Advanced Processing System & Its TechnoEconomics

By: Miss. Pooja Gujar and Mr. Amit Ranjan

Advanced Processing System & Its Techno-Economics

Miss. Pooja Gujar and Mr. Amit Ranjan, (T.E.Textile Engineering,) Anuradha Engineering College, Chikhli. ABSTRACT :Modernization of any process always found to be techno-economical. The studies conducted in this paper were taken the case of Texturisation and weaving looms as both of them are faster growing in Textile industries as well as in all technical aspects. The study reveals in both the cases are common that with the increasing of processing speed and other amenities the same is proven to be more violable towards cost reduction, higher efficiency and better performance. With the modern features of machineries the day by day maintenance schedules are also becoming low and lower. It is also showing lesser power cost and that of man power. This paper also described the latest Models of Texturised Machines with its amenities and advantages over economy. Aim of project Now a day, there is neck to neck competition for each and every aspect of life and the same is also reflected in the textile industry where there are so many producers at fray. The stiff competition at every area is very high. Hence there is always tendency to go for advance technology or advance processing to minimize cost towards production, wages, down gradation and all other relevant aspects to bring the industries at profitable stage. This subject deals with such matter how the relationship can be built between advance processing and that of its technoeconomics. Objective. Right from Blow room to carding, draw frame, ring frame, winding machine, warping machine, sizing machine, loom sheds and even in textile wet processing to texturisation , everywhere the common feature is followed that is cost control and to be more technoeconomical now a days . Hence we would like to highlight certain latest machineries with modern amenities which are producing better quality with lesser cost. The data are generated from the concerned Industries and then brought in to proper shape.

Study No 1 The studies taken in the case of weaving looms of various Types and manufacturers show that with the growth of speed and feature there is good reduction in cost in every aspect. The facts are described at Table no 01. TABLE NO 1 Speed ( rpm) for 60 loom width Production / day/loom ( Mtr) considering 72 PPI

LOOM Ordinery loom

Eff %

Quality %

Motor HP

No of Looms / weaver

Electrical cost/ mtr of fabric ( Rs)

140

85

90

60

3.2

Ruti C

200

95

98

2.5

95

2.48

Air Jet

700

98

99

350

1.92

Rapier Loom Water Jet

400

98

99

196

2.9

525

98

99

257

2.16

Sulzar ( Double width)

350

99

99

346

8 to 12

1.4

Used For Shirting / suiting . Max fab 1 wt. 20 kg Good for any Shirting/ Domestic suiting 0.59 25 kg Denim , suiting of any quality. 0.16 Shirting Shirting / suiting Export 0.48 quality good for polyester 0.21 shirting Any 0.21(8looms) fabric quality 0.14(12 light to looms) heavy.

Wage / mtr of fab ( Rs)

resourse: Btra, Morarjee mill, Nag.

The data collected from the industries are compared for the common width i.e. 60 inch and with common pick per inch i.e. 72. It shows that with the gradual modernization of machineries, there are remarkable improvement in efficiency, quality, less power consumption and savings in wages. As per the studies Sulzar found to be the best in cost saving towards electricity, wages, and efficiency and in quality. However number of looms per weaver as shown in the table is an average data which can be varied from mills to mill. For example in Sulzar loom there can be as high as 12 machines per weaver is found to be allotted for 60 inch looms. The initial price factor is one of the most important subjects. As on to day, Sulzar found to be the costliest one. Hence there is tendency to go for Imported 2nd hand machineries at Indian Textile Industries. However, the maintenance cost is very low on Sulzar machine which compensate the initial cost.

Study No.2 The study was taken with latest Texturising machine prevailing at Market i.e. of Alidhara which is in competition with other manufacturer now a day. The latest modal HF12 having running speed 1100 mpm is found to be more economical than that of old modal AF7 running at 700 mpm. The details are explained on table no 2. TABLE NO 2

Alidhara Machine (Production For 80 Denier 5 Kg Package ) Total no of positions =312 for both machines Modal no. Speed(mpm) Production per day(kg) AF7 700 2800 HF12 1100 4400

Mc. HP

60

Multiple motor with total HP 68

Units consumed per hour per machine Units consumed per kg of yarn produced Expenses on electricity per kg(Rs) Salary per operator per kg(Rs) Savings per mc per day. Resourse : Devika

65 0.55 2.75 0.26 -------

85 0.46 2.3 0.16 Rs.1904

From table no 2 it is clear that there is saving of Rs 1904 per day per machine in comparison to its old model of version AF7. There is hardly any difference on yarn breakage rate during texturisation, quality, down gradation and waste percentage. Rather latest model is more viable for producing export quality because of its unique feature like disc configuration, heater quality and modern cradles etc. It is found although the horse power is higher in latest models where individual motors are been placed the ultimate and total electrical consumption is lesser than that of old model with slow speed. It is because higher rate of production is compensated the electrical consumption. The latest model being Inverter driven there is no time loss during parameter change. Further the latest model can be able to produce the texurised package of as high as 8 kg and plus which is further cost effective . Study No 3 Now a days another new unique feature has come in texturising industry i.e. Auto doffing. The same is described in table no 3 that how it is more economical than that of conventional normal doffing system.

TABLE NO 03 The difference between Auto doffing and normal doffing(taken from Barmag machine) AUTO DOFFING Man power Salary per kg(Rs) Waste % Export quality(%) 1 operator per 2 machines 0.9 0.41 85 (with tail end and uniform package weight) Doffing Doffing efficiency Saving per machine per day Random doffing Less (3-4%) Rs 1375 Resourse : RIL From table it is clear that in auto doffing, the savings per machine per day is Rs 1375.00 The saving consists of waste percentage and wages. There is no difference in breakage rate and quality. In auto doffing system the Export quality found to be higher because of better and uniform tail end with uniform package weight as demanded in Export market. The doffing efficiency is found to be less by 3-4% in case of auto doffing system which is a bit lacuna in tracing back the defective package during processing. However with the implementation of proper system management this lacuna is minimized. The auto doffing is described as random doffing but the normal doffing is told as gang doffing. Both are having no disadvantage as such. Study No 4 There is gradual increase in speed and features in the Himson Machines itself within a span of 25-30 years. With Pin drive model of Scragg and with a speed of just 100 mpm , there is gradual improvement in speed and other technical aspects. In the field of Texurisation as on today, the Himson Machines are having the major share in the market. There are gradual Gang doffing High NORMAL DOFFING 1 operator per 1 machine 1.8 0.45 75

improvements in the models developed by Himson Engineering is shown below. It was done in order to make the matters more techno economic and customer friend. The same is described at Table no 04 TABLE 4 Modal SDS-3 SDS-6 SDS-7 SDS-8 SDS-9 Speed(mpm) 300-350 600-650 703-750 750-800 850 Type of Disc lo.snow lo.snow lo.snow/PU disc PU disc PU disc PU disc with larger size and SDS-12 900 dia. 1-4-1 240,288 with rotary creel No. of disc 0-9-0 0-9-0/0-6-0 0-6-0/1-4-1 1-4-1 1-4-1 No of position 96,144,188,216 144,188,216 144,216,240 240 240,288

Resourse : Himson

All the above models have shown the gradual improvements in speed and in all other technical aspects for the higher production and better quality. As every body is aware that as on today the no. of texturising machine is contributing highest by Himson and hence one comparison study was taken with the latest model of Himson. The same is shown in table no 5 TABLE NO 5 Studies compared in Himson Text. Mc. Model No HSS3-AX3 , Speed 1100 mpm, 312positions Features Breakage rate Downgradation Waste% Power saving Machine maintenance Close heater Same Same Same 15% Slightly high because of cleaning of heater tube and telephone guide Resourse : Himson Open heater Same Same Same

In table 5 a compression study was taken with latest Himson model HSS3-AX3 whose mechanical speed is 1100mpm with 312 positions among its close and open heater . Studies are not being conducted from its old model to the latest as the same trend is already achieved from the studies of Alidhara machine. So, this table has compared in the high speed model its self between open and close heater. It is found that in the case of close heater power saving is 15% whereas in case of maintenance close heater is little bit critical as it require frequent cleaning of heater tube and telephone guides. For the micro yarns it is not suggestible to for close heater. Conclusion :The studies were kept limited only in the case of loom and that of texturising machine because both of them are faster growing in the world of textile. Textile engineering and its field is vast ocean where every aspect right from blow room to ring frame, winding to sizing, loom shed, wet processing, non-woven, technical textile, medical textile, are growing at every aspect and in the same trend. Studies can be taken at each area but the result will be common for all i.e. better the feature better are the techno-economical. Our sample studies have proven the same.

ACKNOWLEDGEMENT The students are grateful to Mr.B.Basu, T&P officer of Anuradha Engineering College for his guidance in preparing the whole report. The student are also grateful to Shri Guru Gobind Singhji Institute of Engineering and Technology,Nanded for their kind permission to present the paper. The acknowledgements are also due to HOD, Department of textile Mr.V.S.Shivankar and Principal Dr. S.V. Agarkar for their kind permission to allow the students in presenting the paper.

Thanks To All

Any Question ?