Multiple Benefits of Fiber Crimping Process for Spinning: From Raw Material Optimization to Quality Upgrade

In the chain of the textile industry, fiber pretreatment process is a key link connecting raw materials and spinning production. As one of the core technologies in this process, the fiber crimping process has a profound impact on the smoothness, efficiency of the subsequent spinning process and the quality of the final product. From the physical modification of natural fibers to the structural design of chemical fibers, the crimping process brings a series of irreplaceable advantages to the spinning process by changing the morphological characteristics of fibers.​

Enhancing fiber cohesion and reducing spinning breakage rate is the most direct contribution of the crimping process. Untreated straight fibers have smooth surfaces and low friction between fibers, which are prone to slip and separate in spinning processes such as carding and drawing, resulting in loose fiber bundles and increased risk of breakage. However, fibers after crimping treatment form regular wavy or spiral crimp structures on their surfaces, which significantly increases the contact area between fibers and enhances the “anchoring” effect of mutual occlusion. This improvement in cohesion enables fibers to maintain a stable aggregated state during the drafting process, reducing breakage caused by fiber slippage. Especially in high-speed spinning equipment, the anti-slip ability of crimped fibers is more prominent, which can reduce the breakage rate by more than 30% and significantly improve production continuity.​

Improving fiber evenness and optimizing yarn structure is another important value of the crimping process. Evenness is a core indicator to measure yarn quality, directly affecting the appearance and performance of fabrics. Crimped fibers can form a more uniform fiber web during carding. Their crimp structure makes the arrangement of fibers closer and more elastic, reducing gaps and weak points in fiber bundles. In the drawing process, the elastic recovery force of crimped fibers helps to offset the uneven tension during drafting, making the output sliver more uniform in thickness. This improvement in evenness not only reduces thick and thin places in the yarn but also improves the flatness of the fabric surface in the subsequent weaving process.​

Enhancing fiber spinnability and expanding the application range of raw materials is an important expanding role of the crimping process. Some natural or chemical fibers are prone to difficulties in direct spinning due to their own structural characteristics, such as short length, smooth surface, and poor elasticity. After modification treatment of these fibers through the crimping process, their cohesion, elasticity, and softness are significantly improved, and spinnability is greatly enhanced. For example, after crimping treatment, short-staple cotton can meet the spinning requirements of medium and high-count yarns; regenerated cellulose fibers can achieve efficient blending with synthetic fibers such as polyester and nylon by optimizing crimp parameters. This not only improves the utilization rate of low-quality raw materials but also provides more possibilities for the development of new functional yarns.​

Reducing spinning energy consumption and improving production efficiency is the embodiment of the crimping process in terms of economy. The good cohesion and elasticity of crimped fibers make fiber drafting in the spinning process smoother, reducing the number of shutdowns caused by breakage, roller winding, and other problems. At the same time, the crimp structure reduces the tension required for fiber drafting, lowering the power consumption of the equipment. Statistics show that spinning with crimped fibers can increase the effective operation rate of equipment by 10% – 15% and reduce energy consumption per unit output by 8% – 12%, significantly improving the economic benefits of spinning production.​

To sum up, through improving the physical properties and structural characteristics of fibers, the fiber crimping process plays a key role in improving spinning quality, enhancing spinnability, and increasing production efficiency. With the continuous development of textile technology, the parameter optimization and intelligent control of the crimping process will further tap its potential, providing strong support for the high-quality development of the textile industry.