Spinning.—The spinning operation, which follows the roving, is done in two principal ways, called respectively dry spinning and wet spinning, the first being used for the lower counts or heavier yarns, while the second is exclusively adopted in the preparation of fine yarns. The spinning frame does not differ in principle from the throstle spinning machine used in cotton manufacture. The bobbins of flax rove are arranged in rows on each side of the frame (the spinning frames being all double) on pins in an inclined plane. The rove passes downwards through an eyelet or guide to a pair of nipping rollers between which and the final drawing rollers, placed in the case of dry spinning from 18 to 22 in. lower down, the fibre receives its final draft while passing over and under cylinders and guide-plate, and attains that degree of tenuity which the finished yarn must possess. From the last rollers the now attenuated material, in passing to the flyers receives the degree of twist which compacts the fibres into the round hard cord which constitutes spun yarn; and from the flyers it is wound on the more slowly rotating spool within the flyer arms, centred on the top of the spindle. The amount of twist given to the thread at the spinning frame varies from 1.5 to 2 times the square root of the count. In wet spinning the general sequence of operations is the same, but the rove, as unwound from its bobbin, first passes through a trough of water heated to about 120° Fahr.; and the interval between the two pairs of rollers in which the drawing out of the rove is accomplished is very much shorter. The influence of the hot water on the flax fibre appears to be that it softens the gummy substance which binds the separate cells together, and thereby allows the elementary cells to a certain extent to be drawn out without breaking the continuity of the fibre; and further it makes a finer, smoother and more uniform strand than can be obtained by dry spinning. The extent to which the original strick of flax as laid on the feeding roller for (say) the production of a 50 lea yarn is, by doublings and drawings, extended, when it reaches the spinning spindle, may be stated thus: 35 times on spreading frame, 15 times on first drawing frame, 15 times on second drawing frame, 14 times on third drawing frame, 15 times on roving frame and 10 times on spinning frame, in all 16,537,500 times its original length, with 8 × 12 × 16 = 1536 doublings on the three drawing frames. That is to say, 1 yd. of hackled line fed into the spreading frame is spread out, mixed with other fibres, to a length of about 9400 m. of yarn, when the above drafts obtain. The drafts are much shorter for the majority of yarns.
The next operation is reeling from the bobbins into hanks. By act of parliament, throughout the United Kingdom the standard measure of flax yard is the “lea,” called also in Scotland the “cut” of 300 yds. The flax is wound or reeled on a reel having a circumference of 90 in. (2½ yds.) making “a thread,” and one hundred and twenty such threads form a lea. The grist or count of all fine yarns is estimated by the number of leas in 1 ℔; thus “50 lea” indicates that there are 50 leas or cuts of 300 yds. each in 1 ℔ of the yard so denominated. With the heavier yarns in Scotland the quality is indicated by their weight per “spyndle” of 48 cuts or leas; thus “3 ℔ tow yarn” is such as weighs 3 ℔ per spyndle, equivalent to “16 lea.”
The hanks of yarn from wet spinning are either dried in a loft with artificial heat or exposed over ropes in the open air. When dry they are twisted back and forward to take the wiry feeling out of the yarn, and made up in bundles for the market as “grey yarn.” English spinners make up their yarns into “bundles” of 20 hanks, each hank containing 10 leas; Irish spinners make hanks of 12 leas, 162⁄3 of which form a bundle; Scottish manufacturers adhere to the spyndle containing 4 hanks of 12 cuts or leas.
Commercial qualities of yarn range from about 8 ℔ tow yarns (6 lea) up to 160 lea line yarn. Very much finer yarn up even to 400 lea may be spun from the system of machines found in many mills; but these higher counts are only used for fine thread for sewing and for the making of lace. The highest counts of cut line flax are spun in Irish mills for the manufacture of fine cambrics and lawns which are characteristic features of the Ulster trade. Exceedingly high counts have sometimes been spun by hand, and for the preparation of the finest lace threads it is said the Belgian hand spinners must work in damp cellars, where the spinner is guided by the sense of touch alone, the filament being too fine to be seen by the eye. Such lace yarn is said to have been sold for as much as £240 per ℔. In the Great Exhibition of 1851, yarn of 760 lea, equal to about 130 m. per ℔, was shown which had been spun by an Irish woman eighty-four years of age. In the same exhibition there was shown by a Cambray manufacturing firm hand-spun yarn equal to 1200 warp and 1600 weft or to more than 204 and 272 m. per ℔ respectively.
Bleaching.—A large proportion of the linen yarn of commerce undergoes a more or less thorough bleaching before it is handed over to the weaver. Linen yarns in the green condition contain such a large proportion of gummy and resinous matter, removable by bleaching, that cloths which might present a firm close texture in their natural unbleached state would become thin and impoverished in a perfectly bleached condition. Nevertheless, in many cases it is much more satisfactory to weave the yarns in the green or natural colour, and to perform all bleaching operations in the piece. Manufacturers allow about 20 to 25% of loss in weight of yarn in bleaching from the green to the fully bleached stage; and the intermediate stages of boiled, improved, duck, cream, half bleach and three-quarters bleach, all indicating a certain degree of bleaching, have corresponding degrees of loss in weight. The differences in colour resulting from different degrees of bleaching are taken advantage of for producing patterns in certain classes of linen fabrics.
Linen thread is prepared from the various counts of fine bleached line yarn by winding the hanks on large spools, and twisting the various strands, two, three, four or six cord as the case may be, on a doubling spindle similar in principle to the yarn spinning frame, excepting, of course, the drawing rollers. A large trade in linen thread has been created by its use in the machine manufacture of boots and shoes, saddlery and other leather goods, and in heavy sewing-machine work generally. The thread industry is largely developed at Lisburn near Belfast, at Johnstone near Glasgow, Bridport, Dorsetshire, and at Paterson, New Jersey, United States. Fine cords, net twine and ropes are also twisted from flax.
Weaving.—The difficulties in the way of power-loom linen weaving, combined with the obstinate competition of hand-loom weavers, delayed the introduction of factory weaving of linen fabrics for many years after the system was fully applied to other textiles. The principal difficulty arose through the hardness and inelasticity of the linen yarns, owing to which the yarn frequently broke under the tension to which it was subjected. Competition with the hand-loom against the power-loom in certain classes of work is conceivable, although it is absolutely impossible for the work of the spinning wheel to stand against the rivalry of drawing, roving and spinning frames. To the present day, in Ireland especially, a great deal of fine weaving is done by hand-loom. Warden states that power was applied on a small scale to the weaving of canvas in London about 1812; that in 1821 power-looms were started for weaving linen at Kirkcaldy, Scotland; and that in 1824 Maberly & Co. of Aberdeen had two hundred power-looms erected for linen manufacture. The power-loom has been in uninterrupted use in the Broadford factory, Aberdeen, which then belonged to Maberly & Co., down to the present day, and that firm may be credited with being the effective introducers of power-loom weaving in the linen trade.
The various operations connected with linen weaving, such as winding, warping, dressing, beaming and drawing-in, do not differ in essential features from the like processes in the case of cotton weaving, &c., neither is there any significant modification in the looms employed (see [Weaving]). Dressing is a matter of importance in the preparation of linen warps for beaming. It consists in treating the spread yarn with flour or farina paste, applied to it by flannel-covered rollers, the lowermost of which revolves in a trough of paste. The paste is equalized on the yarn by brushes, and dried by passing the web over steam-heated cylinders before it is finally wound on the beam for weaving.
Linen fabrics are numerous in variety and widely different in their qualities, appearance and applications, ranging from heavy sail-cloth and rough sacking to the most delicate cambrics, lawns and scrims. The heavier manufactures include as Fabrics. a principal item sail-cloth, with canvas, tarpaulin, sacking and carpeting. The principal seats of the manufacture of these linens are Dundee, Arbroath, Forfar, Kirkcaldy, Aberdeen and Barnsley. The medium weight linens, which are used for a great variety of purposes, such as tent-making, towelling, covers, outer garments for men, linings, upholstery work, &c., include duck, huckaback, crash, tick, dowlas, osnaburg, low sheetings and low brown linens. Plain bleached linens form a class by themselves, and include principally the materials for shirts and collars and for bed sheets. Under the head of twilled linens are included drills, diapers and dimity for household use; and damasks for table linen, of which two kinds are distinguished—single or five-leaf damask, and double or eight-leaf damask, the pattern being formed by the intersection of warp and weft yarns at intervals of five and eight threads of yarn respectively. The fine linens are cambrics, lawns and handkerchiefs; and lastly, printed and dyed linen fabrics may be assigned to a special though not important class. In a general way it may be said regarding the British industry that the heavy linen trade centres in Dundee; medium goods are made in most linen manufacturing districts; damasks are chiefly produced in Belfast, Dunfermline and Perth; and the fine linen manufactures have their seat in Belfast and the north of Ireland. Leeds and Barnsley are the centres of the linen trade in England.
Linen fabrics have several advantages over cotton, resulting principally from the microscopic structure and length of the flax fibre. The cloth is much smoother and more lustrous than cotton cloth; and, presenting a less “woolly” surface, it does not soil so readily, nor absorb and retain moisture so freely, as the more spongy cotton; and it is at once a cool, clean and healthful material for bed-sheeting and clothing. Bleached linen, starched and dressed, possesses that unequalled purity, gloss and smoothness which make it alone the material suitable for shirt-fronts, collars and wristbands; and the gossamer delicacy, yet strength, of the thread it may be spun into fits it for the fine lace-making to which it is devoted. Flax is a slightly heavier material than cotton, while its strength is about double.