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Advancements in Elastic-Covered Yarn Production: Exploring All-in-One Machines

Time : 2024-04-23 Hits : 7


In recent years, significant technological advancements have occurred in the equipment for elastic-covered yarn production. Ten years ago, traditional air-covered machines were nearly obsolete, and five years ago, high-speed air-covered machines faced a similar fate. Today, all-in-one machines, combining elastic and covering functions, dominate elastic-covered production.


However, these new production methods introduce new challenges, necessitating careful analysis by equipment designers and users. Let's delve into the winding system of the all-in-one machine, examining the rolling forms and potential issues.


Spandex mechanical covered yarn consists of an inner elastic core filament (spandex) and an outer synthetic filament. It is produced by spirally wrapping stretched spandex around the core filament. Air-covered yarn (ACY), a type of spandex-covered yarn, is created by drawing outer fiber filament and spandex yarn through a specific nozzle simultaneously, forming a rhythmic network of yarn spots through compressed air injection.


The all-in-one machine, used for POY of polyester or nylon, combines the processes of heating, cooling, false twisting, and spandex yarn covering into one machine. This streamlines production reduces labor and costs, and enhances fabric comfort, softness, and functionality.

Compared to traditional air-covered yarn production, the all-in-one machine offers several advantages: shorter process routes, reduced production cycles and costs, improved fabric attributes, and enhanced production efficiency. It utilizes embedded hardware and software control systems for efficient man-machine dialogue, setting it apart from conventional equipment.


Currently, the maximum processing speed of all-in-one machines reaches 750 m/min, significantly boosting production efficiency. These machines produce well-formed, uniform yarns of consistent quality. Leading manufacturers like Germany's Barmag and Japan's Kawada dominate this field, with domestic manufacturers also making strides.


Covered yarn forming, crucial for producing uniform yarn rolls, can be achieved in two ways: bi-conical and straight-edged forming. However, various factors such as processes, equipment, and operations can lead to poorly formed filaments, including spider web silk, bumpy silk, messy silk, and parallel silk. Addressing these issues is essential to maintain production efficiency and prevent economic losses.


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