Does Spun Yarn Need Assembling/ Doubling ? No

Why is that  2 to 3 yarns of single end are assembled and then doubled before taking into the Twisting Machine ?

Say, 40s yarn of 2 ends are assembled and then made 40s/2 and made 20s count and twisted with desired twist.  Why not simply spin 20s count and give the desired twist. Much higher productivity on 20s and say the same result in twisting as 40s/2.

Assuming, there was comparatively lower strength or lower uniformity. But then for double yarns, these are still acceptable limits.

In the Filament Industry, yarns are directly twisted say 150 denier is directly twisted to 200 TPM or 300 or 600 TPM as the case may be . Only in certain cases, where plied yarns are required for special applications, the plied yarns are used like in Nylon Sewing Threads.

Generally speaking, atleast for coarse yarns, there is no need of assembling and then twisting. These can be directly spun and directly twisted. Much lower cost of manufacturing and almost the same results.

Will we stand up and start questioning our systems and methods laid out in the 18th century.

Double Pick Yarns

In case of making of Twill fabrics, one of the easisest ways of inserting two picks into the fabric would have been Double Pick Yarns, then inserting two picks , one after another.

The Double Pick Yarns can be easily made on a doubling machine , however, will require some special cutting on the drums to ensure that the two yarns are laid side by side on the cone. It should in no way wrap up with one another. In case of precsion winders, it would need two seperate slots on the guide finger , laying two yarns onto the cone at the same time side by side.

The Double Pick Yarns will then Double the Production in weaving and there will be a fully new kind of product which will now be available in the market.

Both the machine makers and the Industry will have to reorient itself, if they want to innovate and see the fruits of lateral thinking.