PROCESS CONTROL IN

SPINNING
Prof. R. Chattopadhyay
IIT, Delhi



QUALITY ASSURANCE IN SPINNING
STEPS

Setting of Norms

Quality of incoming raw material to te !a"i

Institution

Process #onitoring an" Control

Ins$ection of final $ro"uct

#ATERIAL %L&'
Transportation of
Sliver / roving
Internal transportation
CENTRAL SLI(ER
PLANT
Raw cotton
!a"i
Institution )
!a"i
Institution*
!a"i
Institution+
,istri-ute" s$inning
in .illages
Institutional
s$inning
Transportation of
sliver or roving
(illage )
(illage *
(illage + (illage n
Charkha
) * + / )0

PR&CESS
In$ut &ut$ut
Monitor
Com$are
against norm
Correcti.e
action
#onitor
Process $arameters
1Interme"iate $ro"uct
caracteristics1#acine
con"itions1'or2 $ractice 1
$rocess waste
Com$are
against norm
Correcti.e
action
#onitor
Com$are against
norm
PR&CESS C&NTR&L

QUALITY &% INC&#ING RA'
#ATERIAL T& CENTRAL SLI(ER PLANT

Test of raw cotton in terms of $ysical $arameters

an" acce$t if com$ara-le wit norms

Careful trans$ortation 3 storage of cotton -ales

Cec2 sli.er or ro.ing $arameters i4 e

Count an" count C(5
Tras 5 3 Ne$s

Cec2s on material an"ling "uring $ac2aging an"

loa"ing on truc2s
6 Transfer sli.er into $olytene -ags
6 Put ro.ing -o--ins into $olytene -ags
6 Trans$ort sli.er cans7 $olytene -ags
containing sli.er or ro.ing on to te truc2s4
6 Pro$erly co.er sli.er cans7 $olytene -ags
containing sli.er or ro.ing on truc2s

QUALITY &% RA' #ATERIAL RECEI(E, 8Y
!9A,I INSTITUTI&N

Cec2s on material an"ling "uring Unloa"ing from

truc2s
6 Careful unloa"ing of $ac2ages
6 Careful internal trans$ortation to a.oi" "amage
6 Pro$er storage an" segregation of sli.er1 ro.ing
to a.oi" acci"ental mi:ing

Cec2s on "eli.ere" sli.er 1 ro.ing

6 'eiging of $ac2ages
6 Cross cec2ing of a.erage count

,ISTRI8UTU&N &% R&(ING &R
SLI(ER T& T9E SPINNERS
- Ensure tat te sli.er or ro.ing corres$on"s to
te count to -e s$un4
;
6 Te $ac2age is co.ere" in $olyetylene seet4
I
n 6 Instruction a-out careful an"ling of $ac2age
"uring way -ac2 to .illage4


C9AR!9A SPINNING GUI,ELINES
a< 'or2 $ractice relate"
I4 Running of Car2a
6 Run at a slow s$ee" in te -eginning an" ten
raise s$ee" an" maintain s$ee" at a con.enient
le.el4
6 Co.er te car2a once s$inning is o.er4
6 Te -ro2en en" soul" -e $iece" =>oine"<
$ro$erly4 A 2not is to -e a.oi"e" as it -ecomes
too large wit res$ect to te yarn "iameter7
wic "eteriorates fa-ric a$$earance

II4 Lea #a2ing
6All te sections of te lea soul" -e ma"e from
same yarn count4
6Te en" of te yarn soul" -e inserte" in to te
inner $ortion of te lea4
6Leas soul" -e $ro$erly store" in $lastic -ags or
fa-ric -ags wit count wise segregation -y colour
mar24
6If $ossi-le7 lea -un"les soul" -e segregate"
wile storing accor"ing to te ty$e of fi-res use"
or count to a.oi" acci"ental mi:ing4

-< #aintenance relate"
6%ollow a s$ecifie" maintenance sce"ule in terms
of cleaning an" oiling4
6To$ roller $ressure soul" -e cec2e" at regular
inter.als4
6Cec2 te con"ition of te a$rons an" "ri.ing
-elts =mall< an" a">ust if necessary4
-< Parameters selection
6 Select $arameters -ase" on $ast e:$erience tat
suits te raw material4


QUALITY ATTRI8UTES T& 8E
C&NTR&LLE, IN !9A,I YARN

A.erage Count an" It?s C(5

Lea CSP

Yarn Une.enness

Im$erfections

Soft an" ar" twiste" $ortion

%aults

Pote

!acara

#oore

,agi

8a2ar

Slu-s

Possi-le reasons for "eterioration in @uality

Caracteristics an" occurrence of faults

PR&CESS C&NTR&L &% C9AR!9A
SPUN YARN

,etection of significant sift in @uality le.el

In.estigation on te causes of "e$arture

Ta2ing reme"ial action imme"iately to set te $rocess

-ac2 to normal

#onitoring stages an" Caracteristics to
-e monitore"
YARN STAGE
6A.erage count an" count .aria-ility
6Uniformity
6Im$erfections
6Count Strengt Pro"uct =CSP<
INTER#E,IATE STAGES
Sli.er
6Sli.er count an" its .aria-ility
6Sli.er uniformity
6Sli.er cleanliness


Ro.ing
6Ro.ing count an" its .aria-ility
6Ro.ing uniformity
6Ro.ing cleanliness
Process Performance
6'aste le.el
6En" -rea2s in car2a
6 Pro"ucti.ity

,etection of sift in yarn countA
E:am$leA
Nominal Count B *0 Nm
A.erage weigt of lea B C0 gm
Count C( 5 B )0
S4,4 of count B Cgm
'arning limit B #ean * S4,4 B C0 )0
B D0 gm an" /0 gm
Action limit B #ean +* S4,4 B C0 )C
B DCgm an" +Cgm

L
e
a

w
e
i
g

t


=

g
m
<
&$erator I,
Lower 'arning Limit =L'L<
U$$er Action Limit =UAL<
U$$er 'arning Limit =U'L)
Lower Action Limit =LAL<
C0 g
/0 g
+C g
D0 g
DC g
Sift

L
e
a

w
e
i
g

t


=

g
m
<
&$erator I,
Lower 'arning Limit =L'L<
U$$er Action Limit =UAL<
U$$er 'arning Limit =U'L)
Lower Action Limit =LAL<
C0 g
/0 g
+C g
D0 g
DC g

L
e
a

w
e
i
g

t


=

g
m
<
&$erator I,
Lower 'arning Limit =L'L<
U$$er Action Limit =UAL<
U$$er 'arning Limit =U'L)
Lower Action Limit =LAL<
C0 g
/0 g
+C g
D0 g
DC g

'9AT ACTI&N IS T& 8E TA!EN

%or case I
6'rong ,raft Cange Pinion = ,CP<
6Ina".ertent cange in "raft constant
6'rong count of sli.er or ro.ing

%or case II
6Count of sli.er 1 ro.ing su$$lie" is to -e .erifie"
6Too coarse an" too fine sli.er 1 ro.ing are to -e
wit"rawn
6,raft on car2as are to -e a">uste"


Control of Count (aria-ility
&$era
tor
No4
Count (alues of Lea No4
1 2 3 4 5 6 7 8 9 10
)
*
+
/
C
D
E
F
G
)0

Calculation of witin an" -etween count C(

REAS&NS %&R 9IG9 8ET'EEN &PERAT&R C&UNT
(ARIA8ILITY =C(8&<

,ifference in a.erage an2 of sli.er1 ro.ing use"4

,ifference in te total "rafts in te car2as

,ifference in effecti.e "rafts -etween s$in"les of car2as

"ue to cot sli$$age4

Ro.ing stretc
REAS&NS %&R ,I%%ERENCE IN A(ERAGE SLI(ER 9AN!
,ifference in waste le.el an" mecanical "raft in car" -rea2er
or finiser "raw frame4

,I%%ERENCE IN A(ERAGE R&(ING 9AN!

,ifference in sli.er an24

,raft "ifference in s$ee" frames4

,ifferences in waste le.el in car"4

,I%%ERENCE IN A(ERAGE ,RA%T IN C9AR!9AS

'rong "raft constant in car2a or wrong cange

$inions

,ifference in effecti.e "raft witin a car2a

6Sli$$age of to$ rollers7 ina"e@uate roller $ressure4
R&(ING STRETC9ING

Ina"e@uate ro.ing twist7 low inter fi-re coesion

=s$ecially wen fi-res are sort<7"efecti.e -o--in
ol"er

YARN UNI%&R#ITY 1 UNE(ENNESS
)4 A routine cec2 on all te sam$les recei.e" may not
-e $ractica-le4
*4 &nly wen yarn sam$les for any new lot arri.es 7 te
test can -e carrie" out -y ran"omly selecting +0 leas
from as many o$erators as $ossi-le4

REAS&NS %&R UNE(EN YARN

Incorrect setting of -rea2 "raft on ,1%7 S1% or car2a4

Ina"e@uate to$ roller $ressure4

'ear1"amage" a$ron or cots4

Eccentric to$ roller y in car2a4

9ig sort fi-er $ercentage in sli.er or ro.ing4

Too wi"e setting in te front Hone of car2a4

Sli$$ing a$ron4

YARN APPEARANCE

Su->ecti.e assessment -ase" on .isual cec2 of yarn

-oar"s on yarns recei.e" from o$erators wen fres
yarn lots are recei.e" from tem for a new mi:ing 4

#aintain a recor" accor"ing to o$erator I,

REAS&N %&R P&&R APPEARANCE

9ig yarn une.enness

#any e:cessi.ely se.ere tic27 tin $laces an" ne$s

in te yarn

Presence of too many im$urities li2e see" coat7

lea.es7 stal2s etc in te yarn

C&RRECTI(E ACTI&NS T& 8E TA!EN

Cec2 te o.erall con"ition of te car2a an" roller

setting

Re$lacement of "efecti.e "rafting rollers or a$rons

Cleaning of accumulation of stray fi-res on "rafting

elements7 ring7 tra.elers7 gears etc soul" -e a.oi"e"4

Roller sli$$age -ecause of low $ressure or $resence of

oil on roller surface is to -e a.oi"e"4

Ne$s in sli.er to -e maintaine" as $er te norms

Cleanliness of te sli.er

Yarn Count Strengt Pro"uct =CSP<
&$erator I,
LWL
UAL
UWL
LAL
)000
D/0
ED0
gm
)*/0
)+D0
L
e
a

w
e
i
g
h
t

(
g
)
A.erage CSP B )000 for count */ ; +D Nm
CSP C(5 B )*7 CSP S4,4 B )*0
UAL B )000 I + )*0 B )+D0
U'LB )000 I * )*0 B )*/0
LAL B )000 6 + )*0 B D/0
L'LB )0006 * )*0 B ED0

Action to -e ta2en
Case IA Points fall -elow te lower Action Limit or
continues to fall in -etween 'arning an" Action Limit
for many o$erators4
Case IIA Points are "istri-ute" wit a wi"e scatter4
Case IA A re$eat cec2 on te yarn su$$lie" -y te
o$erator wose estimate" CSP .alue fall -elow te
action limit is to -e $erforme"4 At least D leas are to -e
teste" an" te a.erage is to -e foun" out4 If te a.erage
is foun" to -e still lower7 ten reme"ial measures soul"
-e ta2en4


P&SSI8LE REAS&NS %&R L&' A(ERAGE CSP

6Ina"e@uate twist in te yarn4
6%iner yarn count4
6'ea2 fi-res in mi:ing4

Twist an" count testing of te same are to -e
$erforme" to fin" out weter te twist is really low
or te count is fine4 Te lower twist coul" -e
attri-ute" toA
Lower s$in"le s$ee" "ue to sli$$age7 wic can -e
"ue to
Loose "ri.ing cor" of s$in"les4
Accumulation of oil1grease on cor"
"ri.ing te s$in"les =mall<4

Reasons for finer yarn
69iger total "raft4
6Te finer sli.er1ro.ing su$$lie"4

If count an" twist are as $er nominal .alue -ut
CSP is still foun" to -e less7 ina".ertently a sli.er1 ro.ing
may a.e -een su$$lie" from a mi:ing in wic te
fi-res are intrinsically wea24
Reasons for high strength variation
; Intermittent sli$$age of to$ roller in te car2as4
; (aria-ility in -etween yarn count $ro"uce" on
"ifferent car2as4