Spinning Internship report - Alok (Spinning and Testing)
TABLE OF CONTENTS
Chapter 1 Introduction
1.1 Company Profile
1.2 Origin and Growth
1.3 Alok’s Vision and Mission statement
1.4 Alok’s Values
Spinning Division
Chapter 2 Project report
2.1 Aim
2.2 Theory
2.3 Trials and Observations
2.4 Precautions
2.5 Remarks
Chapter 3 General Report
3.1 Processes involved in Spinning for Ringspun yarn
3.2 Processes involved in Rotor spun yarn
3.3 Blowroom
3.4 Carding
3.5 Breaker draw frame
3.6 Unilap
3.7 Comber
3.8 Finisher draw frame
3.9 Simplex
3.10 Ringframe
3.11 Winding
3.12 Quality Assurance Department
3.13 Luwa
3.14 Waste
CHAPTER 1- INTRODUCTION
1.1 COMPANY PROFILE
Benchmarking Quality standards and innovation, Alok Industries Ltd is one of the leading textile groups and among the fastest-growing integrated textile companies in India. They are offering world-class integrated textile solutions. They manufacture world-class home textiles, woven and knitted apparel, garments and polyester yarns selling directly to manufacturers exporters importers retailers and brands the world over.
1.2 ORIGIN AND GROWTH
Alok Industries Ltd was incorporated in the year 1986 with the name Alok Textile Industries Pvt Ltd. The company commenced their activities with the manufacture of texturized yarn by setting up manufacturing facilities at Silvassa.
In the year 1991, they commenced a weaving operation at Bhiwandi in Thane.
In the year 1993, it became a public limited company.
In the year 1994, the company expanded the weaving capacity to 50 common looms in Thane and texturizing capacity of 3 Nos Texturizing machines in Silvassa.
In the year 1995, they made a technical collaboration with Grabal Albert Grabher Gesellshaft mbH & Co of Austria for the manufacture of embroidered products through a joint venture company named Grabal Alok Impex Ltd.
In the year 1996, they set up Knitting Division at Silvassa with 8 Machines and a state-of-the-art eco-friendly Process House at Navi Mumbai with 3 Stenter.
In the year 1998, the company modernized and expanded the weaving division with 24 Sulzer Projectile Looms at Silvassa and in the next year they further expanded to 28 Sulzer Projectile Looms. Also
Subsequently, on 8 November 2000 name of the company was changed to “ALOK INDUSTRIES LIMITED”
They completed the modernization and expansion of the weaving project with 88 Air Jet/ Rapier Sulzer Looms at Silvassa in the year 2002 and
The processing project with 2 Centres at Vapi in the year 2003. In the same year, they set up a Garment Unit at Navi Mumbai with 100 Stitching Machines.
In the year 2004, the company expanded the Texturizing capacity to 30 machines Knitting capacity to 40 machines and Weaving capacity to 170 Air Jet/ Rapier Looms.
1.3 ALOK’S VISION & MISSION STATEMENT
1.3.1 VISION
To be the world's best-integrated textile solutions enterprise with a leadership position across products and markets, exceeding customer & stakeholder expectation
1.3.2 MISSION
We will:
• Be a knowledge leader & an innovator in our businesses
• Maximize people development initiatives
• Optimize the use of all resources
• Become a process-driven organization
• Exceed compliances and global quality standards
• Actively explore potential markets & products
• Offer innovative, customized and value-added services to our customers
• Be an ethical, transparent and responsible global organization.
1.4 ALOK’S VALUES
• CUSTOMER SATISFACTION:
We will be attuned to market needs, wherever possible, we will anticipate market needs, we will respond quickly to the changes in customer requirements, we will be completely focused on quality, and we will keep delivery commitment on time and every time.
• PASSIONATE ABOUT EXCELLENCE
Excellence is non-negotiable in every aspect of our business; superior quality of performance is critical to our business growth and success. We will constantly strive to exceed expectations: be they internal or external.
• FAIR TO ALL
All our actions will be determined by fairness, we shall be fair to our customers, senders, shareholders, all our business partners and society at large. Fairness is not just sticking to the letter of the law or contract but appreciating its spirit and basing all our actions.
• CONCERN FOR THE ENVIRONMENT AND THE COMMUNITY
We will take the utmost care of our environment and the communities in which we operate; we shall nurture our environment and its natural resources and shall ensure that none of our actions depletes or pollute them.
• SAFETY AND HEALTH
We will provide a safe workshop. We will promote the health and well-being of our people and their families. We believe that working safely and protecting the health of our people is working smart and creates greater and more sustainable wealth.
• RESPONSIBLE CORPORATE CITIZEN
We recognize that we have our responsibilities towards the society in which we operate. We commit ourselves to being responsible corporate citizens; our activities should not only create shareholder wealth but also humanity's wealth.
1.5 SPINNING DIVISION
• Number of units: 9
• Spindle capacity: 411840
• Open-end rotor: 5680
• TFO Spindles: 5960
• Type of yarn produced: Compact yarn, Rotor yarn, Lycra yarn, Slub yarn, Double yarn, Double gassed yarn, 3-ply yarn,4-ply yarn.
• Major customer:
Export:
Kmart, KOHL’S, VICTORIA’S SECRET, ALLTAYLOR, IKEA, WAL-MART, JCPenney, GAP, TARGET, NORDSTROM.
Domestic:
Raymond, Pantaloons, WILLS LIFESTYLE, BRFL, COATS, ZODIAC, Creative garment.
1.5.1 SPINDLE CAPACITY OF SPINNING UNIT
Unit No. | Spindle | Rotor | T.F.O. |
1 | 57072 | 936 | - |
2 | 57696 | - | - |
3 | 58704 | - | - |
4 | 63024 | - | - |
5 | 56400 | - | - |
6 | 50400 | 2856 | - |
7 | 68544 | - | - |
8 | - | - | 5960 |
9 | - | 1888 | - |
Total | 411840 | 5680 | 5960 |
Table 1.1: Spindle capacity of the spinning unit
1.6 STATE OF ART MACHINERY WITH THE LATEST
TECHNOLOGIES:
• Spinning unit from Rieter (Switzerland), LMW(Coimbatore) and Trutzschler (Germany) • Automatic rotor spinning from Schlafhorst Der Saurer GMBH
• Automatic cone winders from Murata and Schlafhorst.
• Humidification and Air conditioning plants from LUWA(Switzerland)
• Various press and rollers etc. from Huber + Suhner AG
• Auto doffing and bobbin transport in speed frame and cone palletizing in winding from electrojet (Spain).
1.7 FUNCTION OF VARIOUS DEPARTMENTS:
The spinning division itself comprises no. of departments. Each department plays a vital role in the proper and continuous functioning of the entire division.
1. Production House
2. Maintainance
3. Quality Assurance Department
4. Engineering Department
5. H.R. Department
6. Accounts
7. Security
8. Store and Purchase
1. Production House: The production and planning department will set standards and targets for each section of the production process. The quantity and quality of products coming off a production line will be closely monitored. In businesses focusing on lean production quality will be monitored by all employees at every stage of production, rather than at the end as is the case for businesses using a quality control approach
2. Maintenance department: The main objective of the maintenance department is to eliminate breakdowns, maximise utilization of machine operating time, incorporate new technologies and engineering development in the basic design of the machine, augmentation of machine capability and optimum expenditure on maintenance function and activities.
3. Quality Assurance Department: The function of the department is to control the manufacturing process against the standard of the company or as directed by the buyer conveyed through P.P.C. It deals with the testing of yarns, various process developments, maintaining quality, policy, handling customer complaints, etc.
4. Engineering department: The engineering department itself comprises three departments viz.
• Civil Department: This department deals with the layout of the company.
• Mechanical department: This department deals with the Maintenance and the other mechanical regions of the mill. Any mechanical breakdown with the machine is repaired by this department.
• Electrical department: This department deals with all types of electrical work, breakdowns and lighting systems, and supply of electricity to the whole company.
5. Human Resource Department:
Accounts: Accounts department is mainly responsible for the generation of all kinds of financial reports and bookkeeping. The main activities for which the accounts are responsible are bookkeeping, payments (payment to suppliers, salaries to employees etc.)
CHAPTER 2 - PROJECT REPORT
2.1 AIM:
TO WORK TOWARDS THE INCREASE IN YARN CSP FOR A GIVEN COUNT OF YARN (20s OE).
2.2 THEORY
It is the product of the English count and strength of yarn in pounds. i.e.
C.S.P = Strength of yarn in pound x Count in the English system.
It highly affects the quality of yarn. The more the CSP, the better the yarn quality.
A lea strength tester measures the strength of one lea yarn. One lea means 120 yards. Strength is a measure of the steady force necessary to break material and is measured in pounds. The m/c works at a constant rate of extension.
C.S.P. Calculation:
C.S.P. =Yarn count (Ne) X Tensile strength (lbs.)
2.3 FACTORS THAT AFFECT YARN STRENGTH ARE AS FOLLOWS-
2.3.1 Staple Length
Longer staple cotton gives higher strength. Low twist factors will give stronger yarn in the case of the longest fibre.
2.3.2 Fiber Fineness
Fine fibre gives strong yarn compared to coarse fibres which are spun into the same given count of yarn. This is because more fibres in the cross-section and also increased internal friction is provided by the higher number of fibres in the cross-section of the yarn. Hence the result is higher yarn strength.
2.3.3 Fiber Strength
In the case of cotton fibre, fibres will have a longer length and hence more fine fibre can be accumulated in the same cross-section thus the strength of the individual fibre contributes to the strength of the yarn. Therefore yarn strength is the strength of a group of fibres.
2.3.4 Twist
For a single spun yarn, an increase in twist gives a higher strength but any twist higher than an optimum level will decrease the strength. The amount of twist for maximum strength depends on the twist angle and for any given fibre the twist angle for maximum strength remains constant over a range of yarns. The position of individual fibres in the characteristic yarn will also affect the tensile property since the building up of a spun yarn is a resultant factor of drafting and twisting. The twist is a dynamic property.
2.3.5 Fibre Length Variation and Distribution
Fibre length variation and distribution will also cause variations in CSP. When spinning cotton, containing more short fibres, the resultant yarn will have lower strength. In the presence of short fibres, the resultant yarn will have lower strength. The presence of short fibres influences, to a very great extent, the yarn strength. Therefore limitations have to be introduced while mixing such fibres.
2.4 PROCESS PARAMETERS
Machine | Parameter | Value |
BLOW ROOM | Bale opener (rpm/raw) | |
Traverse speed | 11 | |
Normal index | 4 | |
Varioclean | 650 | |
Carding | Licker in 1 | 836 |
Licker in 2 | 945 | |
Licker in 3 | 1248 | |
Opening roller | 684 | |
Cylinder | 550 | |
Flat Speed | 240 | |
Delivery Speed | 157 | |
Draw frame (RSB-851) | Doubling | 6 |
Draft | 1.28 | |
Gauge | 36/38 | |
Rotor | Rotor Speed | 105000 |
Opening Roller | 9800 | |
TM | 6.8 | |
Twist | 1198 | |
Draft | 196 |
Table 2.1: Process parameters of the open-end spinning line
2.5 TRIALS AND OBSERVATIONS:
The subject 20 OE yarn running in unit number – 06 had a:
• CSP of 1502.
• Mixing: 352. (Mech 40% + Mech B (SH) 5% + Noil 35% + Flat 20%)
And, Yarn parameters:
• Count: 20.23 and Count %CV: 1.22
• Strength: 74.24 and Strength %CV: 5.46
• TM: 6.8
2.5.1 TRIAL 01: Change in speeds of various machine parts.
• Varioclean: 550 to 650
• Cylinder: 600 to 500
• Licker in 980/1104/1458 to 980/1104/1200
Results:
Before
MACHINE | NEP/gm | NEP (um) | SFC (n) %<12.7 | 5.0% (mm) |
Card 33 | 925 | 671 | 62.3 | 29.13 |
Card 34 | 598 | 663 | 57.8 | 30.91 |
Card 35 | 659 | 643 | 57.2 | 29.32 |
Card 36 | 547 | 645 | 57.6 | 29.22 |
Card 37 | 990 | 666 | 60.8 | 29.73 |
Chute common | 1006 | 725 | 66.2 | 26.16 |
RSB- 14 | 895 | 668 | 56.0 | 30.79 |
RSB- 15 | 692 | 653 | 57.4 | 30.17 |
Table 2.2: Before the changes
After:
MACHINE | NEP/gm | NEP (um) | SFC (n) %<12.7 | 5.0% (mm) |
Card 33 | 611 | 651 | 56.6 | 29.38 |
Card 34 | 733 | 654 | 60.7 | 29.51 |
Card 35 | 727 | 650 | 60.5 | 29.08 |
Card 36 | 718 | 653 | 60.7 | 28.9 |
Card 37 | 771 | 657 | 58.1 | 29.66 |
Chute common | 1161 | 735 | 64.5 | 28.64 |
RSB- 14 | 871 | 662 | 58.1 | 30.58 |
RSB- 15 | 638 | 651 | 57.45 | 31.15 |
Table 2.3: After the changes
Testing parameters | Changing Parameters | Actual count | CV% | CSP | IPI | H | Uster |
Full cone fresh matter at running R.H.65%temp.-31.5 | 20.49 | 0.78 | 1398 | 0 | |||
RSB 14 | no. of doubling-5, break draft-1.36, bottom roller gauge-36/38, trumpet-4.2, scanning roll8mm. | 20.39 | 1.06 | 1527 | 59 | 5.42 | 10.67 |
RSB 15 | 20.3 | 1.25 | 1553 | 31 | 5.36 | 10.11 | |
RSB 16 | 20.33 | 1.30 | 1586 | 46 | 5.53 | 10.15 | |
New opening roller | only opening roller speed changed to 8500 | 20.17 | 1.74 | 1500 | 33 | 5.5 | 10.02 |
Card | Cylinder speed 570, flat speed 300 from 240 | 20.46 | 0.71 | 1524 | 0 |
Table 2.4: Further changes
Observation: On increasing certain machine parameters like cylinder speed, Varioclean beater speed, Bottom Roller gauge and flat speed, the CSP increased from 1398 to 1524.
Conclusions: Neps /gm have been significantly reduced and CSP increased.
2.5.2 Trial 02: Change in mixing and some machine parameters.
• Mixing: mech 40% + mech (SH) 10% + noil 30% + flat 20%
• Cylinder speed: 550 to 500
• Flat speed 300 to 240
Results:
Testing Parameters | Changing Parameters | Actual count | CV% | CSP | IPI | H | Uster |
OE | Mixing interchange U1 vs U6 | ||||||
U-1 | U-6 | 20.52 | 1.41 | 1403 | 0 | ||
U-6 | U-1 | 20.32 | 1.72 | 1604 | 0 | ||
MXG change (unconditioned cone) | OE 349 (mech 40% +mech b 20%+ noil 25%+ flat 15%) | 20.42 | 1.12 | 1716 | 0 | ||
Mixing revise (only use flat and noil from U-1,5,7) with card parameters | OE353(mech 40%+mech b 10%+ noil 30%+flat 20%) cylinder Speed 550, flat speed 300 from 240 | 20.45 | 0.68 | 1634 | 54 | 5.6 | 10.24 |
Mixing revise (only use flat and noil from U-1,5,7) with card parameters | OE353 (mech 40%+ mech b 10%+ noil 30%+ flat 20%) cylinder Speed 500, flat speed 240 | 20.50 | 1.13 | 1657 | 67 | 4.9 | 10.96 |
Table 2.5: Trial 02
Observation: On interchanging the mixing the CSP increased to 1634 and the change in machine speeds led to a CSP of 1657. making the mentioned changes the CSP increased to interchanging the material, it was observed that the present mixing required modification and hence OE-353 with cylinder speed 500 and flat speed 240, the CSP increased from 1524 to 1657.
Conclusion: Thus, the mixing required improvement and the changed speeds of the flats and cylinder were subsequently used.
2.5.3 Trial- 03: To study the quality of noil and flat used in the mixing.
NOIL AFIS REPORT
Parameters | Unit 1 | Unit 6 |
Nep(Cnt/g) | 881 | 854 |
Nep(Um) | 668 | 665 |
Scan (Cnt/g) | 71 | 54 |
Scan (Um) | 1009 | 943 |
L (W) (mm) | 11.54 | 10.68 |
L (W) (%cv) | 60.3 | 60.6 |
SFC (W) (%cv) | 64.2 | 68.8 |
SQL (mm) | 14.43 | 13.23 |
L (N) (mm) | 7.98 | 7.75 |
L (N) (%cv) | 67.0 | 64.6 |
SFC (N) (%cv) | 83.4 | 85.7 |
5.0% (mm) | 18.47 | 16.50 |
Fine (mTex) | 123 | 135 |
IFC % | 11.5 | 11.1 |
Mat Ratio | 0.7 | 0.70 |
Length | 16.85 | 15.77 |
S | 34.5 | 341 |
Strength | 20.1 | 17.5 |
Table 2.6: Trial 03
FLATS AFIS REPORT
Parameters | Unit 1 | Unit 6 |
Nep(Cnt/g) | 1187 | 1549 |
Nep(Um) | 824 | 771 |
Scan (Cnt/g) | 338 | 329 |
Scn (Um) | 1168 | 1081 |
L (W) (mm) | 15.63 | 14.32 |
L (W) (%cv) | 59.4 | 62.3 |
SFC (W) (%cv) | 40.2 | 46 |
UQL (mm) | 22.90 | 20.45 |
L (N) (mm) | 9.03 | 8.39 |
L (N) (%cv) | 85.5 | 84.1 |
SFC (N) (%cv) | 72.7 | 76.3 |
5.0% (mm) | 25.64 | 23.41 |
Fine (mTex) | 141 | 130 |
IFC % | 9.0 | 10.4 |
Mat Ratio | 0.75 | 0.73 |
Table 2.7: Flat AFIS report
Observation: The noil and flat from unit 01 are better than those from unit 06. The plausible reason for this outcome could be the raw material and the machine used.
An optimum level of CSP (>1600) was achieved thus the team moved on to work on another set of 20s OE yarn with a different mixing.
2.5.4 Trial 04: To study the quality of noil used from different units.
NOIL AFIS REPORT (ALL UNITS)
Parameters | Unit 1 | Unit 2 | Unit 3 | Unit 5 | Unit 6 | Unit 7 |
Nep(Cnt/g) | 1147 | 919 | 790 | 1104 | 680 | 1039 |
Nep(Um) | 694 | 691 | 660 | 699 | 640 | 701 |
Scn (Cnt/g) | 104 | 40 | 48 | 64 | 54 | 80 |
Scn (Um) | 1015 | 920 | 932 | 1013 | 866 | 1065 |
L (W) (mm) | 11.40 | 10.61 | 11.16 | 11.40 | 10.66 | 11.14 |
L (W) (%cv) | 60.2 | 61.4 | 62.1 | 59.0 | 56.2 | 58.9 |
SFC (W) (%cv) | 64.6 | 69.2 | 67.1 | 63.2 | 67.1 | 66.3 |
UQL (mm) | 14.49 | 13.21 | 13.86 | 14.39 | 13.61 | 14.06 |
L (N) (mm) | 7.89 | 7.34 | 7.68 | 7.90 | 7.61 | 7.76 |
L (N) (%cv) | 66.8 | 67.0 | 67.4 | 66.7 | 63.3 | 66.00 |
SFC (N) (%cv) | 83.8 | 86.5 | 85.2 | 82.7 | 84.7 | 84.7 |
5.0% (mm) | 18.19 | 16.35 | 17.07 | 17.91 | 16.71 | 17.52 |
Fine (mTex) | 134 | 129 | 138 | 135 | 131 | 136 |
IFC % | 9.9 | 10.7 | 9.6 | 10.8 | 10.7 | 11.8 |
Mat Ratio | 0.71 | 0.70 | 0.73 | 0.71 | 0.70 | 0.70 |
Table 2.8: Noil AFIS report
Observation: The noil from U1, U5 and U7 are comparatively better than the other units in terms of SFC, 5% and UQL, which are the main factors affecting the noil quality and hence the yarn strength.
Conclusion: A decision was made to use noil from units 1, 5 and 7 only.
2.5.5 Trial 05: To study the quality of flats from different units. And the change in mixing from 354 to 355 which is Mech 65% + noil 15% + flat 20%.
TRASH ANALYSIS OF FLAT
UNIT–01
Trash: 6.548
Lint: 7.448
Microdust: 1.314
Total: 15.346
UNIT- 05
Trash: 2.634
Lint: 7.094
Microdust: 0.296
Total: 10.024
UNIT- 07
Trash: 6.018
Lint: 7.008
Microdust: 0.196
Total: 13.22
FLATS AFIS REPORT
Parameters | Unit 1 | Unit 5 | Unit 7 |
Nep (Cnt/g) | 1416 | 850 | 934 |
Nep (Um) | 731 | 712 | 756 |
Scn (Cnt/g) | 126 | 92 | 177 |
Scn (Um) | 1106 | 1041 | 1120 |
L (W) (mm) | 17.05 | 14.32 | 15.81 |
L (W) (%cv) | 55.1 | 65.1 | 59.9 |
SFC (W) (%cv) | 33.9 | 47.0 | 39.5 |
UQL (mm) | 23.62 | 20.24 | 22.03 |
L (N) (mm) | 10.48 | 8.09 | 9.20 |
L (N) (%cv) | 79.2 | 87.7 | 84.8 |
SFC (N) (%cv) | 65.7 | 77.9 | 71.8 |
5.0% (mm) | 26.76 | 23.05 | 25.48 |
Fine (mTex) | 142 | 145 | 143 |
IFC % | 82 | 9.6 | 7.6 |
Maturity Ratio | 0.75 | 0.73 | 0.76 |
Table 2.9: Trial 05
Observation: The flat waste of Unit 1 and Unit 5 were better in terms of SFC, 5% and trash content.
Conclusion: Thus, a decision was made to use flats from units 1 and 5 only.
2.5.6 Trial 06: Change in TM. Noil and flat waste were used from units 1 and unit 5 only.
Tm | 6.6 | 6.8 | 7.0 | |||
CSP | 1747 | 1772 | 1751 |
Table 2.10: Trial 06
Observation: The twist multiplier value of 6.8 gave a better value of CSP.
2.5.7 Trial 07: Using noil only from U1 and U5 at Card speed: 157
Test case:
Sample | Machine number | TM | Opening roller speed | Rotor speed | Torque stop | Navel |
A1 | 4 | 6.8 | 105000 | 9800 | Green | Spiral |
A2 | 4 | 6.8 | 105000 | 9800 | White | Spiral |
A3 | 4 | 6.5 | 105000 | 9800 | Green | Spiral |
A4 | 4 | 6.5 | 105000 | 9800 | White | Spiral |
A5 | 4 | 6.3 | 105000 | 9800 | Green | Spiral |
A6 | 4 | 6.3 | 105000 | 9800 | White | Spiral |
Table 2.11: Trial 07
Twist multiplier | 6.3 | 6.5 | 6.8 | |||
Sample | A6 | A5 | A4 | A3 | A2 | A 1 |
torque stop | WHITE | GREEN | WHITE | GREEN | WHITE | GREEN |
Rotor speed | 105000 | 105000 | 105000 | 105000 | 105000 | 105000 |
Opening roller speed | 9500 | 9500 | 9500 | 9500 | 9500 | 9500 |
Carding speed | 157 | 157 | 157 | 157 | 157 | 157 |
Actual Count | 20.44 | 20.28 | 20.35 | 20.31 | 20.18 | 20.41 |
CV% | 1.09 | 1.17 | 1.41 | 0.61 | 1.14 | 0.79 |
Strength | 84.45 | 85.09 | 83.5 | 85.23 | 83.86 | 86.07 |
CV% | 4.16 | 2.54 | 3.93 | 2.26 | 2.77 | 4.06 |
CSP | 1726 | 1725 | 1699 | 1731 | 1692 | 1756 |
Table 2.12: Trial 07 results
Results:-
Observation: The combination of green torque stop with carding speed of 157, TM as 6.8, using flat and noil only from unit 1 and unit 5 gives the best CSP result.
2.5.8 TRIAL-08: At different carding and opening roller speed
Results-
TM | 6.8 | 6 8 | ||
SAMPLE | A2 | A 1 | A | B |
TRQ STOP | WITE | GREEN | GREEN | GREEN |
ROTOR SP EED | 105000 | 105000 | 105000 | 105000 |
O. ROLLER SPEED | 9500 | 9500 | 9800 | 9500 |
CDG SPEED | 157MPM | 157MPM | 135MPM | 135MPM |
ACT COUNT | 20.18 | 20.41 | 19.85 | 20.7 |
CV% | 1.14 | 0.79 | 1.25 | 1.19 |
STRENGTH | 83 86 | 86.07 | 85.99 | 84.24 |
CV% | 277 | 4.06 | 3.21 | 3.08 |
CSP | 1692 | 1756 | 1707 | 1744 |
Table 2.13: Trial 08
Observation: A decrease in the carding speed resulted in a decrease in CSP.
2.5.9 TRIAL-09: Change in opening roller speed along with T.M 6.8
Results-
TM | 6.8 | ||
SAMPLE | 1 | 2 | 3 |
Torque Speed | GREEN | GREEN | GREEN |
Rotor Speed | 105000 | 105000 | 105000 |
Opening Roller | 8000 | 8500 | 9000 |
Carding Speed | 157MPM | 157MPM | 157MPM |
Actual Count | 20.38 | 20.29 | 20.28 |
CV% | 1.22 | 0.51 | 1,24 |
Strength | 86.5 | 86.1 | 84.91 |
CV% | 4.56 | 2 | 3.34 |
CSP | 1763 | 1747 | 1721 |
Uster | 9.92 | 10.07 | 9.8 |
Thin -50 | 2 | 2 | 0 |
Thick +50 | 17 | 16 | 13 |
Neps (+280) | 25 | 15 | 14 |
IPI | 44 | 33 | 27 |
Hairiness | 4.85 | 5.32 | 5.07 |
Table 2.14: Trial 09
Observation: The yarn running at an opening roller speed of 8500 has the least strength, CV%, optimum CSP and IPI.
2.6 PRECAUTIONS TAKEN:
• All the leas for CSP testing were allowed to rest for at least 10 minutes.
• All the sample baby cones were conditioned in the Xorella for the required time.
• The samples for flats and noils were collected from respective blow rooms only rather than from their respective units.
2.7 FINAL REMARKS
The most suitable and quality 20s OE yarn was achieved with
• the mixing 355 (mech 65% + noil 15% + flat 20%)
• using noil and flat waste only from unit 1 and unit 5
• with TM: 6.8
• opening roller speed 8500
• carding speed 157
CHAPTER 3 - GENERAL REPORT
3.1 PROCESSES INVOLVED (SEQUENTIALLY) IN SPINNING FOR RINGSPUN YARN
1: BLOW ROOM
2: CARDING
3: BREAKER DRAW FRAME
4: LAP FORMER
5: COMBER
6: FINISHER DRAW FRAME
7: SPEED FRAME
8: RING FRAME
9: WINDING
10: XORELLA(CONDITIONING)
11: PACKING AND DISPATCHING
3.2 PROCESSES INVOLVED (SEQUENTIALLY) IN SPINNING FOR ROTOR SPUN YARN
1. BLOWROOM
2. CARDING
3. BREAKER DRAWFRAME
4. FINISHER DRAWFRAME
5. OPEN-END SPINNING
6. WINDING
7. CORELLA
8. PACKING AND DISPATCHING
3.3 BLOW ROOM
3.3.1 OBJECTIVES:
1: OPENING
2: CLEANING
3: DUST REMOVAL
4: MIXING
3.3.2 OPERATION IN BLOW ROOM: -
• Opening: The tightly packed fibre bales received from the ginning mills have to be opened by converting the larger fibre tufts into smaller ones and ultimately converting the smaller tufts into individual fibre forms.
• Cleaning: All natural fibres including cotton have a considerable number of impurities in them which have to be removed to produce a clean yarn. Cotton impurities that have to be removed include seed, chaff, dirt, micro-dust and abnormal impurities like iron pieces, cloth fragments, polypropylene etc.
• Mixing: The properties of the cotton fibres differ from each other from bale to bale and fibre to fibre so to obtain a homogenous and consistent quality yarn, they need to be thoroughly mixed together. Sometimes to have the desired quality at the right price high-quality cotton fibres are mixed with low-quality fibres.
• Preparation of feed for next stage: The end product of the blow room should be compatible with the next stage of spinning i.e., carding. The feed to the carding can be either given in the form of a lap or in direct chute form.
3.3.3 ACTION OF AIR CURRENT IN BLOWROOM: -
During processing the movement of cotton from machine to machine is done by air current. It also helps in the segregation of lint & trash.
3.3.4 BALE MANAGEMENT
• In a particular lot Micronaire range of the cotton bales used should be the same for all the mixing.
• Range of colour of cotton bales used should be the same for all the mixing of a lot.
• Average colour of cotton bales should be the same for all the mixing of the lot.
• Range of maturity of the coefficient of cotton bales used should be the same for all mixing of a lot.
3.3.5 TEMPERATURE AND HUMIDITY-
• 35.50 C
• 52 %
3.3.6 MIXING: -
Mix | Count |
Organic | 40 CHX |
S-6 (Shankar 6) | 30s, 26s, 34s |
MM(Mech + MCU5) | 63 CW |
DDM(VCH32 (A+B) + MCU5) | 100 CWC |
Table 3.1: Types of mixing
3.3.7 MIXING SPECIFICATION:-
S-6 | ORGANIC | MM | DDM | |
MIC | 3.91 | 3.78 | 3.93 | 3.76 |
LENGTH | 28.97 | 29.92 | 30.61 | 32.90 |
STRENGTH | 32.73 | 32.8 | 34.72 | 37.11 |
SFI | 8.54 | 7.86 | 7.54 | 6.68 |
RD | 71.15 | 74.88 | 75.21 | 71.21 |
+B | 8.54 | 9.33 | 8.71 | 9.57 |
Table 3.2: Mixing Specifications
3.3.8 MACHINES INVOLVED IN THE BLOW ROOM PROCESS:
Sr.no | Machine Name | Model Name (Phase A) | Model Name (Phase B) | No of machines |
1 | Bale plucker | Trutzchler | ReiterA11 | 2 |
2 | Heavy particle separator | Reiter | Reiter | 2 |
3 | Metal Detector | Jossi | Jossi | 2 |
4 | Uni clean | B11 | B11 | 2 |
5 | Hennatex | Rieter | Reiter | 4 |
6 | Unimix | B70 | B70 | 4 |
7 | The vision shield | Jossi BV3 | Jossi BV3 | 6 |
8 | Uniflex | B 60 | B 60 | 2 |
9 | SP-FPO | Trutzchler | Trutzchler | 2 |
10 | Condensor | Rieter A21 | Rieter A21 | 4 |
Table 3.3: Machines involved in the blow room process
3.3.9 BLOWROOM M/C SEQUENCE
UNIFLOC A11 ➝ HEAVY PARTICLE SEPARATOR ➝ JOSSI METAL DETECTOR ➝ UNICLEAN ➝ HENNATEX ➝ UNIMIX ➝ THE VISION SHIELD ➝ UNIFLEX ➝ SP-FPU ➝ CONDENSOR
3.3.9.1 UNIFLOC
• Manufacturer – RIETER
• Model - A11
• Year – 2006
• Air pressure – 6 Bar
• Machine efficiency – 100% (4hrs)
• The main function of UNIFLOC is to open the bale into a small tuft. The working procedure is controlled by a microcomputer and is fully automatic.
3.3.9.2 SPECIFICATION OF UNIFLOC A11
• Normal take-off depth – 0.8mm
• Take off depth range-0.1-20mm
• Traverse speed – 16 m/m
• Take off rpm-1150 rpm
• Efficiency – Stop-go ratio = 84%
• Machine efficiency – 99.9%
3.3.9.3 OVERVIEW HEIGHT POSITION-
• Height position – 1519.4 mm
• Maximum lift – 1519.4 mm
Fig. 3.1: Unifloc
3.3.10 UNICLEAN
• Manufacturer – RIETER
• Model – B12
• Year – 2004
• Speed- 675 rpm
• Speed Range- 480-960 rpm
Efficiency – 85%
Cleaning intensity – 0.4
Assortment – In case of one assortment the machine will operate with only one type of material Relative waste rate – 5
3.3.10.1 FUNCTION OF UNICLEAN: -
In this zone, the basic function is to open the tuft to a small size and to clean the tuft removing big sizes of trash.
Fig 3.2: Uniclean
\3.3.11 HEAVY PARTICLE DETECTOR
The main function of the gravity box is to separate the seed from the cotton and the seed falls into the component tray whereas the cotton is fed to the next machine.
Fig 3.3: Heavy Particle Detector
3.3.12 JOSSI METAL DETECTOR
The main function of jossi metal detector is to separate the metal components present in the fibre with the help of an electromagnet. This avoids the chances of contamination as Ill as the fire accidents in carding.
Fig 3.4: Jossi Metal Detector
3.3.13 HENNATEX
The function of HENNATEX is to detect and remove heavy particles like stones, sand etc. with the help of a conveyor belt and a suction motor.
Fig 3.5: Hennatex
3.3.14 UNMIX
• Manufacturer – RIETER
• Model – B71
• Degree of opening- 0.8
• Opening Intensity – 0.4
• Waste rate – 7%
• Opening roller speed – 69rpm
• Spiked lattice speed – 125rpm
• Conveyer Belt Speed – 0.27rpm
• Feed Roller Speed – 2.6rpm
• Second Opening Roller Speed – 500rpm
• Position of Grid Bars – 35/34mm
• Year – 2004
• Efficiency- 100%
It is a fine cleaning machine. Mixed cotton is fed to this machine for intensive cleaning. The tuft of cotton is converted into a very small size and cotton is cleaned by removing impurities like small leaves, sand, etc. without damage to fibres. The beater speed, no. of spikes and grid bar setting plays important role in cleaning cotton.
Fig 3.6: Unimix
3.3.15 UNIFLEX
• Manufacturer- RIETER
• Model- B60
• Installation-2002
• Speed- 600rpm
• Speed Range- 340-960 rpm
• Position of grid rod angle- 45mm
• Position of feed through- 45mm
• Efficiency- 100%
• Cleaning Intensity- 0.4
• Relative waste rate- 5
• Commercial Staple- 5/16 inch 33.3mm
• Working width of opening roller- 1200 mm
• Air pressure- 0.4-0.6 m3/sec
3.3.16 THE VISION SHIELD
TVS is nothing but THE VISION SHIELD. The main function of TVS is to detect coloured impurities and removed them from the tuft.
3.3.17 TRUTZSCHLER SP-FPU
• Manufacturer- TRUTZSCHLER
• Model- SP-FPU
• Installation- 2004
• Pressure- 820 Pa
• Ejections(F)- 2700/hr
• Ejections(P)- 361/hr
• Waste- 3 Kg/hr
The function of SP-FPU is to remove coloured contaminations such as hair, other fibres etc.
3.3.18 CONDENSER
• Manufacturer – RIETER
• Model – A21
• Feed Roller Speed – 2rpm
• Opening Roller Speed – 500rpm
• Position Of Grid Bar – 35mm
• Year – 2011
• Power – 3*415V50HZ 9A 6BAR
3.3.18.1 FUNCTION OF CONDENSER: -
The material is passed over the perforated drum. The suction is present in the perforated drum. With the help of suction, the dust is removed from a tuft of cotton.
3.4 CARDING
• Manufacturer – RIETER
• Model no – C60
• Opening Roller Chute Feed – 833rpm
• Batt weight – 796gm/mtr.
• Licker-in Speed – 1200rpm
• Cylinder Speed – 700rpm
• Flat Speed – 0.23m/min
• Delivery draft- 1.45
• Delivery rate- 108 mtr/min
• Efficiency- 88 %
• No. of Flats – 79 (In working- 23)
• Cylinder diameter- 810 mm
• Doffer diameter- 680 mm
• Production – 42kg/hr
• Year – 2006
• Power – 3*400V 50 Hz 33A 6BAR
3.4.1 OBJECTS OF CARDING –
• Opening to individual
• Impurities and dust
• Removing of neps
• Elimination of short fibres
• Fiber blending
• Fiber orientation
• Sliver formation
3.4.2 CARDING ACTION –
If two surfaces have opposite wire direction and their speed direction or relative motion is also opposite, then the action between two surfaces is known as carding action.
• It occurred between the licker – and cylinder
• Wire direction is opposite
• Speed direction is opposite
3.4.5 STRIPPING ACTION –
When two close surfaces have the same wire direction & their speed direction or relative motion is also the same then the action between two surfaces is called stripping action.
• It occurs between the licker – and cylinder
• Same wire direction
• Same speed direction
3.4.6 DOFFING ACTION–
When two close surfaces wire points are inclined in opposite directions & their speed direction is the same then the action between two surfaces is called doffing action.
• Doffing action occurred between cylinder and doffer
• Wire direction is opposite but speed direction is the same
• It is a special type of carding
• Sliver formation – is done by this action
3.4.7 GAUGE OF CARDING –
• Feed plate to feed roller – 1.5 mm
• Feed roller nipping distance- 21mm
• Feed roller to licker –in – 0.9 mm
• Licker –into first knife = 0.35mm
• Licker – into second knife =0.45 mm
• Licker –in to cylinder = 0.25mm
• Stationary back to cylinder = 0.35mm
• Flat to cylinder = 0.35/0.35/0.3/0.3/0.3mm
• Front plate to cylinder = 1mm
• Back top plate to cylinder = 1.2 mm
• Front stationary to cylinder = 0.3/0.3
• Front knife =0.3mm
• Doffer to cylinder = 0.175 mm
• Doffer to stripping roller = 0.15 mm
• Doffer to Take off roller- 1.12 mm
• Take off to delivery roller-1.42 mm
• Stripping roller to delivery roller = 0.15mm
• Delivery to apron = 1.12
• Apron to disc roller-1.06
• Cleaning brush of flat = 0.15 mm
• Licker in diameter = 253 mm
• Cylinder diameter = 1290 mm
• Doffer diameter= 500mm
3.4.8 PRODUCTION DATA-
Parameter | M/C 1to9 | M/C 10 | M/C 11to16 |
Mixing | S-6/Organic | MM | DM/DDM |
Delivery Can colour | White Can+ Black Tape | White Can | White Can+ Green Tape |
Delivery Hank | 0.120 | 0.120 | 0.135 |
No. of Licker-ins | 1 | 1 | 1 |
Opening Roller Speed(rpm) | 835 | 835 | 835 |
Licker-In Speed(rpm) | 1090 | 1090 | 1090 |
Feed Wt.(gm/m) | 610 | 800 | 800 |
Cylinder Speed(rpm) | 700 | 700 | 700 |
Flat speed(m/min) | 0.30 | 0.23 | 0.23 |
Delivery(m/min) | 176 | 102 | 100 |
Production(kg/hr) | 52 | 42 | 25 |
Efficiency% | 94% | 87% | 92% |
CV% | 0.4 | 0.1 | 0.1 |
A% | 0.3 | 0.4 | 0.4 |
Table 3.4: Production data
3.5 BREAKER DRAW FRAME
The main object of the draw frame is given as follows-
· to improve the evenness of the sliver and uniformity
· to remove the dust and foreign material from a sliver
· make the perfect blending of the component
· manufacturer – REITER
· Model- SB-D40
· Installation- 2006
· Number of Machines- 9
· Number of doubling- 5
· Drafting System- 4 over 3
3.5.1 RAW MATERIAL SPECIFICATION
• 100% cotton
• Fibre Length- 28-32 mm
• Fineness- 3.4-4.2 den.
• Input sliver hank- 0.1 – 0.3
• Output sliver hank- 0.1 – 0.13
3.5.2 POWER SUPPLY
• 400 V + 10%
• 50 Hz + 3%
3.5.3 OTHER SPECIFICATIONS
• Compressed Air- 6-8 bar
• Suction- Integrated filter box with motor and fan (1000-2000 m3/hr)
• Dimensions-
Width- 2050 mm
Length- 9505 mm
Height- 3700 mm
Fig 3.10: Breaker Drawframe
3.5.4 MACHINE PARAMETERS
PARAMETERS | M/C 1-3 | M/C 4-5 | M/C 6 |
Mixing | MM | DM/DDM | S-6/Organic |
Feed Can Colour | Blue and White+red tape | White+Green tape | White + Black tape |
Delivery Can Color | Blue Can | Blue + Double Green | Blue+Double Black |
Feed Hank | 0.120 | 0.135 | 0.120 |
Delivery Hank | 0.130 | 0.14 | 0.130 |
Draft | 5.41 | 5.18 | 5.41 |
Delivery Speed (m/s) | 500 | 350 | 500 |
Break Draft | 1.50 | 1.40 | 1.50 |
Efficiency | 96 | 89 | 95 |
No. of Doublings | 5 | 5 | 5 |
Table 3.5 Machine parameters- Breaking Drawframe
3.6 UNILAP
• Manufacturer – RIETER
• Model – E32
• Power – 420V 50Hz 36A 7 BAR
3.6.1 OBJECT OF UNILAP –
The main object of this machine is to convert the sliver into a lap sheet for the use of comber
3.6.2 FUNCTION OF UNILAP –
• Combining several slivers into a lap that is ideal for use in comber
• Creating a batt with sufficient cohesion to ensure good lap winding.
• Orienting the fibres to the point that they are optimal for both the lap condition and combing action
• Produce batt in which the fibres are uniformly distributed in the batt cross-section
• Supply lap that will have good unwinding characteristics on the comber
3.6.3 WORKING PRINCIPLE –
Slivers are entered into drafting and over-feed plate. The slivers are drafted in the drafting system. The calendar roller draws the overlapping fleece into the loop formation head due to the strong compression between the calendar roller, and a lap sheet is formed. This is then rolled onto a tube via the top roller and lap disc, the exchange of lap from supply empty tube takes place automatically.
3.6.4 MAIN FEATURE OF UNILAP (E32): -
• 2 – zone drafting for ideal fibre drawing
• 4 calendar rollers and automatic regulation of the lap loading for a perfect lap build-up
• High production rate and quality level using the VARIO speed
• Improved running conditions and better reliability • Function design for greater ease of operation.
3.6.5 MACHINE PARAMETERS
PARAMETER | M/C 1 | M/C 2 | M/C 3 |
Mixing | MM | S-6/Organic | DM/DDM |
Feed Can Color | Blue Can | Blue + Double Black | Blue + 2 Green |
Spool Marking | Plain | Yellow tape | Green |
No. of Doublings | 24 | 24 | 24 |
Delivery Speed (m/min) | 90 | 89 | 90 |
Delivery Lap Wt. (gms/mt) | 66 | 66 | 66 |
Total Draft | 1.555 | 1.555 | 1.469 |
Table 3.6 Machine parameters- Unilap
3.7 COMBER
• Manufacturer – RIETER
• Model – E 65
• Year -2006
• Power – 420V 50Hz
• Air pressure - 7 BAR
3.7.1 OPERATION OF COMBING PROCESS –
• Elimination of a precisely predetermined quantity of short fibre.
• Noil % = (weight of noil produced)/ (total wt. of cotton fed) * 100
• Elimination of the remaining impurities.
• Elimination of neps in the fibre material.
• Formation of sliver having maximum possible fibre parallelization.
3.7.2 THERE ARE FOUR TYPES OF COMBER –
• Rectilinear comber – Works with stationary or oscillating nippers and is mainly used in short-staple spinning.
• Circular comber – It is used in the English worsted process.
• Rotary comber – It is used in the production of scahappe spun yarn.
• Hackling machine – Used in the processing of blast fibres.
Fig 3.12: Comber
3.7.3 MACHINE PARAMETERS
Parameters | M/C 1,2,6 & 7 | M/C 3-8 & 14 | M/C 9-13 &15-18 |
Mixing | MM | S-6/Organic | DM/DDM |
Feed wt. (gm/mtr) | 66 | 66 | 65 |
Spool marking | Plain | Yellow tape | Green Tape |
Delivery Hank | 0.127 | 0.13 | 0.180 |
Delivery Can Colour | Green Can | Green Can+ Black tape | Green can + Green tape |
Noil | 18% | 18% | 20 |
Comber Speed (Nips/min) | 400 | 351 | 250 |
Top Comb Penetration | +1.0 | +1.0 | +1.0 |
Break draft | 1.50 | 1.50 | 1.5 |
Bottom Roller gauge | 48/54 | 48/54 | 47/56 |
Can filling (mt) | 6000 | 6000 | 6000 |
Lap Length (mt) | 300 | 300 | 300 |
Feed/ Nip | 4.3 | 4.3 | 4.30 |
Feed | Forward | Forward | Forward |
Table 3.7: Machine parameters- comber
3.8 FINISHER DRAW FRAME
3.8.1 TECHNICAL DATA –
• Manufacturer – RIETER
• Model no – RSB – D40
• Year – 2006
• Power – 415V 50Hz 22A
• Air pressure – 6 BAR
3.8.2 OBJECTIVE–
This is the process by which the fibre or sliver is elongated by passing it through a series of pairs of rollers, each pair moving faster than the previous one.
The main object of the draw frame is given as follows –
• To improve the evenness of the sliver and uniformity.
• To remove dust and foreign material from the sliver.
• Make perfect blending of the component.
3.8.3 RECENT DEVELOPMENT OF DRAW FRAME –
· Production rate is higher up to 1000 m/min delivery speed.
· Drafting system arrangement, such as 1.4 over 3 with pressure bar.
Fig 3.13: Finisher draw frame
3.8.4 MACHINE PARAMETERS
Parameters | M/C 1,2 | M/C 3,4 | M/C 5,6 |
Mixing | MM | S-6/Organic | DM/DDM |
Feed can colour | Green | Green + Black Tape | Green Tape + Green can |
Delivery Can colour | White | White + Black tape | White + Double Green |
No. of Doubling | 6 | 6 | 6 |
Delivery sliver hank | 0.130 | 0.100 | 0.200 |
Delivery Speed (m/min) | 300 | 350 | 250 |
Bottom roller gauge | 39/43 | 39/43 | 43/47 |
Break Draft | 1.15 | 1.15 | 1.28 |
Total Draft | 5.74 | 5.74 | 6.67 |
Production (Kg/hr) | 72.85 | 75 | 70 |
Can Capacity | 4000 | 4000 | 4000 |
Table 3.8: Machine Parameters- Finisher Drawframe
3.9 SPEED FRAME
• Manufacturer – RIETER
• Model – F 15
• Installation – 2006
• No. of Spindles - 160
• No. of machines – 9
• Drafting System – 3 over 3
• Power - 415V 50Hz 22A
3.9.1 OBJECTIVES OF SIMPLEX:
1. Attenuation of slivers is the chief task of the simplex machine.
2. Insertion of protective twist to impart coherence to the resulting thin fibre strand to hold the constituent fibres tighter.
3. Winding of the roving formed onto the bobbin packages that can be transported, stored and donned on ring spinning machine.
3.9.2 FUNCTIONS:
• Drawframe slivers are presented to simplex in large consist in the creel some arranged in several.
• Driven transparent rollers are present above the can which guide the slivers to the drafting arrangement.
• Attention of slivers takes place which delivers a very thin strand of fibres.
• Winding of the roving formed takes place on account of the difference in the peripheral speeds of the flyer and bobbin which is kept constant to perform controlled winding action effectively.
Fig 3.14: Speed frame
3.9.3 GAUGE SETTING ON SIMPLEX
Back zone | 55 mm |
Front zone | 46 mm |
Spindle gauge | 121.83 mm |
Table 3.9: Gauge setting of simplex
3.9.4 QUALITY CHECKPOINT
• Daily checking of wrapping.
• weekly checking of stretch %
• Stretch % must be less than 0.75
3.9.5 MACHINE PARAMETERS
Parameters | M/C 1 | M/C 2-5 | M/C 7-9 |
Mixing | MM | DM/DDM | S-6/Organic |
Feed Sliver Hank | 0.130 | 0.200 | 0.127 |
Feed Can Color | White Can | White + Double Green | White + Black tape |
Roving Hank | 1.43 | 2.15 | 1.42 |
Bobbin Color | Chocolate+Yellow tape | Badami/red +green tape | Yellow+Black tape |
Break Draft | 1.14 | 1.2 | 1.14 |
Total Draft | 11.0 | 10.75 | 10 |
Spindle Speed(rpm) | 1050 | 900 | 1150 |
Spacer | 4.5 (black) | 4.5 (black) | 4.5 (black) |
TM | 1.45 | 1.36 | 1.45 |
Maximum Cop Diameter | 6” | 6” | 6” |
Bobbin Tapering | 1.6mm | 1.6mm | 1.6mm |
Table 3.10: Machine parameters- simplex
3.10 RING FRAME:
• To draw the roving to its final count in the drafting system.
• To impart tenacity to the bundle of fibres by twisting it.
• To wind up the resulting yarn in a suitable form for storage, transportation & downstream processing.
FUNCTION:
• The roving bobbins are inserted in holders on the creel.
• Guide bars guide the roving into the drafting system, where they are drawn to their firmly
• After the resulting thin ribbon of fibres leads the delivery roller, twist necessary strength is provided by the spindle rotating at high speed.
• In the process, each rotation of the traveller on ring spinning produces a twist in the yarn and takes up the yarn onto the tube mounted on the spindle.
• The rotation of the ring traveller somewhat lags behind that of the spindle due to the relative traveller on the ring and atmospheric resistance of the traveller and thread balloon between yarn and traveller.
• ** This difference in speed between yarn and traveller results in the thread being wound into cylindrical cop form by raising and lowering of rings by ring rail.
3.10.1 SPECIFICATION: -
• Manufacturer – RIETER
• Model – K 441, G331
• No. of Spindles – 1200, 1200
• Drafting System – 4 Over 3
• Spindle Speed – 19500 rpm
• Twist Direction – S, Z
• Cop full at RR position – 178 mm
• Power – 1kWhr
Fig 3.15: Ringframe
3.10.2 MACHINE PARAMETERS
Parameters | M/C 1-21 | M/C 22-27 | M/C 31-42 |
Mixing | DM | MM | S-6/Organic |
Count | 100 CWC | 63’s CW | 40’s CWC |
Roving Hank | 2.15 | 1.43 | 1.20 |
Feed Bobbin Color | Badami/red + Green tape | Black + Red Tape | Blue + Yellow Tape |
Ring Traveller | 16/0 CPF | 14/0 1 CPF HOW | 7/0 1 UL HRW |
Ring Dia | 36/38 mm | 38 mm | 38 mm |
Avg. Rf. Speed | 16015 | 19151 | 19500 |
TM | 4.45 | 4.4 | 14.3 |
Efficiency | 84% | 85% | 85.1% |
TPI | 44.5 | 34.9 | 34.47 |
Total Draft | 50.2 | 47.50 | 46.5 |
Spacer | 2.5 mm | 2.5mm | 2.75mm |
ABC Ring Size (mm) | 42 | 41 | 41 |
Table 3.11: Machine parameters-Ringframe
3.11 WINDING DEPARTMENT
3.11.1 OBJECTIVES OF WINDING
1. To form the larger packages (cone packages) from smaller packages (ring frame spindles)
2. To remove faults such as thin places, neps, slubs, etc.
3. To wax the yarn during the process.
4. To produce packages which enable feasibility in unwinding for the next subsequent processes (such as warping).
5. to enhance the overall strength and quality of the yarn.
3.11.2 FUNCTION:
1. The ring frame spindles are placed in the magazine creel.
2. With the help of a suction system, threads are guided towards the tensioning and yarn-clearing zone.
3. Combined type tensioner helps in the removal of weak places in the yarn.
4. Yarn faults such as uneven places, neps, and slubs are removed or cleared off using slub catchers.
5. After removing the faults, the two ends one from the final wound package and one from the creel zone are spliced pneumatically.
6. Yarn with faults cleared –off is wound on paper cones on the surface-driven winding principle.
7. Yarn traverses through the grooves of the steel drum and gets wound on the cone forming the final packages.
Mixing | DM/DDM 1 to21 | MM 22 to 27 | Organic/s-6 28 to 42 |
Count | 100CWC | 60’s CW | 40’s CHX |
Drum Speed | 1450 | 1400 | 1400 |
Tension | 25 | 17 | 17 |
P4 pressure | 0.5 | 0.15 | 0.15 |
Table 3.12: Machine parameters- winding machine
Mixing | DM/DDM 1 to21 | MM 22 to 27 | Organic/s-6 28 to 42 |
Count | 100’s CWC | 60’s CW | 40’s CHX |
Cone Sign | Red Yen | Green tick | Red Tick |
Cone Wight(kg) | 1.89 | 1 | 1.89 |
Table 3.13: Machine parameters 2-Winding machine
3.12 QUALITY ASSURANCE DEPARTMENT
3.12.1 INTRODUCTION:
Research and development deal with the raw material, final product and the values intermediate products so that I get a quality final product. Apart from this it also includes various efforts done to further improve the quality of the product. The testing laboratory included the following testing equipment.
3.12.2 LIST OF TESTING EQUIPMENT IN QAD:
1. WRAP REEL.
2. USTER EVENESS TESTER.
3. USTER CLASSIMATE QUANTINUM.
4. LEA STRETGH TESTER.
5. TWIST TESTER.
6. R.K.M TESTER
7. YARN APPERANCE BOARD WINDER.
8. STER HVI SPECTRUM.
9. USTER AFIS PRO.
10. MOISTURE METER.
11. TRASH ANALYSER.
12. VERNIER CALLIPER.
3.12.2.1 USTER TESTER 5
OBJECT:
Uster Tester 5 is a multi-purpose instrument for testing yarn, roving and sliver .it can measure hairiness, CV%, U% shape, diameter density, optical evenness, imperfection index(ipi), Thick and thin place, neps etc.
PRINCIPLE:
Capacitance-based (capacitive sensor measure the mass variation, not diameter). Sample length:
• YARN 400 MT.
• ROVING 50 MT.
• SLIVER 50 MT.
3.12.2.2 USTER CLASSIMATE QUANTUM
OBJECT:
Sample size =100km
Speed = 100m/min
Faults categories =A, B, C, D, E, F, G (THICK FAULTS) H&I (thin faults)
Classes:
7th class: -A4+B4+C3+C4+D2+D3+D4
8th class: - A2+B4+C2+C3+C4+D2+D3+D4
4th class: - D1+C2+B3+A3
5th class: - A1+A2+B1+B2+C1
16th class: - All addition
Long thick: - E+F+G
Long thin: - H1+H2+I1+I2
3.12.2.3 USTER HVI SPECTRUM OBJECT:
Its main objective is to find below characteristics-
• Elongation
• Strength
• Fineness
• Color value
• Micronaire
• Maturity index
• Length
• Uniformity
• Short fibre index
• Moisture regains%
• Trash%
PRINCIPLE: Optical and air pressure.
The HVI spectrogram consists of 4 distinct modules to carry out different analyses:
1. Optical module
2. Length & Strength
3. UV module
4. Fineness module
3.12.2.4. USTER AFIS PRO
OBJECT:
· NEPS SIZE
· NEPS/ GRAM
· SEED COAT NEPS
· SHORT FIBRE CONTENTS
· MATURITY RATIO
PRINCIPLE STANDARD VALUES:
1. Carding std: 70 neps/gm
2. Blow room std: 225 neps/gm
3. After combing: 20-30 neps/gm
4. Short fibre contents (N)
3.12.2.5 TWIST TESTER (TPI METER):
OBJECTS:
• Twist/inch (TPI)
• Twist multiplier (TM)
• TPI gives the twist level in the yarn.
3.12.2.6 YARN APPEARANCE BOARD WINDER:
Its main objective is to: -
• Identifies the defect
• To grade the yarn as A, B, C&D
3.12.2.7 WRAP REEL
A wrap reel is used for making lea of 120 yards of yarn either ring yarn or cone yarn.
3.12.2.8 STATEX TRASH ANALYST: -
To determine lint, trash &dust content within a sample of cotton fibre up to 100gms. Also used to determine the non-fibre content of synthetic fibre and to open and clean fibres for further testing.
3.13 LUWA
Manufacturer: Luwa Textile Air Engg. – Switzerland
Software used: Luwa DIGI 5 CONTROL
3.13.1 FUNCTION:
• Air conditioning in the department
• Filtration
• Waste handling of each machine
• Control RH and temperature
3.13.2 WASTE:
• MBO: Dropping waste (gravity box)
• Licker-in: Dropping waste
• Flat: Flat waste
• Draw frame: Sliver waste, fan waste
• Comber: Noil waste
• Speed frame: Roving waste, pneumafil waste • Ring frame: Pneumaphill waste, thread waste.
• Winding: Hard waste
Usable waste: sliver waste, roving waste, pneumafil waste
Non-usable waste: Dropping waste, fan waste, hard waste
3.13.3 WASTE HANDLING FUNCTION: -
The waste is collected in a rotary screen. The rotary screen rotates intermittently independence of differential pressure above the rotary screen. The dust-laden exhaust air of the waste separator must be subjected to post-filtering.
Due to the feeding of the carrier airflow with textile waste the external side of the rotary screen is coated with the fleece of coats. These coats are also capable to separate a large portion of the existing duct.
When the rotary screen rotates the waste coats are carried free of slippage by four racks positioned on the screen in the range of the cellular cylinder the racks are restarted via a cam. So, the cellular cylinder positioned below the rotary screen can remove the waste that coats the separator against the atmosphere.
BENEFITS: -
• Room temperature & RH are controlled with a single drive module.
• Smooth control of room temperature and RH as per setting.
• The material properties of the yarn are perfectly maintained with the maintenance of room temperature and relative humidity of the plant.
• Waste handling is superior and the plant is free from dust and waste.
• Drivers provide the use monitors for user setting of either temperature or RH.
3.14 MAINTENANCE SCHEDULE: -
Name of m/c | Cleaning Schedule |
Blow room | 15 Days |
Carding | 60 Days |
Breaker Draw Frame | 30 Days |
Unilap | 30 Days |
Comber | 30 Days |
Finisher Draw Frame | 30 Days |
Speed Frame | 30 Days |
Ring Frame | 30 Days |
Autoconer | 35 Days |
TFO | 30 Days |
Table 3.14: Maintenance Schedule
3.15 WASTE
The form, quality and utilization depend upon the machine from which it is generated. The different machine generates different type of waste material, which may or may not be further usable by the company. The waste can be reprocessed, used by the company again and the rest of it is sold in the market.
THE WASTE IN THE TEXTILE UNIT IS BROADLY CLASSIFIED INTO TWO GROUPS:
(1) USABLE WASTE:
• Sliver
• Roving
(2) UNUSABLE WASTE:
• Seeping
• Hard waste
• Fan fly
• Dirty cotton
• Blow room dropping
• Card dropping
• Flat
• Comber noil
• Pneumafil
WASTE PERCENTAGE:
• Blow room:8%
• Carding:4%
• Breaker draw frame:0.5%
• Unilap:0.5%
• Comber:20%
• Finisher draw frame: 0.5%
• Speed frame:0.5%
• Ring frame:1.5%
• Winding :3%
TOTAL WASTE: -38.5%
3.16 COSTING
RAW MATERIAL COST-
• Mech -112 Rs/kg
• DCH – 145 Rs/kg
• Shankar 6 – 112 Rs/kg
WASTE REALIZATION-
• Comber Noil – 80 Rs/kg
• Flat Waste – 56 Rs/kg
• Hard Waste – 65 Rs/kg
• Sweeping Waste – 20 Rs/kg
Continue read,
Part 1 Spinning Internship report - Alok (Spinning and Testing)
Part 2 Textile testing internship report
Part 3 Internship report in the garment Industry
Part 4 Knitting industry Internship report
Part 5 Spinning Internship report - Pashupati (Spinning and yarn Testing)
Part 6 Garment Internship report - Komal, Ahmedabad
Part 7 Internship report in Printing and embroidery industry (Mayur-Jetpur)
Part 8 Printing unit Internship report
Part 9 Spinning internship report - Vinod spinners, Ahmedabad
Part 10 Weaving Internship report (Donear mill)
Writer - Ujala Sharma (Textile technologist - LDCE, Ahmedabad)
