material handling lecture note

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YABA COLLEGE OF TECHNOLOGY

DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY

TET II3: YARN PRODUCTION 1

COURSE OUTLINE

1.0 Understand the handling of raw materials in a typical textile industry.

2.0 Understand the principles of fibre mixing, opening, cleaning and blending processes.

3.0 Understand the functions and operations of the Revolving flat card and the high production card.

4.0 Understand lap preparation by both traditional and modern methods.

5.0 Understand the principles and operations of rectilinear comber.

LECTURE NOTE PREPARED BY MUHAMMED RAJI .A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGYYABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA.

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AREFERENCES

1. R. Senthil Kumar., Process Management in Spinning, CRC Press, Boca Raton, USA, 2015.

2. Uttam, D., Material handling in textile industries. International Journal of Advanced Research in Engineering and Applied Science, June 2013.

3. http://www.bdtextileinfo.blogspot.com.-Assessed on 25.05.16 12:10pm

4. Nkeonye, P.N., Introductory textiles, ABU Press, Zaria, Nigeria, 2003.

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TEXTILE RAW MATERIALRaw materials are unique substance in any production oriented textile industry. They play a vital role in continuous production and for high quality fabric. Textile raw materials are selected as per the manufacturing policy of the company i.e. whether a composite mill or only a spinning, weaving or dyeing/finishing.

Types of Textile Raw Material; they include the following:

1. Fibre 2. Fabric 3. Dyestuff 4. Chemical and Auxiliaries

FIBRE: A fibre has been defined according to ASTM as ‘a unit of matter characterized by flexibility, fineness and a high ratio of length to thickness’.

Name & Source: Cotton, Silk, Jute, Wool, Polyester, Nylon, Spandex, Flax, Acrylic, Aramid, Polyethylene, etc.


http://www.bdtextileinfo.blogspot.com.-Assessed

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FABRIC: Fabric is a planar textile structure formed by interlacing yarns, fibres or filaments. It may be woven, knitted or nonwoven.

Name & Source: 100% cotton fabric, 65% cotton/35% polyester fabric, etc.

DYES: A dye is a coloured substance that has an affinity for the substrate (e.g. fibre, yarn, fabric, paper, etc.), on which it is applied. Dyes are generally applied in an aqueous solution and require a mordant to improve the fastness of dyes on substrate. The following dyes are used; Reactive, Disperse, Acid, Basic, Direct, Sulphur, Azoic, Vat, etc.

CHEMCALS & AUXILIARIES: Dyeing auxiliaries are chemicals or formulated chemical product which enables processing operation in preparation, dyeing, printing or finishing to be carried out more effectively or which is essential if a given effect is to be obtained. Examples are; sequestering agent, lubricants, desizing agent, mercerizing agent, etc.

MATERIAL HANDLINGMaterial handling can be defined as an “art and science of conveying, elevating, positioning, transporting, packaging and storing of materials.”

Starting from the time, the raw materials (such as fibres for spinning unit or yarns for weaving/knitting unit and fabrics for wet processing or garmenting units) enters the mill and goes out of the mill in the form of finished products; it is handled at all stages within mill boundaries such as within and between raw materials stores, various section of production department, machine to machine and finished product stores.

Material handling involves the movement of materials, manually or mechanically in batches or one item at a time within the plant. The movement may be horizontal, vertical or both. Material movements add to the cost but not to the product value. The ideal manufacturing plant will have an absolute minimum material handling and more use of mechanical material handling equipment. Some benefits associated with effective material handling in textile/manufacturing industry are listed below;

Improving productivity Increasing the speed of material movement Reducing man-power Reducing materials wastage and minimizing production cost Promoting easier and cleaner handling


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Eliminating idle time of machines, equipment and workers Reducing fatigue incurred by the workers Locate and stock materials better and in less space Increasing safety and minimizing, etc.

FUNCTIONS OF MATERIAL HANDLING SECTION

There are basically two functions of material handling section:

1. To select production machinery and assist in plant layout so as to eliminate as far as possible the need of material handling. For examples: in a spinning mills chute feed cards, open end spinning machine, auto-doffing ring frames and autoconer etc. reduce the material handling activities hence material handling cost.

2. To choose most appropriate material handling equipment which is safe and can fulfill material handling requirements at the minimum possible overall cost. For example: Air conveyor pipes within the blow room and between blow room and cards, big size plastic container trolley for handling ring frame bobbins, cones and fabrics in a textile mill.

MATERIAL HANDLING EQUIPMENTS

Wide ranges of material handling equipment’s are available in the market; which are suitable to the most of the industrial requirements. Material handling equipment’s are classed as:

1. Industrial trucks: manual and powered

2. Cranes: overhead bridge crane, jib crane and gantry crane

3. Conveyors: belt conveyors, roller conveyor, chain or cable conveyor, etc.

4. Monorail 5. Lift 6. Slides & chutes

7. Hoists: chain type manual, electrical & pneumatic.

8. Tractors & trailers etc.

MATERIAL HANDLING IN SPINNING UNITS

The figures below are some of the material handling equipment’s commonly used in textile mills.


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I. FROM TRUCK TO MILL STORES

Figure 1: 2-wheeled industrial truck/trolley Figure 2: 4-wheeled industrial truck/trolley

Figure 3: Forklifts Figure 4: Platform truck

Types of material handling equipment’s used in the spinning mills are shown in Table 1 below

S.No Process Material Material handling Equipment1. From supplier to mill Cotton/Polyester in bale form Truck or train or ship2. From truck to store Bale of raw material Manual 2,3 or 4 wheeled truck3. Raw material store to mixing

sectionBale Manual 2,3 or 4 wheeled truck

4. Mixing to blow room line Loose cotton Special designed trolleys or lattice or suction

5. Blow room to card Laps or loose cotton Specially designed trolley or Air pipe conveyor and chute

6. Carding to draw frame Sliver cans Manual trolley or cans fitted castro wheels

7. Draw Frames to Speed Frame Sliver cans Manual trolley or cans fitted castro wheels

8. Speed frame to ring frame Roving bobbins Manual trolley/Tapa or special designed trolley

9. Ring frame doffing Ring bobbins Doffing trolleys10. Ring frame to winding Ring bobbins Specially designed plastic trolley


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11. Winding to packing Cones Big size plastic trolley or special designed trolley

Table 1: Material handling in spinning units

ii. FROM MIXING TO BLOW ROOM

Figure 5: Iron trolley Figure 6: Mixing trolley

III.WITHIN BLOW ROOM LINE

Figure 7: Belt Conveyor

Figure 8: Air Pipe Conveyor


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iv. FROM BLOW ROOM TO CARDING DEPARTMENTS

Figure 9: Trolley for blowroom lapsFigure 10: Chute Feeding System

V. FROM CARDING MACHINE TO DRAW FRAME & DRAW FRAME TO SPEED FRAME

Figure 11: Sliver cans


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Figure 12: Cans carrying trolley

vi. SLIVER LAP/RIBBON LAP MACHINE TO COMBER

Figure 13: Sliver/ribbon laps carrying trolley

Vii.FROM SPEED FRAME TO RING FRAME


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Figure 14: Big size trolley for speed frame Figure 15: Porcupine type trolley for speed frame

viii. TROLLEY FOR SPEED FRAME FLYERS

Figure 16: Trolley for speed frame flyers

Ix.FROM RING FRAME DOFF TROLLEY


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Figure 17: Ring frame doffing trolley Figure 18: Ring frame doffing trolley

X.POST SPINNING

Figure 19: Trolley fitted with cone holder pegs

MATERIAL HANDLING & SAFETYA. The Blow room

1. Cotton grown and harvested by the farmer was until 1987 sold to marketing board for onward sales to the textile mills. However, with the abolition of the marketing board, the textile mills or a body representing them buy directly from the cotton farmers.

2. The cotton arrives in the factory premises in the form of a highly compressed mass called BALES one of which weighs between 200-300kg.

3. Bales to be used are moved from the warehouse to the blow room, where they will be opened and allowed to remain for at least 24 hours in order for the fibres to/might absorb moisture before being put onto the machines.

4. During processing in the blow room, the cotton is opened, cleaned, mixed and blended. Heavy and light particles such as stones, sand sticks and cotton seed reminants, leaves and other impurities are removed, and clean cotton formed either into a mat-like sheet called a LAP, or fed directly by chutes to the carding machine.


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Material Handling Precautions:

1. During bales carriage from the warehouse to the blow sroom, care should be taken to avoid accidents caused by a careless lifting of bales which weigh between 200 and 300kg

2. Blowing room standard humidity has to be maintained at 55-65%. This is for better processing of raw materials as well as convenience of the workers.

3. Workers in the blow room are warned to always wear their nose/mouth masks for their safety. Hand gloves may be worn when necessary.

4. To avoid damage to the openers and blowing machine beaters, feeders are instructed to pick any piece found in the raw cotton when feeding is in progress.

NB: Bar magnets are fixed on some machine passages to attract metal piece found in the raw cotton when feeding is in progress. Bar magnets are fixed on some machine passages to attract metal pieces during processing.

B. Carding Section

1. Laps produced in the blow room are laid on the lap stand behind the carding machine. They are lowered and fed to the taker-in just before the previous lap unwinds completely, for continuity.

2. Laps fed to the carding machine are opened are opened, and short fibres, sticks, leaves, sand and small dust particles are removed. The fibres are formed into WEB and the web condensed by calender rollers to form sliver which is coiled into a CAN.

3. Humidity in carding section is between 50-55% and temperature is maintained at 30-350c.


1. Carding machine operatives and maintenance workers are instructed to use mouth/nose masks for health reasons.

2. Carding engines have heavy and fast moving parts e.g. cylinder and taker-in. Workers are to avoid bodily contact with these parts when in operation.

3. A machine due for maintenance should have a sign placed on it to warn everyone not to start it. The power supply to such a machine must be disconnected, and if possible must not be restorable with the knowledge of the maintenance staff.

4. Carding operatives and maintenance workers are advised to be careful when cleaning machine with sticks, brushes and metal hooks. When these are taken into the machine during operation, they will damage the cylinder, doffer and flat teeth.


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C. Drawing Section

Here, card slivers are passes through two sets of drawing machines. These makes individual fibres within the sliver better oriented and parallelized.

The purpose of drafting for light and heavy slivers through the same passage into one sliver is to even out the differences in them and produce a more regular sliver.

The sliver is finally coiled into a can similar to the cards.


The drawing machine is the safest to operate in the spinning department. Only signs are placed on it for notification during maintenance.

D. Roving Section

1. Draw frames slivers are arranged behind the roving frame and drawn through pairs of drafting rollers to form roving. A roving is the drawn sliver further reduced to a smaller size with just a little twist inserted and wound onto a package known as BOBBIN.

2. During operation, breakages may occur along sliver lengths, the operatives should not allow piecing up to exceed 1 ½ inches, and only very little twist applied.

3. Roving piecing should be carried out only by experienced operatives and must be done so as to avoid frequent machine stoppage.


1. The slivers and roving’s in this section should be carefully handled to avoid damage.

2. Operatives and maintenance men should not wear long robes. This can easily get caught by flyers and serious accident may occur.

3. The humidity applied here is about the same as that in the carding and drawing sections.

E. Ring Spinning Section

1. Roving brought from the speed frames are arranged on top of the ring frames and fed to the drafting rollers. Here, the roving is reduced in size, twisted into yarn and wound onto a BOBBIN.

2. Winding of the yarn onto a BOBBIN is done with the aid of travellers.

3. During operation, doffing is so controlled that machines are stopped for doffing alternately and only one machine is stopped at a time for doffing. While the remaining ones are in operation.


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4. Humidity in this section is controlled so that roller lapping shall not occur. Standard humidity in this section is about 50%.


1. Operators are to be careful in the use of hooks when removing roller lapping, because it could damage rollers and rubber aprons.

2. Bobbins and travellers dropped on the spinning floors should be picked immediately. Bobbins can cause accidents and travellers dropped will be wasted.

3. Maintenance workers should place warning signs on the machine when working on it so that other workers could keep off. Rollers and gears can easily cause injuries..


material handling lecture note

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