The spinning processes are multiple and vary with the characteristics of the fibres to be processed and with those of yarns to be obtained. The different stages of the process are complex and oriented to achieve a high quality yarn, regular, resistant and hairiness minimum.
The first step consists in opening the bales, which are organised to keep the cotton clean and separate and avoiding breakage of the fibres. After the opening of the bales, the cotton is put in chargers for the breaking up into flakes. The flakes cleaned of any external agents are then taken to the carding machine.
Following a further refinement of the flakes, adjustment of the yarn count commences by carding. The fibres begin to be parallel, and creates the first stage: the tape.
At this point two grippers levying few centimeters of the lap (the set of multiple tapes carding), which is then subjected to a series of combs mounted on a cylinder. The very short fibres are removed along with the impurities, while the long fibres are selected, smooth and silky that they look like a more regular tape.
The next step is the pressing, which provides for the fibres to slide mutually on one another in order to arrange them on a volume, a surface or a larger length.
The gradual refinement of the tape then eventually will lead to the obtaining of the yarn. The successive refinements produce the wick, to which is imparted a minimal tension with the aim of creating sufficient resistance for the operations of unwinding without being hindered by the ironing actions. To prepare the wick for the final yarn count desired requires final process of pressing to the extent necessary and finally twisting of the fibres upon themselves.
CONTROLS ON THE YARN
The quality of the finished product is the result of a careful planning in which the choice of raw materials and suppliers plays a fundamental role. The controls in acceptance of the yarn are essential to ensure compliance and consistency of the quality of the fabrics. A greige yarn will only be workable if it passes all the controls: humidity check, the staple length, the twist, strength, elongation and regularity.