Reedisha Spinning LTD - Industrial Report

A Practical Methodology throughout Factory Evaluation
Page 1 of 112

CHAPTER ONE CHAPTER ONE CHAPTER ONE CHAPTER ONE

Project Description Project Description Project Description Project Description

Page 2 of 112

CHAPTER 01
PROJECT DESCRIPTION

Name of the Mill : Reedisha Spinning Ltd.
Type : 100% Export Oriented Spinning Mills

Year of Establishment : September, 2006

Head office of the Mill : 36, Shahid Tajuddin Ahmed Sharani
Tajgaon Industrial Area,
Dhaka 1208, Bangladesh
Phone : +880-2-8823227, 9897817-20
Fax : +880-2-8826086
e-mail : spinning@rkl-bd.com

Factory of the Mill : Zamirdia(Square Masterbari),
Valuka,
Mymensingh
Phone : 02-8891498, 01713163897, 01713129260
Fax : 02-8891523, 01713050446
e-mail : rsl_fa@yahoo.com

Sponsor of the Mill : Islami Bank Bangladesh Ltd.
Kawran Bazar Branch,
Dhaka

Project Cost : Investment USD 24 Million
Area of the Mill : 20 Acres of Land
Raw Materials : CIS Cotton (Origin)
COTTONEX (Brand Name)
28~32mm (Staple Length)
3.3~4.9 (MIC Value)

Product Mix : Ring Yarn (Carded & Combed)
Slub Yarn
Mill Capacity : 36,000
Total No. of Spindles : (1008*36) 36,288 Spindles
Production Capacity : 22,000 Kg per day
Production (Produced) : Average 20,000 Kg per day
Production Achievement : 85%
Yarn Count Range : 16~60 Ne
Power Generation : 5.15 MW

Page 3 of 112

Historical Development of the Project :

Reedisha Spinning Ltd. is a sister concern & profitable project of KOHINOOR
Chamical Company (BD), Ltd. The factory is located at Zamirdia, Valuka,
Mymensingh, near to the Valuka and besides the Dhaka-Mymensingh Highway on
about 20 acres of Land. It is covered the Floor Space of total about 1,50,000 SFT
(Factory, Raw Cotton & Finished Godown). The main factory has divided into three
commercial buildings. One is Production building, Second is Utility building & the
Las one is Office building. Reedisha Spinning Ltd. is the new bright baby of the
Textile Sectors of Bangladesh.

Back Ground of RKL Group :

RKL group is a family business which was established in the year of 2006 in
September by Mr. Rezaul Karim. This business is initially started as Garments
Manufacturing Unit on its own premises which is also currently the Corporate
Office. The vision of the Management gradually turned into a Reality with the
formation of the Member Units Marketing a growth pattern of the Group.

Project Name Date of Establishment

Reedisha Knitex Ltd. September, 2004
Reedisha Spinning Ltd. September, 2006

To uphold Social commitment at Highest Level and for achieving expected Quality
production of Exported Garments, the board of Director has decided to establish a
100% Export Oriented Cotton Spinning Mills to turn the Group as Composite Knit
Project in true sense.
Keeping the above in view this good management has started Reedisha Spinning Ltd.
with 36000 spindles to get average 20ton production per day. The total investment of
the Project is about USD 24 Million. The produced yarn will be consumed by Sister
Concern.

Different Departments of the Factory :
1. Administrative Department
2. Security Department
3. Production Department
4. Quality Control and Assurance Department
5. Maintenance Department
6. Utility Department
7. Electrical Engineering Department
8. Civil Engineering Department
9. Store (Local & Foreign) Department
10. Medical Department
Page 4 of 112

Physical Infrastructure :

Reedisha Spinning Ltd. is organized into three major parts,

1. Factory Department
2. Sales & Production Department
3. Finance & Accounts Department

But the factory is consist of mainly Five Control Department,

1. Production Department
2. Quality Control & Assurance Department
3. Maintenance Department
4. Administrative Department
5. Information Department

Again, the factory has various buildings, such as,

- Generator building
- Store building
- Security building
- Raw Cotton Godown
- Wastage Godown
- Family Quarter
- Bachelor Quarter
- Workers(Male) Dormitory
- Workers(Female) Dormitory
- Office building (MD, VP, GM etc.)

Remarks :

Reedisha Spinning Ltd. is a profitable project & sister concern of KOHINOOR
Chemical Company(BD), Ltd. Reedisha Spinning Ltd. earns a lot of Foreign
Currency and contributes the economy of the Country.

Page 5 of 112

CHAPTER CHAPTER CHAPTER CHAPTER TWO TWO TWO TWO

Man Power Management Man Power Management Man Power Management Man Power Management

Page 6 of 112

CHAPTER 02
MAN-POWER MANAGEMENT

MANPOWER :

Reedisha Spinning Ltd. is a well organized company and it is certified by the
OKO Tex and Its management system & manpower management is completely
different from other company.

Man-Power Management for Quality Department :

Serial Designation Shift Schedule No. of
Post
01 Manager/QIC General Shift 01
02 Asst. Manager/Sr. Quality Assurance
Officer
General Shift 01
03 Quality Assurance Officer Shift A / B / C 03
04 Supervisor Shift A / B / C 03
05 Lab Assistant Shift A / B / C 06
06 Lab Helper Shift A / B /C 03
07 Staff General Shift 02
08 Staff (Blow Room) Shift A / B / C 03
09 Worker (Mixing Man) Shift A / B / C 18
10 Worker (Contamination) Shift A / B / C 15
Total 55

Man-Power Management for Maintenance Department :

Post
01 Maintenance Manager General Shift 01
02 Maintenance Officer General Shift 02
03 Senior Foreman General Shift 01
04 Foreman General Shift 03
05 Head Feeder Shift A / B / C 02
06 Senior Feeder Shift A / B / C 04
07 Feeder Shift A / B / C 12
08 Assistant Feeder Shift A / B / C 14
09 Helper Shift A / B / C 17
10 Learner Shift A / B / C 24
Total 80
Page 7 of 112

Man-Power Management for Utility Department :

Post
01 Assistant General Manager General Shift 01
02 Assistant Manager General Shift 02
03 Engineer General Shift 01
04 Sr. Assistant Engineer Shift A / B / C 01
05 Assistant Engineer Shift A / B / C 03
06 Foreman Shift A / B / C 03
07 Head Feeder Shift A / B / C 02
08 Feeder Shift A / B / C 04
09 Assistant Feeder Shift A / B / C 06
11 Learner Shift A / B / C 05
Total 38

Man-Power Management for Store Department :

Post
01 Store In-charge General Shift 01
02 Store Officer General Shift 01
03 Assistant Store Officer General Shift 02
04 Store Keeper Shift A / B / C 02
05 Staff Shift A / B / C 04
Total 12

Man-Power Management for Administrative Department :

Post
01 Sr. Administrative Officer (In-Charge) General Shift 01
02 Junior Administrative Officer General Shift 02
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Time Keeper 02
04 Photocopier-Fax Operator 01
05 Peon 01
06 Driver 04
07 Driver-Helper 03
08 Hostel Super 01
09 Carpenter 01
Page 8 of 112

10 Gardener 02
11 Swifter 07
12 Imam 01
13 Cowboy 01
14 Cooker 07
15 Cooker-Helper 03
Total 37

Man-Power Management for Security Department :

Post
01 Senior Officer General Shift 01
02 Habilder 03
03 Ladies Checker 01
04 Security Guard 17
Total 22

Shift Change Schedule :

General Shift : 09.00 AM to 05.00 PM
Shift A : 06.00 AM to 02.00 PM
Shift B : 02.00 PM to 10.00 PM
Shift C : 10.00 PM to 06.00 AM

Page 9 of 112

RESPONSIBILITIES :

Responsibilities of Quality Control In Charge :

- Maintain proper Quality Control daily and monthly records
- Ensure that the studies allotted in various departments are carried out as per
plan
- Prepare necessary Standards for the product manufactured in the mill
- Fix up the mode of Sampling for the various studies
- Work out the tolerance limits for the data collected by the Investigator
- Monitor the salient studies like Pinion changes in different spinning machine,
average sliver, lap weight over a period of time etc. in a graphical
representation
- Keep himself aware of the technical features of the testing machinery under
his control
- Keep in touch with the modern developments in the field of textile testing and
arrange where ever possible, for the incorporation of advanced features to the
existing testing instruments
- Co-ordinate with the factory manager and spinning master to rectify the
defects found out by the quality control studies. Decide the feasibility of
reducing the repeated studies
- Check the mode of conducting the studies in the shop floor by the
investigators
- Conduct a periodic review of the stores and stationeries like printing paper,
graph sheets, calibration cotton, etc. required by the quality control
department
- Find out rogue machines/parts from the quality control study and plan for
crash programmes to set right those machines in consultation with
Maintenance In-charge
- Co-ordinate with production personnel by giving a patient hearing to the
problems connected with the performance of the machines
- Liaise with Maintenance department for evaluating the performance of the
Machinery in all the department and to take corrective actions
- Inculcate the capacity to guide, motivate and handle the Quality control crew
- Should maintain close contacts with the top management to discuss about his
achievements as well as constraints

Page 10 of 112

Responsibilities of Quality Control Officer :

- Distribute the planned Quality control operations to the quality control crew
(Investigators, Testers & Wrapping boy)
- Inform the Product changes that have taken place to the Quality Control In-
charge for which he should liaise regularity with production officers
- Ascertain whether the action plan decided to rectify some of the deficiencies
found from the quality control studies are implemented in the shop floor
- Should maintain close contact with the investigators wrapping boy and testing
operatives to avoid flaws, if any, in the various studies conducted by them
- Co-ordinate with Production officers and Quality Control In-charge in
implementing the action plan decided to rectify deficiencies, if any in the
process
- Test the accuracy of the testing machines using the calibration tools suggested
by the instrument manufactures
- Inform the instrument service contact personnel about the defects, if found
- Maintain proper records for the servicing operations undertaken for the
testing instruments
- Prepare neat graphical representation of the salient studies like average full
sliver, lap weight; Pinion changes in different spinning machines, End breaks
in Ring frame etc.
- Tabulate monthly average of the Lea CSP, Count CV, Strength CV, Yarn IPI
etc. to have quick glance of the salient quality data of different counts
- Help the Quality Control In-charge in preparing the monthly report by feeding
him the consolidated figures properly
- Check the standards and tolerance limits fixed for the various quality
attributes, before informing for corrective actions
- Plan for periodic spot check in the shop floor to examine the accuracy of the
studies conducted by the investigators
- Check the calculations and interpretations made by the investigators before
submitting the report to the Quality Control In-charge
- Inform the Quality Control In-charge about the reasons for any abnormalities
in the study results for proper interpretation
- Note down the wet bulb and dry bulb temperature before and after completion
of the study
- Inform the shop floor Supervisor after the completion of the study

Page 11 of 112

Responsibilities of Production Officer :

- To check the rules and regulation inside the factory
- To ensure the target production of each machine with appropriate quality
- To arrange necessary punishment for the worker if they violate discipline
- To collect necessary information and instruction from the previous Shift
Officer
- To run his Shift smoothly and accurately
- To supervise Junior officer and worker
- To make decision how to operate whole production process
- To check the worker setting for the spinning process
- To control the production processes and quality parameters
- To control the workers so that they can operate the machine as per
instruction
- To train up the learners & ensure cleanliness of all machine
- In case of any machine breakdown, has to be started as early as possible
- To minimize machine down time & take necessary steps to reduce wastage
- To check of machine settings, gauging, drafting, etc.
- To check the proper use of waste sliver and pneumafil in the Blowroom
- To check the production report, Sticker, Detective cone & Package weight in
finishing avoiding mixing
- To hand over the Shift with all information to the coming Shift officer

Page 12 of 112

Job Description of Production Officer :

- To monitor of Blowroom to Finished good to achieve target production
- To check Humidity of the different section
- To supervise performance evaluation
- To check count wise & lot wise process parameter from Blowroom to Finished
good
- To take the charge from the outgoing shift & hand over the charge to
incoming shift
- To control unusable wastage in every stage from Blowroom to Finished good
- To allow leave of Workers & Subordinate supervising staffs in systematic way
- To check the Attendance
- To control Count mixing, Lot mixing of sliver, Roving yarn and Mixing / Bale
management of Raw cotton
- To charge Ring traveler as per schedule
- To change count wise & lot wise process parameter from Blowroom to
Finished good against standard value
- To attend duties self and subordinate supervising staff and workers by
minimum 15 minutes earlier
- To maintain Doff ticket and control of doffing time in Ring section

Job Description of Quality Assurance Officer :

- To check the Quality parameters of the product
- To direct for changing the Quality settings point according to customer
requirement
- To maintain close contact with Investigator wrapping boys & testing boys
- To test the accuracy of the testing machine in the testing laboratory
- To verify the Quality test result of previous quality test result
- To maintain the proper records of Quality servicing list parameters
- To prepare the Neat graphical representation of every Quality changing
module
- To tabulate the monthly average test result of CV value, Strength value,
Count value, CSP value, IPI value, Graphical Neat sketch etc.
- To decrease the fault appearance of any machine parameters
- To give the direction of worker for improving Quality parameters
- To check the Quality calculation done by Investigator & testing boy for better
sincere of the Calculated result
- To inform the Senior Officer or Quality Control In-charge for any
machine/quality/ product faults
- To maintain the quality control management

Page 13 of 112

CHAPTER CHAPTER CHAPTER CHAPTER THREE THREE THREE THREE

Machine Description Machine Description Machine Description Machine Description

Page 14 of 112

CHAPTER 03
MACHINE DESCRIPTION

Layout plan for Blowroom :

Laydown-1
Laydown-2
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Condenser
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Uni Mix
Uni Clean
Identification:
Page 15 of 112

Layout plan for Back Process :

Carding m/c=16
Breaker D/F=7
Finisher D/F=7
Lap Former=1

Simplex=9
Comber=5
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Page 16 of 112

Layout plan fro Ring to Finishing :

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Identification:
Page 17 of 112

Origin of Machineries & Equipment :

India, Switzerland, China, Japan, Germany, USA

List of Material Processing Machineries :

(A) Blowroom Department : Unifloc(1), Uniclean(1), Unimix(2), Uniflex(2),
Condenser(2)
(B) Carding Department : Carding(16)
(C) Drawframe Department : Breaker Drawframe(7), Finisher Drawframe(7)
(D) Lap Former Department : Lap Former(1)
(E) Comber Department : Comber(5)
(F) Simplex Department : Toyota Simplex(6), China Simplex(3)
(G) Ringframe Department : Ringframe(36)
(H) Autocone Department : SAVIO Autocone(4), SCHLAFHORST Autocone(8)
(I) Quality Department : HVI(1), AFIS(1), USTER Auto Sorter 5(1), Electro
Magnetic Strength Tester(1), Electronic Twist
Tester(1), WIRA Yarn Count Tester(1), Finisher
Wrapping Tester(1), Sliver Roving Reel(1),
Electronic Weight Balance(1), Electro Yarn Reel(1),
Hand Held Moisture Meter(1), MAG Yarn
Appearance Board Winder(1)

Specification of Machineries :

Blow Room Machineries :

(A) Unifloc : Model : Unifloc A11
Origin : Rieter (Switzerland)
Year : 2006
Serial : 40002940-00051
Electrical : 3*400V, 50Hz, 21Amp
No. of M/C : One
Function : To pluck & passes Raw material

Page 18 of 112

(B) Heavy Metal Detector : Origin : Jossi Metal Detector (Switzerland)
No. of M/C : One
Function : To detect the Metal

(C) Uniclean : Model : Uniclean B11
Year : 2006
Serial : 40004050-00061
Electrical : 3*400V, 50Hz, 25Amp
No. of M/C : One
Function : To remove dust & trash particle

(D) Unimix : Model : Unimix B70
Year : 2006
Serial : 40004000-00081
Electrical : 3*400V, 50Hz, 14Amp, 6Bar
No. of M/C : Two
Function : To mix & store the plucked fibre

(E) Uniflex : Model : Uniflex B60
Year : 2006
Serial : 40008240-00075
No. of M/C : Two
Function : For fine mixing & cleaning

(F) Jossi Vision Shield : Model : ED-35.1-1200T
Origin : Jossi (Swiss Made)
Year : 09-02-2006
Serial : 3102381
No. of M/C : Two
Function : To detect the foreign fibre particles

(G) Condenser : Model : Condenser A21
Origin : Riter (Switzerland)
Year : 2006
Serial : 4009560-00027
Function : To condensed the plucked fibre

Page 19 of 112

Carding Machineries :

Model : Carding C60
Year : 2006
Electrical : 3*400V, 50Hz, 6Bar
No. of Machine : 16
Function : Drafting & attenuating of the fibre.

Breaker Drawframe Machineries :

Model : Breaker Drawframe SB-D 40
Year : 2006
No. of Machine : 7
Function : Drafting & Parallelization

Finisher Drawframe Machineries :

Model : Finisher Drawframe RSB-D 40
Year : 2006
No. of Machine : 7
Function : Drafting & Parallelization

Lap Former Machineries :

Model : Lap Former E-32
Year : 2006
Electrical : 3*400V. 50Hz, 6Bar
No. of Machine : 1
Function : To form the lap

Comber Machineries :

Model : Comber E-65
Year : 2006
No. of Machine : 5
Function : Combing, Removing various impurities.
Page 20 of 112

Simplex Machineries :

Model : Simplex FL100 & Simplex HY492C
Origin : Toyota(Japan) & Hong Yuan (China)
Year : 2006
No. of Machine : 9
Function : To form roving imparting necessary amount of twist

Ringframe Machineries :

Model : Ringframe LR 6/A
Origin : Laxmi (India)
Year : 2006
No. of Machine : 36
Function : To form yarn with the desired strength of twist

Autoconer Machineries :

Model : Autoconer 338 & Autoconer Orion M
Origin : Schlafhorst/Saurer (Japan) & Savio
Sensors : Uster Quantum 2 & Loepee
Year : 2006
Electrical : 3*400V, 50Hz, 6bar
No. of Machine : 12
Function : Cone winding

Heat Seating Machineries :

Model : XORELLA AG
Specification : LT-0/2000*4000
Year : 2006
Electrical : 40-45
0
C, 55min,
Relative Humidity : 65%
No. of Machine : 1
Function : Conditioning & Weighting

Page 21 of 112

CHAPTER FOUR CHAPTER FOUR CHAPTER FOUR CHAPTER FOUR

Raw Materials Raw Materials Raw Materials Raw Materials

Page 22 of 112

CHAPTER 04
RAW MATERIALS

Raw Cotton Parameters :

Model : CIS Cotton (Uzbekistan)
Brand Name : COTTONEX
Staple Length : 28~32mm
MIC Value : 3.3~4.9

Source of Raw Materials :
Required of Raw Materials are purchased by L/C
Price : 92 cents/lb

Raw Materials related Parameters :

Binding material used for bales : Steel wire

No of binder : 10

Bale size:
Height: 59 cm
Length: 95 cm
Width: 80 cm

Bale weight : 220 kg

Tare weight : 2.6 kg

Bale loading & unloading system : It is done by FORKLIFT.

Capacity of raw cotton godown : 12000 bales

Maximum maintain of raw cotton godown : 8,000

Bales used in per laydown : 75 bales

Bales consumption/day : 150 bales/day

Page 23 of 112

Contamination of Raw Materials :

Black cotton
Piece of cotton cloth
Color thread
Piece of polythene
Piece of white cloth
Piece of plastic
White thread
Polypropylene
Feather
Wooden piece
Bale covering cloth
Color cotton
Jute
Hair & Wool
Others

Processing of Cotton before Bale form :

Cotton fibre originated from seed, which is called seed cotton. In cotton plant several cotton
pot or ball produced. Cotton growing origins are USA, CIS countries, Egypt, Africa,
Australia, China and also India and Pakistan. In our country cotton is mainly imported from
huge cotton grower USA, CIS, Australia, Africa, Egypt etc. because cotton of India and
Pakistan fails to meet our demand from view of quality and quantity. During harvesting seed
cotton pots are collected from the plant which is known as picking of cotton. Picking can be
done manually and mechanically. Manual picking can ensure cotton pot selection,
segregation and collection separately. So manual picked cotton is less trashy but
collection/production is very low. Again in mechanical picking, production rate is very high
but have no choice. Big cotton growing countries like USA use mechanical picking which in
the other hand reduce cost of cotton. After picking seed cottons, fibers are separated from
seed by ginning machine for subsequent processing. Seedless cotton fibres are then
compressed to bales of around 500 lbs for easy shipment to users. Seed cotton process flow
and a typical bale size (95cm*59 cm*80 cm)is shown as below.In REEDISHA SPINNING
LTD. CIS(Uzbekistan) cotton is used.

Page 24 of 112

Spinning mill purchase those cotton bales under contract of some fibre property like fibre
length, fineness, strength, trash content etc. But modern spinning mills test all fibre
properties for each and every bale under Id. no. prior use taking representative samples of
about 4 ounces from both side of each bale. For this, thousands of bales need to be tested
within very short time where HVI has no alternatives. HVI i.e. High Volume Instrument
offers all possible fibre property tests at a very high speed.

95cm
80 cm
59 cm
Page 25 of 112

CHAPTER FIVE CHAPTER FIVE CHAPTER FIVE CHAPTER FIVE

Production Planning Sequences & Operations Production Planning Sequences & Operations Production Planning Sequences & Operations Production Planning Sequences & Operations

Page 26 of 112

CHAPTER 05
PRODUCTION PLANNING SEQUENCES & OPERATIONS

Production parameters & Description of production process :

1. Blow Room section :

Wastage percentage(max) : 4.0%
Production rate : 800kg/hr/line
Machine efficiency : 85%
Total production : 16,320 kg/machine/day

2. Carding section :

Production rate : 60 kg/hr
Production speed : 176m/min
Total production : 1368 kg/machin/day

3. Drawframe section :

Breaker Drawframe :
Total production : 4455 kg/machine/day

Finisher Drawframe :

4. Lap former section :

Production speed : 125 m/min
Page 27 of 112

5. Comber section :

Wastage percentage(max) : 13.5 %
Production speed : 430 nip/min

6. Simplex section :

Spindle speed : 950 rpm
TPI : 1.03

7. Ringframe section :

Spindle speed : 17000 rpm
TPI : 19.58

8. Autoconer section :

Winding speed : 1500 m/min

Description of production process :

1. 100% combed cotton (knit)
2. 100% carded cotton (knit)

Page 28 of 112

Flow chart for 100% combed cotton production process :

Flow chart for 100% carded cotton production process :

Blow Room
Carding
Breaker Drawing
Lap Former
Comber
Finisher Drawing
Simplex
Ringframe
Autocone
Blow Room
Carding
Breaker Drawing
Finisher Drawing
Simplex
Ringframe
Autocone
Page 29 of 112

Spinning plan for 20 ton per day production(30KH Ring yarn)

Spinning
process
Wastage
rate(%)
Required
Production
(Kg)
TPI Count
(Ne)
Speed No. of
Head /
Spindles
Machine
efficiency
Production
(kg/m/c/day)
No. of
machine
required
Actual
machine
required
Autocone
winding
0.6% 20,000 - 30 1550m/min 60 70% 1846 10.83 11
Ringframe
machine
2.0% 20,120 19.58 30 17,000rpm 1008 95% 599 33.59 34
Simplex
machine
0.6% 20,530 1.03 0.80 950rpm 120 80% 2391 8.59 9
Finisher
drawframe
0.5% 20,654 - 0.11 500m/min 1 96% 3712 5.56 6
Breaker
drawframe
0.5% 20,757 - 0.11 600m/min 1 96% 4455 4.66 5
Carding
machine
6.0% 22,862 - 0.104 176m/min
60kg/hr
1 95% 1368 15.25 16
Blowroom 4.0% 22,193 - - 800kg/hr/line 2 line 85% 16,320 1.36 2 line
Bale
management
--- 23,118 - - Per bale weight 220 kg 105.08 105

Production =
spndIc spccd 60No.o] Hcud24c]]ccnc
1PI368402.2046Count
or
spccd 601.09424c]]ccnc
8402.2046Count
or
spccd 60No.o] Hcud24c]]ccnc1.094
8402.2046Count
or spccJ 24 c.
Page 30 of 112

CHAPTER SIX CHAPTER SIX CHAPTER SIX CHAPTER SIX

Quality Assurance Quality Assurance Quality Assurance Quality Assurance System System System System

Page 31 of 112

CHAPTER 06
QUALITY ASSURANCE SYSTEM

Quality Control & Assurance System :

Bale Management :

The efficiency of production and the quality of the end product is determined by the
suitability and quality of the fibre input. It is the process of inventory control and
selection of fibre according to its properties and also to mix fibre homogeneously to
get consistent production and quality of yarn.

Basic Principle Bale Management :

Bale management refers to a choice of cotton bales according to the fibre
characteristics in order to achieve acceptable and economical processing conditions
and a constant yarn quality. The quality of yarn is primarily determined by the worst
bales. In this respect, the specific remarks should be maintained,
- Each individual bale contributes to the fibre blend and to a large extent, the
yarn properties. Therefore, the fibre characteristics of each individual bale have
to be checked.
- The final mix is only completed at the last passage of drawing. The best place,
therefore, to check the resulting fibre properties of a mix is at the finisher
sliver.
- The influence of the individual fibre properties of a mix on the yarn properties
is not fully known because there are many contributing factors.
- With bale management the random uncontrolled variation of the bale mix can
be improved for this reason the variation of each fibre characteristic in every
bale mix and in the blen material as well as the variation in the yarn properties
are to be carefully monitored.

Page 32 of 112

Quality Assurance Department : (Reserved & New Lot Cotton Calculation, CIS DAWEOO)

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o
.

o
f

B
a
l
e

U
s
e
a
b
l
e

U
s
e
a
b
l
e

T
o
t
a
l

U
s
e
a
b
l
e

U
s
e
d

B
a
l
e

S
t
o
c
k

B
a
l
e

A
c
t
u
a
l

B
a
l
e
/

L
a
y

P
r
e
s
e
n
t

B
a
l
e
/

L
a
y

Lot 50/10 59/10 60/10 59/10 60/10 50/10 59/10 60/10 59/10 60/10
3.2 Residue Residue
3.3 Z 7.0-7.4 7.2
3.4 A 7.5-7.8 7.65
3.5 B 7.9-8.2 8.05 3 19 1 23 22 1 0.06
3.6 C 8.3-8.6 8.45 2 69 12 83 50 33 2.10 2
3.7 D 8.7-9.0 8.85 22 200 32 254 180 74 4.70 5
3.8 64 172 12 248 144 104 6.60 4 E 9.1-9.4 9.25 13 428 82 523 360 163 10.35 10
3.9 31 119 18 168 108 60 3.81 3 F 9.5-9.8 9.65 24 548 180 752 504 248 15.75 15
4.0 11 126 16 153 108 45 2.86 3 G 9.9-10.2 10.05 48 372 340 760 540 220 13.97 15
4.1 16 145 22 183 144 39 2.48 4 H 10.3-10.6 10.45 48 157 481 686 504 182 11.59 13
4.2 4 250 40 294 230 64 4.06 7 I 10.7-11.0 10.85 34 30 414 478 324 154 9.78 9
4.3 5 358 46 409 324 85 5.40 9 J 11.1-11.4 11.25 13 4 232 249 180 69 4.38 4
4.4 1 342 74 417 324 93 5.91 9 K 11.5-11.8 11.65 6 6 61 73 36 37 2.35 2
4.5 1 185 194 380 310 70 4.45 8 L 11.9-12.2 12.05
4.6 18 75 334 427 346 81 5.14 9 M 12.3-12.6 12.45
4.7 18 27 346 391 302 89 5.65 9 N 12.7-13.0 12.85
4.8 30 15 347 392 288 104 6.60 8 O 13.1-13.4 13.25
4.9 14 19 386 419 72 347 22.04 2 P 13.5-13.8 13.65
5.0 Q 13.9-14.2 14.05
5.1 R 14.3-14.6 14.45
5.2 S 14.7-15.0 14.85
5.3 T 15.1-15.4 15.25
Total 213 1833 1835 3881 2700 1181 75.0 75.0 213 1833 1835 3881 2700 1181 75.0 75.0
Average MIC 4.503 4.412 Average +b 10.02 10.01
CV% 6.42 CV% 7.04

Lot T_Bale Bale Par% T_Laydown B.N. Out
59/10 1833 39.01 52.01

46.99
4.9 300
60/10 1478 31.46 41.94
Before 213 4.53 6.04

TOTAL 3524 75.00 100%

Page 33 of 112

BALE MANAGEMENT PROCEDURE :

Reedisha Spinning Limited
Valuka, Mymensingh

Quality Assurance Department

Date : 01-08-2010 Cotton Lot : (59/10+60/10) CIS Daewoo
After Lay Down = 36 Yarn Lot : Comb 119/10
Lot Normal Card 228/10
Lot Semi Comb 230/10

S.
N.
Grade of +b +B Grade of +b +B Grade of +b +B Avg.
+B
Remarks
01 E 9.25 G 10.05 I 10.85 10.05
02 G 10.05 F 9.65 H 10.45 10.05 Lot Bale
03 D 8.85 I 10.85 G 10.05 9.92 59/10 38
04 I 10.85 Pneu.+Sliver 10.013 E 9.25 10.04 60/10 33
05 F 9.65 G 10.05 H 10.45 10.05 56/10 4
06 G 10.05 J 11.25 D 8.85 10.05 57/10
07 I 10.85 E 10.25 F 9.65 9.92 Total 75.00
08 E 9.25 Pneu.+Sliver 10.013 I 10.85 10.04
09 H 10.45 F 9.65 G 10.05 10.05
10 K 11.65 C 8.45 F 9.65 9.92 Grade of +b
Distribution 11 G 10.05 H 10.45 E 9.25 9.92
12 F 9.65 Pneu.+Sliver 10.013 H 10.45 10.04 A
13 E 9.25 J 11.25 F 9.65 10.05 MIC
Distribution
B 0
14 H 10.45 G 10.05 E 9.25 9.92 C 2
15 F 9.65 H 10.45 G 10.05 10.05 3.8 4 D 5
16 H 10.45 Pneu.+Sliver 10.013 F 9.65 10.04 3.9 3 E 10
17 E 9.25 G 10.05 I 10.85 10.05 4.0 3 F 15
18 C 8.45 J 11.25 H 10.45 10.05 4.1 4 G 15
19 G 10.05 D 8.85 I 10.85 9.92 4.2 7 H 13
20 F 9.65 Pneu.+Sliver 10.013 H 10.45 10.04 4.3 9 I 9
21 G 10.05 H 10.45 F 9.65 10.05 4.4 9 J 4
22 D 8.85 F 9.65 K 11.65 10.05 4.5 8 K 2
23 I 10.85 G 10.05 E 9.25 10.05 4.6 9 L
24 H 10.45 Pneu.+Sliver 10.013 F 9.65 10.04 4.7 9 M
25 J 11.25 D 9.85 G 10.05 10.05 4.8 8 N
26 I 10.85 F 9.65 E 9.25 9.92 4.9 2 O
27 G 10.05 H 10.45 F 9.65 10.05 5.0 P
Average MIC 10.006 10.027 10.006 10.013 Total 75 75
Standard Deviation 0.7792 0.6882 0.6687 0.0581 Avg. MIC 4.412
CV% 7.79 6.86 6.68 0.58 CV% = 7.04

CV% = 7.04%

___________ __________ ________________
Prepared by (Q.C.O.) Manager (Q.C.D.)
Page 34 of 112

Raw Cotton Colour Grading in HVT :
S/
N
Colour Grade (Rd)
S
y
m
b
o
l

L
e
a
f

Colour Code (+b)

W
h
i
t
e

C
.

C
.

L
i
g
h
t

S
p
o
t
t
e
d

C
.

C
.

S
p
o
t
t
e
d

C
.

C
.

T
i
n
g
e
d

C
.

C
.

Y
e
l
l
o
w

S
t
a
i
n
e
d

C
.

C
.

01 Good Middling GM 1 11 12 13 -- --
02 Strict Middling SM 2 21 22 23 24 25
03 Middling M 3 31 32 33 34 35
04 Strict Low Middling SLM 4 41 42 43 44 --
05 Low Middling LM 5 51 52 53 54 --
06 Strict Good Ordinary SGO 6 61 62 63 -- --
07 Good Ordinary GO 7 71 72 -- -- --
08 Blow Colour Grade 8 81 82 83 84 85

Raw Cotton Colour Grade Value :

Serial Range of colour grade value Colour grade
01 < 7.4 Z
02 7.5 7.8 A
03 7.9 8.2 B
04 8.3 8.6 C
05 8.7 9.0 D
06 9.1 9.4 E
07 9.5 9.8 F
08 9.9 10.2 G
09 10.3 10.6 H
10 10.7 11.0 I
11 11.1 11.4 J
12 11.5 11.8 K
13 11.9 12.2 L
14 12.3 12.6 M
15 12.7 13.0 N
16 13.1 13.4 O
17 13.5 13.8 P
18 13.9 14.2 Q
19 14.3 14.6 R
20 14.7 15.0 S
21 15.1 15.4 T

Page 35 of 112

List of Testing & Quality Control Equipments :

S/N Machines Name Model No. Manufacturer
01 High Volume Instrument (HVI) HVI Spectrum Switzerland
02 Advance Fibre Information System (AFIS) AFIS Pro Switzerland
03 Uster Auto Sorter 5 Switzerland
04 Electro Magnetic Strength Tester MAG-Y0251 India
05 Electronic Twist Tester Germany
06 WIRA Yarn Count Tester 075306 Italy
07 Finisher Wrapping Tester MAG-F0701 India
08 Sliver Roving Reel England
09 Electro Yarn Reel England
10 Hand Held Moisture Meter England
11 MAG Yarn Appearance Board Winder MAG-Y0801 India
12 Electronic Weight Balance (For Package Weight) KERN TB England
13 Electronic Weight Balance (For Sliver Weight) ALT310-4 England
14 Heat Setting machine XORALLA AG

USTER HVI Spectrum(Quality Assurance Machine):

1. Name of the equipment : USTER High Volume Instrument (Version :
Spectrum)
2. Objectives: To measure MIC, Maturity, SCI, Length, Amt, Uniformity,
Strength, Short Fibre Index, Elongation, Moisture, Rd, +b, Color grade, Trash
Content, Trash Area, Trash Grade, UV.
3. Testing type:
(i) System testing : Length, Moisture, maturity, SCI, Rd, +b, length
uniformity, SFI, strength, elongation, micronaire, trash and color
determined together
(ii) Module testing :
Length & Strength module
Micronaire module
Color & Trash module
4. Test parameters:
(A) Main menu :
System testing
Module testing
Calibration
Data manager
Status
Man-made fibre test
Diagnostics
Page 36 of 112

(B) Quality parameter :
ICC (International Cotton Calibration) mode
Fibre length (2.5% span length, 50% span length in
mm or inch)
Length uniformity (Uniformity Ratio)& SFI
Strength & Elongation

HVI (High Volume Instrument) mode
Fibre length (Upper Half Mean Length, Mean
length in mm or inch)
Length uniformity (Uniformity Ratio)& SFI
Strength & Elongation
5. Operating procedure:
Switch on the power of the machine.
Calibrate the color, MIC, length and trash.
At first mic of the fibre sample is carried out followed by the
color and length-strength test.
The print-out of test results can be obtained.
6. Report type:
HVI Quality Report
Results of each tested sample
Summary of the results with statistics
Graphical presentation of each and every parameter

7. Inspection procedure method:
Visual inspection of the printed individual and summary test
results.
Segregation of the raw cotton bales and reject the below standard
bales.
Bale management is carried out with BIAS from these results.

8. Details about three modules:

(A) Micronaire (MIC) module:
Working Principle Air flow method
Fibre thickness, Inter space, Air pass, MIC, Fineness
Sample weight 8.511.5 gm
Application range of MIC 2.07.0
Micronaire: Micronaire is the measure of fibre fineness and
maturity. An airflow instrument is used to measure the air
permeability of a constant mass of cotton fibres compressed to a
fixed volume. The rate of airflow represents fibre fineness as per
Page 37 of 112

previous calibration and expressed in terms of Micronaire i.e. per
inch fibre weight in microgram [1g=10
-6
gm].
Fibre maturity: The fibre indeed a hollow pipe like material where
the degree of the cell wall thickness is expressed in terms of fibre
maturity.
The table below can be used as a guidance in interpreting
micronaire and maturity measurement :

+Fibre fineness (g / // / ) Fibre Maturity (Maturity
Ratio)
below 3.3 Very fine below 0.7 Uncommon
3.4-4.3 Fine 0.7-0.8 Immature
4.4-5.0 Average 0.8-1.0 Mature
5.1-5.8 Coarse above 1 Very mature

(B) Color & Trash module:
Working principle Electro-optical method
Color grade is determined by the combination of Rd and +b.
Rd
Expresses degree of brightness
Rd, Brightness
Application range of Rd 35%90%
+b
Expresses degree of yellowness or degree of pigmentation
+b, more white cotton
Application range of +b 4.018.0
Leaf grade
Trash is expressed by Leaf grade or Trash code
Application range of leaf grade 1.07.0
Measure of color This module offers some light source to expose
over the cotton sample that placed on the color tray/window. What
happened is the exposed light partially absorbed by the cottons and
the rest subjected to reflection. Light absorption results the degree
of pigments in cotton sample i.e. yellowness (+b) and reflectance
(Rd) measured from the light reflection from cotton sample which
sensed by a video camera. The HVI Rd reading indicates how bright
or dull a sample is and the +b indicates the degree of color
pigmentation. A three digit color code is thus determined by plotting
the values on the Nickerson-Hunter cotton colorimeter diagram and
locating the point at which the Rd and +b values intersect. Each
grade area in the diagram aside is subdivided into quadrants to
denote small color differences.
Page 38 of 112

The color of cotton fibres can be affected by rainfall, freezes, insects
and fungi, and by staining through contact with soil, grass or the
cotton plants leaf. Excessive Moisture and temperature levels can
also affect color deterioration while cotton is being stored.

(C) Length & Strength module:

Working Principle
For length Photo-electric cell or Electro-optical
method
For strengthPneumatic or Mechanical break
Fibro-comb and Fibro-sampler are used to prepare sample. A test
sample is prepared with Fibro-comb by Fibro-sampler.
Length measurement Fibre length and length distribution
(Uniformity) measured through light scanning prior strength
measurement. HVI tests fibre length in terms of span length by
geometrical analysis of fibre array (orderly arrangement). Here 2.5%
Span Length (S
2.5%
) is very close to classers staple length. It also
tests 50% Span Length (S
50%
) and Uniformity Ratio (UR) to evaluate
length distribution of fibre in ICC mode. In HVI mode respective
terms are Upper Half Mean Length (UHML), Mean Length (ML)
and Uniformity Index (UI).
UR = 1
0
0
1
0
0
1
0
0
1
0
0
L
e
n
g
t
h
L
e
n
g
t
h
L
e
n
g
t
h
L
e
n
g
t
h
S
p
a
n
S
p
a
n
S
p
a
n
S
p
a
n
2
.
5
%
2
.
5
%
2
.
5
%
2
.
5
%
L
e
n
g
t
h
L
e
n
g
t
h
L
e
n
g
t
h
L
e
n
g
t
h
S
p
a
n
S
p
a
n
S
p
a
n
S
p
a
n
5
0
%
5
0
%
5
0
%
5
0
%

UI = 1
0
0
1
0
0
1
0
0
1
0
0
U
H
M
L
U
H
M
L
U
H
M
L
U
H
M
L
M
L
M
L
M
L
M
L

Fibre length and uniformity affects yarn strength, evenness and the
efficiency of the spinning process. Some USDA (United States
Department of Agriculture)cotton grades are given as under :

Upper Half Mean Length Uniformity Index
Below 0.99 Short below 77 Very low
0.99 ~ 1.10 Medium 77 ~ 79 Low
1.11 ~ 1.26 Long 80 ~ 82 Average
above 1.26 Extra long 83 ~ 85 High
above 85 Very high

Fibre length and uniformity is also related to short fibre (< )
content. Cotton with a low uniformity index is likely to have a high
percentage of
Page 39 of 112

short fibres. It is in HVI expressed as Short Fibre Index (SFI) and
can be defined as follows:
SFI = 122.56 (12.55 UHML) (1.22 UI)
Strength measurement Strength module is offered the very same
test sample beard gripped with Fibro-comb by one end. A moveable
clamp grips the sample fibre beard at distant opposite end and
moves until break just after length test. Measurement of fibre
strength is reported in terms of gm/tex. A tex is equal to the weight
in grams of 1000 meters of fibre. Therefore the strength reported is
the force in grams required to break a bundle of fibres of one tex
unit in size. The bundle fibre of course elongates to some extent
prior breakage. An elongation percentage also measured from initial
clamp distance (L1) i.e. over final clamp distance (L2) prior fibre
breakage during strength measurement.
Elongation% = 1
0
0
1
0
0
1
0
0
1
0
0
L
1
L
1
L
1
L
1
L
1
L
1
L
1
L
1
- -- - L
2
L
2
L
2
L
2

The following tabulation can be used as guideline in inter fibre
strength & elongation measurement

Fibre strength
( gauge strength in gm/tex)
Fibre elongation
(%)
17 & below Very weak Below 5.0 Very low
18 ~ 21 Weak 5.0 ~ 5.8 Low
22 ~ 25 Average 5.9 ~ 6.7 Average
26 ~ 29 Strong 6.7 ~ 7.6 High
30 & above Very strong Above 7.6 Very high

In ICC mode fibre strength is accurate, on the other hand in HVI
mode strength is 25% more than the actual.

Page 40 of 112

USTER AFIS PRO(Quality Assurance Machine):

Objectives: To measure following fibre properties-
Nep (Cnt/gm)
Nep (m)
SCN (Cnt/gm)
SCN (m)
L(w) (mm)
L(w) (%cv)
SFC(w) (mm)
SFC(w) (%<12.7)
UQL(w) (mm)
L(n) (mm)
L(n) (%cv)
SFC(n) (%<12.7)
IFC (%)
Maturity Ratio

Technical data:
Its Application ranges are as below,
Number of fibres : maximum-10000 & default- 3000
Sample weight : 0.5 gm
Sample length : 30

Modules Testing :
Multidata testing module : UQL, SFC, Fineness, IFC, M.R.,
Neps, SCN, Dust, Trash, VFM
Neps module : Neps, SCN
Length & Dia module : UQL, SFC, IFC,M.R., Fineness
Trash module : Dust, Trash, VFM

Operating procedure :
Switch on the power of the m/c.
Select measurement from the main menu.
Select module
Select identifier
Select sample type
Input filename
Press start button.
Feed the prepared samples in the feed nozzle
The print out of the tested results could be obtained after the
test.
Page 41 of 112

Report type :
AFIS quality report
Results of each tested sample
Summary of the results with statistics
Graphical representation of each and every parameters e.g.
histogram etc.

Inspection :
Visual inspection of the printed individual and summary test
results.
Raw cotton selection is done from the measured neps, SFC,
Maturity Ratio etc.
Test results help to select proper process parameter.

USTER TESTER-5(Quality Assurance Machine):

Name of the Equipment : Uster tester-5 (UT-5)
Objectives : To test below the parameters,
Thin -50% /km
Thick +50% /km
Neps +200% /km
U%
CV
m

CV
m
3m
CV
m
10m
Hairiness

Number of Slots : For Slivers :1 Slot
For Roving : 1 Slot
For Yarn : 2 Slot

Measuring principle :
Electronic Capacitance Method.

Testing speed:
For yarn 400 m/min
For roving 50 m/min
For sliver 50 m/min
Page 42 of 112

Testing results :
Mass variation (U%, CV%)
Imperfections (Thin/km, Thick/km, Neps/km)
Hairiness
Periodic faults of machine parts
Fabric Construction.

Quality parameters :
(i) Unevenness (U
m
%, CV
m
% at different cut length)
Cut length For sliver: 20mm
For roving: 12mm
For yarn: 8mm
(ii) Imperfections
Thin place/km : at -30%,-40%,-50%&-60% sensitivity
Thick place /km : at +35%,+50%,+70%&+100% sensitivity
Neps/km : at +140%,+200%,+280%&+400% sensitivity
(iii) Hairiness (at different cut length and CV% of hairiness)
(iv) Periodic faults (mechanical)

Operating System :
Switch on the power of the machine.
Select Test Program and then press recall button.
Write the changeable parameter through keyboard and start
the test with start button.
Feed the test sample manually through the proper guide. No
interruption is valid during test period.
The printer automatically prints a report along with diagrams
just after a test is being completed.

Report type :
Single / Overall values
Diagram (mass)
Diagram (hairiness)
Spectrogram (mass)
Spectrogram (hairiness)
Histogram
Variance-Length curve

Page 43 of 112

ELECTRONIC TWIST TESTER:

Machine specification :
Sample clamp
Load adjusting cursor
Scale
Level adjusting screw
Plum bob
Change lever of untwisting direction both S and Z twist.
Sample elongates and shrinks scale
Handle for move the revolve chuck.

Operating procedure :
Set the reference length (e.g. 10 cm) in the twist tester.
Adjust deflecting needle deflection 0 degree as weight free.
Select proper weight from weight table.
Adjust deflecting needle again to the centre of the graduated
scale (i.e. deflection 0 degree) while attaching the sample
yarn with rear end by fixed and rotating jaw.
Rotate the wheel against the twist in the yarn allowing the
deflection needle to move not or more than three graduations.
Rotate the wheel until deflection angle becomes 0 degree
again.

Report type : Calculation of twist per inch or cm from display counter

Inspection : Check the twist variation and take necessary action.

Page 44 of 112

Waste percentage calculation in Blowroom & Carding :

m/c
no
Initial
Reading(Kg)
Final
Reading(Kg)
Actual
Production
1 334 439 105
2 333 438 105
3 329 434 105
4 315 420 105
5 306 411 105
6 298 404 106
7 297 403 106
8 329 428 99
9 330 429 99
10 327 426 99
11 330 429 99
12 284 370 86
13 151 183 32
14 285 378 93
15 281 374 93
16 282 375 93
17 281 371 93
18 309 414 90
Total 1725

Wastage Produce in Blow Room =45.85 Kg
Wastage Produce in Carding =130.60Kg

Total =176.45Kg

Total Raw Cotton Production=1725+176.45
=1901.45 Kg

Percentage of wastage in Blowroom =
45.85100
1901.45
= 2.41%

Percentage of wastage in Carding =
130.6100
1901.45
= 6.87%

Page 45 of 112

End Breakage Study :

Start time 12.24pm
Ring frame no 21
Stop time 2:50 pm
Lot no 06/07(A)
Total time observed(min) 146
Bobbin wt 43 gm
TPI 23.39
Traveller no 5/0
Avg spindle speed(rpm) 18500
Temperature 29 C

Patern
position
Length(
%)
Spee
d
patte
rn
speed
(rpm)
Avg
speed
No of end
breaks/posi
tion
Total no
oftends
breaks/posit
ion
Tota
l end
brea
ks
Ends
break
1000
spi/h
0 0-10% 18000 20
1 10-20% 18000 7
2 20-30% 18500 3
3 30-40% 19000 3
4 40-50% 19000 4 55 19
5 50-60% 19000 18500 3
6 60-70% 19000 4
7 70-80% 19000 2
8 80-90% 19000 6
9 90-100% 18100 3

Page 46 of 112

Weight increase in percentage after conditioning :

Yarn count : 26/1 KH
Yarn Lot : 09/09
Steaming Temp : 70
0
C
Steaming Time : 45 min

Cone no. Weight
W1(kg)
Weight
w2(kg)
Weight diff
Wx(kg)
Weight
increase in
%
1 2.11 2.15 0.04 1.89%
2 2.10 2.14 0.04 1.9%
3 2.10 2.14 0.04 1.9%
4 2.11 2.14 0.03 1.4%
5 2.12 2.16 0.04 1.8%
6 2.11 2.14 0.03 1.4%
7 2.10 2.14 0.04 1.9%
8 2.11 2.14 0.03 1.4%
9 2.10 2.14 0.04 1.9%
10 2.11 2.15 0.04 1.8%
11 2.10 2.14 0.04 1.9%
12 2.11 2.15 0.04 1.8%
13 2.12 2.16 0.04 1.8%
14 2.09 2.13 0.04 1.9%
15 2.09 2.13 0.04 1.9%
16 2.10 2.14 0.04 1.9%
17 2.09 2.12 0.03 1.4%
18 2.10 2.14 0.04 1.9%
19 2.10 2.13 0.03 1.42%
20 2.11 2.14 0.03 1.45

# Yarn Weight W1= mlt before conditioning
# Yarn Weight W2= mlt after conditioning
# Yarn Weight Increase Wx = W2-W1(MR)

Page 47 of 112

Snap Study in a Particular day :

Monitoring Date : 14-08-2010
Monitoring Time Start : 10.30 am

Machine type No. of m/c Stoppage time Causes
Carding 5 10:40 Maintenance
Carding 11 10:40 Maintenance
Carding 16 10:40 Cleaning
Breaker D/F 2 10:45 Maintenance
Lap former 3 10:45 Lap change
Comber 1 10:50 Operator short
Comber 8 10:52 Can change
Finisher D/F 4 10:58 Maintenance
Simplex 9 11:00 Maintenance
Simplex 8 11:00 Back side cleaning
Simplex 6 11:00 Roving break
Simplex 2 11:00 Sliver short
Finisher D/F 4 11:02 Opening & cleaning
Ring 14 11:02 Maintenance
Autocone 5 11:06 Maintenance
Autocone 2 11:07 Uster Quantum Jam
Autocone 8(Drum-12) 11:08 Uster Quantum Jam

Page 48 of 112

Material Flow Processes Machineries Quality Parameters :

1. Blowroom Quality Control & Assurance :

Blowroom machine parameters :
Blowroom line : 2
Bale lay down : Double sided
Actual bale lay per lay down : 75
Total spaces per lay down : 81
Total lay down time : 16-17 hours
Bale management procedure : According to MIC value & +b
Blowroom wastage name : Dropping-2
Blowroom wastage percentage : 3-6%
Wastage by metal detector : 200-500gm per detection
Blowroom machine efficiency : 85%

Blowroom various settings points :

(A) Uniclean :
Cleaning intensity (C.I.) = 0.3-0.4
Relative Wastage Ratio (R.W.) = 0.6-0.8

(B) Unimix :
Production level = 85=86
Degree of opening = 0.3

(C) Uniflex :
Cleaning intensity (C.I.) = 0.2
Relative Wastage Ratio (R.W.) = 0.4-0.6

(D) Cotton Staple Length : 1
1
/
8
inch

(E) Jossi Settings(Foreign Fibre Detection) :
Particle size = 140-150
Colour grade = 0-4

Page 49 of 112

2. Carding Quality Control & Assurance :

Carding Machine Parts Parameters :
Sliver Weight : 80.0 grains/yards
Production (in weight) : 60 kg/hr
Production (in length)/ Delivery : 176 m/min
Sliver Count : 0.104 Ne
Total Draft (Actual) : 100-150
Carding Wastage Percentage : Flat Stripping/Dropping-1 = 1.5-5.5%
Neps Removal Efficiency : 60-70%
Machine Efficiency : 95%
Input : Mat (Chute feeding)
Output : Carded Sliver
Delivery Can Size : 1200 1000 mm
Delivery Can Capacity : 7500 meter
Delivery Can Weight : 42.5 kg
Opening Roll Speed (Chute) : 838 rpm
Feed Roller Speed : 17-30 rpm
Cylinder Speed : 855 rpm
Flats Speed : 0.37 m/min (Depends on Cylinder)
Licker in Speed : 1452 rpm
Creep Speed : 15 m/min
Deliver Roller Speed : 17-30 rpm
Doffer Speed : Depends on Delivery
Stripping Roller Speed : Depends on Delivery
Squeezing Roller Speed : Depends on Delivery
Cleaning Roller Speed : Depends on Delivery
Disc Roller Speed : Depends on Delivery
Diameter of Cylinder : 840 mm
Diameter of Doffer : 680 mm
Diameter of Licker in : 260 mm
Diameter of Opening Roller : 292 mm
Diameter of Feed Roller : 172 mm
Diameter of Stripping Roller : 118 mm
Diameter of Delivery Roller : 156 mm
Diameter of Squeezing Roller : 80 mm
Diameter of Cleaning Roller : 100 mm
Diameter of Disc Roller : 72 mm
No. of Stationery : 3 (One Stationery placed two flat)
No. of Flat in Whole circumference : 79
No. of Motes Knife : 4
No. of Waste Plate : 3
Page 50 of 112

Gauge Settings of Carding :

S/N Machine Points Distance
01 Feed Roller to Feed Plate 0.1mm
02 Feed Roller to Licker In 0.9mm
03 Licker In to Cylinder 0.25mm
04 Cylinder to Bottom Plate 1.00mm, 1.20mm
05 Cylinder to Bottom Stationery 0.45mm
06 Cylinder to Bottom Waste Plate 1.50mm
07 Cylinder to Bottom Motes Knife 0.40mm
08 Cylinder to Top Stationery 0.40mm
09 Cylinder to Top Waste Plate 1.50mm
10 Cylinder to Top Motes Knife 0.40mm
11 Cylinder to Top Plate 1.10mm
12 Cylinder to Flat (Back, Middle, Front) 0.225mm, 0.2mm, 0.125mm
13 Cylinder to Top Plate 1.00mm
14 Cylinder to Motes Knife 0.9mm
15 Cylinder to Waste Plate 1.40mm
16 Cylinder to Motes Knife 0.35mm
17 Cylinder to Stationery 0.35mm
18 Cylinder to Bottom Plate 1.00mm
19 Cylinder to Doffer 0.2mm
20 Doffer to Stripping 0.15mm
21 Stripping to Cross Roller 0.15mm
22 Cross Roller to Cross Roller 0.15mm

Page 51 of 112

3. Drawframe Quality Control & Assurance :

Breaker Drawframe Machine Parts Parameters :

Production (in length)/ Delivery : 615 m/min
Total Draft : 1-1.5
Doubling : 6:1 (Card) & 5:1 (Comb)
Drafting System : Pneumatic 4 Over 3
B/D Wastage Percentage : Sliver 0.5%
Input : Carded Sliver
Output : Drawn Sliver
Delivery Can Size : 1200 600mm
Delivery Can Capacity : 4500 meter
Delivery Can Weight : 28.0-29.0 Kg
Diameter of Top Front Roller : 38mm
Diameter of Top 2
nd
& 3
rd
Roller : 38mm & 38mm
Diameter of Top Back Roller : 38mm
Diameter of Bottom Front Roller : 40mm
Diameter of Bottom Middle Roller : 35mm
Diameter of Bottom Back Roller : 35mm
Diameter of Creel Roller : 100mm
Diameter of Condenser(Inside) : 4.6mm
Gauge Settings Front to Middle : 40mm
Gauge Settings Middle to Back : 44mm
Quartz Length : 157mm
Sensors Present : Delivery Sensor, Can Change Sensor
Pneumatic Pressure : 140 bar (Card Process) &
120 bar (Combed Process)
Cot Roller Hardness : 70
0
Shore (comb) & 80
0
Shore (card)

Page 52 of 112

Finisher Drawframe Machine Parts Parameters :

Production (in length) / Delivery : 500 m/min
Total Draft : 1-1.5
Doubling : 8:1 (Card & Combed Process)
Drafting System : Pneumatic 4 over 3
Auto Leveling System : G&G Autoleveler
F/D Wastage Percentage : Sliver 0.25%
Input : Sliver (Carded & Combed)
Output : Drawn Sliver
Delivery Can Size : 1100 500mm
Delivery Can Capacity : 3300mm
Delivery Can Weight : 21.0-21.5 Kg
Diameter of Top Front Roller : 38mm
Diameter of Top 2
nd
& 3
rd
Roller : 38mm
Diameter of Top Back Roller : 38mm
Diameter of Bottom Front Roller : 40mm
Diameter of Bottom Middle & Back : 35mm
Diameter of Condenser (inside) : 4.6mm
Diameter of Creel Roller : 101mm
Gauge Settings Front to Middle r/r : 39mm
Gauge Settings Middle to Back r/r : 44mm
Quartz Length : 157mm
Sensors Present : Delivery Sensor, Can Changer Sensor
Pneumatic Pressure : 140 bar (card process)
120 bar (comb process)
Cot Roller Hardness : 70
0
shore (comb) & 80
0
shore (card)

Page 53 of 112

4. Lap Former Quality Control & Assurance :

Lap former machine parameters :

Lap Weight : 20 kg or 80gm/meter
Lap Width : 300mm
Production (in length) / Delivery : 125 m/min
Lap Count : 0.0074 Ne
Doubling : 26:1
Doubling Capacity : 28:1
Drafting System : 3 over 3
Input : B/D Sliver
Output : Lap
Diameter of Front Roller : 39mm
Diameter of Back Roller : 32mm
Maximum Diameter of Lap : 650mm

5. Comber Quality Control & Assurance :

Comber machine parameters :

Delivery Speed : 430 nip/min
Feed/nip : 4.7mm
Total Draft : 9.12 - 25.12
Doubling : 8:1
Drafting System : 3 over 3
Batt Feed Tension : 9.1%
Comber Wastage Percentage : Noil 8.5-13.5%
Input : Lap
Output : Combed Sliver
Delivery Can size : 1200mm 600mm
Delivery can capacity : 4500 m
Diameter of Top Front detaching : 24.5mm
Diameter of Top Back detaching : 24.5mm
Dia of Bottom Front detaching : 25mm
Dia of Bottom Back detaching : 25mm
Page 54 of 112

Dia of Front draw box roller : 35mm
Dia of Middle draw box roller : 27mm
Dia of Back draw box roller : 27mm
Roller gauge of Front to Middle : 42mm
Roller gauge of Middle to Back : 50mm
Roller Hardness : Front 76 degree shore
Middle 80 degree shore
Back 80 degree shore

6. Simplex Quality Control & Assurance :

Simplex machine parameters :

Count range : 0.8~1.01 Ne
TPI range : 1.02-1.08
Twist multiplier : 0.9-1.2
Spindle speed : 850-900rpm
No. of spindle/machine : 120
Drafting system : Pneumafil 4 over 4
Wastage name : Sliver
Wastage percentage : 1%
Input of Simplex : Sliver
Output of Simplex : Roving
Length of Bobbin : 2000 meter
Weight of Bobbin : 2.5 lb
Colour of bobbin : blue, orange black, white, red, brown, yellow
Stop Motion : Auto stop motion, Problem indicating lamp
Sensor used : Cover open, Roving breakage, Roving breakage
in bobbin, Sliver breakage
Diameter of Front top roller : 28mm
Diameter of 2
nd
& 3
rd
top roller : 28mm, 25mm
Diameter of Back top roller : 28mm
Diameter of Front bottom roller : 28.5mm
Diameter of 2
nd
& 3
rd
bottom roller : 28.5mm
Diameter of Back bottom roller : 28.5mm
Roller settings of Front to 2
nd
roller : 37.5mm
Roller settings of 2
nd
to 3
rd
roller : 48.5mm
Roller settings of 3
rd
to back roller : 48.5mm
Creadel type : OH 514
Dimension of Spacer : Black(4.5mm), Baise(5.4mm), Gray(6.5mm)
Page 55 of 112

7. Ringframe Quality Control & Assurance :

Ringframe machine parameters :

Count range : 16-60 Ne
TPI range : 144-27.72
Twist multiplier : 3.6(+-0.1)
Spindle speed : 13,000-17,000 rpm
No. of spindle/machine : 1008
Drafting system : Pneumafil 3 over 3
Wastage name : Bonda, Pneumafil
Wastage percentage : 2%
Input of Ringframe : Roving
Output of Ringframe : Yarn
Weight of cop : Average 40gm
Colour of bobbin : Brown, yellow, red, blue, black, baise, green,
orange, violet, white, ash
Auto Motion : Auto stop motion, Auto doffing
Diameter of Front top roller : 30mm
Diameter of Middle top roller : 25mm
Diameter of Back top roller : 30mm
Diameter of Front bottom roller : 27mm
Diameter of Middle bottom roller : 27mm
Diameter of Back bottom roller : 27mm
Roller settings of Front to Middle : 42.5mm
Roller settings of Middle to Back : 60mm
Creadel type : OH 2024
Specification of Apron : Top = (38.1*30*1.05)mm
Bottom = (80.5*32*1.05)mm
Roller Pressure :

Color Front Middle Back
Green 14 kg 10 kg 12 kg
Red 18 kg 14 kg 16 kg
Black 10 kg 10 kg 10 kg

Traveller No :

Color Front Middle Back
Green 14 kg 10 kg 12 kg
Red 18 kg 14 kg 16 kg
Black 10 kg 10 kg 10 kg

Page 56 of 112

8. Autocone Quality Control & Assurance :

Autocone Machine parameters :

Count range : 16-60 Ne
No of drum/machine : 60
Wastage name : Hard waste
Wastage percentage : 0.6%
Sensor Used : Uster Quantum-2 & LOEPEE
No of machines : Schlafhorst Autoconer 338 (8 m/c)
Savio TIPO Autoconer (4 m/c)
Important parameters :

PARAMETERS DIMENSION/VALUES
Winding Position 60
Drum Dia 100 mm
Tensioning Device Tensioner
Yarn Speed 1350 m/min
Splicing System Auto
Finished Package Wt. 2070 gm
Yarn Length 126503 m
Electronic Clearer Uster Quantum 2
Yarn Strength 250 CN
Package Hardness Std.
Vegetable filter Without cotton, any type of fibre
Splicing zoned Under measuring system
Magazine 9 bobbin feed
Measuring head Ray type
Cutter Ceramic
Traverse length 6 inch
Drum type 2-2.5 turns

Uster Quantum Data-2 :
For N/S/L

Page 57 of 112

% Cm
N 340
S 160 1.6
L 32 22
H
1
140 3.0
H
2
125 3.5
H
3
100 4
H
4
60 8
H
5
30 32
H
6
28 40

C/CC Yarn count Deviation
C
P
+12% CC
p
+14%
C
m
-12% CC
m
-14%
C 2.m CC-5m

For Thin

% Cm
T 30 16
H
1
40 3
H
2
36 5
H
3
34 7
H
4
30 12
H
5
26 40
H
6
0 0

For FD

% Cm
FD 6 0.5cm
H
1
15 0.1
H
2
5 1.4
H
3
0 0
H
4
0 0
H
5
0 0
H
6
0 0

Page 58 of 112

Classimat System & EYC :

Classimat defect classification:

Fault Cross-sectional size

+400

+250

+150

+100

+45%
-30%

-45%

-75%

0.1 1 2 4 8 32 CM

A4 B4 C4 D4
A3 B3 C3 D3
A2 B2 C2 D2
A1 B1 C1 D1
F G
H1 I1
H2 I2
Page 59 of 112

Packing Section

Length of packing bag : 37 inch
Height of packing bag : 48 inch
TR weight : 1 kg 300 gm(Cone + poly bag)
Total packing bag weight : 51.3 kgs
Yarn weight : 50 kgs
Contains in label :
Count
Lot no.
Quantity
Net wt.
Serial no.
Packing date
Yarn length/package :

Yarn count Length(m)
36/1 CH 125276
30/1 CH 104397
32/1 KH 111354
30/1 KH 104395
26/1 KH 90475
18/1 KH 62637
20/1 KH 69596

No. of cone/packing bag : 24(Generally)
RH% of packing section : 62
Page 60 of 112

Quality testing results of different section :

Page 61 of 112

Page 62 of 112

Page 63 of 112

Page 64 of 112

Page 65 of 112

CHAPTER SEVEN CHAPTER SEVEN CHAPTER SEVEN CHAPTER SEVEN

Maintenance Maintenance Maintenance Maintenance Department Department Department Department

Page 66 of 112

CHAPTER 07
MAINTENANCE

Maintenance of Different machineries :

At the beginning of the Maintenance operation, all the covers of the machines are
opened and the machines is cleaned with a cloth internally, which is called General
Cleaning.
Inside the machine the conveyor belt tension is checked and wooden lattice is also
cleaned and conveyor belt is cleaned if needed.

Jam in the two sides of spiked lattice is opened and under cover of spiked lattice is
opened and cleaned. Jam in the sides of the bearing house of evener roller, cleaner
roller with oils or lubricants as instructed by the manufacturer.

Chain box is checked and jam is cleaned if necessary.

Machine parts are checked conveniently or changed if necessary.

Maintenance Tools/Equipments and their functions

(A) Section Wise :
1. Blowroom & Carding : Mounting machine, Grinding Machine
2. Drawframe & Simplex : Long card mounting machine, Flyer
washing machine, Grinding machine,
Barcolizing machine, Brush cleaning m/c.
3. Ringframe : Cot grinding m/c, Barcolizing m/c, Spindle oil change
m/c, Cot mounting machine.

(B) Various Tools :

1. Hard Hammer : For opening & cleaning, tied & united the differential
parts.
2. Soft hammer : In where soft material are used.
3. Adjustable Range : For tied & untied nut, bolts etc.
4. Ring range : For tied & untied nut.
5. Socket range : In where normal range is not use.
6. Flat screw driver : To tied & untied the flat type nut.
7. Star screw driver : For tied & untied the screw type nut.
8. Cutting pliers : For cutting something .
Page 67 of 112

9. Nose pliers : For some sensitive cutting.
10. Combination pliers : For cutting both performance.
11. Spinner : For ring opening.
12. Inner scarlet pliers : To put/set bearing in the inner side of
bush/shaft/house.
13. Outer scarlet pliers : To put/set bearing in the outside of bush/shaft/house.
14. L-Key : For opening L-cord key.
15. Flat pile : For sharpening.
16. Scissor : For cutting something.
17. Hack saw frame & blade : For holding & cutting anything rod.
18. Belt lacing : For belt arranging.
19. Inside calipers : To measuring the inside diameter of the roller.
20. Outside calipers : To measure the outside diameter of rollers.
21. Variable calipers : To measure both side diameter.
22. Measuring tape : To measure length of different parts.
23. Puller : To open the gears.
24. Roller setting gauge : To adjust roller to roller distance.
25. Leaf/file gauge : To adjust different setting of carding machine.
26. Spindle gauge : To set the spindle vertically in ringframe.
27. Hook : For tied & untied the bush.
28. Roller hardness tester : To measure the hardness of different types of
roller.
29. Oil cane : For oiling inside the machine.
30. Spindle oil machine : To change oil in the machine.

Page 68 of 112

Maintenance of Machinery, Procedure & maintenance schedule/routine :

1. Maintenance Schedule for Blowroom Machine

(A) Rieter Unifloc A11 (Origin = Switzerland)

Intervals Maintenance Points
Daily - Normal Cleaning
- Cleaning of Dust & collected fly from the m/c
15 Days - Checking Chain & Sprocket
- Cleaning & Greasing Chain & Sprocket
- Take-off unit correct balance checking
4 Years - Changing Chain & Sprocket
- Changing Roller change
5-6 Years - Opening roller teeth change

(B) Rieter Uniclean B11 (Origin = Switzerland)

15 Days - Checking Grid bars & Polishing

(C) Rieter Unimix B70 (Origin = Switzerland)

1-5 Months - Checking Conveyor belt & Balancing
- Remove dust & fly from conveyor belt drive roller
- Checking Spike lattice(Pin change of Not & roller check)
4-6 Years - Changing Conveyor belt
6-7 Years - Changing Spiked lattice

(D) Rieter Uniflex B60 (Origin = Switzerland)

15 Days - Perforated drum cleaning
- Feed roller cleaning
- Grid bar checking & polishing
- Opening roller cleaning
After 12000 - Opening roller wire change
Ton production

Page 69 of 112

2. Maintenance Schedule for Carding Machine

- Daily Routine Cleaning
- Checking all gauge settings
- Autoleveller : Short term autoleveller & Long term autoleveller
- Stripping roller wire change 2200-2400 ton production
- Cylinder, Doffer & Flat drops wire change 800-900 ton production
- Licker-in wire change 400-500 ton production
- Back Stationery & Front Stationery 300-400 ton production
- Grinding : Cylinder grinding (400 ton)
Doffer grinding (250 ton)
Flat grinding (300 ton)
Licker-in grinding (250 ton)

- Internal Grinding System : Integrated Grinding System(IGS), grinding is
done periodically after a fixed time in the Cylinder.

3. Maintenance Schedule for Drawframe Machine

Normally it is expressed,

- Cleaning : Drafting zone Every two hours
Suction filter spring Every 2-3 hours
Every belt 10days
- Greasing : Top roller end bush 2 times in Weekly (Special A = LDS 18)
All greasing points 2 months (Special A = LDS 18)
- Hardness : Cot Hardness (Karded Process) = 80 & 83 degree
Cot Hardness (Combed Process) = 74 & 75 degree
- Changing : Top roller & brush gearing = Every weeks two times
Cot grinding = After one month
Flat belt = After 8-12 months (435-5m-15) & After 1-1.5 years
- (others) :
Top roller cot change = After one year
Top & Bottom clearer leaf = After 3-4 years
Gas pressure spring = After 3-4 years
Different types V-ripped belt = After 3 years
Top roller & End bush = After 6-7 years

Page 70 of 112

Intervals Maintenance Points Operation / Task
Interval the
Cleaning &
Controlling,
Depending
on the
Waste &
Short fibres
Count in the
Material
Cleaning of Power Crel - Clean all contact rollers
- Clean all feeding rollers
- The sliver rake for the sliver feed
located on the back of the machine
Clean creel - Clean all sliver guides
- Clean the light barriers BIO with rod
- Clean the all cross bar
- The sliver rake for the sliver feed
located on the back of the machine
Clean entry plate - Fibre accumulation on the entry
plate should be removed periodically
Clean scanning rollers - Fibre accumulation around the
scanning rollers 1 & 2 should be
removed periodically
Clean the filter screen on
the main motor and check
on the main motor fan
- The Main motor sucks its cool air
from the outside, on the back side of
the machine, with a spiral enforce
hose
- The filter sieve on the rear side of
the machine clean the sucked in
cooling air
- The exhaust air is divided up into
several areas
- The fan hood for the main motor and
the connection for the spiral hose are
accessible from the front side of the
machine
- Vacuum or Wipe-off the filter screen
at regular intervals
- The cover sheet with the filter sieve
can be removed if required
Check the gas pressure
springs of the weighting
arms in the drafting
system
- The gas pressure springs are wear &
tear parts and have to be replaced
within the order time frames
- In addition, with all task of loading
arm need to be paid attention, that
the two gas pressure are in perfect
working condition
- With the slightest deviation, the gas
pressure spring should be replace
immediately for safety reason
Page 71 of 112

Clean pressure bar - Clean pressure bar periodically
- The pressure bar can wear out. The
wear and tear is dependent on the
material & its friction behavior as
well as the delivery speed
- In this case, the pressure bar can be
removed or turned over
Clean guide rails - Clean the guiding tracks periodically
Clean the timing belt for
the setting device
- Periodically clean the timing belt
Clean the setting spindle
for the adjustment of the
draft zone distance
- Clean the two setting spindles from
the left & on the right
Clean the clearer lip for
the draft system cylinder
- All of the clearer lip must be cleaned
periodically
Clean and control clearer
for the top roller
- Clean the clearer lip on the suction
head and intervals
- Check the clearer lips for the sign of
wear and tear
Cleaning of top rollers - Clean all top rollers periodically
Clean insert for web
funnel
- Clean the inside of insert from the
web funnel
Clean sliver duct - Thoroughly, clean the sliver funnel,
especially the two small injector
holes
- Additionally, clean the hole of the
compressed air in the swivel plate
Clean optical sliver jam
monitor
- During the periodic clean of the
machine, the area around the optical
sliver jam monitor should be cleaned
as well as
Clean sliver duct (Coiler) - The sliver duct must be periodically
with the provided cleaning tool
Clean the SERVO
controller G90 and the
Fan M92
- The cleaning is done with short
compressed air blows in the
direction, top to bottom, on the
SERVO controller G90 and by
vacuuming the electrical panel area
- The fan on the fan motor must be
cleaned periodically
Clean the ventilator - Clean the ventilator blades of the
Page 72 of 112

blades of the suction fan suction fan in periodic intervals,
from coarse fibres waste
accumulation and vacuum
thoroughly
Clean the filter screen - Vacuum the filter screen in front of
the suction fan with the aid of
vacuum clearer
Clean the sliver deposit
can changer
- Clean the entire area of the can
changer periodic
Interval 300
Operating
Hours
Lubricate the lubricating
nipple on the central
lubrication : Variant with
lubricating nipple
- Grease used Medium S22
- Location Z(1)
- Place Central lubrication : Variant
with lubricating nipple
- The lubricating system Central
Lubrication must be adjusted and
welly operated
Interval 500
Operating
Hours
Lubricate lubricating
point 10 (Top Roller
Bearings)
- Clean the top roller bearings and
studs prior to the re-lubrication with
a suitable cleaning agent
- Lubricate the top roller bearings of
all top rollers one after the another
- Location 10
- Place Top Roller Bearings
Buff top rollers cot - Prior to buffing, establish the actual
diameter of the cot as long as they
are cooled
- Nominal diameter of the Top roller
cot is 38mm
- During the buffing cycle, the buffing
depth is approximately 0.2mm
- The buffing tolerance for the entire
concentric running of the top roller
cot, between the two studs must be
<.03mm
- The buffing tolerance at parallel
settings of the cots must be
<0.08mm
- Grinding disc diameter 200-500mm
- Grinding disc width 25-45mm
- Circumference speed of the grinding
Page 73 of 112

disc is 1800-2000m/min
Replace top rollers cot - Remove the cots from arbor
- Replace the top roller cots
Interval
1500
Operating
Hours
Lubrication on version
with lubrication bar
- Distribute the required amount of
lubricant to all grease nipples on
lubrication bar
point 1.1 on the
lubricating strip (Loose
calendar roll bearing, left)
- Location 1.1
- Place Loose calendar roll bearing,
Left
point 1.2 on the
lubricating strip
(Stationery calendar roll
bearings, left)
- Location 1.2
- Place Firm calendar roll bearing,
Left
point 1.3 on the
lubricating strip (Cylinder
bearings of the front
roller, left)
- Location 1.3
- Place Cylinder bearings of the
Delivery roller, Left
point 1.4 on the
bearings of the middle
roller, left)
- Location 1.4
Delivery roller, Left
point 1.5 on the
bearings of the feed
cylinder, left)
- Location 1.5
Entry cylinder, Left
point 1 on the lubricating
strip (Main shaft, left)
- Location 1
- Place Main shaft, Left
strip (Main shaft, middle)
- Location 2
- Place Main shaft, Center
point 2.1 on the
lubricating strip (loose
calendar roll bearings,
right)
- Location 2.1
- Place Loose calendar roll bearings,
Right
Page 74 of 112

point 2.2 on the
lubricating strip
(Stationery calendar roll
bearings, right)
- Location 2.2
- Place Firm calendar roll bearings,
Right
point 2.3 on the
bearings of the front
roller, right)
- Location 2.3
Delivery roller, Right
point 2.4 on the
bearings of the middle
roller, right)
- Location 2.4
Middle cylinder, Right
point 2.5 on the
bearings of the feed
cylinder, right)
- Location 2.5
- Place Cylinder bearings of the Feed
cylinder, Right
strip (Main Shaft, right)
- Location 3
- Place Main shaft, Right
point 5 (Universal of Can
table drive)
- Apply lubricant on the two upper &
lower grease nipples of the universal
shaft
- Grease used Medium K3
- Location 5
- Place Universal of can table drive
point 6 (Can table, only
with spinning can
diameters 800-1000mm)
- Location 6
- Place Can table, only with spinning
can diameters 800-1000mm
point 11 (Calendar roller
bearing-swiveling axis)
- Location 11
- Place Calendar roller bearing
swiveling axis
point 12 (Calendar roller
bearing-Connecting rod)
- Location 12
- Place Calendar roller bearing-
connecting rod
Page 75 of 112

Interval
5000
Operating
Hours
point 7 (Can table-Cog
wheels)
- Location 7
- Place Can table-Cog wheels
point 8 (Can table-Cog
wheels)
- Location 8
- Place Can table-Cog wheels
Interval,
Depending
on the filling
capacity of
the
Lubricant
Container
(Cyclic,
repeatedly)
Lubrication on Central
Lubrication : Variant with
electrical lubricating
pump
- Location Z(6)
- Place Central lubrication : Variant
with electrical lubricating pump
- The pump should be refilled in the
sufficient time with clean lubricant

Interval
10000
Operating
Hours
Replace the Oil on the
Lubrication Point 9
(Differential)
- Grease used Medium CC220
- Location 9
- Place Differential

4. Maintenance Schedule for Lap Former Machine

- General cleaning of the machine & machine parts by compressed air
- Cleaning the different gear and belt
- Cleaning the top roller, feed roller, calendar roller, conveyor belt etc.
- Cleaning all cot rollers and coil spring
- Cleaning all cotton & others parts of the machine
- Gauge setting or resetting
- Over hauling of pneumatic unit
- Cleaning & polishing of sliver table, calendar rolls etc.
- Cleaning of top roller bushes by spindle oil
- Greasing the ball/needle bearings shell roller bearings open gear
- Checking & tightening of nuts, bolts etc.
- Top roller cot grinding, buffering & pressure setting
- Greasing with EP2 in all greasing points

Page 76 of 112

5. Maintenance Schedule for Comber Machine

Intervals Maintenance Points Operation / Task
Interval 4-8
Operating
Hours
Cleaning Bearings on
Combing Position
- Clean bearings on bottom roller
and Circular comb shaft with
roller picker
Clean area around spring
assemblies, nipper, top-
detaching roller pressure
unit from fibre and trash
accumulation
- Dry clean the whole area
assemble at the combing position
Remove fibre and dust from
the top comb
- Push accumulate trash in the top
comb from the front by
repeatedly pushing it downwards
Removing accumulated
fibres from the clearer roller
- Take the clearer roller off the
machine
- Clean with the aid of cleaning
truck
Interval 24-165
Operating
Hours
Cleaning technological parts - Remove cotton completely from
the combing position
- Wash all listed parts
- Rub all cleaned parts dry with a
clean rag
- Polish the parts with a Chalk
powder
Remove fly and fibres in the
of Drafting system
- Remove the accumulated fibres
behind the bottom draft rolls
- Remove fibre and trash deposits
from around the top and bottom
draft rolls
Washing draft system - Wash the strippers with water
- Wash the bottom drafting rolls
- Wash top rollers & Web
collecting
- Remove honeydew and grease
deposits on the metal plate
Interval 165
Operating
Hours
Clean area around the
Nipper shaft, Nipper crank,
Fly duct outside from
accumulated fibres
- Dry clean the whole area
accessible at the combing
position
Clean area around the - Open the flap cover
Page 77 of 112

Conveyor belt, Delivery rolls - Dry clean the whole area of
accessible parts
Interval 660
Operating
Hours
Wash technological parts - Clear away cotton completely
from the delivery zone
- Wash all parts that come into
contact with the material
Lubricate the bearing bushes
of the top detaching roller
- Clean top detaching rolls
- Remove the bearing bushes
- Push the bearing bushes back
onto the Journal pin
- Clean access grease from the
outside of the bearing bushes
- Grease used Medium EP2
- Location 308
- Place Top detaching roller
Lubricate the bearing bushes
of top roller bearing
- Take the bearing bushes off the
Top roll
- Insert the lubrication tools on
the bearing bushes
- Location 44
- Place Draft system top rolls,
bearing bushes
Interval 1320
Operating
Hours
Wash stripper & fly duct - Remove the fleece bowl
- Wash the strippers of the bottom
roller
- Wash inside the fly duct
Clean out Circular comb - Scrape out the accessible rear
half of the circular comb
- Set the machine exactly to Index
35
- Scrape out the accessible front
half of the circular comb
Oil level check - Check oil level at the inspected
glass and top up if necessary
- Oil used Medium S14
- Location 1 & Place Gear Box
Lubricating points on Front
lengthways shaft
- Location 21, 22 & 23
- Place Bottom delivery roller,
Table calendar roll &
Page 78 of 112

Eccentric shaft
Lubricating points on Rear
lengthways shaft
- Location 11, 12, 13, 14, 15 & 16
- Place Circular comb shaft,
Rear detaching roll, Front
detaching roll, Drive shaft
delivery, Nipper shaft &
Brush shaft
Lubricating points on the
Nipper
- Location 301, 302, 303, 304, 305
& 306
- Place Top spring assembly,
Nipper-top nipper, Crank
nipper, Front support at top,
Front support at bottom &
Eccentric top nipper
Lubricating the bearing bush
of the feed roll
- Clean the bearing bushes of the
journal pin and the bearing
guide of dirt and lubricant
residue
- Lubricate the bearing bushes
- Location 307
- Place Nipper-Feed cylinder
- Remove excess grease from the
outside area
Lubricating the bottom
drafting rolls
- Clean the lubricating nipples
- Location 41
- Place Draft system bottom roll
- Wipe of grease that has come out
of the side bearings
Lubricating can turntable
bearings
- Clean the side supports and the
slide platform
- Location 42
- Place Can turntable bearings
Lubricating can turntable
chain drive
- Clean &lubricate drive chain
- Location 43
- Place Can turntable chain
drive
Page 79 of 112

Clean the lubricating nipples - Clean the lubricating nipples
with a dry cotton cloth before
and after lubricating
Interval 4000
Operating
Hours
Oil change - Drain of Old oil & Refill new Oil
- Location 1 & Place Gear box
Lubricating journal pin of
top draw-off roller
- Clean dirt and lubricant residue
of Journal pin and bearing bush
- Grease used Medium CC150
- Location 310
- Place Top draw-off roll
Clean Housing & Filters - Clean accessible parts from dust
and accumulated fibres
Wash fibre separator - Remove filter cloth and wash
- Wash metal parts and clean off
any honeydew residue
Interval 8000
Operating
Hours
Cleaning the Motor - Dry clean the impeller and fan
cowl
Wash Fan - Dismantle the Motor with fan
wheel
- Dismantle duct elbow
- Wash fan wheel & fan housing
Interval 32000
Operating
Hours
Lubricate spur gear drive for
can turntable drive
- Dismantle the spur gear
- Drain the old oil and Refilled
with new oil
- Location 45
- Place Spur gear drive for Can
turntable drive

Page 80 of 112

Standard Lubricant :

Code Designation Viscosity DIN ISO Description
EP2 Grease Viscosity
of the
Basic Oil
100-250
KP2G-20
(51825)
EP-lubricant, Iithium base or
equivalent penetration ; 260-
310, NLGI-Class 2. High load
additives phosphor-sulphur-
based or equivalent EP
additives. Aging and corrosion
protection, No aggression
toward bronze
CC
150
EP Oil Viscosity
according
to ISO
mm2/s
40
0
C 150
CLP 150
(51517/3)
CC 150 Oil on paraffin base, VI>90. No
or no significant swelling of O-
rings or any other synthetic
seals, No aggression toward
bronze, Good load bearing
ability; FZG-Test load class 12.
High load additives phosphor-
sulphur-based or equivalent EP
additives

Special Lubricant :

Code Designation Viscosity Description
S 14 SHC-Oil Heavy 150 Oil for high temperature, based on synthetic
carbonic hydrogen(SHC) or Polyalphaolefine, wear
resistant additives, Not aggressive to bronze
S 21 Chain Spray Optimol Viscogen KL 23 von Optimol-Werke
GmbH, Friedenstrasse 7, Munchen, Deutschland
S 13 SHC-Oil Light 68 Oil for high temperature, based on synthetic
carbonic hydrogen (SHC) or Polyalphaolefine.
Wear resistant additives

Page 81 of 112

6. Maintenance Schedule for Simplex Machine

Interval Maintenance Points Operation/Task
Daily
Cleaning
Flyer Rail & Roller Beam - Clear fly or fleece
Fly Spindle & Bobbin Rail - Wipe them with a clothed dampened
with a silicone oil
Top Clearer - Clear Accumulated fibres
Bobbin Rail - Clear fly or fleece
Floor - Clear the floor in front of & at rear of
FL100 & HY492C
CWC belt, Pulleys & their
surroundings
- Remove fly or fleece
Fan cover mesh on the GE
Head
- At the rear of FL100 & HY492C
- Clear fly or fleece

Every 2
Weeks
Back of the FL100 &
HY492C
- Remove fly or fleece from the Lifter
racks & pinions
- Remove fly or fleece from the Balance
springs & Chains
- Remove fly or fleece from the Lifter
slides & Spring pieces
- Clean the creel & its surroundings
- Clean the floor

Every 6
Weeks
Roller Part - Remove fibres and entangled the
bottom roller neck
- Remove fly or fleece accumulated on
the top & bottom faces on the top &
bottom clearers
- Remove fly or fleece accumulated on
the Clearer drive shaft
Flyer Rail - Clean the bottom of the flyer rail
- Clean the roving path in the flyer rail
- Always in contact with the passing
roving
Bobbin Rail - Clean the bobbin rail and its
surroundings
Main Gearing - Open the GD door and Clear fly or
fleece
Inside the GE Head - Clean fly or fleece from Inside of GE
Head
Page 82 of 112

- Clean fly or fleece from the Motor fan
cover & clothy from mesh
- Clean the inside of the Control box
- Clean fly or fleece accumulated on
Cooling fan
OE (Open End) - Open the OE door and Clear fly or
fleece

Every 6
Weeks
(Checking)
Roller Part - Check the sliver guides, condenser and
collector from damage
- Check the top & bottom aprons to make
sure that they are not damaged or missed
- Check the top & bottom clearers
- Check the pressurized state of the
weighting arms by using a height gauge
Main Gearing - Check the engagement of the gears
- Check the tension of the Timing belts
Draft Gearing - Check the engagement of the gear
Tension Roller Settings - To keep the tension sensors optimum
setting condition, Check the Tension
sensors

Every 24
Weeks
(Semiyearly)
Grease Tank Refilling filters
of the Centralized
Lubrication System
- Check & Clean refilling filters which may
become clogged with fly or fleece or other
foreign materials

Every 48
Weeks
(Yearly)
Simplex FL100 & HY492C - Check the machine according to the Check
sheet and adjust or replace the faulty
sections if any

Triennially Simplex FL100 & HY492C - Check the Levelness of the machine
between the left and right sides as well as
between the front and back on top of the
roller beam triennially

Page 83 of 112

7. Maintenance Schedule for Ringframe Machine :

(A) Interval 15 Days :
- Routing Cleaning
(B) Interval 2 Months :
- Bottom Roller Greasing
(C) Interval 4 Months :
- Spindle Gauging
- Lapped Hook Gauging
- Top Arm Settings (Seddle Gauge)
(D) Interval 6 Months :
- Bottom Roller Settings
- Spindle Oil Change
- Jocky Pulley Greasing
(E) Interval 1 Years :
- Bottom Roller eccentrically checking
(F) Interval (1.5-2.5) Years :
- Bottom roller top apron change
- Cot Changing
- Spindle tape changing
(G) Interval (2.5-3) Years :
- Cot roller greasing
- Cradle roller greasing
- Over hauling
(H) Interval (3-5) Years :
- Snarl wire/Lapped hook Changing
- Wooden clearer roller/Top clearer roller changing
(I) Interval (2-7) Years :
- Ring Cup Changing (Demands on Quality)
(J) Interval (4-7) Years :
- Bobbin Holder Change
(K) Interval 6-8) Years :
- ABC ring change
(L) Interval (4-10) Years :
- Spindle Change (Demands on Quality)

Page 84 of 112

8. Autoconer Maintenance :

- General cleaning of magazine peg
- Checking & removal of blow cleaner waste
- General cleaning of blower motor, filter cam shaft, motor filter control box,
chipper filter.
- Measuring head, blow cleaning, motor amp checking
- Gauge settings/re-settings
- Drum checking
- Lubricant & wax checking
- Replacement of damage parts/over life time
- Checking cone sensors

Page 85 of 112

Maintenance Schedule for the Month of August 2010 :

Date & Time Blowroom & Carding D/F, S/F & Comber Ringframe Autocone
Date Day Time Schedule Maintenance Cleaning S. Maintenance Cleaning S. Maintenance Cleaning S.Maintenance Cleaning
01 Sunday C-8, C-13 Daily B-5, F-7, S-1, C-4 Daily R-14, R-35, R-36 Daily A-1, A-10 Daily
02 Monday C-2, C-10 Daily B-4, F-3, S-7, C-2 Daily R-18, R-21, R-24 Daily A-11, A-12 Daily
03 Tuesday C-1, C-3, B/R Daily B-1, F-6, S-3, C-1 Daily R-1, R-7, R-13 Daily A-3, A-6 Daily
04 Wednesday C-7, C-9 Daily B-3, F-4, S-9, C-3 Daily R-5, R-30, R-33 Daily A-7, A-9 Daily
05 Thursday C-6, C-11 Daily B-2, F-5, S-4, C-5 Daily R-2, R-15, R-28 Daily A-4, A-8 Daily
06 Friday C-4 Daily B-7, S-2 Daily R-12 Daily A-2, A-5 Daily
07 Saturday C-5, C-12, B/R Daily B-6, F-2, S-5 Daily R-17, R-19, R-34 Daily A-10 Daily
08 Sunday C-14, C-16 Daily F-1, S-8, C-2 Daily R-4, R-10, R-29 Daily A-12 Daily
09 Monday C-15 Daily B-4, S-6, C-4 Daily R-22, R-26, R-27 Daily A-1, A-11 Daily
10 Tuesday C-2, C-13, B/R Daily B-5, F-3, C-1 Daily R-3, R-8, R-9 Daily A-6 Daily
11 Wednesday C-8, C-10 Daily F-6, S-7, C-3 Daily R-23, R-25, R-32 Daily A-3, A-7 Daily
12 Thursday C-3, C-9 Daily B-3, S-1, C-5 Daily R-6, R-11, R-20 Daily A-9, A-4 Daily
13 Friday C-1 Daily F-2, S-3 Daily R-16 Daily A-8 Daily
14 Saturday C-5, C-11, B/R Daily B-2, F-4, S-9 Daily R-14, R-24, R-31 Daily A-5 Daily
15 Sunday C-4, C-6 Daily B-1, F-5, S-2, C-4 Daily R-7, R-15, R-30 Daily A-2 Daily
16 Monday C-14, B/R Daily B-7, F-7, S-4, C-3 Daily R-1, R-5, R-33 Daily A-10, A-12 Daily
17 Tuesday C-12, C-16 Daily B-6, F-1, S-5, C-2 Daily R-18, R-21, R-27 Daily A-1, A-6 Daily
18 Wednesday C-7, C-15 Daily B-4, F-3, S-6, C-5 Daily R-2, R-16, R-28 Daily A-11 Daily
19 Thursday C-2, C-8, B/R Daily B-5, F-6, S-8, C-1 Daily R-12, R-9, R-3 Daily A-7 Daily
20 Friday C-9 Daily F-2, S-7 Daily R-35, R-36 Daily A-3 Daily
21 Saturday C-1, C-13 Daily B-3, F-4, S-1 Daily R-8, R-10, R-34 Daily A-8, A-9 Daily
22 Sunday C-3, C-10, B/R Daily B-2, F-5, S-3, C-1 Daily R-17, R-19, R-22 Daily A-4 Daily
23 Monday C-6, C-11 Daily B-1, F-7, S-9, C-3 Daily R-4, R-27, R-29 Daily A-2, A-5 Daily
24 Tuesday C-4, C-5 Daily B-7, F-1, S-2, C-5 Daily R-16, R-32, R-34 Daily A-12 Daily
25 Wednesday C-12, B/R Daily B-6, F-3, S-4, C-2 Daily R-11, R-20, R-25 Daily A-1 Daily
26 Thursday C-14, C-16 Daily B-4, F-6, S-5, C-4 Daily R-6, R-23 Daily A-10, A-6 Daily
27 Friday C-15 Daily B-5, S-8 Daily R-14, R-24 Daily A-7, A-11 Daily
28 Saturday C-2, C-7 Daily B-3, F-2, S-7, C-3 Daily R-1, R-7, R-31 Daily A-3, A-8 Daily
29 Sunday C-8, C-9, B/R Daily B-2, F-4, S-1, C-4 Daily R-13, R-18, R-33 Daily A-9 Daily
30 Monday C-10, C-13 Daily B-1, F-5, S-3, C-1 Daily R-5, R-28, R-30 Daily A-2 Daily
31 Tuesday C-1, C-3 Daily B-7, F-7, S-9, C-2 Daily R-2, R-27 Daily A-4, A-5 Daily
Page 86 of 112

Maintenance schedule for the Month of September 2010 :

Date & Time Blowroom & Carding D/F, S/F & Comber Ringframe Autocone
Date Day Time Schedule Maintenance Cleaning S. Maintenance Cleaning S. Maintenance Cleaning S.Maintenance Cleaning
01 Wednesday C-1, C-13 Daily B-3, F-4, S-1 Daily R-8, R-10, R-34 Daily A-8, A-9 Daily
03 Friday C-6, C-11 Daily B-1, F-7, S-9, C-3 Daily R-4, R-27, R-29 Daily A-2, A-5 Daily
04 Saturday C-4, C-5 Daily B-7, F-1, S-2, C-5 Daily R-16, R-32, R-34 Daily A-12 Daily
05 Sunday C-12, B/R Daily B-6, F-3, S-4, C-2 Daily R-11, R-20, R-25 Daily A-1 Daily
06 Monday C-14, C-16 Daily B-4, F-6, S-5, C-4 Daily R-6, R-23 Daily A-10, A-6 Daily
07 Tuesday C-15 Daily B-5, S-8 Daily R-14, R-24 Daily A-7, A-11 Daily
10 Friday C-10, C-13 Daily B-1, F-5, S-3, C-1 Daily R-5, R-28, R-30 Daily A-2 Daily
11 Saturday C-1, C-3 Daily B-7, F-7, S-9, C-2 Daily R-2, R-27 Daily A-4, A-5 Daily
12 Sunday C-8, C-10 Daily F-6, S-7, C-3 Daily R-23, R-25, R-32 Daily A-3, A-7 Daily
13 Monday C-3, C-9 Daily B-3, S-1, C-5 Daily R-6, R-11, R-20 Daily A-9, A-4 Daily
14 Tuesday C-1 Daily F-2, S-3 Daily R-16 Daily A-8 Daily
15 Wednesday C-5, C-11, B/R Daily B-2, F-4, S-9 Daily R-14, R-24, R-31 Daily A-5 Daily
16 Thursday C-4, C-6 Daily B-1, F-5, S-2, C-4 Daily R-7, R-15, R-30 Daily A-2 Daily
17 Friday C-14, B/R Daily B-7, F-7, S-4, C-3 Daily R-1, R-5, R-33 Daily A-10, A-12 Daily
19 Sunday C-7, C-15 Daily B-4, F-3, S-6, C-5 Daily R-2, R-16, R-28 Daily A-11 Daily
20 Monday C-2, C-8, B/R Daily B-5, F-6, S-8, C-1 Daily R-12, R-9, R-3 Daily A-7 Daily
21 Tuesday C-9 Daily F-2, S-7 Daily R-35, R-36 Daily A-3 Daily
23 Thursday C-2, C-10 Daily B-4, F-3, S-7, C-2 Daily R-18, R-21, R-24 Daily A-11, A-12 Daily
24 Friday C-1, C-3, B/R Daily B-1, F-6, S-3, C-1 Daily R-1, R-7, R-13 Daily A-3, A-6 Daily
26 Sunday C-6, C-11 Daily B-2, F-5, S-4, C-5 Daily R-2, R-15, R-28 Daily A-4, A-8 Daily
27 Monday C-4 Daily B-7, S-2 Daily R-12 Daily A-2, A-5 Daily
28 Tuesday C-5, C-12, B/R Daily B-6, F-2, S-5 Daily R-17, R-19, R-34 Daily A-10 Daily
29 Wednesday C-14, C-16 Daily F-1, S-8, C-2 Daily R-4, R-10, R-29 Daily A-12 Daily
30 Thursday C-15 Daily B-4, S-6, C-4 Daily R-22, R-26, R-27 Daily A-1, A-11 Daily

Page 87 of 112

CHAPTER EIGHT CHAPTER EIGHT CHAPTER EIGHT CHAPTER EIGHT

Utility Services Utility Services Utility Services Utility Services

Page 88 of 112

CHAPTER 08
UTILITY SERVICES

Utility Department is one of the most valuable department in a factory or mill.

In REEDISHA SPINNING LTD. Utility department facilitates various Utility
Facilities, Which are available below,

(A) A/C Plant
(B) Chiller
(C) Boiler
(D) Generator
(E) Compressor
(F) Water treatment Cooling Tower

A/C Plant :

There are various types of A/C Plant. Such as :
- LTG A/C Plant (Germany, France)
- BEST AIR A/C Plant (Germany)
- LOWA A/C Plant (Germany)
- BATLY BOIL A/C Plant (China)

In REEDISHA SPINNING LTD. the categories of A/C plant is LTG A/C Plant. The
capacity & design of A/C plant is goes according to the different companies. Again,
This LTG A/C Plant mainly three of types,

1. Spilyte Type A/C :
This Spilyte type A/C has two of machine parts. One is Condenser which
condensed the air and Another is Evaporator which evaporates the
Compressed air. Its production capacity varies 1 ton, 2 ton, 5 ton etc. USRT
value.

2. Window Type A/C :
This Window type A/C also has two of machine parts same as Spilyte Type
A/C.

3. Centralizes Type A/C :
This Centralizes Type A/C is centralized settings up for the air flow. It has no
such several parts of the machine. Its production capacity ranges higher varies
from 1000-more required amount of USRT value.
Page 89 of 112

Generator :

Every generator is completely setup of three parts, such as
1. Engine
2. Generator/Alternator
3. Control system
In on alternator/generator it has mainly three parts, such as
1. Rotor
2. Armature
3. Exciter

Electrical :

In the flow of electrical transferred there is several properties such as,
From the BBT by the taking off box with circuit breaker the electrical line is
placed
By isolator or circuit breaker the electrical line is given to the different
machine.

In the REEDISHA SPINNING LTD. there is three BBT on capacity, such as
A. Back-side BBT : 4000 amp power
B. Ring frame BBT : 4000 amp power
C. Autoconer BBT : 2000 amp power

Page 90 of 112

Features of Utility machineries :

Features of Chiller :

A. Steam Fire Chiller :
Model : LSH-SO635
Cooling Capacity : 560 USRT
Chilled Water Flow Rate : 338.7 m
3
/h
Chilled Water Temperature : 13 9
0
C
Cooling Water Flow Rate : 630.2 m
3
/h
Cooling Water Temperature : 32-37
0
C
Heating Source Type : Steam
Heating Source Consumption : 2490 kg/h
Steam Pressure : 3 kg/cm
3

Electric Power : ~3 420V 50Hz
Serial Number : 054301098900201C
Manufacture Date : 2005/12

B. Hot Water Chiller :
Model : LWM-W048
3
/h
0
C
Cooling Water Flow Rate : 587.3 m
3
/h
Cooling Water Temperature : 32 37
0
C
Heating Source Type : Hot Water
Heating Source Consumption : 115.100 kg/hr
Heating Source Temperature : 95 80
0
C
Serial Number : 051201098900101C
Manufactured Date : 2005/12

C. Direct Fire Chiller :
Model : LDF-S056S
Heating Capacity : 1.118.000 Kcal/h
3
/h
0
C
Cooling Water Flow Rate : 484 m
3
/h
Cooling Water Temperature : 32 37
0
C
Hot Water Flow Rate : 266.1 m
3
/h
Hot Water Temperature : 55.8 60
0
C
Page 91 of 112

Fuel Type : LNG
Total Calorific Value : 9.200 Kcal/Nm
3
kg
Gas Pressure : 4.000
Fuel Consumption (cooling) : 1,295,000 Kcal/h
Fuel Consumption (heating) : 1,295,00 Kcal/h
Serial Number : 051201098900401 H
Manufactured Date : 2005/12

Features of Boiler :
Model : WHR-4115/10
Standard : TRD
Standard Capacity : 4.11 ton/h
Max, Allowable Working Pressure : 10 barg
Total Pressure : 18.1 barg
Serial No. : 0396
Manufactured Date : 2006

Features of Generator :
Model : G3516
Generator Serial : 8GW01402
Manufactured In : LAFAYETTE, IN
Manufacturer : Caterpiller (USA)
Manufactured Date : 2006
Rated Power (Capacity) : 1287 KVA (1030 KW)
Phase Rotation : Counter Clockwise
Rated Ampere : 1857 Ampere (P = VICos0)
Electric Power : ~ 30, 400V, 50Hz
Ambient : 40
0
C
Maximum Temperature Rise : 105
0
C
Bore : 1070 mm
Stroke : 190 mm
Pole : 4

Features of Compressor :
Model : S 60-2
Type : BOGE SCREW TYPE
Manufacturer : Germany
Serial Number : 5016872
Year of Construction : 2007
Page 92 of 112

Rate of Flow : 6.34 m
3
/min
Maximum Service Pressure : 10 bar
Motor Speed : 3,000 rpm
Motor Power : 45+1, 10 KW
Continue Heat upto : 110
0
C

Features of Dryer :
Model : BOGE TYPE DB 130
Type No. : 753A
Serial Number : 061/18318/07
Electric Power : 220-230V, 1N~/50Hz
Compressed Air : PS 16bar, TS
2
2
0
C, TS
H
60
0
C
Refrigerant : R 134a/1.60kg, PS
L
16bar, PS
H
20bar
TS
L
-10
0
C, TS
L
120
0
C

Features of Water Treatment Cooling Tower :
Model : STA 600 SUN
Suction Pipe Dimension : 25 cm
Capacity : 468 m
3
H
Water in : 37
0
C
Water out : 32
0
C
Fan Motor : 7.5Q H.P.
Poler Volts : 10p 400V
Air Capacity : 132400 m
3
/min
Manufactured Date : 2006/03/07

Page 93 of 112

Log Sheet for Temperature & RH% Control : (Date = 20-09-2010)

(a) Blow Room A/C Plant-1 Log Sheet :

Time Section A/C Plant No. 1 Outside Air
Standard
R.H.%
Existing
R.H.%
Existing
Temp.
0
C
Existing
R.H.%
Existing
Temp.
0
C
08.00am

B
l
o
w

R
o
o
m

D
e
p
a
r
t
m
e
n
t

49 49.0 32.9 92.5 27.2
09.00am 49 49.1 33.2 82.6 28.6
10.00am 49 48.9 33.7 79.1 29.0
11.00am 49 49.0 33.9 75.3 30.1
12.00pm 49 48.8 34.2 78.4 30.4
01.00pm 49 49.1 34.2 75.5 30.3
02.00pm 49 49.1 34.3 61.1 30.9
03.00pm 49 49.0 34.2 70.8 31.0
04.00pm 49 49.0 34.3 61.6 32.8
05.00pm 49 49.2 34.8 62.5 32.9
06.00pm 49 49.1 34.9 60.0 33.0

(b) C/D, D/F, Comber & S/F A/C Plant-2 Log Sheet :

Time

Section
A/C Plant No. 2 Outside Air
Standard
R.H.%
Existing
R.H.%
Existing
Temp.
0
C
Existing
R.H.%
Existing
Temp.
0
C
09.00am

Carding
Department
50 50.0 33.8 82.6 28.6
10.00am 50 48.8 33.9 79.1 29.0
11.00am 50 50.1 33.8 75.3 30.1
12.00pm 50 50.0 34.1 78.4 30.4
01.00pm 50 49.9 34.0 75.5 30.3
02.00pm 50 50.2 34.5 61.1 30.9
03.00pm 50 50.1 34.2 70.8 31.0
04.00pm 50 49.0 34.6 61.6 32.8
05.00pm 50 50.6 35.0 62.5 32.9
09.00am

Draweframe,
Lap Former &
Comber
Department
48 47.9 33.9 82.6 28.6
10.00am 48 48.0 33.0 79.1 29.0
11.00am 48 48.6 33.4 75.3 30.1
12.00pm 48 47.3 34.6 78.4 30.4
01.00pm 48 46.8 35.0 75.5 30.3
02.00pm 48 49.0 35.1 61.1 30.9
03.00pm 48 50.0 34.8 70.8 31.0
04.00pm 48 50.0 34.1 61.6 32.8
05.00pm 48 48.9 34.0 62.5 32.9
Page 94 of 112

09.00am

Simplex
Department
46 47.0 34.8 82.6 28.6
10.00am 46 46.9 34.2 79.1 29.0
11.00am 46 45.8 34.0 75.3 30.1
12.00pm 46 46.7 34.6 78.4 30.4
01.00pm 46 47.1 34.9 75.5 30.3
02.00pm 46 46.1 35.1 61.1 30.9
03.00pm 46 46.0 35.4 70.8 31.0
04.00pm 46 46.2 34.0 61.6 32.8
05.00pm 46 46.0 33.9 62.5 32.9

(c) Ring Spinning A/C Plant-3 Log Sheet :

Time

Section
Ring Spinning Frame
Existing
R.H.%

Existing
Temp.
0
C
Standard
R.H.%
Existing
R.H.%
Existing
Temp.
0
C
09.00am

East-01
Side
52 51.8 33.0 82.6 28.6
10.00am 52 52.0 33.0 79.1 29.0
11.00am 52 51.9 33.9 75.3 30.1
12.00pm 52 51.8 33.0 78.4 30.4
01.00pm 52 51.9 33.9 75.5 30.3
02.00pm 52 52.1 34.0 61.1 30.9
03.00pm 52 52.0 341 70.8 31.0
04.00pm 52 52.0 34.6 61.6 32.8
05.00pm 52 52.1 34.7 62.5 32.9
09.00am

East-02
Side
52 51.9 32.1 82.6 28.6
10.00am 52 51.6 32.8 79.1 29.0
11.00am 52 51.9 33.0 75.3 30.1
12.00pm 52 52.5 33.6 78.4 30.4
01.00pm 52 52.9 34.8 75.5 30.3
02.00pm 52 53.0 34.2 61.1 30.9
03.00pm 52 52.9 34.0 70.8 31.0
04.00pm 52 53.0 33.5 61.6 32.8
05.00pm 52 52.4 34.0 62.5 32.9
09.00am

West-01
Side
52 52.9 32.9 82.6 28.6
10.00am 52 52.4 32.8 79.1 29.0
11.00am 52 51.5 32.9 75.3 30.1
12.00pm 52 51.4 33.1 78.4 30.4
01.00pm 52 52.8 33.0 75.5 30.3
02.00pm 52 51.7 33.2 61.1 30.9
03.00pm 52 51.6 33.6 70.8 31.0
04.00pm 52 52.0 32.9 61.6 32.8
05.00pm 52 52.1 33.1 62.5 32.9
Page 95 of 112

09.00am

West-02
Side
52 52.3 33.7 82.6 28.6
10.00am 52 52.8 33.9 79.1 29.0
11.00am 52 52.0 34.1 75.3 30.1
12.00pm 52 51.9 34.0 78.4 30.4
01.00pm 52 52.2 33.8 75.5 30.3
02.00pm 52 52.9 34.9 61.1 30.9
03.00pm 52 53.0 35.0 70.8 31.0
04.00pm 52 52.8 35.1 61.6 32.8
05.00pm 52 42.9 34.9 62.5 32.9

(d) Ring Spinning A/C Plant-4 Log Sheet :

Time

Section
Ring Spinning Frame
Existing
R.H.%

Existing
Temp.
0
C
Standard
R.H.%
Existing
R.H.%
Existing
Temp.
0
C
09.00am

East Side
52 51.9 32.1 82.6 28.6
10.00am 52 52.1 33.9 79.1 29.0
11.00am 52 52.0 32.8 75.3 30.1
12.00pm 52 51.8 33.0 78.4 30.4
01.00pm 52 51.7 32.8 75.5 30.3
02.00pm 52 52.8 34.0 61.1 30.9
03.00pm 52 52.6 34.1 70.8 31.0
04.00pm 52 52.0 34.2 61.6 32.8
05.00pm 52 52.7 33.7 62.5 32.9
09.00am

West Side
52 52.1 31.8 82.6 28.6
10.00am 52 52.0 32.0 79.1 29.0
11.00am 52 52.3 32.3 75.3 30.1
12.00pm 52 52.8 31.8 78.4 30.4
01.00pm 52 51.7 31.9 75.5 30.3
02.00pm 52 51.4 32.0 61.1 30.9
03.00pm 52 52.9 33.0 70.8 31.0
04.00pm 52 53.0 32.8 61.6 32.8
05.00pm 52 52.8 32.6 62.5 32.9

Page 96 of 112

(e) Autoconer A/C Plant-5 Log Sheet :

Time Section A/C Plant No. 5 Outside Air
Standard
R.H.%
Existing
R.H.%
Existing
Temp.
0
C
Existing
R.H.%
Existing
Temp.
0
C
08.00am

A
u
t
o
c
o
n
e

D
e
p
a
r
t
m
e
n
t

66 66.1 29.9 92.5 27.2
09.00am 66 66.8 29.8 82.6 28.6
10.00am 66 67.0 30.0 79.1 29.0
11.00am 66 66.7 30.1 75.3 30.1
12.00pm 66 66.2 31.2 78.4 30.4
01.00pm 66 66.0 30.9 75.5 30.3
02.00pm 66 66.0 31.6 61.1 30.9
03.00pm 66 66.8 32.8 70.8 31.0
04.00pm 66 65.9 32.9 61.6 32.8
05.00pm 66 66.0 32.0 62.5 32.9
06.00pm 66 66.1 31.8 60.0 33.0

Air Exchange Rate :

S/N Department Air Exchange Rate
01 Blowroom Department 12.8/hr
02 Carding Department 44.1/hr
03 D/F, Lap Former & Comber Department 9.8/hr
04 Simplex Department 11.2/hr
05 Ringframe Department 47/hr
06 Finishing Department 33.4/hr

Process flow in Air Compressor :

Microfilter Air filter cartridge Compressed screw Air separator Oil cooler
Receiver Dryer Spinning Machineris.

Compressed air used in different section for different purposes :
A. Blowroom Section :
Damper on and off
Material distribution
Air valve open(in jossi)

B. Carding Section :
Coiler tray up and down
Sliver cutting
Page 97 of 112

Dust removal from suction hood by air flow
Grinding

C. Breaker Drawframe :
In drafting system
In weighting arm gripping

D. Finisher Drawframe :
Scanning roller pressure
Weighting arm lock

E. Comber :
Detaching roller pressure
Draw box
Blowing
For cylinder

F. Lap Former :
In drafting zone

G. Ringframe :
SCD (Stationary cop doffing)
Tray moving
Cop gripping
Doffing bar in and out

H. Winding :
Cradle lifting
Suction mouth lifting
Retie pipe lifting
Tension device
Balcon

Maintenance of Compressor :

Air filter change (after 2000 hours)
Oil filter change (after 2000 hours)
Oil change
Oil separator change (after 4000 hours)
Motor greasing (after 4000 hours)

Page 98 of 112

CHAPTER NINE CHAPTER NINE CHAPTER NINE CHAPTER NINE

Power Consumption Power Consumption Power Consumption Power Consumption

Page 99 of 112

CHAPTER 09
POWER CONSUMPTION

Power Consumption of Reedisha Spinning Ltd. (Existing Machineries)

S/N Name of
Section
Ampere Load

Avg.
Volt/m/c
(KW)
Avg.
Load/m/c
(KW)
Exist.
M/C No.
Total
Load
(KW) L1 L2 L3
01 Blowroom +
FDP Unit
264 266 268 390 89.08 Complete
Unit
89.08
02 Carding C-60 13 13 13 390 8.52 16 136.32
03 B/D SB D-40 7 7 7 390 4.58 7 32.06
04 F/D RSB D-40 7.5 7.4 7.3 390 4.85 7 33.95
05 Lap Former
E-32
14.4 14.0 14.5 392 9.41 1 9.41
06 Comber E-65 5.5 5.4 5.01 390 3.47 5 17.35
07 S/F FL100 &
HY492C
14.2 14.45 14.0 390 9.33 9 86.97
08 Ringframe
LR 6/A
44.5 44.0 45 395 29.53 36 1063.08
09 Autocone 26 25.5 25 395 16.92 12 203.04
10 Yarn
Conditioning /
Heat Setting
228 227 227 393 149.87 - 149.87
11 A/C Plant-01 150 152 151 391 99.19 - 99.19
12 A/C Plant-02 650 645 648 391 425.66 - 425.66
13 A/C Plant-03 548 547 550 394 363.40 - 363.40
14 A/C Plant-04 254 255 256 392 167.93 - 167.93
15 A/C Plant-05 200 200 200 394 132.38 - 132.38
16 Compressor 88 89.1 89 392 58.61 4 234.44
17 Dryer 9.3 230 2.07 4 8.28
18 Q.C. & Shop
office Lighting
14.5 8.8 11.5 393 7.65 - 7.65
19 B/R to S/F
Lighting
70 92 65 391 49.70 - 49.70
20 Ring to A/C
Lighting
108 91 90 394 63.76 - 63.76
21 Family
Quarter
15.15 31.73 22.27 394 15.25 - 15.25
22 Female
Quarter
23.19 15.97 2.97 391 9.22 - 9.22
23 Office (Admin) 1.80 4.14 19.98 394 5.73 - 5.73
Total Load 3403.72KW
Page 100 of 112

Power Consumption in Utility Building (Existing machineries) :

S/N Name of
Section
Ampere Load

Avg.
Volt/m/c
(KW)
Avg.
Load/m/c
(KW)
Exist.
M/C No.
Total
Load
(KW) L1 L2 L3
01 Chiller-01
(Steam)
10.84 11.37 10.76 391 7.22 1 7.22
02 Chiller-02
(Hot Water)
9.4 9.8 9.7 392 6.32 1 6.32
03 Chiller-03
(Direct Fire)
9.2 9.5 9.8 391 5.89 1 5.89
04 Boiler 6.2 6.36 3.65 390 3.54 1 3.54
05 Deep Tube
Well
36 37 36 394 28.82 1 28.82
06 45KW Chiller
Pump
58 56 57 393 37.63 7 263.41
07 37KW Chiller
Pump
50 49 50 393 33.01 6 198.06
08 30KW Genera.
Pump
28 27 28 394 18.53 4 74.12
09 11KW Genera.
Pump
18 17.8 17.8 394 11.72 6 70.32
10 Chiller
Cooling Tower
14 15 14 394 9.26 10 92.6
11 Generator
Cooling Tower
8 8 8 394 5.29 4 21.16
12 Make up
Water Pump
10 11 10.5 394 6.95 1 6.95
13 Generator
Exhaust Fan
17.46 25.98 49.6 391 22.56 Complete 22.56
Total Load = 795.08KW

Total Power Consumption : (3403.72 + 795.08)KW = 4198.8KW

Therefore, in Reedisha Spinning Ltd. the existing Power Consumption is 4.2MW.

Page 101 of 112

CHAPTER TEN CHAPTER TEN CHAPTER TEN CHAPTER TEN

Store & Inventory Control Store & Inventory Control Store & Inventory Control Store & Inventory Control

Page 102 of 112

CHAPTER 10
STORE & INVENTORY CONTROL

Inventory system for raw material :

In REEDISHA SPINNING LTD. there different inventory system for different raw
material.

Raw Cotton Store :

All the raw cotton are stored in godown, near the blow room section.

Spears :

In this mills required amount of spears of different machine are stored in mechanical
store room. All the spears are listed in a sheet which is controlled mechanical and
maintenance personal. Spears are arranged in store room according their size,
quantity and requirements. There are selves in store room to keep small spear parts.

Finished Goods :

MSML supplies its finished yarn to different fabric manufacturing industry. So,
package yarn are stored for short time in the finishing section. All the delivered yarn
are noted on tally khata according to lot no, count, quantity, buyers name and other
technical parameter.

Inventory system :

From the Head office any one of the Audit officer is done 01
st
date of every month.

Stores Various Document :
1. Delivery order
2. Quality certificate
3. Store purchase requisition
4. Store requisition book
5. Packing list
6. Transfer advice of finisher yarn
7. Accounts voucher
8. Scrap return memo
9. Waste cotton transfer advice
10. Money receipt
11. Store return memo (for credit)
12. Gate pass (returnable)
Page 103 of 112

CHAPTER ELEVEN CHAPTER ELEVEN CHAPTER ELEVEN CHAPTER ELEVEN

Cost Analysis Cost Analysis Cost Analysis Cost Analysis

Page 104 of 112

CHAPTER 11
COST ANALYSIS

In REEDISHA SPINNING LTD. The main raw material is cotton. The conversion of
fibre into yarn is made in spinning department of a textile mill.

Since the cost center wise computation of the cost of productions the lengthy and
consuming process, presentation of such an exercise is not possible in a short
training course. The board of categories of cost of spinning process is mention bellow,

Raw materials
Packing materials
Power and gas
Store and gas
Salary and wages
Depreciation
Other manufacturing overhead

Raw Material Cost :

Cotton is raw materials used in spinning mill for the production of yarns. Raw
material costs constitute about 55% to 65% of total yarn costs.
A typical example of the computation of raw material cost is given below,

Name of the fibre Fibre Lot Price($) Price(Tk)
CIS-Uzbek-Cottonex 01/05(I,II) 0.72 50.40
CIS-Uzbek- Cottonex 01/05(III,IV) 0.72 50.40
CIS-Uzbek-OLAM 02/05(I) 0.64 44.80
CIS-Uzbek- OLAM 04/05(II) 0.64 44.80
CIS-Uzbek-Cargil 13/05(II) 0.65 45.50
CIS-Uzbek-Cargil 18/05 0.65 45.50

Page 105 of 112

Rate of count wise yarn Price/Kg :

Yarn count Rate/kg US $ Rate/kg Taka Rate/Lbs Taka
Knitting
20/1k 2.40 168.0 75.6
22/1k 2.45 171.5 77.6
24/1k 2.50 175.0 79.2
26/1k 2.58 180.6 81.8
28/1k 2.70 189.0 85.6
30/1k 2.70 189.0 85.6
32/1k 2.80 196.0 80.7
34/1k 2.90 203.0 91.9
20/1c 2.95 206.5 93.5
22/1c 2.85 199.5 90.3
24/1c 2.85 199.5 90.3
26/1c 2.90 203.0 91.9
28/1c 3.05 213.5 96.7
30/1c 3.05 213.5 96.7
32/1c 3.05 213.5 96.7

Page 106 of 112

CHAPTER TWELEVE CHAPTER TWELEVE CHAPTER TWELEVE CHAPTER TWELEVE

Marketing Activities Marketing Activities Marketing Activities Marketing Activities

Page 107 of 112

CHAPTER 12
MARKETING ACTIVITIES

Exported Consumer of the Product :

Reedisha Spinning Mills is a 100% export oriented company. The main buyers of this
factory are given below,

Reedisha Knitex Ltd.
P.A. Knit Composite Ltd.
Apex Knitwear
Greenland Garments Ltd.
Unlima Knitting Mills Ltd.
HR Textiles Ltd.
Fokruddin Textile Ltd.
Jointex Knitwear Ltd.
KAC Fashion Ltd.
Girds Group Ltd.
Nigra Textile
Meghna Knit Composite Ltd.
GMS Group
Gross Line Garments
Flamigo Fashion Ltd.
Jinnat Fashion Ltd.
B.Brothers Ltd.
Epilion Knitwear Ltd.
Harun Twisting Ltd.
Kushiara Composite Ltd.
Padma Poly Cotton
Etc.

Local Consumer of the Product :

Reedisha Spinning Mills produce only Export Quality Yarn. This company does not
sell yarn in local market.

Importing Country :

Raw cotton is imported mainly from Uzbekistan only.

Page 108 of 112

Exporting Country :

Reedisha Spinning Ltd. Does not export yarn directly? They sell yarn to the various
factory of Kohinoor Group and other export oriented factory. They make Knitted
garments & Dyed fabric, then export final product.

Package Level :

Package level contain following information as shown below,
Yarn count
Types of yarn
Code no
Lot no
Factory name
Date of making yarn
Weight in Kg

Measurement of Packaging Bag :

The following measure for the delivery packages as shown below,
Length of Packaging bag = 37 inch
Height of Packaging bag = 48 inch
Weight of Packaging bag = 51.3 Kg
In a bag contains 24 cones of the output product
Each cone contains 2.04 Kg yarn

Marketing Strategy :

The marketing men at first analysis value of raw cotton present time & future time.
If they see that it will be better to buy cotton at present time, they will contract with
foreign company by L.C. immediately otherwise they will buy cotton in future time.
Bellow the result of topic,
Analysis the market
Price strategy
How will act the market
100% export oriented
To take part on the economic condition of Bangladesh
To earn foreign currency

Page 109 of 112

Responsibilities & Duties of Sales man :

The main duty and responsibilities of a sales men are as below,
Introductory call script
Standard call script
Create new customer by giving then concession
To introduce into new product
To increase use procedure
To protect competition
To express the quality product for the customer
To analysis the test of customer
To bring stability of sales by following different techniques

Responsibilities & Duties of Marketing officer :

Marketing officer is a very important person of a company and his duty and
responsibilities are as below,
Buying, selling & transportation
Financing and packaging
Publicity and advertising
Collection of marketing information
Development of strategy for attacking & penetration customer master list
The analysis total consumption of yarn all over the year
They produce a cost sheet of yarn
They visit different textile mills to realize total yarn required
They always look after to world market

Page 110 of 112

CHAPTER THIRTEEN CHAPTER THIRTEEN CHAPTER THIRTEEN CHAPTER THIRTEEN

Conclusion Conclusion Conclusion Conclusion

Page 111 of 112

CHAPTER 13
CONCLUSION

Technical education and its adoption in practical field we involved inextricably,
without the implementation of the knowledge gathered in technical education its
success is bound to suffer. Therefore, this two month industrial attachment as a
partial fulfillment of our B.Sc. in Textile technology course helped us to
accomplish the gap between theoretical and practical knowledge by providing an
elementary idea about industrial environment processing machines, tools and
equipments, production system and maintenance, administration and management
system.
Page 112 of 112

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