Yarn Winding: Soft Winding and Hard Winding Machines

Yarn winding machines prepare yarn packages for downstream textile processes — they wind yarn from cones or bobbins onto take-up packages at controlled tension and traverse. There are two main winding types: soft winding (precision or hybrid winding, used for weft insertion and delicate yarns requiring uniform package density) and hard winding (non-precision or drum winding, used for weft winding and warping where softer outer layers aid subsequent processing). SSM and FADIS are the two dominant manufacturers in this space, and this guide walks through their machine parts, yarn paths, and key differences.

If you haven’t already, read our previous post covering the basics of yarn winding technologies, which explains the three winding principles:

1. Non-precision/ Drum Winding
2. Precision Winding
3. Digicone/ Hybrid/ Conotronic Winding

Let’s get started with soft winding machines first.

Different Parts and Yarn Path Diagram of Soft Winding Machine

Among all the soft winding machines available in the market today, SSM and FADIS are the most dominant brands. They share some very similar features and some distinct differences. We’ll examine them one by one. Let’s start with the Swiss manufacturer—SSM.

Yarn Path Diagram of SSM TW2W Soft Winding Machine

Stage – 1: Yarn Guide (Pig-tail Type)

Stage – 2: Feeder (Rotating)

Stage – 3: Disc Tensioner

Stage – 4: Knot Catcher

Stage – 5: Moving Guide (Gives Traverse Motion)

Winding Arrangement of SSM TW2W

• When the package holder is engaged, the package is indirectly driven.
• This type of driving system is called “Friction Drive.”
• The traverse motion is provided by the moving guide.

Yarn Path Diagram of SSM PS6W Soft Winding Machine

Stage – 1: Yarn Guide

Stage – 2: Feeder (Rotating)

Stage – 3: Disc Tensioner

Stage – 4: Knot Catcher

Stage – 5: Sensor (Yarn Breakage Detector)

Stage – 6: Rotating Blade

Winding Arrangement of SSM PS6W

• The package is driven directly by a motor.

• The traversing motion is provided by rotating/propeller blades.

Traversing Mechanism (Left) & Propeller Blades (Right) of SSM PS6-W

Balloon Control Guide/ Balloon Breaker of PS6-W (2011)

• There are two models of PS6-W: the PS6-W (released in 2007) and the PS6 Plus-W (released in 2011).
• The PS6-W (2007) model lacks a balloon control guide, but the PS6 Plus-W includes this feature.

• If the space between the package and guide is too long, the balloon diameter increases, which causes higher hydrodynamic drag (friction between air and the yarn). This leads to yarn breakage.
• The guide descends and ascends according to the balloon diameter. It functions as a Balloon Breaker.

Yarn Path Diagram of FADIS P300 Soft Winding Machine

This Italy-based machine has some unique features. We’ll discuss them one by one. First, let’s go over its yarn path.

Stage – 1: Yarn Guide (Closed Type)

Stage – 2: Feeder (Rotating)

Stage – 3: Yarn Guide

Stage – 4: Spring Tensioner 

Stage – 5: Yarn Guide (Pig-tail Type)

Stage – 6: Yarn Clearer & Tensioner

Stage – 7: Sensor (Detection of Yarn Breakage)

Stage – 8: Yarn Guide (Open Type)

Stage – 9: Moving Guide

Unique Yarn Clearer and Tensioner of FADIS Soft Winder

You’ve likely noticed from the yarn path diagram that the FADIS yarn clearer and tensioner looks different from other designs. It is distinct! We’ve covered the tension setting of winders in a separate post if you’re interested. Let’s examine how these two mechanisms work in this single unit.

1. Yarn Clearing

2. Yarn Tensioning

Winding Arrangement of FADIS P300

• One spindle is directly driven by the motor, while the other receives drive through a shaft connected to the motor.

• A moving guide provides the traverse motion. The guide is connected to the adjacent guide by a toothed belt.
• This design produces rounder packages, which leads to better dyeing performance. The traverse is relatively shorter, so package-to-package gap is higher.

That marks the end of our lesson on soft winding machines. Now, we’ll examine hard winding machines.

Different Parts and Yarn Path Diagram of Hard Winding Machine

Hard winding machines operate on the Random Winding principle, which has the following characteristics:

Properties of Non-precision/ Drum Winding

• The winding angle remains constant throughout the process.
• As the package diameter increases, the number of coils per turn of the package decreases. This makes the package softer at the outer layers.

• When the winding ratio becomes a whole number/integer, the yarn lays over the yarn wound in the previous traverse. This results in the formation of a “ribbon” defect.

An ideal Hard Winding machine must have the following features:

• Anti-patterning device
• Weight release mechanism
• Length measuring device
• Balloon breakers
• Yarn tension controlling system

Comparison: Soft Winding vs Hard Winding Machines

Feature	Soft Winding	Hard Winding
Winding Principle	Precision/ Hybrid	Random (Non-precision)
Package Drive	Direct motor drive (PS6W) or friction (TW2W)	Friction drive via grooved drum
Traverse Mechanism	Moving guide or propeller blades	Grooved drum
Package Density	Higher, uniform density	Softer outer layers, varying density
Winding Ratio	Precisely controlled (typically 2.5-3.2)	Varies with diameter (integer ratios cause ribboning)
Typical Application	Weft insertion, delicate yarns	Weft winding, warping
Yarn Tension	0.1-0.3 cN/tex typically	0.3-0.8 cN/tex typically
Balloon Control	Required for high-speed operation	Balloon breakers standard

Quick Reference: Choosing a Winding Type

Your Need	Recommended Winding Type	Why
Uniform package density for consistent dyeing	Soft Winding	Precision/hybrid winding maintains constant winding ratio
Delicate or high-value yarns	Soft Winding	Lower tension (0.1-0.3 cN/tex) reduces breakage
Weft winding for weaving	Hard Winding	Softer outer layers accommodate loom drafting tensions
Warping preparation	Hard Winding	Random winding produces packages that release evenly from the side
Rounder “pineapple” packages for dye vats	FADIS P300 Soft Winding	Adjustable traverse length produces tapered, rounder packages
High-speed production with balloon-prone yarns	SSM PS6 Plus-W (2011+)	Integrated balloon control guide reduces yarn breakage at speed
Minimizing wax consumption	SSM CW8-W (2016)	Spring-pressurized waxing unit reduces wastage vs. dead-weight systems

Key Specifications for Major Soft Winding Machines

Specification	SSM TW2W	SSM PS6W	FADIS P300
Yarn Path Stages	5	6	9
Drive Type	Friction (indirect)	Direct motor	Direct motor + shaft
Traverse Mechanism	Moving guide	Rotating propeller blades	Moving guide (toothed belt)
Balloon Control	Not available	PS6 Plus-W (2011) has it	Integrated design
Tensioner Type	Disc tensioner	Disc tensioner	Spring tensioner + yarn clearer
Package Shape	Cylindrical	Cylindrical	Can produce rounder (pineapple) packages

Yarn Path Diagram of SSM CW2-W Hard Winding Machine

Stage – 1: Yarn Guide (Pig-tail Type)

Stage – 2: Disc Tensioner (Hand Adjustable)

Stage – 3: Waxing Unit

Stage – 4: Knot Catcher

Stage – 5: Sensor

Stage – 6: Winding Drum (Grooved)

Yarn Path Diagram of SSM CW8-W Hard Winding Machine

Stage – 1: Yarn Guide (Pig-tail Type)

Stage – 2: Disc Tensioner (Hand Adjustable)

Stage – 3: Waxing Unit (Rotating)

Stage – 4: Knot Catcher

Stage – 5: Sensor

Stage – 6: Winding Drum (Grooved)

Winding Arrangement of SSM CW2-W & CW8-W

• The package is indirectly driven by the surface contact of a rotating grooved drum.
• The traverse motion is provided by the grooving of the drum.
• The grooved angle is fixed, which enables only “Random Winding.”
• As the package diameter increases, the number of coils per turn decreases. This makes the package softer at the outer layers.

Yarn Path Diagram of FADIS P300 (Hard Winding Configuration)

Stage – 1: Yarn Guide (Closed Type)

Stage – 2: Feeder (Rotating) 

Stage – 3: Yarn Guide

Stage – 4: Spring Tensioner 

Stage – 5: Yarn Guide (Pig-tail Type)

Stage – 6: Yarn Clearer and Tensioner 

Stage – 7: Sensor (Detection of Yarn Breakage)

Stage – 8: Waxing Unit (Rotating)

Stage – 9: Moving Guide

Winding Arrangement of FADIS P300 (Hard Winder)

• The winding arrangement closely resembles the soft winding machine. The primary difference lies in the fed bobbin, which is conical.

Differences in Waxing Units of Hard Winding Machines

The waxing units differ in appearance because their mechanisms differ as well. Each design offers distinct advantages for yarn lubrication during the winding process.

1. Waxing Unit of SSM CW2-W Hard Winding Machine

• The waxes are pressurized by dead weights, as shown in the figure above.
• The weights are changeable, but the process is time-consuming.

2. Waxing Unit of SSM CW8-W Hard Winding Machine

There are two variations of the CW8-W. The older version (2011) has the following arrangement:

• The loading can be varied easily, as shown in the figure above.

The newest version (2016) has the following arrangement:

• Pressure is applied by a spring. To increase pressure, more wax can be inserted.
• This unit has a major advantage over other units: lower wax wastage.

3. Waxing Unit of FADIS P300 Hard Winding Machine

• Pressure is applied by a fixed dead weight.
• The presser is made of plastic with relatively flat edges, which reduces wax wastage.

Sampling Device of Hard Winding Machine

Among the two brands, the SSM CW8-W (2016) model includes a sampling device, which proves very useful during quality control.

• The newest SSM CW8-W (2016) and CW2-W include a sampling device. When engaged, the yarn winds on the extreme edge of the package, which facilitates the sampling process.

Hard Winding Machine Waxing Systems Comparison

Feature	SSM CW2-W	SSM CW8-W (2011)	SSM CW8-W (2016)	FADIS P300
Loading Type	Dead weight (changeable)	Variable loading	Spring pressurized	Fixed dead weight
Wax Wastage	Moderate	Moderate	Low (advantage)	Low
Adjustability	Time-consuming changes	Easy adjustment	Easy + insert more wax	Limited (fixed)
Edge Design	Standard	Standard	Optimized	Flat plastic edges
Year Introduced	Earlier model	2011	2016	N/A

Frequently Asked Questions

1. Can we use hard winding machines as soft winding?

Technically, you can after certain modifications, starting with the bobbin holder. The waxing unit must be removed as well. However, it is not worth the trouble because patterning becomes unavoidable. You will not achieve the desired dyeing results. Additionally, there is no significant benefit in terms of production speed.

2. What is the winding ratio of a drum winding machine?

The winding ratio is measured by counting the number of coils formed by a double traverse. Initially, the winding ratio doubles the number of coils grooved on the drum. However, as the package diameter increases, you will observe a fall in the winding ratio.

3. Why can we make pineapple packages with FADIS but not with SSM?

The difference comes down to traverse length adjustability. FADIS allows gradual traverse length changes during winding. As the traverse length decreases, the package becomes rounder. The moving guide facilitates this process.

SSM machines lack traverse length changing features. The rotating blade system is not ideal for traverse length variations during package build-ups.

Key Takeaways: Choosing Between Soft and Hard Winding

• Soft winding produces packages with uniform density and precise winding ratios, making it suitable for weft insertion and delicate yarns requiring consistent dyeing.
• Hard winding uses random winding with a grooved drum, producing softer packages ideal for weft winding and warping where package softness aids subsequent processing.
• FADIS P300 excels at producing rounder “pineapple” packages due to its adjustable traverse length capability.
• SSM PS6 Plus-W includes balloon control technology (introduced in 2011) to reduce yarn breakage at higher speeds.
• Waxing systems vary significantly: spring-pressurized units (CW8-W 2016) offer the lowest wax wastage, while dead-weight systems require more maintenance time.

If you’re interested in finding the best yarn ball winder, do give our other article a read. After reading this article, you should have a thorough understanding of the similarities and differences between the machines of these two major brands.

References

• Durur, F. & others. Cross Winding of Yarn Packages. Journal of Textile & Apparel, Technology and Management. View on Semantic Scholar.
• Textile Research Journal. Suitable Traverse Ratios for Step Precision Winding. Science and Engineering Research, 2016. View on Springer.
• Goswami, B. C., Anandjiwala, R. D., & Hall, D. (2004). Textile Sizing. Marcel Dekker, Inc.
• SSM Machinery AG. Product documentation: Winding Machines PS6 Plus-W Series. Switzerland.
• FADIS S.p.A. Product documentation: P300 Soft/Hard Winding System. Italy.