Every stage decides how much length survives.
From bale or textile waste to finished yarn, each machine can preserve fibre length or destroy it. This is where we look first.
- FeedstockSorting, hard-part removal, cutting
- Opening and tearingBack to fibre, with minimal breakage
- CardingIndividualise and align into sliver
- DrawingDouble and draft for evenness
- RovingAttenuate and add light twist
- SpinningRing or rotor, to the target count
- Yarn testingProve strength, evenness, length
STAGE 1Feedstock
Sorting by fibre type and colour, removing buttons, zips and heavy seams, then cutting to size.
FOR FIBRE LENGTHCut size sets the longest fibre you can recover. Cutting too small caps length for every stage after it.
STAGE 2Opening and tearing
Pinned or sawtooth cylinders pull fabric back into fibre over several passes.
FOR FIBRE LENGTHThe biggest source of fibre breakage. Number of passes, cylinder speed, wire condition and fibre moisture all count.
STAGE 3Carding
Cylinder and worker rollers separate tufts into individual fibres, clean them and form a web, then sliver.
FOR FIBRE LENGTHTight settings and worn card clothing break fibre, and short fibre leaves the card as waste.
STAGE 4Drawing
Several slivers are doubled and drafted between roller pairs to even out weight and straighten fibres.
FOR FIBRE LENGTHRoller settings must match the fibre length distribution. Settings too wide for short fibre lose control and add unevenness.
STAGE 5Roving
Further drafting with a light twist onto bobbins, ready for ring spinning.
FOR FIBRE LENGTHThe same roller-setting rules apply. Rotor spinning skips this stage.
STAGE 6Spinning
Ring or rotor spinning to the target yarn count.
FOR FIBRE LENGTHShort fibre limits the finest count and the yarn strength. Rotor tolerates shorter fibre than ring, so route and blend are chosen together.
STAGE 7Yarn testing
Strength, evenness and hairiness of the yarn, with fibre length measured at each stage.
FOR FIBRE LENGTHMeasuring length before and after each stage shows exactly where it is lost, and gives evidence for recycled-content claims.
Talk to us about your line.
Feedstock, machinery, or a yarn problem you want solved.