+

NAHAR INDUSTRIAL
ENTERPRISES LIMITED (NIEL II)

SUMMER TEXTILE INTERNSHIP

Submitted to : Submitted by :
Mr. Dharmendra Chaudhary Akash Verma
Training Officer Nikhil Sharma

NIEL II, Lalru (Punjab) JNGEC

SUNDERNAGAR(H.P)

1
 ACKNOWLEDGEMENT
Success in any endeavour calls for co-operation and guidance from all, especially ear-ones,
seniors and environment. This was amply brought to us while undergoing industrial
training and project work.

This Project Report gives us an opportunity to thank all those who have helped us to make this
training a learning experience.

Above all, we are thankful to the God almighty and our parents, who are our idols.

We express our heartiest thanks to ER Vivek Sharma (Placement incharge), Gaurav

Grover(Training guider) for arranging our training at NAHAR INDUSTRIAL
ENTERPRISES LTD, LALRU.

We are extremely grateful to MR.NITIN KAPUR (HR&ADMIN), MR.VIKAS RAINA (GM

NIEL II), MR J L VERMA(HR NIEL II) for providing us an opportunity to do industrial training
in this organization. We owe our indebtedness to MR.DHARMENDER CHAUDHARY(HOD
PRODUCTION) ,MR.BRIJMOHAN SINGH(HOD R&D.), MR.RAKESH SAHU (HOD
MAINTINANCE)under whose able guidance and kind control, we have completed our training
successfully. We are grateful to them for all their support, which helped us to know the practical
aspects of the various services. Finally we express our gratitude to the entire staff of NAHAR
INDUSTRIAL.ENERPRISES.LTD., LALRU. for their kind co-operation and assistance
during the course of our training.

With regards,

AKASH VERMA
NIKHIL SHARMA

2
 INDEX
S.NO. CONTENTS PAGE NO.

1. INDUSTRY PROFILE 04

2. INTRODUCTION TO NAHAR INDUSTRIAL ENTERPRISES LTD. 05

3. PROCESS FLOW 11

4. DEPARTMENTAL INFORMATION 12

5. PROCESS /PRODUCTION PARTICULARS 25

6. MAINTENANCE SCHEDULE 56

7. WASTE AND USES 57

8. R&D 59

9. PACKING 63

10. PLANT LAYOUT 65

11 TIME OFFICE & STAFF 66

INDUSTRY PROFILE

3
 QUALITY POLICY

We are committed to produce as per customers requirement by using specified yarn, continuous
improvement in process & optimum realization at all stages. We shall achieve this by:-

 UPGRADING THE QUALITY OF PRODUCT

 BY IDENTIFYING THE CUSTOMER REQUIREMENT AND FULFILL
THEM
 PERSUING THE PROCESS OF CONTINUOS IMPROVEMENT BY
EMPLOYEES OF ORGANISATION
 ENSURING THE QUALITY STANDARD ARE MAINTAINED

INTRODUCTION TO NAHAR GROUP

4
NAHAR GROUP, established in 1949 with Oswal Woolen Mills, Ludhiana, surges a head in
establish itself as a repudiated industrial conglomerate with a wide range from spinning, knitting,
fabrics, hosiery, garments, soaps, vegetable oils and sugar.
.
.

Oswal Woolen Mills Limited.

Nahar Spinning Mills Limited.

Nahar Export Limited.

Nahar Industrial Enterprises Limited

Nahar International Limited

Nahar Sugar and Allied Industries Limited

NAHAR INDUSTRIAL ENTERPRISES LIMITED (NIEL)

5
Nahar Industrial Enterprises Limited (NIEL) was incorporated on 27th September, 1983 as
Oswal Fats & Oils Ltd. NIEL is a vertically-integrated textile manufacturer, with operations
ranging from spinning, weaving & processing and also having sugar unit with 2500 TCD per
day. NIEL is evolution of amalgamation of different group companies with it. NIEL's strategic
objective is to capitalize on the growth opportunities that it believes are available in the domestic
and global textile industry. At the same time the company recognizes the competitive nature of
the industry, especially with pressure from Asia, and that to maintain growth it must continue to
improve production process and reduce costs.

The Journey

1983 Incorporated as Oswal Fats & Oils Limited.

1994 Name changed as Nahar Industrial Enterprises Limited.
1997 Merged Nahar Fabrics Limited (manufacturer of greige fabric).
Merged Oswal Cotton Mills Limited (manufacturer of Processed
2002
fabrics and finished garments).
Merged Nahar International Limited (manufacturer of yarn)
2005 &Nahar sugar & Allied Industries Limited (manufacturer of sugar &
steel).

INTRODUCTION TO NAHAR
6
 INDUSTRIAL ENTERPRISES LTD.
GENERAL INFORMATION:

Name Of The Mill NAHAR INDUSTRIAL ENTERPRISES LTD. SPINNING UNIT-2

Address Vill: Jalalpur; Chandigarh-Ambala road;

P.o.- Dappar; pin-140506; Distt. -Mohali(pb).

Nature of mill Cotton yarn.

Transport Raw material is brought to mills by trucks.

Finished products are sent by same means.

No of shift/day 3 shifts.
A shift : 8 am – 4 pm
B shift: 4 pm – 12 am
C shift: 12 am – 8 am

Source of raw material HARYANA, MUMBAI, GUJRAT, Rajasthan

PUNJAB, MADRAS, WEST BENGAL etc.

Godown Total 8
Raw material=4; waste=1;
Packing=1, Storage=1,Conditioning=1

ORGANIZATION SET-UP

7
 GM(MR.VIKASH RAINA)

HR(MR.AJAY SHARMA)

HOD PROD.(MR.DHARMENDER
CHAUDHARY)

HOD R&D(MR.BRIJMOHAN SINGH)

HOD MAINT.(MR.RAKESH SAHU)

EXECUTIVE PROD(MR.KULDEEP BOORA)

EXECUTIVE PROD(MR.AZAD SINGH)

(MR.KARAN ARORA)

FUNCTIONS OF DIFFERENT DEPARTMENTS

8
The whole unit has been divided into various departments such as production, human resources,
R&D and QA etc. The brief functions of each dept. are as follows:

MARKETING:

1. Brand building
2. To formulate strategies ,plan & policies.
3. Promotion of the business in overseas market.
4. Ensures achievement of sales/financial objectives.

MIS, COSTNG & BUDGETING

1. To prepare daily reports.(including profitability reports).

2. To prepare product costing & related information.
3. To conduct physical verification of stock as & (Monthly)when required.
4. To monitor the unit performance against set targets.
5. To ensure correct & timely information flow across the organization including areas of
concern.
6. To facilitate monthly planning processes/BSC/weekly planning.
7. To analyze performance parameters and making trends to analyze it etc.

MAINTENANCE:
1. To ensure uninterrupted availability of machines.
2. To ensure & execute best maintenance work practice, system and SOP of textile and their
compliance of the unit.
3. To improve the technical skills the subordinate to enhance decision making.
4. 0To maintain best health of machines to produce quality yarn.
5. To execute orders for the various spare parts.

ELECTRICAL:

9
 1. To implement the preventive maintenance schedules of plant machinery.
2. To provide electrical maintenance support for all production equipments.
3. To implement energy saving initiatives and process improvement activities.

R&D:

1. To plan and manage R&D activities in the unit.

2. To plan and manage raw material for the whole year.
3. To conceptualize, Visualize, Plan and develop new products.
4. To plan and execute process improvement activities.
5. To operate and maintain all testing activities.
6. To coordinate with production and marketing functions
7. To produce customer centric products.

PRODUCTION:

1. Production Planning.
2. Ensure timely availability of resources in coordination with commercial department.
3. Continuously monitor and evaluate performance of production machinery to achieve
desired quality standard.

HUMAN RESOURCE:

1. Manpower planning and recruitment.

2. Ensure adherence to approved policies ,procedures(internal & external)
3. Develop and enhance the potential of all members.
4. Maintaining harmonious industrial relations.
5. Controlling personnel costs.
6. To implement HR policies in true spirits.

PROCESS FLOW
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 SEQUENCE OF DEPARTMENTS IN PRODUCTION

RING SPINNING OPEN/END

CARDED COMBER BLOW ROOM

BLOW ROOM BLOW ROOM CARDING

CARDING CARDING FINISHER D/F

BREAKER D/F BREAKER D/F O/E WINDING

FINISHER D/F LAP FORMER CONDITIONING

SPEED FRAME COMBER

RING FRAME FINISHER D/F PACKING

AUTO CONER SPEED FRAME

CONDITIONING RING FRAME

PACKING AUTO CONER

CONDITIONING

PACKING

DEPARTMENT INFORMATION

11
LIST OF MACHINES & THEIR SALIENT FEATURES

BLOWROOM

 LINE NO.-01

Blendomat

MAKE : TREUTZSCHLER
MODEL : BDT BOA 2300
YEAR : 2009

Precleaner

MAKE : TREUTZSCHLER
MODEL : CLP
YEAR : 2009

Multimixer

MAKE : TREUTZSCHLER
MODEL : MPM-8 1200
YEAR : 2010

12
 Cleanomat Cleaner

MAKE : TREUTZSCHLER
MODEL : CLC-1 1600
YEAR : 2010

Vetal

MAKE :
MODEL :
YEAR : 2010

 Line no.-02

Blendomat

MAKE : TREUTZSCHLER
MODEL : BDT BOA 2300
YEAR : 2009

.Precleaner

MAKE : TREUTZSCHLER
MODEL : CLP
YEAR : 2009

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 Multimixer

MAKE : TREUTZSCHLER
MODEL : MPM-8 1200
YEAR : 2010

Cleanomat Cleaner

MAKE : TREUTZSCHLER
MODEL : CLC-1 1600
YEAR : 2010

Vetal

MAKE :
MODEL :
YEAR : 2010

 LINE NO.-03
BALE PLUCKER

MAKE: LAKSHMI
MODEL: LA23
YEAR: 2007

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 VARIO CLEAN
MAKE: LAKSHMI
MODEL: LB9/2
YEAR: 2007

UNIMIX

MAKE: LAKSHMI
MODEL: LB7/4
YEAR: 2007

.Vetal Scan
MAKE: VETAL SCAN
MODEL:
YEAR: 2014

FLEXICLEAN

MAKE: LAKSHMI
MODEL: LB5/6,LB5/5
YEAR: 2010,1995

Vetal

MAKE: VETAL SCAN

 LINE NO.-04

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 BALE PLUCKER

MAKE: LAKSHMI
MODEL: LA23
YEAR: 2007

VARIO CLEAN
MAKE: LAKSHMI
MODEL: LB9/2
YEAR: 2007

UNIMIX

MAKE: LAKSHMI
MODEL: LB7/4
YEAR: 2007

Vetal
MAKE: VETAL SCAN
MODEL:
YEAR: 2014

FLEXICLEAN

MAKE: LAKSHMI
MODEL: LB5/6,LB5/5
YEAR: 2010,1995

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 Vetal

MAKE: VETAL SCAN

.CARDING

DEPARTMENT-1
MAKE: LAKSHMI
MODEL: LC300A,LC333
TOTAL NO. OF MACHINES: 19
SERIAL NO.OF MACHINES: LC300A(1-19) LC333(19)

DEPARTMENT-2
MAKE: TREUTZSCHLER
MODEL: TC-5-3,TC03,
TOTAL NO. OF MACHINES: 17
SERIAL NO.OF MACHINES: TC-5-3(20-22,27-38,24),TC03(23)

.DRAWFRAME-I

DEPARTMENT-1

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MAKE: LAKSHMI
MODEL: LD-2,
TOTAL NO. OF MACHINES: 3
DRAFTING ARRANGEMENT: LD-2= 4/3
NO.OF DELIVERIES: 2 EACH
NO.OF DOUBLING: 5
CREEL CAPACITY: 16

DEPARTMENT-2
MAKE: Rieter
MODEL: SB-20
Total NO.OF MACHINES: 2
DRAFTING ARRANGEMENT: 3/3
NO.OF DELIVERIES: 2 EACH
NO.OF DOUBLING: 5
CREEL CAPACITY: 16

LAP FORMER

DEPARTMENT-1
MAKE: LAKSHMI

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MODEL: LH10
TOTAL NO.OF MACHINES: 3
DRAFTING ARRANGEMENT: 4/4
NO.OF DELIVERIES: 1
NO.OF DOUBLING: 22
CREEL CAPACITY: 28

COMBER

DEPARTMENT-1
MAKE: LAKSHMI
MODEL: LK64
TOTAL NO.OF MACHINES: 05
SERIAL NO.OF MACHINES: LK64−(11-15)
DRAFTING ARRANGEMENT: 3/5
NO.OF DELIVIERS: 1
NO.OF HEADS: 8 EACH
TYPE OF FEED: FORWARD FEED

DEPARTMENT-2
MAKE: LAKSHMI
MODEL: LK-54
TOTAL NO.OF MACHINES: 10
SERIAL NO.OF MACHINES: 1-10

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DRAFTING ARRANGEMENT: 3/5
NO.OF DELIVIERS: 1
NO.OF HEADS: 8 EACH
TYPE OF FEED: BACKWARD FEED

DRAWFRAME-II

DEPARTMENT-1
MAKE: LAKSHMI
MODEL: RSB851
TOTAL NO.OF MACHINES: 10
DRAFTING ARRANGEMENT: 3/3
NO.OF DELIVIERS: 2
NO.OF DOUBLING: 8
CREEL CAPACITY: 8

DEPARTMENT-2
MAKE: RIETER
MODEL: D-221
TOTAL NO.OF MACHINES: 4
DRAFTING ARRANGEMENT: 4/3

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NO.OF DELIVIERS: 2
NO.OF DOUBLING: 8
CREEL CAPACITY: 8

.SPEED FRAME

DEPARTMENT-1
MAKE: LAKSHMI
MODEL: LFS1660
TOTAL NO.OF M/C: 09
DRAFTING ARRANGEMENT: 3/3
NO.OF SPINDLES: 120
TOTAL NO.OF SPINDLES: 1080

DEPARTMENT-2
MAKE: ZINSER
MODEL: 68 i
TOTAL NO.OF M/C: 5
DRAFTING ARRANGEMENT: 3/3

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NO.OF SPINDLES: 160
TOTAL NO.OF SPINDLES: 800

.RING FRAME

DEPARTMENT-1
MAKE: LAKSHMI
MODEL: LR6-AX , LR60-AX , LR63-AX
TOTAL NO.OF M/C: 31
SERIAL NO.OF M/C: 1-31
DRAFTING ARRANGEMENT: 3/3
NO.OF SPINDLES: 1200 EACH
TOTAL NO.OF SPINDLES: 37200

DEPARTMENT-2
MAKE: KTTM
MODEL: RXI-240
TOTAL NO.OF M/C: 05
SERIAL NO.OF M/C: 31-36
DRAFTING ARRANGEMENT: 3/3
NO.OF SPINDLES: 1440 EACH
TOTAL NO.OF SPINDLES: 7200

WINDING
DEPARTMENT-1
a.AUTOCONER

MAKE: SCHLAFHORST

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MODEL: AC5 D , AC5 RM , AC338 RM
TOTAL NO.OF MACHINES 09
SERIAL NO.OF MACHINES: AC5 D(2,7,8,10) , AC5 RM(3,4,5,6,) ,
AC338 RM(9)
NO.OF DRUMS: 540

b.LINK CONER

MAKE: MURATEC
MODEL: 21-C
TOTAL NO.OF MACHINES 16
SERIAL NO.OF MACHINES: 4-7,25-31,32-36
NO.OF DRUMS: 477

c.CHEESE WINDING
MAKE: RESHAMI , PEASS
MODEL: RAW-P(RESHAMI) ,
PPW-A V1 , PPW-A V1(PEASS)
TOTAL NO.OF MACHINES: 05
NO.OF DRUMS: 146

d. T.F.O.

MAKE: VEEJAY LAKSHMI , MURATEC

MODEL: VJ 150 MN(VEEJAYLAKSHMI) ,
3C-1(MURATEC)
TOTAL NO. OF MACHINES: 12

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TOTAL NO.OF DRUMS 2442

OPEN END MACHINE

MAKE: SCHLAFHORST
MODEL: AC-08
NO.OF DRUMS: 432

AIR COMPRESSOR
MAKE: ATLAS COPCO
MODEL: GA 132 W , GA 110 W FF , GA 90 VSD ,
GA 18+
CAPACITY: 2108 CFM
NO.OF MACHINES: 04

PROCESS / PRODUCTION PARTICULARS

RAW MATERIAL PROCUREMENT AND BALE MANAGEMENT

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 INTRODUCTION:

Raw materials are direct input with pre- requirement to produce output of desired quality
and characteristics. Raw material department has to endure extreme pressure generated in
view of the present international scenario where “ consistent quality ’’ is the success slogan.

ROLE OF RAW MATERIAL DEPT. SUMMARISED AS:

 It ensures regular flow of materials to the production unit. It has to maintain the stock
position of various raw materials and send it to corporate raw material department for day
to day planning and decision making raw materials.
 It also ensure proper storage of raw material.

COTTON

Introduction

Cotton is defined as white fibrous substance covering seeds harvested from cotton plant. Seed
Cotton(called Kapas in India) is harvested from Cotton Plant. Lint Cotton (ruia in Hindi) is
obtained by removing the seeds in a ginning machine. Lint Cotton is spun into Yarn, which is
woven or knitted into a Fabric. Researchers have found that cotton was grown more than 9000
years ago. However large scale cultivation commenced during middle of 17th Century AD.

RAW MATERIAL

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 Domestic sources = J-34, S-6 from Maharashtra, mech-1 from Tamil Nadu
 Imported sources= PIMA 7 GIZA from Egypt, FOUNDLANDS from USA
 No. of fibres per cross section of yarn = 15000/count × MIC
 Bale size = 165kg
 Storage area= 50×100m.sq
 Count:
o <40s count: Indian
o 40s – 50s count: blend of imported & Indian used
o >50s: imported cotton

TYPE OF COTTON USED:

J-34
SHANKAR-6
H-4
MECH-1

26
 PV BRAHMABANNI
MCU-5
GIJA
SULTAN

PARAMETERS OF J-34:

Staple length 28mm

Trash percentage 4.50%
Range of count spun 9s to 34s
Micronaire value 4.4 ugm/inch
Strength 30 rkm
Elongation 6.00%
Wt. of bale 165 to 170 kg
Dimension 45cm x 60cm x 120cm
Purchasing station Punjab,Haryana, rajasthan

PARAMETERS OF SHANKER-6:

Staple length 30mm

Trash percentage 3.50%
Range of count spun 9s to 34s

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 Micronaire value 4.3 ugm/inch
Strength 31 rkm
Elongation 6.50%
Wt. of bale 165 to 170 kg
Dimension 45cm x 60cm x 120cm
Purchasing station Gujrat

MIXING
OBJECTS:

1. To have a uniform distribution of different types of cotton.

2. To reduce the cost of raw material used.
3. To apply spin finish & tint ( if required ) on material to improve process
performance & to segregate the material from other kinds.
4. Removing waste and contamination by sorting.

In order to have best result, following points should be under consideration

1. Fibres must
have same origin.
2. Price, colour
& grade of cotton is also kept
in mind while laying mixing.
3. Quality of
mixing to be laid.
4. Soft waste
should be added as per
requirement.

AVG. WEIGHT OF BALE OF QUALITY:

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MECH-1, SHANKAR-6, B.B =175 KG

J-34 = 165 KG

CONTAMINATION PER BALE:

3-4 gm (J-34)
6-8 gm (OTHER COTTONS)

MOISTURE IN COTTON:

6-8 %

YARN REALISATION:

650g/1000g OF COTTON

CONTAMINATIONS REMOVED DURING SORTING PROCESS:

29
 1. Plastic dori
2. Paper
3. Cloth
4. Polythene
5. Wires
6. Coconut material
7. Feather
8. Coloured thread
9. Wood
10. Leather
11. Hair
12. Sutli
13. Yellow cotton

PRECAUTION WHILE LAYING MIXING:

 Material should not spread out of yellow line marked on floor.

 The top layer of mixing should be in same level.
 Waste should be added uniformly.
 Bales should not fall after opening them.
 House keeping should be prop

Blow Room

With all harvesting methods, however, the cotton seed, together with the fibers, always gets into
the ginning plant where it is broken up into trash and seed-coat fragments. This means that ginned

30
cotton is always contaminated with trash and dust particles and that an intensive cleaning is only
possible in the spinning mill.
Nep content increases drastically with mechanical harvesting, ginning and subsequent cleaning
process. The reduction of the trash content which is necessary for improving cotton grade and
appearance unfortunately results in a higher nep content level.

Basic operations in the blow room:

1. Opening
2. Cleaning
3. Mixing or blending
4. Micro dust removal
5. Uniform feed to the carding machine
6. Recycling the waste

AT = total waste (%); AF = good fibers

eliminated (%).

For example, if AT = 2.1% and AF =

0.65%:

Technical Specification:
 Working width = 2300mm
 Maximum production rate at 100% efficiency = 1500kg/hr
 Production rate = 800kg/hr
 Transverse speed = 3-12m/min
 Plucking roller dia. = 288mm
 Contact roller dia.= 125mm
 Power required = 12.4KW
 No. of bales required:

Width of the bale = 165kg

Width of the bale = 0.6m
Standard production per shift = 800*8 = 6400kg
Thus no. of bales required = total martial wt./standard wt. of a bale = 6400/165 = 39
bales

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 Cleaning
General factors which affect the degree of opening, cleaning and fibre loss are,
1. Thickness of the feed web
2. Density of the feed web
3. Fibre coherence
4. Fibre alignment
5. Size of the flocks in the feed (flock size may be same but density is different)
6. The type of opening device
7. Speed of the opening device
8. Degree of penetration
9. Distance between feed and opening device
10. speeds of the opening devices
11. Throughput speed of material

Flexi Clean:

Salient Features
o Production up to 600 kg / hr

o Infinitely variable production achieved by inverter drive

o Controlled fibre feed for optimum opening and maximum cleaning

efficiency

o Fine opening achieved by Saw tooth or Needle beaters

Effective Suction
 Efficient micro dust removal arrangement

 Controlled waste removal through adjustable grid bar

Fig 4

Technical specification:

32
  Working width = 1600mm
 Maximum production rate at 100% efficiency = 1500kg/hr
 Production rate = 800kg/hr
 Beater dia. = 800mm
 Beating mode = 180
 m/c speed = 700rpm

Carding

It is always considered by experts that the card is the heart of spinning unit.

The statement “well carded is half spun” demonstrates the significance of the operation.

It is the process of disentangling & straightening the fibers into a parallel length wise arrangement.

Objectives:
 opening to individual
fiber
 fiber alignment/ straightening
 disentanglement of neps
 elimination of short fibre
 elimination of foreign matter
 elimination of dust
 sliver formation

Part of machine
1. chute feed system
2. feed roll
3. licker in roll

33
 4. cleaner bars
5. cylinder
6. flats
7. doffer cylinder
8. doffer comb
9. crushing rollers
10. coiler head

Process:

 Opening the tufts into individual fibres;

 Eliminating all the impurities contained in the fibre that were not eliminated in the previous
cleaning operations;

 Selecting the fibres on the basis of length, removing the shortest ones;

 Removal of neps;

 Parallelizing and stretching of the fibre;

 Transformation of the lap into a sliver, therefore into a regular mass of untwisted fibre.

Operating principle and Elements of Card:

34
 Fig 5

1) Pipe ducting for supplying raw material,

2) Chute feed; evenly compress a bat of 500 – 900 Ktex.
3) Transport roller; forwards the material to feed arrangement,
4) Feed arrangement, consists of feed roller and feed plate,
5) Taker-in, opens the material to small flocks, when the material passes to main cylinder, mote
knifes; grid bars and carding segments eliminate a great part of impurities.
6) Grid equipment,
7) Suction duct to carry away the waste
8) Main cylinder
9 and 12) Fixed carding segments designed to assist the carding operation.
10) Flats
The main carding operation occurs between flats and cylinder. Flats comprise 80 to 116 individual
carding bars combined into a band moving on an endless path. 30 to 46 of flats are always in
action.
11) Cleaning unit, strips fibers, neps and foreign matters from flats,
13) Grid or cover plate
14) The doffer, combine the fibers into a web, because of its substantially lower peripheral
speed relative tothe cylinder.
15) Stripping deice, Doffing master, draw the web from the doffer.
16) Calendar roller
proverbs of the experts “The Card is the heart of the Spinning Mill” and “Well Carded is half spun”
demonstrate the immense significance of carding for final result of the spinning operation. Carding
is carried out by passing entangled fibers between closely spaced surfaces of cylinder and flats

35
covered with sharp metal teeth .The surfaces are moved relative to each other and so the fibers
are disentangled.

The tasks of the card:

o Opening to individual fibers, this enables elimination of impurities and The
performance of other operations.
o Elimination of impurities occurs mainly in the region of the taker-in. The degree of
cleaning achieved by modern card is very high, in the range of 90 -95%. Thus, the
overall degree of cleaning achieved by the blow-room and carding room together
is as high as 95 -99%. Card sliver still contains 0.05 – 0.03% of foreign matter.
o Elimination of Dust, which are bound to the fibers. Significant fiber/metal and/or
fiber/fiber friction is needed in order to loosen such particles, this are available in
carding operation.
o Disentangling of neps. The number of neps increases from machine to machine in
the blow-room, the card reduces the remaining number to a small fraction, they
are mostly opened out.
o Elimination of short fibers, this may occur at flats. Long fibers have more contact
with the clothing of the main cylinder than the short fibers. Thus longer fibers are
continuously caught and carried along the main cylinder, where the short fibers
stay caught in the flats clothing, press into it and leave the machine in the flat
stripping. The card eliminates very small percentage of short fibers about 1%.
o Fiber blending, transverse blending occurs because the card is the only machine
to process individual fibers. In formation the web, and with repeated rotation of the
fibers on the main cylinder, intimate fiber with fiber mixing is achieved.
o Fiber orientation: The card is often attributed the effect of paralyzing. A parallel
condition is achieved on main cylinder, but it disappears during web formation
between cylinder and doffer.
o Sliver formation, for further processing.

Technical specifications:
 Production at 100% efficiency = 80kg/hr
 Dlivery speed = 300m/min
 Feed roll dia. = 80mm
 Total flats = 94
 Licker in roll dia. Over clothing = 253 mm
 Cylinder dia. Over clothing = 1290mm
 Doffer dia. Over clothing = 680mm
 Cross roll dia. = 80mm
 Cylinder speed = 550rpm
 Doffer speed = 30 rpm
 Licker in speed = 1000rpm
 Flat speed = 322rpm
 Power required = 12.8KW per m/c

36
  Can specs:
Capacity = 11000m
Dia. = 40”
Height = 48”

Production calculations:
Required hank = delivery speed*0.625
Production per shift = actual hank/2.2/target count
Draft = cylinder surface speed : licker – in surface Speed

Draw Frame

Although the fibers are separated up to individual state but they are in random disorganized
manner in the card sliver. Draw frame straightens and align the fibre along the axis of the sliver
in order to have strong and even spinning. Draw frame is a very critical machine in the spinning
process. Its influence on quality, especially on evenness is very big. If draw frame is not set
properly, it will also result in drop in yarn strength and yarn elongation at break.Drawing is the
final process of quality improvement in the spinning mill Drafting is the process of elongating a
strand of fibers, with the intention of orienting the fibers in the direction of the strand and reducing
its linear density. In a roller drafting system, the strand is passed through a series of sets of rollers,
each successive set rotating at a surface velocity greater than that of the previous set. During
drafting, the fibers must be moved relative to each other as uniformly as possible by overcoming
the cohesive friction. Uniformity implies in this context that all fibers are controllably rearranged
with a shift relative to each other equal to the degree of draft. In draw frame, the rollers are so
rotated that their peripheral speed in the through flow direction increases from roller pair to roller
pair, then the drawing part of the fibers, i.e. the draft, takes place. Draft is defined as the ratio of
the delivered length to the feed length or the ratio of the corresponding peripheral speeds.

Drafting arrangement is the heart of the draw frame. The drafting arrangement should be
 simple
 stable design with smooth running of rollers
 able to run at higher speeds and produce high quality product
 flexible i.e. suitable to process different materials , fibrelengths and sliver hanks
 able to have good fibre control
 easy to adjust
Roller drafting causes irregularities in the drafted strand since there is incomplete control of the
motion of each individual fibre or fibregroup. The uniformity of the drafted strand is determined by
 draft ratio
 roller settings
 material characteristics
 pressure exerted by the top roller
 hardness of top roller

37
  fluting of the bottom rollers
 distribution of draft between the various drafting stages
 drafting is affected by the following raw material factors
 no of fibers in the cross section
 fibre fineness
 degree of parallelization of the fibers
 compactness of the fibre strand
 fibre cohesion which depends on
 surface structure
 crimp
 lubrication
 compression of the strand
 fibre length
 twist in the fibre
 distribution of fibre length

Lap Preparation

Sliver from card which is passed through the breaker drawframe is not suitable to feed in the
comber because the feed material or the comber is lap sheet so preparation process known as
lap preparation is done and machine used for the preparation is known as lap forming machine.
Objective of lap preparation:

 To make even feed for comber

 To present sliver hooks as leading hooks to the comber
 To make the fibre more parallel

Combing

The combing process is normally used to produce smoother, finer, stronger and more uniform
yarns. Therefore, combing is commonly confined to high grade, long staple natural fibers. In
recent years, combing has been utilized for upgrading the quality of medium staple fibers. In
addition, a yarn made of combed cotton needs less twist than a carded yarn. However, these
quality improvements are obtained at the cost of additional expenditure on machines, floor-space

38
and personnel, together with a loss of raw material. Yarn production coast is increased by
something under 1 US$/Kg of yarn (depending on the intensity of combing).

To improve the yarn quality, the comber must perform the following operations:
➢ Elimination of precisely pre-determined quantity of short fibers;
➢ Elimination of the remaining impurities;
➢ Elimination of a large proportion (not all) of the neps in the fiber material;
➢ Formation of a sliver having maximum possible evenness;
➢ Production of more straight and parallel fibers

Elimination of short fibers produces an improvement mainly in staple length, but also affects the
fineness of the raw material. The micron ire value of combed sliver is slightly higher than that of
feedstock (elimination of dead fibers).

Technical specifications:

 Feed weight
 Delivery hank
 Forward feed
 Basic draft = 14.6
 Break draft = 1.38
 Nips/min = 350
 Feed/min = 5.2

Sequence Of Combing Operation:

39
  Lap feeding by feed roller
 Nipping by the top nipper
 Combing by cylinder comb
 Forwarding of bottom nipper
 Web returning by the detaching roller
 Web piecing
 Combing by top comb
 Delivery by detaching roller
 Top comb withdrawn
 Waste extraction by brush roller

Finisher Draw Frame

Sliver from comber before feeding to speed frame is passed through draw frame to get maximum
possible evenness which result in the even roving at roving frame.

Objectives:
 To make sliver with maximum possible evenness

 To make required hank for input in speed frame

Material flow on the Draw frame is given by following flowchart

Fig 7
When sliver is passed through the scanning rollers then it measures the thickness of material.
Scanning rollers are connected to the signal generator which converts thickness variation in the
electronic signals. These signals are compared by standard value by the electronic memory and
then it gives the signal to the servo drive to maintain the proper draft with particular thickness.

40
STOP MOTIONS ON DRAWFRAME:

 Sliver Break stop motion

 Sliver lapping stop motion
 Can exhaust stop motion

FINISHER DRAW FRAME

Technical specification:

 High delivery speed up to 500mts/min

 Production up to 360kg/hr
 3 over 3 draft roller system
 1 delivery per machine
 Calendar roll dia. = 60mm
 Feed weight = 20-50 ktex
 Sliver weight = 2.5 – 7 ktex

AUTO LEVELLING

Objective: To measure the sliver thickness variations and then continuously to after the draft
according so that more draft is applied to thick places and less to the thin places with the result
that the sliver delivered is less irregular .

Types Of Autoleveller:

41
  Open loop Autoleveller : this type of autoleveller is used for short term variation
and mostly this type of autoleveller is used. But in this type of autoleveller lack of
self monitering.

 Closed loop Autoleveller: this is used for long term variation and also have self
monitering . But used very rare.

Autoleveller Parts :

 Scanning roller

 Signal converter

 Levelling processor

 Servo derive

 Quality monitor sensor

42
 Roving

’
Fig 8

SIMPLEX (ROVING) FRAME

Simplex is the intermediate machine between draw frame and the ring frame. This machine is
important to be to use by the spinner for the following two reasons.
1. Sliver is thick, untwisted strand that tends to be hairy and to create fly. Drafting arrangements
of ring frames are not capable of processing this strand in a single drafting operation to create a
yarn that meets all the normal demands on such yarns.
2. Draw frame cans represent the worst conceivable mode of transport and presentation of feed
material to the ring spinning frame.

OBJECTIVES OF ROVING FRAME

 To draft the material to the required linear density.

 To insert minimum required level of twist.
 To produce a suitable package for the next process.
 To reduce the thickness of the sliver.

43
In general two condensers are used in the drafting arrangement. The purpose of these
condensers is to bring the fibre strands together. It is difficult to control, Spread fibre masses in
the drafting zone and they cause unevenness. In addition, a widely spread strands leaving the
drafting arrangement leads to high fly levels and to high hairiness in the roving. The size of
condensers should be selected according to the volume of the fibre sliver. Flyer inserts twist. Each
flyer rotation creates one turn in the roving. Twist per unit length of roving depends upon the
delivery rate.

Turns per meter = (flyer rpm)/ (delivery speed (m/min))

Higher levels of roving twist, therefore, always represent production losses in Roving frame and
possible draft problems in the ring spinning machine. But very low twist levels will cause false
drafts and roving breaks in the roving frame. Centrifugal tension is created at the bobbin surface
as the layers are being wound and is created by the rotation of the package. Each coil of roving
can be considered as a high-speed rotating loop of roving on which centrifugal tension increases
with increasing diameter of the package. Centrifugal tension in the roving is proportional to the
square of the winding surface velocity. Apart from inserting twist, the flyer has to lead the very
sensitive strand from the flyer top to the package without introducing false drafts. Flyers have a
very smooth guide tube set into one flyer leg and the other flyer leg serves to balance the flyer.
The strand is completely protected against air flows and the roving is no longer pressed with
considerable force against the metal of the leg. Frictional resistance is considerably reduced, so
that the strand can be pulled through with much less force. False twisters are used on the flyers
to add false twist when the roving is being twisted between the front roller and the flyer. Because
of this additional twist, the roving is strongly twisted and this reduces the breakage rate. Spinning
triangle is also reduced which will reduce the fibre fly and lap formation on the front bottom roller.
Because of the false twister, the roving becomes compact which helps to increase the length
wound on the bobbin. This compactness helps to increase the flyer speed also. Roving strength
is a major factor in determining winding limitations. It must be high enough for the fibers to hold
together in a cohesive strand and low enough for satisfactory drafting at the spinning machine.

The factors affecting roving strength are as follows:

 the length, fineness, and parallelization of fibers
 the amount of twist and compactness of the roving
 the uniformity of twist and linear density
Technical data:
1. Spindles per machine 48 - 160
2. Flyer rotation speed, rpm up to 1 500
3. Production rate, g/sp.h 250 - 2 000
4. Sliver hank, ktex 3.8 - 5.5
5. Roving hank, tex 170 - 1 500
6. Draft 5 - 22
7. Bobbin weight, kg up to 3

44
 RING FRAME

MANUFACTURER: LMW, INDIA

OBJECTIVE:

 To draft the roving until the required fineness is achieved

 To impart strength to the fiber, by inserting twist

 To wind up the twisted strand (yarn) in a form suitable for storage, transportation and further
processing.

DEFECTS IN RING FRAME:

 Uneven drafting
 Non-uniform yarn count
 Roller lapping
Frequent breakage

THE MAIN ELEMENTS OF THE MACHINE ARE:-

 Creel zone
 Drafting zone
 Twisting and winding zone
 Suction unit
 Gearing system
 Spacer
 Separtor
 Balloon control ring(BCR)
 Spindles
 Ring traveler arrangement

45
 PARTS OF RING FRAME

1. Roving holder
2. J-roll
3. Roving carrier rod
4. Top arm
5. Traverse guide or roving guide
6. Back cots
7. Bottom apron
8. Top apron
9. Cradle
10. Nose bar
11. Spacer
12. Suction tube
13. Lappet hook
14. ABC ring
15. Ring rail
16. Ring circle
17. Fly catcher
18. Lifting tap
19. Poker rod
20. Ring traveler
21. Spindle
22. Spindle break
23. Spindle tap
24. Drum pulley
25. Tap jacking pulley
26. Top clearer
27. Bottom clearer
28. Tension spring
29. Extra holder
30. Hose pipe

46
PROCESSING OF THE MATERIAL THROUGH THE MACHINE:

The Speed frame roving is fed from the creel zone above the drafting system. The roving is led
into the drafting system through a condenser. The drafting system is 3/3 with a double apron
system. The drafted material i.e. yarn comes out of the drafting system and it is led to the bobbin
through the ring traveler arrangement which leads to the cop building.

The ring spinning frame has fixed spindle rails. It accommodates the drives (main drive and the
suction motor), controls and instruments. All bearings are of rolling contact types or self-
lubricating brushes.
Ring rails, anti balloon rings and thread guides are controlled jointly. The various operations are
controlled electro pneumatically. The functions that are controlled automatically are:
# Under winding
# Preparation for doffing
The thread suctioning system has a drum filter and ensures adequate vacuum throughout the length
of the suction duct.

The spindle speed control is electro pneumatic. The spindle runs at a minimum speed till the motor
switches from star to delta, then at reduced rpm.

47
 Fig: RING FRAME

Autoconer

Winding:
Winding is the process of making yarn into a suitable package ready for sales. Apart from the
above, another primary aim is to eliminate the faults in yarn. Neps, thick places, thin places,
count variations are some of the notable defects in the spinning yarn which has to be removed,
while winding into suitable package known as cone.
1) Manual winding

In manual winding, the faults are removed using either mechanical slub catcher or electronic
yarn cleaner. This processes is more labor intensive and the faults can be cleared only to a
limited extend, say 8 breaks per lakh meter. The speed of winding will be 450 meter per minute.
Every worker is allotted for 40 winding heads .So the production will be limited .Here when any
faults is noted by EYC (Electronic Yarn Cleaner, the yarn is cut down then the worker , using
knottier joins the yarn by a knot.

48
2) Autoconer

The main drawbacks of manual winding are labor intensive, less productive and less effective. In
order to overcome the limitations , the autoconer winding machine has been introduced four
decades ago , now the fifth generation machine is also been launched .The improvements in
autoconer machine has been a continues process . In autoconer machine, the speed is 1300
meter per minute. The EYC used, will clear the faults to the maximum possible extend. Usually
50 to 60 breaks per lakh meter faults are cleared. The joining of the ends is made by a unique
process known as splicing ,were the ends are opened, mingled and retwisted by which the
appearance will be uniform and knot is eliminated here. The labor requirement is very much
reduced and the splicing is carried out by the machine itself. The autoconer machines are now
been widely used to overcome the labor shortage, improve machine productivity and the quality
of yarn dispatched for sales.
.

 Fig 9

49
 Process parameters

Carding

Delivery rate 100 mtr./min.

Sliver hank 0.135

Total draft 100

Hank feed 0.00135

Cylinder speed 346.18 rpm

Doffer speed 47.29 rpm

Licker-in speed 885.24 rpm

Flat speed 5 inch/min

Efficiency % 90 %

Breaker drawframe
SPECIFICATION LDO/6

I/P hank 0.135

O/P hank 0.118

Total draft 5.24

Drafting system 3 over 3 roller

Drafting pressure Pneumatic

Roller gauge 40/44

No. of doubling 6

No. of delivery 2

50
 Delivery rate 400mtrs/min

Lap former
Delivery rate 120 mtrs/min
I/P hank 0.118
O/P hank 72Ktex
Total draft 1.67
Drafting system 3 over 3 roller
Drafting pressure Pneumatic
Lap width 300mm
Doff length 270 mtrs.
Doffing Automatic
.Front roll diameter. 32mm
Middle roll diameter 32mm
Bottom roll diameter 32mm
Lap wt. ~20KGS.
No. of doubling 24

Comber
I/P hank 72ktex

O/P hank 0.125

No.of head 8

Drafting system 3 over 3 roller

Drafting pressure Pneumatic

Feed/nip 4.7

Nip/min. 440

Total draft 15.24

Doff length 6800 mtrs

Doffing Automatic

51
 Delivery rate 18 mtrs/min

Noil% 18%

Finisher drawframe
I/p hank 0.125

O/p hank 0.125

Total draft 8

No. Of doubling 8

Drafting system 3 over 3 roller

No. Of delivery Single

Doff length 4250 mtrs

Delivery rate 400 mtrs

Speed frame

Flyer rpm 950

Rove hank 1.2

Sliver hank 0.125

TPM 62

Total draft 9.6

Drafting system 3 over 3 double apron

`Drafting pressure Spring loaded

Delivery rate 20.2 mtrs/min

52
Ring frame

Yarn hank 30S 40S 50S

Rove hank 1.2 1.2 1.2

Spindle speed 19500 19900 20100

Delivery rate 17.70 mtrs/min. 16.30 mtrs/min 15 mtrs/min

TPI 28 31 34

TM 4.4 4.4 4.3

Total draft 25 33.3 41.6

Break draft 1.19 1.19 1.23

53
 T.F.O.

OBJECT

 The fundamental object of T.F.O. Is-

 To make single yarn by giving twist to the two
yarn of a cheese;
 To increase the strength of the yarn.

OPEN END

OBJECT

To prepare yarn directly from carded sliver.

 SEQUENCE OF OPEN END SPINNING

BLOW ROOM

54
 CARD(M/C NO.=27,28,29)

RIETER D-221 [FINISHER D/F NO.11]

AUTOCORO AC -08[OPEND END]

 TECHNICAL DETAILS OF AUTOCORO 360

M/c no. 1
Count 16 GOLD OE
Cheese Red tip (paper)
Opening roll type D-174DN
Yarn length on cheese 69000
Feed can Sky blue
Drum 1-432
Rotor type T633BD
Novel KSK4A
Adopter 31+1.5
Draft 146
Tpm 899.1
Tm 5.7
Group no. 06
Take up temp. 98.3

55
 MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE

Name of m/c Cleaning schedule Lubricants/ oils used

Blendomate Twice / month Ap3 grease
Bale plucker Twice / month Ap3 grease
Precleaner Twice / month Ap3 grease
Unimix Once / month Ap3 grease
Vario cleaner Twice / month Ap3 grease
Veetal Once / month Ap3 grease
Carding Once / month Ap3 grease, 150 no. Oil
Draw frame, Lapformer, Twice /month Ap2 grease, ap3 grease, oks
Comber 475 hs grease; 68, 100, 150,
629 no. Oil
Speed frame, Ring frame, Once / month Ap2 grease, ap3 grease, oks
Auto couner, Cheese 475 hs grease; 12, 100 no. Oil
winding,
T. F. O

SPINNING DEFECTS
 Slubs
 Mending mark
 Contamination
 Knot
 Thick weft
 Uneven weft
 Slubby weft
 Four ply
 Fine wrap
 Uneven dyed
 Dead Cotton
 Thick

56
 WASTE%

WASTE% & ITS USES:

The form, quality and its utilization depends u pon the m/c from which it is generated.the different
m/c generate different types of waste material ,which may or may not be further usable by the
company. The waste can be reprocessed, is used by the company again and rest of it is sold in the
market.
Waste in textile unit is broadly classified into two groups

1. Useable waste

2. Unusable waste

Waste

Unusable waste unusable waste

Or saleable waste -sliver
-noil(in open end)
-pneumafil

57
DEPARTMENT WASTE EXTRACTION(%)
Blow room 7%
Carding 4%
Draw frame-I 0.3%
Lapformer 0.3%
Comber 18-20% noil
Draw frame-II 0.3%
Speed frame 0.3%
Ring frame 1-2%(pneumafil)
0.98% (hard waste)
Sweeping 0.34%

58
 RESEARCH & DEVELOPMENT
QUALITY CONTROL SYSTEMS:

COTTON TESTING LAB:-

INSTRUMENT : COTTON TESTER ART

(SPIN LAB HVI)

It test following properties of fibres:-

 Spinning consitancy index
 Micronaire value of fibes
 Length of fibres
 Uniformity of fibres
 Elongation of fibres
 Trash% in fibres
 Moisture% in fibers

YARN TESTING LAB:-

INSTRUMENTS USED
1.USTER CLASSIMAT ( Peass Schlafhorst

It gives following values of yarn:-

o Short thick places as a1,a2,b1,b2,c1,d1
o Objectionable faults as a3,b3,c2,d2
o High objectionable faults as a4,b4,c3,d3
o Long thich faults as e,f,g
o Thin faults as h1
o Objectionable thin faults as h2,i1,i2

2.USTER TESTER :

59
 It gives following values of yarn:-
o U%
o Cv %
o Cv %(m)
o Cv%(10m)
o Thin places (-40%,-50%)
o Thin places (+35%,+50%,+70%,+100%)
o Neps(+140%,+200%,+280%,+400%)
o Rel. Cnt %

3.PREMIER RKM TESTER ( TENSOMAXX 7000)

4.LEA STRENGTH TESTER ( STRETCH 500 M)

5.WARP REEL ( TECCHNO )

6.YARN APPEARANCE BOARD TESTER ( TECCHNO TYT-04 )

7.TPI TESTER ( STATEX )

8.NATI (NEPS & TRASH INDICATOR ,MESDAN LAB )

9.CONE CS TESTER ( TEX LAB INDUSTRIES )

10.OVEN ( TEX LAB INDUSTRIES )

11.TRASH ANALYSER ( STATEX)

INTRODUCTION:

60
Research and development deals with the testing of the raw material, final product and the various
intermediate products so that we get a quality final product. Apart from this it also include various
efforts done to further improve the quality of the product. The testing laboratory included
following testing equipments:
1. USTER HIGH VOLUME INTRUMENT
2. USTER TESTER
3. USTER CLASSIMAT SYSTEM
4. LEA STRENGTH TESTER

USTER HVI;
This instrument is used to determine the following parameters.
 Fiber lengt
 Fiber strength
 Length uniformity
 Elongation
 Micronaire
 Color
 Trash

USTER CLASSIMATE 2:
This instrument is used to determine following parameters.
 Total classimat faults of yarn(short thick, long thick and long thin faults).
 Objectionable faults
 Scatter diagram of the faults

LEA STRENGTH TESTER

This instrument is used to determine lea strength of single and plied yarns.

TYPE OF YARN FAULTS

61
SINGLE YARN FAULTS PLY YARN FAULTS

 FLUFF FLY
 SLUB HIGH TPI KNOT
 BUNCH BIG KNOT
 BAD PIECING TOW TPI KNOT
 EXTRA YARN BAD SPLICE
 WEAK YARN KNOT
 SNARLING OPEN KNOT
 THIN PLACE ROUND KNOT
 THICK PLACE SNARLING

62
 PACKING SYSTEM
PACKING SYSTEM
THE PACKING OF YARNS OF DIFFERENT COUNTS IS DONE IN CARTONS & IN
PALLETS OF CONDITIONED CONES & CHEESES. THE PACKED MATERIAL OBTAINED
IS KEPT IN YARN GODOWN & TRANSPORT TO ITS DESTINATION AFTERWARDS.
PACKING DEPARTMENT

For easy and safely transportation, yarn is packed in different forms. Forms of packing depend
upon the customer but mostly packaging is categorized with the domestic and international market.

TYPES OF PACKING:

1. Pallet form.
2. Carton form

PALLET PACKING:

Mostly pallet packing is used when they send their material to the fabrics division. This is very
cheap method of packing in which 11 layers of cones separated by groobed cardboard is placed
one over another. At the bottom there is wooden stand.

VARIOUS PARAMETERS OF PALLET PACKING:

Dimension 1150x750mm
Total cones 300
Gross weight 757.00 Kg
Net weight 710.00 Kg
Cone weight 2.58 Kg

CARTON PACKING

Carton packing is used in export market generally 5 ply carton opted for domestic market and 7
ply carton for international market. Export packing is done as per carton.

63
VARIOUS PARAMETERS FOR 5-PLY CARTON PACKING

Total cones 32
Dimension 700x360x665mm
Net weight 22.700 Kg
Cone weight 1.6 Kg

64
 PLANT LAYOUT

PLANT LAYOUT – NIEL II

65
 TIME OFFICE
TIME OFFICE

 It is the initial and final stage for the worker. The function of time office is to record
keeping (record for rest ,leave ,CPL) and to keep the record of the attendance through
RMS machine.

 The function of the time office is to maintain the workers in shift as per requirement of
the shift.

 The function of the time office is to keep the record of over time and give extra benifit
to that worker.

66
67