himanshu training report 2016

HIMANSHU SINGH, B.Tech(CTT),Indian Institute of Carpet Technology,Bhadohi page
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 Singh
Asstt. Vice President ,Unit head (3,4&5)
Arihant Spinning Mills,Malerkotla

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 givenVardhman 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.
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
Chief Manager (M4)
Senior Manager (M3)
Junior Manager (M2)
Dept. Manager (M1)
Executive (E2)
Shift Officer

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.”

HIMANSHU SINGH, B.Tech (CTT), Indian Institute of Carpet Technology, Bhadohi Page 11
COMPANY OVERVIEW
NAME OF INDUSTRY: ARIHANT SPINNING MILLS
LOCATION: Industrial area,Malerkotla,Distt.Sangrur,PUNJAB
The 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

Unit 3: An Introduction
Unit 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: 21600
Total 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. of
Machines
Manufacturer Model
1 Multi Bale Opener 4 LMW B ¾,LB 3/6
2 Blendomate 1 Trutzschler Type-0916108
3 Cleanomate 1 Trutzschler LVSA 375
4 Multimix 3 Trutzschler B 7/3
5 Flexiclean 4 LMW LB 5/6
6 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 Rieter
Rieter
RSB- 851
SB-2
LRSB B51
9 Unilap 1 Rieter E 32
10 Comber 5 Rieter
LMW
E 7/5
LK64
11 Simplex 8 Lakshmi Rieter
LMW
LF 1400 A
LF 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 Consumption
As 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
Staple
Length(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 0
GIZA86 33-35 36-38 4.3-4.8 Egypt Egyptian 50
GIZA88 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 Handling
In 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 godownboy.
• 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
Blowroom
Objectives:
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/hr
Working width : 1200 mm
Beater dia. : 400 mm
Beater speed : 600 rpm

Beater type : disc type
Exhaustion 4 m3
/second
Inlet power
Airflow Rates:
: 15-16 kw
Suction delivery : 0.4 m/sec
Dust extraction : 4 m/sec
Material supply : 1.6 m/sec
Setting:
Inclined lattice to Evener roller : 1.5 mm
Inclined lattice to Stripper roller : 6 mm
Disc beater to feed roller : 1 mm
Disc beater to grid bars : 3 mm
Between feed rollers : 1 mm
Traverse plate : 3 mm
Waste plate
Space requirement:
: 0, 0, 2, 3, 4
Total width : 1500 mm
Length : 7000 mm
Height : 1500 mm
BLENDOMATE
MODEL : A/10
MAKE : TRUTZSCHLER
YEAR : 2000
NO. OF MACHINE : 1
Introduction:
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 swiveltower 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 mm
Production rate :-One assortment-up to 1500 kg/hr
Two assortment-up to 1100 kg/hr
Three assortment-up to 750 kg/hr
Four assortment-up to 600 kg/hr
Machine efficiency :- 50%
Installed power :- 12.98 kw
Contact roller dia. :- 125 mm
Plucking roller dia. :- 288 mm
Plucking roller speed :- 1800 rpm
Legs on each beater :- 4
Teeth on each legs :- 38
Traverse drive speed :- up to 12.0 m/min
Take off depth (Index) :- up to 20 mm
Main frequency :- 50 hz
Operating mode :- Automatic mode

DRIVE:-
1. Traverse drive
2. Lifting drive
3. Take off roller drive
4. Tower swiveldrive – for 180 rotation
5. Fan drive
6. Axiliary fan
LIMIT SWITCHES:-
1. Foreign body monitoring.
2. Lift limitation top/ bottom
3. Door safeguards
4. 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.
CLEANOMATE
MAKE :- TRUTZCHLER
MODEL :- LVSA 375
YEAR :- 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 mm
Width of machine : 1100 mm
Working width : 1600 mm
Height of machine : 2000 mm
Beater type : Pin type

Beater speed : 400-800 rpm
No. of grids : 30
Motor speed : 1440 rpm
Beating point : 1
Production 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 :- Trutzchler
MODEL :- 2361037
YEAR :- 2000
NO. 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/hr
Width :- 1800 mm
Working width :- 1200 mm
Height buffer storage :- 3500 mm
Section to mid feed pipe :- 3750 mm
Storage capacity :- 250 kg
No. of beater :- One
Beater :- Pin type
Dia. Of motor pulley :- 108 mm
Dia. Of machine pulley :- 365 mm
Motor speed :- 1440 rpm
Beater speed :- 400 rpm
Conveyer belt speed :- 0.62 rpm
Inclined 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 : LAXMI
Model : LB 5/6
Year : 2014
No. of machine : 4
Production rate : 400 kg/hr

Feed roller dia. : 60-80 mm
Plain drum dia. : 250 mm
Perforated drum dia. : 250 mm
Beater speed : 600-1000 rpm
Motor speed (fan) : 2850 rpm
No. of beater : 1
Beater type : Saw toothed
Beating point : 1
Air discharge rate
SETTING :-
: 14-175 /sec
Feed roll to feed roll : 2 mm
Beater to feed plate : 2.7-3 mm
Beater to grid bar : 1-4 mm
Feed 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 chute
The 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 Fibre
3. 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*1.20
Wire height :- 5.5 mm
Wire angle :- 100
Wire thickness :- 1.2 mm
PPSI (TPSI) :- 8.46
CYLINDER WIRE :- R 2030*0.5

Wire angle :- 300
PPSI (TPSI) :- 863.6
DOFFER WIRE :- N-4030*.85R
Wire angle :- 300
PPSI (TPSI) :- 388.47
FLAT TOPS :- PT 52KV4
SFL :- 5F+2K-CO
SFD :- 3F+1K Syc62
SETTING (GAUGE) IN CARD :-
Feed plate to Licker in : 0.8 mm
Licker in to Cylinder : 0.2 mm
Licker in to Mote-knives : 0.3 mm
Licker in to Combing segment : 0.55 mm
Carding plate Gauge : 0.35, 0.3, 0.3 mm
Back 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 mm
Front Top plate
:
0.75 mm
Flat comb Blade gauge
:
0.25 mm
Cylinder to Doffer gauge : 0.125 mm
Doffer 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 kw
Doffer motor : 1.8 kw
Fan motor : 3.7 kw
Feed motor : 0.75 kw
Philliption brush motor : 0.25 kw
Control system : 0.65 kw
Web doffing motor : 0.55 kw
Brush motor : 0.12 kw
Total : 13.57 kw
Total 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/hr
Connecting 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
Drawframe
Draw 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 autoleveller
11.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 Rieter
Model : SB 2
No. of machine : 2
Motor pulley dia. : 110 mm
Machine pulley dia. : 192 mm
Creel capacity : 12
No. of delivery : 2
Drafting system : 3/3
Draft range : 3.6-11
Break draft : 2 (for carded)
Main draft : 1.78 (for combed)
Weighting system : Pneumatic
Load on top roller : 33 kg
Material processed : Dia. of
bottom roll :
Cotton (EL- up to 75 mm)
Front : 52 mm
Middle : 28 mm
Bottom : 28 mm
Shore Hardness : 820
Pressure on C.R. : 0.5-2.5 bar
Can dia. : 500 mm
Can 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 Rieter
Model : RSB 851
No. of machines : 4
Material used : Cotton
Staple length : 25-80 mm
Doubling : 8
No. of delivery : 1
Top arm loading : Dia.
of Top rollers :
spring loaded
Front : 38 mm
Middle : 38 mm
Back : 38 mm
Dia. of Bottom rollers :
Front : 40 mm
Middle : 30 mm
Back : 30 mm
Draft range : 3.5-11.6
Waste : 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 : Rieter
Model : E 32
No. of machine : 1
Year : 2005
No. of delivery : 1
Creel capacity : 24
For fibre length : up to 60 mm
Drafting system : 4/4
Top arm pressure : 600-800 N
Sliver wt./mt : 4.5-5.0 ktex
Lap wt./mt : 60-80 ktex
Lap width : 300 mm
Full lap dia. : 510 mm
Break draft : 1.0406
Intermediate draft : 1.051
Main draft : 1.305-1.637
Total draft : 1.624
Delivery rate : 100 m/min
Production rate : 350 kg/hr
Efficiency : 95 %
Servo trolley is used for supply the lap roll to the comber.
Comber
Comber 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:
MAKE :- RIETER
MODEL :- E 7/5A
NO. OF MACHINE : 6
YEAR :- 1994
No. 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 gm
Raw material/fibre length :- Cotton/1”-2”
Total draft :- 9.0-20.4
COMBER LK 64
MAKE :- LMW
MODEL :- LK64
NO. 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 gm
Raw material/fibre length :- Cotton/1”-2
Efficiency :- 90 %
Speed Frame

Objects :-
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.

MAKE : LAKSHMI
MODEL : LF 1400
NO. OF SPINDLE : 120
Drafting 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 mm
Middle & back roll gauge : 50-80 mm
Top apron thickness : 0.8-1.04 mm
Shore hardness of cots : 830
Bobbin length : 340+_2mm
Bobbin base dia. : 70 mm
Roving hank range : 0.5-3.5 Nes
Saddle gauge : 52/58
Drafting pressure : 0-2.5 kg/cm2
Main pressure : 0-6 kg/cm2
Apron 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.
MAKE : KTTM
MODEL : 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 MM
TIN ROLLER DIA. : 250 MM
RING DIA. (INNER) : 38 MM
RING DIA. (OUTER) : 44 MM

RING TYPE : SINGLE FLANGE
WEB THICKNESS
HEIGHT OF TRAVELLER
: 1.0 MM
CLEANER : 6.0 MM
BOBBIN TYPE : POLY CARBONITE
RING RAIL SECTION LENGTH : 5.5 FEET
NO. OF RING IN 1 SECTION : 24
SPINDLE HEIGHT : 340 MM
NOSE BAR WIDTH : 23 MM
NOSE BAR HEIGHT : 540 MM
LENGTH OF BOBBIN : 180 MM
DRAFTING ANGLE : 450
DIST. B/W F.R. TO M.R. : 50 MM
DIST. B/W M.R. TO B.R.
DIST B/W THREAD GUIDE TO
: 65 MM
SPINDLE BASE
TRAVERSE SPEED OF
: 295 MM
TRAVERSE GUIDE : 8 MM/MIN
DIST. B/W F.R. TO B.R. : 107.5 MM
SADDLE GAUGE : 50-67 MM
CRADLE LENGTH : 36 MM
BOTTOM APRON SIZE : 80.5*30*1.05 (MM)
TOP APRON SIZE : 38.1*3O*1.05
BOTTOM ROLLER DIA. : 27 MM
ARM TYPE : P 3-1
LAPPET HEIGHT : 30/35 MM
LAPPET HOLE : 3.5 MM
ABC RING : 41 MM
SPACERS 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 Processes
WINDING 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 SAURER
Model Autoconer 338
No. of machine 5
No. of head/machine 60
Bobbin magazine capacity 6
Winding speed 900-1500m/min
Time 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 SPEED
8 600-900
10 900-1000
20 1200-1400
30 1100-1300
40 1150-1200
60-80 700
YARN FAULT REMOVED BY AUTOCONER:
N/S/L Thick places
T Thin places
C/CC/PC Count pearl
FD Foreign matter dark
FL Foreign matter light
J/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/MC
8 1 worker for 20 drums
40 3 worker per 2m/c
Auxiliary Devices :
1. Automatic splicer/ knotter.
2. Magazine creel.
3. Conveyer belt for empty Ring tubes.
4. Dust removal system
5. Anti ribbon
6. Blower
7. Electronic thread stop motion.
Conditioning
OBJECTS:
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 (0
C) 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 18
DOMESTIC PKG. 30” x 14.5” x 27.25” 24
TYPE COUNT(Ne) EMPTY CONE
WEIGHT
FULL CONE
WEIGHT (KG)
Combed hosiery 13 Cone 50gm 2.60-2.70
Combed compact 32 Cone 50gm 2.80-2.180
Combed warp 40 Cone 50gm 2.80-2.180
Pilot package,slub40 --------- 1.980-2.80
H-Plant
RELATIVE 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 frame
o 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.

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