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44
PREFACE
Our project is a descriptive report on “IN PLANT TRAINING &
VISIT TO WORK”. It is a part of our syllabus. We al...
44
NATIONAL TEXTILE
CORPORATION
LIMITED NEW DELHI
(A Govt. of India undertaking)
Brief description
Natioal Textile Corpora...
44
NTC (MP) LTD was also a subsidiary of NTC ltd
New Delhi which operates 7 continuously droping
mills in the region. Thes...
44
NTC has 3 composite textile greenfield units which
are stablished at Ahmedabad(Gujrat),
Achalpur(Maharastra) and Hasan(...
44
BURHANPUR TAPTI MILLS
Burhanpur, Madhya Pradesh
BRIEF DESCRIPTION
Burhanpur Tapti Mills is a unit of NTC LTD. ,New Delh...
44
At the time of nationalization of mill , it has a total of 47.85
acre land. In that composite textile mill, it has abou...
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mill in primary stage
Spindle strength of mill
in secondary stage
31968 spindles
Total spindle
strength of mill
51269 s...
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Index
01.Introduction
Chapter No. Name of the chapter Page No.
01 INTRODUCTION 08-12
02 MIXING & BLENDING 13-14
03 BLOW...
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Spinning:-
Spinning may be defined as the art or techniques to produce
yarn by twisting of fibrous materials or any oth...
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(b) the preservation of the further fibre
slippage usually by twist insertion.
(c) winding on to a package which is con...
44
of required raw material.
To receive the fresh goods or material from concerned department
and disparch it according to...
44
 BIRLA GRAM(VSF)
Denier× length=1.2×38
Type =B.B.G.S
Gross wt. =264.4 kg
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SPINNING UNIT
MILL CAPACITY
There are two section in NTC tapti mill. One section has
run blended fibre P/v, P/C, 100% p...
44
02.MIXING& BLENDING
 MIXING:-mixingis the process in which different grade same fibre
are kep together,then it si call...
44
 MIXING PROCEDURE:-
 Polyester: viscose=55:45
 Water:-2.26%
 Antistatic agent:- SLV- 80 oil & PEG- 0.02%
 24 hours...
44
03.BLOWROOM
 BLOWROOM:- blow room consist for a series of machine and
material feed by air current.
 OBJECT:-
 Mixin...
44
 Opening and cleaning
 To removal of impurities
 Formation of lap
 INPUT:- MIXED FIBRE
OUTPUT:-BLOW ROOM LAP
 MIXI...
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 Grey section (lap system)
 Expansion (lap system)
 PASSAGE OF MATERIAL:-
Feed table feed lattice inclind lattice...
44
14. Feed roller diameter : - 80 mm
 SETTING:-
1. Evener roller to inclined lattice :-30mm
2. Gauge of piano feed :- 0....
44
BEATER:- a beater is a combination of material
bars or pin it arranged in a cylinder form
carried on arm attached to ce...
44
FEED ROLLER:- feed roller is two metallic strong fluted
roller. It determines the rate of speed used to carry the
fibr...
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• Manual scutcher,
• Auto scutcher.
MANUAL SCUTCHER AUTOSCUTCHER
1. Cage 1. Cage
2. Condenser 2. Krishner beater
3. Two...
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• UNEVEN LAP:- due to important feeding of the
material.
• CONTTAIMINATION IN LAP:- due to improper
cleaning
04.CARDING...
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Elimination of dust
Elimination of short fibres
Fibre blending
Fibre orientation or alignmen
 Sliver formation
PA...
44
TABLE CALLENDER ROLLER
SLIVER GUIDE
COILER
CAN
ACTION IN CARDING MACHINE:-
 COMBING ACTION:- combing action
takes pla...
44
c. one roller is slower and softer is faster, so
carding action is known as ”point again in
point”
action
 STRIPPING A...
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Diameter of cylinder - 814mm
Liker-in - 253mm
Doffer -680mm
No. of m/c-
Plant-A…………..14
Plant-B…………..08
Total- 20
Make:...
44
Plant-B
Model No.: DK800
Year: 2007
Sliver hank ----------------------0.068
Cylinder speed -----------------786rpm
Fl...
44
CAUSES FOR NEP FORMATION IN CARDS:
Lap too heavy, close settings and higher licker in speeds.
Blunt Ickier in wire or d...
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05.Draw frame Breaker
 The main object of breaker draw frame is
parallelization of card sliver to remove the trailing ...
44
No. of machine
In plant A:  3
In plant B:  3
Total :  6
Make: 
Plant-A
Model No.  LD2
Year :  2004
Power requirem...
44
Pressure bar 6 bar
Trumpet Diameter 4.2 mm
Bottom roller setting
MAIN PARTS and function IN DRAW FRAME
BREAKER:-
 CRE...
44
delivery roller through trumpet to form sliver, and
second to deliver this material into the coiler and so
to then can....
44
06.Draw Frame Finisher
TASKS OF DRAWFRAME
1. Fineness Through doubling the slivers is made even.
2. Doubling results in...
44
Model No : HSR1000
Year 2007
Addition feature of this m/c is autolever
Auto leveler is an additional device which is ...
44
SCANING ROLLER
TOP ROLLER
BOTTOM ROLLER
CALENDER ROLLER
COILER ROLLER
CAN
PROCESS PARAMETER
Sliver hank 0.170
Delivery ...
44
Bottom roller setting
MAIN PARTS and function IN DRAW FRAME
FINISHER :-
 CREEL DRAFT:- the draft between the lifter r...
44
 CALENDAR ROLLER:-the object of the calendar
roller fast to draw the web delivered at the front or
delivery roller thr...
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07. Speed frame
It is process the winding, twisting stands in the bobbin and
inserts the small amount of the twist in r...
44
 CREEL:-creel us a suitable plastic structure in
which can sliver is placed as feeding material to
the machine. The ar...
44
order to have wound on it’s the same length as on
the samall diameter.
 BOBBIN LEADING:- the bobbin goes faster than
f...
44
 To stock the combing dust
 To control movenent of short fibre
 Fibre and thus gives a better yarn with draft.

No ...
44
ROLLER SETTING
Note all top roller dia 27 mm
Process parameter
Speed frame hank 1.82
Spindle speed 1000 -1100rpm
Lift 1...
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Coats cleaning :  22 days
Over oiling of machine:  6 months
The factors affecting roving strength are as follows:
The...
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 To insert twist of required amount for different count.
 Producing yarn by drafting and imparting twist.
 To wind t...
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Draft = No. of fiber’s available at cross sectional area of feed
material ÷No. of fiber’s available at cross sectional ...
44
 RING RAIL MOVEMENT : Ring rail movement can be slow when
It is goes up and fast when it is coming down. This is calle...
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03 SHANSHAI
ERFANGJI
CO.LTD
EJM 1382 14 12096
04 JINGWEI FI 520 06 5184
Total spindle =49248
PROCESS PARAMETER OF RING...
44
Twist change wheel :TCA.
Twist change wheel : TCB.
 Drafting change pinion : DFC
 Draft
CHANGE WHEEL
COUNT(Ne) 15 ...
44
MEAN = 3688/5
=737.6
TPI =737.6/9.37
= 18.73
 THE RELATION BETWEEN LENGTH OF YARN & SPEED OF
RING BOBBIN :-
SPEED ( RP...
44
 CALCULATION :-
MOTER POWER =1440 rpm (3.5 HP)
MOTOR PULLEY DIA. = 250 mm
JACK PULLEY DIA. = 45 mm
MACHINE PULLEY DIA....
44
09.AUTOCONER
This machine is an automatic under with individual winding
units independently driven winding units that p...
44
 To prepare bigger package from smaller bobbin package.
 To colour code is maintained for identify different count an...
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S.N MAKE MODEL NO. OF
M/C
NO. OF CHEESE
OR CONE
YEAR OF
MANUF.
01 VEEJAY
LAKSHMI
EXCELLO 06 360 2008
 EXCELLO AUTOMATI...
44
01 COUNT(Ne) 15&20 40&50
02 SPEED MPM 1000 1000-1200
03 LENGTH SHORT 1.6 1.6
04 Dia. SHORT 2.6 2.8
05 LENGTH LONG 25 25...
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INPUT :- Twisted yarn OUTPUT:- Complete
yarn
PROCESS PARAMETER FOR STEAMING-ELGI :-
S.N PROGRAMME
NAME
(UNIT) ( PV SY...
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Conditioning machine
Make :  XDRELLA AG
YEAR  2004
Capacity - 500 cones
Conditioning time - 1 hour
Temp - 70-80 degre...
44
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  1. 1. 44 PREFACE Our project is a descriptive report on “IN PLANT TRAINING & VISIT TO WORK”. It is a part of our syllabus. We all Textile Engg. branch student have worked on it. This project work presents the various information of spinning mill section, followed by a wide range of chapters to explain the concept clearly. We have explained the concepts clearly in simple language. we want to give respect to teachers MR. Kaushal Kant sir, MR. Anand Krishna sir, MR. Surya nath chaudhary sir and Mr. Ranjit sir who helped as for visiting a 4 week summer trainning. After that, we also want to thanks to Mr. Rajeev Ranjan sir, Mr. Anand sir, Mr. Arvind sir and Mr. Sinde sir who instructed as in training period. We also thanks our senior who guided to make this project. At last, to make this project. mistake or fault left in this project then excuse us. Any suggestions for the improvement of this project work will be warmly welcomed. - ALL TEXTILE ENGG. STUDENTS
  2. 2. 44 NATIONAL TEXTILE CORPORATION LIMITED NEW DELHI (A Govt. of India undertaking) Brief description Natioal Textile Corporation (NTC) is a central public sector interprizes which comes under the "Ministry of Textile". It was stablished in April 1969 for running the sick textile mills in private sector, which was undertaken by government. In 1968, Primary period of NTC , there were total 16 mills running. This number increases continuously and in 1972-73 total 103 mills were joined under it . In 1974 , under the act of sick textile undertaking act , all the mills were nationalised.In 1995, the number of mills under NTC increases upto 119. All the 119 mills were operated by NTC Ltd. though total of 9 subsidiary , in which 10 crore ( 1.81 million us dollar) was invested which increases time by time. And now , it is about 7000 crore (1.27 million us dollar) and paid-us share capital is about 4000 crore (727 million us dollar).
  3. 3. 44 NTC (MP) LTD was also a subsidiary of NTC ltd New Delhi which operates 7 continuously droping mills in the region. These mills have old machines and require heavy expence and great manpower, due to that it continuously lose its economy and in 1992, they have to register in BIFR. There were 5 mills out of 7 stoped by the recognized project of BIFR. The remaining 2 mills Burhanpur Tapti Mills, Burhanpur and New Bhopal Textile Mills, Bhopal were updated. Under the project, all the labours working in that 5 mills were given retirement by giving the WRF. And the labours working in the 2 mills were given MWRS. Due to the decreasing number of mills and condition of contemporary industries, On 01-04-2006 all 9 subsidiary companies are consolidated in NTC headquarter, New Delhi. A total of 78 non-profitable mills have been enclosed and 2 mills are handover to the state government of Pondicheri. NTC has to update its all units by using its own sources and 5 mills have been given joint venchor. Fund required for upgradation will come by selling the left or remaining land of NTC.
  4. 4. 44 NTC has 3 composite textile greenfield units which are stablished at Ahmedabad(Gujrat), Achalpur(Maharastra) and Hasan(Karnataka). NTC has started a technical textile project with the help of all the world leaders underjoint industrial project. ************
  5. 5. 44 BURHANPUR TAPTI MILLS Burhanpur, Madhya Pradesh BRIEF DESCRIPTION Burhanpur Tapti Mills is a unit of NTC LTD. ,New Delhi, Indian Government , situated in Burhanpur, M.P.. Burhanpur is situated at the bank of river Tapti and the border of Maharastra. It is an ancient and historical city where many monuments of mugal times like Mumtaj Mahal, Moti mahal, Kundi Bhandara, Asirgarh fort. This city is ringed from three direction by the heavy and thick walls of Shahi Mahal, which was made by Farukhhi Emperors in 1502 and in one direction Tapti river is situated. This city is situated at the railway line of central railway New Delhi-Mumbai and near the Bhusawal station. Burhanpur Tapti Mill was stablished on 29 sep 1906 by Mesars Hajibhai Laljibhai and co. Due to continuous change in technology and no any invest by the company , makes it in the row of sick udhhyog and in 1970 it completely ceases. After a year, In 1971, this mill started under state government. Under the act of sick textile undertaking (nationalisation) act 1974 by Govt. of India, Burhanpur Tapti Mill was nationalized on 1 April 1974.
  6. 6. 44 At the time of nationalization of mill , it has a total of 47.85 acre land. In that composite textile mill, it has about 806 powerlooms, 38648 spindles and process house contains everyday 2524 labours and 146 staffs on placement. On 16 Dec 1987 , In spinning section of mill a very serious fire accident happened which affect seriously the machinary and building. After this accident, the mill had left 7040 spindles only. After the fire accident, the mill run a total of 48 looms and 7000 spindles and the process house also loosed its strength. The mill protected its existance somehow, wherein there is a vast contribution of labours of this mill. In 2008, there was a total of 24 crore invested in the₹ primary stage of innovation which makes it a mill of 19296 spindles and 250 daily labours. In the secondary stage of innovation , a total of Rs. 96 crore waswas invested which stablished 31968 new spindles. It increases the strength of mill from 31968 spindles to 51264 spindles and everyday average production of cotton and synthetic yarn increases to 12 ton . The company is able to give daily work to 600 labours in both old cotton spinning unit and new synthetic unit. There is about 1000 peoples benifiting from this company and its annual turn over reached about Rs. 90 crore. Mill has also got ISO certificate. Spindle strength of 19296 spindles
  7. 7. 44 mill in primary stage Spindle strength of mill in secondary stage 31968 spindles Total spindle strength of mill 51269 spindles Invest in primary stage Rs. 24 crore Invest in secondary stage Rs. 96 crore Total invest Rs. 120 crore Production of main cotton count 44's & 46's Increased spindle in secondary stage PC blend 32's , 54's & 58' s There is also a cantin made under the developement scheme M.S.- 08 of BIFR, which gives convenience to the labours for taking lunch, sitting and drinking pure water. *********
  8. 8. 44 Index 01.Introduction Chapter No. Name of the chapter Page No. 01 INTRODUCTION 08-12 02 MIXING & BLENDING 13-14 03 BLOW ROOM 15-19 04 CARDING 20-25 05 DRAW FRAME BREAKER 26-29 06 DRAW FRAME FINISHER 30-34 07 SPEED FRAME 35-39 08 RING FRAME 40-47 09 WINDING (AUTOCORNER) 48-50 10 STEAMING 51-51 11 PACKING 52-53
  9. 9. 44 Spinning:- Spinning may be defined as the art or techniques to produce yarn by twisting of fibrous materials or any other method from the fibre forming agents. spinning is the first step in the textile manufacturing process for staple articles. . there are several spinning process (rotor spinning, friction spinning, dref spinning) depending upon the fibre used. However, the principle of spinning is the same. YARN:- yarn is an assembly of fibres that are twisted together to form of continuous strand. Yarn may be made from either sraple fibres or filament fibres. staple fibres are twisted to hold them together into yarns. the type and lenght of fibre, the type, ply and size of yarns and the amount of twist given to yarns determine many of the characteristics of fabrics made from the yarns. STAGE OF SPINNING PROCESS the spinning process basically consists of three stages:- (a) Reduction of strand thickness from the supply roving or sliver to the required yarn count.
  10. 10. 44 (b) the preservation of the further fibre slippage usually by twist insertion. (c) winding on to a package which is conveient for handling and which protects the yarn Raw material godewn is the most primary and obviously integral part of any mill, including Burhanpur tapti mill, Burhanpur . its function is to receive raw material from ourside or same department and deliver the material to the respective department as per reuirment for further processe.
  11. 11. 44 of required raw material. To receive the fresh goods or material from concerned department and disparch it according to the requirement . To receive the wastage and storing according to category and packing also. Type of godown:- (a)Raw material godown (b) top godown (c)waste godown Name of raw material:- (a)cotton (b) polyester staple fibre. (c)viscose staple fibre Material Supplier Polyster staple fibre Indorama synthetic(I) LTD Viscose staple fibre Grasim industries LTD Birla Gram Nagda(M.P) Cotton Bikangaone, Sanawad, Bodwad, Khargone, khetia, Barwaha. Indorma Synthetic LTD (PSF):-  den×cl=1.0×51mm merge=45133 gross wt=429.5kg net wt=428.2 kg  den×cl=1.0×44mm merge=44133 gross wr=426.3 kg met wt.= 425 kg luster =sd
  12. 12. 44  BIRLA GRAM(VSF) Denier× length=1.2×38 Type =B.B.G.S Gross wt. =264.4 kg
  13. 13. 44 SPINNING UNIT MILL CAPACITY There are two section in NTC tapti mill. One section has run blended fibre P/v, P/C, 100% polyester(PLANT-A) , 100% cotton and Other section has run only 100% cotton (PLANT-B). PLANT - A = 1296 × 20 = 25920 Spindles PLANT – B = 336× 2× 09 = 6048 Spindles 504× 2× 14 = 14112 Spindles 432× 2× 06 = 5184 Spindles TOTAL = 51264 Spindles
  14. 14. 44 02.MIXING& BLENDING  MIXING:-mixingis the process in which different grade same fibre are kep together,then it si called “MIXING”.  Blending:-when different fibres of same or different grades are kept together then it is called “BLENDING”  OBJECT OF THE MIXING:-  Opening of viscose & polyester fibres.  Conditioning &spraying of polyester.  To mixing the different varieties of fibres.  INPUT:- bale form OUTPUT:- mixed fibres.  MIXING & OPENING :- polyester staple fibre mainly coming from dyeing department and staple fibre tufts are opened in mixing & staple fibre bale coloured.  REQUIRED MATERIAL FOR MIXING:-  Dyed, sparkal, normal white fibres etc.  Polyester- length (44mm), denier(1.5)  Visocse – length (38mm), denier(1.4)
  15. 15. 44  MIXING PROCEDURE:-  Polyester: viscose=55:45  Water:-2.26%  Antistatic agent:- SLV- 80 oil & PEG- 0.02%  24 hours left in atmosphere condition.  NOTE:-water and SLV-80 used for only polyester(chemical)fibres and PEG is used for sparkal fibres.  HUMIDITY AND TEMPERATURE:-  Dry bulb = 86 F  Wet bulb = 80 F  Difference = 76 F  Time = 02:00 PM  R.H = 76%  Date = 26/03/2015
  16. 16. 44 03.BLOWROOM  BLOWROOM:- blow room consist for a series of machine and material feed by air current.  OBJECT:-  Mixing and blending
  17. 17. 44  Opening and cleaning  To removal of impurities  Formation of lap  INPUT:- MIXED FIBRE OUTPUT:-BLOW ROOM LAP  MIXING:- mixing is the process in which different grade of some fibres are mixed together.  BLENDING:- when different fibres of same or different grade are blend together.  OPENING:- to open the bale fivers into small tufts, which will allow foreign material to be separated from the fibre and prepare the material for easy carding.  CLEANING:- to chain the fibre by removing the foreign matter as the waste. The foreign matter consist mainly of seed coats, leaf sand and dust.  FORMATION OF LAP:- finally blowroom to form a compact uniform sheet of lap fibres.  IT HAS THREE SECTIONS:-  Dyed section (aero feed)
  18. 18. 44  Grey section (lap system)  Expansion (lap system)  PASSAGE OF MATERIAL:- Feed table feed lattice inclind lattice evener roller  stripper roller Stripper roller  PARAMETERS OF BLOW ROOM:- 1. Speed of the feed table :- 6.6m/min 2. Speed of feed lattice :- 6.0 m/min 3. Speed of evener roller :- 175 rpm 4. Speed of evener roller :- 320rpm 5. Speed of stripping roller :- 290 rpm 6. Speed of first beater :- 852.71rpm 7. Speed of second beater :-753.85rpm 8. Speed of first fan :- 1781 rpm 9. Speed of second fan :- 2177 rpm 10. Speed of moter pulley :- 1440rpm 11. First beater diameter :- 230 mm 12. Second beater diameter :- 90 mm 13. Cell roller diameter :- 245 mm
  19. 19. 44 14. Feed roller diameter : - 80 mm  SETTING:- 1. Evener roller to inclined lattice :-30mm 2. Gauge of piano feed :- 0.1mm 3. Feed roller to beater :-10-12mm 4. Stripping blade to beater :- 10-12mm 5. Efficiency of blowroom :- 90%  IMPORTANTS PARTS OF BLOWROOM:- FEED LATTICE:- feed lattice which is made by leather sheet and arranged on centre roller. BOTTOM LATTICE:- bottom lattice which is also made by leather sheet and arranged on centre roller. INCLINDE LATTICE:- inclinde lattice which is made by wooden and on which inclined spike arranged which is material sent to evener roller and completely open.
  20. 20. 44 BEATER:- a beater is a combination of material bars or pin it arranged in a cylinder form carried on arm attached to central draft.  OBJECT OF BEATER:- a) To open the fibres by pulling small tufts away from the sheet being threat. b) To clean the fibres by the series of blows in rapid succession which knock out the heavier dirt.  BEATING POINT:- M.B.O :-1/2 Krishner beater : -1 Krishner beater :- 1
  21. 21. 44 FEED ROLLER:- feed roller is two metallic strong fluted roller. It determines the rate of speed used to carry the fibre into the machine. CAGE:- there are two cages. Its shape is a cylindrical shape. It is made of mesh wire and perforated metal sheet. Cage is used to collects the fibres, after it has passed from the beater condenser draws the fibres by air suction. GRID BAR:- grid bars are long steel bars generally triangular in shape. The grid bars fare below the feed roller under the beater partially inclosing the beater chamber. PIANO FEED REGULATING MOTION:- The objects of piano feed regulating motion are to feed the fibres in suctcher in a uniform normal regular way. Triporel link arrangemnt and a pair of conedrum to the operation. • Total no. of piano feed in back side :-16 • Total no. of piano feed in front side :-16 • Total piano feed :-32 SCUTCHER:- scutcher is the last machine of blowroom section to formed fibres to lap and also do opening and cleaning.  SCUTCHER OF TWO TYPES:-
  22. 22. 44 • Manual scutcher, • Auto scutcher. MANUAL SCUTCHER AUTOSCUTCHER 1. Cage 1. Cage 2. Condenser 2. Krishner beater 3. Two & three bladed beater MOTION IN SCUTCHER:- • Piano feed regulation motion • Beating motion • Length regulation motion • Lap compressing and hardening motion CONEDRUM:- it is part of scutcher. It drives the fibre on feed roller and it control the fibre high and low. SEANSOR:- the main function of sensor to be stop the motor when material is passing extra or gathering extra. When material finished again sencor start automatically. DEFFECT AND CAISED IN THE BLOWROOM LAP:- • LAP LICKING:- due to higher bulk of fibre and the static charge.
  23. 23. 44 • UNEVEN LAP:- due to important feeding of the material. • CONTTAIMINATION IN LAP:- due to improper cleaning 04.CARDING  INTRODUCTION carding is the “heart” of spinning department. In this machine open of the small tufts of raw material and individually separated and remove small fibre or impurities. To forming the web from and at last sliver. THE PURPOSE OF CARDING:  To open the flocks into individual fibres cleaning or elimination of impurities Reduction of neps
  24. 24. 44 Elimination of dust Elimination of short fibres Fibre blending Fibre orientation or alignmen  Sliver formation PASSAGE OF MATERIAL:- LAP ROLLER FEED PLATE FEED ROLLER LICKER-IN CYLINDER FLAT DOFFER RE-DIRECTING ROLLER CRUSH ROLLER TRUMPET
  25. 25. 44 TABLE CALLENDER ROLLER SLIVER GUIDE COILER CAN ACTION IN CARDING MACHINE:-  COMBING ACTION:- combing action takes placed between combing segment and licker-in. Here the pin or wire direction of the two surfeced are the same. Combing is the straightening and paralleling of the fibe and the reomved of short fibres and impurities by using coms.  CARDING ACTION:-carding action takes placed between flat and cylinder. Case of carding action:- a. direction of wire in two surfaces are opposite. b. the moving direction of roller are also opposite.
  26. 26. 44 c. one roller is slower and softer is faster, so carding action is known as ”point again in point” action  STRIPPING ACTION:-stripping action takes place between two as :- a. licker-in and cylinder b. doffer and stripping roller case of stripping:- a. wire direction will be same b. roller moving will be same c. one roller will be faster than another so as stripping action is known as “point back” action.
  27. 27. 44 Diameter of cylinder - 814mm Liker-in - 253mm Doffer -680mm No. of m/c- Plant-A…………..14 Plant-B…………..08 Total- 20 Make:  LMW (INDIA) Plant-A Model No.:  LC333 Year:  2012
  28. 28. 44 Plant-B Model No.: DK800 Year: 2007 Sliver hank ----------------------0.068 Cylinder speed -----------------786rpm Flat speed -----------------------30mpm Licker-in speed-----------------1076rpm Chute opening roller speed –686rpm Delivery speed -----------------80m/min Kg/hr-----------------------------30.2 Feed gms/m---------------------31.6 Total draft---------------------- ? Setting:- Nipping distance----------8mm Cylinder to flat------------0.25mm Cylinder to licker-in ----0.225mm Licker-in to mote knives-0.924mm Cylinder to doffer------0.2295mm Front plate ----------------1mm Cylinder under caging ----1.2mm MAINTAINANCE SCHEDULES – Cleaning & greasing------7days Gears box oil change----6months Testing parameter:-U-90 lot Neps/gm------60-65 Neps/um------600 Ulster---------3-5% CV ------------2%
  29. 29. 44 CAUSES FOR NEP FORMATION IN CARDS: Lap too heavy, close settings and higher licker in speeds. Blunt Ickier in wire or dull flats. Jammed wire on doffer. Rough surface in front and back plate. Use of blunt grinding stone and inadequate or too high grinding frequency. Insufficient striping. Dirty under casings. Doffer not stripped after lapping. Under casing choked with fly. Waste packed between cylinder, doffer, and licker-in sides. Ends of front and back plates and milled ends of flats dirty. Uneven flat settings. licker in set too far from feed plate. High doffer . DEFECTS IN CARDING:-  sliver variation:-to high tension draft and stretching of web different in draft between in cards.  Neps formation:- uneveen tension flat setting rough surface of front and back plate, high doffer speed.
  30. 30. 44 05.Draw frame Breaker  The main object of breaker draw frame is parallelization of card sliver to remove the trailing and leading hook .  PRINCIPLE OF THE DRAW FRAME:-  Doubling  Drafting  Drawing  Doubling:-the process of combing several slivers into one. This term is not restricted to be combination of two units only.  Drafting:- the process of increasing the length per unit weight of sliver.  Drawing:- in the cotton industry, the term applied exclusively to processing on the drar-frame,where the operation is one of doubling and drafting slivers. PASSAGE OF THE MATERIAL:- Sliver  creel  guide bar  feed roller  trumpet  coiler roller  can
  31. 31. 44 No. of machine In plant A:  3 In plant B:  3 Total :  6 Make:  Plant-A Model No.  LD2 Year :  2004 Power requirement:  Process parameter (for 54 Ne counts Thread) Hank 0.105 Doubling 08 M P M Speed 454 m / min Type of drafting 3 over 4 Draft 6.05 Break draft 1.05 Web draft 1.00w Creel draft 1.00w Table tension Draft -----
  32. 32. 44 Pressure bar 6 bar Trumpet Diameter 4.2 mm Bottom roller setting MAIN PARTS and function IN DRAW FRAME BREAKER:-  CREEL DRAFT:- the draft between the lifter roller and back roller.  WEB DRAFT :- the draft between the front roller to coiler roller.  TENSION DRAFT:-the draft between front roller to calendar roller frequently called a tension draft.  CALENDAR ROLLER:-the object of the calendar roller fast to draw the web delivered at the front or
  33. 33. 44 delivery roller through trumpet to form sliver, and second to deliver this material into the coiler and so to then can. The calendar rollers are to large smooth steel rollers.  TRUMPET:- trumpets are made up of cast iron while others are made of bronze.  STOP MOTION:-a stop motion is a device arrangs to stop the machine. Stop motions are applied several place in draw frame, although stopping the frame causes reducing the production. There are four common stop motions in draw frame:- 1. The spoon or back stop motion. 2. Trumpet or calendar roller stop motion. 3. The full can stop motion. 4. The wrong data feed stop motion.  DEFECT IN DRAWFAME SLIVER:- o Roller lapping o Uneven sliver o Roller slippage o Wrapping variation.
  34. 34. 44 06.Draw Frame Finisher TASKS OF DRAWFRAME 1. Fineness Through doubling the slivers is made even. 2. Doubling results in homogenization (blending). 3. Through draft fibres get parallelized. 4. Hooks created in the card are straightened. 5. Through the suction, intensive dust removal is achieved . 6. Auto leveler maintains absolute sliver. No of machine In plant A:  06 In plant B;  03 Total  09 In plant A:- Make :  Model No :  RSB851 Year 2012 In plant B:- Make : INDIA
  35. 35. 44 Model No : HSR1000 Year 2007 Addition feature of this m/c is autolever Auto leveler is an additional device which is meant for correcting the linear density variations in the delivered sliver by changing either the main draft or break draft of the drafting system, according to the feed variation. Passes of material in draw frame f/s SLIVER CAN SLIVER GUIDE CREEL GUIDE
  36. 36. 44 SCANING ROLLER TOP ROLLER BOTTOM ROLLER CALENDER ROLLER COILER ROLLER CAN PROCESS PARAMETER Sliver hank 0.170 Delivery speed 350 m/ min Creel Tension Draft 1.02 Table Tension draft 1.01 Web Draft 1.01 Break Draft 1.15 Total draft 6.06 Scanning roller size 5.5 mm Scanning roller load 120 den Doubling 6 Trumpet 3.5mm Pressure Bar 6.5 Leveling action point 948
  37. 37. 44 Bottom roller setting MAIN PARTS and function IN DRAW FRAME FINISHER :-  CREEL DRAFT:- the draft between the lifter roller and back roller.  WEB DRAFT :- the draft between the front roller to coiler roller.  TENSION DRAFT:-the draft between front roller to calendar roller frequently called a tension draft.
  38. 38. 44  CALENDAR ROLLER:-the object of the calendar roller fast to draw the web delivered at the front or delivery roller through trumpet to form sliver, and second to deliver this material into the coiler and so to then can. The calendar rollers are to large smooth steel rollers.  TRUMPET:- trumpets are made up of cast iron while others are made of bronze.  STOP MOTION:-a stop motion is a device arrangs to stop the machine. Stop motions are applied several place in draw frame, although stopping the frame causes reducing the production. There are four common stop motions in draw frame:- 5. The spoon or back stop motion. 6. Trumpet or calendar roller stop motion. 7. The full can stop motion. 8. The wrong data feed stop motion.  DEFECT IN DRAWFAME F/S SLIVER:- o Roller lapping o Uneven sliver o Roller slippage o Wrapping variation.
  39. 39. 44 07. Speed frame It is process the winding, twisting stands in the bobbin and inserts the small amount of the twist in roving.  ROVING:- A name given individually to the relatively fine fibrous stand used in the fixed process of preparation for yarn. In the other hand roving is such a form which is thinner than sliver which is spun into the yarn for easily.  INPUT:-drawing sliver OUTPUT:-roving  OBJECT:-  To draft the sliver to reduce weight per unit length  To insert small amount of twist to strength them the roving to prevent breaking during next process.  To make conical or tapper shape of the bobbin  To wind twisted strand on the bobbin. PASSAGE OF MATERIAL OF SPEED FRAME:- Creel  guide bar  condenser  back roller  middle roller front roller flyer presser foot roving bobbin  SOME IMPORTANT PARTS OF SPEED FRAME:-
  40. 40. 44  CREEL:-creel us a suitable plastic structure in which can sliver is placed as feeding material to the machine. The arrangement of the creel depends upon the package which is feed to the speed frame.  ROVING:- output of the speed frame on the bobbin in a uniform drafted, twisted & wind in a compact package is called “ROVING”.  DRAFTING MECHANISM :- to draft the sliver and reduce the weight per unit length. The drafting system consist of 3 over 3 systems. In draft apron is a most successful thing in a speed frame.  TWISTING MECHANSIM:-to insert a small amount of twisting to straighten the roving. Twisting is done by flyer. A flyer is an inverted ‘u ’ shaped body having two legs, one being hollow and other solid. The flyer are placed on spindle top rotated with spidnle.  WINDING MECHANISM:-the roving that comes out form the front roller nips is continuous and constant which a rate depends on the srface speed of front roller, hence the roving the must be the wound on the bobbin at exactly the same rate which it came out from the roller nips. There are basically to mehods adopted for winding the roving.  FLYER LEADING:- in the flyer leading the flyer revovles quicker then the bobbin as the bobbin increase in diameter. Its speed must increases in
  41. 41. 44 order to have wound on it’s the same length as on the samall diameter.  BOBBIN LEADING:- the bobbin goes faster than flyer and push to its self the material delivered by front roller, this called bobbin leading.  CONEDRUM OF SPEED FRAME:- the function of the conedrum in speed frame which is corporate on the flyer frame to reduce the speed of the bobbin as it increased in diameter. The top cone drum is run at a constant speed with the changes in the position of the belt.when the bobbin diameter increases then the belt is shifted the smaller diameter top cone drum and larger diameter of the bottom cone drum revovles at a slow speed when its diameter is larger.  DIFERENTIAL MOTION:- the differential motion is the combination of and epicyclical train of wheels, which gives the vrying excess speed to bobbin through the cone drum, so the winding process is possible. If the differential motion is not avaible the varying excess to the bobbin through cone drum is impossible, therefore roving process is breakge and winding.  APRON:- apron is endless belt made up of rubber, leather and synthetic material. This apron is placed between the front and second roller. Object of apron:-  To reduce roller chocking  To guide the material
  42. 42. 44  To stock the combing dust  To control movenent of short fibre  Fibre and thus gives a better yarn with draft.  No of machine Plant –A:- 06 Plant- B:- 08 Total -14 Make:  Z MODEL NO.  LF4200/A(2012) LF4200/A(2007) Made in Germany Voltage & frequency:  415V/50HZ Winding system:  Bobbin leading No. of spindle:  120
  43. 43. 44 ROLLER SETTING Note all top roller dia 27 mm Process parameter Speed frame hank 1.82 Spindle speed 1000 -1100rpm Lift 14 -16 TPI 1.48 Tm 1.9 Creel tension draft 3.7 Break draft 1.05 Main Draft 10.69 Initial tension 1.90 Bd 1.90 Kd 3.260KH Spacer --- No. of turns of flyer 3 Back condenser Green Middle condenser Green Floating condenser Green Maintenance scheduling
  44. 44. 44 Coats cleaning :  22 days Over oiling of machine:  6 months The factors affecting roving strength are as follows: The length, fineness, and parallelization of fibres He amount of twist and compactness of the roving The uniformity of twist and linear density.  DEFECTS SPEED FRAME ROVING:- 01 soft bobbin 02 uneven bobbon 03 roller lapping 04 hard bobbin & roving breakges. 08.RING FRAME Ring frame is a machine in which happen drafting , twisting & winding on the bobbin and yarn is prepare from roving .  INPUT:- Roving bobbin OUTPUT:- Ring bobbin OBJECT OF RING FRAME:-  To draft the roving for convert roving into a uniform yarn.
  45. 45. 44  To insert twist of required amount for different count.  Producing yarn by drafting and imparting twist.  To wind the twisted yarn. PASSAGE OF MATERIAL IN RING FRAME:- Bobbin holder Guide bar Condenser Back Roller Middle roller Front roller Lappet guide Balloon breaker Traveler Ring bobbin. The ring frame is a continuous spinning machine i.e. draft, twist and wind simultaneously. This is a double sided machine having 1296 spindles which are give at speed of 14,000 rpm approximately. DRAFT The amount of attenuation of textile material at different stages of spinning preparatory and spinning process, for example. 1 m of input material when delivered as 5 m is said to have undergone a draft of 5.In other words reducing the linear density of textile material with respect to time by passing the material through successive pair of roller’s rotating at higher peripheral speeds. Various formulas used in textile industry to calculate the draft as follows: Draft (mechanical) = surface speed of the delivery roller÷ Surface speed of feed roller Draft (Actual) = Feed material linear density or weight per unit length fed÷Delivered material linear density or weight per unit length delivered
  46. 46. 44 Draft = No. of fiber’s available at cross sectional area of feed material ÷No. of fiber’s available at cross sectional area of delivered material Draft is just a mere number and has no unit’s.  DRAFTING : It is a process of reducing the bulk and weight per unit length of a semi processed textile material such as rove or sliver and simultaneously parallelizing its fibrous components, as it passes through the various machines used in making yarn  TWISTING : To insert necessary amount of twist on yarn .  WINDING : To wind the twisted yarn on the cylindrical bobbin.  CONDENSER : Condenser is used between the aprons and front rollers to keep the fibre together when living the front roller. This help in better twist flow of to the nip of front rollers.  SPINDLE : The spindle are on which bobbin are mounted.  RING : Ring are made of harder steel several cross section Shape of ring.  TRAVELER : The traveller is very important for work in ring frame . It is a small metal clip made in the shape alphabet ‘c’. It is a small and in expensive part .It is made of steel but are Slightly less hard than the ring.
  47. 47. 44  RING RAIL MOVEMENT : Ring rail movement can be slow when It is goes up and fast when it is coming down. This is called conventional movement of ring rail in this case the upwared movement of ring puts winding coils and downward movement of ring rail puts binding coil.  LIFT : The distance between the lowest points of ring rail to the high point during formation complete bobbin is termed lift. DETAIL OF RING FRAME MACHINE :- S.N MAKE MODEL NO. OF M/C NO. OF SPINDLE 01 LMW (NEW SETION) LR 9/AX 20 25920 02 LMW LR 9/AX 09 6048
  48. 48. 44 03 SHANSHAI ERFANGJI CO.LTD EJM 1382 14 12096 04 JINGWEI FI 520 06 5184 Total spindle =49248 PROCESS PARAMETER OF RING FRAME :- 01 FRONT ROLLER DIA. 30mm 02 MIDDLE ROLLER DIA. 27mm 03 BACK ROLLER DIA. 30mm 04 COTS DIA. 32-35mm 05 TRUMPET SIZE 3.5-4.0mm 06 TOP APRON SIZE 41.5×27×1.5mm 07 BOTTOM APRON SIZE 41.6×30×1.5mm 08 WHARVE DIA. 21mm 09 CRADLE SIZE 43mm 10 SPINDLE GAUGE 70mm 11 ROLLER GAUGE 57.5/70.5 to 57.5/78.5mm 12 LIFT 180mm 13 BREAK DRAFT 1.32-1.8 14 ACTUAL DRAFT 22.54-24.22 15 FEED HANK 1.22-1.8 16 DELIVERY COUNT Ne (15,20,29,33,40,50) 17 RING BOBBIN WT. WITH YARN 93.67-97.54grm 18 EMPTY BOBBIN WT. 35.87-37.01grm 19 ACTUAL YARN WT. IN BOBBIN 56.66-61.67grm  CHANGE PLACES IN RING FRAME :  Draft change pinion : DC.  Draft change pinion : DCA.  Draft change pinion : DCB.  Twist change wheel :TC.
  49. 49. 44 Twist change wheel :TCA. Twist change wheel : TCB.  Drafting change pinion : DFC  Draft CHANGE WHEEL COUNT(Ne) 15 20 29 40 50 36 24 33 40(V.R) A 84 78 80 82 85 88 84 85 85 B 81 87 79 83 80 77 81 80 80 C 91 91 65 72 65 65 82 72 65 D 46 46 72 65 72 72 55 65 72 RATCHET 32 27 18 15 14 17 22 22 22 N. OF PIN 02 02 02 02 02 02 02 02 02 CALCULATE TWIST PER INCH(TPI) :- S.N TPM (1/2 m) TPM (1 m) 01 372 744 02 367 734 03 369 738 04 366 732 05 370 740 Total 1844 3688
  50. 50. 44 MEAN = 3688/5 =737.6 TPI =737.6/9.37 = 18.73  THE RELATION BETWEEN LENGTH OF YARN & SPEED OF RING BOBBIN :- SPEED ( RPM) LENGTH(m) 14000 0 14600 50 15300 75 15600 100 16500 200 16800 300 17100 400 17200 850 17500 1150 17600 1200 18000 1280 17900 3900 17900 4000  CALCULATION OF COUNT IN RING FRAME :- Total weight =9.61 Avg. weight =9.61/5 =1.922grm Count(Ne) =64.8/wt. in gm =64.8/1.922 =33.72 LENGTH(yds) 120 120 120 120 120 WEIGHT(grm ) 1.89 1.97 1.94 1.89 1.92
  51. 51. 44  CALCULATION :- MOTER POWER =1440 rpm (3.5 HP) MOTOR PULLEY DIA. = 250 mm JACK PULLEY DIA. = 45 mm MACHINE PULLEY DIA. =300 mm TIN ROLLER DIA. =240 mm SPINDLE WHARVE DIA. = 18.5 mm PRESSURE ARM :- Top apron =18-20 kg Bottom apron =14-16 kg Spindle apron =16-18 kg Spindle tape =2331-2371 TIN ROLLER SPEED = (1440×250)/300 = 1200 rpm SPINDLE SPEED = (Tin roller speed×Tin roller dia.)/Spindle wharve dia. =(1200×250)/18.5 =16216 rpm. PRODUCTION :- Spindle speed =17500 rpm =17500/(39.37×18.77) =23.68 mpm Count (Ne) =33 TPI =18.77 Efficiency =95% No. of m/c =01 No. of spindle =480 Prod./shift =(spindle speed×8×60×1.094×effi.×no. of spindle)/840×2.205×counts =(23.68×8×60×1.094×95×840)/840×2.205×33×100 = 92.77 kg.
  52. 52. 44 09.AUTOCONER This machine is an automatic under with individual winding units independently driven winding units that performs high speed winding with a hairness reducing device and the pack 21 system. It produce efficiency and subsequent process.  OBJECT OF AUTOCONER :
  53. 53. 44  To prepare bigger package from smaller bobbin package.  To colour code is maintained for identify different count and 60 cones are prepared at a time .  To remove the yarn fault like thick, thin and weak places.  Suction and splicer remove the broken and yarn dust.  To get the best quality of yarn , due to splicer.  INPUT : Ring bobbin OUTPUT : Cheese cone  PASSAGE OF MATERIAL THROUGH IN AUTOCONER Ring bobbin Balloon controllerElectronic device Tensioner Yarn splicerYarn cleaner Tension measureWaxingWinding drum Cheese package  DETAIL OF AUTOCONER : NEW SECTION:- S.N MAKE MODEL NO. OF M/C NO. OF CHEESE OR CONE YEAR OF MANUF. 01 VEEJAY LAKSHMI EXCELLO 09 540 2012 OLD SECTION:-
  54. 54. 44 S.N MAKE MODEL NO. OF M/C NO. OF CHEESE OR CONE YEAR OF MANUF. 01 VEEJAY LAKSHMI EXCELLO 06 360 2008  EXCELLO AUTOMATIC CONE WINDER:- The Excello is a custom built Automatic Cone Winder suitable for winding wide range of yarn counts from 2s Ne to 120s Ne. It can process both types of fibre natural and manmade. The air pressure of this m/c is 7 bar. The machine is designed to accept all latest generation electronic yarn clearers like Uster Quantum 2, loepfe Zenit/ Spectra plus and Keisokki tri-chord, Over head traveling cleaner, Bobbin magazine. TENSION SETTING:- S.N COUNT(NE) COUNT(NM) TENSION WT. (C.N) SPEED RPM LENGTH Mtr. 01 15 25 30 1200 63750 02 20 34 28 1200 86700 03 28 48 25 1000 124200 04 33 56 22 1200 142800 05 40 68 20 1200 173400 06 40(V.R) 68(V.R) 20 1000 173400 07 50 84 18 1000 214200  PROCESS PARAMETER OF AUTOCONER:
  55. 55. 44 01 COUNT(Ne) 15&20 40&50 02 SPEED MPM 1000 1000-1200 03 LENGTH SHORT 1.6 1.6 04 Dia. SHORT 2.6 2.8 05 LENGTH LONG 25 25 06 DIA. LONG 1.5 1.5 07 THIN PLACE 25 40 08 LENGTH(-L) 40 60 09 (-D) 30 30 10 (N) 05 05  PRODUCTION:- Delivery speed of drum = 1600 rpm Count = 50 Efficiency = 95% No. of m/c =01 No. of cheese cone = 60 Prod./ shift =del. Speed×8×60×1.094×eff. × no. of cheese ÷ 840×2.205×Count =1600×8×60×1.094×95×60 ÷840×2.205×50×100=517.12kg 10.STEAMING Steaming is the process drying to the yarn through the dry Heating machine.  OBJECT OF STEAMING :-  To avoid snarling in the yarn.  To set the twist on the yarn.
  56. 56. 44 INPUT :- Twisted yarn OUTPUT:- Complete yarn PROCESS PARAMETER FOR STEAMING-ELGI :- S.N PROGRAMME NAME (UNIT) ( PV SY) (PW SY) 01 BLEND COMP* 65/35,55/45 02 VACUUM PRESSURE % 80 84 03 TEMP* Cellc. 60 87 04 TIME MIN 55 55 11.PACKING Conditioning machine are used before yarn packing
  57. 57. 44 Conditioning machine Make :  XDRELLA AG YEAR  2004 Capacity - 500 cones Conditioning time - 1 hour Temp - 70-80 degree c Premium working pressure - 110.5 bar at 110 degree c Volume 14200 Power - 415 V / 50Hz Packing parameter Cotton capacity  650 × 350 × 665 mm Yarn Count  20 S No of Cones  18 Lot no.  U – 90 Gross wt.  41.40 kg Net wt.  37 kg
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