How to reduce the hairiness and ends breakage of wool blended yarn during weaving

Wool blended yarns are widely used in the apparel and home textile industries because they combine wool's natural warmth with the performance advantages of blended fibers. However, during the weaving process, excessive hairiness and frequent ends-off yarn breakage directly impact fabric quality and production efficiency, becoming a pressing challenge for the industry.

Optimizing Fiber Raw Materials and Improving Fiber Quality Consistency
The root cause of hairiness and ends-off yarn issues in wool blended yarns often lies within the raw fiber itself. Wool fibers with uniform fiber length and moderate crimp contribute to a dense, smooth yarn structure. Blended fibers such as polyester and acrylic should be selected with fiber lengths that match the wool to avoid significant fiber length discrepancies that can cause yarn hairiness.
Fiber quality uniformity is also crucial. Low-quality wool contains a high concentration of short fibers and impurities, which can easily cause ends-off yarn breakage during spinning. Using modern grading and impurity removal equipment to strictly control the proportion of short fibers in the raw wool can significantly reduce the risk of yarn breakage.

Optimizing Spinning Process Parameters to Ensure a Dense Yarn Structure
The spinning process significantly impacts the hairiness and ends-off yarns of wool blended yarns. Combing effectively removes short fibers and impurities, improving yarn uniformity and strength while reducing hairiness.
Twist is an important indicator of yarn density. Properly increasing twist strengthens fiber bonds, reduces loose and exposed fibers, and thus reduces hairiness and end-of-life. However, excessive twist can make the yarn too stiff, affecting both hand feel and subsequent processing. It should be adjusted appropriately based on the specific blending ratio and intended use.
Controlling the tension and speed of the spinning machine maintains a balanced fiber tension to prevent yarn breakage. Modern intelligent spinning equipment is equipped with online monitoring systems that detect end-of-life in real time and adjust process parameters promptly to improve overall stability.

Optimizing the weaving process reduces yarn stress. During the weaving process, yarns are subjected to multiple mechanical stresses, including tension, friction, and compression. Properly adjusting loom tension and weaving speed is a key measure to reduce hairiness and end-of-life.
Reducing weaving tension reduces relative movement between yarn fibers and reduces hairiness caused by friction. Improved loom lubrication systems can also effectively reduce friction between yarn and machine parts, extending yarn life.
Excessively high weaving speeds increase the risk of yarn breakage and should be adjusted to a reasonable range based on yarn properties to ensure a balance between production efficiency and quality.
Use anti-static equipment to reduce static electricity accumulation, which causes yarn fibers to attract dust and repel each other, increasing the risk of yarn breakage.

Scientifically apply finishing processes to improve yarn surface properties.
Post-weaving finishing processes are equally important for controlling hairiness and yarn breakage. Softening and anti-hairiness finishing processes can form a protective film on the fabric surface, reducing fiber exposure.
Use finishing agents and coatings suitable for wool blends to enhance fiber surface bonding and reduce fiber shedding during yarn penetration and friction.
Precise temperature and time control during washing and drying processes is crucial to avoid high temperatures and excessive mechanical forces that can lead to fiber brittle breakage.
The application of nanotechnology offers new avenues for yarn surface functionalization. For example, nanocoating can significantly enhance yarn abrasion resistance and anti-hairiness.