PROCESSING TECHNOLOGY
・Yarn Gassing
● Processing content
・Yarn Gassing is the process of passing each thread through the fire of a gas burner to burn off fluff (dust).
It is also possible to change the singeing rate according to the application and yarn count.
● Processing effect
By Yarn Gassing, fluff is eliminated, the gloss increases as you can see, and the texture is smooth.
By eliminating fluff and improving the feel, it is effective when the added value of the product is increased or when the fluff interferes with the production process (for example, it cannot be woven smoothly and cannot be knitted).
Nowadays, there are many materials with various functions, so they are sometimes used for processing that applies thermal reaction.
Example ... Wearable clothing, fishing line, etc.
・ Eliminates fluff peculiar to short fibers
・ Improved color development during dyeing → The pattern is clear
・ The fabric is glossy enough to be seen.
・ As it becomes a fine texture, good-quality glossiness appears
・Since the area that touches the skin is reduced, it becomes smooth to the touch.
・ Add value increases
・ Strength and durability increase
・ Pilling grade goes up
・ Effectiveness as heat treatment process
● Our original technology
If the gas is not kept at a certain temperature at a certain place, the quality will not be stable and color unevenness will occur during dyeing, so it will not be a high value-added product. In addition,High skill and experience are required because oversinge to minimize fluffing can result in singeing.
We handle yarn counts from 10/2 to 100/1, including single yarn, twin yarn, and 3 yarns (3 twisted yarns). We also handle raw materials other than cotton yarn, and we can also process TC (Tetron blend), hemp, wool, silk, and polyester span depending on the item. It is also possible to change the singeing rate according to the customer's intended use and yarn count.
We have a our original Yarn Gassing machines jointly developed with from SSM, a European textile equipment manufacturer, a Japanese textile equipment manufacturer. (2015 manufacturing subsidy)
Effects of gas-singeing process.
100% organic cotton
Top: Unprocessed raw cotton yarn
Bottom: Gassed yarn
100% Ramie
Left: gassed yarn Right: untreated raw yarn
Left: Unprocessed raw cotton yarn Right: Gassed yarn
Left: Unprocessed raw cotton yarn Right: Gassed yarn
Before gas firing, the fabric looks blurred, but when it is made into a fabric, the fluff is gone and the grain stands out. This gives the fabric a much more pleasant feel and a silky sheen.
Left: Unprocessed raw cotton yarn Right: Gassed yarn
Yarn Twisting
● Processing content
Yarn Twisting is the process of twisting one or more yarns.
● Processing effect
By twisting yarns, it is possible to add strength to yarns and combine different materials. The increased strength makes the fabric more durable than fabric using single yarn and allows it to maintain its high quality.
It is also active in various situations by giving strength to threads for material applications.
Various twisting times can be set according to each need, and the texture of the knitted or woven fabric can be varied. Basically, we will twist the number of twists specified by the customer.
・ Finish the yarn with the required count and strength according to the application.
・ Since fluff is screwed in, fluff is reduced.
-・Twisting increases the strength of the yarn, increasing durability and maintaining high quality.
Heat Setting
● Processing content
With Heat Setting, the thread to be processed is placed in a pot made of a hot iron plate, the pot is sealed, and the air inside the pot is sucked out by the power of a motor pump to create a vacuum and It is the process of spraying the steam created by the boiler into the vacuum state.
● Processing effect
This process is essential for processing hard-twisted yarns that have a high number of twists (simply how many twists per inch).
This is because when the yarn has a strong twist, the force acts in the twisting direction, causing tangling of the yarn (snarl, billi), which causes needle breakage and fabric defects when knitting the fabric. Therefore, if set processing is performed, the complete vacuum creates extremely uniform vapor penetration, which stabilizes the shape of the yarn itself, further increases the strength, and improves the texture of the yarn, which is extremely difficult during weaving. It is easy to weave and there is no uneven dyeing, which makes it much easier to use in the next process.
However, if the humidity, heat retention time, and water content are not set appropriately with the thread, the effect will not be sufficient. We use our experience and know-how to perform optimum processing according to the characteristics of the yarn.
・ Provides the required moisture content for natural fibers
・In the case of strongly twisted yarn, it is difficult to handle as it is, so it suppresses untwisting.
・ Used to avoid the problem of skewing of knitted fabric
・Increases thread strength
-・The texture of the thread is good, it is very easy to weave during weaving, and there is no color unevenness during dyeing.
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(Quoted from Tamada Co., Ltd.)
Effect of heat set processing
Yarn Rewinding
● Processing content
Yarn Rewinding is the process of rewinding threads. Wax processing or Wooster processing are performed during the process of rewinding.
● About WAX processing (rewind)
When using the yarn for knitting, it is necessary to attach wax to the yarn surface to make the knitting smooth.
Generally, paraffin wax is used, but silicon type or special wax may be used depending on the raw material and application.
Waxes are also essential to the yarn used to create some of the most difficult woven fabrics. In conjunction with this wax process, the thread is rewound into a cone shape that is easy to melt. It is also possible to divide it into small pieces.
● About Worcester processing
Pass a Wooster (a device that detects thread dust such as slabs and neps) slightly in front of the waxing device to remove defective parts mixed in the thread.
Wooster measures the change in the capacity of the yarn passing through the Wooster device from the material and count of the yarn by the capacitance method, and detects and cuts the part where the capacity of the yarn is large (the thickness is different). As a result, it is possible to eliminate defects that cause needle breakage with a knitting machine, and to suppress the loss by holding the part corresponding to the defect part at the time of inspection within the allowable range.
* According to the machine manufacturer, the upper limit of the defect removal rate is 70%, so if the defect is too fine (too many), it is necessary to allow the residual defect.
* In the case of spun yarn, since it is manufactured with high bulk due to its characteristics, if there are too many defects, the number of cuts will increase and the yarn will be full of cuts, so it is often impossible to maintain the quality of the subsequent product (Wooster processing itself). Can be difficult)
●Processing effect
・ Prepare the thread so that it can be used easily in various processes.
・ Removes lint and defective parts such as slabs and neps
・ Can be divided into small pieces
・ Wax adhesion, etc.
(Quoted from Sato Sangyo Co., Ltd.)
By combining the above processing techniques, it is possible to produce better quality yarn.
Processing example
1: Gas Singeing + WAX
2: Twin yarn + Heat set + WAX
3: Twin yarn + Heat set + Gas Singeing + WAX
4: Triple twisted yarn + Heat set + WAX
5: Triple twisted yarn + Heat set + Gas Singeing + WAX
6: Single yarn additional twist + Heat set + WAX
7: Single yarn additional twist + Heat set + Gas Singeing + WAX
8: Single yarn additional twist + Heat set + Twin yarn + Heat set + WAX
9: Single yarn additional twist + Heat set + Triple twisted yarn + Heat set + WAX
10: Single yarn additional twist + Heat set + Triple twisted yarn + Heat set + Gas Singeing + WAX
In addition to these, we will process according to your request, so please feel free to contact us!
Toyotashigyo's technology provides comprehensive services for textile quality management. The process of adding value to these yarns helps our customers to solve issues fast, to become more efficient in their processes, and excel in their quality.
Handling raw yarn
Cotton, TC (Tetron blend), linen, wool, silk, polyester span, etc.
Cotton count 0.6 / 1 ー 160 / 1
We are always consulting about new raw materials.
The company also offers high-end yarns such as organic cotton and silk!
