OPTIMIZING YARN QUALITY THROUGH CLEANING INTERVENTIONS: EFFECTS OF WIRE CYLINDER AND STATIONARY FLAT MAINTENANCE ON NEPS COUNT AND UNEVENNESS PERCENTAGE (U%) IN CARDED SLIVERS

Maintaining yarn quality is crucial in textile manufacturing, where neps count and sliver unevenness percentage (U%) significantly impact production consistency and fabric performance. This study evaluates the effect of cleaning wire cylinders and stationary flats on neps count and U% in carded slivers, providing a cost-effective alternative to advanced predictive maintenance techniques. Using a randomized experimental design, measurements were conducted on two production lines (B2 and B3) before and after cleaning interventions. Neps count and U% were assessed using the Advanced Fiber Information System (AFIS) and Uster Tester, respectively. Statistical analysis, including t-tests and effect size calculations, revealed significant reductions in neps count (B2: 76.08 to 39.50; B3: 88.00 to 40.23) and U% (B2: 7.19% to 4.34%; B3: 8.27% to 4.25%), meeting industry benchmarks. The findings demonstrate that routine cleaning enhances fiber alignment, reduces defects, and improves production consistency without the high costs of predictive maintenance systems. This study highlights the importance of structured maintenance practices and provides a foundation for optimizing cost-effective and sustainable textile manufacturing processes.