How Cotton Yarn is Made into Yarn Cones & Yarn Balls


Today, join me to learn how Cotton Yarn is
made into yarn skeins. Join me for the behind the scenes front seat
with Spinrite Yarns, the leading manufacturer of Lily Sugar’n Cream and Bernat Handicrafter
Yarns that you see on store shelves today. Yarn goes to Spinrite already spun and in
large hanks of yarn. I’ve have already shown you the process
of dying to get those beautiful rich colours that you see with Lily Sugar’n Cream and
Bernat Handicrafter. Refer to our How it’s Made Episodes to see
that process as it’s really neat. We will start from the point of the natural
cotton that has been washed and dried and the dyed cotton has been dried that has emerged
from the Dye House inside of Spinrite Yarns. The yarn has gone through it’s preparation
of being prepared for the winding area. Unlike acrylic or other blends, cotton doesn’t
need to go through steaming before going to the yarn package. Cotton doesn’t expand with steam as it’s
at it’s final tension. It’s a natural product that doesn’t stretch. If you crochet something with it, it’s not
the yarn that is stretching, it’s the stitches that are stretching. It’s why items like bags and much more can
be made with cotton for strength. Cotton is also heat resistant and tough. It can scrub those dishes. It can be the hot pad that separates that
hot dish from the surface of a table. It’s great for the kitchen. It can be tossed into the washing machine
and dried without a problem. Going back to the yarn, the yarn is still
in large hanks and needs to be prepared before it can go to the yarn ball. The yarn can take one of two journeys through
the factory. Both Journeys start as a large hank on a swift
that will wind it into a manageable cone. This is where the journeys can divide. Journey One may be a direct yarn cones right
from the hank. A cardboard cone is inserted onto the machine. The yarn cones are lying on their sides and
auto feeding the yarn by the rotation of the cone. The cones will continue to rotate until it
hits his required size and then stop. The operator will then come back to the machine,
remove the cone and reset with a new cardboard cone and start the machine. The operators are monitoring many at the same
time. Once they remove the cone, they will put on
the label and it’s ready to ship to a store. Journey Two, on the other hand, could be that
the same winder that is making the retail cones but is actually making industrial cones. These cones can be massive and hold lots of
yarn balls worth of yardage per cone. The large cones are being made the same way
but with reusable plastic cones inside that are recycled back to this station at the end
of the process. Like the retail size, the cones are just much
bigger. Once the cone is done, it’s placed on a
skid and then taken over to another section of the plant for Yarn Finishing. On the other side, you can see winders making
Bernat Handicrafter and Lily Sugar’n Cream in different ball formats. You may know both of these yarns and that
they come in different sizes of balls. From apple sizes, cones and jumbo ball formats,
it’s all fabulous. The winder that winds it will determine the
size. Each winder has it’s own application and
format that it’s able to make. Here the large cones a table. It goes directly from table to winding without
passing through steaming. The machines are automated as the smaller
balls second merely seconds to make. The machines feed themselves, releases and
moves the yarn down the line all through automation. The operator monitors the quick motion and
is responsible for final packaging. The skeins are now moving down the line. The machine is loading the label at the top
of the arm. It rotates the arm down. The suction brings the ball into the enclosure
and the label is secured around the ball. It’s then rotated and released to the next
station. There, the operator places the balls into
a protective bag and it goes down the line into a bin where it will be placed nicely
into a box with accurate counts. The cotton yarns are a quicker process for
winding but usually longer process for dying to get those rich colours you love. This is the journey of how cotton is prepared
and packaged for a store shelf near you. On behalf of Yarnspirations and The Crochet
Crowd, have an amazing day!

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