Yarn Process

Rawmaterial

1. Types of Cotton Waste Used:

  1. Lickerin Fly

  2. Lickerin Droppings

  3. Lickerin Flat Strips

  4. Lickerin Cylinder Fly

  5. Flat Strips

  6. Best Droppings

 Count Types of Waste Used:

We process waste originating from finer count yarn production, including:

  • 40’s Count Waste

  • 60’s Count Waste

  • 80’s Count Waste

 

Blow Room Process

 2. Blow Room Process 

Our multi-stage blow room system prepares the raw material for spinning through mechanical opening and impurity removal:

 GPR Opener

  • Opens compressed cotton waste into soft, aerated tufts

  • Breaks clumps for easier downstream processing

 RK Beater

  • Removes coarse dust, heavy particles, and large contaminants

  • Improves overall fiber opening and pre-cleaning efficiency

 Dustex Unit

  • Advanced dust extraction system

  • Eliminates micro-dust and airborne impurities

  • Enhances air quality and improves raw sliver cleanliness

This ensures a clean, loose, and uniform fiber blend ready for cardi

Double Carding

3.  Carding 

To ensure fiber alignment and consistent yarn structure, we run material through two high-performance carding machines:

      Separates fibers

  • Removes neps (fiber knots), short fibers, and trash

  • Forms an initial sliver with aligned fibers

  • Further straightens and cleans fibers

  • Enhances sliver evenness and parallelization

  • Prepares a high-quality sliver ideal for drawing

Double carding significantly improves the yarn’s strength, smoothness, and count consistency.

Drawing Process

4.  Drawing Process 

In this phase, multiple carded slivers are fed into drawing frames which:

  • Combine them into a single, even sliver

  • Straighten and align fibers perfectly

  • Ensure uniform mass per unit length

This process directly influences yarn quality, preventing count variation and improving mechanical strength in the final product.

Open- End Spinning

5. Open-End Yarn 

We use a combination of SN OE and RN OE  machines to convert prepared sliver into final yarn. Both machines offer high-speed production with consistent yarn characteristics:

 SN OE (Smooth & Balanced Yarn Output)

  • Produces soft yarn suitable for warp, weft, and doubling

  • Ideal for weaving and fabric production

 RN OE (Rugged & Durable Yarn Output)

  • Capable of handling heavier tension and load

  • Best suited for rope, towel, and industrial fabric applications

Both spinning systems are optimized for energy efficiency and low contamination, ensuring quality at scale.

Quality Control & Testing

Quality Control & Testing

6.  Quality Control & Testing

Each yarn batch undergoes rigorous in-house testing for:

  • CSP Strength: Consistently above 1200 CSP, ensuring strong tensile performance

  • Count Accuracy: Ensures every cone maintains exact 10s count

  • Twist & Evenness: Measured for balanced performance during weaving

  • Hairiness & Contamination: Minimized through double carding and clean handling

All results are monitored by our QC team, and only compliant lots are packed for dispatch.

7. Packaging & Dispatch

Finished yarn cones are:

  • Neatly wound and checked

  • Packed in moisture-resistant HDPE bags

  • Labeled with batch, count, CSP, and quality details

Yarn is prepared for local delivery or bulk shipment, ensuring safe and timely arrival to clients.

Final Output

The result is premium-grade 10s OE cotton yarn that is:

✅ Strong and uniform
✅ Ideal for warp, weft,  towels, ropes, and reeling
✅ Eco-friendly and cost-effective
✅ Manufactured with care, precision, and commitment

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