Qasir Spinning Report

INTRODUCTION TO NISHAT

GROUP

Nishat has grown from a cotton export house into the premier business group of

Pakistan with 5 listed companies, concentrating on 4 core businesses; Textiles,

Cement, Banking and Power Generation

I recently have done my internship in Nishat Mills Limited Unit #3, Sheikhupura

Road Faisalabad, in which I got training from each of its department. The

internship basically revolved around the product knowledge training. The system,

the style of working & the commitment of the employees in NML is really

exemplary.

In this report, a brief review of the Nishat Mills Limited Unit #3 is being

presented. The internship has been done according to the schedule. The textile

technologies, production processes have been explained according to my

knowledge that I have acquired during my internship. My practical efforts have

been explained in this manuscript that is an asset for my future career.

SPIN PLAN

Spin planning is the job to control production and quality of end product i.e. yarns

at various stages of spinning process.

Factors on which “SPIN PLAN” will depend

1. Type of raw material.

2. Production capacity of mills.

3. Capacity of each machine.

4. Counts to be spun and their quantities.

5. Number of machines available.

6. Number of qualified personals.

MIXINGNumber of bales used daily = 140 bales

Jute picked daily = 250g

Method of mixing = Mechanical

BLOW ROOMNumber of lines = 2

Waste % = 5.6%

Beating point = 4 ½

Cleaning efficiency = 60%

CARDINGTotal no. Of cards = 14

Grains/yd = 67

Mechanical draft = 98.317

Actual draft = 105.60

Waste % = 5.3 %

Cleaning efficiency = above 80 %

Production efficiency = 85 %

Production = 420 - 450 lbs / hr / card

DRAW FRAME BREAKERTotal number of frames = 5

Grains / yd = 67

Draft = 8.03

Doubling = 8

Delivery rate = 350 m / min

Efficiency = 85 %

Production = 322 lbs / hr / frame

DRAW FRAME FINISHERTotal number of frames = 5

Grains / yd = 67

Draft = 7.9

Doubling = 8

Delivery rate = 700 m / min


Production = 336.6 lbs / hr / frame

SIMPLEXTotal number of frames = 6

For carded quality = 4

Flyer speed = 1050 rpm

Total draft = 7.2

Delivery rate = 23.64 m/min

Twist per inch = 1.12

Production rate = 322 lbs / hr / frame

RING FRAMECount = 20/1, 30/1

Total no. Of frames = 22

Draft = 25.09

T.P.I = 17.4

Delivery rate = 21.52 m / min

Spindle speed = 14750.8 rpm

O.P.S. calculated = 10.765


WINDINGTotal no. Of machines = 6

Winding rate = 1000 m / min

Cone weight = 4.167 lbs

Tolerance limit = + 20 gm

Efficiency = 86 %

Production = 181.38 lbs / hr / frame

PACKINGNo. Of cones / bag = 24

Net weight of bag = 100 lbs

Raw Material

Cotton

Cotton, belonging to a family that

includes hibiscus and okra, produces a

natural vegetable fiber used in the

manufacture of cloth. Cotton produces

sweet nectar that attracts a variety of

destructive insect pests, including the

boll weevil, bollworm, armyworm and the

red spider. In addition to insect pests,

there is also a very destructive fungus,

called the wilt, which attacks the root system of the cotton plant.

Fiber Thickness:

The thickness of the fiber is termed as fiber fineness which is numerically

represented as micronaire value. The lesser the value the finer would be the

micronaire (mic). Fiber fineness is one of the most important fiber properties and

is expressed as

“Weight of one inch of fiber in microgram”

Very Fine 3.0

Fine 3.1-3.9

Medium 4.0-4.9

Coarse 5+

Fiber fineness influence following factors of the following

Yarn strength

Yarn regularityYarn bulk

Luster

Fuzz Fiber:

The longer cotton fibers when detached from the seed are called lint. The

undergrowth of fuzz which develops at the tip of the seed is called linters. These

are coarse and very short in length.

Staple Length

Staple length is one of the most important characteristics of cotton. It

defines the spinability of the fiber. Staple length has been basis for trading the

cotton more then a century. In this regards, cotton is divided into three large

categories.

Grade:

The grade is given by the external appearance of the cotton and is determined on

the basis of the major or minor brightness of the fibers, by its more or less white

color, by the major or minor presence of particles of the leaf or other extraneous

substances.

Trash:

Trash content is assessed from scanning the cotton sample surface with a video

camera and calculating the percentage of the surface area occupied by trash

particles. The values of trash content should be within the range from 0 to 1.6%.

Trash content is highly correlated to leaf grade of the sample.

Color:

The color is another important element of evaluation of cotton. In fact, from the

major or minor whiteness of the cotton depend on the facility of later

workings and the possibility of obtaining good yarns. Natural colour of

cotton highly influences the chemical processing and dyability of the finished

product.

Fiber Strength :( grams/tex)

Fiber strength is measured in grams per tex (g/t) or centinewton per tex CN/tex.

The force necessary to break the beard of fibers, clamped in two sets of jaws, (1/8

inch apart).The breaking strength of cotton is about 3.0-4.9 g/tex, and the breaking

elongation is about 8-10%.

Properties

Cotton, as a natural cellulose fiber, has a lot of characteristics, such as:

• Comfortable Soft hand

• Good absorbency

• Color retention

• Prints well

• Machine-wash able

• Good strength

Bale Management

Testing, sorting and mixing bales according to the properties of fibre for producing

specific good quality of yarn at minimum cost is called Bale management.

Object of Bale management:

An evening out of the quality characteristics of a yarn.

A means of avoiding quality jumps.

A possibility of reducing costs as a result of an improved knowledge of the

fibre characteristics

MIXING

Mixing is done to thoroughly mix the fibres with each other as they have different

physical parameters. The natural fibres always differ from each other in the

following properties i.e. length, maturity, strength cleanliness, moisture etc.

.

Uniform mixing is very essential to achieve uniform yarn results

Homogeneous mixing ends down can minimize rate.

Higher production rate can be achieved.

Some times different varieties of cotton are mixed for two purposes.

To achieve the required results of yarn

To minimize the cost

METHOD OF MIXING IN NISHAT TEXTILE MILLS UNIT NO. 3

No. of bales blended daily = 140 bales

No. of lots present = 44 lots

No. of bales taken / lot = 1-7 bales / lot

Net weight of bale = 145-149 kg

Bale dimensions = H = 45˝, W = 20.5˝, L = 31.5˝

Bale volume = 16.93 ft3

In Nishat Textile Mills Unit No.3 mixing is done mechanically by means of 5

Auto Pluckers, 20 bales are placed in each Plucker. 140 bales are fed in all Auto

Pluckers and time taken to open and mix all the bales is 24 hours. Condenser takes

the material from Auto Plucker. Two condensers are used for Auto Plucker. From

condenser material is passed to a conveyer lattice. From here feeding of cotton is

done on the feed lattice of Bale opener. The entire condensers are fitted with the

yellow color pipes that are used to carry waste to the filter bags.

AUTO PLUCKERThe function of this machine is to pluck the cotton, medium length fibre and

synthetic fibres.

It consists of following parts.

Telescope pipe

Carriage

Plucking beater

Center axle

Inner round frame

Outer round frame

Rail

It is also included that some roving, sliver and pneumaphil waste are also added in

the plucker along with bales in the following quantity;

Sliver 50 kg

Roving 15 kg

Pneumaphil 50 kg

TECHNICAL DATA:Name Automatic Disk Plucker

M/C model = FA002

No. of Machines = 05

Out put = 1800 kg/hr

Beater rpm = 800-900

No. of Motors = 3

Time taken = 2-4 min/rev

Dia of rail = 5200mm

Main Motor speed = 960 rpm

CONDENSER The condenser is on of the most important machine in blow room line. Function of

the condenser is to pneumatically convey the opened fibre material and is used for

transporting the fibers from on machine to next.

Constructions:

A fan is fitted in a sheet metal structure.

Through channels at both sides, suctions are

provided for a Dust Cage, the outside lower

part of which is an Air screen Plate. The

finned Stripper Roller Situated below the dust

cage is enclosed in a two part cover such that

the suction of the fan does not exert an adverse influence on the discharge of

marteials.

Fan speed = 1600 rpm

Cage speed = 90-110 rpm

Leather beater speed = 250-300 rpm

Suction pressure = 300-350 Pa

Mixing is done for whole day in general shift and then machines are cleaned. Any

major maintenance is done when require

BLOW ROOM

Basic operations in the Blow Room:

Opening

Cleaning

Micro dust removal

Foreign matter removal

Uniform feed to the carding machine

Drafting

Recycling the waste

Blow room installation consists of a sequence of different machines to carry out

the above said operations. Moreover Since the tuft size of cotton becomes smaller

and smaller, the required intensities of processing necessitates different

machine configuration. Almost all the machines associated with blow room work

with air currents hence this unit of machines is called Blow Room.

TECHNICAL POINTS IN BLOWROOM

Opening in blow room means opening into small flocks.

The larger the dirt particle, the better they can be removed.

Since almost every blow room machine can shatter particles, as far as

possible a lot of impurities should be eliminated at the start of the process.

Opening should be followed immediately by cleaning, if possible in the

same machine.

The higher the degree of opening, the higher the degree of cleaning.

The cleaning efficiency is strongly dependent on the TRASH %age. It is

also affected by the size of the particle. Therefore cleaning efficiency can

be different for different cottons with the same trash %age.

If cotton is opened well in the opening process, cleaning becomes easier.

Mechanical action on fibers causes some deterioration on yarn

quality, particularly in terms of naps. Moreover it is true that the staple

length of cotton can be significantly shortened.

Air streams are often used in the latest machine sequence, to separate fibers

from trash particles.

PRINCIPLE OF WORKING

Following are the principles on which different machines of blow room work.

Opposing spikes action

Actions of air currents

Action of beaters

Regulating action

Action of gravitational forces and centrifugal forces.

BLOW ROOM LINESequence of machines with make and model

Bale Opener

Maxi Flow

Multi Mixer

Cleanomat CVT 1

Cleanomat CVT 3

Dustex

Argus AD

Loptex

BALE OPENERBale opener is the first machine in the blow room line which is used to open large

tufts of cotton into smaller tufts and remove waste.

WORKING PRINCIPLEThe material supplied by the feed lattice is deposited on the feed table where it is

fed to the spiked lattice. The material is supplied by the spiked lattice to the

stripper roller.

The evener roller brushes off the

excess material through it back

into the blending chamber, so

that the evener roller does not

become clogged with fibred, a

cleaner roller is installed. The

fibres brushed off by the cleaner roller are also thrown back into the blending

chamber. The quantity of the material in the blending chamber is controlled by the

light barrier. Material which falls b/w the feed table and the spiked lattice into the

segment pipe is extracted by the waste extractor. From the stripper roller, the

material is conveyed to the delivery trunk and from there into the down line

machine.

MAXI FLOWThe Maxi flow is the 2nd machine in the Blow room line. The function of MAXI-

FLOW is to break the large lumps into smaller lumps.

WORKING PRINCIPLE

The pre-cleaner Maxi flow is charged with material from above by a condenser

LVSA. The condenser LVSA is mounted

on a frame above the pre cleaner MAXI

flow. The tuft material enters the m/c

vertically and is drawn in b/w the rotating

first beater roll and the adjustable grid.

The second beaters roll which rotates in

the same sense as the first beater roll takes

over the tufts and flings them up. In this

way, the tufts are simultaneously turned over several times coming into contact

with the grid bars all over. During this process a large proportion of the impurities

are discharged. The procedure is repeated several times until the tufts reach the

outlet area. From the outlet area, the tufts are transferred to the next down stream

m/c via pipelines equipped with a volumetric nozzle and two fresh air inlet

screens.

The discharged impurities drop onto the delivery roll via chute plates and

eventually reach the waste conduits. The impurities are extracted from above the

pipelines. There must be a permanent under pressure in the m/c in order to ensure

the proper operational sequence.

MULTI MIXERThis matchine is made up of three parts: storage suction, an intermediates chamber

and a delivery section.

WORKING PRINCIPLE

The material is charged by an external fan

through the connection for material feed into

the trunks. The key operated switch is in on

position. At least one set point memory must

contain operating values.

The material is drawn out of the trunks by the

delivery rolls and known by the continuously

rotating opening rolls into the suction duct. The

material is drawn through the material intake funnel by the air current generated

by a fan or a condenser and delivered to the down line machine.

The desired speed of the dc geared motor of the delivery rolls can be set

Via key board

Via analog signal

Each trunk is filled until the set pressure is reached. The pressure is measured at

the measuring points and transmitted to the pressure sensors. When the pressure is

reached the controller identifies the trunk as full. The corresponding bar in the

display is set to max. Height and the next trunk are filled. The filling level is

continuously are calculated according to the discharge speed and the discharge

time set in P function 15.

The trunk is ready to receive material again only when the calculated filling level

has fallen to 75% all the trunks are ready to receive material. The system switches

to the next trunk after not more than 30 seconds. If the trunks are identified as full,

the material delivery is switched off, but the material transport fan remains in

operation. This is necessary in order to maintain the necessary pressure on the

material in the trunks.

As soon as a trunk is ready to receive material again, the material delivery is

switched on again. If all the trunks are ready to receive material, the system

switches to the next trunk after a maximum of one minute even if the change over

pressure has not been reached.

CLEANOMAT CVT1

This machine is used to remove the dust from the material which is going to be

processed.

WORKING PRINCIPLE

From the feeding m/c, the material is

carried on the feed lattice beneath the

pressure roll to the two feed rolls. The

feed rolls draw in the material and

transfer it to roll. The roll has two mote

knives. A carding segment is installed

after the first mote knife. Waste is extracted directly from the mote knives i.e. a

continuous suction stream removes the impurities produced at the extraction

points.

Once separated, any waste and dust cannot drift anymore throughout the waste

chamber and drawn in again bit is immediately carried off via the suction hoods.

A deflector blade is situated before the second mote knife and can be step lessly

adjusted during production. In this way the quantity and composition of the waste

can be regulated. From here the material is extracted to the next m/c.

CLEANOMAT CVT3The type plate is situated on the left end above the air inlet opening. It consists of

the following data.

WORKING MACHINE

From the feeding m/c, the

material is carried on the feed

lattice beneath the pressure

roll to the two feed rolls. The

feed rolls draw in the material

and transfer it to roll. The roll

has two mote knives. A

carding segment is installed after the first mote knife. Waste is extracted directly

from the mote knives i.e. a continuous suction stream removes impurities

produced at the extraction points.

Once separated, any waste and dust cannot drift anymore throughout the waste

chamber and drawn in again bit is immediately carried off via the suction hoods.

A guide wing is situated before the second mote knife and can be adjusted during

production. In this way the quantity and composition of the waste can be

regulated.

Roll 2 which runs faster than roll 1 receives the material. Roll 2 is equipped with a

guide wing, a carding segment, a separating wing and a connected suction hood.

Roller 3 which in turn runs faster than roll 2 is also equipped with a guide wing, a

separating wing and a connected suction hood. From here the material is extracted

to the next m/c.

DUSTEXThe function of this machine is to remove any remaining dust in the material.

WORKING PRINCIPLE

The m/c is used for detecting the fibre material. The fibre material is drawn in by a

transport fan and guided uniformly on to perforated plates by distribution flaps.

Due to their size, the dust particles in the fibre material flow fall through the holes

in the perforated plates are drawn in by a

transport fan and transported to the waste

disposal unit. The dust free tufts are

drawn by the transport fan and pass

through the material outlet to the down

stream machine. The machine is equipped

with a separate control in the control

cabinet. It is operated by way of display

and operated unit. During operation the

following standards messages appears on

the display.

LOPTEX SORTER

The function of this machine is to analysis the presence of foreign matter in the

material and gives display in the form of spectrogram

WORKING PRINCIPLE

Loptex sorter analysis the material that flows

in the channel without causing any

perturbation. A number of optical sensors

continuously check the material illuminated

by fluorescent tubes. During the start up phase

180 seconds are dedicated to amp pre heating.

After the pre heating phase, following the

acquisition phase of means value gathered by

each of 256 sensors. The phase is called limit adjustment and has duration of 60-

182 seconds according to the setting entered into the m/c dates.

During this phase the sorter will analysis the material that passes without making

expulsions.

At the end of limits acquisition time, this value is expressed on the scale of v0-

4095, gives an indication of the grey level of the material with 0 = black. After the

acquisition of limit mean, the sorter begins with the procedure of analysis and

explosion. It will only stop in case of an alarm. The data limits are now used for

automatically updating the limits assuring a continuous adaptation to the shade of

the material being analysis.

METAL DETECTOR:

Argus (Ad-50) Metal Detector detects any

metal part in blow room line. There are

tow metal detector in two blow room lines

of unit #3.

Waste calculations in Blow room

Waste = Lint + Trash

Trash = Foreign matter only

Waste % = (input-output) x 100 Input

CLEANING EFFICIENCY:

Cleaning efficiency of the machine is the ratio of the trash removed by the

machine to that of total trash fed to the machine, expressed as percentage.

Cleaning efficiency % =Trash%in mixing-Trash % in lap х 100 Trash % in mixing

CARDING

"Card is the heart of the spinning mill” and “Well carded is half spun” are two

proverbs of the experts. These proverbs inform the immense significance of

carding in the spinning process. High production in carding to economies the

process leads to reduction in yarn quality. Higher the production, the

more sensitive becomes the carding operation and the greater danger of

a negative influence on quality. The technological change that has taken

place in the process of carding is remarkable.

Card Machine DK 903

Make Trutzschler

Model DK 903

No. of card 13

Temp. 34 oC

RH% 51 %

OBJECTS OF CARDINGIn short the objects of carding are:

To open the lap into individual fibres

Elimination of impurities

Reduction of neps

Elimination of dust

Elimination of short fibres

Fibre blending

Fibre orientation

Sliver formation

PRINCIPLES OF CARDING

Point to point

The point of wire end of one surface faces the point of wire end of other surface.

These results in opening of fibres into single fibre state which causes cleaning of

material.

Point to back

The point of wire point of one surface faces the back of wire point of other

surface. This results in transfer of material from latter to the former surface.

DIFFERENT ACTION IN CARDING

1. Carding action:

When two close surfaces have opposite wire direction and their speed direction or

relative motion is also opposite. Then the action between two surfaces is called

carding action.

Function: It is occurred between flats and cylinder.

Maximum individualization of fibers is achieved in this region.

Neps, short fibers, dirt and dust are removed by this action.

There always should be point against point action

2. Stripping action:

When two close surfaces have same wire direction and their speed direction or

relative motion is opposite then the action between two surfaces is called stripping

action

Function: It is occurred between licker in and cylinder.

There are should be point against back action.

Individualization of fibre is also by this action.

3. Doffing action:

When two close surfaces have opposite wire direction and their speed direction or

relative motion is also opposite then the action between two is called doffing

action

Function:

It is occurred between cylinder and doffer.

Web formation is accrued by this action.

There always should be point against point action

TECHNICAL DATA

1st licker in

Diameter = 172.5 mm

No. Of revolutions = 621-1373 rpm

2nd licker in

Diameter = 172.5 mm


3rd licker in

Diameter = 172.5 mm


Cylinder

Diameter = 1287 mm


Doffer

Diameter = 700 mm

No. Of revolutions = 96 rpm

Card flats

Total quantity = 84

In operation = 30

Speed = 80-320 mm/min

Production

Sliver Delivery = 140 Kg /hr

SPECIFICATION OF WIRE POINTS

For Cylinder

Type = CU-76-WKD

Height = 2.3 mm

Angle = 63o

Thickness = 0.65 mm

Wire points/inch2 = 760

For Doffer

Type = CU 39-3

Height = 4 mm

Angle = 63o

Thickness = 0.85 mm

Wire points/inch = 388

For Taker-In

Type = TC-50 KH

Height = 5.6 mm

Angle = 80o

Thickness = 1.1 mm

Wire points/inch2 = 5

For Top Set

Type = KBS-450

Height = 8mm

Angle = 75o

Wire point = 450

Life of Clothing

Doffer clothing life = 3years

Taker-in clothing life = 11months

Cylinder clothing life = 3years

Flats clothing life = 3years

Stationary flats life = 3years

POINTS IN CARD OF WASTE EXTRACTION

There are five points where waste is separated from fibres on the card. These

waste points are:

Mote knife separation

Taker-in under-casing

Cylinder under-casing

Flats waste separated by stripping roller

Cylinder wire waste separated by stationary flats

A suction system collects all the falling waste at one end of card. From there they

are conveyed to the filter room, in which fibres are separated from dust and other

material on a special machine called fibre separator.

The fly waste is also sucked by vacuum pipes and carried to filter room by a

separate duct.

OBSERVATIONS AND CALCULATIONS

Cylinder

Rpm of cylinder = 519

S.S of cylinder = πDN

= π × 51×519

= 83112.66 inch/min

1st Taker In

RPM of taker in = 1200

S.S of taker in = π×1200×6.791

= 25588.48 inch/min

2nd Taker In

RPM = 1500

S.S of crush roll = π×1500×6.791

= 31985.61 inch/min

3rd Taker In

Rpm = 1777

S.S of taker in = π ×1777×6.791

= 37892.28 inch/min

Doffer

RPM of doffer = 96 rpm

S.S of doffer = π×96×27.55

= 8307.40inch/min

Feed Roll

RPM of feed roll = 5.2rpm

S.S of feed roll = π×5.2×7.08

= 115.60 inch/min

DRAFT CALCULATION

Major draft between roller and doffer

= S.S of doffer/ S.S of feed roll

= 8307.40/ 115.60

= 71.86

Total mechanical draft

= 43.62×2.13

= 92.91

Actual draft = Wt per yd fed /Wt per yd

delivered

= (14/16) × (7000/65)

= 94.23

Flats

Flats No. = 84

Linear speed = 7.87 inch / min

Note:In cotton card actual draft is always greater than mechanical draft due to

waste removal.

Draft constant = Mechanical draft × DCP

= 92.91 × 25

= 2136.93

Carding Ratio or Power

=10560.69

Stripping Ratio or Transfer Ratio

= 83112.66/37892.28

= 2.193

Condensation Factor

= 10.04

DRAW FRAMEDrawing is an operation by

which slivers are blended,

doubled or leveled and by

drafting reduced to proper sized

sliver suitable of being fed to the

simplex. Draw frame contributes

less than 5% to the production

cost of yam; however its

influence on quality of yam is

significant. Draw frame process considerably influences the final product, as draw

is last point of compensation for the elimination of errors produced by subsequent m/c.

the inadequacies in the sliver leaving the draw frame pass in to the yarn and are

reinforced by the drafting after the draw frame that is why yam can never be better

in evenness than the sliver.

NEED OF DRAW FRAME

From a purely commercial viewpoint the draw frame is of little significance. It

usually contributes less than 5% to production costs of the yarn. However, its

influence on quality, especially evenness, is advantage of this. Further if the draw

frame is not perfectly adjusted there will also be effects on yarn strength and

elongation.

There are two main reasons for the considerable influence of the draw frame on

evenness. First, within the sequence of machines in the cotton-spinning mill, the

draw frame is definite compensation point for eliminating errors. The yarn can

never be of good quality without draw frame passage.

TASK OF DRAW FRAME

Through doubling the slivers are made even

Doubling results in homogenization (blending)

Through draft fibers get parallelized

Through the suction, intensive dust removal is achieved

Auto leveler maintains absolute sliver fineness

Blending

TECHNICAL POINTS:

Quality of the draw frame sliver determines the yarn quality.

Drawing is the final process of quality improvement in the spinning mill.

Drafting is the process of elongating a strand of fibers, with the intention of

orienting the fibers in the direction of the strand and reducing its linear density.

Drawing apart of the fibers is affected by fibers being carried along with the

roller surfaces. For this to occur, the fibers must move with the peripheral speed of

the rollers. This transfer of the roller speed to the fibers represents one of the

problems of drafting operation.

Roller drafting adds irregularities in the strand.

Drafting also actually reduced the strand irregularities by breaking down the

fiber groups. Drafting is accompanied by doubling on the draw frame,

this off sets the added irregularity.

THE FACTORS THAT AFFECT THE YARN QUALITIES ARE

The total draft

No. of draw frame passages

Break draft

No. of doublings

Grams/meter of sliver fed to the draw frame

Fibre length

Fibre fineness

Delivery speed

Type of drafting

In Nishat Textile Mills Unit No. 3, there are total ten drawing frames. Five

drawing frames are used as breaker, five as finisher.

BREAKER DRAWING

Total No. of frames = 5

Make = Rieter

Model = RSB–D35

Mfg. Year = 2003 (Rieter)

FINISHER DRAWING

Total no frames = 5

Make = Rieter

Model = RSB-D35

Mfg. Year = 2003 (Rieter)

About RSB-D30

Length of machine = 1800 mm

Height of machine = 2000 mm

Width of machine = 2410 mm

Drafting system = 4/3 with pressure bars

Draft range = 4 – 12

Delivery speed = 400 m / min

Can dimension = 20 × 42 inches

No. of deliveries = single

No. of doublings = 8

Length of sliver in cane = 5000 yards

SETTING OF DRAFTING ROLLER

For RSB-D35

Back zone

Roller gauge = 5 mm

Nip to nip setting = 40 mm

Middle zone

Roller gauge = 5.5 mm

Nip to nip setting = 40.5

Front zone

Roller gauge = 6 mm

Nip to nip setting = 41 mm

FACTORS ON WHICH SETTING WILL DEPEND

Hank sliver

Shorter fiber %age

Staple length

Level of draft

TOP ROLLER WEIGHTING / PRESSURING

Pressure system = spring pressure

Color of spring use = Red

Amount of pressure used

On front and IV roller = 40 kg on each side

On 2nd and back roller = 30 kg on each side

On pressure bar = 10 kg on each side

Life of cots = 2 Years

Diameters of different roller

Bottom rollers dia = 35 mm (all)

Top rollers dia = 34 mm

2nd top roller dia = 27 mm

Calendar roller dia = 51 mm each

ROTARY SPEED CALCULATIONS

Motor speed = 1450 rpm

Motor pulley dia = 167 mm

Machine pulley dia = 100 mm

CALENDAR ROLLER

Rotary speed of front roll = 1450

= 2421.5 rpm

Surface speed of calendar roll = πDN

= 3.14×51/1000×2421.5

= 387.78 m/min

FRONT ROLLER

Rotary speed = 2421.5 × 44 ×48

49 30

= 3479.05 rpm

Surface speeds of front roll = 3.14×3479.05×35/1000

= 382.34 m/min

2ND ROLLER

Rotary speed

= 634.008 rpm

Surface speed = πDN

= 3.14×35/1000×634.008

= 69.71 m/min

3RD ROLLER

Rotary speed = 2421.5×23/77×71/81×37/59×47/30

= 622.904 rpm


= 3.14 × 35/1000 × 622.904

= 68.49 m/min

BACK ROLLER

Rotary speed =2421.5×44/75×68/59×37/114×44/52

= 449.65 rpm


= 3.14 × 35/1000 × 449.65

= 49.44 m/min

DRAFT CALCULATIONS

DRAFT B/W 3RD AND BACK ROLLER

D1 = Surface speed of 3 rd roll

Surface speed of back roll

= 68.49

49.44

= 1.385

DRAFT B/W 2ND AND 3RD DRAFTING ROLLER

D2 = S. speed of 2 nd roll

S. speed of 3rd roll

= 69.74

68.49

= 1.018

Draft b/w front roll and 2nd drafting roller

D3 = S. speed of front roll

S. speed of 2nd roll

= 382.34

69.71

= 5.48

Draft b/w front and calendar roller

D4 = S. speed of calendar roll

S. speed of front roll

= 387.78

382.34

= 1.014

Total draft of drafting system

D = D1 × D2 × D3 × D4

= 1.385 × 1.018 × 5.48 × 1.014

= 8.01

PRODUCTION CALCULATIONS

Actual production

= S. speed of C.R. (˝/min) × 60 × 67 ×8 ×85 Lbs / shift.

7000 100

= 387.78 x 39 ×60× 67 ×8 × 0.85

36× 7000

= 1640.53 lbs / shift / delivery

= 3281.06 lbs/ shift / D.F.

STOP MOTION

Photo-cells are mounted at creel which sense the absence of any sliver

A motion stops m/c in case of roller lapping.

M/C stops automatically when said length is completed in the can.

CAN CHANGE MOTION

When one can is filled, it is replaced by empty can and machine starts

automatically.

ATMOSPHERIC CONDITIONS

Temperature = 96oF

Relative humidity = 58%

ROVING FRAMERoving machine is complicated, liable to faults, causes defects, adds to production costs and delivers a product that is sensitive in both winding and unwinding. This machine is forced to use by the spinner for the following two reasons

Sliver is thick, untwisted strand that tends to be hairy and to create fly. The

draft needed to convert this is around 300 to 500. Drafting

arrangements of ring frames are not capable of processing this strand in a

single drafting operation to create a yarn that meets all the normal demands

on such yarns.

Draw frame cans represent the worst conceivable mode of

transport and presentation of feed material to the ring spinning frame.

TASKS OF ROVING FRAME

Drafting the sliver into roving

Protective twist to drafted strand

Winding the twisted roving on a bobbin

TECHNICAL POINTS

Fiber to fiber cohesion is less for combed slivers. Rollers in the creel can

easily create false drafts. Care must be taken to ensure that the slivers are

ROVING FRAME

passed to the drafting arrangement without disturbance.

Bobbin and flyer are driven separately, so that winding of the twisted

strand is carried out by running the bobbin at a higher peripheral speed than

the flyer.

The bobbin rail is moving up and down continuously, so that the coils must

be wound closely and parallel to one another to ensure that as much as

material is wound on the bobbin.

Since the diameter of the packages increases with each layer, the length of

the roving per coil also will increase. Therefore the speed of movement of

bobbin rail must be reduced by a small amount after each completed layer.

Length delivered by the front roller is always constant. Owing to the

increase in the diameter of the package for every up and down movement,

the peripheral speed of package should keep on changing , to maintain the

same difference in peripheral speeds between package and flyer.

Flyer inserts twist:

Each flyer rotation creates one turn in the roving. Twist per unit

length of roving depends upon the delivery rate.

Front roll delivery (inch/min) = (flyer rpm) / (TPI)

Turns per inch = (flyer rpm) / (Front roll delivery)

Higher levels of roving twist, therefore, always represent production losses in

Roving frame and possible draft problems in the ring spinning machine. But very

low twist levels will cause false drafts and roving breaks in the roving frame.

T.P.I

T.P.I depends on the following factors

Yarn Count

The finer counts require more twist because the number of fibers per cross section

of the thread is less.

Staple Length

The longer staple length of cotton requires less t.p.i as compare to the short staple

Man Made Fibers

Man made fibers require less t.p.i as compared to the natural fibers

Roving strength:

Roving strength is a major factor in determining winding limitations. It

must be high enough for the fibers to hold together in a cohesive

strand and low enough for satisfactory drafting at the spinning

machine.

The factors affecting roving strength are as follows:

The length, fineness, and parallelization of fibers

The amount of twist and compactness of the roving.

The uniformity of twist and linear density.

SIMPLEX DEPARTMENT

In Nishat Textile Mills Unit 3 there are 6 simplex frames of Toyoda FL-16

Observations:Total no of machine = 6

Machines used for 30s coun = 4

Machines used for 20s count = 2

No. of spindles per frame = 120

Model = FL-16

Make = Toyoda

Mfg. Year = 1991 model

Spindle speed = 1050 rpm

Delivery rate = 23.64 m/min


TPI = 1.02

Drafting System = 4/4 arrangement

Range of draft = 5-25

Applied draft = 7.21

Twist range = 0.7 - 1.5

Twist applied (T.P.I) = 1.02

Rail balancing method = Dead weight

Temperature = 96Fo

R.H. % = 58 %

CreelType of creel = Power creel

Creel angle = Can be changeable

SETTING ON SPEED FRAME

Front zone settingRoller gauge = 6.5 mmNip to nip setting = 35.0 mm

Middle zone settingRoller gauge = 20.5 mmNip to nip setting = 49 mm

Back zone settingRoller gauge = 21.5 mmNip to nip setting = 50 mm

FACTORS ON WHICH SETTING WILL DEPEND Hank sliver Short fibre % age Staple length Level of draft

Top Roller PressurePressure system = spring pressurePressure on front roller = 10 kgPressure on second roller = 21 kgPressure on third roller = 14 kgPressure on Back roller = 14 kg

Spacer:For 1st hank roving black spacer is used which cause 7 mm apron nip.

STOP MOTIONSCondition Color Machines is at rest Red lightSliver breakage at creel by photocell Green lightRoving breakage by photocell Yellow light

Indication of doffing White light

CALCULATIONSMotor speed = 960 rpm

Motor pulley dia = 190 mm

Drive pulley dia = 222 mm

Twist change gear = 43 T

Total draft change gear = 46T

Back draft change gear = 61 T

Lifter change wheel = 29 T

Spindle speed = Motor rpm × 190 × 47 × 47 222 54 32

= 960 х 190 × 47 × 47 222 54 32

= 1050.325 rpm

Front roller speed = Motor rpm × 190 × 82 × 72 × T.C 222 91 91 91

= 960 х 190 × 82 × 72 × 43 222 91 91 91

= 276.797 rpm2nd roller speed = Motor rpm ×190×82×72×43×20

222 91 91 91 21

= 960 х 190 × 82 × 72 × 43 × 20 222 91 91 91 21

= 263.616 rpm

3rd roller speed = Motor rpm×190×82×72×43×26×46×33×60 222 91 91 91 104 83 61 26

= 960 х 190 × 82 × 72 × 43 × 26 × 46 × 33 × 60 222 91 91 91 104 83 61 26

= 47.88 rpmBack roller speed = Motor rpm × 190 × 82 × 72 × 43 × 26 × 46

222 91 91 91 104 83

= 960 х 190 × 82 × 72 × 43 × 26 × 46 222 91 91 91 104 83

= 38.35 rpm

Draft calculations

D1=front zone draft = Surface speed of F.R Surface speed of 2nd roll.

= 276.79× D × π

263.616× D × π = 1.05

D2= draft b/w 2nd&3rd rolls = Surface speed of 2nd roller Surface speed of 3rd roller

= 263.616 47.88

= 5.50

D3 (Break draft )

Break draft = surface speed of 3rd rollerSurface speed of back roller

= 47.88 38.35

= 1.25Total draft = D1 × D2 × D3

= 1.05 × 5.50 × 1.25 = 7.22

Draft constant = Total mechanical draft × TDC= 7.22 × 46= 332

T.P.I = Spindle speed rpm Surface speed of front roller

= 1050.325 π D N (inch/min) = 1050.325 975.19= 1.0765

Twist constant = T.P.I. × T.C.= 1.0765 × 43= 46.29

PRODUCTIONCalculated production (lbs/shift) = spindle rpm × 60 × 8 T.P.I × 36 × 840 × count

= 1050.325 × 60 × 8 1.0765 36×840×0.98 = 15.80 lbs / shift / spindlesEfficiency of simples = 85 %

So actual production = 15.80 × 85 100

= 13.43 lbs/shift/spindleTotal no of spindles = 120 / frameTotal production = 13.43 × 120

= 1611.6lbs/shift/frame

= 1611.6

RING FRAMEAfter the roving frame yarn-manufacturing process is started. The

process is accomplished by using ring frame which performs following

functions.

FUNCTIONS OF RING FRAME

To draft the roving until the required fineness is achieved.

To impart strength to the fiber, by inserting twist.

To wind up the twisted strand (yarn) in a form suitable for storage,

transportation and further processing.

ADVANTAGES OF RING FRAME

It is universally applicable, i.e. any material can be spun to any required

count.

It is simple and easy to master.

The know-how is well established and accessible for everyone.

CREEL

Creel is a simple device as design is concerned. These are mounted on several rails

arranged one behind the other and extending over the whole length of machine.

There is one holder for each spindle.

DRAFTING

Drafting arrangement is the most important part of the machine. It influences

mainly evenness and strength. If higher drafts can be used with a drafting

arrangement, then coarser roving can be used as a feeding material. This results in

higher production rate at the roving frame and thus reducing the number roving

machines required, space, personnel.

SPINDLE & THERE DRIVES

Spindles and their drive have a great influence on power consumption and noise

level in the machine. The running characteristics of a spindle, especially

imbalance and eccentricity relative to the ring flange, also affect yarn quality and

of course the number of end breakage. Almost all yarn parameters are affected by

poorly running spindles

LAPPET GUIDE

Lappet guide performs the same sequence of movements as the ring rail, but with a

shorter stroke. This helps to control the yarn tension variation with in control, so

that ends down rate and yarn characteristics are under control

TRAVELER

Traveler imparts twist to the yarn. Traveler and spindle together help to wind the

yarn on the bobbin. Length wound up on the bobbin corresponds to

the difference in peripheral speeds of the spindle and traveler. If traveler weight

is too low, the bobbin becomes too soft. If a choice is available between two

traveler weights, then the heavier is normally selected, since it will give greater

cop weight, smoother running of the traveler and better transfer of heat out of

traveler. When the yarn runs through the traveler, some fibers are liberated. Most

of these fibers float away as dust in to the atmosphere, but some remain caught on

the traveler and they can accumulate and form a tuft. This will increase the mass

of traveler and will result in end break because of higher yarn tension.

Ring department of Unit No. 3

Total no. of frame = 22

Make = Toyoda

Model = RY5

Mfg. Year = 1991 (RY5)


Total no. of spindle = 21120

DIAMETERS OF DIFFERENT ROLLERS

Dia of front drafting roller = 25 mm

Dia of middle bottom drafting roller = 25 mm

Dia of back bottom drafting roller = 25 mm

Top roller dia = 28 mm

Cots’ dimension = 19 × 28 × 26

Hardness = 70 shore

Top apron dimensions = 37 × 28 × 1.1

Bottom apron dimension = 73 × 30 × 1.1

Top apron life = 2 years

Bottom apron life = 1 ½ years.

DRAFTING ROLLER

Front zone = 44 mm

Back zone = 46 mm

PRESSURE ON TOP ROLLERS

Pressure on front top roller = 18 kg

Pressure on middle top roller = 16 kg

Pressure on back top roller = 14 kg

ATMOSPHERIC CONDITIONS

Temperature = 94 Fo

Relative Humidity = 60 %

PNEUMAFIL ARRANGEMENT

This arrangement is attached with the ring frame with the help of a suction fan at

one end of the frames. If thread breaks and workers is not attentive it piles on the

floor and also touches the neighboring threads and breaks them. Therefore, quality

deteriorates this is why pneumatic pipe is attached with ring frame.

SPEED CHANGE MECHANISM

Speed change from low o high or from high to low is accomplished by changing

the driving pulley speed with the pelt-shifter according to the commands from the

auto counter or independent changeover switch operation. Limit switches make

control LS-20 and LS-21. The mechanism is as shown in figure.

OPERATIONS

When the auto-counter reaches the specified setting after the start of spinning

frame operation and acceleration signal AC10.1 is set, the motor installed at the

gear-box starts to rotate the driving shaft

The belt shifter connected to the driving shaft is operated to move the belt to the

high-speed side. The time for shafting from the low speed to the high speed is 3 to

5 seconds. When the belt is shifted to the specified position, limit switch LS-20

installed at the gearbox is actuated to stop the motor and start the specified high-

speed operation. When the pinning frame approaches the full bobbin state, the auto

counter reaches the specified setting and declaration signal AC10.2 is set. The

motor installed at the gearbox starts reverse revolution to move the belt to the low

speed side.

SAFETY SWITCHES

Ring Ralloverturn Stop Device

This device brings the machine to full shutdown when the ring rail is raised

beyond the specified total lift because of incorrect setting of the full bobbin stop

timing the specified total lift because of incorrect setting of the full bobbin stop

limiting.

Door Safety Switches

The rod moves in the direction of the arrow shown by solid line to actuate the limit

switch.

Penumtic Clearer

The model RY5 ring spinning frame employs the cage revolution type pneumatic

clearer made by Towa Koygo as an optional component. When the yarn fed from

the front roller is cut the pneumatic clearer sucks fibers through, flute pipes

provided for each staff and carries them through the duct under the top board to

the filter box on the out end. Then, the filter separates the fibers from the air.

Speed Calculations

Motor rpm = 1460 rpm

Motor pulley Dias = 196.185 mm

Driven pulley dia = 185.196 m

Belt thickens = 4 mm

Spindle speed at start = 1460 × 185+4 × 200+0.5

of package 196+4 20.5+0.5

= 13172.85 rpm

Spindle speed at middle = 1460 × 196+4 × 200+0.5

of package 185+4 20.5+0.5

= 14750.8 rpm

Spindle speed at end

of package = 13172.85 rpm

Speed of main driving = 1460 × 196+4

shaft 185+4

= 1544.97 rpm

Speed of front roller = 1460 × 39 × 63 × 38 × 36

67 97 81 36

= 274.0174 rpm

Speed of middle roller = 274.0174× 36 × 41 × 43 × 33 × 38

87 84 104 69 28

= 14.85 rpm

Speed of back roller = 274.017 × 36 × 41 × 43 × 33 × 32

87 84 104 82 27

= 10.914 rpm

DRAFT CALCULATIONS

Break draft b/w back roller and middle roller

D1 = Surface speed of middle roller

Surface speed of back roller

= π ×(25+(1.1 × 2 × 0.8) × 14.85

π × 25 × 10.914

= 1.456

Note: 0.8 is the 80% thickness of apron

Main draft b/w middle roller and front roller

D2 = π ×25+274.0174

π × (25+ (1.1×2×.8)) ×14.85

= 17.239

Total mechanical = D1× D2

M.D. = 1.456 × 17.239

= 25.09

Total M.D = Surface speed of front roller

Surface speed of back roller

= π ×25+274.0174

π × 25× 10.914

= 25.10

Draft constant = T.M.D. × D.C.

= 25.09 Χ 43

= 1078.87

Actual Draft

Count delivered = 20

Hank roving = 0.83

A.D. = 20

0.83

= 24.09

TWIST CALCULATION

As T.M. = 3.89

Count = 20

T.P.I. = T.M. v Count

= 17.396

Also T.P.I. = Spindle r.p.m.

Front roller delivery (in/min)

= 14750.8 .

π × 25 × 274.0174

= 17.4

By shortcut method

T.P.I. = 1× 36 × 81 × 97 × 67 × 200+0.5 × 25.4

36 38 63 39 20.5+0.5 π ×25

= 17.4

Twist constant = T.P.I. Χ T.C.

= 17.4 Χ 63

= 1096.2

LIFTER CALCULATIONS

Yarn length delivered per revolution of heart cam (meter)

= 1× 65 × 39 × 60 × LCB × 59 × front roller dia (mm) × 3.14

1 32 55 LCA 36 1000

= 1× 65 × 39 × 60 × LCB × 59 × 25 × 3.14

1 32 55 LCA 36 1000

= 5.96 meter

TWIST CONTRACTION

Twist contraction = 2.64(T.M)-4.82

= 2.64(3.89) – 4.82

= 5.48

Due to twist contraction, the count becomes coarser, so we have to put more draft

Existing draft = 25.09

Actual draft (which should be employed)

= 25.09 × (100 × 5.48)

100

= 26.46

Due to twist contraction, turns per inch would also increase.

Calculated T.P.I. = 17.4

Actual T.P.I. (being observed in the yarn)

= 14.4 × (100+5.48)

100

= 18.35

PRODUCTION CALCULATIONS

Spindle speed changes during building of package so we take

Spindle speed = 14750.8 rpm

T.M. = 3.89

T.P.I = 17.4

No. of ring frames for 20 CD/H = 22


So

Calculated production = spindle speed × 60 × 8

T.P.I. 36 × 840 × count

= 14750.8 ×

60 × 8 .

17.4 36 × 840 × 20

= 0.67 lbs/shift/spindle

= 10.765 OPS/shift

Efficiency of ring = 95%

Actual production = 10.765 × 95

100

= 10.23 OPS

Total production of 20 CD/H = 10.23 ×22 × 960

= 13503.60lbs/shift

= 40510 lbs/day

= 405 bags / day

Where weight of each bag = 100 lbs

WINDINGINTRODUCTION

“Winding is the process which result in producing a good package of long length

and fault free yarn.” Most of the spinning mills use automatic winding machines.

Quality of yarn and package and winding machine production are improving day

by day. The requirement of yarn from the ring department comes in the small

packages (Ring Bobbins). This yarn is full of defect i.e., thick and thin places etc.

these defects are removed on the winding machines. The objects of winding are:

To prepare a bigger package having sufficient length of yarn on it.

To remove spinning faults i.e. thick and thin places.

To improve the quality of the yarn

AUTO CONER

The development of automatic winding has reduced the labour requirement of

winding and along with the development of electronic yarn clearer has been a

major factor leading to the most universal adoption of single yarn winding and

cleaning. There are three main types of automatic winding machines.

Machines with one automatic knotter per winding head.

Machines with traversing knotter to serve a number of spindles.

Carousel machine in which the winding heads circulate around a fixed control unit

incorporating a magazine and knotter

INFORMATION ABOUT DEPARTMENT

No. of machines 6

Make MURATA

Model Mach coner 7-11

Mfg. Year (4) 1984, (1) 1986, (1) 1992

No. of spindle per machine 84

Cradle Cantilever type

Winding speed 1000 m/min

Winding range 800 - 1200 m/min

Winding angle 50- 57˝

PRODUCTION

Delivery speed of winding drum = 1000 m/minEfficiency = 86 %No. of spindles for 20 CD/M = 84

Production =1000 × 1.0936 × 60 × 1 × 86 840×20

100 = 3.359 lbs/hr/drum

Total production of 20CD = 3.359 × 84 = 282.149 lbs/shift = 2257.19 lbs/day

No. Of bags/day = 67.716 bags

Packing

Packing is the last stage in the yarn manufacturing process. Packing in charge

under the super vision of GM mills is held responsible for all the issues relating to

the packing of the yarn. There are two types of packing

Export Packing

“Cartons are used in the export packing”

Local Packing

“Poly propylene bags are used for local packing”

Each bag weight is 100 lbs or 45.36 kgs(excluding tare) In packing department

following kinds of cones are packed:

FIBER TESTING LABORATORY

Quality lab has following instrument for testing quality parameters of cotton fibre,

yarn and fabric. Polyester fibres are also tested here.

MOISTURE METERThis moisture meter is used for measuring

moisture content of cotton. Samples from

lot are tested by this meter and reading of

moisture content is noted from three

different places and then takes its average

for accurate reading of moisture content.

Oven for moisture measurement

This is also used for moisture measurement. Weight of cotton sample before and

after heating in chamber of oven is noted and then moisture is calculated. If

W = Sample weight

W1 = Dry sample weight

M = Moisture content

Then

M = W – W1

TRASH ANALYZERIt is also called Shirley analyzer. It is used to

determine amount of trash in raw cotton.

Sample of cotton is weighted before and

after trash drop out and so amount of trash is

calculated by difference of weight.

UV METER:It is also called as ultra violet meter. It is used for testing color fastness of

polyester. A sample is tested from four sides by UV meter and then average of

four readings is calculated for accurate results. As reading is high polyester is of

good quality and vice versa.

HVI SPECTRUM

HVI Spectrum is used to determined micronair value, maturity, length, uniformity,

amount of fibres, short fibre index, strength, elongation, moisture, Rd value, +b

value, color grade, trash count, trash area and trash grade. Moisture and maturity

are two additional properties of HVI spectrum as compared to HVI 900

HVI 900HVI 900 is used to determine micronair

value, length, uniformity, amount of

fibres, short fibre index, strength,

elongation, Rd value, +b value, color

grade, trash count, trash area and trash

grade

AFIS:

AFIS is used for advance fibre integration

system. This instrument is used for nep testing,

length and maturity testing and trash

classification testing. Three testings can also be

done separately. A sliver of weight 0.4-0.6gm

with length 30 cm is used for accurate

determination of neps, trash and fibre count.

Qasir Spinning Report

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Transcript of Qasir Spinning Report