industrial yarn winder

Types of Industrial Yarn Winders

An industrial yarn winder is a machine that winds the yarn into hanks or coils, usually for the benefit of easy storage and transportation. There are several types of industrial yarn winders, such as the tube winder, hank winder, pirn winder, cones & pallets winder, ball winder, shuttle winder, bobbin winder, cross winder, flat winder, automatic yarn winder, and so on.

• TUBE INDUSTRIAL YARN WINDERS: This type of yarn winder is frequently used to wind yarn onto cylindrical containers or tubes. It offers simple control systems and variable-speed motors suitable for small operations.
• HANK WINDERS: The hank winder is the most popular winder type for knitting yarns. The yarn is pulled taut across the machine as the skein is rotated. The yarn is then wound into circular bundles, known as hanks. The hanks can easily be looped in the center for storage or sold as is.
• PIRN WINDERS: Unlike bobbins, pirns have a tapered shape, which requires them to be wider at the top. The tapered shape helps keep the yarn even throughout the pirn. When filling a pirn, a horizontal yarn winder is used, and the yarn is laid across a metal rod in a zigzag pattern.
• CONES & PALLETS WINDERS: The cone yarn winder is often used in weaving since it can hold a large amount of yarn. Weaving requires frequent changes of yarn. Therefore, it is essential to change the yarn type quickly. Changing yarns on cone containers is quick and inexpensive. Furthermore, the cone size is relatively small and can easily fit on a cone stand while weaving.
• BALL WINDERS: The industrial yarn winder ball winder works similarly to a hank winder but produces smaller and tighter yarn balls. The yarn is pulled quickly across the machine and wrapped around in a ball. The yarn is tensioned as it is wound, which helps create a tight and smooth ball.
• SHUTTLE WINDERS: It is commonly used in the textile industry to pre-feed yarn into shuttles for weaving operations. Generally, a yarn shuttle is an object used to carry yarn over a warp thread to create fabric. The sewing machine that runs the yarn directly into the shuttle is known as a shuttle winder. By pre-loading the yarn into a shuttle, shuttle winders facilitate quicker and more effective weaving operations.
• BOBBIN WINDERS: As briefly described above, a bobbin is a small, cylindrical object that holds thread or yarn. Bobbin winding is used primarily in sewing and stitching yarns. Therefore, the bobbin winder is used to fill the bobbins with the required yarn for the purpose of sewing.
• CROSS WINDERS: Compared to other types of yarn winders, cross winders are the most used industrial winders. They are based on the yarn traversing motion or the yarn guiding system, which winds the yarns in a cross pattern. This method helps prevent yarn tangling and ensures even distribution of the yarn on the package.
• FLAT WINDERS: The flat winder refers to a yarn winder that is designed to accommodate hanks of yarn that are flat. The hanks are pulled taut and wound onto the winder in a flat manner. In comparison to cylindrical yarn packages, flat yarn packages are quicker and easier to maneuver in sewing and embroidery operations.
• AUTOMATIC WINDERS: Automatic yarn winders can stop, cut, and tie the yarn automatically. It makes high-speed winding possible and cuts down on operator input. Automatic winders frequently come with modern features like touch screen controls, programme storage, and yarn tension management system for precise and automated winding.

Specification and Maintenance

Industrial yarn winders are designated by a variety of specifications determined by the usage, model, and manufacturing brand. Here are some key specifications with general details about their maintenance.

• Yarn Tension Control

  Yarn tension control is crucial as it helps to maintain uniform tension of yarn and is therefore important to the accuracy of winding, and the quality of the final product. Winders are usually fitted with tension controlling devices that adjust and regulate the tension of the yarn as it is being wound. Maintenance entails regularly calibrating the tension controller to ensure it gives accurate readings. When it is maintained properly, it helps to prolong the lifespan of the yarn winding reel machine.

• Automatic cutting

  In many modern-day yarn winders, automatic yarn cutting and clipping has been introduced to enhance efficiency and improve product quality. This function gives a clean cut with minimal fraying and uneven edges. For a yarn winder machine with automatic cutting, it is important to ensure that the cutting component is sharp and clean. This aids precision and ensures quality cutting as the name suggests. If it's very worn out, or blunt, it should be replaced immediately.

• Core Size and Type

  A yarn winding machine usually comes in two main options: rigid cores such as cardboard, paper, or PVC and flexible ones like warp or weft yarn that are made from textile materials. The core determines how the yarn is wound and how it is subsequently unwound during the weaving or knitting process. Depending on the material, size, and type, a yarn winder's core can wear out, especially if it's used continuously. One tells that a winder’s core needs replacement when there is uneven yarn displacement, fraying, or yarn tension issues. Some may need cleaning as residues build up on them, while others will need to be replaced. Also, improper use may damage them, calling for repair services.

• Compatibility with Yarn Types

  Industrial yarn winder machines are usually compatible with various yarn types, such as natural fibers (cotton, wool, linen), synthetic fibers (polyester, nylon, acrylic), blends, and specialty yarns (elastic, metalized). Nonetheless, users should take note of the maximum yarn weight ratings and yarn textures. They should also check and ensure that the yarn winder they get has adjustments and settings that allow it to wind the specific yarn type seamlessly. Compatibility is key as it affects yarn tension and final product quality.

Usage scenarios for industrial yarn winders

The following sectors make regular use of industrial yarn winders:

• Textile industry

  In the textile industry, an automatic yarn winder machine is used to wind yarn from large feed spindles or bobbins into smaller, easily manageable bobbins or balls. This process is an integral part of quality control, as it assists in detecting and correcting any issues with the yarn before it is used in production.

• Knitting and weaving factories

  Knitting and weaving factories utilize yarn winders to prepare yarn that can be easily fed into knitting machines or weaving looms. Properly wound yarn helps maintain consistent tension and prevents interruptions during the production process.

• Garment manufacturing

  Garment manufacturers use industrial yarn winders to customize yarn quantities and sizes for different clothing items. Specialize winding techniques, such as plying and doubling, are often employed to create yarns with particular characteristics for specific applications.

• Carpet and rug production

  In the production of carpets and rugs, yarn winders are used to wind multiple yarns onto a single spindle or bobbin. This allows for efficient feeding of the yarns into tufting machines or weaving equipment, streamlining the production process.

• Specialized yarn production

  When producing specialized yarns, such as boucle, chenille, or effectively mixed yarns, industrial yarn winders are used to maintain the unique construction of the yarns. These may involve intricate winding patterns or the combining of multiple fibers.

• Fire retardant yarns

  Fire retardant yarns are employed in scenarios where safety is paramount, such as in the manufacturing of protective clothing, industrial safety gear, and high-performance fabrics for aerospace, automotive, and building infrastructure applications.

• Marine rope and netting production

  Marine rope and netting producers use industrial yarn winders to create heavy-duty, corrosion-resistant yarns for maritime applications. These can include ropes for docking, fishing nets, and protective sleeves for underwater cables and equipment.

• Composites reinforcement

  Composite reinforcement manufacturers use industrial yarn winders to consolidate fibers, such as carbon, glass, or aramid, into yarns utilized in composite materials. These are employed in various sectors like aerospace, automotive, and construction for strengthening materials.

• Yard signs and oilfield pumping units

  Oilfield production and yard signage companies use industrial yarn winders to create durable, weather-resistant signage. This is often done to inform or ensure safety in the vicinity of oil extraction operations and oilfield pumping units.

• Entangled yarn production

  Entangled yarn production involves creating yarns that are typically used for friction, grip, or stretch applications. Heavy-duty industrial yarn winders can help wind these kinds of yarns onto spools or bobbins, making them easier to handle and process further.

How to choose industrial yarn winders

Choosing the right yarn winding machine is crucial for improving productivity, reducing costs, and meeting specific winding requirements. When selecting a yarn winder, it is essential to consider the factors critical in evaluating the suitability of a yarn winding machine for particular needs.

• Winding capacity

  It refers to the amount of yarn that can be wound in a single operation. This is usually indicated in terms of the diameter and length of the package. It is essential to consider the required winding capacity based on production volume and scheduling demands.

• Speed

  The speed at which a yarn is wound is an important consideration, as it directly impacts production efficiency. It is good to choose a yarn winder with an appropriate winding speed to meet production targets without compromising yarn quality. The availability of speed control is also an important benefit that comes with modern yarn winders.

• Automation and control

  Automation features such as electronic controls, preset programs, and automatic shut-off can simplify the winding process and improve consistency. Consider the level of automation and control required to streamline operations and enhance product quality.

• Yarn compatibility

  Consider industrial yarn winders compatible with various yarn types and materials, such as cotton, polyester, nylon, and specialty fibers. Flexible machines can accommodate different yarn qualities reduce the need for multiple winding systems.

• Yarn winder design

  Several yarn winding machines are available in the market, such as cone winders, bobbin winders, pirn winders, cheese winders, etc. Each has its own functionalities and advantages. It is essential to select the right design that meets production requirements while maximising efficiency.

• Space requirements

  Industrial yarn winders are different sizes and shapes. It is crucial to consider available spaces and production layouts so as to accommodate the selected machine without disrupting existing workflows.

• Cost and budget

  Initially, it is necessary to understand the overall cost of ownership, including maintenance expenses, energy consumption, and operating costs. Balancing performance, quality, and cost-effectiveness is key to making a budget-friendly and sustainable investment.

Industrial yarn winder FAQ

Q1: What does an industrial yarn winder do?

A1: An industrial yarn winder is a machine that winds yarn into uniform bundles or packages for storage, sale, or further processing. It does this by controlling the tension and speed at which the yarn is wound onto the winder's core or cone.

Q2: What factors affect the cost of an industrial yarn winder?

A2: Several factors can affect the cost of an industrial yarn winder, including the machine's capacity and speed, the number of threads it can wind simultaneously, the winding method (e.g., direct, simple, or confederate), any additional features or automation, and the machine's brand and quality.

Q3: Can an industrial yarn winder accommodate different types of yarn?

A3: Yes, an industrial yarn winder can accommodate different types of yarn, such as synthetic, natural, or blended fibers, as well as specialty yarns like textured or pushed yarns, depending on the machine's design and capabilities.

Q4: What is the difference between a yarn winder and a yarn skeiner?

A4: An industrial yarn winder is a machine that winds yarn into cones, packages, or balls. In contrast, a yarn skeiner winds yarn into a skein or coil. While both machines can package yarn for storage or sale, the yarn winder is more suitable for higher-volume production and winding directly from the spinning frame, while the yarn skeiner is more suitable for handling smaller quantities and making custom lengths or weights.