11. Spindle bands.
12. Sifter plate or rail.]
Worsted yarn is spun by two different methods known respectively as the Bradford or English system and the French system. The difference in these systems of spinning worsteds lies principally in the drawing and spinning processes, a radically different class of machinery being used for each. The combing process is practically the same in both cases, but the wool is combed dry for the French system, and by the English method the stock is thoroughly oiled before being combed. The result of the English method is the production of a smooth level yarn in which the fibers lie nearly parallel to each other. The yarn made according to the French system is somewhat fuzzier and more woolly. On account of the absence of oil, the shrinkage of French spun worsted is considerably less than that made by the Bradford system.
=Characteristics of Worsted Yarn.= The unique structure of worsted yarn makes it invaluable in the production of textile fabrics in which luster and uniformity of surface are the chief characteristics. The methods by which worsted is formed render it capable of sustaining more tension in proportion to its size than the pure woolen yarn. This feature, combined with its lustrous quality, gives it a pre-eminent position in the manufacture of fine coatings, dress goods, etc. The method of arranging the fibers in the formation of a woolen yarn is such as to produce a strand with a somewhat indefinite and fibrous surface, which destroys to a large degree the clearness of the pattern effect in the woven piece. In the construction of worsted yarn the fibers are arranged in a parallel relationship to each other, resulting in the production of a smooth, hard yarn having a well-defined surface; hence weave-ornamentation of a decided or marked type is possible by its use. There is, in a word, more scope for pattern effects, since the level and regular structure of the yarn imparts a distinction to every part of a woven design. From this peculiarity arises the great variety of effects seen in the worsted dress fabrics, coatings, trouserings, etc., both in colored patterns and in fabrics of one shade throughout.
[Illustration: SPOOL ROOM
1. Jack Spooler frame.
2. Drum upon which Jack Spool rests.
3. Jack Spool.
4. Guides for spool ends.
5. Spools containing yarn.
6. Pressers which rest on spools to prevent slack ends.
7. Spool creel.]
[Illustration: FRENCH SPINNING
1. Balling heads.
2. Bobbins upon which stock is wound.
3. Rub or condenser aprons.
4. Gearing for driving rub motion.
5. Shipper rod and handles.
6. Bobbins held in place in creel by skewers.
7. Weights with system of levers for applying pressure to rollers.]
Worsted yarn can be made of pure wool; and as a rule, the wool used in the English system is of fairly good length and uniform staple, for if otherwise it is only with difficulty that the yarn can be spun straight. Shorter wool can be combed and spun under the French system, and this is the reason why the French system of spinning is being introduced. On the other hand, in the spinning of woolen yarns great length of staple is not essential, for the machinery employed will work the small fibers.
=Uses of Worsted Yarn.= Worsted yarn may be used in any of the following fabrics:
1. Combed wool yarn for ornamental needlework and knitting, as Berlin, Zephyr, and Saxony wools.
2. Cloth made from combed wool not classified according to material.
_a._ Fabrics of all wool--serge, bunting, rep, dress goods, with weave effects.
_b._ Wool and Cotton--union goods, serge linings, lathing.
_c._ Wool and Silk--rich poplin, pongee, henrietta, bombazine.
_d._ Alpaca and Mohair--alpaca, mohair dress goods, lusters, braids, laces.
=Counts.= Yarn is measured by a system of "counts"--the number of yards of yarn to the pound. The counts of worsted yarn are based on the number of hanks in one pound, each hank containing 560 yards. Thus No. 30 worsted yarn consists of 30 hanks of 560 yards each, or 16,800 yards to the pound.
FOOTNOTES:
[12] The distinct difference between worsted and woolen yarns is that worsted yarn is made of fibers that are parallel, while the fibers of woolen yarn run in all directions. The worsted yarn is stronger.
[13] Mills that manufacture worsted yarn.
CHAPTER V
WOOLEN YARN
In manufacturing worsted yarn every necessary operation is performed to arrange the wool fibers so that they will lie smoothly and parallel to each other. In the case of woolen yarn every operation is performed so as to have the fibers lie in every direction and to cross and overlap each other.
To produce yarn of the woolen type a set of machinery entirely different from that used in worsted manufacture is necessary. The wool is carded, but no attempt is made to get the fibers parallel. The reduction in thickness of the sliver is not brought about upon the so-called drawing frame, but by a mule frame where the drawing and twisting are done at the same operation. As neither combs nor gills are employed, there is not the same smooth, level yarn, but one which possesses a fringe-like covering or fuzzy appearance that makes the woolen yarn so valuable.
The operation is as follows:
=Carding.= After washing the material for woolen yarn, it is passed through three carding processes, and from the last of them is taken direct to the spinning frame to be made into yarn. The object of woolen carding is different from carding in any other textile manufacture.
In most processes of carding the fibers are subjected to a "combing"
principle, and the aim is to lay the fibers parallel. Woolen carding aims to open the raw wool fiber, and put it in a perfectly loose condition, without leaning toward any definite arrangement.
The carding machines are called, respectively, first, second, and third breaker. Each machine consists of a complicated series of card-covered cylinders of different sizes, running at different rates of speed--sometimes in the same and sometimes in an opposite direction. These rollers take the wool from one another in regular order until it is finally delivered from the third breaker in a soft, fluffy rope or roll called a sliver. This sliver is wound on a bobbin, and taken from the card to the mule spinning frame.
The sliver on the bobbins from the card is taken to the mule spinning frame where it is passed through rolls, and the sliver attenuated by means of a traveling carriage.
=Count.= In the case of woolen yarn there are numerous systems for denoting the count, varying with the locality in which it is spun and the character of the product. In the United States there are two systems employed, but the one in most general use is known as "American run counts." This is based on the number of "runs," each containing 1,600 yards to the pound. Thus, a yarn running 8,000 yards to the pound is called a 5 "run" yarn, a yarn with 5,200 yards to the pound is equal to a 3-1/4 "run."
In the vicinity of Philadelphia woolen yarn is based on the "cut,"
each cut consisting of 300 yards, and the count is the number of cuts in a pound. Thus, No. 30 cut yarn consists of 9,000 yards to the pound. No. 15 contains 4,500 yards to the pound.
Woolen yarn is suitable for cloths in which the colorings are blended and the fibers napped, as exemplified in tweed, cheviot, doeskin, broadcloth, beaver, frieze, chinchilla, blanket, and flannel.
CHAPTER VI
WEAVING
=Preparatory to Weaving.= Yarn is wound on bobbins on the ring or mule spinning frame. These bobbins are transferred to a machine called a spooler where the yarn is re-wound on a spool preparatory to making the warp.
A warp is formed by obtaining a definite number of threads (called ends), usually in a precisely designed order of given length, and allowing the ends to wind over a cylinder called a beam. In order to do this it is necessary to have spools placed in a definite position in a frame called a creel.
Before the warp can be placed in the loom so as to weave or interlace it with filling it must be sized. This is necessary for all single twist warp yarns. Its primary object is to increase the strength and smoothness of the thread, thus enabling it to withstand the strain and friction due to the weaving operation. Other objects of sizing are the increase of weight and bulk of the thread and the improvement and feel of the cloth. The warp is usually sized by passing it over a roller and through a bath of a starch mixture. The machine for sizing is called a slasher. The warp is now ready to have the ends drawn in and placed in the loom.
=Weaving.= Every woven piece of cloth is made up of two distinct systems of threads, known as the warp and filling (weft), which are interlaced with each other to form a fabric. The warp threads run lengthways of the piece of cloth, and the filling runs across from side to side. The manner in which the warp and filling threads interlace with each other is known as the weave. When the word "end"
is used in connection with weaving it always signifies the warp thread, while each filling thread is called a pick. The fineness of the cloth is always expressed as so many picks and ends to the inch.
The fabrics produced by weaving are named by the manufacturers or merchants who introduce them. Old fabrics are constantly appearing under new names, usually with some slight modification to suit the public taste.