himanshu training report 2016

Summer Internship Report

(19th June 2016 – 23rd July 2016)

ARIHANT SPININNIG MILLS (A Unit of Vardhman Textiles) Malerkotla, Dist-Sangrur ,Punjab

Submitted by: Mr. Himanshu Singh B.Tech (CTT), Third Year Indian Institute of Carpet Technology, Bhadohi.

Submitted to:Mr. Balbir SinghAsstt. Vice President ,Unit head (3,4&5) Arihant Spinning Mills,Malerkotla

HIMANSHU SINGH, B.Tech (CTT), Indian Institute of Carpet Technology, Bhadohi page

ACKNOWLEDGEMENT I would like to express my sincerest gratitude towards

VARDHMAN Textiles Ltd. for providing me the best facility & good working environment during my training period, at their esteemed organization. I am grateful towards each and every

employee of the ARIHANT SPINNING MILLS, MALERKOTLA (PB) for providing me their valuable time & experience.

It is indeed a great pleasure for me to express my profound and sincere thanks to Mr.Balbir Singh (AVP) for his co-operation. I would

like to thank Mr. Charanjeet Goyal (SM of unit 5) for giving his valuable time & attention during my training. Their instructions proved

to be quite beneficial during the training period.

I would like express my warmest gratitude to Mr.Om Narayan,Mr. Lovepreet Singh,& Mr. Manjeet Rohilla for providing me a

friendly & stress free learning environment.

Mr. Charanjeet Goyal assigned me a project titled, STUDY ON SOFT WASTE AND ITS MANAGEMENT IN SPINNING

for completion during my training period. I would like to thank Mr.Manjit rohila,Mr. Thakur ji & the Relievers for guiding me smoothly

through to the completion of this project. They provided me all the guidance, their valuable time and resources without which it would

have been a difficult task for me to successfully complete the project assigned to me.

My association with the Vardhman Textile Ltd. over the past five week has been immensely fruitful & I sincerely hope that this association will

continue.

Thank You Vardhman!!!

Himanshu Singh, Summer Trainee 2016


Contents

1. VARDHMAN: An Introduction.2. Unit 3: Machineries, their Make & Model. 3. Departmental Functioning.4. Raw Material Consumption. 5. Raw Material Handling. 6. Machineries & Processes:

• Blowroom• Mixing Bale Opener • Blendomate• Flexiclean• Unimix• Cleanomate• Carding • Draw frame • Unilap• Comber • Speed Frame • Ring Frame • Post Spinning Processes • Conditioning • Packing

7. H-Plant. 8. Cleaning Schedules. 9. Counter Measures for Alarm Generation.


Vardhman: An Introduction

Vardhman Group is a leading textile conglomerate in India having a turnover of $1200 million. Spanning over 27 manufacturing facilities in five states across India, the Group business portfolio includes Yarn, Greige and Processed Fabric, Sewing Thread, Acrylic Fibre and Alloy Steel.

Vardhman Group manufacturing facilities include over 10,00,000 spindles, 65 tons per day yarn and fibre dyeing, 900 shuttle less looms, 90 million meters per annum processed fabric, 33 tons per day sewing thread, 18000 metric tons per annum acrylic fibre and 100,000 tons per annum special and alloy steel.

Vardhman has evolved through history from a small beginning in 1965 into a modern textile major under the dynamic leadership of its chairman, Shri S.P.Oswal. His vision and insight has given Vardhman an enviable position in the textile industry. Under his leadership, Vardhman is efficiently using resources to innovate, diversify, integrate and build its diverse operations into a dynamic modern enterprise.

Vardhman Mission:

Vardhman aims to be world class textile organization producing diverse range of products for the global textile market. Vardhman seeks to achieve customer delight through excellence in manufacturing and customer service based on creative combination of state-of-the-art technology and human resources. Vardhman is committed to be responsible corporate citizen. “Our Quality is the result of the state of the art technology and in house R&D efforts .We continue to move towards exploring new horizons”

S.P.Oswal Chairman Vardhman

Group History:


The industrial city of Ludhiana, located in the fertile Malwa region of Central Punjab is otherwise known as the "Manchester of India". Within the precincts of this city is located the Corporate headquarters of the Vardhman Group, a household name in Northern India. The Vardhman Group, born in 1965, under the entrepreneurship of Late Lala Rattan Chand Oswalhas today blossomed into one of the largest Textile Business houses in India. At its inception, Vardhman had an installed capacity of 14,000 spindles, today; its capacity has increased multifold to over 8 lacs spindles. In 1982 the Group entered the sewing thread market in the country which was a forward integration of the business. Today Vardhman Threads is the second largest producer of sewing thread in India. In 1990, it undertook yet another diversification - this time into the weaving business. The grey fabric weaving unit at Baddi (HP), commissioned in 1990 with a capacity of 20,000 meters per day, has already made its mark as a quality producer of Grey poplin, sheeting, and shirting in the domestic as well as foreign market. This was followed by entry into fabric processing by setting up Auro Textiles at Baddi and Vardhman Fabric at Budhni, Madhya Pradesh. Today the group has 900 shuttleless looms and has processing capacity of 90mn meters fabrics/annum.

In the year 1999 the Group has added yet another feather to its cap with the setting up of Vardhman Acrylics Ltd., Bharuch (Gujarat) which is a joint venture in Acrylic Fibre production undertaken with Marubeni and Exlan of Japan. The company also has a strong presence in the markets of Japan, Hong Kong, Korea, UK and EU in addition to the domestic market. Adherence to systems and a true dedication to quality has resulted in obtaining the coveted ISO 9002/ ISO 14002 quality award which is the first in Textile industry in India and yet another laurel to its credit.

Business Portfolio:

The group portfolio includes Yarn, Fabrics, Sewing Thread, Fibre and Alloy


Steel.

Yarns:

Yarn Manufacturing is the major activity of the group accounting for 47 percent of the group turnover. Vardhman is virtually a supermarket of yarns, producing the widest range of cotton, synthetics and blended, Grey and Dyed yarns and Hand Knitting Yarns, in which Vardhman is the market leader in India. The group has twenty one production plants with a total capacity of over 8 lacs spindles, spread all over the country. In many of the yarn market segments, Vardhman holds the largest market share. Vardhman is also the largest exporters of yarn from India, exporting yarns worth more than USD 150 million.

Sewing Threads:


Vardhman is the second largest producer of sewing thread in the country. The sewing thread manufacturing capacity is being expanded from 17 tons per day to 33 tons per day in its sewing thread plants located at Hoshiarpur, Baddi and Ludhiana. Sewing threads contributes 11 percent of the group turnover.

Fabrics:The group has created state-of-the-art fabric weaving and processing facilities in its plant at Baddi, Northern India. The group has installed 900 shuttleless looms and a fabric processing capacity of 90 million meters per annum in collaboration of Tokai Senko of Japan. Fabrics business contributes 22 percent to the group turnover.

Fibre:

The group has set up an Acrylic Staple Fibre plant at Bharuch in Gujarat in collaboration with Marubeni and Japan Exlan of Japan. The plant has annual capacity of 18000 tons per annum. Fibre contributes 8 percent to the total turnover of the group.

Steel:

The Group is also present in upper-end of the steel industry. The group has manufacturing capacity of 100000 tons of special and alloy steel. The group supplies its steel products to some of the most stringent quality steel buyers like Maruti and Telco. It contributes 10 percent to the total turnover of the group.

Manufacturing Units of Vardhman Group:

• Vardhman Spinning and General Mills, Ludhiana. • Auro Spinning Mills, Baddi (HP). • Auro Dyeing, Baddi (HP). • Auro Weaving Mills, Baddi (HP). • Auro Textile, Baddi (HP). • V.S.G.M. 100% E.O.U, Baddi (HP). • V.S.G.M. Unit 2, Ludhiana.


• V.S.G.M. Unit 3 Ludhiana. • Mahavir Spinning Mills Limited, Baddi (HP). • Mahavir Spinning Mills Limited, Hoshiarpur. • Arihant Spinning Mills, Malerkotla. • Anant Spinning Mills, Mandideep. • Vardhman Special Steel, Ludhiana. • M.S.M.L. Sewing Threads Unit 2, Ludhiana. • Arisht Spinning Mills, Baddi (HP). • Arisht Spinning Mills 100% E.O.U, Baddi (HP). • Vardhman Polytex, Bhatinda. • Anshupati Textiles, Ludhiana. • V.M.T. Spinning Corporation Limited, Baddi (HP). • Vardhman Acrylic Limited, Bharuch. • Vardhman Yarns & Threads Limited, Baddi (HP).

Major highlights of the group:

• Largest producer of cotton, synthetic and blended yarns in the country. • Largest dyeing capacity of fiber and yarn • Largest exporter of cotton yarn. • Largest range of textile products. • Second largest producer of sewing threads in the country. • Collaborations with specialists worldwide. • Installation of state of art machine from Switzerland, Germany, South

Korea, Japan and Italy. • Exporting to the countries with the most stringent quality standards

requirements like Hong Kong, Switzerland, Germany, South Korea, Japan, Spain, Brazil and Italy.

• First in the Indian textile industry to get ISO certification. • Winners of the maximum export achievement awards.


Chief Manager (M4)

Senior Manager (M3)

Junior Manager (M2)

Dept. Manager (M1)

Organizational Structure:Vardhman is a vertically structured organization, envisaging a new era of textile materials under the leadership & guidance of Shri S P Oswal& the dynamism of Mr. Sachit Jain. The Organizational Hierarchy of Vardhman can be depicted in the form of a flow chart is as follows:

Chairman

Executive Director

Unit Heads

VP (C & A) GM (Technical)


Supervisors & Relievers

Vardhman TPM Policy:“Maximize overall effectiveness & reliability of the plant & machinery, by aiming at zero breakdowns, reducing defects, reducing losses & improving safety by nurturing team work & continuous development of all employees, following JIPM roadmaps for implementation of TPM in the company.”


COMPANY OVERVIEWNAME OF INDUSTRY: ARIHANT SPINNING MILLSLOCATION: Industrial area,Malerkotla,Distt.Sangrur,PUNJABThe campus of Arihant spinning mill is very beautiful and green.The industry has various departments and for production purpose the mill is divided into five units. Due to new thinking & good leadership, the Arihant Spinning Mills achieved tremendous excellence in all fields of the yarn manufacturing business.

Arihant Spinning has never looked back; and it is the cascading effect of Arihant Spinning’s success that today the product of 5 units of this industryexported to all over world. Today these units are pledging us even greater success in the future, under the able leadership of Mr.Kuldeep jain, the Head of Arihant spinning mills.The list of varios department in ARIHANT SPINNING MILLS are:

1.PRODUCTION DEPARTMENT 2.MAITENANCE DEPARTMENT 3.RESEARCH & DEVELOPMENT DEPARTMENT 4.COMMERCIAL & ACCOUNTS DEPARTMENT 5.ENGINNERING DEPARTMENT 6.INDUSTRIAL RELATIONSHIP & HUMAN RESOURCE DEPARTMENT

Capacity:Production Unit Spindles (R/F) No. of Machines

(R/F)Major Products

Unit 3(Mr.Charanjit Goyal)

21600 25 Mélange yarn

Total Spindle Capacity: 21600 Total Production Capacity: 8 Tons/day. Statistical Quality Control Department Research & Development Department Export Oriented Unit

HIMANSHU SINGH, B.Tech (CTT), Indian Institute of Carpet Technology, Bhadohi

Unit 3: An IntroductionUnit 5 has got the distinction of being the most versatile production unit in Arihant Spinning. Other than having the highest spindle capacity amongst all production halls, it ably manages to balance the wide range of yarn manufacturing that comes under its ambit. Right from the normal combed yarn, to the core spun yarn & specialty yarns like elitwist are manufactured here. Interesting & effective, as though it may seem, but managing a production hall with such varieties is a difficult job & the various types of new blends & mixings that keep coming up, make the task that much more complex for the people at helm. Unit 5 maintains its steady, stable & successful run owing to the following people: 1. Mr. Balbir Singh (AVP) 2. Mr. Charanjit Goyal(SM) 3. Mr. Om Narayan (Shift Officer)4. Mr. Lovepreet Singh (Shift Officer) 5. Mr. Mandeep Singh (Shift Officer) 6. Mr. Manjeet Rohila (Shift Officer)

Overview:Total Spindle Capacity: 21600Total Production Capacities: 8 Tons Count Ranges: 40-200 Ne Normal Combed Yarns

20-80 Ne Slub Yarns 20-80 Ne Blended Yarns 25-120 Ne Compact Yarns

Product Types: 100% Combed, CSY, Slub, Multicount, Multitwist, Cotton Yarn.

Machineries:1. Blow Room : LMW MBO, Trutzschler Blendomate, Trutzschler

Cleanomate, Trutzschler multimix, LMW Flexiclean,Trutzschler Maxiflow. 2. Carding : Trutzschler DK903, Trutzschler TC 03, LMW 363 LC.3. Unilap :Rieter E-32.4. Drawframes: LMW LDO6, Laxmi Rieter LDO6,Laxmi Rieter RSB851,LMW

LRSB851 Rieter SB-2.


5. Combing : Rieter E7/5, LMW LK64.6. Speed Frames : LMW LF 1400A, LMW 4200A. 7. Ring Frames : KTTM Rxi240.8. Winding : Schlafhorst 238 & 338.

Machineries, their Make & Model

S.No.

Machine name No. ofMachines

Manufacturer Model

1 Multi Bale Opener 4 LMW B ¾,LB 3/62 Blendomate 1 Trutzschler Type-09161083 Cleanomate 1 Trutzschler LVSA 3754 Multimix 3 Trutzschler B 7/35 Flexiclean 4 LMW LB 5/66 Cards 22 LMW ,Trutzschler LC 363,DK

903,TC-5,TC-03

7 Breaker Drawframe 4 Lakshmi Rieter LDO 6

8 Finisher Drawframe 5 Lakshmi RieterRieter

RSB- 851 SB-2 LRSB B51

9 Unilap 1 Rieter E 32

10 Comber 5 RieterLMW

E 7/5 LK64

11 Simplex 8 Lakshmi RieterLMW

LF 1400 ALF 4200

12 Ringframe 25 Lakshmi KTTM.

13 Cone Winding 10 Schlafhorst Autoconer 338 Autoconer238

14 Yarn conditioning m/c

1 Xorella Conditioner

Profix 1500 (2M)


Material FlowDepartmental Function ARIHANT Spinning enjoys a smooth running of the various industrial processes,as

result of the proper coordination & working of its different departments. The functions of all departments of Arihant Spinning are as follows:

1. PRODUCTION DEPARTMENT:

1. To make yarn. 2. To give maximum production & reduce material loss. 3. Effective handling man power so to get maximum production

2. MAINTENANCE DEPARTMENT: 1. Routine checks of the machine. 2. Changing the spare parts from time to time. 3. Oiling & greasing of machine.

3. PERSONNEL & ADMINISTRAIVE DEPARTMENT:

1. Recruitment of various employees. 2. To decides salary & wages. 3. Placements. 4. Attendance record. 5. Housekeeping. 6. Industrial relation. 7. Activity of employer.

4. R&D DEPARTMENT:

1. To check quality of material. 2. To check waste at each stage & reduce waste. 3. To decide quality parameters. 4. To assure the outgoing quality of products.

5. COMMERCIAL DEPARTMENT : 1. To purchase raw material. 2. Accounts management. 3. To store various material as per requirements.


6. ENGINNERING DEPARTMENT:

1. To manage the breakdown of the machine. 2. To install new machines.

Raw Material ConsumptionAs a result of the prevalence of a large number of mixings & blends in Unit 3, the raw material (fibers) consumption is also quite high & varied. Several types of Indian & Foreign Varieties of Cotton are used in unit 3. A tabular description of all such fibers along with their properties is as follows:

Cotton Variety

StapleLength(mm)

Strength(g/tex)

Micronaire

Region of Produce

Type Bales Issued*

J-34 28.5-29.5 29-30 4.5-5 Punjab,Haryana,Rajasthan

Indian 1124

Shankar6

29-30.5 29.5-31 3.9-4.5 Gujarat Indian 1402

Shankar6 (OG)

30.86 32.82 3.9-4.5 Gujarat Indian 584

Shankar6 (SOG)

30.39 32.60 3.9-4.5 Gujarat Indian 434

MCU-5 (Normal)

29.5-31.5 30-32 3.7-4.6 Maharashtra Indian 916

MCU-5 (SOG)

31.42 32.39 3.7-4.6 Maharashtra Indian 190

MCU-5 (OG)

30.75 32.10 3.7-4.6 Maharashtra Indian 725

DCH-32 (Normal)

34-36 35-38 3.5-3.9 Andhra Pradesh

Indian 41

DCH-32 (OG)

35.14 37.98 3.5-3.9 Andhra Pradesh

Indian 120

SUVIN 28.53 29.60 3.2-3.5 Tamil Nadu Indian 0GIZA86 33-35 36-38 4.3-4.8 Egypt Egyptian 50GIZA88 35-38 38-40 4-4.5 Egypt Egyptian 0 *in one month to UNIT 5.


Other foreign cotton varieties used are: MOT, AKALA and SHIKALA.

Raw Material HandlingIn order to handle order & receive of Raw Materials, following set of Standard Operational Procedures (SOP) is followed at Arihant Spinning Mills:

1. Steps of Receipt of Material & its weighting:

• Entry of Raw Material Truck & its Parking • Handing over of Raw material invoice to Security Department. • Verification of Invoice &Issual of a running Serial No. to the Truck. • Intimation of arrival of Raw materials to the Commercial/Raw Material

Department & handing over of its documents to the latter. • Inspection of the Truck, as a measure of security. • Weighment of the material, at the Weighment Bridge, up to a capacity of

60 tons. • Issual of Weighment slips to the truck, in double copy, along with all

particulars. • Guiding the Truck to the correct Raw materials godown.

2. Steps of Unloading & Sampling for R&D Department:• At the godown, the godown Boy whether the Truck & Raw material inside

is in perfectly sealed condition. • After the above verification, the material is unloaded & stacked inside

the godown in the order of their Bargain Nos. • After unloading, the godown boy collects samples of raw material under

the supervision of R&D Department official, for testing at R&D. • After testing the Raw material, the R&D department sends the report to

Raw Materials Department for cross checking, so that any deviations from actual order can be seen & appropriate measures be taken.

• In case of Imported Raw Cotton, bales are arranged in Godown, according to the Grade of cotton.

• The receipt of receival of raw materials is issued by the Commercial Department.

3. Steps of Storage of Materials:• Raw Material In charge handles the safe maintenance & stacking of

materials in the godown. • Fire & other risk coverage are provided to the raw material by the Unit.


• Raw material is arranged in the godown by a hand trolley & is stacked up to a height which is sufficiently less than the godown height.

• Three registers are maintained by the godown boy, namely; Raw Material receipt register, godown wise Stock register & Raw Material issue register.

4. Requisition by R&D Department to the Raw Material Department:• R&D department prepares the data of raw cotton available within the

unit, in their system & gives an issue slip through production department to the Raw material department.

5. Issuance of Raw material & punching in the ERP System:• Checking & verification of issue slips & instruction of issue of raw

material to the godown boy. • Pasting of issue slips on each bale, which is to be issued. • Transport of bales from godown to the Production department by

driven trolley cars. • Intimation of transfer to the raw material Department. • Raw materials assistant cross checks the stock & then punches the

issue slip in the ERP System. • In case of inter unit material transfer, intimation shall be sent to the

R&D Department

BlowroomObjectives:

Opening The raw material enters spinning mill in the highly compressed form to enable optimum transport and storage condition in blow room. The bigger tufts of fibers are made into smaller tufts with minimum damage to the fibers. Cleaning To remove foreign seed particles leave from fibers. During opening and cleaning there is always loss of good fibers. So the blow room line is selected such that the optimum opening and cleaning is obtained with minimum loss of good fibers. The cleaning efficiency of cotton in blow room section is approximately 75 – 80%. Dust Removal


To remove finer impurities like dust particles and very short fibers by suction units e.g. cages. As the opening of the material increases the dust removal capacity also increases. Blending To mix the different varieties of cotton bales thoroughly. This will give a homogeneous distribution of fiber in the yarn cross section.

Cleaning in Blowroom:A Blow room line eliminates app. 70-80% impurities. Result depends upon raw material and the machine & on the environment condition.

Dust Removal:Almost all machine of blow room line remove some amount of dust. Suction unit takes out dust removal. About 65-70% dust removed

Mixing Bale Opener

MAKE : LMW MODEL : B 3/4 YEAR : 1999 NO. OF MACHINE : 4

It is first installation of B/R line after hand opening & mixing. Cotton is fed onto the creeper lattice & spikes of inclined lattice lift flocks. There are 39 spikes in each row having 1” height. Then pair of spikes roller come in contact and cut the large flocks & fed to pair of feed rolls and to disc type beater with 6 grids under it which cleans the dust, dirt and other mass impurities. The trash removed by MBO is approx- 3.14 %.

MACHINE DATA:


Processed Raw Material: Cotton : All varieties. Manmade fibre : Up to 65 mm Technical Data: Production : 400 Kg/hrWorking width : 1200 mmBeater dia. : 400 mmBeater speed : 600 rpmBeater type : disc typeExhaustion 4 m3/secondInlet powerAirflow Rates:

: 15-16 kw

Suction delivery : 0.4 m/secDust extraction : 4 m/secMaterial supply : 1.6 m/secSetting: Inclined lattice to Evener roller : 1.5 mm Inclined lattice to Stripper roller : 6 mm Disc beater to feed roller : 1 mmDisc beater to grid bars : 3 mmBetween feed rollers : 1 mmTraverse plate : 3 mmWaste plateSpace requirement:

: 0, 0, 2, 3, 4

Total width : 1500 mmLength : 7000 mmHeight : 1500 mm

BLENDOMATE

MODEL : A/10


MAKE : TRUTZSCHLERYEAR : 2000 NO. OF MACHINE : 1Introduction:Blendomate is a fully automatic machine manufactured by Trutzschler. It is important section of Blow Room line in spinning department. It is bale-plucking device. Simultaneously mixing is done by this machine. By using this machine we can directly take the cotton tuft from bale & send it for further processing. It can move left & right traverse and pluck the bale cotton.

Basic Function:The basic function of blendomate is stripping bales & feeding to the down stream machine with flock shaped material. The rotating take off roller, moves over the bales, the material removed in the form of tufts, is transported pneumatically to the downstream machine. The swivel tower with the take off unit can be turned through 180 automatically. The flock shaped material taken pneumatically conveyed to next machine. These small tufts are essential for optimum cleaning .These small tufts offer a large surface area so trash, dust & dirt are exposed and can be removed gently.

Technical Data:

Material :-Cotton, MM fibre up to 60 mmProduction rate :-One assortment-up to 1500 kg/hr

Two assortment-up to 1100 kg/hrThree assortment-up to 750 kg/hrFour assortment-up to 600 kg/hr

Machine efficiency :- 50%Installed power :- 12.98 kwContact roller dia. :- 125 mmPlucking roller dia. :- 288 mmPlucking roller speed :- 1800 rpmLegs on each beater :- 4Teeth on each legs :- 38Traverse drive speed :- up to 12.0 m/minTake off depth (Index) :- up to 20 mmMain frequency :- 50 hzOperating mode :- Automatic mode


DRIVE:-

1. Traverse drive2. Lifting drive3. Take off roller drive4. Tower swivel drive – for 180 rotation5. Fan drive6. Axiliary fan

LIMIT SWITCHES:-

1. Foreign body monitoring.2. Lift limitation top/ bottom3. Door safeguards4. Overload protection on take off unit

STOP MOTION SENSOR:- All drive will automatically shut off immediately as soon as anybody is detect in the range of motion sensor.

CLEANOMATEMAKE :- TRUTZCHLERMODEL :- LVSA 375YEAR :- 2000

NO. OF MACHINE :- 1


Introduction:This is a machine for cleaning and extracting dust from cotton of any origin. Impurities are removed gently and efficiently. The raw material is feed through without nipping. The material enters via the tube connection. The clean material is sucked through the tube & fed to the next machine.

Working:The machine has only one roller. The material enters into the machine at one side and streams through to the other side. In order to prevent flocks being drawn straight through the machine. The different type of beating elements result in- Coarse opening, Medium opening, Fine opening. Of tufts so that the impurities are liberated, micro dust are taken away by the positive suction through perforated sheets. The tufts are caught by the special tines on the roller. Cleaning intensity (rotating speed of the roller) can be infinitely adapted to the raw material while the machine is running. The guides plate carry the tufts in a spiral over the grid seven times. The combination of cleaning intensity and waste rate ensures efficient cleaning with only few second fibers left in the waste and no crushed waste particle.

Waste Disposal:Waste is removed periodically via the air lock roller and the conduit. The interval is determined by the pneumatic waste transport system. The air lock roller separates the waste room from the transport air conduit. In this way the waste extraction process at the grid is not affected.


Machine & Technical Data:-Length of machine : 2450 mmWidth of machine : 1100 mmWorking width : 1600 mmHeight of machine : 2000 mmBeater type : Pin typeBeater dia. : 750 mmBeater speed : 400-800 rpmNo. of grids : 30Motor speed : 1440 rpmBeating point : 1Production rate : Up to 900 kg/hr

Salient Features:1.Grid adjustment is done by two electrical cylinder automatically by a microprocessor. 2.The whole operation of machine is controlled by microprocessor. 3.High production rate up to 900 kg/hr. 4.Opening cleaning & de-dusting Combined. 5.Individually adjustable traversing grids. Waste collection by conveyor. Multiple element beater. Higher cleaning efficiency. No. Of machines = 2 Functions :- Loose feeding to avoid breakage Free flight opening Relative amount waste = 10 Cleaning intensity = 0.9 Pin roller speed = 733-768 rpm(actual/nominal) Grid angle = 20


No. Of machines = 2 Functions :- Loose feeding to avoid breakage Free flight opening Relative amount waste = 10 Cleaning intensity = 0.9 Pin roller speed = 733-768 rpm(actual/nominal) Grid angle = 20

MULTI MIX

MAKE :- TrutzchlerMODEL :- 2361037YEAR :- 2000NO. OF MACHINE :- 1

INTRODUCTION :- The material supplied is segregated into layers by the partition. Mixing occurs by displacement of the material entry and material exit.The spike lattice remove material simultaneously from al layers so that homogenous mixing occur. The take off roller removes the material from the spike lattice while the tufts are pneumatically sucked off.

WORKING:-It consist of six chamber so that homogeneous mixing take place first of all the material comes from Varioclean with the help of ventilator. Ventilator is place the above the Varioclean after that material falls in six chambers and collects to the beater. Beater is a saw tooth type roller. Another object of the beater is opening and cleaning of cotton. It consists of three parts.


1. Storage section 2. Intermediate section 3. Delivery section 4.

MACHINE & TECHNICAL DATA :-

Machine efficiency :- 20-25%Production :- 600 kg/hrWidth :- 1800 mmWorking width :- 1200 mmHeight buffer storage :- 3500 mmSection to mid feed pipe :- 3750 mmStorage capacity :- 250 kgNo. of beater :- OneBeater :- Pin typeDia. Of motor pulley :- 108 mmDia. Of machine pulley :- 365 mmMotor speed :- 1440 rpmBeater speed :- 400 rpmConveyer belt speed :- 0.62 rpmInclined spiked lattice to take off roller : .05 mm Spiked feed lattice :- 209 rpm Pressure with full storage :- 400 Pa Actual pressure :- 200 Pa Operating mode :- Automatic mode Waste (%) :- 0.7-1.0 % Beating point :- 1

SETTINGS :-

Inclined spiked lattice to take off roller : 05 mm


Inclined spiked lattice to stripper roller : 20 mm Grid bar to beater : 03 mm Beater to feed roller : 05 mm Feed roller to feed roller : 01 mm

SALIENT FEATURES:-1. It produces up to 600 kg/hr with Blending, Opening & with Cleaning. 2. It is equipped with intensive opening & micro dust removal achieved by means of a

feed roller pair, cleaning roller with grid & positive suction. 3. It could be used as a feeding machine. 4. Photoelectric cells are used for monitoring the fibre flow.

Flexiclean

In this machine a fan sucks the flocks &effect them into filling chutes. The rear wall of machine (chute) consists of individual Aluminum lamella with slot opening through which the air escape. The raw material remains in the chute is condensed, is fed to opening rollers by means of filling drums, blind drums and feed roller pair. The opening roller is exchangeable & can be fitted with blades, discs or saw toothed clothing.The grid arranged under the roller consists of 8 blades

MACHINE SPECIFICATION :-

Maker : LAXMIModel : LB 5/6Year : 2014No. of machine : 4

Production rate : 400 kg/hr


Motor speed : 1440 rpmFeed roller dia. : 60-80 mmPlain drum dia. : 250 mmPerforated drum dia. : 250 mmBeater dia. : 400 mmBeater speed : 600-1000

rpmMotor speed (fan) : 2850 rpmNo. of beater : 1Beater type : Saw toothedBeating point : 1Air discharge rate

SETTING :-

: 14-175 /sec

Feed roll to feed roll : 2 mmBeater to feed plate : 2.7-3 mmBeater to grid bar : 1-4 mmFeed roll to beater : 2-7 mm

Working principal of Aero feed system :-

In the Rieter blow room one or two fine opener / cleaners open the fibres and feed them into the distribution system. The fibres pass through the fan and are blown into the transportation ducts that pass over the tops of the chutes. The top chamber of the chute has a perforated side sheet though which the transporting air flows. All of the transportation air has to pass through the perforated sheets, and depending upon the degree of chute filling the fibre passes to the chute with the least resistance to air flow. When all top chambers of the chutes are full, there is reduced airflow and the over-pressure increases in the feeding ducts. A pressure sensitive switch, between the fan and the first chute detects the pressure increase and stops the feeding machine. Similarly, when the air pressure drops to a pre-set low level the feeding machine is again started.


The chute is part of the aero feed pneumatic card feeding system. It can be used in a linear arrangement or in the “U” form. A cross-sectional view of a typical chute is shown in the illustration. The fan blows the fibres through the fibre duct (1). Gravity and the airflow cause the fibres to fill the upper feed chamber (2). The transport air passes through the perforated sheet into the extraction air duct. As fibre is fed to the lower chute, the perforated sheet is exposed allowing more air to flow bringing additional fibre to the upper chuteThe upper feeding chamber is equipped with a single feed roller (3), a feeding plate with a defined nipping point to control the fibre flow to the opening roller (4), which opens the material into tufts and transport the lower chute (5).

Specification of Chute feed system:-

Production=15-80kg/hr/chute.Feed wt=600-800gm/mt.Opening roller speed=815 rpm.Motor pulley of opg. Roller=129mm.Pressure=5-6 bar.


CARDING Objects:Carding is considered to be the culmination of those preparatory operations aimed at opening, blending, and cleaning the fiber stock .The functions of a carding machine vary with the card design, raw material, and end product but these can be generalized as

1. Fibre to fibre separation 2. To affect thorough mixing of the Fibre3. Short fiber removal 4. Removal of remaining trash of B/R process 5. Nep reduction 6. Individualization and partial parallelisation of fibers 7. Conversion of Lap or opened fiber into sliver

Card Clothing (wire specification) :-

LICKER-IN WIRE :- E 5510*1.20Wire height :- 5.5 mmWire angle :- 100

Wire thickness :- 1.2 mmPPSI (TPSI) :- 8.46

CYLINDER WIRE :- R 2030*0.5Wire height :- 2.0 mm


Wire angle :- 300


DOFFER WIRE :- N-4030*.85RWire height :- 4.0 mmWire angle :- 300


FLAT TOPS :- PT 52KV4SFL :- 5F+2K-COSFD :- 3F+1K Syc62

SETTING (GAUGE) IN CARD :-

Feed plate to Licker in : 0.8 mmLicker in to Cylinder : 0.2 mmLicker in to Mote-knives : 0.3 mmLicker in to Combing segment

: 0.55 mm

Carding plate Gauge : 0.35, 0.3, 0.3 mmBack bottom plate

:0.6 mm

Back top plate :

0.7 mm

Cylinder under casing :

1.3, 1.5, 1.3, 2.6 mm

Flat to Cylinder :

0.3, 0.25, 0.25, 0.25, 0.25 mm

Front Bottom plate :

0.55 mm

Front Middle plate : 0.25 mmFront Top plate

:0.75 mm

Flat comb Blade gauge :

0.25 mm

Cylinder to Doffer gauge : 0.125 mmDoffer to Stripper roller

:0.15 mm

Stripper roll to Groove roll gauge :

0.15 mm

Groove roll to Crush roll gauge : Top Crush roller to

Bottom Crush

0.15 mm

roller gauge :

0.125 mm


C-cleaner setting :

0.25 mm

STOP MOTIONS:1. Chute feed stop

motion 2. Feed roll stop motion

3. Flat stop motion 4. Calendar stop motion 5. Sliver break stop motion

6. Full can stop motion

INSTALLED POWER FOR FILTER BOX VERSION:

Main motor : 5.5 kwDoffer motor : 1.8 kwFan motor : 3.7 kwFeed motor : 0.75 kwPhilliption brush motor : 0.25 kwControl system : 0.65 kwWeb doffing motor : 0.55 kwBrush motor : 0.12 kwTotal : 13.57 kwTotal for central section : 9.62 kw

COMPRESSED AIR REQUIREMENT:System pressure : 6 bar minimum (87 psi) Operating pressure : 4-5 bar (58-72 psi)


Air consumption : 0.7 Nm3/hrConnecting hose dia. : 8 mm

SUCTION REQUIREMENT:

All waste together (upward/downward) : 900 Pascal at 1.1m3/sec Separate waste collection Licker in (upward/downward) : 800 Pascal at 0.4m3/sec Others (upward/downward) : 800 Pascal at 0.8m3/sec

DrawframeDraw frame is a very critical machine in the spinning process. It's influence on quality, especially on evenness is very big. If draw frame is not set properly, it will also result in drop in yarn strength and yarn elongation at break. The faults in the sliver that come out of draw frame cannot be corrected. It will pass into the yarn. A series of rollers rotating at different rates of speed elongate the sliver into a single more uniform strand that is given a small amount of twist and fed into large cans. The factors that affect the yarn quality are

1. The total draft 2. No of draw frame passages 3. Break draft 4. No of doublings 5. Grams/meter of sliver fed to the draw frame 6. Fiber length 7. Fiber fineness 8. Delivery speed 9. Type of drafting 10. Type of autoleveller11. Autoleveller settings

Objects:

Fiber orientation:To obtain an original strength of yarn the fibers must be arranged parallel in the yarn. By drafting the fibers are straightened and lie parallel to the sliver axis.

Improve evenness of sliver:


The regularities of card sliver is very much affected due to the variation in the removal of waste of the card and piecing after every stripping in flexible card clothing. The process of doubling improves the regularity of the final sliver by averaging out the weight variations existing in sliver feed to draw frame.

Blending:The practice of feeding several slivers side by side through the draw frame and recombing them at the front allows a very thorough blending of fibers in the individual slivers and thus making the final sliver more uniform than card sliver in fiber composition along its length.

Dust removal:The draw frame is provided with a suction clearer which removes the dust, short fibers tending to adhere to the roller during drafting

Breaker and Finisher:

Generally the card sliver is passed two times through the draw frame. The first passage on draw frame is called breaker draw frame. In this passage carded can sliver is fed to the draw frame, the can which is produced on the machine is called breaker can. In the second passage comber can sliver is fed and the can produced contains lesser number of hooks, known as the finisher can.

BREAKER DRAW FRAME:- The sliver from carding is feed in this draw frame. Here primary drafting is done by means of drafting rollers (Loose bush type). The top drafting rollers are weighted pneumatically having spiral grooved on it’s periphery for better drafting. 8-12 cans are fed to it and deliver 2 cans.

FINISHER DRAWS FRAME:- The sliver from comber is feed in this draw frame. Here final drafting is done. The top rollers are weighted pneumatically. 6-8 cans are fed to it and only one can is delivered by it. It delivers one can


Machine description :-

Make : Lakshmi RieterModel : SB 2No. of machine : 2Motor speed : 2850 rpmMotor pulley dia. : 110 mmMachine pulley dia. : 192 mmCreel capacity : 12No. of delivery : 2Drafting system : 3/3Draft range : 3.6-11Break draft : 2 (for carded)Main draft : 1.78 (for combed)Weighting system : PneumaticLoad on top roller : 33 kgMaterial processed : Dia. of bottom roll :

Cotton (EL- up to 75 mm)

Front : 52 mmMiddle : 28 mmBottom : 28 mmShore Hardness : 820Pressure on C.R. : 0.5-2.5 barCan dia. : 500 mmCan length : 1200 mm

Change places :-


1. Draft change gear 2. Break draft change gear 3. Feed change gear 4. Delivery change gear 5. Coiler wheel change gear 6. Can change gear 7. Motor pulley

Important features and advantages :

1. Processed fibre length up to 80 mm. 2. Feeding weight of material between 20-50 ktex. 3. 4/3 drafting system with pressure bar for fibre control. 4. Electronic leveling system for short, medium and long term variation. 5. Automatic can changer. 6. Power creel for sliver feeding. 7. Delivery speed up to 800 m/min

Technical data :-Make : Lakshmi RieterModel : RSB 851No. of machines : 4Material used : CottonStaple length : 25-80 mmDoubling : 8No. of delivery : 1Top arm loading : Dia. of Top rollers :

spring loaded

Front : 38 mmMiddle : 38 mmBack : 38 mm

Dia. of Bottom rollers :Front : 40 mm


Middle : 30 mmBack : 30 mm

Draft range : 3.5-11.6Waste : 0.5-1.0 %Efficiency : 85 %Scanning roll dia. : 94 mm

COMBING PREPARATION:-

INTRODUCTION: The carded and drawn material is further attenuated on the speed frame and ring frames. The quality of yarn of spun by using sequence of processing does not reach high level. This is because of the presence of short fiber in the sliver. The process of combing is introduced for reducing the short fiber content in the material and for improving the fiber configuration. Consequently, combed material gives more even and stronger yarn which contains less nep as well as

Unilap

OBJECT :-


The main object of this machine to convert the sliver into lap sheet for the use in the comber.

FUNCTION OF UNILAP :-1. Combining a number of slivers into a lap that is ideal for the combing operation. 2. Creating a batt with sufficient cohesion to ensure good lap winding. 3. Orienting the fibres to the point that they are optimal for both the lap condition

and combing action. 4. Produce a batt in which the fibres are uniformly distributed in the

battcrosssection. 5. Supply laps that will have good unwinding characteristics on the comber.

Working principle :-Slivers are entered into drafting and over feed plate. The SB 2 slivers are drafted in the drafting system. The calendar roller draw the overlapping fleece into the loop formation head due to the strong compression between the calendar roller, a lap sheet is formed. This is then rolled onto a tube via the top rollers & lap discs. The exchange of lap from supply empty tube takes places automatically.

Technical Specification :-

Make : RieterModel : E 32 No. of machine : 1 Year : 2005 No. of delivery : 1Creel capacity : 24For fibre length : up to 60 mmDrafting system : 4/4Top arm pressure : 600-800 NSliver wt./mt : 4.5-5.0 ktexLap wt./mt : 60-80 ktexLap width : 300 mmFull lap dia. : 510 mmBreak draft : 1.0406Intermediate draft : 1.051Main draft : 1.305-1.637Total draft : 1.624Delivery rate : 100 m/minProduction rate : 350 kg/hr


Efficiency : 95 %Servo trolley is used for supply the lap roll to the comber.

ComberComber is a machine which removes short fibres. It is the most complicate machine of the spinning department. The combing operation serves to improve the raw material and influences yarn characteristics like yarn evenness, strength, cleanliness, smoothness, and visual appearance. The yarn made of combed cotton needs less twist than s carded yarn.

Objects:

Elimination of precisely pre-determined quantity of short fibers. Elimination of remaining impurities. Elimination of large proportion of the neps in the fiber material. Formation of a sliver having maximum possible evenness.

TYPES OF FEED :-

There are two types of feed- Forward feed &Backward feed. In Forward feed the lap is feed during the forward movement of the Nipper. In the Backward feed the lap is feed while the Nipper is rocking backward i.e. detaching before the circular combs the fringe of the fibre.

Arrangement of the combing elements:


Technical Specification :-

MAKE :- RIETER MODEL :- E 7/5A NO. OF MACHINE : 6YEAR :- 1994No. of head :- 1 Type of feed :- Forward feed Nips/min :- 250-350 Delivery :- 120 m/min Feed amount :- 5.2 mm Noil % :- 16-18 % Empty spool dia. : 200 mm Lap width :- 300 mm Full lap dia. :- up to 650 mm Can dia. :- 600 mm Can height :- 1200 mm Batt weight/m :- 60-80 gmRaw material/fibre length :- Cotton/1”-2” Total draft :- 9.0-20.4

COMBER LK 64Technical Specification :-

MAKE :- LMWMODEL :- LK64NO. OF MACHINE : 4 YEAR :- 2010 No. of head :- 1 Type of feed :- Forward feed Nips/min :- 210


Delivery :- 120 m/min Feed amount :- 4.3 mm Noil % :- 16 % Empty spool dia. : 200 mm Lap width :- 300 mm Full lap dia. :- up to 650 mm Can dia. :- 600 mm Can height :- 1200 mm Batt weight/m :- 62 gmRaw material/fibre length :- Cotton/1”-2 Efficiency :- 90 %

Speed FrameObjects :-1.It decreases the no. of fiber per cross section as intermediate process in between

draw frame and ring frame.

2.Attenuation of sliver with protective twist to hold the fiber together. 3.Formation of roving in to a package form from the sliver. Function of Simplex :-1. Drafting :To reduce the size (wt./unit length) of strand. 2. Twisting : To provide the necessary strength. 3. Winding : To put successive layers on the bobbin at the proper rate of speed.

4. Layering : To put the coils on the bobbin in a regular arrangement. 5. Building : To shorten successive layers to make conical ends on the package of

roving

Drafting system :-There is 3/3 drafting system is used in the simplex. Speed Frame usually comprises fluted bottom roller and rubber coated top roller.

The hardness of cots lies between 800-850.


Technical Specification :-MAKE : LAKSHMI MODEL : LF 1400 NO. OF SPINDLE : 120Drafting system : 3/3 (apron)


Draft range : 3-16 Spindle gauge : 121.83 mm Flyer speed : 1400 rpm Bobbin speed : 900-1400 rpm Empty bobbin dia. : 48 mm Full bobbin dia. : 169 mm Top arm weighting : pneumatic (in P-3), spring loaded (in SKF) Cradle length : 36 mm Bottom roller type : fluted (front back), knurled Bottom roller dia. : 27, 27, 27 mm Top roller dia. : 29, 29, 29 mm Front & middle roll gauge : 46-64 mmMiddle & back roll gauge : 50-80 mmTop apron thickness : 0.8-1.04 mmShore hardness of cots : 830

Bobbin length : 340+_2mmBobbin base dia. : 70 mm

Roving hank range : 0.5-3.5 Nes

Saddle gauge : 52/58Drafting pressure : 0-2.5 kg/cm2Main pressure : 0-6 kg/cm2Apron thickness : Top (0.80-1.04mm) Bottom (0.86-1.04mm) Running data :-Break draft : 1.10 Main draft : 6.125 Feed hank : 0.121 Delivered hank : 0.845 Spindle speed : 850 Change places :-1.Draft change pinion

2. Twist wheel


3. Ratchet wheel 4. Lifter wheel 5. Break draft change pinion

Ring Frame

Objects:1. Drafting : To attenuate the roving to required fineness. 2. Twisting : To improve strength to the fiber strand by twisting. 3. Winding : To wind up the resulting yarn on a suitable package for storage,

transportation or further use. 4. Building : To give the package of desired shape.

Technical Specification :-MAKE : KTTMMODEL : LG 5/1 & LR 6/S TOTAL NO. OF R/F : 25 LG 5/1 : 2 (432 SPINDLE EACH)


TOTAL SPINDLE : 21600 SPINDLE GAUGE : 70 MM WHARVE DIA. : 18.5 MMTIN ROLLER DIA. : 250 MMRING DIA. (INNER) : 38 MMRING DIA. (OUTER) : 44 MMRING TYPE : SINGLE FLANGEWEB THICKNESSHEIGHT OF TRAVELLER

: 1.0 MM

CLEANER : 6.0 MMBOBBIN TYPE : POLY CARBONITERING RAIL SECTION LENGTH : 5.5 FEETNO. OF RING IN 1 SECTION : 24SPINDLE HEIGHT : 340 MMNOSE BAR WIDTH : 23 MMNOSE BAR HEIGHT : 540 MMLENGTH OF BOBBIN : 180 MMDRAFTING ANGLE : 450

DIST. B/W F.R. TO M.R. : 50 MMDIST. B/W M.R. TO B.R.DIST B/W THREAD GUIDE TO

: 65 MM

SPINDLE BASETRAVERSE SPEED OF

: 295 MM

TRAVERSE GUIDE : 8 MM/MINDIST. B/W F.R. TO B.R. : 107.5 MMSADDLE GAUGE : 50-67 MMCRADLE LENGTH : 36 MMBOTTOM APRON SIZE : 80.5*30*1.05 (MM)TOP APRON SIZE : 38.1*3O*1.05BOTTOM ROLLER DIA. : 27 MMARM TYPE : P 3-1LAPPET HEIGHT : 30/35 MMLAPPET HOLE : 3.5 MM


ABC RING : 41 MMSPACERS SIZE :-BROWN : 2.50 MM DARK GREY : 2.75 MM NATURAL WHITE : 3.00 MM YELLOW : 3.25 MM BLACK : 3.50 MM CREAM : 3.75 MM RED : 4.00 MM GREEN : 4.50 MM BLUE : 5.00 MM

GREY : 5.50 MM Limitations of Ring Frame :-The amount of heat developed in the traveler at high speeds is considered and it is extremely difficult to conduct this heat away. So traveler speed is limited and hence the production.

Modern developments:

1.Short stretch length:- (The distance from the center of the front bottom roller to the lower edge of the bobbin) It reduces yarn tension and enables higher machine speeds with fewer end breakages.

2.Automatic speed control inverter for enhanced production:- It offers precise control over the spindle speed in 7 different steps according to the count pattern.

3.Twin traverse:- It enhances life of apron and cots especially while processing coarse count and blends.

4.Double side simultaneous drive system for bottom rollers. 5.Powerful pneumatic suction system. 6.Automatic doffing 7.E-control- feed the required data at the control panel and machine itself will calculate the required chase length, yarn length per chase, shift per chase, cop base etc.


Post Spinning ProcessesWINDING SECTION:

Yarn produced at ring frame is taken out in the form of processing and transportation. During winding various faults such as neps, long thick ,short thick, thin places, variation in color of yarn contamination in yarn etc are removed.

OBJECT:1. To produce a package with long continuous length of yarn. 2. To produce cone or cheese of specific length. 3. To remove weak places, slubsetc i.e. the yarn should be free from all types

of imperfections.

Precautions to be taken during winding:

1. Quality of splicing should be such that it does not spoil the appearance and at the same time the strength loss in spliced yarn should be minimized.

2. Important yarn properties like yarn strength, elongation at break, appearance should not be deteriorated.

3. Package should not contain winding faults i.e. hairiness and the no. of naps shold not increase during winding.

The path of yarn in winding machine:


The bobbin is held in the bobbin holder called peg. The bobbin during unwinding remains stationary. The path of the yarn in the winding section in such that it Passes from the unwinding unit to tensioning unit after passing through balloon breaker and lower thread sensor. The function of the balloon breaker is to prevent the formation of a larger balloon so that more o. of ground drums can be accommodated in a lesser space. The function of lower thread sensor is to sense the presence of thread in the lower portion. If it does not finds the thread in the lower portion then the mother thinks that the bobbin has finished, so it ejects the bobbin & rotates the creel to clamp the new bobbin. After the disc type tensioned, the yarn passes from splicing unit. It then passes from splicing unit to yarn clearer. Then from the electronic yarn clearer to tension sensor & from the tension sensor it passes through the waxing pin. The waxing device applied the minute wax particles on the surface of the running yarn. After it passes in front of the holding pipe (which is used to catch fly) and finally to the package holder.

BOBBIN CHANGE:The winding unit computer initiates the bobbin change. If no yarn is present in measuring lot of the lower end yarn sensor. The winding unit bobbin change linkage ejects the empty bobbin and checks a new bobbin from the circular magazine in which we can keep at maximum 5 bobbins and one has to leave empty.

YARN GUIDE DRUM:The guide grooves of the yarn guide drum place the yarn in cross wound layers on the delivery package. Simultaneously the circumference of the yarn guide drum drives the delivery package. This type of package drive has the advantage that the winding speed remains uniform from the starting to the finishing of the package regardless of the diameter. The yarn guide drum rotated in opposite direction while the splicing of broken end is to carry out.

PACKAGE LIFT:The package lift function lifts the package of the yarn guide drum at each yarn break (or bobbin run out), in order to prevent the disturbance of outer yarn layers of the delivery package. Disappearance of yarn from the measuring slot of electronic clearer (e.g. due to yarn break or bobbin run out) triggers a signal Activating the package lift function .


The yarn is placed in across wound fashion on the delivery package. The yarn traversing occurs because of the yarn guide drums grooved can figured.

YARN TENSIONER:The yarn tensioner applies uniform winding tension to the yarn in order to remove the thin places and to obtain desired density of delivery package. At the top there is a sensor, which senses the tension in the yarn & tries to control the tension around the specified value, which has been feed in the informatory of the machine. The sensor controls the tension in the yarn by continuously monitoring the tension in the yarn & giving the signal to


motherboard , which in turns control it by the help of the disc tensioner.

DELIVERY PACKAGE DOFFER:Each delivery package contains the reselected yarn length. The automatic package doffer places the full packages on a conveyor belt, positioned in upper rear of the machine. The empty cone for doffing is taken from individual magazines above each winding unit.

ELECTRONIC YARN CLEARER:To remove the objectionable faults present in the yarn, the electronic yarn clearer is provided. Following are the common faults-

Short thick faults Long thick faults Thin faults

We have decide the setting in the electronic yarn clearer to remove the type and size of faults as per requirement. The clearer efficiency varies from 80%-90%. Depending on the winding speed the clearer recognizes the predetermined limits of yarn. At reorganization of the yarn fault beyond these limits the clear instantly cuts the yarn initiating a winding unit stop and a subsequent joining cycle.

SPLICING OF YARN:Utilizing compressed air, the splicer whirls the yarn ends together forming knot less yarn. The tensile strength of the splice is nearly identical to yarn strength. The two cut ends are inserted either into a mechanical device which tapers them and intermingles the fibers or into air vortex tube which untwists them and extracts the loose fibers thereby forming two correct lengths for splicing. Splice testing takes place automatically at the winding unit start as the splice pass through the clearer’s measuring slot.

AUTO SPEED REDUCTION:Automatic reduction of speed when the yarn exceeded from a particular decided length on bobbin. For example-if we have set a length of 5200m. then after consuming or winding the 5200m length yarn of bobbin the speed of groove drum automatically reduces to 80% for the rest length of yarn on bobbin.

WINDING MACHINES


SCHLAFHORST :

TECHNOLOGICAL DATA:

Make SCHLAFHORST SAURERModel Autoconer 338

No. of machine 5No. of head/machine 60Bobbin magazine capacity 6Winding speed 900-1500m/minTime for splicing 8-9 sec.Time for doffing 50-60 sec.Time to replace the bobbin 8sec.Cone weight 1.89 kg.

WINDING SPEED ACCORDING TO COUNT:

YARN COUNT WINDING SPEED8 600-900

10 900-100020 1200-140030 1100-130040 1150-120060-80 700


YARN FAULT REMOVED BY AUTOCONER:

N/S/L Thick placesT Thin placesC/CC/PC Count pearlFD Foreign matter darkFL Foreign matter lightJ/U Channels, cleaning fancy yarn

WORK LOAD :

In AUTOCONER one m/c have 60 drums and one drum have 6 bobbins. WORKERS/MC ACCORDING TO COUNT:

COUNT WORKERS/MC8 1 worker for 20 drums

13 1 worker for 20 drums16 1 worker for 30 drums30 1 worker for 40 drums32 1 worker for 40 drums40 3 worker per 2m/c50 1 worker for 60 drums80 1 worker for 60 drums

Auxiliary Devices :1. Automatic splicer/ knotter. 2. Magazine creel. 3. Conveyer belt for empty Ring tubes. 4. Dust removal system 5. Anti ribbon6. Blower 7. Electronic thread stop motion.

ConditioningOBJECTS:


1. To improve yarn quality i.e. hairiness is reduced. 2. Strength of yarn is increased. 3. Weight of package is increased.

CHECK POINT:cones are checked by using ULTRA VOILET RAY. If in a trolley a different count yarn cone is remained it will be determined. Because in UV ray different count yarn give different brightness.


PRE-CONDITIONING:

in preconditioning room there are two nozzles,. Nozzles spray water and heaters convert waters to water vapour. Cones trolly remain in this room for two hours.

PROFIX: It is a large closed drum. In it 6 trolley cone are placed. In a trolley 72 cone are placed.

Time (min.) Temperature (0C) Vacuume (%)Hosiery yarn 90 59 0.90

Warp yarn 20 42 0.90

Packing

Cones obtained from the conditioning are sent to the packaging section. There are two types of packaging- 1. Neutral packaging: LOGO is not there on the cartoon. 2. Regular packaging: LOGO is there on the cartoon. Cardboard used for making cartoons is of 5 ply or 7 ply. Dimensions of cartoon=26” 18” 20.5” Proper care is taken for packing the material export purpose. The packed material obtained is kept in the go down and transport to its destination afterwards. Following particulars are put on the packing cartoon-

• 100% combed cotton yarn on cones • Count • Excise number • Lot number • Cartoon number • Gross weight


• Net weight • Cartoon size • In one cartoon box=24 cones•

TYPE OF PACKAGE

SIZE OF PACKAGE NO. OF CONES IN ONE PACK

EXPORT PKG. 26” x 18” x 20.5” 18

DOMESTIC PKG. 26” x 18” x 20.5 18DOMESTIC PKG. 30” x 14.5” x 27.25” 24

TYPE COUNT(Ne) EMPTY CONE WEIGHT

FULL CONE WEIGHT (KG)

Combed hosiery 13 Cone 50gm 2.60-2.70Combed compact 32 Cone 50gm 2.80-2.180Combed warp 40 Cone 50gm 2.80-2.180Pilot package,slub40 --------- 1.980-2.80

H-PlantRELATIVE HUMIDITY AND TEMPRETURE CONTROL:

EFFECT OF R.H. ON PROCESSING: Low humidity gives:

o Crimped fiber o Bulky slivers and roving o Change in winding

condition in speed frameo Failure of bulky sliver tie

pass through the coiler tube oStatic charge generation on synthetic fibre and bottom metallic

o Roller slippage o Higher humidity

gives: oStraightness of fiber. oFiber length is increase. oBetter draft.

o More regular yarn. oStronger yarn.

o Reduce extensibility


o Very high humidity gives:

o Fibers become sticky. o Roller lapping(top roller)

R. H. REQUIRED IN VARIOUS DEPARTMENT:MONTH DEPARTMENT

B/R C/D,S/L,R/L D/F,S/F,COMBER R/F WDG. PACKING

APR-JUN

40-70%

40-60% 45-65% 40-60%

50-65%

80-95%

MAY-SEP

50-70%

50-70% 55-70% 50-65%

50-70%

80-95%

OCT-MAR

45-70%

45-65% 45-65% 50-60%

45-65%

80-95%

Cleaning Schedules

The following sets of cleaning schedules are adopted for each specific step of the Yarn Manufacturing line. The time mentioned, is the duration after which each of the mentioned tasks are repeated:

Blowroom Cleaning Schedule:• Unimix waste box cleaning: 2 hours. • ERM waste box cleaning: 2 hours. • Varrioclean waste box cleaning: 2 hours. • Charge cleaning: At the end of shift. • Hall Cleaning: 1 hour. • General Cleaning: 2 hours.

Carding Cleaning Schedule: • Cleaning of cross role side: 30 hours. • Cleaning of feed roll: 2 hours.


• Cleaning of Philip son’s Brush: 2 hours. • Cleaning of Apron &Calender roller: 30 minutes. • Cleaning of Doffer Undercasing: 2 hours. • Hall area cleaning: 2 hours. • Cleaning at charge change time: At the end of shift. • General Cleaning time: 24 hours.

Unilap Cleaning Schedule:• Cleaning of creel: 8 hours. • Cleaning of top & bottom clearers: 2 hours. • Cleaning of Drafting Zone: 2 hours. • Cleaning ofDisc side: 8 hours. • Cleaning of back of Unilap: 2 hours. • Cleaning of lap table: 2 hours. • Hall cleaning: 2 hours. • Machine body cleaning: 4 hours. • Top roll cleaning: 24 hours. • General Cleaning: once per shift.

DrawframeCleaning Schedule:• Drafting Zone cleaning: 2 hours. • Feed Zone cleaning: once per batch. • Top roll cleaning: 2 hours. • Fan cleaning: 2 hours. • Cut checking, scanning roll & coiler cleaning: 4 hours. • Creel cleaning: 2 hours. • Scanning roll stripper cleaning: end of shift. • Drafting stripper cleaning: 2 hours. Machine covers cleaning: 4 hours. • General cleaning: 24 hours.

Comber Cleaning Schedule:• Top comb cleaning by brush: 2 hours. • Top comb cleaning by detachment: 4 hours. • Daffoo cleaning: 3 hours. • Half lap cleaning: 4 hours. Nipper cleaning: 16 hours. • Drafting zone cleaning: 4 hours. • Detaching roll washing: 24 hours. • Fan cleaning: 4 hours. • Coiler cleaning: 8 hours. • Back cover cleaning: 8 hours. • Hall cleaning: 4 hours. • Machine body cleaning: 4 hours. • General Cleaning: once per shift.


Speed frame Cleaning Schedule:• Drafting Zone cleaning: 4 hours. • Top combs’ comb waste cleaning: 1 hour. • Bottom combs’ comb waste cleaning: 1 hour. • Spindle Zone cleaning: upon doffing. • Box cleaning: upon doffing. • Machine cleaning: 4 hours. • Flyer cleaning: upon doffing. • Fan cleaning: upon doffing. • Creel cleaning: per batch. • Back cover cleaning: 2 machines per shift. • Hall cleaning: from time to time. • Toli wheel cleaning: 15 toli per shift.

Ring frame Cleaning Schedule:• Drafting Zone: 8 hours. • Elicots: 8 hours. • Cradle: 8 hours. • Jockey Pulley: 24 hours. • Lifting tape & separator: 24 hours each. • Tension pulley: 48 hours. • Brake: 24 hours. • Foot step: 24 hours.

Winding & Packing Zone Cleaning Schedule:• Machine full cleaning: 24 hours. • Floor cleaning: 2 hours & 8 hours. Hard waste: 12 hours.

Counter Measures for Alarm Generation

1. CV Alarms:• First we have to identify the Ring frame in which Alarm is coming; this

information should be given winding supervisor. • Check last layer of cotton batch. • Cots buffing schedule. • Cut cots’ checking in whole Ring frame. • Ring traveller schedule. • Ring traveller conditioning for burning. • Flute cleaning. • Various cleaning in points in Ring frame. • Mesh apron checking in Compact reed frame. • Poor quality speed frame bobbin, even checked by naked eye.


2. IP Alarms:• Ring traveller loading that can be checked by stopping Ring frame. • Ring traveller changing schedule. • Ring traveller condition for burning. • Blower condition.

3. Hairiness Alarms:• Balloon condition. It should not touch with bobbin top. • Ring traveller changing schedule. • Ring traveller condition for burning. • Blower condition.

4. Count Alarms:• Roving piecing at Batch. • Last material layer at Batch. • Check Uster of Ring frame bobbin. • If Alarms are continuous count alarms, check ring frame wrappings at short

length, even preparatory at short length, even preparatory wrapping also.


himanshu training report 2016

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