Description:FIELD
The present disclosure relates to a process for the preparation of ultra-low twist yarn.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used, indicate otherwise.
Absorbency: The term ‘absorbency’ refers to the propensity of a material to take in and retain liquid, usually water.
Blending: The term ‘blending’ refers to mixing of quantities of typically the same fibre taken from many lots or of different types of fibre to produce a uniform result.
Breaker Draw frame: The term ‘breaker draw frame’ refers to a textile machine in which the feed material is carded sliver, and during the process the infeed slivers are parallelized, straightened and homogenized to form breaker-drawn sliver.
Break draft: The term ‘break draft’ refers to a draft applied to a passing sliver as it enters the first or “back” zone of a multi-roller system.
Carding: The term ‘carding’ refers to a mechanical process that disentangles, cleans and intermixes fibres to produce a continuous web or sliver suitable for subsequent processing.
Combed slivers: The term ‘combed sliver’ refers to the slivers obtained after passing a lap through a combing machine, which aligns the fibres in parallel to produce a smoother and stronger sliver.
Count strength product (CSP): The term ‘count strength product (CSP)’ refers to the product of the yarn count and the yarn strength in Pounds.
Doubling: The term ‘doubling’ refers to combining of two or more different feeds to make one continuous sliver to increase uniformity.
Drafting: The term ‘drafting’ refers to a mechanism of reduction in the weight per unit length of a sliver/yarn by passing it through three or four rollers with different speeds.
English count (Ne): The term “English count (Ne)” refers to number of hanks of 840 yards per pound, an indirect measurement of the yarn size. Higher the number, finer the count.
Finisher Draw frame: The term ‘finisher draw frame’ refers to a textile machine in which the feed material is breaker drawn slivers or combed slivers, and during the process the infeed slivers are parallelized, straightened and homogenized to form finisher-drawn sliver.
Free fibre: The term “free fibre” refers to the fibre which has been opened from the bale, which can also be termed as “opened fibre”.
Hank: The term ‘hank’ refers to a definite length of textile material that varies according to the material. A hank of cotton is 768.096 meter or 840 yards.
Micronaire: The term ‘micronaire’ refers to a number used to denote cotton fibre fineness and maturity.
Pile: The term ‘pile’ refers to low twist or untwisted loops of yarn that stand up from the body of the fabric.
Polyvinyl alcohol (PVA): The term ‘polyvinyl alcohol (PVA)’ refers to a synthetic polymer that is available in the form of spun yarn or free fibres that are easily dissolved in warm or hot water at about 40 degrees Celsius to 110 degrees Celsius without the aid of any chemical agents.
Sliver: The term ‘sliver’ refers to a continuous strand of loosely assembled fibres without twist, that ultimately forms yarn after processing.
Strand: The term ‘strand’ refers to a non-specific general term which may be used to refer to: carded sliver, combed sliver, roving or yarn depending on the context.
Twist multiple value (TM): The term ‘Twist multiple value (TM)’ of a yarn refers to a factor that is directly proportional to the tangent of the twist angle. The ranges of TM required for yarns of various counts have been determined experimentally and are in use as empirical standards. An increase in TM increases yarn strength but very high values increases yarn roughness.
Twist per inch (TPI): The term ‘Twist per inch (TPI)’ refers to a number of Twists per inch in a yarn. It is the product of TM and square root of the yarn count. An increase in TPI leads to an increase in strength but very high TPI increases yarn roughness.
Ultra-low twist yarn: The term ‘ultra-low twist yarn’ refers to a specific class of yarn whose TPI value is lower than regular yarn, often used as pile yarn.
Warp: The term ‘warp’ refers to yarns that are running lengthwise in a woven fabric and are interwoven with weft yarns.
Weft: The term ‘weft’ refers to yarns that are running perpendicular to the warp yarns, making up the ground.
Yarn: The term ‘yarn’ refers to a continuous strand of textile fibres created when a cluster of individual fibres is twisted around one another.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Terry towels are an important marketing commodity and have been continuously gaining customers since they have been launched. A terry fabric comprises three different yarns, wherein the ground and weft yarn are interlaced at a perpendicular angle forming the base of the towel. The terry fabric also comprises two pile yarns that are woven synchronously following the direction of the warp yarn. The loosely bound pile yarn forms terry loops on the towel surface providing an enhanced surface area for absorbing high volumes of water. A prominent factor which influence the water adsorbent powers of the terry loop, is the amount of twist the yarn has been subjected to during the process of spinning. A low amount of twist on the loops keep the yarn fibres loose, creating air pockets, consequently leading to higher towel absorbency and a quicker rate of drying.
The presence of a large number of uniformly arranged low twisted terry loop on the towel surface makes the towel soft to touch, while additionally providing an aesthetically pleasing, and elegant look.
Softness of terry towels is one of its key ingredients for popularity. To construct a soft and plush terry towel, a concept of “zero twist” was implemented for the last few decades. One of the most common methods for generating a low twist or zero twist towel is as follows: Coarse count cotton yarn (10 Ne to 14 Ne) with a single-yarn twist in the Z-direction and with a low TPI of 11 and PVA yarn with 80 Ne and a TPI of 32 to 36 with a single yarn twist in the Z-direction are parallel wound without any twist onto a cone. The parallel wound cone is placed in a TFO Doubling machine where the cotton-PVA yarn is given a twist in the S-direction. This results in untwisting of the cotton yarn (TPI = 0) and lowering of the twist in the PVA yarn to a TPI = 25. The resultant yarn is used as pile yarn during terry towel production. During desizing, the PVA is washed off in hot water, leaving zero-twist or low-twist pile yarn.
Even though the resultant product has a high demand, the PVA water that is released in the process adds substantially to environmental problems. PVA is a highly hydrophilic synthetic polymer with a molecular weight of > 80000 Da. PVA rich water has a high tendency to foam when agitated, and forms plastic-like films upon drying, inhibiting the exchange of gaseous matter between soil, water and air, which disrupts the eco system. Moreover, PVA, due to its highly hydrophilic nature can accumulate toxins, xenobiotics and heavy metals, leading to bio accumulation upon consumption.
There is, therefore, felt a need to provide a process for the preparation of the ultra-low twist yarn that mitigates the aforementioned drawbacks or at least provides a useful alternative.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the background or to at least provide a useful alternative.
An object of the present disclosure is to provide a process for the preparation of ultra-low twist yarn.
Another object of the present disclosure is to provide a process for the preparation of the ultra-low twist yarn that does not utilize polyvinyl alcohol (PVA) yarn.
Still another object of the present disclosure is to provide ultra-low twist yarn that is bulkier in diameter.
Yet another object of the present disclosure is to provide a pile fabric that is bulkier, has high water absorption capacity and shorter drying time.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a process for the preparation of ultra-low twist yarn. The process comprising the steps: preparing carded breaker-drawn slivers of a first predetermined count or combed slivers of a second predetermined count.
The carded breaker-drawn slivers or the combed sliver are fed to a finisher draw frame running at a first predetermined speed, with a first predetermined number of doublings, having a first predetermined bottom roller setting, providing a first predetermined break draft to obtain finisher drawn slivers of a third predetermined count.
The finisher drawn slivers of the third predetermined count is fed to a Roving frame machine, running at a second predetermined speed, having at least three condensers of a predetermined dimension and a first predetermined spacer gap, providing a second predetermined break draft having a second predetermined bottom roller setting, a first predetermined top roller setting, and a fixed direction of rotation to obtain Z-twist rovings of a fourth predetermined count, with a predetermined number of twist per inch (TPI), and a predetermined number of twist multiple (TM).
At least two Z-twist rovings of the fourth predetermined count (Ne) are fed simultaneously to a Siro ring frame having a predetermined spacer gap, having a third predetermined bottom roller setting, and a second predetermined top roller setting, at a predetermined total draft, at a third predetermined break draft, at a predetermined average spindle speed, providing a S-directional twist to obtain the ultra-low twisted yarn.
In accordance with the embodiments of the present disclosure, the carded breaker-drawn slivers are prepared by the following sub-steps:
Cotton fibers are obtained followed by cleaning the fibres in a blow room to obtain the free fibres. The cotton fibres are at least one selected from virgin cotton fibres, regenerated cotton fibres, reusable cotton fibres, and blended cotton fibres. The free fibres are joined in parallel in a carding machine to form carded slivers having a count in the range of 0.08 Ne to 0.16 Ne , wherein the carding machine is operated with the parameters: a feed plate to licker-in setting in the range of 0.73 mm to 0.77 mm, a licker-in to cylinder distance in the range of 0.23 mm to 0.27 mm, a cylinder to flat (front to back) distance of 0.225 mm, 0.2 mm, 0.2 mm, 0.2 mm, 0.2 mm, 0.2 mm, a cylinder to doffer settings in the range of 0.15 mm to 0.25 mm, a licker-in speed in the range of 1048 rpm to 1052 rpm, a cylinder speed in the range of 485 rpm to 495 rpm, flats speed in the range of 318 mm/min to 322 mm/min, a doffer speed in the range of 133 meters/min to 137 meters/min. The carded slivers having count in the range of 0.08 Ne to 0.16 Ne is fed to a breaker-drawn frame at a speed in the range of 790 meter/min to 810 meter/min, with bottom roller settings of 40 mm to 44 mm; a break draft in the range of 1.5 to 1.8, with number of doublings in the range of 4 to 8 to obtain said carded breaker-drawn slivers having the first predetermined count.
In accordance with the embodiments of the present disclosure, the combed slivers are prepared by feeding the carded breaker-drawn slivers of the first predetermined count to a lap former running at a speed in the range of 85 meter/min to 110 meter/min with number of doublings in the range of 18 to 24, providing a break draft in the range of 1.038 to 1.044, to obtain a lap having a weight in the range of 50 grams/meter to 80 grams/meter. The lap is fed in a combing machine running at a speed in the range of 290 nips per minutes to 310 nips per minutes, having a feed/nip in the range of 4 mm to 4.4 mm, a bottom roller setting of 41 mm, providing a break draft in the range of 1.48 to 1.52 to obtain combed slivers of the second predetermined count (Ne).
In accordance with the embodiments of the present disclosure, the carded breaker-drawn slivers have the first predetermined count (Ne) is in the range of 0.08 Ne to 0.16 Ne, and the combed slivers have the second predetermined count (Ne) is in the range of 0.08 Ne to 0.16 Ne.
In accordance with the embodiments of the present disclosure, the first predetermined speed is in the range of 250 meter/min to 350 meter/min; the first predetermined break draft is in the range of 1.14 to 1.34; the first predetermined bottom roller setting of 33 mm to 47 mm, 48 mm to 56 mm; the first predetermined number of doublings is in the range of 4 to 8; the third predetermined count is in the range of 0.08 Ne to 0.16 Ne.
In accordance with the embodiments of the present disclosure, the second predetermined speed is in the range of 650 rpm to 1100 rpm; the predetermined dimension of an inlet condenser is in the range of 18 mm to 8 mm x 6 mm x 2 mm, the predetermined dimension of a middle condenser is in the range of 14 mm to 6 mm x 1 mm to 3 mm, the predetermined dimension of a floating condenser is in the range of 15 mm to 8 mm, and the first predetermined spacer gap is in the range of 2 mm to 7 mm; the second predetermined break draft is in the range of 1.1 to 1.35; the second predetermined bottom roller setting of 40 mm to 60 mm, 52 mm to 57 mm, 43 mm to 47 mm; the first predetermined top roller setting of 40 mm to 60 mm, 51 mm to 55 mm, 41 mm to 53 mm; the fourth predetermined count (Ne) is in the range of 0.4 Ne to 3 Ne; the predetermined number of twist per inch (TPI) is in the range of 0.85 to 2.66; and the predetermined number of twist multiple (TM) is in the range of 1.34 to 1.53.
In accordance with the embodiments of the present disclosure, the second predetermined spacer gap is in the range of 2.25 mm to 6.5 mm; the third predetermined bottom roller setting of 42 mm to 45 mm, 60 mm to 70 mm; the second predetermined top roller setting is of 50 mm to 55 mm, 60 mm to 72 mm; the predetermined total draft is in the range of 30 to 40; the third predetermined break draft is in the range of 1.12 to 1.45; and the average spindle speed is in the range of 5,500 rpm to 15,000 rpm in an anti-clockwise direction.
In accordance with the embodiments of the present disclosure, the generated yarn count is in the range of 6 Ne to 60 Ne.
In accordance with the embodiments of the present disclosure, the blended cotton fibres are the fibres having a blend of cotton fibres and non-cotton fibres in a blend percent ratio in the range of 1:100 to 100:1; the non-cotton fibres are selected from natural fibres and synthetic fibres. The synthetic fibres are selected from the group consisting of rayon, polyester, nylon, polyurethane, polyvinyl, polyacrylate, and polypropylene. The synthetic fibres have a staple length in the range of 32 mm to 51 mm. The natural fibres are selected from the group consisting of hemp, flax, bamboo, banana, and pineapple. The natural fibres have a staple length in the range of 25 mm to 51 mm.
In accordance with the embodiments of the present disclosure, the virgin fibres have a length in the range of 20 mm to 40 mm; the reusable fibres are selected from roving waste cotton fibres, reconstituted cotton fibres, and recycled cotton fibres.
In accordance with the embodiments of the present disclosure, the ultra-low twist yarn with counts in the range of 6 Ne to 60 Ne is characterized by having a count strength product (CSP) in the range of 2200 to 4000; twist per inch (TPI) in the range of 7.2 to 25.3; and twist multiple (TM) in the range of 2.5 to 3.5.
In accordance with the embodiments of the present disclosure, the ultra-low twist yarn is woven into a pile fabric of weights in the range of 150 grams/m2 to 800 grams/m2, wherein the pile fabric is characterized by having an increase in pile diameter in the range of 20% to 30%; an increase in bulkiness in the range of 5% to 10%; an increase in absorbency in the range of 5% to 15 %; a reduction in water drop absorption in the range of 30% to 70%; an increase in moisture retention capacity is in the range of 10% to 30%; and a reduction in drying time in the range of 15% to 25%, when compared with regular yarn.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWING:
The present disclosure will now be described with the help of the accompanying drawing, in which:
Fig. 1 illustrates the process for the preparation of the ultra-low twist yarn with the count of 20 Ne in accordance with the present disclosure;
Fig. 2a illustrates an image of a yarn pile of 20 Ne count of 450 grams/m2 cotton towel having average diameter of 0.95±0.148 mm, taken at a magnification of 20, wherein the short darker lines are the pile diameter at various locations in accordance with the present disclosure;
Fig. 2b illustrates an image of PVA-based pile of average diameter = 0.72±0.11 mm for the PVA-based towel with similar properties, taken at a magnification of 20 and the short darker lines are the pile diameters at various locations; and
Fig. 2c illustrates a close-up view of the ultra-low twist yarn of the present disclosure (left) and the PVA-based pile (right) with the former displaying more parallel oriented fibres, less hairiness, and greater diameter.
DETAILED DESCRIPTION
The present disclosure relates to a process for the preparation of ultra-low twist yarn.
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, known processes or well-known apparatus or structures, and well known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure are not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Terry towels are an important marketing commodity and have been continuously gaining customers since they have been launched. A terry fabric comprises three different yarns, wherein the ground and weft yarn are interlaced at a perpendicular angle forming the base of the towel. the terry fabric also comprises of two pile yarns that are woven synchronously following the direction of the warp yarn. The loosely bound pile yarn forms terry loops on the towel surface providing an enhanced surface area for absorbing high volumes of water. A prominent factor which influence the water adsorbent powers of the terry loop, is the amount of twist the yarn has been subjected to during the process of spinning. A low amount of twist on the loops keep the yarn fibres loose, creating air pockets, consequently leading to higher towel absorbency and a quicker rate of drying.
The presence of a large number of uniformly arranged low twisted terry loop on the towel surface makes the towel soft to touch, while additionally providing an aesthetically pleasing, and elegant look.
Softness of terry towels is one of its key ingredients for popularity. To construct a soft and plush terry towel, a concept of “zero twist” was implemented for the last few decades. One of the most common methods for generating a low twist or zero twist towel is as follows: Coarse count cotton yarn (10 Ne to 14 Ne) with a single-yarn twist in the Z-direction and with a low TPI of 11 and PVA yarn with 80 Ne and a TPI of 32 to 36 with a single yarn twist in the Z-direction are parallel wound without any twist onto a cone. The parallel wound cone is placed in a TFO Doubling machine where the cotton-PVA yarn is given a twist in the S-direction. This results in untwisting of the cotton yarn (TPI = 0) and lowering of the twist in the PVA yarn to a TPI = 25. The resultant yarn is used as pile loop during the terry towel production. During desizing, the PVA washes off in hot water, leaving zero-twist or low-twist pile yarn.
Even though the resultant product has a high demand, the PVA water that is released in the process adds substantially to environmental problems. PVA is a highly hydrophilic synthetic polymer with a molecular weight of > 80000 Da. PVA rich water has a high tendency to foam when agitated, and forms plastic-like films upon drying, inhibiting the exchange of gaseous matter between soil, water and air, which disrupts the eco system. Moreover, PVA, due to its highly hydrophilic nature can accumulate toxins, xenobiotics and heavy metals, leading to bio accumulation upon consumption.
The present disclosure relates to a process for the preparation of ultra-low twist yarn. The process is described in detail as:
Initially, carded breaker-drawn slivers of a first predetermined count (Ne) or combed slivers of a second predetermined count (Ne) are prepared.
In accordance with the embodiments of the present disclosure, the carded breaker-drawn slivers have the first predetermined count is in the range of 0.08 Ne to 0.16 Ne. In an exemplary embodiment, the carded slivers have the first predetermined count is 0.14 Ne.
In accordance with the embodiments of the present disclosure, the combed slivers have the second predetermined count is in the range of 0.08 Ne to 0.16 Ne. In an exemplary embodiment, the combed slivers have the second predetermined count is 0.13Ne.
The carded breaker-drawn slivers are prepared by the following steps:
Cotton fibres are obtained followed by cleaning the fibres in a blow room to obtain the free fibres. The cotton fibres are at least one selected from virgin cotton fibres, regenerated cotton fibres, reusable cotton fibres, and blended cotton fibres.
In accordance with the embodiments of the present disclosure, the blended cotton fibres are the fibres having a blend of cotton fibres and non-cotton fibres in a blend percent ratio in the range of 1:100 to 100:1. The non-cotton fibres are selected from natural fibres and synthetic fibres. The synthetic fibres are selected from the group consisting of rayon, polyester, nylon, polyurethane, polyvinyl, polyacrylate, and polypropylene. The synthetic fibres have a staple length in the range of 32 mm to 51 mm. The natural fibres are selected from the group consisting of hemp, flax, bamboo, banana, and pineapple. The natural fibres have a staple length in the range of 25 mm to 51 mm.
In accordance with the embodiments of the present disclosure, the virgin cotton fibres have a length in the range of 20 mm (short fibres) to 40 mm (extra-long fibres). In an exemplary embodiment, the virgin cotton fibres have a length of 34 mm. The reusable cotton fibres are selected from roving waste cotton fibres, reconstituted cotton fibres, and recycled cotton fibres. In another embodiment, short or long staple cotton fibres are used.
The free fibres are joined in parallel in a carding machine to form carded slivers having a count in the range of 0.08 Ne to 0.16 Ne, wherein the carding machine is operated with the parameters: a feed plate to licker-in setting is in the range of 0.73 mm to 0.77 mm, a licker-in to cylinder distance is in the range of 0.23 mm to 0.27 mm, a cylinder to flat (front to back) setting of 0.225 mm, 0.2 mm, 0.2 mm, 0.2 mm, 0.2 mm, 0.2 mm, a cylinder to doffer settings is in the range of 0.15 mm to 0.25 mm, a licker-in speed is in the range of 1048 rpm to 1052 rpm, a cylinder speed is in the range of 485 rpm to 495 rpm, flats speed in the range of 318 mm/min to 322 mm/min, a doffer speed in the range of 133 meters/min to 137 meters/min.
In an exemplary embodiment, the fibres are joined in parallel in a carding machine to form carded slivers having first predetermined count of 0.14 Ne, wherein the carding machine is operated with the parameters: the feed plate to licker-in setting of 0.75 mm, the licker-in to cylinder distance of 0.25 mm, a cylinder to flat (front to back) distance of 0.225 mm, 0.2 mm, 0.2 mm 0.2 mm, 0.2 mm, 0.2 mm, a cylinder to doffer settings of 0.2 mm, the licker-in speed in of 1050 rpm, the cylinder speed of 490 rpm, the flats speed of 320 mm/min, the doffer speed of 135 meters/min.
The carded slivers, having count (Ne) in the range of 0.08 Ne to 0.16 Ne, are fed to a breaker-draw frame at a speed in the range of 790 meter/min to 810 meter/min, with bottom roller settings of 40 mm to 44 mm; a break draft in the range of 1.5 to 1.8, with number of doublings in the range of 4 to 8 to obtain the carded breaker-drawn slivers having the first predetermined count (Ne). In an exemplary embodiment, the carded slivers of 0.14 Ne are fed to a breaker-draw frame at a speed of 800 meters/min, the break draft of 1.7, with number of doublings of 5 to obtain the carded breaker-drawn slivers of 0.14 Ne.
The combed slivers are prepared by the following sub-steps:
The carded breaker-drawn slivers of the first predetermined count (Ne) are fed to a lap former running at a speed in the range of 85 meters/min to 110 meter/min with number of doublings in the range of 18 to 24, providing a break draft in the range of 1.038 to 1.044, to obtain a lap having a weight in the range of 50 grams/meter to 80 grams/meter.
In an exemplary embodiment, the carded breaker-drawn slivers are fed to a lap former at running speed of 90 meter/min for number of doublings of 20, providing a break draft of 1.042 to obtain a lap having weight of 60 grams/meter. In accordance with the present disclosure, the number of doublings in a lap former stage is 4% to 5% less than a regular sliver. In accordance with the present disclosure, the weight of the lap is 9% to 10% lesser as compared to a regular lap.
The lap is fed in a combing machine running at a speed in the range of 290 nips per minutes to 310 nips per minutes, having a feed/ nip in the range of 4 mm to 4.4 mm, a first bottom roller setting of 41 mm, providing a break draft in the range of 1.48 to 1.52 to obtain the combed slivers of the second predetermined count (Ne). The delivery count (Ne) of the combed sliver is 95% to 105% higher than the delivery counts of regular sliver. The speed of feeding the lap in the combing machine is 13% to 15% higher speed than that for regular lap.
In an exemplary embodiment, the lap is fed in a combing machine running at a speed of 300 nips per minutes, having a feed/ nip of 4.2 mm, a first bottom roller setting of 41 mm, providing a break draft of 1.50 to obtain the combed slivers of the second predetermined count (Ne).
The so prepared carded slivers or the combed slivers are fed to a finisher draw frame running at a first predetermined speed, with a first predetermined number of doublings, having a first predetermined bottom roller setting, providing a first predetermined break draft to obtain finisher drawn slivers of a third predetermined count (Ne).
In accordance with the embodiments of the present disclosure, the first predetermined speed is in the range of 250 meter/min to 350 meter/min, which is 12% to 16% less as compared to regular yarn; the first predetermined break draft is in the range of 1.14 to 1.34 which is 4% to 7% less than regular combed sliver; the first predetermined bottom roller setting of 33 mm to 47 mm, 48 mm to 56 mm; the first predetermined number of doublings is in the range of 4 to 8; and the third predetermined count is in the range of 0.08 Ne to 0.16 Ne, which is 95% to 105% higher than a regular sliver of similar desired count. In an exemplary embodiment, the first predetermined speed is 300 meter/min; the first predetermined break draft is 1.16; the first predetermined bottom roller setting is of 44 mm, 52 mm; the first predetermined number of doublings are 6, and the third predetermined count is 0.13 Ne.
The finisher drawn slivers of the third predetermined Count (Ne) are fed to a Roving frame machine having 4 over 4 rollers running at a second predetermined speed, having at least three condensers of a predetermined dimension, and a first predetermined spacer gap, providing a second predetermined break draft, having a second predetermined bottom roller setting, a first predetermined top roller setting, and a fixed direction of rotation to obtain Z-twist rovings of a fourth predetermined count, with a predetermined number of twist per inch (TPI), and a predetermined number of twist multiple (TM).
In accordance with the embodiments of the present disclosure, the second predetermined speed is in the range of 650 rpm to 1100 rpm; the predetermined dimension of an inlet condenser is in the range of 18 mm to 8 mm x 6 mm to 2 mm, the predetermined dimension of a middle condenser is in the range of 14 mm to 6 mm x 1 mm to 3 mm, the predetermined dimension of a floating condenser is in the range of 15 mm to 8 mm, and the first predetermined spacer gap is in the range 2 mm to 7 mm; the second predetermined break draft is in the range of 1.1 to 1.35, which is 1.5 to 2% less than regular sliver; the second predetermined bottom roller setting of 40 mm to 60 mm, 52 mm to 57 mm, 43 mm to 47 mm; the first predetermined top roller setting of 40 mm to 60 mm, 51 mm to 55 mm, 41 mm to 53 mm; the fourth predetermined count (Ne) is in the range of 0.4 Ne to 3 Ne, which is 95% to 105% higher than regular roving counts for 6 Ne to 60 Ne; the predetermined number of twist per inch (TPI) is in the range of 0.85 to 2.66; and the predetermined number of twist multiple (TM) is in the range of 1.34 to 1.53.
In an exemplary embodiment, the second predetermined speed is 1000 rpm; the predetermined dimension of an inlet condenser is of 12 mm x 2.5 mm, the predetermined dimension of a middle condenser is of 8 mm x 2 mm, the predetermined dimension of a floating condenser is of 9 mm, the first predetermined spacer gap is 3 mm; the second predetermined break draft is of 1.19; the second predetermined bottom roller setting of 45 mm, 55 mm, 45 mm; the first predetermined top roller setting of 53 mm, 53 mm, 45 mm; the fourth predetermined Count (Ne) is of 1.20; the predetermined number of twist per inch (TPI) is of 1.54; and the predetermined number of twist multiple (TM) is 1.41.
The two Z-twist rovings of the fourth predetermined Count (Ne) are fed to a Siro ring frame, having a predetermined spacer gap, having a third predetermined bottom roller setting, and a second predetermined top roller setting, at a predetermined total draft, at a third predetermined break draft, at a predetermined average spindle speed, providing a S-directional twist to obtain the ultra-low twisted yarn.
In accordance with the embodiments of the present disclosure, the fourth predetermined Count (Ne) is in the range of 0.4 Ne to 3 Ne (for the final desired yarn count of 6 Ne to 60 Ne), which is 95% to 105% higher than a regular yarn of similar count; the second predetermined spacer gap is in the range of 2.25 mm to 6.5 mm, the third predetermined bottom roller setting is of 42 mm to 45 mm, 60 mm to 70 mm; the second predetermined top roller setting is of 50 mm to 55 mm, 60 mm to 72 mm, the predetermined total draft is in the range of 30 to 40, which is about 32% to 34% higher than general roving; the third predetermined break draft is in the range of 1.12 to 1.45, which is 1.5 to 2.5% less than a regular roving; and the average spindle speed is in the range of 5,500 rpm to 15,000 rpm in an anti-clockwise direction, which is 45% to 50% less than that used for regular ring spun yarn. In an exemplary embodiment, the fourth predetermined count is 1.2 Ne, the second predetermined spacer gap is of 3 mm, the third predetermined bottom roller setting of 44 mm, 65 mm, the second predetermined top roller setting is 51 mm, 61 mm, the predetermined total draft is 36.7, the third predetermined break draft is 1.19, and the average spindle speed is 7500 rpm in an anti-clockwise direction. The imperfections of the ultra-low twist yarn being less than 75 per km with 20% to 30% bulkier in diameter when compared to regular Z twisted yarn of similar count. The bulkiness of the ultra-low twist yarn increases the overall bulk of the towel.
In accordance with the embodiments of the present disclosure, at least two rovings are led in parallel through the Siro drafting system (Siro ring frame), separated by two specially developed condensers, and drafted separately.
The ultra-low twist yarn of the present disclosure can be used as pile yarn during weaving in combination with regular cotton or cotton blended with regenerated cellulose fiber as ground and/or weft yarn. The resultant ultra-low twist yarn has a twist value in the range of 20 T/110 cm to 24 T/ 10 cm.
In accordance with the embodiments of the present disclosure, the generated yarn count by the process of the present disclosure is in the range of 6 Ne to 60 Ne, with suitable fine adjustments of the machine parameters.
In accordance with the embodiments of the present disclosure, the ultra-low twist yarn with counts in the range of 6 Ne to 60 Ne is characterized by having a count strength product (CSP) in the range of 2200 to 4000, twist per inch (TPI) in the range of 7.2 to 25.3, and twist multiple (TM) in the range of 2.5 to 3.5. In an embodiment, the CSP for the yarns prepared from cotton fibres and cotton blended natural fibres is in the range of 2200 to 2750. In another embodiment, the CSP for the yarns prepared from cotton blended synthetic fibres is in the range of 2500 to 4000. The given range of TPI and TM is for both the unblended and blended cotton fibres. In an exemplary embodiment, the CSP is 2492, TPI of 12.5, and TM of 2.78.
In accordance with the embodiments of the present disclosure, the ultra-low twist yarn is woven into a pile fabric of weights in the range of 150 grams/m2 to 800 grams/m2, wherein the pile fabric is characterized by having an increase in pile diameter in the range of 20% to 30% as compared to regular fabric containing PVA pile yarn; an increase in bulkiness in the range of 5% to 10% as compared to regular fabric containing PVA pile yarn; an increase in absorbency in the range of 5% to 15 % as compared to regular fabric containing PVA pile yarn; a reduction in water drop absorption in the range of 30% to 70% as compared to regular fabric containing PVA pile yarn; an increase in moisture retention capacity is 10% to 30% as compared to regular fabric containing PVA pile yarn; and a reduction in drying time in the range of 15% to 25% as compared to regular fabric containing PVA pile yarn.
In accordance with the embodiments of the present disclosure, the higher diameter of the ultra-low twist yarn is attributed to the open, airy structure, which upon being used as a pile yarn, allows the resultant towels fabric to dry 19±2% faster, 11.3% higher absorbency and a 30% increase in the absorption capacity.
In accordance with the embodiments of the present disclosure, the ultra-low twist yarn is woven into a pile fabric of 220 to 750 grams/m2. The pile fabric is characterized by having pile diameter in the range of 0.5 mm to 1.25 mm, which is 30% bulkier than the pile diameter of a PVA-towel woven using a similar yarn count; bulkiness in the range of 110 mm to 120 mm as determined by ASTMD 1777, which is 9% greater than a PVA-towel woven using a similar yarn count; absorbency in the range of 70 to 80 as determined by ASTM D4772, which is 10% to 12% higher than PVA-towel woven by using a similar yarn count; water drop absorption in the range of 0.5 to 1.5 as determined by ATCC 79, which is 65% higher than the PVA-towel woven using a similar yarn count; moisture retention capacity in the range of 850% to 1050% as determined by ISO 20158 absorption capacity test, which is 29% higher than the PVA-towel woven using a similar yarn count; and drying time in the range of 25 minutes to 35 minutes, which is 19±2% less than the PVA-towel woven using a similar yarn count.
In an exemplary embodiment, the ultra-low twist yarn is used as pile yarn to make a pile fabric of 450 grams/m2, where the pile yarn is characterized by having a diameter of 0.95 mm, bulkiness of 115 mm as determined by ASTMD 1777; absorbency of 75.7 % as determined by ASTM D4772; water drop absorption is 1.0 sec as determined by ATCC 79; moisture retention capacity 952% as determined by ISO 20158 absorption capacity test; and drying time of 29 minutes.
In accordance with the embodiments of the present disclosure, the woven pile fabric is subjected to wet processing, finishing and drying to produce towels that has a pile loop of 30±5% higher diameter when compared to a towel made with yarn of similar count.
The so obtained yarn can be woven into a towel by using 3, 4, 5 or 6 pick terry. In an exemplary embodiment, the towel prepared by using the ultra-low twist yarn of the present disclosure have the parameters: Ends per inch (EPI) = 64 to 72; Pile ratio = 8.5:1 to 9.5:1; Pile height = 5 to 5.8 mm; Picks per inch (PPI) = 52 to 58. A pick is a single weft yarn that crosses a warp yarn; a 3-pick terry indicated that after each 3 picks insertion full beat-up was made (the three picks are pushed tighter against each other) and one loop pile is formed of the fabric.
The towels woven prepared by using the above parameters with the ultra-low twist yarn as the pile may have one side terry towel or both side terry towel, while each towel sample may range from low weight in the range of 200 grams/m2 to 340 grams/m2, moderate weight in the range of 350 grams/m2 to 450 grams/m2, heavy weights in the range of 460 grams/m2 to 550 grams/m2 and very heavy towels with > 550 grams/m2, while the towels made by combination of any of the above parameters can range from fingertip towel, hand towel, face towel, bath towel, beach towel and bath robes.
In accordance with the embodiments of the present disclosure, the towel prepared by using the ultra-low twist yarn. The ultra-low twist yarn is used as pile yarn with the pile diameter of the finished towel displaying 30±5% more bulk than piles made using a similar yarn count, consequently making the towel spun with the ultra-low yarn about 10±5% bulkier than towels woven using a similar yarn count.
In accordance with the embodiments of the present disclosure, the spun ultra-low yarn is utilized as a pile yarn to create terry loops in terry towels during weaving.
In accordance with the embodiments of the present disclosure, the process of the present disclosure can be carried out without lap forming and combing step.
In accordance with the embodiments of the present disclosure, the woven towel may be subjected to scouring, neutralizing and washing with regular standard procedures followed by finishing to make a white towel.
In accordance with the embodiments of the present disclosure, the woven towel, after scouring and neutralization, can be dyed with various shades ranging from very light, light, medium, dark, and very dark with appropriate standard dyeing procedures in a soft-flow or vat dyeing unit, followed by soaping, finishing and drying.
The present disclosure provides a process for the preparation ultra-low twist yarn, which ultimately produces a high quality towel, in terms of hand feel, fluffiness, absorbency, bulky appearance, laundry performance, and ease of weaving. The resultant towel prepared by using the ultra-low twist yarn displays a bulky appearance. The towel also exhibits high absorbency and good laundry performance, including a lint collection in washing machine and dryer of 0.15% (w/w of towel), compared with 0.5% to 0.8% (w/w of towel) of conventional regular low twist products.
The present disclosure provides a process to create ultra-soft towels with high absorbency that avoids the technical defects, waste, and environmental problems associated with traditional low twist towel production. The process of the present disclosure does not require any doubling to be done after the yarn has been produced. In particular, the present invention does not use PVA fiber in its process of making a low twist towel, which thus decreases production costs, avoids water pollution, and helps protect and improve the environment.
The present disclosure relates to the textile products. More particularly, the present disclosure relates to a process for preparing ultra-low twist towel without the use of PVA. Even though the present disclosure primarily focuses on terry towels, experts in the field can realize that the process may be extended to other textile products.
The ultra-low twist yarn or “Shaiza” yarn, when utilized as a terry pile, displays a higher diameter with a more open structure, creating tiny but numerous air pockets within the pile yarn. The air pockets lead to increased rate of water transfer, leading to higher absorbency and faster drying when compared to regular low twist or zero twist towels. Therefore, utilization of the ultra-low twist yarn as terry loop can lead to production of a low twist towel that performs better than PVA-made towels.
The open structured, low-twist nature of the yarn of the present disclosure imbibes towels with higher bulkiness and a softer hand feel when compared to regular low twist or zero twist towel. The ultra-low twist yarn of the present disclosure may have equal or more strength than the regular low twist or zero twist towel.
In general, PVA water treatment is extremely cumbersome, incurring a high price. Alternatingly, untreated PVA leads to loss of large volumes of water and the PVA accumulates in the environment forming films and harming the eco-system. Utilization of the ultra-low twist (Shaiza) yarn leads to reduction in environmental pollution due to complete elimination of PVA.
The ultra-low twist (Shaiza) yarn of the present disclosure can replace the PVA in producing zero twist or low twist towels, thus providing sustainability and reduction in pollution. The ultra-low twist (Shaiza) yarn of the present disclosure is obtained by loading a carded breaker drawn and combed cotton sliver to the roving frame and creating a Z-twisted roving, followed by loading two Z-twisted rovings onto a Siro spinning frame, drafting the Z-twisted rovings separately and spinning them onto a bobbin while providing them with a S-twist, creating the Shaiza yarn. The Shaiza yarn upon being used as a terry loop, displays a larger diameter, creating more air pockets within its structure, leading to increased absorbency, higher water holding capacity, and faster drying. The towels with Shaiza terry loops also display higher bulkiness and a softer hand feel when compared to PVA-based towels.
In accordance with the embodiments of the present disclosure, the ultra-low twist yarn is obtained by loading a carded breaker drawn or combed cotton sliver to the roving frame and creating a Z-twisted roving, followed by loading two Z-twisted rovings onto a Siro spinning frame, drafting the Z-twisted rovings separately and spinning them onto a bobbin while providing them with a S-twist, creating the ultra-low twist yarn.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further illustrated herein below with the help of the following experiments. The experiments used herein are intended merely to facilitate an understanding of the ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the experiments should not be construed as limiting the scope of embodiments herein. These laboratory scale experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial/commercial scale.
EXPERIMENTAL DETAILS
Process for the preparation of ultra-low twist yarn in accordance with the present disclosure
The process for the preparation of the ultra-low twist yarn (S-twisted Shaiza yarn) are detailed in Table 1, and in Fig. 1. The example given is that for a Shaiza yarn with 20 Ne count.
Table 1: Steps for spinning fibres into a Shaiza yarn with specific example for 20 Ne count
Process parameters 20’ s CWC SIRO – S Twisted (in accordance with the present disclosure) 20 Ne CWC – Z Twisted (comparative)
Blow room LMW LDB 3 LMW LDB 3
Bale plucker LA – 23
Plucker roller speed in rpm 1200 1200
Unimix LB7/4R
Beater speed in rpm 610 rpm 610 rpm
Beater to feed roll setting in mm 3 3
Grid bar setting in mm 2.5,2.5,3.0,3.0,4.0 2.5,2.5,3.0,3.0,4.0
Vario cleaner LB9
Beater speed in rpm 500 500
Grid bar setting in mm 2.5, 2.5, 3.0, 3.0, 4.0 2.5, 2.5, 3.0, 3.0, 4.0
Flexi cleaner LB5
Beater speed in rpm 610 610
Beater to feed roll setting in mm 3 3
Grid bar setting in mm 2.5,2.5,3.0,3.0,4.0 2.5,2.5,3.0,3.0,4.0
Carding Truetzschler TC5 Truetzschler TC5
Feed plate to licker-in settings in mm 0.75 0.75
Licker-in to cylinder distance in mm 0.25 0.25
Cylinder to flat settings (front to back) in mm 0.225, 0.2, 0.2, 0.2, 0.2, 0.2 0.225, 0.2, 0.2, 0.2, 0.2, 0.2
Cylinder to Doffer settings in mm 0.2 0.2
Licker-in speed in rpm 1050 1050
Cylinder speed in rpm 490 490
Flats speed in mm/min 320 320
Doffer speed in meters/min 135 135
Sliver Count (Ne) 0.14 0.14
Breaker-Draw frame LMW - LDB3 LMW - LDB3
Speed in meters/min 800 800
Feed Count (Ne) 0.14 0.14
Delivery Count (Ne) 0.14 0.14
Break draft 1.7 1.7
Bottom roller setting in mm 40, 44 40, 44
No. of Doublings 5 5
LAP FORMER LMW - LH10 LMW - LH10
Speed in metre/min 90 90
Feed Count (Ne) 0.14 0.14
Delivery Count (Ne) 0.00983 0.00894
Lap weight in grams/metre 60 66
No. of Doubling 20 21
Break draft 1.042 1.042
COMBER LK54 LK54
Speed in nips/min 300 350
Feed Count (Ne) 0.0098 0.0089
Delivery Count (Ne) 0.13 0.09
Break draft 1.50 1.50
Bottom roller setting in mm 41 41
Noils % 18% 11%
Feed/nip in mm 4.2 4.2
Finisher Draw frame Trutszchler TD03 Trutszchler TD03
Feed Count (Ne) 0.13 0.09
Delivery Count (Ne) 0.13 0.09
Speed in metres/min 300 350
Break draft 1.16 1.23
Bottom roller setting in mm 44, 52 44, 52
No. of Doubling 6 6
Speed or Roving Frame LF 1400A LF 1400A
Speed in rpm 1000 1000
Feed Count (Ne) 0.13 0.09
Delivery Roving Count (Ne) 1.20 0.6
Break draft 1.15 1.17
Bottom roller settings in mm (in a direction of feed to delivery) 45, 55, 45 45, 55, 45
Top roller settings in mm (in a direction of feed to delivery) 53, 53, 45 53, 53, 45
TPI 1.54 1.12
TM 1.41 1.57
Inlet condenser, mm 12×2.5 15×3
Middle condenser, mm 8 × 2 11
Floating condenser, mm 9 mm 14 mm
Spacer gap, mm 3mm 5mm
Ring frame KTTM KTTM
Yarn Count (Ne) 20.2 20.2
Roving hank count 1.2 0.6
Total Draft 36.7 27.52
Break draft 1.19 1.19
TPI 12.5 15
TM 2.78 3.34
Spacer gap, mm 3.8 3.8
Bottom roller settings in mm (back to front) 44, 65 44, 65
Top roller settings in mm (back to front) 51, 61 51, 61
Ring traveller 1 UL HRW JETX-1/0 1 UL HRW JETX-3/0
Avg. spindle speed in rpm 7500 14000
AUTO CONER
(Auto winding machine) Muratech QPRO Muratech QPRO
Winding speed in mpm 1000 1300
EYC CLEARED, AUTO SPLICED and AUTO CONED EYC CLEARED, AUTO SPLICED and AUTO CONED

The above process of the present disclosure was equally applicable to the ultra-low twist yarn with counts ranging from 6 Ne to 60 Ne by changing in machine parameters according to the percentages mentioned below:
(001) Cotton bales with fibres having length of 28 mm to 32 mm, Micronair of 3.8 to 4.6, fibre strength of 23 to 26 g/tex, short fibre index of 5% to 7% and uniformity of 45% to 48% were lined up in the blow room and a thin layer was plucked from the top of the bale by a LMW bale plucker with the roller speed at 1200 RPM. The fibres were transported to the Unimix machine which blends the incoming fibres in various proportions. The beater speed, beater-to-feed roll setting maintained and the Grid Bar setting were maintained as mentioned in Table 1. Blending of fibres from different bales created a consistent and uniform feed for the subsequent stages of spinning to obtain free fibres. Table 1 also showed a control set of data for non-Shaiza regular yarn (20 Ne CWC – Z Twisted).
(002) The cleaned and opened free fibres were fed into to a Carding machine where the fibres were subjected to differentially moving surfaces sheathed with a firm flexible material having outwardly projected metal pins. As the fibres pass, they were disentangled, aligned, cleaned and intermixed finally producing a continuous web of sliver suitable, obtaining carded slivers for further processing. The machine specifications for forming the sliver were similar to that of regular yarn, as mentioned in Table 1. The resultant Shaiza sliver had a count of 0.12 to 0.16 Ne and was specific for only a final desired 20 Ne yarn count. The sliver counts that are required for a final Shaiza yarn count from 6 Ne to 60 Ne are listed in Table 2.
(003) This carded Shaiza sliver was fed into a LDB3 breaker-drawing machine where crisscrossed and hooked fibres were straightened and the fiber orientation was improved. The set-up consisted of a set of rollers that rotate at different speeds to create a draft. The sliver was fed at a count of 0.12 Ne to 0.16 Ne and subjected to a break draft of 1.6 to 1.8 with a doubling number of 4 to 6. The drawn sliver was maintained at a count of 0.10 Ne to 0.16 Ne and this was specific for only a final desired 20 Ne yarn count. The post-breaker counts that were required for a final Shaiza yarn count from 6 Ne to 60 Ne are listed in Table 2.
(004) The post-drawn Shaiza slivers were fed into the feeding/creeling zone of a LH10 Lap former in preparation for combing. The Shaiza slivers were passed through guide rollers and fed into the combing section at a feed count of 0.13 Ne to 0.15 Ne where it was provided with a break draft of 1.038 to 1.044 and 19 to 21 doublings (4% to 5% less than regular sliver). The delivery count was maintained to 0.0090 Ne to 0.010 Ne (8% to 12% more than regular sliver). The final Shaiza lap so obtained had weight of 58g/m to 62 g/m, which was 9% to 10% less when compared to a regular lap, due mostly to the lower number of doublings. The lower lap weight for Shaiza leads to higher efficiency of the downline comber machine. The lap former delivery counts and the finished lap weight ranges that were required for a final Shaiza yarn count from 6 Ne to 60 Ne are listed in Table 2.
(005) The Shaiza laps were subjected to combing in a LK54 Comber machine to exclude shorter and deformed fibres, while simultaneously straightening the remaining fibres, and increasing parallelization ultimately resulting in uniform thickness to obtain combed slivers. As seen in Table 1, the machine was run at 290 to 310 nips per min, about 13% to 15% lower speed then regular sliver, thus ensuring a higher combing effectiveness. The sliver was fed with a feed count of 0.0090 – 0.010 Ne, a range that was 8% to 12% higher than regular sliver in order to obtain a finer yarn count. Contrastingly, the feed per nip (4 to 4.4 mm per nip) and break draft provided (1.48-1.52) was quite similar to that of regular yarn. However, the delivery count was maintained at 40% to 46% higher (0.12 to 0.14 Ne) values than regular yarn, a crucial factor for producing finer counts in the Siro spinning.
Overall, the combination of 13% to 15% lower nips per min, 8% to 12% higher feed count and 40% to 46% higher delivery count ensured a final yarn formation with a finer count. A small price to pay for maintaining the above values was the accretion in noil generation by about 5% to 8% more than regular yarn.
(006) The combed Shaiza sliver was drawn on a Trutszchler Finisher Draw Frame with a feed count of 0.12 Ne to 0.14 Ne (40% to 46% higher than regular combed sliver) while the speed was maintained at 275 to 310 meters per min (12-16% less when compared to regular yarn) to maintain a higher quality. The break draft was maintained at 1.14 to 1.18, which was 4% to 7% less than regular combed sliver. The drawn slivers, with a delivery count of 0.12 Ne to 0.14 Ne, about 40% to 46% higher than regular slivers, were coiled in cans and fed into the roving frame. The finished drawing counts that were required for a final Shaiza yarn count from 6 Ne to 60 Ne are listed in Table 2.
(007) The roving frame provided the function of decreasing the linear density of draw frame sliver and introduced a small amount of twist. A 4-over 4 roller drafting system with a double apron was used to draft the sliver. As mentioned earlier (also in Table 1), the Shaiza sliver feed count was maintained at 0.12 to 0.14, which was about 40% to 46% more than regular sliver. The break draft provided was about 1.14 to 1.16, which is 1.5% to 2% less than regular sliver. After emerging from the front roller, the drafted Shaiza roving was passed through a moving flyer and wound around a bobbin, at which point a Z-twist was imparted. The major factors that control the twist introduced in the roving was the rotation speed of the flyer, direction of rotation, and the delivery hank. For imparting a Z-twist, the flyer was run in a clockwise fashion, forcing the fibres to turn right along the axis of the yarn. Concomitantly, the Shaiza delivery roving count was maintained at 0.9 Ne to1.22 Ne, which was 80% to 105% higher than regular roving count. The warping speed was maintained at 1000 rpm. The resultant roving displays TPI in the range of 15 to 18.5, and TM within a range of 1.38 to 1.44, which was 8% to 12% higher than regular rovings. The roving bobbins, after doffing were loaded onto a Siro spinning ring frame. The roving hanks that were required for a final Shaiza yarn count from 6 Ne to 60 Ne are listed in Table 2.
(008) The major function of a ring frame was to minimize sliver dimensions into a size suitable for spinning into a yarn. This was performed by two ways – by applying a draft and by inserting a twist. Two kinds of twists, depending on the direction of axial rotation, may be introduced into the roving – right handed (Z-direction) or left handed (S-direction). The present disclosure followed inserting a left handed or S-twist into the roving, which required winding the ring and traveller in an anticlockwise direction. Since the twist provided is in a direction opposite to that of the roving, spinning in a normal ring frame induced higher hairiness and low strength. This necessitates the utilization of a twin-roving Siro ring frame that lowered the spinning triangle, resulting in a yarn with lower hairiness and acceptable strength.
In the present disclosure, two roving yarns as obtained from the roving frame, each with a count of 1.0 to 1.4 Ne (95% to 105% more than that of a single roving unit for a Z-twisted yarn) were hung onto the creel section of a Kirloskar Toyota Textile Machinery (KTTM) Siro spinning frame. The hank was maintained at such high levels because otherwise, it would lead to formation of coarser yarn as exemplified below.
For example, if one desires a regular Z twisted ring spun yarn with 10 Ne count, a feed count of 0.5 Ne with 20 drafts was sufficient to create = 0.5×20 = 10 Ne count yarn. However, if two rovings, each of 0.5 Ne were used for Spiro spinning, the resultant will be 0.25 Ne, which when given 20 drafts, will only result in 5 Ne Ne.Thus, if the initial feeding hanks were increased by 100% to a value of 1, the resultant count would be 0.5 Ne, which when drafted 20 times, will result in 10 Ne count. Hence, feed rovings were maintained at 100% higher hanks to compensate for this averaging tendency in Siro spinning.
The rovings were guided to the rear rollers which further guide them into the pre-drafting zone condenser, thus ensuring both rovings were kept separate while they were drafted. The break draft provided individually to the two rovings were around 1.18 to 1.20, which was 1.5% to 2.5% less than a regular roving. As the rovings were moved to the front drafting zone, a total draft of 32 to 38 was provided individually. Following the formula given in the previous paragraph, the final count expected for getting a 20 Ne Shaiza yarn was 19.2 Ne to 22.8 Ne.
The drafted rovings emerged through a set of two separate front rollers, again ensuring they were kept separate. As the drafted rovings emerged, they wind around themselves followed by winding around each other to form a single Siro-spun yarn. This passed through the break detector, onto the pigtail guide and was wound onto the bobbin by the ring.
The major factors that controlled the twist introduced in Siro spinning was the rotation speed of the flyer, direction of rotation, and the draft provided. For imparting a S-twist, the flyer was run in an anti-clockwise fashion, forcing the fibres to turn left along the axis of the yarn. Concomitantly, the warping speed was maintained at 7400 – 7600 RPM, which was 45% to 50% less than that used for regular ring spun yarn, ensuring higher quality of the finished yarn. The resultant Shaiza yarn displayed TPI in the range of 11.5 to 13.5, 12% to 18% less than regular Z-twisted yarn and TM within a range of 2.5 to 2.8, 30% to 33% less than that in Z-twisted general yarn (3.6 to 4.2). The imperfections/km (IPK) in Shaiza yarn was less than 75, which was similar to that of a regular yarn.
The advantage of Siro ring spinning lies in the fact that since two distinct rovings were separately drafted and joined to form one yarn, the area of the spinning triangle decreased drastically. This ensured that the resultant yarn had lower levels of hairiness, which is an absolute necessity for a S-twisted yarn which was being used to produce a towel. At the same time, the S-twist provides the final yarn with a bulkiness, which is 25% to 35% higher than a regular Z-twisted yarn.
(008) Yarn from 6 Ne to 60 Ne count was made based on the percentage deviations of machine specifications when compared to regular yarn of a similar count. Table 2 lists the exact Hank and TPI specified at each stage of spinning to obtain Shaiza yarn with Count 6 Ne to 60 Ne.
Table 2: Characteristics of the ultra-low twist (Shaiza) strand required at each stage of spinning to create the ultra-low twist (Shaiza) yarn with count 6 Ne to 60 Ne
To get Shaiza yarn with Count Post-Carding sliver Count (Ne) Breaker Drawing sliver count (Ne) Lap former delivery count (Ne) Lap weight (g/m) Finisher Drawing sliver count (Ne) Roving count (Ne) TPI of Shaiza roving TPI of Shaiza yarn CSP of final Shaiza yarn
6 Ne to 10 Ne 0.09 to 0.12 0.09 to 0.13 0.00781 to 0.00909 65 to 75 0.09 to 0.12 0.5 to 0.7 0.99 to 1.17 7.2 to 10.5 2450 to 2650
11 Ne to 14 Ne 0.09 to 0.12 0.09 to 0.13 0.00781 to 0.00909 65 to 75 0.09 to 0.12 0.7 to 0.9 1.17 to 1.33 7.2 to 10.5 2450 to 2650
16 Ne to 20 Ne 0.09 to 0.15 0.09 to 0.15 0.00781 to 0.0099 58 to 75 0.09 to 0.15 0.9 to 1.3 1.33 to 1.56 11 to 13.5 2450 to 2650
21 Ne to 40 Ne 0.1 to 0.15 0.1 to 0.15 0.0081 to 0.0099 55 to 65 0.1 to 0.15 1.2 to 1.6 1.51 to 1.77 13.5 to 18.2 2450 to 2750
41 Ne to 60 Ne 0.1 to 0.15 0.1 to 0.15 0.0081 to 0.0099 55 to 65 0.1 to 0.15 1.6 to 2.6 1.77 to 2.26 18.2 to 25.3 2450 to 2750

Process for weaving a towel by using the ultra-low twist (Shaiza) yarn in accordance with the present disclosure
For weaving a terry towel, the ultra-low twist yarn (S-twisted Shaiza yarn) of the present disclosure was used as the pile yarn while the ground and weft yarns may be Z-twisted yarns of natural, reconstituted or synthetic fibre. The weft and ground yarns may have a TM between 3.2 to 4.2. The yarns were warped on sizing rollers and made to undergo sizing to create stiffness allowing for ease of weaving. The rollers with the sized yarn were loaded onto an Air-Jet or a Rapier loom machine. The former uses a jet of air to push the filling thread across the loom, creating the weft yarn. Contrastingly, in a Rapier machine the weft was carried across the ground and pile by using two rapiers, a giver and a taker.
The terry weave can be 3 pick, 4 pick, 5 pick, 6 pick terry. In the present disclosure, the weave was 3 pick terry. Other weaving parameters set were as follows:
Ends per inch (EPI) = 64 to 72
Pile ratio = 8.5:1 to 9.5:1
Pile height = 5 to 5.8 mm
Picks per inch (PPI) = 52 to 58
The towels woven using the above parameters with the ultra-low twist yarn (S-twisted Shaiza yarn) of the present disclosure used as the pile yarn comprises one side terry towel or both side terry towel, while each towel sample may range from low weight 200 to 340 grams/m2, moderate weight of 350 to 450 grams/m2, heavy weights of 460 to 550 grams/m2 and very heavy towels with > 550 grams/m2, while towels made by combination of any of the above parameters can range from fingertip towel, hand towel, face towel, bath towel, beach towel and bath robes.
Processing the ultra-low twist (Shaiza) pile-based fabric
After the weaving was completed, the fabric roll was scoured and dyed in regular fashion in a fabric dying machine. While scouring, bleaching, and dyeing, the operating temperature range from about 95° C to about 120° C. In the regular process, the higher temperature was an absolute necessity for removal of PVA. In the present enclosure, the temperature is kept in the lower ranges owing to the absence of PVA from the process. The liquor ratio ranges from 1:5 to 1:30. In the present disclosure, the liquor ratio was 1:10. After dyeing the bath was neutralized followed by soaping at 90°C. This was followed by neutralization, washing and treatment with finishing agents.
Drying and straightening of the ultra-low twist (Shaiza) pile-based fabric
The washed fabric was subjected to centrifugation in a Hydro-extractor in the standard manner to reduce the moisture from 200% to 60%. After moisture removal, the material was passed through a rope opener equipped with de-twisters both at feed and delivery ends, to straighten the twist in the rope. Then the material was loaded onto a hot air dryer equipped with drumbeaters ensuring proper lifting of the pile. Drying was carried out in two stages, with an initial drying at about 80°C for 4 to 5 minutes and a final drying at 135 to 155° C for 4 to 5 minutes. The full width fabric was then passed through a hot air stenter and a weft straightener to straighten the fabric and return it to its proper dimensions.
Conditioning the ultra-low twist (Shaiza) pile-based fabric
The stented materials were passed through a shearing machine with both the sides exposed to oppositely placed blades. The shearing was performed in a manner so that only protruding fibers were cut, leaving the piles intact. This ensures reduced linting during home laundry. The fabric was subsequently subjected to length cutting, length hemming, cross cutting, cross hemming, checking, folding, and packing according to the standard practice.
Tests to check performance of the ultra-low twist (Shaiza) pile-based towel
The Shaiza towel was tested via various standard parameters. For comparison, some of the test results were compared with a regular PVA-based towel of similar dimensions and weight (grams/m2). Bulkiness was checked using the ASTMD 1777 method. Absorbency of the towel was checked using the AATCC-79 drop sink method and the ASTM D-7242 method while vertical wicking properties of the towel in both weft and warp direction was measured by AATCC 197. Drying time was tested using internal standard procedures. Dimensional stability of the towels to washing and measurement of lint generated during washing was measured as per JIS L 1930 C4M.
Colour fastness is defined as the resistance of a fabric to change in any of its colour characteristics due to a chemical or physical process. It is the ability of a fabric to hold onto its colour and not allow any transfer of its colorant(s) to adjacent materials during end-use. The fastness of the Shaiza pile towel were tested against a variety of conditions by standard methods. Briefly, the towel was made to be in close contact with a chemical or physical agent for a predetermined amount of time followed by measuring the colour difference between the original and treated using a Grey scale. The scale ranges from 1 to 5 with intermediate values being, 1 to 2, 2, 2 to 3, 3, 3 to 4, 4, 4 to 5, and 5 with 1 being very high difference (poor performance) and 5 being no difference post-treatment (Ideal performance). A towel with scores above 3 was generally desired. The Shaiza towel colour fastness to enclosed carbon arc lamp light was tested using the JIS L 0842:2021. Colour fastness to washing or home laundry using a detergent was checked as per JIS L 0844 A-2. Color fastness to perspiration was measured using JIS L0848 under both acidic and alkaline conditions. Colour fastness to water was tested using JIS L 0846. Color fastness to rubbing in both dry and wet condition was evaluated as per JIS L 0849.
The formaldehyde levels in the towels were detected using JIS L 1041: test method for resin-finished textiles. Fibre composition of the pile and ground material were determined as per JIS L 1030.
Results of the ultra-low yarn (Shaiza) pile-based Towel parameter analysis are presented in Table 3:
Table 3: Towel properties and parameters tested
Towel properties
Parameters Ultra-low twist (Shaiza) towel Control PVA-based towel
Length (cm) 122 121
Width (cm) 62 62.4
Weight (grams/m2) 448 452
Test Performed Shaiza towel (Avg. of 3 trials) Control PVA-based towel (Avg. of 3 trials) % improvement
ASTMD 1777 Fabric bulkiness (mm) 115 ± 2 105 ± 2 9.5
ASTM D 4772 Absorbency 75.7 ± 2.1 68 ± 1 11.3
ATCC 79 Drop absorption 1 ± 0 sec 3 ± 0 sec 66.7
JIS L1907 clause 7.1.3 Sink test 3.81 ± 0.19 sec 6 ± 0.1sec 36.5
ISO 20158 Absorption Capacity 952.7 ± 57.3 % 733.2 ± 8.1 % 29.9
AATCC 197 Vertical wicking
Short wick weft (2.5cm) 10 ± 1.4 sec 19 ± 1.4 sec 47.3
Short wick warp (2.5cm) 8.5 ± 0.7 sec 16.5 ± 0.7 sec 48.5
Long wick weft (10 cm) >10 min >10 min 0
Long wick warp (10 cm) >10 min >10 min 0
Drying Time - Internal standard (min) 29 ± 3.2 36 ± 2.8 19.4

Fig. 2a illustrates an image of a yarn pile of 20 Ne count of 450 grams/m2 cotton towel having average diameter of 0.95±0.148 mm, taken at a magnification of 20, wherein the short darker lines are the pile diameter at various locations in accordance with the present disclosure. Fig. 2b illustrates an image of PVA-based pile of average diameter = 0.72±0.11 mm for the PVA-based towel with similar properties, taken at a magnification of 20 and the short darker lines are the pile diameters at various locations. Fig. 2c illustrates a close-up view of the ultra-low twist yarn of the present disclosure (left) and the PVA-based pile (right) with the former displaying more parallel oriented fibres, less hairiness, and greater diameter. As seen in Fig. 2, the average thickness of the ultra-low twist (Shaiza) pile yarn was 0.95±0.148 mm, which was about 28% to 32% higher when compared to a regular pile yarn of 0.72±0.11 mm. The higher thickness of the Shaiza pile was reflective of open structure of the Shaiza yarn, which allows easy air circulation. Consequently, the Shaiza pile was able to trap a greater amount of air within its fibres. Since air had low thermal conductivity, the towel produced a warm feeling when pressed against the body. The larger pile diameter also allows the towels to be bulkier and fluffier as compared to PVA-based towels. As seen from Table 3, the ultra-low twist (Shaiza) pile based towel displays 9% more bulkiness when compared to a towel of similar characteristics. Also, the greater air space would lead to similar, if not better absorbency, when compared to PVA-based towel.
As visualized in Table 3, the absorbency of the ultra-low twist (Shaiza) pile based towels, as tested by ASTM D722, was not only equal to that of PVA-based towel, but it exceeds them by 11.3%. The AATCC 79 drop absorption was checked by adding a drop and checking the time for it to disappear followed by disappearance of the wet shimmer. In all the 3 cases, the ultra-low twist (Shaiza) pile absorbed the drop leading to disappearance of the shimmer within 1 second. The sink time of the Shaiza towel was about 36.5% faster than its regular PVA-based towel, with a water holding capacity of 952.7 ± 57.3 %, which was about 30% more than its regular counterpart. The vertical short wick in both warp and weft directions were about 47% to 48% faster when compared to the control. However, since wicking was mostly dependent on the ground weft and warp yarns with only a minimum contribution of pile, the long wick was about the same for both the towels. The drying test confirmed that the open yarn structure of ultra-low twist (Shaiza) yarn allowed the towels to dry faster. Based on the above results, it was evident that the bulky, open pile structure of the Shaiza yarn lead to the faster water absorption and also allowed a greater amount of water to be held by the towel. At the same time, the open Shaiza pile structure also allowed the towel to be plush and soft, maintaining and exceeding the basic requirements of a terry towel.
Table 4: Dimensional Stability to washing
Dimensional stability to washing Width before wash (cm) Width after wash (cm) Shrinkage in width (%) Length before wash (cm) Length after wash (cm) Shrinkage in length (%) Lint generation (%)
Average of 3 towels 61± 0.14 59.85 ± 0.07 1.88 ± 0.34 122.15 ± 1.06 118 ± 1.27 3.40 ± 0.2 0.135 ± 0.02
Acceptable 5% 5% 0.2

As seen in Table 4, the ultra-low twist (Shaiza) towels demonstrated acceptable shrinkage in length and width after wash. The lint generation was also within the standard acceptable limits.
Table 5: Colour Fastness testing results with various shades. Each test was carried out 6 times by taking different areas of the towel.
Towel (Ex. No.) T1 T2 T3 T4 T5 T6
Shade Used White Very Light Light Medium Dark Very Dark
JIS L 0842:2021; colour fastness to enclosed carbon arc lamp light
Standard : 3 & above >3 >3 3 3 3 3
JIS L 0844)/ AATCC 61: Colour fastness to washing
Standard : 3 & above 4 4 4 4 3 to 4
JIS L 0848)/ AATCC 15; colour fastness to perspiration
Acid 4 4 4 4 4
Alkali 4 4 4 4 4
JIS L 0846: Colour Fastness to Water
Standard : 3 & above 4 4 4 4 4
JIS L 0849) / AATCC 8: Colour fastness to rubbing
Dry 4 to 5 4 to 5 4 to 5 4 to 5 4 to 5
Wet 3 4 to 5 4 4 4 to 5
JIS L 1041: test method for resin-finished textiles
Formaldehyde (ppm) Acceptable: < 100 ppm 35 35 35 35 35 35

Table 5 demonstrated the results of the fastness test based on 6 different colour shades (T1 to T6), including a white Shaiza towel. As visualized, the fastness test results were all within the acceptable limits. The formaldehyde levels of the towels were in the range of 32 to 36 ppm, which was well within the accepted range. Based on the results of the JIS L 1030, the pile and the base materials were identified to be 100% cotton.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of: a process for the preparation of the ultra-low twist yarn that:
• does not used the polyvinyl alcohol (PVA) fibres; and
• can be run on the available machines and does not require new set up;
and
the ultra-low twist yarn that
• is capable of replacing the polyvinyl alcohol based yarn providing sustainability;
• displays larger diameter when used as a terry loop creating more air pockets within its structure; and
• is capable of producing towels having increased absorbency, higher water holding capacity, and faster drying.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A process for the preparation of ultra-low twist yarn, said process comprising the following steps:
(a) preparing carded breaker-drawn slivers of a first predetermined count or combed slivers of a second predetermined count;
(b) feeding said carded breaker-drawn slivers or said combed slivers to a finisher draw frame running at a first predetermined speed, with a first predetermined number of doublings, having a first predetermined bottom roller setting, providing a first predetermined break draft to obtain finisher drawn slivers of a third predetermined count;
(c) feeding said finisher drawn slivers of said third predetermined count to a Roving frame machine, running at a second predetermined speed, having at least three condensers of a predetermined dimension and a first predetermined spacer gap, providing a second predetermined break draft having a second predetermined bottom roller setting, a first predetermined top roller setting, and a fixed direction of rotation to obtain Z-twist rovings of a fourth predetermined count, with a predetermined number of twist per inch (TPI), and a predetermined number of twist multiple (TM); and
(d) feeding at least two Z-twist rovings of said fourth predetermined count to a Siro ring frame having a second predetermined spacer gap, having a third predetermined bottom roller setting, and a second predetermined top roller setting, at a predetermined total draft, at a third predetermined break draft, at a predetermined average spindle speed, providing a S-directional twist to obtain said ultra-low twisted yarn.
2. The process as claimed in claim 1, wherein said carded breaker-drawn slivers are prepared by the following sub-steps:
i. obtaining cotton fibres, followed by cleaning the fibres in a blow room to obtain free fibres; wherein said cotton fibres are at least one selected from virgin cotton fibres, regenerated cotton fibres, reusable cotton fibres, and blended cotton fibres;
ii. joining said free fibres in parallel in a carding machine to form carded slivers having counts in the range of 0.08 Ne to 0.16 Ne, wherein said carding machine is operated with the parameters: a feed plate to licker-in setting in the range of 0.73 mm to 0.77 mm, a licker-in to cylinder distance is in the range of 0.23 mm to 0.27 mm, a cylinder to flat (front to back) setting of 0.225 mm, 0.2 mm, 0.2 mm, 0.2 mm, 0.2 mm, 0.2 mm, a cylinder to doffer settings is in the range of 0.15 mm to 0.25 mm, a licker-in speed in the range of 1048 rpm to 1052 rpm, a cylinder speed in the range of 485 rpm to 495 rpm, flats speed in the range of 318 mm/min to 322 mm/min, a doffer speed in the range of 133 meters/min to 137 meters/min; and
iii. feeding said carded slivers having count in the range of 0.08 Ne to 0.16 Ne to a breaker-drawn frame at a speed in the range of 790 meter/min to 810 meter/min, with bottom roller settings of 40 mm to 44 mm; a break draft in the range of 1.5 to 1.8, with number of doublings in the range of 4 to 8 to obtain said carded breaker-drawn slivers having said first predetermined count.
3. The process as claimed in claim 1, wherein said combed slivers are prepared by the following sub-steps:
(i) feeding said carded breaker-drawn slivers of said first predetermined count to a lap former running at a speed in the range of 85 meter/min to 110 meter/min with number of doublings in the range of 18 to 24, providing a break draft in the range of 1.038 to 1.044, to obtain a lap having a weight in the range of 50 grams/meter to 80 grams/meter; and
(ii) feeding said lap in a combing machine running at a speed in the range of 290 nips per minutes to 310 nips per minutes, having a feed/ nip in the range of 4 mm to 4.4 mm, a first bottom roller setting of 41 mm, providing a break draft in the range of 1.48 to 1.52 to obtain combed slivers of said second predetermined count.
4. The process as claimed in claim 1, wherein, in step (a), said carded breaker-drawn slivers have said first predetermined count is in the range of 0.08 Ne to 0.16 Ne, and said combed slivers have said second predetermined count is in the range of 0.08 Ne to 0.16 Ne.
5. The process as claimed in claim 1, wherein, in step (b),
• said first predetermined speed is in the range of 250 meter/min to 350 meter/min;
• said first predetermined break draft is in the range of 1.14 to 1.34;
• said first predetermined bottom roller setting of 33 mm to 47 mm, 48 mm to 56 mm;
• said first predetermined number of doublings is in the range of 4 to 8; and
• said third predetermined count is in the range of 0.08 Ne to 0.16 Ne.
6. The process as claimed in claim 1, wherein, in step (c),
• said second predetermined speed is in the range of 650 rpm to 1100 rpm;
• said predetermined dimension of an inlet condenser is in the range of 18 mm to 8 mm x 6 mm to 2 mm;
• said predetermined dimension of a middle condenser is in the range of 14 mm to 6 mm x 1 mm to 3 mm;
• said predetermined dimension of a floating condenser is in the range of 15 mm to 8 mm;
• said first predetermined spacer gap is in the range of 2 mm to 7 mm;
• said second predetermined break draft is in the range of 1.1 to 1.35;
• said second predetermined bottom roller setting of 40 mm to 60 mm, 52 mm to 57 mm, 43 mm to 47 mm;
• said first predetermined top roller setting of 40 mm to 60 mm, 51 mm to 55 mm, 41 mm to 53 mm;
• said fourth predetermined count is in the range of 0.4 Ne to 3 Ne;
• said predetermined number of twist per inch (TPI) is in the range of 0.85 to 2.66; and
• said predetermined number of twist multiple (TM) is in the range of 1.34 to 1.53.
7. The process as claimed in claim 1, wherein, in step (d),
• said second predetermined spacer gap is in the range of 2.25 mm to 6.5 mm;
• said third predetermined bottom roller setting of 42 mm to 45 mm, 60 mm to 70 mm;
• said second predetermined top roller setting is of 50 mm to 55 mm, 60 mm to 72 mm;
• said predetermined total draft is in the range of 30 to 40;
• said third predetermined break draft is in the range of 1.12 to 1.45; and
• said average spindle speed is in the range of 5,500 rpm to 15,000 rpm in an anti-clockwise direction.
8. The process as claimed in claim 1, wherein the generated yarn count is in the range of 6 Ne to 60 Ne.
9. The process as claimed in claim 2, wherein said blended cotton fibres are the fibres having a blend of cotton fibres and non-cotton fibres in a blend percent ratio in the range of 1:100 to 100:1; said non-cotton fibres are selected from natural fibres and synthetic fibres; said synthetic fibres are selected from the group consisting of rayon, polyester, nylon, polyurethane, polyvinyl, polyacrylate, and polypropylene; said synthetic fibres have a staple length in the range of 32 mm to 51 mm; and said natural fibres are selected from the group consisting of hemp, flax, bamboo, banana, and pineapple; said natural fibres have a staple length in the range of 25 mm to 51 mm.
10. The yarn as claimed in claim 2, wherein said virgin cotton fibres have a length in the range of 20 mm to 40 mm; said reusable fibres are selected from roving waste cotton fibres, reconstituted cotton fibres, and recycled cotton fibres.
11. The process as claimed in claim 1, wherein said ultra-low twist yarn with counts in the range of 6 Ne to 60 Ne is characterized by having
• a count strength product (CSP) in the range of 2200 to 4000;
• twist per inch (TPI) in the range of 7.2 to 25.3; and
• twist multiple (TM) in the range of 2.5 to 3.5.
12. The process as claimed in claim 1, wherein said ultra-low twist yarn is woven into a pile fabric of weights in the range of 150 grams/m2 to 800 grams/m2, wherein said pile fabric is characterized by having:
• an increase in pile diameter in the range of 20% to 30%;
• an increase in bulkiness in the range of 5% to 10%;
• an increase in absorbency in the range of 5% to 15 %;
• a reduction in water drop absorption in the range of 30% to 70%;
• an increase in moisture retention capacity is 10% to 30%; and
• a reduction in drying time in the range of 15% to 25%.

Dated this 19th day of June, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI