arvind spin weav
TRANSCRIPT
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SPINNING
Ring Spinning:
In the Ring spinning, yarn is formed from cotton fibres that are twisted together after
being drafted by passing between a set of top and bottom rollers. The yarn then is
wrapped on a bobbin as it spins on a spindle by use of a traveller. The relationship
between roll speeds, traveller speeds and spindle speeds controls the amount of twist in
the yarn.
Flow Chart of spinning process:
Removal & Sliver Pr
BlowRoom
Cotton Tuft
Opening, Cleaning and Blending
Card
Sliver
Individualization of fibers, neps
Removal & Sliver Preparation
Pre Drawframe
BreakerSliver
Parallisation & Improvement in sliver
Unilap
Comber Lap
To prepare Lap sheet suitable for combing
Comber
Combed Sliver
Short fiber removal, individualization & Sliver
preparation
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Post Drawframe
FinisherSliver
Parallisation & Improvement in Sliver Quality
Speedframe
Roving Bobbin
To prepare a suitable Roving for Ringframe by inserting
twist
Ringframe
Yarn
To produce Yarn on smaller package
Random Winding
ClearedY
arn
To prepare bigger package after Removing faults
T.F.O
Double Yarn
To impart twist in assemble yarn & Produce bigger
acka e
Singeing
Singed Yarn
To remove the protruding fibers on the yarn surface
Assembly Winding
Assembled Yarn
To assemble the yarn
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BLOWROOM:-
Blowroom is the first step of yarn production in the spinning mills. Following are the
objective of objective of blowroom department
Opening
Cleaning
Mixing or blending
Microdust removal
Uniform feed to the carding machine
Recycling the waste
Flow chart of blowroom operation:
BLANDOMAT
SPARK DETECTOR
METAL DETECTOR
BALE OPENER
AFC
ASTA
LOPTEX
CVT4 CVT4
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BLENDOMAT
Opening of bales and transporting them to the downstream machine by suction
after blending,cutting and plucking of small tufts.The working process is controlled by a
microcomputer and is fully automatic. The bales are placed manually on the floor in the
marked working area. BDT 019 travels over the bales and holds back the material against thepull of the toothed disc rolls. The material protrudes between the bars of the grids. The
supporting rollers rotate at a peripheral speed, which is identical to disc rolls or grids.
The teeth of the toothed disc rolls pluck the bulging tufts from the surface of the bales and
fly them into the air stream, which removes the tufts by suction. Machine make:
Trutzschler (Germany)
Model no. : BDT 019/2300
Bale layout: Both sides (2 rows)
Number of bales: 50-60
Weight of bales: 110-167 kg
Mode of bale laying: Manual
Material in process: Cotton with seeds and impurities
BALE OPENER (BO)
Objective of this matchine is to clean cotton fibers.Material is fed by the
Feed Lattice and stored in the Reserve Tank and then transferred to the Feed Table that
supplies material to the Spiked Lattice, which then passes it o nto the Evener and Stripper
rollers. The Evener roller brushes the excess material of the spiked lattice and tosses it back
to the Mixing Chamber where a Cleaning roller is installed.Striper roller releases the material
from the Spiked Lattice.
Model no.: BOA 046
Major parts: Feed lattice, inclined spike lattice, perforated condense
Gauge: Distance b/w inclined lattice and opening roller is 20 mm.
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CLEANING AND MIXING:-
If cotton is opened well in the opening process, cleaning becomes easier
because opened cotton has more surface area, therefore cleaning is more efficient.
Due to machine harvesting, cotton contains more and more impurities, which furthermore
are shattered by hard ginning. Therefore cleaning is always an important basic operation.Incleaning, it is necessary to release the adhesion of the impurities to the fi bers and to give the
particles an opportunity to separate from the stock. The former is achieved mostly by picking
of flocks; the latter is achieved by leading the flocks over a grid.
DUST REMOVAL:-
Cotton contains very l ittle dust before ginning. Dust is therefore caused by
working of the material on the machine. New dust is being created through shattering of
impurities and smashing and rubbing of fibers. But dust removal is not simple. Dustparticles are very light and therefore float with the cotton in the transport stream.
Furthermore the particles adhere quite strongly to the fibers. Machines for this process
are:-
AXI-FLOW CLEANER
MULTIPLE MIXER
ASTA
LOPTEX
CVT
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AFC (AXI-FLOW CLEANER):
Objective of AFC is separation of heavy parts (impurities) from cotton.The
opened up mass of fiber rotates around two cleaning rollers (beaters) with cylinder steel pins
which beat the fiber material, allowing the coarse particles to be separated.The time (in
hours) of the passage of material can be regulated by a detector in the in-jet and thedeflector above the beater. The air volume of the extractor machine and the input time can
be regulated with a flash on screen at the outlet.The coarse particles drop through adjustable
grids and are made available by means of a wheel lock.The cleaned tufts are carried through
outlet pipes to the downstream machine with the help of air flow.
Machine details:
Machine make: Trutzschler (Germany)
Model: 052-2502
Pressure: 50-75 bar
Major parts: Two metallic perforated cylinders and waste collector
MPM 10 (MULTIPLE MIXER):
Objective 0f multiple mixer homogeneous mixing of cotton fibers .Material from different heights
are fed to ensure proper mixing.
Machine details:
Make: Trutzschler
Model: 10236
Motor speed: 1750 rpm
Opening rolls speed: 800-850 m/min
Number of chambers: 10
Output: 30-36%
Pressure: 350 bar
Major parts: This machine consists of material feed, reserve tank, reserve tank
flaps, optical sensor,delivery,rollers, and material suction funnel.
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ASTA
Objective of ASTA Heavy trash separation from cotton. The air
and material enters the separation tank in a stream via upper channel and strikes the
baffle plates. Heavy particles are removed away from the lighter fibers by negative
acceleration and the force of gravity. The lower channel generates an opulent air
stream in the area of baffle plates, which guides the fibers to the outlet.
Machine details:
Make: Trutzschler (Germany)
Model: ASTA 800
Principle: principle of aerodynamics
LOPTEX
Machine details:
CVT;-
Main operation is Separation of residual trash from cotton. From ASTA
the material is carrie twodifferent lines BS 1 and BS 2. The feedrollers throw the material and
transfer it to the first roller where the opening takes place less aggressively. The material isthen passed through other rollers sequentially which beat the cotton and hence remove the
residual trash.
Make: Trutzschler (Germany)
Model: Optasonic t 120
Voltage: 415 v
Frequency: 50 Hz
Power: 1.5 KwA
Pressure: 0.6 to 0.8 M Pa
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Machine details:
Make: Trutzschler (Germany)
Model: CVT-4 1600
No. of machines: 2
Cleaning efficiency: 18-30%
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Feeding process to card
There are two process to feed the raw material that is open fibre to carding machine
1. scutcher lap
Linear density of the lap is very good and it is easier to maintain(uniformity)
The whole installation is very flexible
Deviations in card output will be nil, as laps can be rejected
Investment cost and maintenance cost is less
Transportation of lap needs more manual efforts( more labour)
2. Flock feed system
High performance in carding due to high degree of openness of feed web
Labour requirement is less due to no lap transportation and lap change in
cards
Flock feeding is the only solution for high production cards
Linear density of the web fed to the card is not as good as lap
Installation is not flexible
Autoleveller is a must, hence investment cost and maintenance cost is more
Machine details:
Number of machines: 14
Make: Trutzschler (Germany)
Model: DK 803
Humidity: 56.5%
Temperature: 33.3 degree Celsius
Production: 80 kg/hr.
Card cleaning efficiency: 62-67%
CV%: 1.2-1.7
Front Delivery speed: 210-240 meters per minute
Pressure: 325 pas
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Licker in:
Diameter: 102 mm
Speed: 1960 rpm
Cylinder:
Diameter: 1290 mm
Speed: 600 rpm
Doffer:
Diameter: 700 mm
Speed: 96 rpm
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COMBING:-
Combing is an optional process introduced into the spinning of finer and high -
quality yarns from finer cotton for great evenness, smoothness, fineness and strength. For
coarser cotton fibers, the combing operation is usually omitted. This operation combines several
card slivers which are drawn into the comber and, once again, spread into a web. The fibers
continue to be cleaned and straightened as the web is formed. Short fibers and all residual non -
lint materials are removed.
It influences the following yarn quality
Yarn evenness
Strength
Cleanness
Smoothness
Visual appearance
Objectives of combing:
Removal of short fibers
Removal of remaining impurities
3 .Removal of neps
FLOWCHART OF OPERATION IN A COMBER:-
Feeding of lap to machine
Through nipper griped by fed lap
Lap is combed by circular comb
Detatchin roller ri the combed la
Mean while top roller comes into action for further
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Machine details:
Make: Reiter
Model: Reiter E60
Input 8 laps
Output 2 cans
Machines 15
Feed cotton laps:
Width 300mm
Diameter 600mm
Fixed quantity of laps 60 - 70gsm
Length of cotton Spinning fiber: 25 - 51mm
Fixed output of combed strips: 3 - 6gsm
Pressure of compressed air: 0.6 - 0.8MPa
Air consumption: 1.5Nm3/h
Total power: 14.25 KW
Dimensions: 7,230 x 2,120 x 1,700mm
Lap
Roller
Comb
Combed sliver
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UNILAP
Objective of unilapis formation of laps. The laps produced in the
unilap machine are stored on creels which can be transported to the combing machines .
Machine details:
Make: Rieter
Model: E 30
No. of machines: 3
Major parts: Creel, Scanning roller, Drafting zone, Delivery roller and sliver deposit
Input cans: 26
Output laps: 1
Length of lap: 300 meter.
Speed: 650 m/min.
Efficiency: 75%
Temperature: 31 degree Celsius
RH%: 50%
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Drawframe
Drawing follows either combing or carding, depending on the
quality of yarn desired. Several strands of sliver (typically eight to ten) from different carding
machines are combined and conveyed to the drawing machine, where they are pulled
together and drawn out into a new sliver no larger than one of the original single slivers. The
loose, rope like strand of fibers resulting from this process is called drawn sliver. The purpose
of drawing is to make yarn more uniform by combing and elongating multiple slivers, thus
eliminating the randomly occurring defects.After drawing, rotor yarns go directly to the
spinning frame.
Objectives of drawframe:
Hooks created in the card are straightened
Through doubling the slivers are made even and results in homogenization.
Through draft fibers get parallelized
Through the suction ,intensive dust removal is achieved
From the cards the material passes to the draw frames, where the thick and thin areas are
removed, i.e. the sliver is smoothened. Sliver quality is improved and the sliver is doubled,
drafted, parallelized, and leveled. Here three or more slivers are blended and one sliver of
same diameter is formed.
Breaker draw frame:
Process is carried out after carding and mainly doubling of yarn takes place
Machine details:
Input 8 cans
Output 1 can
Mainly 50s count used
Machines used Reiter (7 m/cs)
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Doubling (6) Drafting (6)
Finisher draw frame:- Auto leveling as well as doubling takes place
Machine details:
Auto levelling as well as doubling takes place.
Input 6 cans
Output 1 can
Speed 250 mt. /min.
Machines used: Reiter (7 machines)
Model: RSB 1 draw frame
1 operator required for all the machines
Doubling (6) Drafting (6)
15 min
16 Cans from
card
Twin Delivery
3 min
8 cans from
breaker draw
frame
Single
Delivery
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SPEEDFRAME
Thedraw frame sliver is drafted into a thin material called Rove and a
minor amount of twist is imparted to it to withstand loads in further process . As the roving
strand is ready to leave the roving frame, a slight twist is imparted to hold the fibers
together. Roving machine is complicated, liable to faults, causes defects, adds to productioncosts and delivers a product that is sensitive in both winding and unwinding. This machine is
forced to use by the spinner.
OBJECTIVE OF ROVING FRAME:
Attenuation- drafting the sliver into roving
twisting the drafted strand
winding the twisted roving on a bobbin
Drafting is the process of elongating a strand of fibers, with the
intention of orienting the fibers in the direction of th e strand and reducing its linear density.
In a roller drafting system, the strand is passed through a series of sets of rollers, each
successive set rotating at a surface velocity greater than that of the previous set. During
drafting, the fibers must be moved relative to each other as uniformly as possible by
overcoming the the cohesive friction.
The factors affecting roving strength are as follows:-
the length, fineness, and parallelization of fibers
the amount of twist and compactness of the roving
the uniformity of twist and linear density.
Machine detail:
Machine : Toyota FL16
No. of machines: 13
Speed: 900 rpm
Efficiency: 82-87%
Power consumption: 5.5 kW
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RING FRAME
The two most widely used processes for making cotton yarn
are ring spinning and rotor spinning, ring spinning is used for high quality, smaller yarns
(shirtings); rotor spinning is typically used for larger yarns (denim).Most combed yarns are
ring spun. It is the process where the actual yarn formation takes place. Here the Rove
material is again drafted to a very thin strand and considerable twist is imparted to it to get
the final yarn.
Objective of ringframe:
To draft the roving until the required fineness is achieved
To impart strength to the fiber, by inserting twist
To wind up the twisted strand (yarn) in a form suitable for storage , transportation
and further processing.
Machine details:
Machine used: Laxmi LG551
No. of machines: 33
No. of spindles per machine: 512
Speed: 18500 rpm
Efficiency: 85%
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Winding
It is the process wherein the single small yarn package formed at Ring Frame stage is
converted into a big package called cone. In this conversion process, single yarn packages
from Ring Frame are taken and continuously unwound and wound on a package called cone
and during this winding process, faults in the yarn will be cleared . Winding process serves to
achieve additional objectives made necessary by the requirements of the subsequent
processing stages.
Objective of winding
Extraction of all disturbing yarn faults such as the short, long thick ,long thin,
spinners doubles, etc
Manufacture of cones having good drawing - off properties and with as long a
length of yarn as possible
paraffin waxing of the yarn during the winding process
introduction into the yarn of a minimum number of knots
achievement of a high machine efficiency i.e. high production level
T.F.O.
Two for one means there are two twist is inserted in one revolution. This is used for plying or
cabling yarns.
Machine detail:
Machine used: SaurerVTS-09 Volkman
No. of machines: 18(per machine 2200 spindle)
No. of cones: 200 per machine
Speed: 900 rpm
Efficiency: 96%
Power consumption: 30 kW
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YARN SINGEING
Singeing is a process applied to yarns and to produce an even
surface by burning off protruding fibers or hairs from the surface of yarn. This is
accomplished by passing the yarn over a gas flame at a speed sufficient to burn away the
protruding material without scorching or burning the yarn . The singeing of yarns is done on
special machines, on which singeing and winding are done simultaneously.
Machine detail:
Make: PEASS Industrial Engg. and SSM (Scharer SchweiterMettler)
No. Of machine: 1 PIE and 1 SSM
Speed : depends on count ranges from 1000 -1500mpm
No. Of spindle: 60 in PIE and 40 in SSM
Spinning related Defects:
Warp Slub
Weft Slub
Thick end
Coarse/fine weft Weft bar
Moir
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WARPING
Warping is the process of transferring multiple yarns from individual
yarn packages onto a single package assembly.
There are two types:
Direct
Indirect
In case of direct warping Normally, yarns are collected in a sheet form where
the yarns lie parallel to each other and in the same plane onto a beam, which is a
cylindrical barrel with side flanges. In indirect warping the yarns from the yarn packages
are wound onto an intermediate cylinder (mill) in many parallel groups with a specified
density, and then they are back wound onto the warp beam.
The main objectives of warping are :
To form a pre-determined number of single end package such as cone,pirn or cheese
or a continuous sheet of yarn of specified length and width.
The individual ends of sheets should be spaced uniformly across its full width.
All ends of sheet should be wound at uniform tension.
Machine details:
Make Benninzer,Vamatex & Ukil
Made in Germany,India& Italy
No. of machine 10 Benninzer,4 Vamatex & 1 Ukil
Creel capacity 720,700 & 800
Machine speed Upto 500 rpm
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Width 64-72 inch
Beaming tension 12-20 gm
Tentioner type Disk
Cone Length 1050mm
Cone Height 210mm
Beam Diameter max 32 can be used.
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SIZING
The process consists of laying warp yarn parallel and sizing the yarn
with a mixture to strengthen it to withstand the rigours of weaving. Warp yarn is
withdrawn in sheet from from warp beams which are placed at the back of the sizing
machine. The yarn is then passed through sow box. Size solution is applied by immersion.
After removing surplus solution that occurs at this state, the yarn is dried and arranged
on a loom beam.
Objectives of sizing:
To improve the weavability of warp .
To reduce hariness of the yarn.
To withstand the stresses and strains of weaving.This can be attained by improving
primarily the abrasion resistance of the yarn.this is achieved with the formation of a
film around the yarn along with size penetration o9f size ingredients.
To reduce generation of static charges for polyester blend yarns.
to improve the breaking strength of the yarn.
Machine detail:
Make Hokoba,SukerMuller
No. of machine 4 Hokoba& 1SukerMuller
Speed 35 rpm
Double saw box
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WEAVING
The object of weaving to produce the fabric by the interlacement
of warp & weft. The other object is to produce defect free fabric . The warp threads run
lengthways of the piece of cloth, and the weft runs across from side to side.
Three motion are involved in weaving:
Primary Motion
Shedding
Picking
Beating up (Battening)
Secondary Motion
Let off motion
Take up motion
Auxillary Motion
Warp protector motion
Weft protector motion
Shedding:-
Shedding is the raising of the warp yarns to form a shed through which the
filling yarn, carried by the shuttle, can be inserted. The weave pattern determines which
harness controls which warp yarns, and the number of harnesses used depends on the
complexity of the weave.
Picking:-
The filling yarn in inserted through the shed by a small carrier device called a
shuttle. A single crossing of the shuttle from one side of the loom to the other is known as a
pick.
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Beating up (Battening):-
With each picking operation, the reed presses or battens each filling yarn
against the portion of the fabric that has already been formed. The point where the fabric is
formed is called the fell.
Taking up and letting off:-
With each shedding, Picking, Battening operation, the new fabric must be
wound on the cloth beam which is called 'taking up'. At the same time, the warp yarns must
be released from the warp beam which is called 'letting off'.
Warp protection:-
The object of warp protector motion is to stop the loom , if shuttle fails to
reach the opposite side as a result of faulty pick or some obstruction in the warp shed or
breaking of picking strap
Weft protection:-
To detect the absence of weft yarn & stop the loom.
Classification of Weaving Machines:
Weaving machines are classified according to their filling insertion mechanism.
The classification is as follows:
1. SHUTTLE LOOM
2. SHUTTLE-LESS LOOM
Rapier
Projectile
Air-Jet
Water-Jet
AIR-JET WEAVING:
Air-jet weaving is a type of weaving in which the filling yarn is
inserted into the warp shed with compressed air. Air -jet system utilizes a multiple nozzle
systems and a profiled reed.Yarn is drawn from a filing supply package by the filing feeder
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and each pick is measured for the filling insertion by means of a stopper. Upon release of the
filling yarn by the stopper, the filling is fed into the reed tunnel via tandem and main nozzles,
which provide the initial acceleration. The relay nozzles provide the high air velocity across
the weave shed. Profiled reed provides guidance for the air and separates the filling yarn
from the warp yarn.
The advantages of air jet weaving machines are:
y High productivity.
y Low initial outlay.
y High filling insertion rates.
y Simple operation and reduced hazard because of few moving
parts.
y Reduced space requirements.
y Low noise and vibration levels
y Low spare parts requirement.
y Reliability and minimum maintenance
PROCESS FLOW CHART
WEAVERS BEAM
DRAWING IN
CREELING WEAVERS BEAM
BEAM KNOTTING / BEAM GAITING
LOADING THE EMPTY CLOTH ROLL
SETTING OF INFORMATION IN PANNEL
TYEING UP OF ENDS ON THE CLOTH ROLL
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STARTING OF THE MACHINE
MACHINE IS STOPPED AFTER COMPLETION OF REQ. LENGTH WOUND ON THE CLOTH ROLL
FABRIC IS CUT AFTER THE REQ. CLOTH LENGTH
UNLOADING THE CLOTH ROLL
WEAVERS BEAM CHANGE IS DONE WHEN THE BEAM GETS EMPTY
There are mainly two types of shirtings:-
1. CLASSIC SHIRTING
2. CASUAL SHIRTING
Machine detail:-
In Arvind mill ,classic shirtings are mainly manufactured on two types of machines
1. RAPIER LOOM
Machine name PICANOL GAMMA Length : 545 mtr
Count : 2/50s, 2/60s,2/84s etc
Total Ends : 8082
Reed Space : 64.50
Denting order : 3/4 dent
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2. AIR JET LOOM
Machine name PICANOL OMNI Length: 650-700 mtr
Count: 2/50s, 2/60s,2/84s etc
Total Ends : 8082
Reed Space: 64.50
Denting order : 3/4 dent
Defects and Faults commonly found after weaving:
Floats
Short pick
Defective shedding
False Stop
Breakage
Missing Ends
Knots, Pulls
Fluffs Starting mark
White patti
Pick finding
Tight end
Weft float
Bent pick
Knot
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Repaired warp
Double end
Weft patti
Size Residue
Start Marks
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INSPECTION
4-point grading system is used for inspection of fabrics and this includes:
Size of defect Penalty Points
3 or less 1 Point
3 to 6 2 Points
6 to 9 3 Points
More than 9 4 Points
Holes or Openings(Largest
Dimension)
1 or less 2 Points
More than 1 4 Points
At the beginning of the month the inspection department gets the production plan for the
entire month and they plan their procedures accordingly. The finishing department gives the
material transfer note to the inspection department where the material is checked for the
following defects:
Spinning related Defects:
Warp Slub
Weft Slub
Thick end
Coarse/fine weft
Weft bar
Moir
Weaving preparatory related defects
Knot
Slack end
Ball formation
Size patches
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Weaving related defects
Starting mark
White patti
Pick finding
Tight end
Weft float
Bent pick
Chira
Knot
Repaired warp
Double end
Weft patti