Suitability of Rayon Fibers in Spinning process

1. The suitabililty of Rayon fibers in Staple spinning processes - suitability of
Rayon Staple fiber is discussed, in particular the fiber parameters, and
enduser application.

2. Due to rising cost factors of raw materials, factory owners are made to face
harsh realities:
When purchasing Modal fibers with excellent fiber parameters, the
procurement department has to make a
tough choice.
It comes as no surprise, many factories in the Spinning sector will fall into
this trap, for lack of knowledge of t responsible personnel could bring
them to the brink of ruin.
One must consider several factors : cost of raw material as the major
factor in production cost, with a share of near 50 %.
Considering a purchase of fiber, the following criteria is essential :

3. Origin
Fiber properties ( wet-, conditioned -, dry Tenacity, Elongation, shrinkage, Pilling
resistance, etc.) are excellent indicators of fiber quality
Staple length - obviously - is of extreme importance in order
to achieve final desired tenacity and Elongation
Active fiber add on and its source (Origin and type of fatty Ester application as well
as percentage)
Price and Terms of fiber lot purchase
Packing
Date of Manufacture
Storage of fibers (extremely important)
Mode of shipment (sea-transport can cause problems, extreme temperatures
always do)
In my many years of managing Spinning Mills I came across various fiber
Manufacturers world wide. Manufacturers outbid each other in order to receive a
Purchase order.

4. Fiber parameters
In normal temperate climates, fibers manufactured by a renowned supplier
will be accompanied by sound warranties, and nothing or little can go
wrong in the spinning process.
Prime lots, however, carry a hefty price tag, and with margins in cents
one would have to consider such choice carefully.
Many Spinning mills in Europe went out of business, the fiber
manufacturers are still operating.
With competition coming on stream, lower grade raw materials are being
used. One particular candidate is
Cotton lint. One must imagine the lint being the base material, passing
through the full caustic soda process, filtered and extruded. The fiber
length of lint, passed through the process is in fractions mm.

5. Financial Cost
As against Viscose derived from Nordic wood, with fiber lengths of 1-2 mm, the
parallels are very far apart. So are the prices of the two.
When a prospective buyer goes for a cheaper Viscose fiber, he must realize that
he may have to prepare for
essential modifications on his plant. In very few cases, personnel is able to adapt
to changing fiber properties.
When things go bad, the culprit is always the purchaser.
Technical Personnel which handles issues on the manufacturing floor, normally are
of limited capacity when confronted with such scenarios. They quickly point their
fingers to the raw material, without considering
that a change of raw material can bring financial advantages to the Employer.

6. Changes required are often time consuming and need Expert knowledge in
all Spinning processes.
This has to be acquired over years, and will not be taught in Colleges.
It will invariably involve first hand knowledge of Blowroom machinery,
Carding -, Drawing, and subsequent
Roving - and Spinning Machinery, i.a. Ringspinning -, OE-Spinning -,
Airjet (MVS), as well as subsequent - Machinery, and its processes.
When in the Spinning process high ends down, slubs, imperfections, are
shown, then mostly the fault is not on the machine, but rather in the
preparation. Standard Efficiency can never be achieved thus.

7. other Details
In case with Microfiber, yarn cross sections would contain hundreds of
individual fibers which must be controlled, guided, and this under the
constraints of factors of speed, quality, and damage free processing.
Not an easy task. For a novice an impossible one.
continued : Fibers tend to lap in all processes, impairing production
efficiency, quality.
Published by:
Heinz Rainer - Technical Advisor