhibits excellent softness, surface clearness and dimensional stability. Garments made with such fabrics would not twist or distort even after many washes.

Technology Features & Specifications

Using low or zero residual torque produced singles ring yarn is a new technology which can be incorporated into the conventional ring-spinning process without any additional processing step. It simply requires adding a mechanical device to the existing spinning machine to achieve fibre torque balance.
 
This technology makes a revolutionary breakthrough in the textile industry:

  • Production of yarns with a linear density of 7 - 100Ne using twist lower than normal twist by 25~40%
  • Saving cost by 10% (due to lower spirality and clearer surface with symmetrical loops)
  • Saving 335 kWh of electricity per one ton of yarn produced
  • Increasing spinning productivity by 25 - 40%
  • No chemicals, water or steam is required for production

Potential Applications

This technology is applicable to woven, knitted and denim fabrics. In terms of material, cotton is most commonly used in garments and textile products, for example, towels, T-shirts and polo shirts. Low or zero residual torque produced fabric is hugely popular in high-end markets throughout the world, including Europe, the U.S. and Japan. Knitted sweaters made by this technology are particularly well-received in Japan, mainly because they do not distort even after repeated washes. A Japanese casual wear chain used this technology in T-shirts and jeans, and their products have entered the high quality and value-added market worldwide.
 
Catering to the increasing demand of high quality textile products, the technology improves manufacturers production capability and enhances their production efficiency by producing yarns with low residual torque and high strength.

Customer Benefits

From a consumer s point of view:

  • Fabric produced has extremely smooth surface and softness.
  • Even regular grade cotton can be woven into lavish fabric with a touch like expensive cashmere fibres.
  • Highly comfortable to wear.
  • Textiles produced are durable to wear and wash.

From a manufacturer s point of view:

  • Significantly brings down cost of raw materials, man-hours, electricity and fabric finishing.
  • Regular ring-spun yarn has to be spun three times—two thinner yarns are spun separately first, and then the two are spun together into one thicker yarn. This technology does all in one step, saving electricity and labour costs. For every 100,000 spindles of yarn produced, this system uses 8,000 units less electricity than conventional ring spinning systems.
  • Key element is structural modification of the yarn so that residual torque of individual fibre is balanced.
  • A truly green technology, as no chemicals are used
  • Low degree of twisting requires less cotton for balancing the residual torque during production, ergo the cost of fabric finishing is also reduced.

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