summer internship report - vardhman

O

Ravi Shekhar SEM-V, NIFT DELHI Auro Spinning Mills – Hall 5

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TABLE OF CONTENTS

ACKNOWLEDGEMENT 1 2

VARDHMAN GROUP 2 3-6

INTROUCTION 2.1 3 MANUFACTURING 2.2 3 PORTFOLIO 2.3 5 ADMINISTRATION 2.4 5 QUALITY POLOCY 2.5 6 PHILOSOPHY 2.6 6

AURO SPINNING MILLS 3 7-27

PRODUCTION DETAILS 3.1 7-8 AURO LAYOUT 3.2 9 RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3 10 PROCESS FLOW 3.4 11 BLOWROOM 3.5 12-15 CARDING 3.6 16-17 DRAWING 3.7 18 LAP FORMER 3.8 19 COMBING 3.9 20-21 FINISHER DRAW FRAME 3.10 22 DRAW FRAME 3.11 23 SPEED FRAME 3.12 24 RING FRAME 3.13 25 WINDING 3.14 26 PACKING 3.15 27

SPIN CALCULATION & PLANNING PRODUCTION 4 28-46

GOAL OF THE PROJECT 4.1 28 THE PROPOSAL 4.2 29 AN INTRODUCTION TO NEW SYSTEM 4.3 30 ASSESMENT OF CURRENT SYSTEM 4.4 31 SILENT FEATURES OF NEW SYSTEM 4.5 33 TECHNICAL REQUIREMENT FOR NEW SYSTEM 4.6 34 DEVELOPERS REQUIREMENT 4.7 35 DATA FLOW DIAGRAM 4.8 36 UNIT CONVERSION AND SPIN CALCULATION 4.9 37 MAINTENANCE : UPDATION & SUPPORT 4.10 44 SNAP SHOTS 4.11 45

BIBLIOGRAPHY 5 47

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ACKNOWLEDGEMENT |

This Internship Proved to bridge the gap between the theoretical and Practical Aspects of textile Field. It was a great pleasure to be part of Vardhman Group. All Thanks to my institute NIFT, New Delhi for providing me the opportunity for getting the practical knowledge at such an eminent company.

I am also greatly thankful to my subject faculty Dr. Senthil Venkat for the full support and step-‐by-‐step assistance. I am also Thankful to my Internship Mentors Dr. Noopur Anand and Ms. Suruchi Mittal.

I am very thankful to the whole Vardhman Group for providing me the best possible facilities and good environment during the period of my internship. I acknowledge deep gratitude towards each and every employee of the Auro Spinning Mills, Baddi for providing me with their valuable time.

I would also like to express my gratitude towards my mentor Ms Parul (HRD) and Project Guide Mr. Punit Singhal (R&D) for giving me chance to work on such a nice project. I pay my thanks to Mr. Vipin Sachan, Mr. Sunil Mishra and Mr Harpeet Rana (Shift Officer, Unit 5) who gave his valuable time and attention during my training and completion of project report.. Instructions of each person I meet in Auro were very beneficial for the successful completion of my project report.

I pay my special thanks to all the other HODs also for their valuable time, co-‐operation,, guidance and providing useful data, namely Mr Ravindra Yadav (R&D), Mr Devendra Vasist(R&D) and Un-‐doubly Mr Ravi Ranjan (TPM) for his all source of inspiration all along.

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VARDHMAN GROUP 2|TWO

Vardhman is a leading conglomerate with interests in textiles and steel having a turnover of Rs.2100 crores. The Vardhman group comprises six companies and twenty production units located in Punjab, Himachal Pradesh and Madhya Pradesh. A growth rate of almost 15% per year in turn over the last five years has been reflected in the financial results of the group.

MANUFACTURING 2.2|TWO

Vardhman group consists of integrated facilities of spinning, weaving and finishing. By and large it has a strong focus on textiles, which remains the largest industry in our country.

• Over 8, 00,000 spindles

• 65 tons per day yarn and fiber dyeing

• 900 shuttle-‐less looms

• 90 million meters per annum processed fabric

• 33 tons per day sewing thread

• 18000 metric tons per annum acrylic fiber

• 100,000 tons per annum special and alloy steel

Vardhman started its operation in 1965 from Ludhiana with a modest capacity of 14000 spindles. Today 5, 00,000 spindles which is largest any single group has in India. Besides it has weaving capacity of 264 looms and fabric finishing capacity of 95,000 meter per day. In addition it has mercerizing and dyeing of yarn and fiber and an acrylic production unit at Gujarat.

Spin Weave Process

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MANUFACTURING UNITS 2.2.2|TWO

Vardhman group consists of integrated facilities of spinning, weaving and finishing. By and large it has a strong focus on textiles, which remains the largest industry in our country.

• Vardhman Spinning and General Mills Ltd.

• Vardhman Spinning and General Mills Ltd. Ludhiana

• Auro Spinning Mills Baddi, H.P.

• Auro Dyeing Baddi, H.P.

• Auro Weaving Mills Baddi, H.P.

• Auro Textiles Baddi, H.P.

• V.S.G.M. 100% E.O.U. Baddi, H.P.

• V.S.G.M. Unit 2 Ludhiana

• V.S.G.M. Unit 3 Ludhiana

• Mahavir Spinning Mills Ltd.

• Mahavir Spinning Mills Ltd. Hoshiarpur

• Arihant Spinning Mills Malarkotla

• Anant Spinning Mills

• Vardhman Special Steel Lidhiana, Punjab

• M.S.M.L. Sewing Threads Unit 2 Ludhiana, Punjab

• Arist spinning Mills Baddi, H.P.

• Arist Spinning Mills 100% E.O.U. Baddi, H.P.

• Vardhman Polytex ltd.

• Vardhman Ploytex ltd. Bhatinda, Punjab

• Anshupati Textiles Ludhiana, Punjab

• V.M.T. Spinning Co. Ltd. Baddi, H.P.

• Vardhman Acrylic Ltd. Bharuch, Gujrat

• Vardhman Threads Ltd. Baddi, H.P.

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PORTFOLIO 2.3|TWO

ADMINISTRATTION 2.4|TWO

Corporate office located in Chandigarh road in Ludhiana adjacent to Vardhman Spinning and General Mills Ltd.(Ludhiana). It came into being in 1995.

Vardhman Group has administrative and marketing branches all over India and in more than 20 countries for its various businesses. The group is well diversified in making sewing threads, fabrics, hand knitting yarns, cotton yarns, acrylic yarns etc. with a capacity of over 5,00,000 spindles and 264 looms producing yarns and fabrics.

Shree S.P. Oswal, a gold medalist in M.Com. heads the group who is the chairman and managing director of all group companies.

Fiber 8%

Power Plant 2%

Steel 10% ST

11%

Fabric 22%

Yarn 47%

Business Wise TurnOver for Financial Year 2008-2009

Fiber PowerPlant Steel ST Fabric Yarn

Actual 2008-09 Group Total

( � crores) USD Million % Share

Yarn 1513 329 47%

Fabric 689 150 22%

Sewing Thread 337 73 11%

Steel 327 71 10%

Power plant 66 14 2%

Fibre 254 55 8%

Total 3186 693 100%

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QUALITY POLICY 2.5|TWO

Quality should be built into company’s products to not only meet customer requirements continuously but also exceed them. The company shall achieve this through an interface with the market place, access to state of the art technology, R&D process development and adoption of innovative manufacturing and marketing strategies.

The quality policy shall be implemented through a network of systems and procedures understood and followed throughout the company.

The quality policy shall be integrated with the company’s main objectives: 1. To remain market leader in the quality. 2. Increase market share with focus on niche segments. 3. Improved productivity. 4. Cost reduction. 5. Reduction in percentage of seconds. 6. The management shall be committed to provide capital and human resources to achieve the above objectives. A companywide quality culture shall be created through training and motivation of people at all levels of organization.

PHILOSOPHY 2.6|TWO

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AURO SPINNING MILLS (77904 SPINDLES) 3|THREE

Auro Spinning Mills Baddi (Himachal Pradesh) 77904

Auro weaving mills, a weaving subsidiary of Vardhman Spinning and General Mills Limited, has now emerged as one of the premium companies in India.

PRODUCTION DETAILS 3.1|THREE

Production Halls Production Units 5

UNIT 1 (HALL1) 3.1.1|THREE

Manufacturing Activity Greige Cotton ( both cared & combed) and core

spun with lycra.

Unit Capacity • 24,422 spindles

• Production of yarn per day: 16,000 kg

Product Range 10s-60s

UNIT 2 (HALL 2) 3.1.2|THREE

Manufacturing Activity Sliver preparatory and sample line

Unit Capacity • 1382 spindles

• Production of sliver per day: 9,000 kg

Product Range Lycra, compact, compact+lycra, slub+lycra,

slub, Blends

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Manufacturing Activity Cotton and lycra (bulk orders)

Unit Capacity 38592 spindles

Product Range Lycra, slub, fancy yarns


Manufacturing Activity Open- end yarn

Unit Capacity • 1248 rotors

• Production of yarn per day: 12,000 kg



Manufacturing Activity Compact ( Elite) spun yarn

Unit Capacity 14256 spindles

Production of yarn per day: 4000 kg


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AURO LAYOUT 3.2|THREE

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RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3|THREE

BALE SPECIFICATION 3.3.1|THREE

• Fiber

• Net Weight

• Origin/Supplier

• Length

• Width

• Staple length

BALE INSERTION PARAMETER 3.3.2|THREE

• Origin:

• Thickness or Fineness (micronaire)

• Bale weight: 165 or 220 kgs (approximately).

• Staple length: 30-‐35mm

• Degree of Reflection (RD): 60-‐80Degrees

• Strength : 24-‐29 gram/tex

• Moisture regain

• Evenness

• Maturity

MACHINE USED FOR TESTING OF FIBER 3.3.3|THREE

• HVI: High Volume Instrument

• AFIS: Advance Fiber Information System

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PROCESS FLOW 3.4|THREE

Godown Mixing (MBO)

Sorting (Manualy)

Bale Formation Blow Room Carding

Pre-Combing Combing Drawing (F D/F)

Speed Frame Ring Frame Winding

Conditioning Packing Dispatch

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BLOW ROOM 3.5|THREE

INTRODUCTION 3.3.1|THREE

Blow-‐room consists of a number of machines used in succession to open and clean the cotton fiber. About 40% -‐ 70% trash is removed in blow-‐room section.

PROCESS FLOW IN BLOWROOM 3.3.2|THREE

• pre opening with Blendomat BDT

• metal or fire detection by SPMF

• pre cleaning by Maxi-‐flow

• mixing or blending by MPM

• fine opening by CVT

PROCESS PARAMETER IN BLOWROOM 3.3.3|THREE

The basic purpose of Blow-‐room is to supply

• small fiber tufts

• clean fiber tufts

• Homogeneously blended tufts if more than one variety of fiber is used,

without increasing the fiber rupture, fiber neps, and broken seed particles

and without removing more good fibers.

PRE-‐OPENING 3.3.4|THREE

Effective preopening results in smaller tuft sizes, thus creating a large surface

area for easy and efficient removal of trash particles by the fine openers.

Vardhman Textiles uses Trutzschler Blendomat BDT (019) as the preopening

machine.

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PRE-‐OPENING FEATURES 3.3.5|THREE

• It helps maintaining the homogeneity of the long term blending

• cotton is opened gently without recycling as it is done in manual bale

openers

• the tuft size can be as small as 50 to 100 grams without rupturing the fibers

• the opening roller speed is around 1500 to 1800 rpm.

• the depth of penetration of the opening should be as minimum as possible

for better quality

• If the production per feeding machine is less than 150 kg, then four mixings can

be done

METEL / FIRE DETECTION 3.3.6|THREE

Cotton fiber may catch some metal components while its fiber extraction

process which needs to be removed before it goes into any further processing.

Cotton fiber also may generate sparks due to friction while passing through

connecting ducts. Thus it needs to be blown out. This is done just after the

blendomat takes up the fiber from the manually opened bales.

Vardhman Textiles uses Trutzschler SPMF for this process.

PRECLEANING AND BEATING 3.3.7|THREE

Vardhman Textiles uses Trutzschler Maxi flow for this work.

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VARIOUS MACHINE PARAMETERS 3.3.8|THREE

• The fiber treatment in this machine is very gentle because the fibers are

not gripped by the feed roller during beating. Fiber tufts treated by the

pin beater when it is carried by air medium

• all heavy trash particles fall down before it is broken

• cleaning efficiency of this machine is very high in the blow room line

• Mostly all heavy seeds( full seeds) fall in this machine without any

problem

• around 50 pascal suction pressure should be maintained in the waste

chamber for better cleaning efficiency

• beater speed, air velocity through the machine, grid bar setting and gap

between grid bars will affect the cleaning efficiency

• higher the cleaning efficiency, higher the good fiber loss, higher the nep

generaion and higher the fiber rupture

• the optimum cleaning means maximum cleaning performance,

minimum loss of good fibers, a high degree of fibre preservation and

minimum nep generation

• in general the beater speed is around 750 and minimum 50 pascal

suction pressure to be maintained in the suction chamber

MIXING OR BLENDING 3.3.9|THREE

If different grade of same fibers are kept together, then it is called mixing,

whereas, when different fibers of same or different grades are kept together,

then it is called blending. Physical properties (fibre length, fineness, strength)

of the resultant blend can be predicted, and are reproducible.

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MIXING OR BLENDING: OBJECTIVES 3.3.10|THREE

• To achieve uniform quality.

• To improve performance.

• To reduce and control the production cost.

• To meet the functional and user requirements.

• To enhance aesthetic properties i.e. appearance, color, lusters etc.

• To enhance physical properties i.e. tensile strength, abrasion

resistance, stretch etc.

Vardhman Textiles uses Trutzschler MPM machine for uniform mixing and

blending of fibers.

FINE CLEANING 3.3.10|THREE

Vardhman employs Trutzschler CVT1. The cleaning points in CVT1 consist of

opening roller, deflector blades, mote knives and suction hood. Trash particles

released due to centrifugal forces are separated at the mote knives and

continuously taken away by the suction. This gives better cleaning.

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CARDING 3.6|THREE


Carding process is considered as heart of spinning. Any defects occurring in this

process continue throughout the remaining process of spinning resulting in

defective yarn. In this process the cotton fibres pass through in between two

sets of wire points moving in opposite direction resulting in the parallelization of

fibers.

High production in carding to economize the process leads to reduction in yarn

quality. Latest machines achieve the production rate of 60 -‐ 200 kgs / hr, which

used to be 5 -‐ 10 kgs / hr, up to 1970.

MACHINES AVAILABLE 3.6.2|THREE

Machine: Trutzschler DK-‐800

No. of Machines: 10

Delivery Speed: 76 mt/min

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PURPOSE OF CARDING 3.6.3|THREE

• cleaning or elimination of impurities

• to open the flocks into individual fibers

• reduction of neps

• elimination of dust

• elimination of short fibers

• fiber blending

• fiber orientation or alignment

• sliver formation

TYPES OF FEEDING 3.6.4|THREE

• Feeding material in the form of scutcher lap

• Flock feed system (flocks are transported pneumatically)

PROPERTIES OF FLOCK FEEDING (TRUTZSCHLER USES) 3.6.5|THREE

• high performance in carding due to high degree of openness of feed web

• labor 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

• auto leveler is a must, hence investment cost and maintenance cost is more

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DRAWING 3.7|THREE


The sliver from the carding section is combined together to form one dense

sliver. The process is called as Doubling One for Six (DO/6). It means 6 slivers

are taken together to form one sliver which is the input for the formation of

laps.


Machine: Lakshmi Reiter

No. of Machines: 2

Drafting arrangement: 3 over 3

Type of weighing: Pnuematic Loaded

High delivery speed: upto 500 mts/min

Production: upto 360 kg

MAIN OBJECTIVES 3.7.3|THREE

• To straighten the fibers and make them parallel

• To improve uniformity

• To improve evenness

PROCESS PARAMETER 3.7.4|THREE

1. Flexibility: The pneumatically loaded 3-‐cylinder pressure bar drafting

arrangement makes the processing of noils as well as fibres of a staple

length upto 75 mm possible Controlled positive sliver feed table for can size

of 600 x 1100 mm (24''x42'')

2. Sliver Compression: Sliver compression before coiling increases can

content

3. Automatic can change: Increases the efficiency of the machine

4. Cleanliness: Dust extraction improves working condition Doubling 6 for 1.

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LAP FORMER 3.8|THREE


Lap former machines form the lap from the sliver of desired fineness and

weight. The D/F slivers are drafted and wound into a lap. 8-‐12 slivers are fed

into drafting arrangement from both sides and these are drafted in drafting

system to produce fleeces. These are then drawn into the lap head by the

calendar rolls which compresses its strongly to form a lap sheet (batt). This is

then wound onto a tube by the lap rolls and lap roller flanges. When tube is full

it is automatically changed for an empty one.


Machine: Lakshmi UNIlap (LH-‐10 & LE4/1a)

No. of Machines: 2

Delivery speed: up to 120 mts/min

Batt weight: up to 80 gms/mt

Time to complete one lap: 2.5 min

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COMBING 3.9|THREE


Combing is the operation in which the short fibers in the cotton are removed so

that the final yarn appearance and strength of the yarn is improved. It is

optional as per the end-‐use of the yarn.


Machine: -‐ Lakshmi REITER E-‐65 and LK 54

Number of machines: -‐ 6

Capacity: -‐ 3000-‐5000mtr

MACHINES SPECIFICATION 3.9.3|THREE

Comber E-‐65 Comber LK-‐54

No. of heads 8 8

No. of Deliveries 1 1

Drafting arrangement 3 over 3 3 over 5

Weighing arrangement Pneumatic 250 to 300 N Pneumatic 250 to 300 N

Lap Diameter 550 mm (500-‐650 mm) 540 mm ( 500-‐650 mm)

Hank Delivered 0.16 Ne 0.16 Ne

Delivery speed 250 mpm 300 mpm

Production (in kg)

( per shift per machine)

689.93 965.9

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PROCESS & OBJECTIVES 3.9.4|THREE

Combing is a process which is meant for upgrading the cotton raw material so

that the following yarn properties will improve compared to the normal carded

yarn.

• Tenacity

• gms/tex

• Trash in the yarn

• Lustre

• Visual appearance

Slivers from carding section can go either directly to Finisher Drawing through

Breaker Drawing or through Uni Lap/Comber to Finisher Drawing.

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FINISHER DRAW FRAME 3.10|THREE



Machine: Trutzschler D-‐40 & TD-‐03

No. of machines: 3


Doubling Upto 8 ply

Drafting arrangement 4 over 3 ( with adjustable pressure bar)

Type of weighing Pneumatic loaded

Material Combed

Delivery speed 300-‐1000 mt/min

Auto can changer Yes

Auto-‐leveller Yes

Waste quantity Max 0.15 kg/hr

Suction air rate 800 m3 per hr

Operation pressure 450 Pa


1. Used for weight control to form products of fine quality.

2. To contribute towards doubling and draft of the combed material and to

change hooks disposition.

3. To straighten the fibres and to make them parallel.

4. To improve uniformity and eveness(homogenous sliver structure).

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SPEED FRAME 3.11|THREE



Machine: Lakshmi LFS 1660 Simplex

No. of spindles: 120 spindles

No. of machines: 4 machines

Delivery rate: up to 50 m/min


Count: 0.7 Ne ( running)

Twist per Inch: 1.21 tpi ( running)

Production Rate: 21.3 mt/min ( roving)

Machine Efficiency: 75.1%

PROCESS & OBJECTIVES 3.11.4|THREE 1. to draft the draw-‐frame sliver to make roving

2. to impart necessary twist to the roving

3. to wind the roving on the bobbin for ring frame machine

Ultima/ MCU5 J34/ S6

Drafting Array 4 over 4 4 over 4

Type of weighing Pneumatic Pneumatic

Total Draft 10.31 8.1

Hank Fedytg6 1.8 1.38

Efficiency 85% 85%

Production ( in kg)

per shift per spindle)

2.13 2.75

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RING FRAME 3.12|THREE


The roving bobbins of the speed frame are brought to and crewed on ring

frame. These machines convert the roving into yarn. These machines further

attenuate and draft the roving to the desired thickness of yarn, which is then

wound on bobbins.


Machine: LR6 R/frs with ELITE Attachments

No. of Machine: 16 ring frame


PROCESS & OBJECTIVES 3.12.4|THREE 1. To attenuate the roving to get the desired fineness.

2. To insert the required twist to provide sufficient strength.

3. To form a suitable package of required dimension for subsequent

processing.

ELITE Compact Elitwist

Drafting arrangement 3 over 4 3 over4

Type of weighing Spring Spring

Spindle speed 16300 rpm 18362 rpm

Max. Speed 17500 rom 21000rpm

Tpi (nominal) 13.89 z 33.07 z

Delivery Rate (spindle speed/Tpi) 326.60 590.22

Hank Fed 1.8 1.38

Production (in gm )

( per shift per spindle)

40.82 68.04

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WINDING 3.13|THREE


Machine: Autoconer-‐ 338 with Uster Quantum clearer 2

No. of Machines : 5


1. To form a suitable bigger package with continuous length

2. To clear objectionable faults

3. To clear excessively weak spots in the yarn by tensioning

4. High degree of tension is not given as it can lead to loss of elongation of

yarn.


Material 58s 60s 80s

Package Wt. 2.01 kg 1.89 kg 1 kg

Pkg. Length 195200 m 195200 m 135000 m

Speed 1200 mpm 1200 mpm 1000 mpm

Tension (cN) 14 14 9

No. of Drums 60 60 60

Pkg. Density 0.5 gm/cc 0.5 gm/cc 0.5 gm/cc

Splicing Pneumatic Pneumatic Pneumatic

Splice strength 80-‐85% 80-‐85% 80-‐85%

Actual Production 70-‐75% 70-‐75% 70-‐75%

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CONDITIONING 3.14|THREE

OBJECTIVES 3.14.1|THREE

1. Twist setting of the final yarn.

2. To let the material reach required moisture regains value so that the

company does not suffer commercial losses.


Machine: CONTEXX or Xorella AG

Heating medium: Saturated steam

Power Consumption: 150kW

Working pressure: -‐1 to 3 bar

Starting temperature: 400 C

Maximum conditioning time: 12 hrs.

Efficiency: 70-‐75%

Time Temp. Pressure

Hoseiry 5 min

25 min

550C

600 C

88%

88%

Warp 5 min

10 min

760 C

800 C

80%

80%

Perforated

Cheese

5 min

10 min

760 C

800 C

80%

80%

Improved Strength

Improved Elongation

Improved Elongation

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PACKING 3.15|THREE

TYPES 3.15.1|THREE

After conditioning, the material is packed according to the customer’s

demand. There are two ways of packing:

1. Carton packing

2. Pallet packing

SIZE 3.15.2|THREE

Carton Packing

1. Normal Size

• Dimension: 655 mm x 460 mm x 515 mm

• Capacity: 18 cones

• Headed to other countries

2. Maha-‐Bali Lot

• Dimension: 640 mmx 480 mmx 350 mm

• Capacity: 24 cones

• Headed to Japan

Pallet Packing

1. Normal Size

• Dimension: 1150 mm x 790 mm

• For 1.89 kg cones: 24 layers x 13 cones

2. Maha-‐Bali Lot

• Dimension: 1150 mm x 1150 mm

• For 2.5 kg cones: 25 layers x 13 cones

• For 1.89 kg cones: 36 layer x 13 cones

summer internship report - vardhman

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