Production of single yarn

The raw materials are cotton fibres or synthetic cut staple or schappe spun fibres, which are delivered in compressed bales. The loose fibre material is processed into roving in various steps:

• Loosening and cleaning
• Arranging and parallelising the fibres
• Sliver formation
• Drawing out
• Pre-spinning to form roving

At AMANN, both rovings made from cut staple fibres and schappe spun fibres are processed. When processing cut staple fibres, the length of the fibres is identical to the average staple length of cotton fibres, meaning that the roving can be processed on ring spinning machines in what is known as three-cylinder spinning.
The fibres are stretched and doubled several times to produce a fibre yarn of the desired fineness. Pre-spinning and yarn twisting are carried out on ring spinning machines in the three-cylinder spinning process.
Cotton yarns are spun on ring spinning machines in three-cylinder spinning mills. The yarn is twisted on the ring spinning machine.

For core yarn production, raw material made of continuous filament material must be combined with a covering of cut staple fibres. The manufacturing principle for the covering is similar to that for spun yarns. The fibre material is delivered in pressed bales and processed into roving. The spinning process on the ring spinning machine then combines the covering and the continuous filament core. Finally, the yarn is twisted. The core yarn is the starting product for the core spun thread.

Continuous filament yarn is used as the raw material, which is sourced directly from the chemical fibre industry. This raw material consists of fine, parallel individual filaments that are only slightly twisted or twisted for protection. 
The number of individual filaments varies greatly and depends primarily on the overall fineness of the material. In some cases, continuous filament bundles with up to 200 individual filaments are used. The required yarn twist is only applied shortly before the yarn is plied and twisted on the twisting machine.

Polyester or polyamide continuous filaments are used as the starting material, which are further processed into bulk yarns through texturing. There are various texturing processes. The false twisting process is generally used for this application of bulk yarns. In this process, the smooth filament, consisting of numerous individual filaments, is passed through a heated zone, at the end of which a high-speed twisting device produces the desired twist. The twist is fixed by heat treatment and subsequent cooling. The yarn is then untwisted again, but the puckering remains and creates the familiar bulk effect.

In braiding, yarns are intertwined on a horizontal plane. This is done by rotating 6 or 8 of a total of 12 or 16 bobbins clockwise and 6 or 8 counterclockwise around a common axis. The clapper path describes a wave pattern, as the clappers have to avoid each other. The braided yarn produced in this way is then wound onto a so-called tambour. The yarn has a tubular shape, is hollow on the inside and lies flat. As the yarn has no twist, it must be pulled off by rolling. Pulling it overhead, as with standard sewing threads, would cause the braided yarn to twist, resulting in an unattractive seam. Braided yarn is therefore unrolled throughout the entire process chain up to the sewing machine.