Challenges in yarn manufacturing due to high humidity, high temperature, and low air quality

Spinners face several operational and quality-related challenges due to high humidity, temperature, and low air quality. These factors can significantly impact fiber behavior, machine efficiency, worker health, and overall productivity. Here is a breakdown of the challenges and suggested strategies to mitigate them:

Challenges due to temperature rise

Problems

• Reduced machine efficiency: Motors and bearings overheat, causing more breakdowns.
• Fiber damage: Excess heat can dry out or alter the natural properties of cotton or synthetic fibers.
• Worker fatigue: Leads to reduced concentration and higher error rates.

Mitigation strategies:

• Install industrial cooling systems (HVAC or spot cooling).
• Use heat-resistant lubricants and components in machinery.
• Shift-based scheduling to avoid peak heat hours and reduce worker fatigue.
• Roof insulation and reflective paints to lower ambient temperature inside mills.

Challenges due to high humidity

Problems

• Fiber swelling and stickiness it’s especially problematic for cotton, leading to inconsistent yarn formation.
• Static electricity issues are reduced, but excessive moisture leads to machine corrosion.
• Doffing and drafting inefficiencies due to sticky fibers.
• Mold/mildew risk in storage areas.

Mitigation strategies

Maintain optimal relative humidity (RH) at 55 –65 per cent for cotton spinning.

• Install dehumidifiers and climate-controlled zones around sensitive machinery.
• Use hygrometers and automated humidity controllers to monitor real-time conditions.
• Adopt better ventilation systems to balance humidity without drastically altering temperature.

Challenges due to poor air quality

Problems

• Fly and lint accumulation affects machinery performance and yarn quality.
• Respiratory health issues for workers due to long-term exposure
• Dust buildup causes electrical and fire hazards.

Mitigation strategies

• Install high-efficiency air filtration systems (HEPA filters) in spinning halls along with frequent air exchange systems (exhaust fans, blowers).
• Regularly clean ducts and workspaces to prevent fly build-up.
• Acquire personal protective equipment (PPE) like masks for workers.

Cross-cutting strategies

To reduce operational costs, spinners can implement the these strategies…

• Install automated environment monitoring systems for temperature, RH, and air quality.
• Upgrade energy-efficient infrastructure to improve airflow and reduce thermal load.
• Organize training sessions for floor staff to identify and report environmental issues quickly.
• Install green walls or indoor plants (where feasible) to improve air quality and reduce indoor heat.