Indian Journal of Fibre & Textile Research

Vnl. 17. Dec<:mhcr 1992. pp. 263-266

Recent developments in two-for-one twisting and their relevance to Indian

textile units
R G PatiL A K Agrawal. K A Patel & J M Grover
A hm<:dahad Textik Industry's Researc h Association. Ahmedabad JXO (lIS. Indi a
Received 6 April 1992

T"'o -for-one t\\'isters ha ve gained wide acce ptance in the international as well as in the Indian market s.
This paper oescribes the recent developments, including th ose exhibited at ITMA-91 . in TFO twi ste rs and
their relevance to Indian tex tile units. The developments are mainly in the application areas . machine
producti vity. refinement in the functional parts. automation and process control instrumentation. and
environmental compatibilit y of the machines . A cost comparison of twi sting on low-cos t co mpletely
indigeno us machine and high-cost but high productivity machine is also made .
Keywords: Automation . Two-for-one twisting. Machine productivity, Pneumatic threading

I Introduction
The two-for-one '(TFO) twisters have the
following inherent advantages over the ring twisters:
(i) production oflong lengths of knot-free yarn which
facilitates better performance in subsequent
processes; (ii) higher productivity per spindle, about
twice that of ring twisters; (iii) fewer pre- and
post-twisting operations as compared to that in
ring-twisting process; and (iv) low manpower
requirements. However, as the TFO machines are
capital and energy intensive, the production cost per
kg of doubled yarn is higher compared to that on
ring-doublers in India. Even so there is demand for
TFO twisted yarns mainly from the synthetic spun
yarn sector and from the exporters of cotton yarns,
where the buyers are willing to pay extra price for the
knot-free long lengths.
The concept ofTFO twisting was first mentioned in
a British Patent in 1855. The practical exploitation
came in 1930s for filament yarns 1 and in 1950s for
spun yarns. Till then, there was neither market
pressure for the long lengths of knot-free twisted yarn
nor the technology was sufficiently developed . TFO
twisting entered India in early 70s and the
manufacture ofTFO twi sters started in late 70s, when
a t.extile machinery manufacturer developed
indigenous TFO twister with the assistance of South
India Textile Research Association (SITRA),
Coimbatore. This machine had certain limitations in
speed. applications, etc. In the early 80s, Volkmann
GmbH (Germany), a world leader in TFO twister
manufacturing, started the manufacturing activities

in India in a Joint venture. At present, four

manufacturers make TFO twisters in India.
This paper describes the developments in TFO
twister for spun yarns on the international scene. The
relevance of these developments to Indian textile
units is indicated in each case.
2 Developments in TFO Twister
The developments that have taken place during the
last decade in the TFO technology can be classified
under the following areas:
Application areas
Machine productivity
Refinements in functional parts
Handling aids, automation and process control
instrumentation
Environmental compatibility of the machine.
2.1 Wider Applications

The possible applications are governed by the

design of the machine, mainly those of spindle zone
and feed package assembly. With the improvements
in these functional parts, TFO twisters can now also
be used to twist the following yarns :
Synthetic fibre spun yarns
Open-end yarns
Air-jet yarns.
Twisting of synthetic spun yarns on TFO machine
became economical mainly due to the incorporation
of on-line lubricating system which facilitates
twisting at high speeds without impairing the yarn
quality. Suitable redesigning of feed-package

264

INDIAN J. FIBRE TEXT. RES., DECEMBER 1992

Table I- Co mpa ra tive twisting cos ts on T FO A and TFO B

Efficiency

TPI

Co.unt

"A,

Spindle
speed
rpm

Twisting cos t". Rsfl OOO kg prod uction/shift

Power

Labour

Stores

Sub-t ota l

Capit<l l

Total

2263
54 10
9442

TFO Type A
21105
2/ 20s
2/30s
2/40s

1119

154

7A

1347

916

368
450

177
3 16

3220

2190

9000

2675
4770

9000

7 170

676

474

5536
8320

3906
5871

141 9 1

IOl)O

13 7
276
289

66
133
203

1293

2 195
3359

2606

1901
2875

3 194
548 1

5048

434

305

3851
5787

4394
6604

8245
1239 1

10.6
14.4
17.3

95
96

8000
9000

97

19.5

97

10.6
14.4

95
96

TFO Type B
2/ IOs
2/ 205
2/30s
2/40s

17.3

l)7

9000
12000
140()0

19.5

97

14000

"Calcu l<l ted with the following ass umpti on:

Power requirements
TFO A
TFO 13
Powe r factor
Load fact o r
Powe r cos t

189 W/spind le
207 W/spindle
0.95
0.75
Rs' 1.90 per kWh

Wage rate
Stores cos t
C<l pita l cos t
TFO A
TFO B
Interes t rate
Depreciation

ISr------------------------------------,
14
13
12
-

II

"ca

10

~
o

9
6

.g-

TFO A

o Produc1 lon cosl

+ Capilal cosl
0 Total cost
TFO B
Produc t ion cost
xCopilol cosl
vTotal co!>t

Rs 85 per day
Re 0. 15 per spindle shift
Rs 6000/spindle
Rs 10500/spindle
20%
12%

The change in twi stin g costs by using a low-cost

indigenous machine (TFO A) a nd a high-cost
imported machine or an India n machine with
imported critical components (TFO B) is shown 1n
Ta ble I and Fig. I. It may be observed that the twisting
cost for counts beyo nd 2/20s is compa ratively low~ r
on B type of TFO twi sters due to higher
producti vi ty.

a:

2.3 Refinements in Functional Parts

OL-L-________- L__________L -________

21105

21205
Count, Ne

2/305

-L~

21405

Fig. I- Twistin g cost ( Rs per 1000 kg production per shi ft) o n

TFO A a nd TFO B twisters

formats has resulted in acceptance of the open-end

and air-jet spinning packages on TFO twi sters.
2.2 Higher Machine Productivit y

In the internationa l ma rk et, TFO twisters with

mechanica l speed s of up to 15,000 rpm a re ava ilable
but in India TFO twi ste rs with mechanica l speeds o f
up to 10,000 rpm are being manufactured
indigenously with all indigenous components.

In the last o ne decade , commenda ble

impro vements have been made in some of the
functional pa rts of TFO twi ster toward s reduced
energy consumption, lowe r noise level, gentl e
handling of ya rn , lon ger life (less wear and tea r), etc.
The salient improvements are discussed below:
2.3.1 Spindle and Feed Zone"

(i) Qptimization of the shape a nd dimensions of

the spindle di ameter for minimi zing twi sting costs
through reduced energy consumption, labour
complement, etc.--the number of models offered by
leading manufacturers is large to suit the va rying
requirements, e.g. Volkmann offers a bo ut 10 model s
"The na mes of the ma nufacturers <I re given here to illustr<lte th e
point. As a policy. A TI RA does not recommend <l ny
manufacturer or suppli er.

PATIL et af.: TWO-FOR-ONE TWISTING

with 6 different spindle specifications to cover counts

from? 11.2s Ne to 2/ 118s Ne and Savio offers about 13
models with 7 different spindle specifications.
The energy requirement , as claimed by one of the
manufacturers, is about 115 W per spindle for
twisting 2/50s yarn at 12,000 rpm with 1300 g feed
package and about 155 W per spindle for twisting
2/ 20s yarn at 8750 rpm with 2300 g feed package.
The indigenous machines are available in limited
ranges and hence limiting the choice available to user
for minimizing twisting costs. One leading
manufacturer, offers only 2 models, each with
different spindle diameter. However, another leading
manufacturer, with foreign collaboration , offers 6
models with 4 different spindle specifications.
However, in India , the users prefer to have a
versatile machine. This thinking needs to be
re-examined.
(ii) Acceptance of much wider feed package
formats like two separate single-end packages, thus
eliminating assembly winding, and of denser
precision wound assembly packages which result in
lower ends down and also in reduction of
labour- Redesigning of feed package assembly has
permitted quick adoption ofTFO technology to the
developments in spinning, specifically the open-end
spinning and the air-jet spinning, and also to the
automation in the processes.
Some of the machines are designed to accept
assembly wound packages of traverse as high as 254
mm or two single packages of traverse 152 mm
(2 x 152 mm), which is equivalent to a feed package
weight of about 4500 g, depending on yarn count,
material, etc.
Most of the indigenous machines are lacking in this
area and also many users are reluctant to adopt two
single-end feed packages. The slow adoption of
single-end feed packages is mainly due to: (i) the
difficulty in maintaining identical lengths of yarn on
feed packages which otherwise result in higher yarn
waste, (ii) the higher end-breaks due to greater
variation in tension, and (iii) the difficulty in piecing
due to larger feed package assembly.
(iii) Provision for unwinding aids like 'floppy
discs' between two single-end feed packages or on top
of the upper package to reduce tension peaks and to
prevent snarling.
(iv) Redesigning of tensioning devices to suit the
pneumatic threading.
(v) Coating of protection pot with low friction
material. This ensures minimal damage to yarn even
at high speeds.

265

2.3.2 Winding Zone

Winding of take-up packages to suit different end

uses , e.g. soft wound package to suit dyeing.
2.3.3 Drives

Redesigning of driving systems mainly (i) to

enhance the versatility of the machine, e.g. double
gear system to facilitate independent driving of the
two sides and driving of different shafts individually
using low power motors which facilitate quick
adjustments in machine parameters, and (ii) to suit
the changing designs of TFO machines, e.g. long
length machines with about 372 spindles . These
machines are equipped with two motors to drive each
side individually.
2.4 Handling Aids, Automation and Process Control Instrumentation

The developments in the area of automation , ease

of operation, process control systems, etc. have been
dramatic in the international scenario . However,
most of the indigenous TFO twisters have remained
virtually unchanged in these areas since their
introduction. Some of these recent developments are
as follows :
2.4.1 Pneumatic Threading

Traditionally, threading in case ofa end-down is

performed using a plastic leader. This operation,
though simple on machines having smaller feed
packages, becomes cumbersome and time consuming
with the larger packages. Incorporation of
pneumatic threading simplifies the operation and
also saves operators time. The pneumatic threading
system may be either an integrated system with the
machine or a portable one serving many spindles. The
system works either on blowing principle or injector
principle. Pneumatic threading offers an added
advantage in the form of forced cleaning of the inside
of the spindle by the air current. This is particularly
advantageous while processing rotor-spun yarns.
Owing to the poor techno-economic returns from
the system of pneumatic threading in India, this
system is not popular. Howevcr, the adoption of
larger feed packages/ two single feed pakages,
increase in wage rates, etc. may necessitate the
simplification of piecing operation by suitable
means.
2.4.2 Material Transport Aids

(i) Tak e-up package cOllveyer helt: In the TFO

twister meant for coarse yarn twisting, take-up
pakages sometimes measure up to 350 mm in
diameter and 250 mm in traverse length . Manual

266

INDIAN J. FIBRE TEXT. RES., DECEMBER 1992

ha ndling of these heavy packages becomes

pro blematic. Hence, such mac hines are often
provided with a conveyer belt between the two rows of
take-up packages and the package holders are such
that after opening the spindleless holders, the
package has onl y to be rolled back onto the belt. At
the end of th e machine, the belt delivers the packages
into a transfer device, which puts the full twisted yarn
packages into the transport containers.
(ii) Feed-package conveyer belt: This a utomation
equipment links the preceding processes,e.g. winding
with the TFO twisting. The modern spinning systems,
viz. OE spinning and air-jet spinning, which deliver
large single packages, can be easily linked to TFO
machine by using bobbin conveyer system. One of the
bobbin co nveyer systems offered by Volkmann in
associa tion with Schlafhorst can select the single
packages originating from the same winding position
and then deliver to the individual twisting position on
TFO machine 2 .
2.4.3 Package Transfer Robots

Recently , some of the manufacturers like Murata,

Saurer-Alima and Volkmann have demonstrated the
use of package tran sfer robot for loading and
unloading of packages. The prototype robot
ex hibited by Mura ta can replace full package with
empt y tubes and string up the thread.
2.4.4 Process Data Collection System

Data collection systems help in the production

control. ' Volkotronic', a system supplied by
Volkmann, collects data from various machines and
thi s can be evaluated from a central point. The ' BDE'
system of Sa urer-Alima monitors individual
spindles also for the end-breaks, feed package
changes, etc. a nd the data cqn be called upon a
terminal provided on the machine.
At present, none of the indigenous TFO twisters
are equipped with d a ta collection systems. It is
desirable to equip TFO twister with these systems
since they provide vital information essential for
better process control.
2.5 Environmental Compatibility (If the Machine

The present machines are environment-friendly in

the sense they have better noise control, dust control
and ambient climate control equipments.
2.5.4 Noise Control

Several technical improvements have contributed

to reduction in noise. Some of these are:

(i) Suppressing or reducing the noise at its point of
origin by design meas ures like specia lly engineered
sp indle bea rings, spindle drive mech a nism , etc.
(ii) Preve nting the propaga tion of noise by
measures like encapsulating the machine parts, use of
noi se a bsorbing ma terial s, etc.
(iii) Use of balloon limiters which reduce noi se
levels by about 5%; the a pplication of balloon
limiters has been extended to synthetic yarns beca use
of efficient on-line lubrica tion system .
2.5.2 Dust and Ambient Climate Control

Fly a nd dust are generated during twisting. Also ,

heat is dissipated at spindle and other machine part s.
The heat dissipated at spindles ranges from 100 to 300
W depending on speed and yarn count. Some of the
measures provided on the new generation machines
are:
(i) Use of travelling blowers which blow and/or
suck the fly deposited in the vicinity of the twisters.
(ii) Provi sion of an air conditioning unit
integra ted with the machine: thi s can effectively
maintain the ambient humidity a nd temperature and
also keeps the machine clean.

3 Conclusion
The devel opments in the two-for-one twi sters are
mainly in the area of increasing productivity, keeping
the twi sti ng costs low by the proper selection of
machine specifications a nd simplification of
operations; a nd automation and process control
instrumentation . The developments in automation
are intended to sati sfy the market requirements in the
developed countries.
In India, some of the developments rel ating to
higher productivity, wider application range, and
simplification of operations need to be adopted in the
machines having majority of components
manufactured indigenously. Al so, to enter into the
field of export ofTFO twisters, incorporation of some
of the advanced developments like pneumatic
threading as well as making the machine compatible
to adapt to further automation are essential.

References
I Lorenz R R C. Texl Prog. 16(1 /2) (1987) 3.
2 Anon. Volkmann T F 0 twisters with Schlafborst Autoconer
238. Spinning/ TlVisling/ Winding Year Book (CTI), 1989.36.
3 Brochures of Various TFO Twister Manufacturers.