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Winding system of one-step air covering integrated machine

August 15,2023

In recent years, equipment of elastic-covered yarn has gained the significant technological progress and development. Basic air-covering machines from a decade ago have been largely phased out, and even the high-speed air-covered machines from 5 years ago are facing the same problem. Currently, the one-step air covering integrated machine (referred to as the "integrated machine") has become the mainstay equipment for producing elastic covered yarn.

However, these new production methods have also given rise to new issues that equipment designers and users need to carefully analyze and study.

Here, we will analyze the winding system of the integrated machine and subsequently examine the forming of the yarn as well as some adverse cases.

Basic Concepts:

1. Spandex Covered Yarn

Spandex covered yarn consists of a stretched spandex filament as the inner core, which are wrapped or covered in a spiral manner by filaments or staple fiber yarns to form elastic yarn.

Air-covered yarn  (abbreviated as ACY) is a type of spandex covered yarn. It involves simultaneously stretching the external filament and the spandex filament through a specific nozzle and subjecting them to high-pressure compressed air, resulting in yarn with a rhythmic network of periodic air pressure-formed knots.

2. Integrated Machine

The integrated machine refers to the air covering and texturing integrated equipment, primarily used to process polyester and nylon POY  filaments. These filaments are transformed into DTY  filaments through processes like heating, cooling, and false twisting. Subsequently, under the action of compressed air, they are combined with spandex filaments through network nozzles to create elastic air-covered yarn.

Traditional air-covered yarn production involves two processes: Firstly, transforming POY filaments into DTY filaments using a texturing machine. Secondly, using a Basic air covering machine to cover DTY and spandex together.

The integrated machine employs a one-step draw texturing and covering processing technique, combine the two processes into a single piece of equipment. In comparison to traditional air-covered yarn production equipment, the integrated machine offers several advantages:

1. Shorten the process route and production cycle of air-covered yarn, reduce the equipment to occupy the site, the labor intensity and production costs, improve the attached value, and achieve a variety of fiber composite, to improve the comfort of the fabric, softness, bulkiness, functionality, which can form a variety of styles and functions of the fabric products.

2. The all-in-one machine adopts an embedded hardware and software control system to achieve man-machine dialogue for deformation and laminating process settings, which is innovative in terms of reliability, convenience, and quickness compared with the existing secondary forming and laminating machine that is commonly used in China, which relies on the way of changing gears to adjust the process parameters.

3. At present, the production speed of the conventional domestic processing technology is generally not more than 400 m / min, the use of a one-time completion of the elastic air-coating machine, the maximum processing speed of 750 m / min, the production efficiency has been greatly improved.

4. The air-covered yarns produced are well-formed and of a more uniform and consistent quality. At present, Germany Barmag and Japan Kawada's production of integrated machine equipment is in the world's leading position, of which Barmag is the market leader in this field. Domestic Shaoxing Yue Jian, Jiangsu Hongyuan, and other spinning machine manufacturers in the past few years have also developed a bomb covering the integrated machine. Air-covered yarns are mainly used in textile applications, weaving, knitting, sock machines, and so on.

Formation of Integrated Machine Covered Yarn

Yarn formation refers to the process in which yarn passes through the winding system of the integrated machine, forming a certain width, height, and shape on a paper tube. In simple terms, it refers to yarn winding and shaping.

The finished yarn produced by the integrated machine can be formed into two shapes: bi-conical and straight-edge.


The reference dimensions for the two types of winding forms:







65-90 (std:70)

Cone Diameter




Yarn Diameter
















Due to various factors such as processes, equipment, and operations, various forms of poorly formed yarn are often seen. These include spider-web yarn, uneven yarn, tangled yarn, and parallel-striped yarn, among others. Poor formation can lead to difficulties in subsequent weaving processes, and in severe cases, it may even result in impossible to unwind. This not only reduces the efficiency of the manufacturer but also leads to economic losses.

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