• D&W
    Double sided spinning machine, fed by slivers coming from cans


For as long as loop-cut rugs have been produced, plied yarns have been used in order to present balanced yarns to the loom. In the Middle East, where these rugs were originally made in wool, production has grown massively in the second half of the 20th century thanks to technological improvements and, acrylic fiber has taken over where staple yarn used to be used.

The basic yarns for production of these rugs are Nm 10,5/2 or Nm 15/3 and the trend is towardfiner counts and thicker rugs, employing Nm 12/2, Nm 18/3, Nm 19,5/3 or even as fine as Nm 30/3 in the upper end of the market. In the 1980's heat-setting, a system originally studied for adding bulkiness to the yarn used for weaving yarns, also increased the so called visual "point effect" by thermally fixing the coils of the twist on the yarn.

The following is a typical acrylic spinning line for the production of carpet yarns based on Nm 15/3:

  • (a)    Blending + one semi-worsted card;

  • (b)    Three drawing frames for long staple;

  • (c)    One automatic vertical finisher;

  • (d)    Automatic worsted ring spinning frames;;

  • (e)    Automatic winders;

  • (f)    Assembly winders;

  • (g)    TFO twisters (usually 8" package);

  • (h)    Continuous heat-setting.

In 2012 Officine Gaudino S.p.A. developed a new concept for the production of the basic yarn used to produce staple loop-cut rugs. As the yarns have to be heat-set, and therefore the coil of the twist is thermally fixed and stable, the ply yarns are replaced by a single yarn Nm 5 (instead of Nm 15/3), which is reinforced by a flexible binding composed by a ttexturized filament which makes the single yarn with better quality properties compared to the ply yarns (in terms of average strength, CV% of the strength, elongation and CV% of the elongation, thus a better working mass). This process allows great savings in the preparation of the yarn and better efficiency on the loom. As the loop or the single thread is cut on the loom, the filament dissapears from the surface but stays in the depth to increase the resistance from pressure and friction, besides keeping loose fibers stuck to the carpet backing better than regular cut ply yarns. The economics are good on all aspects of production: space, labor, energy,; moreover the cost of the filament is offset by the savings of the waste of yarn from the ply process (especially spinning and winding waste).

The new acrylic spinning line for the production of carpet yarns based on Nm 5/1 would be as follows:

  • (a)    Blending + one semi-worsted card;

  • (b)    Two drawing frames for long staple with can delivery;

  • (c)    One filament winder and sliver fed machines model D&W delivering 4 Kg roving cones;

  • (d)    TFO twisters (10" package);

  • (e)    Continuous heat-setting.

The unique way to make the basic carpet yarn with this new system has been patented, along with the main machine for producing it. The spinning machine model D&W (Draft & Wind) is a double sided machine fed by sliver cans, with a double draft system. The rear draft zone has two rows of soft rubber control barrels and the second draft zone is provided with a double apron system. Feed, draft and delivey rollers are of large diameter (45 - 51 mm). The feed roller of the rear draft zone can be moved by means of a wheel. The sliver weighs 15 to 20 gr/m is fed to a creel and goes to a draft area (photo).

The roving coming out of the draft area is wrapped by a texturized filament, goes through a hollow spindle (photo), a pre-tensioning roller, a deviating roller (photo) and is wound onto large cylindrical cones weighing 4 kg (acrylic fiber) located on two decks (photo). The delivery speeds of this machine are 100 - 120 mt/m. The content of texturized filament on the hollow spindle is up to 480 gr. The machine stops automatically when one end breaks. A "Pneumafil" system is provided for the broken ends. A manual splicer (optional) can be provided for joining broken ends. The hollow spindle is supplied with a special "anti-fuzz" device that prevents the formation of loose fibers on the filament balloon in the wrapping position.

The head stock is electronically driven: the draft, delivery rollers, the pre-tensioning rollers and the delivery drums are driven by brushless motors, the hollow spindles are driven by an AC motor controlled by an inverter, with a tangential belt. Each hollow spindle can be stopped and tilted, in order to change the flanged bobbin. All spinning parameters are set on a touch-screen panel, located on the drive head-stock.