jute manufacturing

JUTE MANUFACTURING BY GIGO

Jute Spinning Technology• Jute is long soft, shiny vegetable fiber that

can be spun into yarn. Jute is one of the cheapest natural fibers. • Raw jute in the form of bales are processed

in jute mills to produce Hessian, sacking, jute yarn, bags, and other useful products. • Raw jute bales from jute fields or

suppliers, carried by trucks are unloaded are stacked in the jute mills godown.

Characteristics of Jute Fibre:Jute is a long, soft, shiny fibre that can be spun into coarse, strong threads. It is one of thecheapest natural fibres, and is second only to cotton in amount produced and variety of uses :Jute fibres are composed primarily of the plant materials cellulose, lignin, and pectin. Boththe fibre and the plant from which it comes are commonly called jute.

JuteJute is a long, soft, shiny vegetable fiber that can be spun into coarse, strong threads. It is produced from plants in the genus Corchorus, family Tiliaceae. Jute is one of the cheapest natural fibres

Flow chart of jute yarn manufacturing process:

Flow Process chart of Jute Spinning

Jute yarns:

Bangla White Jute – White /Creamy White/Light

Cream/Straw / Light Grey/Light Reddish Or Any

color.

Generally raw jute is divided into two main categories:

Bangla Tossa Jute - Golden/Red/Grey/Coppery

Grey/Mixed in Color.

Raw Jute Fiber Grading:

Physical properties:

1. Specific gravity- 1.482. Moisture – St. M.R 13.75 & absorb 35 – 40% water

of its dry weight.3. Strength- Tenacity-dry 3.5-5 g/d wet lower than dry.4. Elasticity-Breaking extension – 1.8% Recovery (%)

very low. For high tenacity, less extension, high stiffness Jute fibres is brittle & can holds less twist. So Emulsion is

5. added to make it soft.6. Specific heat is 0.3257. Resiliency-bad, Abrasion resistance moderate,

Dimensional stability-good.

Chemical properties:

1. Effect of bleaches: Not affect by oxidizing or reducing bleaches.

2. Acids & Alkalis: Easily damaged by hot dilute or cold concentrated acids. Resistant

3. to alkalis.4. Organic solvents: Resistant to organic solvents.5. Sun light & heat: Poor resistant scorches at high

temperature.6. Resistant to stains: Poor resistant to water borne

stains.7. Biological properties: Scoured jute has good to

excellent resistant to microorganisms8. & insects.9. Heat: Burns rapidly, Soldering red after glow.10. Conductivity: Moderate conductor of electricity &

heat.

Cellulose 65.2 %

Hemicelluloses 22.2 %

Lignin 10.8 %

Water soluble 1.5 %

Fats & wax 0.3 %

Chemical Composition of Jute

Batching:All the process preparatory to carding includes in the batching. It is the primary stage of jute processing.

Object of batching:1. To help the fiber movement freely during

processing.2. To get expected dampness and flexibility.3. To reduce harshness or stiffness.4. To control and reduce the yarn cost.5. To reduce waste.6. To intermix the batch component effectively.7. To produce improve graded yarn.

Batching:

Emulsion:A mixture of some lubricating agents which is applied on jute fiber to make the fiber soft and flexible.An emulsion is an intimate mixture of two immiscible liquid where one is dispersed in small globules on the other and addition of a third substance brings stability. Emulsion is made by splitting up oil into minute drops which are prevented from reuniting in water.

General recipe: Water 73% Oil 25.4% Emulsifier 1.6%

Emulsifier: Emulsifiers are surface active agents. These are soaps, detergents, wetting agents.

Emulsion:

OD Automatic Batch Mixer:Specification:

1. Capacity of mixing cylinder: 1000L2. Motor for paddle(1 HP)3. Volume of machine: Length 5’’-3’’, width 2”-2 ¾,Height

5”-10”.4. Power of production:1-6 tones/hr.

‘OD’ batch mixer is a simple automatic m/c for producing batching emulsion for jute. The percentage of emulsifier, oil and water are measured accurately and automatically by volume.

The percentage of oil and emulsifier can be adjusted easily by setting the pointers on oil and emulsifier scale. When adjusted, the machine automatically adds the required percentage of water to complete 1000L. Once the required percentages are set, the machine will automatically continue to measure and mix these percentages each time.

OD Automatic Batch Mixer:

After all the ingredients are added, the agitator or paddle starts to rotate at a high r.p.m. then emulsion is formed which is then stored to the storage tank under the mixing tank.

OD Automatic Batch Mixer:

Single softener m/c:Construction:

These machines consist of 24-64pairs of rollers and these rollers are spirally fluted and jute goes through them. A feed sheet and a delivery sheet is placed before feed rollers and after deliver rollers respectively.

Single softener m/c:

Pilling or conditioning:The process by which after applied emulsion, jute fiber is stored at a specific condition for certain time is called pilling.

Objects:1. To soften and split up of jute fiber.2. To loosen the fiber.3. To convert the rooty material into spinnable fiber.

Pilling or conditioning:

Carding:Carding is a combining operation where jute reeds are spitted and extraneous matters are removed. Jute fibers are formed into ribbon called "sliver".

Breaker Carding :In different jute mills the carding operations has been carried out in two ways: a. Hand feed breaker carding b. Rool feed breaker cardingThe material after piling more than 24 hours is used in hand feed breaker where the material after piling for 12 hours used in the rool feed carding. Finisher Carding: Finisher carding machine make the sliver more uniform and regular in length and weight obtained from the Breaker carding machine. Finisher carding machine is identical to the Breaker carding machine, having more pair of rollers, staves, pinning arrangement and speed. Nearly 4 to 12 slivers obtained from Breaker carding machine is fed on this machine. The material thus obtained is send to drawing section.

Jute Spinning

Drawing:Drawing is a process for reducing sliver width and thickness by simultaneously mixing 4 to 6 sliver together. There are three types of Drawing Frame machine.

First Drawing: The first drawing frame machines makes blending, equalizing the sliver and doubling two or more slivers, level and provide quality and colour. This machines includes delivery roller, pressing roller, retaining roller, faller screw sliders, check spring, back spring, crimpling box etc.

Second Drawing: In second drawing, the Second Drawing Frame machine obtain the sliver from the First drawing machine. The Second Drawing machine makes more uniform sliver and reduce the jute into a suitable size for third drawing.

Drawing Process (%) Productivity Mt/mc/shiftIst Drawing 55 - 73 1.75 - 2.2

IInd Drawing 64 - 74 1.62 - 1.9IIIrd Drawing 67 - 70 1.31 - 1.4

Third Drawing: In the third drawing, the Third Drawing frame machine uses the sliver from second drawing. The Third Drawing machine is of high speed makes the sliver more crimpled and suitable for spinning. The comparison of the three drawing process:

WindingWinding is a process which provides yarn as spools and cops for the requirement of beaming and weaving operations. There are two types of winding : (i) Spool Winding (ii) and Cope Winding

Spoll Winding:In Spool Winding yarn is produces for warp .Spool winding machine consists of a number of spindles. .The Spool are used in making sheets of yarn to form warp portion used during interlacement of weaving

Cop Winding: Cop Winding machine obtain yarns from the spinning machines. The spinning bobbins are placed on a suitable pin on top of the cop machine and yarn tension is maintained by means of a small leaver.

Winding

Jute Spinning

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