In the yarn dyeing process; the soft winding section is the first section. In the soft winding section; Yarns are transferred from a paper cone to a plastic tube or spring tube to facilitate the dyeing process. It is one type of re-winding process. During rewinding different problems could occur due to the lack of awareness of the respective personnel which can be harmful to the coloration process. The following problems are the most common problems that occurred in the soft winding section.
Faults in Soft Winding Section:
Following problems are generally found in the soft winding section.
Sometimes a lot of mixing occurs in this section. Due to this problem, different problems are appearing in the dyeing section. The shade of the yarn package varied from one package to another. Also, shade varies in the same package.
Count Mixing :
Count mixing is another problem in this section. Sometimes different count yarn packages mixed with one another, which produced shade variation in the yarn package.
The density of the yarn package is one of the important factors. Density problems are occurred due to wrong setting of tension, angle of winding, overfeed speed, etc. Due to this problem shade variation is occurred package to package.
Hardness and Softness:
hardness and softness are other problems, sometimes packages become hard or very soft due to wrong tension and overfeed speed. A hard package is harmful to dyeing because it does not permit liquor or dye solution to penetrate uniformly through the package. A very soft package makes shade variation.
A cleaning device is used to collect flies or dust, which is with the yarn. If dust does not clean then it increases the tension and the package becomes hard.
Yarn breakage is another problem. This problem happens due to the low strength of yarn or high tension of the winding machine. For this reason, production of the winding section is hampered.
It needs to maintain a uniform supply of electricity. Due to this problem, the flyer becomes stopped but the supporting roller moves, and the yarn wind to the tube as a line because traversing is stopped.
Wrong Program Setting:
The wrong program setting is another problem. Tension, angle, overfeed speed should be adjusted to the count of yarn.
Yarn should be fed according to the yarn path; otherwise winding will not be accurate.
Lack of Spring or Plastic Tube:
Spring or Plastic tubes should be available, otherwise, production efficiency will decrease.
The cleaning device should keep clean; otherwise, it will be jammed by dust which increases the hardness of the package.
Manpower is essential. Lack of manpower decreases production efficiency.
If dust or fly enter into nose or mouth then it creates breath and other physical problems.
Remedies way of Soft Winding Problems:
The following are the remedies way of soft winding problems. They are-
- Lot should not mix with one another. Numbering should be in every package. Operator should be careful during winding.
- Different count yarn should keep separately.
- Tension of each lot package should be uniform and accurate.
- Cleaning device should keep clean.
- Different winding parameter which is standard for different count should set properly.
- Density of each lot package should be uniform and it needs to monitor the process. Density test should work out for each lot package.
- Better quality yarn should use, it increases the winding efficiency.
- Operator, helper and others, who enter in winding section, should put musk.
So, we should be careful about the problems which are created in the soft winding section. Also, we should take steps for solving these problems.