Systematic investigation and optimization of fine cotton yarns produced in a modified ring spinning system using statistical methods

A modified ring spinning technique has been recently developed by incorporating false twisting devices into a conventional ring frame for producing a low torque and soft handle singles yarn. Our previous studies showed that this technology can be applied for producing coarse modified yarns (7–32 Ne) with improved yarn and fabric performance. The present paper extends the work for the production and optimization of modified yarns at a fine yarn count (80 Ne). Compared with the conventional ring spinning system, the modified system presents a different and complicated spinning condition in terms of yarn tension and twist distributions, as well as the interaction between the false twisting device and conventional ring frame. Therefore, this paper aims to systematically investigate the quantitative relationship between spinning system parameters and physical properties of the fine modified yarns using the combined statistical methods of fractional factorial and response surface methodology. In this paper, potential spinning system parameters are proposed and the significances of their effect on yarn properties are quantitatively evaluated. Then the statistical relationships between the significant system parameters and the properties of fine modified yarn are fully examined and optimized. With these optimum parameters, the fine modified yarn and woven fabric were produced and their properties were assessed and compared with the conventional ones.