Safety in Textile Industry: Chapter - 21

CHAPTER – 21
Safety in Textile Industry
THEME
1. Need of Safety in Textile Industry 6.6 Ring (Spinning) Frames

2. Types of Textile Industry 6.7 Doubling Machines (Frames)
3. Statutory Provisions : 7. Hazards and Safety Measures of Weaving
3.1 General Preparatory and Weaving Processes :
3.2 Health Provisions 7.1 Winding Machines
3.3 Safety Provisions 7.2 Warping Machines
3.4 Welfare Provisions 7.3 Sizing Machines
3.5 Cotton Ginning & Pressing Factories 7.4 Looms
Act & Rules 8. Hazards and Safety Measures of Processing
4. Indian Standards (Finishing) and Folding Machines :
5. Flowcharts of Textile Processes : 8.1 General Precautions
5.1 Composite (Textile Mill) Flowchart 8.2 Bleaching Process
5.2 Other Flowcharts 8.3 Processing Machines (Dyeing, Printing etc.)
Short & long Staple, Viscose rayon, 9. Fire & Explosion Hazards and Controls
Synthetic fibre, Spun & Filament 10. Health Hazards and Controls :
Yarn, Jute Cotton Dust, Heat & Humidity, Noise and
6. Hazards and Safety Measures of Spinning Other Hazards
Preparatory and Spinning Processes : 10.1 Health Hazards in Cotton Textile Industry
6.1 Opening and Blow Room Machines 10.2 Health Hazards in Other Textile Industry
6.2 Carding Machines 11. Effluent Treatment and Waste Disposal in
6.3 Silver and Ribbon Lap Machines Textile Industry
6.4 Combers and Drawing Frames
6.5 Roving (Speed) Frames
1. NEED OF SAFETY IN TEXTILE INDUSTRY
Clothing is the basic need for all of us and with the modernisation a want of more and more
attractive (durable, shining, anti-crease and colourful) fabrics is increasing day by day. Therefore the
foundation of textile industry is very old, ever changing and ever lasting. The continuous blow room line,
replacement of mule spinning by ring spinning, rotor spinning, high speed shuttle-less and workerless
looms and computerised processing machinery has rapidly changed the structure of textile industry and
the mills not following such modernisation and automation are becoming sick in market competition. Yet
it is a fact that the old textile machines are still in use in some mills. From safety point of view, such old
and poorly guarded (and without built-in safety) machinery needs more attention.
Indian textile industry is the oldest one in the world. Cotton was invented and planted "by
'Grutsmad' Rushi some 20,000 years ago. Yarn and threads were manufactured by hands and cloth was
woven by hand looms. A reference is published that a ginning machine made in India was sent to
England. Dhaka's 'malmal' (the thinnest and lightest cloth) was famous. British rulers cut off the palms
and fingers of Indian weavers so that they cannot compete with cloth from England. Dyeing by natural
colours was also in use. Old Indian garments were white and colourful.
Fundamentals of Industrial Safety and Health 21- 1 Safety in Textile Industry

The textile mills established during 19th century in Lancashire and in New England initiated the
Industrial Revolution and their cotton fabrics dominated the world markets for many years. Indian textile
mill industry is also as old as the first Indian Factories Act 1881 and Gujarat is still leading in textile
industries. Man made synthetic fibres such as polyamides and polyester are now blended with cotton and
a trend of such artificial fabrics is increasing.
In 1979 there were 19728 cotton textile factories working with 1147000 workers and 3244 wool,
silk and synthetic fibre factories working with 179000 workers out of total 135173 working factories with
total workers 6797000 in India. This gives 10.33% textile (cotton and others) factories and 19.50% textile
workers.
In 1999 estimated registered textile factories in India and Gujarat were ©16000 and 4000
respectively. Similarly estimated textile workers in India and Gujarat were @14 lakhs and 3.0 lakhs
respectively.
Table 5.16 of Chapter-5 gives following figures of textile factories in Gujarat as on 31-12-2001.
NIC Code (for Textile) Working Factories Average Workers

17 2634 163714
18 170 9284
Total 2804 172998
This indicates there was 13.21% textile factories (cotton, man-made fibres, wool, silk, jute and
textile products) and 19.07% textile workers in these factories in Gujarat in 2001.
Any estimate of unregistered textile factories is vague. Most of such weaving and texturising units
employing less than 10 workers are many times more than the registered weaving factories. For example,
against 100 registered factories, an estimate runs up to 10,000 unregistered (partitioned) establishments.
Therefore in want of correct and latest statistics, it seems difficult to figure out total textile
factories and textile workers.
Table 5.6 (Chapter-5) gives following figures for textile industry in India for the year 1992 :
Accidents Fatal 67, Nonfatal 33047, total 33114

Incidence Rate Fatal 0.02, Nonfatal 8.55
Frequency Rate Fatal 0.03, Nonfatal 14.80
Table 5.19 (Chapter -5) gives following figures for textile accidents in Gujarat :
Type of Accidents 1996 1997

Fatal 32 36
Nonfatal 3978 6967
Total 4010 7003
Percent of total textile & non-textile fatal & nonfatal accidents 35.62 58.02
Thus total textile accidents occupy nearly 35 to 55%- of all industry accidents in Gujarat. This
indicates high need to control textile accidents.
US incidence rates for the year 1995, of some textile processes are as under :

Carpets & rugs 10.0 Yarn & thread mills 9.1
Knitting mills 8.2 Wool fabric mills 7.5
Manmade fabric mills 6.1 Cotton fabric mills 5.8
Textile finishing 7.8 Misc textile goods 12.0
Comparing with all manufacturing incidence rate 11.6, it indicates little higher proportion of
accidents in textile industry in USA (Accidents Facts, 1997, NSC).
A case study of one good composite textile mill employing @3500 workers indicates following
figures :
Year 1984 1985 1986

Total accidents 281 343 368
Due to unsafe 135 161 156
conditions (48%) (47%) (42%)
Due to unsafe actions 146 182 212
(52%) (53) (58%)
Mandays lost 2100 7276 3995
Frequency 32.78 40.25 45.04
Severity Rate 245.04 849.0 466.16
The department wise accidents in above study give following figures for the year 1986.
1. Weaving 111 6. Bleaching, Finishing 23

2. Engineering 51 Lab etc.
3. Contract workers 65 7. Dyeing 22
4. Spinning 53 8. Folding, Store, Office 15
5. Printing 28
Total 368
The causation wise accidents in above study gives following figures for the year 1986 :
1. Striking against objects 103 6. Fall from height 24

2. Struck by falling bodies 48 7. Burn by hot substance, 16
3. Cut by sharp edges 34 chemicals etc.
knife, tools etc. 8. Cut by bobbin shields 14
4. Caught between objects 30 9. Others 72
5. Flying shuttles 27
Total 368
Another case study of 2100 accidents in II composite mills, carried out by the Central Labou
Institute, Bombay gives following figures :
S. N Department Accidents Percent

1 Spinning Preparatory & spinning 738 35.2
2 Weaving Preparatory & Weaving 1019 48.6
3 Finishing & other Departments 343 16.2
Total 2100 100

Agency distribution is as follows
S. N Agency Accidents Percent

1 Looms 617 29.4
2 Ring Frames 321 15.3
3 Other Machines 335 15.9
4 Material Handling 228 10.9
5 Working Conditions 202 9.6
6 Hand Tools 176 8.4
7 Hand Trucks and Transport 121 5.8
Equipment
8 Chemicals 34 1.6
9 Others 66 3.1
Total 2100 100
Above statistics ascertains that the textile industry is one of the biggest industries in India
employing more than 20% of total labour force and contributing more than 50% of total industrial
accidents thus highlighting the great need of safety and accident prevention in this industry. Heavy and
numerous machineries, health hazards including machine accidents, shuttle flying, cut by bobbin shield,
byssionosis, heat stress, humidity, high noise, fire hazards and higher number of employment also stress
for the higher need of safety.
Almost 50% accidents occurring in textile industry are due to unsafe conditions. Therefore
machine guarding and other safety conditions need much attention. The latest design of textile machinery
having built-in safety, dust suction device and computer controls has eliminated many hazards of old
machinery.
2 TYPES OF TEXTILE INDUSTRY
Cotton being the natural and old product, light, human body (particularly for hot days), cotton
textile is pioneering and oldest industry. But with invention; of new fibres, natural and synthetic, it has,
now become a mixed industry. The industry includes the spinning, weaving, knitting and finishing of all
type; of natural, synthetic and artificial fibres. The machine; vary from handlooms of cottage industry to
very expensive and intricate modern machines. Some are only spinning mills, weaving units or dyeing
and finishing houses while some are composite textile mill; carrying out all operations at one place.
A classification of various types of the fibres is as follows :

All these fibres are used for various purposes such as garments, protective wears, ropes, carpets
etc. They are the raw materials for various types of textile industries.
3 STATUTORY PROVISIONS

3.1 General:
Section 15 (Artificial humidification), 27 (Cotton openers) and 31 (Pressure plant) of the

Factories Act are generally applicable to textile plants. The Gujarat Factories Rules has made some
specific provisions by Sch. I & II under rule 54 and also under rule 68C & D,and Sch. 12, 23 & 27 u/r
102.
The statutory requirements are individual machine drive, belt shifting devices, inter locked covers
for beaters, card cylinders, headstocks and dangerous parts, fixed fencing for dust chamber, beater grid
bars, guards for lap and fluted rollers, nip guards for calendering machines etc., and a wall fencing with
locked doors for the underground line shafts of ginning factories.
More details are provided by a substituted Schedule I under rule 54 of the Gujarat Factories
(Amendment) Rules 1995. This schedule defines calendar, card, comber, combing machinery, rotary
staple cutter, garnet machine, gill box, in-running rolls, interlocking arrangement, kier, ribbon lapper,
sliver lapper, loom, starch mangle/water mangle, mule, nip, openers and pickers, paddler, plating
machine, roller printing machine, continuous bleaching range, mercerizing range, sanforizing machine,
shearing machine, singeing machine, slasher, stenter frame and warper. Safety requirements for these
machines and other machines such as centrifugal extractors, rope washers, laundry washer, printing
machines, plating machines, baling machines and flat work ironer are also prescribed. For details of Sch I
& II u/r 54, see Part 4.4 of Chapter-14.
Rule 68C for polymerising or curing machine (fixing print by emulsion technique), requires
thoroughly drying of printed fabrics, exhaust flap or damper, cutting off electrical heaters in emergency
or solvent dropping, interlocking of the exhaust fan with main drive of the machine, thermostats to
regulate temperature, explosion doors (flaps) to let off the fumes outside the workroom, weekly cleaning
of filter gauge and exhaust dust, checking of V-belt tension, examination and a register therefore. See
Part 3.3 for more details.
Rule 68D for thermic fluid heaters used to circulate hot oil in stenter and other drying machines,
prescribes many provisions. See Part 10 of Chapter18 for details.
For Rule 68G, GFR, for Oven & Driers, see Part 27 of Chapter-23.
For Sch. 12 & 19 u/r 102, GFR, for chemical works, sets Part II of Chapter-23 and for Sch. 23 u/ r
102, for high noise, see Part 4 of Chapter-12.
Chapter-3 (Health), 4(Safety),5(Welfare), 6(Working hours), 7(Employment of young persons)

and 8(Annual leave with wages) of the Factories Act are mostly applicable to textile factories as they are
applicable to other factories.
Some relevant provisions of the Factories Act & Rules applicable to textile industry are
mentioned below in brief.
3.2 Health Provisions :
Cleanliness (removal of cotton dust from work .area), disposal of waste and effluent from dyeing
and printing processes, good ventilation, temperature and lighting, removal of dust and fume from dusty

and heating area, artificial humidification required for cotton fibre strength, drinking water, latrines and
urinals and spittoons are applicable health provisions under Chapter-3 of the Factories Act.
Artificial Humidification:
Section 15 of the Factories Act requires that water to be used to increase humidity of air
artificially (mostly in spinning department) should be clean and from a source of drinking water.
Rules 19 to 29 prescribed u/s 15, require other details as under :
1. Artificial humidification is not allowed in spinning or weaving factory when room temperature
exceeds 29.5°C (85°F) or when wet bulb reading of the hygrometer is higher than that specified in
the schedule u/r 19 in relation to the dry bulb reading of the hygrometer at that time.
2. Provision of hygrometer.
3. Copy of schedule u/r 19 to be affixed near every hygrometer.
4. Temperature to be recorded in humidity register (Form No.6) at each hygrometer.
5. Specifications of hygrometer.
6. Thermometer to be maintained in efficient order.
7. Inaccurate thermometer not to be used without fresh certificate.
8. Hygrometer not to be affixed to wall etc. unless protected by wood.
9. No reading to be taken within 15 minutes of renewal of water.
10. Method of introducing steam for humidification (pipe dia < 2.5 cm , pressure < 5 Kg/Cm2 , jet
projection < 11.5 cm , insulation thickness > 13 mm.)
Byssionosis is included in the third schedule of the Act as an occupational disease due to cotton
dust exposures to workers. It is reportable u/s 89. For details see Part 10 of this chapter.
For monitoring and control of 'cotton dust' (TLV), new schedule 27, 'handling and processing of
cotton' u/r 102 is added in GFR vide Notification dated 19-1-2006. It requires
1. Applicability to factories where any of the processes-opening of cotton bale, carding, combing of
cotton, spinning of cotton yarn or cleaning of waste cotton - are carried out.
2. For removel of cotton dust, local exhaust ventilation is required on processes and machines
where cotton dust is generated.
3. Workers should be given necessary PPE.
4. Six monthly madical examination for LFT, immunoglobulim test and any other test necessary.
5. Limit of cotton dust in workroom should not be more than 0.2 mg/m'\ Record of area monitoring
should be available to the inspector.
6. Other control measures like vacuum stripping of cards and vacuum cleaning should be adopted.
7. High standard of houskeeping should be maintained.
3.3 Safety Provisions:
Section 21 of the Factories Act regarding general machine guarding is application to all textile
machines.
Section 27 prohibits employment of woman or child in a cotton press room where a cotton opener
works. If feed-end of a cotton-opener is separated by full partition, they can be employed on feed-end
side. This is due to the risk of more flying cotton dust on delivery side and hit-injury when any revolving
beater breaks or any solid material is thrown out on delivery side.

Hoist, lift and lifting machine provisions are applicable to those machines. Section 30 on
revolving machinery is applicable to hydroextractor to remove water from wet fabric. The top cover of
the revolving basket should be interlocked and safe working peripheral speed should not be exceeded.
Section 31 and rule 61 are most important for all pressure vessels to be used in a textile industry.
Jet dyeing or beam dyeing vessels, ager, kier, drum washers, cooking-pans, drying cylinders, drying
range, sizing cylinders, air receiver tanks etc. are all subject of this provision. Their design, construction,
use and maintenance must be safe. They must be tested by a competent person periodically. Their safely
devices like safety valve, pressure gauge, stop valve, drain valve and PRV or pressure regulator must be
provided and maintained in a safe working condition. Steam traps and vacuum breakers are also essential.
Precautions against toxic or flammable gas and fire are also applicable to textile processes using
solvent (eg. blancket cleaning) and cotton godowns.
Schedules I & II for detailed machine guarding u/r 54 are summarised in Part 4.4 of Chapter 14.
Rule 68C,GFR, provides following safety precautions for Polymerising and Curing Machines:
1. Printed fabrics shall be thoroughly dried before feeding to such machines (to allow less solvent in
the m/c).
2. 2/3 portion of the exhaust damper/flap should always be open.
3. Infrared ray heaters shall be cut off while running the prints.
4. Electrical heater should have separate circuit and switch to isolate it at the time of emergency.
5. Leakage of solvent should not come in contact with the heaters.
6. Exhaust fan drive should be interlocked with main drive of the machine so that when exhaust
motor stops, the machine (with heating device) should also stop. (Exhaust fan should start first
before the fabric moves into the chamber).
7. Thermostat to regulate the temperature of the heater, not allowing it to go beyond the preset value.
8. Explosion flaps to be provided at top to let off the fumes in case of explosion.
9. Filter gauge and exhaust duct should be cleaned weekly. Vee-belt tension should be checked
weekly.
10. Trained supervisor to examine the machine. A register to be maintained to enter all checks.
When thermic fluid heaters are used to circulate hot oil instead of steam in textile machines (eg.
stenter for cloth drying) rule 68D, GFR, is applicable. See part 10 of Chapter-18 for details.
Rule 68E, requires suitable ladders, crawling board and work permit to prevent fall from fragile
roofs..
Rule 102, Sch: 23 requires ear protection for noise level above 90 dBA, and -auditory
examination every year. Weavers are mostly exposed to high noise. Sch. 27 requires protection from
cotton dust.
Man-made Fibre (Cellulosic and noncellulosic) industry is listed in the First Schedule of the
Act as a hazardous industry. Therefore while manufacturing such synthetic fibre. Chapter 4A of the Act
and rules 68K to N, P and Q of the Gujarat Factories Rules are applicable. These provisions may be
referred in statute books for details. Then Schedule 19 u/r 102 also becomes applicable for chemical
work. Schedule 12 u/r 102 is applicable where acids or alkalis are used.
3.4 Welfare Provisions :

Chapter-S (Sections 42 to 50) of the Factories Act is fully applicable to textile factory. Washing
facilities, first-aid appliances, canteen, lunch room and rest room, creche and welfare officers are required
depending on number of workers employed.
Rules 68R to W of the Gujarat Factories Rules regarding health records, qualified supervisors,
medical examination, occupational health centre, ambulance van and safety showers are applicable to
hazardous processes in man-made fibre textile industry.
3.5 Cotton Ginning and Pressing Factories Act and Rules :
This old Act and Rules are applicable to cotton ginning and pressing factories.
Sch. 2, u/r 54, GFR requires wall or fancing for line shaft of gin machines. (Individually driven
gins require separate guards.)
4 INDIAN STANDARDS
From a variety of IS on textile machinery, some are given below :
Textile motors 2972 (Part I for loom motors, Part II for card motors. Part III for spinning frame
motors). Code for fire safety in cotton textile mills 3079, rings for spinning and doubling frames 3078,
6317, ring doubling and twisting frames 5938, 7614, ring frame, warp spindle 3698, tin rollers 838, metal
travellers 3523, shaft bottom for cotton looms 833, shuttle blocks for automatic looms 9280, 9287,
shuttles-classification of terms 8684, spinning frames-bottom rollers 2510, spindles 3934, top roller 3176,
machinery nomenclature 6068, methods for identification of application classes of dyes on textile
materials 4472 (Part I for cotton and cellulosic fibres, Part II for wool, silk and protein fibres. Part III for
man-made fibres), natural fibres 2364, drafting in spinning machinery 4474, finishing machines, nominal
widths 7952, treatment and disposal of effluents 9508, tolerance limits for effluents 2490 (Part I to 10),
water for quality tolerances 201, twisting machinery 6068, warp bobbins 1724, warper's beams 9292,
warp stop motion 3683, warp ring frame 3698, weavers 'beams 3165, weaving looms and preparatory
machines 3199, weft pirns for shuttles 3265, winders-cone and cheese 8567, pirn 8568, winding rollers
for finishing -machines 8304, wooden bobbins for ring doubling and twisting frames 7614, woven fabrics
testing 9, 2977, 7903, 10100, yarn acetate and rayon filament 1229, blended 7866, polyester and
polyamide 7703, 7867, cotton count determination 237, cotton winding cones 4888, twist determination
832, linear density determination 1226, textile conditioning 6359.
Cotton handloom colour fastness 6906, residual chlorine 2350, scouring loss determination 1383.
Dyes fastness 1688, Fibres, methods of identification 667, flammability and flame resistance test
11871, water quality tolerances 201, textile items made up, glossary 14281, processing glossary 9603,
testing handbook SP'.15, textile terms - wool and animal fibres 11206, mmf 1324, natural fibre 232,
woven fabrics 2364, textile belting 1891, floor coverings, flame resistance 12722, asbestos yarn 13362,
electrical insulation and plastic laminate 13128.
5 FLOWCHARTS OF TEXTILE PROCESSES
5.1 Composite (Textile Mill) Flowchart:

It is essential to understand a textile process flow chart before proceeding towards the textile
machines. Therefore it is shown below in Fig 21.1. General layout of a composite textile mill is shown in
Fig. 21.2.
Above flowchart is self-explanatory, yet some main processes are explained below :
Ginning : The fibres and the cotton seeds are separated by 'gin' machines in a ginning factory.

Pressing & Baling : The ginned cotton is compressed and packed into bales by cotton presses
(mostly hydraulic) in a pressing factory. Generally ginning and pressing factories are combined and
situated in villages where cotton is collected. The cotton bales are transported to a spinning mill or a
composite textile mill. The cotton-seeds are separately collected. They are used to extract oil therefrom
and also for cattle-food.
Schedule-2, rule 54, GFR is applicable to ginning and pressing factories while Sch-l is applicable
to following processes.
Bale Opening and Scutching: In a blow room the bales are opened by bale openers, sometimes
tinted in a tinting room for quality separation and mixed with cotton from other bales or man-made fibres
through a hopper feeder. By a moving spiked lattice, beaters and a series of rolls the fibres are thoroughly
mixed, cleaned and further opened by revolving beaters and air currents against a grid through which the
dirt is separated. A cotton lap is formed and lap-rolls are sent to the carding machines
Carding : The fibres are made parallel to each other, remaining hard tuffs are broken and short
thin fibres and impurities are removed. A sliver (flat untwisted rope) is formed and it is collected in cans.
Spinning : Through pre-comb drawing frames, sliver lap machines, comber machines, drawing
frames and inter frames the sliver is converted into inter-end by drawing, drafting, combing and twisting
processes. More slivers are passed through pairs of suitably spaced rollers, each pair revolving at a higher
speed than the preceding pair. Further attenuation of the yam is accompanied by ring frames and doubling
frames. Inter roving ends are converted into yarn of required count by drafting and twisting in the ring
frame machines. A new method known as open-end or rotor spinning is most suitable for spinning coarse
yarns and can replace not only the ring frame but some other initial processes as well. Texturising is done
to synthetic yarn to reduce its denier.
Weaving Preparatory : In winding department yarn defect is removed and cheese and beam (by
warping machine) are produced. Pirn bobbins are filled to put them in shuttles. Yarn singeing is carried
out to burn off the projected fibres (hairs). Sizing (starch) process is carried out in sizing machines.
Weaving : After the weaving .preparatory processes, the warp threads (beams) and weft threads
(pirn bobbins) are fed to looms to weave cloth. Various types of looms are used. New alternations to the
shuttle for weft insertion are - rapier, water jet, air jet and ripple or wave shedding. The cloth is sent to
the grey folding department for cleaning, mending, inspection and folding (plaiting) purposes.
Artificial humidification is employed in carding, spinning and weaving departments to reduce

yarn breakage, because moist thread has relatively higher breaking strength than a dry thread. But high
humidity causes discomfort. Therefore its regulation is required by hygrometers and by rules 19 to 29
under the GFR.
Finishing Processes : Here shearing - cropping, cloth singeing, piling, mercerising, drying,
washing, desizing (removing starch by enzymes solution), scouring (removing fats and waxes by
hydroxide solution), bleaching (by H,O, or Cl,>, dyeing (wide range of dyes available) and printing
(screen or multicolour rotary printing) processes are carried out in sequence. The dyed or printed cloth is
dried, smoothed and pressed. It may also be subjected to other treatments to improve its appearance or
wearing qualities. It may be made waterproof, flame repellent or rotproof. Synthetic resins are used for
these purposes. The finished cloth (fabric) is sent to finish folding department, for checking, sample
cutting, folding and baling purposes.
Now we shall see the flowcharts of different types of fabrics.

5.2 Other Flowcharts:
To understand flowcharts of fabric manufacturing it is necessary to understand sequence or

stages of manufacture from fibres to fabrics and then bleaching, dyeing, printing and other finishing
processes on the fabrics.
The first stage in the production of a fabric is to clean and mix fibres thoroughly. The fibres are
then generally straightened, but for the production of certain types of fabric they must be brought into a
condition in which they are all parallel. The fibres are next drawn out into the form of sliver, which
resembles a flat rope but with the fibres having no twist. Repeated drawing (extenuating) and twisting
follow. This twisting is to give the resulting roving i.e. just sufficient strength to prevent breakage in its
manipulation (extenuation). Thus a fine roving is produced which is finally twisted into yarn. The yarn is
used to produce fabrics by either knitting or weaving.
It will be realised that for the carrying out of these manufacturing processes a wide range of
different types of complicated machines and a great variety of methods are used. Such processes have
taken more than two centuries to perfect and even now, partly owing to the increasing use of rayon and
synthetic fibres, modifications are constantly being introduced.
Fibres are of two types - staple fibre and continuous fibre. Staple fibres are of certain lengths
while continuous fibre is a very long filament made from chemicals. Continuous fibre can be cut to
required lengths which may be short or long, for the purpose of mixing with other short or long staple
fibres.
Short and Long staple Fibres :
Staple fibres are classified as short, medium or long. Normally less than 2 inch (5 cm) long are
short staple fibres and longer than that are called long staple fibres. Wool is called short staple if less than
2.5 inch long and called long staple or worsted if more than 2.5 inch long. In short staple spinning
process, gilling machine (gill box) is not used. In long staple process 'gilling' machinery is used to
straighten the sliver. Carding is an excellent method for straightening and attenuating short fibres. Gilling
is not satisfactory if the fibres are short. Therefore in the preparation of wool fibres for combing, it is
preferred to straighten diem by carding if the fibres are less than about 9 inch (230 mm) in length and to
gill if the fibres are longer, say up to 15 inch (380 mm) in length.
Long staple worsted wool, jute, coir and flex can be classified as long staple fibres, cotton as short
staple fibre and man-made synthetic filament including -stretchable 'textured' yarn as continuous fibre.
Process flowcharts are shown from Fig 21.3 to
5.2.1 Process Flowchart of Short Staple i.e. Cotton Spinning and Finishing :

Fig. 21.4 : Cotton Processing Flowchart
5.2.2. Process Flowchart of Long Staple (i.e. Worsted Wool) Spinning :

Raw greasy wool
Sorting, selection and blending to suit type of yarn required
Opening-out and loosening of fibre packages
·1
Scouring to remove grease and suint (sheep's dried perspiration)
and carbonisation (if necessary) to remove cellulose impurities
(in lap form)
(in sliver form) Carding (in sliver form)
Backwashing (scouring) Condensing

(in sliver form) (in roving form)
Gilling Spinning on mule

(in sliver form) machine into woollen
yarn
Backwashing
(in sliver form)
Gilling
(in sliver form)
Combing
(in sliver form)
Gilling
(in roving form)
Wool tops
(in roving form)
Drawing and doubling

(several stages)
(in roving form)
Spinning by flyer, cap, ring
or mule machine into
worsted yarn
Fig. 21.5 : Process Flowchart of Wool spinning.
A complete flowchart of wool processing - spinning, weaving & finishing is shown below in Fig 21.6.

Fig. 21.6 : Wool Processing Flowchart
5.2.3. Process Flowchart of Viscose Rayon and Synthetic Fibre Manufacture :

Fig. 21.7 : Process Flowchart of Viscose Rayon Manufacture
5.2.4. Process Flowchart of Spun and Filament Yarn :
(A) Manufacture of Nylon - 6.

Fig 21.8 : Process Flowchart of Filament Yarn (Nylon-6)
(B) Manufacture of Spun or Oriented Yarn (LOY, POY, HOY & FOY) :
Polyesters:
Polyesters were initially discovered and evaluated in 1929 by W.H. Carothers, who used linear
aliphatic polyester materials to develop the fundamental understanding of condensation polymerisation,
to study the reaction kinetics, and demonstrate that high molecular weight materials were obtainable and
could be melt-spun into fibres.
Polyethylene Terephthalate (PET) is a fibre of great commercial significance, useful in cordage,

apparel fabrics, industrial fabrics, conveyor belts, laminated and coated substrates, and numerous other
areas. However, to engineer specific properties for special uses, many product variants have been
developed and commercialised. These variants include alternative cross sections, controlling polymer
molecular weight, modifying polymer composition by using co-monomers and using additive including
delusterants, pigments and optical brightners.
High molecular weight polymer is used for high strength fibres in tyres, ropes, and belts. High
strength and toughness are achieved by increasing the polymer molecular weight from 20000 to 30000 or
higher by extended melt polymerisation or solid-phase polymerisation. Special spinning processes are
required to spin the high viscosity polymer to high strength fibre. Low molecular weight fibres are weak
but have a low propensity to form and retain pills, i.e. fuzz balls, which can be formed by abrasion and
wear on a fabric surface. Most pill-resistant fibres are made by spinning low molecular weight fibres in
combination with a melt viscosity booster.
Most of the textile fibres are delustered with 0.13.0% wt TiO, to reduce the glitter and plastic
appearance. Many PET fibres also contain optical brighteners.
Manufacturing and Processing:

Terephthalic Acid (TA) or dimethyl terephthalate (DMT) reacts with ethylene glycol (EG) to
form bis (2-hydroxyethyl) terephthalate [959-26-2] (BHET) which is condensation polymerised to PET
with the elimination of EG. Molten polymer is extruded through a die (spinneret) forming filaments that
are solidified by air cooling. Combinations of stress, strain and thermal treatments are applied to the
filaments to orient and crystalize the molecular chains. These steps develop the fiber properties required
for specific uses. The two general physical forms of PET fibers are continuous filament and cut staple.
Raw Materials :
For the first decade of PET manufacture, only DMT could be made sufficiently pure to produce
high molecular weight PET. After about 1965, processes to purify crude TA by hydrogenation and
crystallisation became commercial. In Japan, oxidation conditions are modified to give a medium purity
TA suitable to manufacture PET, provided colour toners such as bluing agents or optical brighteners are
added during polymerisation. Compared to DMT, advantages of TA as an ingredient are lower cost, no
methanoi by-product, lower investment and energy costs, higher unit productivity, and more pure
polymer because less catalyst is used. Catalysts are used in the transesterification reaction of DMT with
EG and in polycondensation. Many compounds have catalytic activity. Divalent zinc and manganese are
the prevalent transesterification catalysts. Antimony, titanium and germanium are the predominant
polycondensation catalysts. Up to 3% delusterant is added to many PET fibre products to make them
more opaque and scatter light; titanium dioxide is the most common delusterant. PET fibre blended with
cotton for apparel frequently contains small amounts of fluorescent optical brighteners added during
polymerisation.
Commercial production of PET polymer is a two-step process carried out through a series of
continuous staged reaction vessels. First, monomer is formed by transesterification of DMT or by direct
esterification of TA with EG.
In general, esterification is conducted in one or two vessels forming low molecular weight
oligomers with a degree of polymerisation of about I to 7. The oligomer is pumped to one or two pre-
polymerisation vessels where higher temperatures and lower pressures help remove water and EG; the
degree of polymerisation increases to 15 to 20 repeat units. The temperatures are further increased and
pressures decreased in the final one or two vessels to form polymer ready to spin into fibre. For most
products, the final degree of polymerisation is about 70 to 100 repeat units. Average molecular weight is
about 22,000; weight average molecular weight is about 44,000.
Spinning:
PET fibres are made either by directly spinning molten polymer or by melting and spinning
polymer chips. A special, precise metering pump forces the molten polymer heated to about 290°C
through a spinneret consisting a number of small capillaries, typically 0.2 to 0.8 mm in diameter and 0.3
to 1.5 mm long, under pressures up to 35 MPa (5000 psi). After exiting the capillary, filaments are
uniformly cooled by forced convection heat transfer with laminar-flow air.
Following solidification, the threadline is passed over a finish applicator and collected. A spin
finish is applied to reduce friction and eliminate static change.
It is convenient to classify commercial PET spinning processes according to the degree of molecular
orientation developed in the spun fiber. Generally, the classification is a function of spinning speed. Low
oriented yarn (LOY) is spun at speeds from 500 to 2500 m/min; partially oriented yarn (POY) is spun at
2500 to 4000 m/min; highly oriented yarn (HOY) is spun at 4000 to 6500 m/min; and fully oriented yarn
(FOY) is spun at greater than 6500 m/min.

Drawing and Stabilisation:
Drawing is the stretching of low orientation, amorphous spun yarn {LOY) to several times their
initial length. This is done to increase their orientation and tensile strength. Drawing in two or more
stages is useful to optimise te'nsile properties and process continuity. Stabilisation is heating the fiber to
release stress within the molecular chains melt and reform crystals and increase the level of crystallinity
in order to stabilise the fibre structure.
Staple Processes:
In staple processing, the containers of combined spun ends are further combined to form a tow
band and fed to a large drawline. The tow band is spread out into a flat band tracking over multiple feed
and draw rolls. Crimping is the process by which two dimensional configuration and cohesive energy is
imparted to synthetic fibres so they may be carded and converted to spun yarns. The tow band is cut to
precise lengths using a radial multiblade cutter, normally 30 to 40 mm for blending with cotton, 50 to 100
mm for blending with wool and up to 150 mm for making carpets. Cut staple is packaged in up to 500 kg.
bales at densities greater than 0.5g/ m3.
Safety and Environmental Factors :
Health & Safety : PET Fibres pose no health risk to humans or animals. Fibres have been used
extensively in textiles with no adverse physiological effects from prolonged skin contact. PET has been
approved by the U.S. Food and Drug Administration for food packaging and bottles. PET is considered
biologically inert and has been widely used in medical inserts such as vascular implants and artificial
blood vessels, artificial bone arid eye sutures.
Environmental Factors : PET materials are no dangerous to the environment and cannot
contamination surface or ground water. During polymerisation, non condensible organic by-products are
stripped from this process outflow streams and burned. Glycol and water are separated by refining. The
water is treated in standard water spray facility. The glycol is reused The method from the DMT
transesterification is refined and reused. Like all materials, polyesters should be
Fig 21.9 : Block Diagram for Polyester Manufacturing by Continuous Polymerisation Process

5.2.5. Jute manufacture :
The jute plant flourishes in hot and damp regions of Asia, mainly in India, Bangladesh, Pakistan,
Burma and Thiland. Jute is a natural fibre and is used to make sack cloth, jute ropes, bags, camp beds,
filter cloths etc.,
In 1820, jute was sent to England from India and was spun experimentally at Abingdon near
Oxford. In 1822 Dundee mills in Scotland began spinning of jute. By 1850 the jute industry was well
established.
In India and Bangladesh, the jute plants (Corchorus) are harvested with a hand sickle. Jute plant
grows to 5 mt with a stalk diameter of 2 cm. The fibres are separated from the stem. The strands of fibre,
as much as 2 mt long, are washed and hung up in the sun to dry. They are compressed into bales and sent
off to the mills for spinning disposed of properly to avoid litter and can bi disposed of by landfill or
incineration.
A key environmental advantage for PE" materials is the ability to recycle. Polyester materials
especially bottles, can be separated from contammated materials such as aluminium caps and paper label
and remanufactured by direct remelt extrusion into fibres for filling products or carpets or into layered
constructions for good-grade bottles.
A block diagram of above mentioned process i «ihnwn in Pip- 21 9.
Small amount of mineral spindle oil is added into the fibre during conversion into yarn. Normal
jute goods may contain upto 5% oil, but so-called 'stainless' yarns to be used for special purposes like
wall coverings, cables etc., contain I % or less oil.
Jute Processes:
Raw jute is first passed through the softening machine. Oil and water emulsion is sprayed on to
the jute. Sometimes sodium alkyl phosphate (Teepol) is also used. This process is known as 'batching'.
After preparation, the fibres are carded or combed, drawn and spun. Then cop and spool winding,
weaving, finishing, croppong, cutting and lapping complete the processing.
Bleaching and dyeing of jute is also possible. Dyestuffs used for cotton, are also useful for jute.
The fibre has a special affinity for basic dyes, which provide brilliant effects even on unbleached base.
The increased demand for rugs, mats and carpets require dyed jute yarns and fabrics suitable for these
applications. Azoic and vat dyes give very bright and fast results but their high cost limits their use with
jute. The tendency of jute to turn brown in sunlight is a permanent disadvantage. Hazards and Controls:
Machinery hazards are high as in case of cotton textile machinery. Main drives, gears, in-running
nips of rollers or bowls, spindles and shafts, knives and cutters, flying shuttles etc. need efficient
guarding. Fire may occur due to friction and heat. Water hydrants are necessary. Pesticides used in
cultivation of jute may cause poisoning. Dust is given off in bale opening and spinning. Local exhaust
ventilation is a must. Dermatitis gives skin trouble due to dust, batching oil, dyes etc. Excessive noise in
weaving operation may cause hearing loss. Ear protection is necessary. Carrying heavy loads may cause
strains. Medical examination of workers is necessary.
6 HAZARDS AND SAFETY MEASURES OF SPINNING PREPARATORY

AND SPINNING PROCESSES
6.1 Opening and Blow Room Machines:
Purpose is to open cotton bales, to open and beat cotton to remove dirt/dust from it and to make it
loose for the next process of spinning.
Types of machines used are :
1. Bale opener or breaker. Hard waste breaker, step cleaner. Super cleaner. Cotton opener -
Porcupine or Chrighton opener. Roving waste opener. Scutcher, Combined opener and Scutcher
Scutcher and Lap machine, Axi-flo, hoppel feeder etc. Tinting room is used to colour the cotton or
synthetic fibres for their mixing.
2. Each machine should be driven by separate motor or by separate counter-shaft with fast and loose
pulleys and efficient belt shifting device All main drives, counter drives and reductior gears shall
be securely guarded.
3. All beater covers or doors giving access to any dangerous part of the machine should be
interlocked or be securely fenced. Dirt door or desk door should have hinged or fixed grill as a
guard and door for dirt/dust removal.
4. Dust chamber opening should be so fenced that while admitting light, prevents contact between
any portion of a worker's body and the beater grid bars.
5. All belt and chain drives should be guarded.
6. In Roving waste opener, cage-wheel and side shaft wheel should be guarded.
7. In opener machine, door giving access to the nip between the lattice and the fluted guide roller of
the lattice and evener rolls etc, be interlocked.
8. Inspection doors (covers) on trunkings should be properly situated and closed. If their location is
dangerous, it should be changed or interlocked.
9. Spiked or fluted rollers which feed the materials from conveyors should be guarded. In-running
nips of Feed and Calendar rollers must be guarded or interlocked.
10. Safe means of access i.e. catwalk, guard-rails, steps, ladders, hand-rails etc., should be provided
on top of the machine where a worker has to work.

11. Lap rods - Lap stand should be proper. Lap rods should not fall out of it. Stacking of lap-rods
should be proper
12. Knock-off lever - Its design or placement should be proper and the knock-off wheel should not hit
a person.
13. Unsafe actions : The interlocks (micro-switches) on machines should not be tempered with. The
supervision should he-proper for loading dead weight on a buckley opener, handling a guard,
cleaning the inside of a buckley cage or bottom dust chamber collecting cotton or waste from near
any revolving part, placing spiked lattice on a bale breaker, removing jam med material from rack
and rack wheel, climbing the opener, feeding the lap on a scutcher and removing choked cotton
through anopening in a pneumatic pipe.
6.2 Carding Machines :
Purpose is to spin and open cotton fibres.
1. Spacing between the cards should be sufficent. All dangerous parts such as belts, ropes, pulleys,
gears etc., should be securely guarded. Main drive shall be guarded.
2. The cylinder-doors must be interlocked (R. 54, Sch. 1) and effective. Stripping (cleaning cylinder)
operation with open doors should be done by a trained man. The newer machines have safer
stripping attachment.
3. The belt shifting devices for fast and loose pulleys should be properly maintained.
4. The nip between the plate-wheel and the side shaft wheel should be guarded.
5. Coiler : (i) Coiler head should not fall down (ii) Gears of the coiler box be guarded, (iii) The nip
between the calendar roller wheel and the coiler back shaft wheel should be guarded or fenced.
6. Licker-in : (i) The access to the underside of the licker-in should be properly guarded by a hinged
swing door or flap guard swinging back upwards to prevent contact while collecting dust (ii) The
checking of the clearance between the licker-in and its casing while the licker-in is in motion must
be prohibited (it may be done while the licker-in is stationary).
7. Doffer & Comb Blade : (i) Covers on doffer wheels should be closed, (ii) Work at or near the
doffer cover and doffer comb blade must be done with care and properly supervised.

8. High Speed Carding machine : The in running nip between cross rolls should be securely
guarded.
9. Mounting or dismounting of belt or rope and stripping and grinding operations should be done
with care and should be properly supervised. It should be checked that while such stripping or
grinding, the stripping brush is properly positioned so that it may not be loosened, the idler wheel
and the umbrella wheel are properly fitted (so that they may not get loosed and fell down) (ii)
Gauging the clearance between the flats and the card-cylinder should 130 done with the cylinder
stationary (not rotated even manually) and by a standard angular gauge for this operation. It
should be so supervised.
10. Local Exhaust Ventilation : Modern card machines have built-in local exhaust system with dust
collection chamber to extract the cotton dust generating in the machine and to prevent its exposure
in the work environment. This system should be efficiently maintained
6.3 Sliver and Ribbon Lap Machines:
Purpose is to make a sliver and lap from spinned cotton.
1. Types of these machines are : Sliver lap, lap m/c or lap-former, Derby doubler. Ribbon lap m/c
etc. The main and counter drive shall be securely guarded.
2. Nip between the lap forming rollers (lap roller and fluted roller) should be guarded. It is desirable
if it is interlocked (R. 54, Sch. 1).
3. Ribbon lap m/c : The lap drum and calendar drum gap should be interlocked.
4. Sliver lap m/c : Nip guard at the intake end of the calendar rollers necessary.
5. The carding slivers should be made parallel and combined to form a lap sheet suitable for feeding
to a combing m/c.
6. Unsafe actions : Care must be taken during operations such as cleaning cap bars of a lap m/c,
placing laps on lap rack, putting a lap rod on a lap stand, removing the chain drive from lap
forming m/c, cleaning the ribbon of lap m/c and putting a lap end around a spool.
6.4 Combers and Drawing Frames :
Purpose is to comb (to make fibres parallel), pull and draw the fibres of lap of cotton.
1. Comber Machine : (i) The main drive shall have fixed guard (ii) The moving spiked cylinder
should be interlocked, (iii) The cylinder covers i.e. hood of the comb near comber cylinder and
the coiler covers should be fixed so as not to fall down and hit (iv) Hinged transparent guard to
prevent contact with rotating segment i.e. nipper or gripper (v) Guard on top comb and detaching
rolls (vi) Guard on calendar rollers and gears (vii) Interlock guard on coiler and draw-box gears.

2. Drawing frames : (i) Guards be provided on moving calendar rollers and gears (Nip between
rollers should be covered), (ii) The gear wheels should be guarded or fenced, (iii) The head stock
gearing must be guarded, (iv) The mango vacuum box of the top roller should be securely fixed,
(so as not to fall down) (v) Sharp projections on the coiler bottom plate should be removed or
rounded (vi) Off-end gear cover should be guarded.
6.5 Roving (Speed) Frames :
Roving means drawing of the first thread from the sliver. Purpose is drawing and twisting of
fibres (thread).
1. Types of these m/cs are : Slubbing frames, inter frames etc. The main drive shall be securely
guarded.
2. The head stock gearing (jack box wheels) should be interlocked. (R. 54, Sch I GFR).
3. Slubber Frames : (i) The driving bevel and bevel wheel should be guarded, (ii) The spindle shaft
wheel should be guarded, (iii) Bobbin and spindle bevel gears should be guarded, (iv) The ratchet
wheel should be guarded, (v) Work close to revolving flyers should be done only after stopping
the flyers. It should be supervised so. (vi) Care should be exercised while handling of rollers and
weights.
4. Inter (Speed) Frames : (i) The guard of the head stock gearing should be adequate or interlocked
(ii) The stacking of bobbins on creel top should be done in safe manner, (so that the bobbins may
not fall down) (iii) The height of creel top should be proper, (so as to reach easily). If not suitable,
foot boards and hand holds should be provided (iv) Work close to rotating flyers should be done
after stopping them (v) Draft rolls, draft gears, inter gears (jack box), cone drive and main drive
should have guards.
The new open end or rotor spinning system eliminates some steps of the spinning
preparatory operation and reduces many accidents.
6.6 Ring (Spinning) Frames :
Main process is twisting (rotating) and winding thread on bobbins.
Return-air system with humid air suppliers (diffusers) is used for better ventilation and
humidification. Purpose of humidifiction is to prevent thread breaking. It provides large duct area through
floor openings, air cleaning, rapid air changes, more humidification and more reduction in flying fluffs.
1. Transmission parts : (i) The main drive and the other driving belts and ropes should be guarded,
(ii) Mounting of taps on jockey pulleys should be done after stopping the pulley by cutting of
power, (iii) The headstock gears should be interlocked. Tieing ribbon on limitswitches and
making interlocking ineffective is noticed many
times. By frequent checking such unsafe practice
must be discouraged, (iv) Drafting gear and drafting
rollers, warm and warm wheel should be guarded.
2. Damaged Bobbin Shields : Sharp edges of the
broken metal shields of bobbins cause many injuries
on fingers while piecing or doffing operations.
Following remedies should be provided, (i)
Inspection and rejection of damaged shields, (ii)
Use of plastic bobbins instead of wooden with metal

shields, (iii) Suitable kneebrake or hand brake as shown in the figure for each spindle to stop it.
The .height of this brake should coincide with the knee of the worker. This is the design
(ergonomic) aspect.
3. Struck against various m/c parts : (i) The sharp edge of a protruding metal sheet on the frame
and broken edge of a ring frame may cause struck injury. Such damaged components should be
replaced, (ii) Care should be taken while creeling, de-creeling, piecing, cleaning rollers, cleaning
cotton fluff, stopping bobbins for piecing, fixing bobbins on spindles, doffing and adjusting arbor
so as not to be struck against rollers, their supporting brackets or roller beams; work near lappet
rail, filter-box, lappet middlerollers, top arm and cradle and middle arbor and cradle assembly,
pocker rod, tube bracket and dashing against the frame of the machine while attending to different
jobs. Proper supervision necessary.
4. Fall of bobbins from creel top : (i) Stacking of bobbins on creel top should not be haphazard.
Only one row of bobbins should be stacked, (ii) Safe means of access i.e. suitable foot-boards and
hand-holds should be provided for climbing up.
5. Fall of rollers : (i) Fall of clearer rollers and dead weight rollers occur in the course of operations
such as releasing auto-lever, piecing, removing the rollers or holding them for cleaning. Care is
necessary, (ii) Mechanism holding the rollers in position should be maintained in good condition.
6. Auto-lever : (i) Care should be taken while releasing or replacing the auto-lever, (ii) Condition of
the saddle should not be defective.
7. Ring travellers : These can fly and injure persons unless there is an effective system of periodical
replacement. Also the travellers should be of good quality and properly fitted.
8. Dotting boxes : (i) The hook on the doffing boxes for placing them on the rail should be proper.
(ii) Splintered condition of the boxes and the protruding metal band may cause accident. Their
periodical inspection and repair is necessary.
9. Suction pipes : Sharp or broken edge of a suction pipe may cause injury. It should be checked
and required or replaced. Suction fan with duct is provided to collect broken ends.
10. Others : (i) Side plate of a frame may get loose and fall down. It should be periodically
inspected, (ii) All motor fans should be closed by the covers.
6.7 Doubling Machines (frames) :
Two or more threads are joined, twisted and wound on bobbin.
1. Drives : Main drive pulley belt and head stock gearing should have guards. Delivery roll gears
should be guarded.
2. Knee-brakes : They should be provided to stop bobbin for piecing operation and maintained
properly. They should be at proper knee height.
3. Cans : (i) The edges of cans for storing bobbins should not be broken or sharp, (ii) They should
be inspected and repaired or replaced, (iii) Plastic cans are desirable.
4. Ring Travellers : (i) They should be of good quality and properly fitted, (ii) They should be
periodically inspected and replaced.
5. Machine Parts : The creel tops to store bobbins should be within the arms reach. Foot rails
should be provided.
6. Unsafe actions : Striking against knee-brakes, ring travellers, top roller, tap on a spindle, rough
edge of jockey pulley etc., may cause accidents. Care should be exercised and supervised.
7 HAZARDS AND SAFETY MEASURES OF WEAVING

PREPARATORY AND WEAVING PROCESSES

7.1 Winding Machines :
Purpose is to wind weft on bobbins.
Types of machines used are : Barber-Coleman ITI/C, Auto-coner, pirn winder etc.
1. Guards should be provided on main drive, revolving drum, drum drive motor, timer drive, cam
drive, traveller pulley and track nip and conveyor drive. Knotter-carriage assembly & spindle
assembly should have cover.
2. The gap between the moving parts of conveyor and fixed parts should be checked all along its
length and reduced to the minimum by suitable covers/guards.
3. Bobbins/sleeves used on the m/cs should be inspected for broken edges, burrs etc. as also for their
proper fitment on driving spindles.
4. Haste in loading spindles with empty bobbins should be avoided. Also, dust and other extraneous
materials on spindle and moving yarn should not be removed while they are in motion. Dust
collecting blower and bag are useful.
5. Automatic winders like cone winder and spoolers prevent hands reaching near the rotating drum
and are preferable.
7.2 Warping Machines :
Purpose is to wind warp on warp beam. Different types of warping m/cs are available.
1. The flanges of rotating beam should be properly guarded. Aluminium flange beam without metal
flange ring is safer. Metal flange ring may open, fly out and hit.
2. The main drive, gear wheels, motor pulley, clutch pulley-belt and other parts should be properly
guarded.
3. The nip between the driving roll and warp beam should be guarded. Trip cum distance guard
should be provided for protection from rotating beam.

4. Beam side distance guard (rod) should be interlocked (contact switch) with drum which drives
the beam-.
5. Multiple photo-electric device is more safe.
6. Hydraulic braking system should be provided to stop the beam within shortest possible time.
7. Stop motion indicator lamp is useful.
8. Wheels of moveable stands should have guards.
9. Drum drive motor pulley, beam drive chain, beam ends and section warping gears should be
guarded.
10. Unsafe actions : Dashing against rotating beam, leading the thread from the creel to the drum (at
this time the m/c should be stopped), removing ball bearing from the shaft of the warp roll,
stepping on the slopping platforms of the m/c, removing empty pegs from bobbins on creels and
loading and unloading the beams can cause injuries.
7.3 Sizing Machines :
Purpose is to apply starch on yarn or cloth.

1. Nips : Nip guards should be provided on in running nips between the driving rolls and other
revolving rolls at the front of the m/c. Guards on drag rolls and squeeze rolls are essential.
2. The main drive, beam drive chain, size box drive chain and speedometer chain should be guarded.
3. Suction hood necessary to arrest steam vapour.
4. Gears : The gears of the marking mechanism of the m/c should be guarded. Other m/c parts be
guarded.
5. Beam weights : The counter weights of a beam should be properly placed so that they may not
fall down while touching.
6. Loading and unloading of beams can cause accidents. Care should be exercised.
7. Rule 61(8) GFR : (i) These provisions should be followed for thin wall cylinders, (ii) Form No.
11- test report - should be available for each sizing cylinder, (iii) Pressure reducing valve, safety
valve, pressure gauge, steam trap and drain-cock for condenset, steam stop valve etc., should be
properly provided, set and maintained for ensuring safety, (iv) Maximum permissible working
pressure shall be reduced 5% every vear (v) Maximum life 20 vears. (vi) New and second hand
pressure vessel shall be tested at 1.5 times 'its Maximum Permissible Working Pressure.
7.4 Looms (power looms) :
Purpose is to weave cloth by using weft (pirn) bobbins and warp beam by a machine known as
loom.
1. Types of looms are : Ordinary power looms, automated jacquard looms, drop-box, dobby, air-jet,
water-jet, rapier etc. Loom sizes are 46", 52", 56", 60" and 64".

2. Flying Shuttles : (i) Shuttle flight may be caused by warp breakage, broken or improper heald
(heddle) wires, slackness in picking mechanism and other causes. Shuttle less looms (auto looms)
is the best remedy for shuttle flights, but it is not economical. Therefore, the practical remedy is
the shuttle guard. The shuttle guards be properly provided. It should extent sufficiently forward
and the gap below it should not be too much. Because of possibility of change in this gap and
despite the guard the shuttle car fly and hit Certainly they protect the upper body of a worker from
hitting, (ii) To protect from injury due to shuttle flying from the adjacent loom, every loom must
be equipped with barrier guard placed close to each end of the slay beam Such guards of strong
wire netting or similar material are advisable, (iii) Reasons for shuttle flights should be properly
recorded, investigated and removed.
3. Shuttles : (i) Shuttle receptacle should be provided near each end of the slay to place the shuttle
properly, (ii) Removing empty pirn (bobbin in shuttle) 'and loading wound pirn into the shuttle
may cause injury. Also care should be exercised while placing shuttle on the slay. (iii)
Automation of process of filling up the empty shuttle can reduce these hazards where a pirn
battery loads the shuttle as soon as the weft yarn on it is exhausted. This device of modern looms
is advisable.
4. Picking stick assembly : (i) Vertical picking stick is less dangerous than horizontal one. Work
near the proximity of the stick should be done carefully, (ii) Spacing between two looms should
be at least 55 cm measured from the farthest projecting point of an adjacent loom or wall. The
aisles (alleys) should atleast be one meter wide. It is so desirable for safe movement, (iii) Picking
stick (arm) should be securely guarded along its fixed path of movement so that hitting by it can
be avoided, (iv) The loom spindle on which the picker moves may crack or fly out and hit.
Defective spindle should be found out and replaced, (v) Picking spring should be inserted in
position carefully (vi) The picking wheel should be guarded, (vii) All parts of picking mechanism
and heald frame should be sound for proper fitment, wear and tear.
5. Beam Weighing : (i) Compound lever should be adopted for beam weighing wherever possible.
The shape of the weights should be such that they would not come off the lever and hit. Weights
of shape '8' should be preferred to those of shape 'C'. Weights must be harnessed to the beam by
strings or straps of adequate strength (ii) Spring loaded mechanism used for beam weighing
should be inspected at least once in a week and defects, if any, rectified. Defects of spring, lever
handle, threads used if any, should be found and removed.
6. Cloth and Emery rolls : (i) The support brackets of the cloth roll should be examined once a
week for any defects to ensure that the cloth roll sits tight in the brackets, (ii) Care should be
taken from hitting the cloth or emery rolls while walking near them (iii) Heavy cloth rolls should
be handled mechanically or by more workers, (iv) Guards should be provided on emery roll and

guide roll, crank tappet gears, take-up gears, bottom cam drive gears, motor drive, shedding
motion etc.
7. Slay beam : (i) The slay moving towards and away from the weaver may hit the hand and fingers
may get trapped between the moving slay and the front rest head frame, temples etc. Hands
should not be placed on the slay or at places near its path. (ii) Clearance between the slay bolts of
two adjacent looms should be adequate, (iii) Setting of die weft fork holder and hammer should be
proper, (iv) Removing fluff or wastes and attending to minor adjustment on the loom must be
done only after stopping the loom.
8. Duck bill and Hitter : The duck bill and hitter should be guarded on every loom to prevent
contact with sharp edges of these moving parts or being trapped between them. Such guards can
be in the form of close pitched springs surrounding the duck bill and extending 3 to 5 cm beyond
so that approach to the sharp edges from the sides is prevented.
9. Others : (i) Driving pulley-belts (main drive) of the loom must be securely guarded by a fixed
guard. (ii) Ratchet and pawl or crank and tappet mechanism (including gears) should be guarded.
The edges of the guards should not be sharp so that it may injure, (iii) The tuning of the loom
should be checked once in every shift and adjusted wherever necessary (iv) Spare pirns and their
boxes should be examined for their broken edges etc., and should be rectified, (v) The operators
must be alert to join the broken ends. They should be joined only after stopping the loom. (vi) Pall
of various improperly fitted loom parts on workers while cleaning, oiling etc., dashing against
loom parts, getting caught between loom parts due to accidental starting, striking weft box while
loading or unloading pirns, striking heald wire while drawing ends or doing adjustments nearby
etc., may cause accidents. Care should be exercised and supervised in such operations, (vii)
Suction device for pirn-battery return air system, diffusers, sprinklers, hydrants, fire extinguishers
etc. should be in good working order.
10. Noise : Hearing loss is possible due to high noise in loom shed. Noise level should be below 90
dBA. Shuttle less loom gives less noise. Good lubrication and maintenance, proper tuning, quick
replacement of damaged parts of picking mechanism and stroke resistors help to reduce noise.
Workers should wear ear protection.
8. HAZARDS AND SAFETY MEASURES OF PROCESSING

(FINISHING) AND FOLDING MACHINES
8.1 General Precautions :
1. Types of machines in use are : Shearing, singing, washing, bleaching, kiers, yarn and cloth
dyeing, printing, polymerising, sanforising, stentering, padding, finishing, folding, bale (cloth)
pressing machine etc.
2. The in-running nips between rollers and similar parts, unless the nips are inaccessible, should be
securely guarded with nip guards (bars) along the whole length on the intake side (Rule 54, Sch II,
GFR).
3. In dryers and similar machines where there is a risk of access from the sides to nips referred to in
item (2) above and driving gears should-be guarded to prevent such access.
4. Other machine parts such as main and counter drive, belts, pulleys, shafts, gears and flappers
should be guarded.
5. Removing crease from die cloth on rollers should never be done when the machine is in motion.

6. Oiling, greasing, adjustment or repairing near dangerous parts should not be done with the
machine running.
7. Entanglement with the cloth in process is a serious hazard in some of die machines. While
working here, care should be exercised and supervised.
8. To the extent possible, splash guards should be provided for containing the likely splashes of
chemicals and hot liquids at those parts of machine where- splashes generally occur. These would
also facilitate keeping the floor free from spillage.
9. Wherever risk of splashes from chemical or hot solutions exists, operators should be provided
with PPE such as face shields or goggles, hand gloves, aprons and gum-boots.
10. Wherever persons have to reach and work at parts of machine situated at heights, suitable means
of access in the form of catwalks and platforms should be provided. Wherever these are not
provided due to infrequency of the operations or any other reason, alternative arrangements such
as scaffolding or safe ladder should be provided and the operations carried out confirming to
standard safe practices.
11. Dismantling and fitting of heavy parts of machine should be done with care. To the extent
possible, mechanical handling devices should be used for the purpose.
12. Acids, alkalis, bleach liquors or whitening agents, dyestuffs and solvents are used for process or
cleaning purpose. Their storage should be kept away in a separate room. They should be handled
in small containers with lids. Their spillage or leakage should be avoided and cleaned
immediately. Cleaning by solvent is risky. Source of ignition must be avoided while using solvent
to clean printing machine, vessel, container etc. Then nearby electric fitting should be flameproof
or switched off. Ordinary short circuit has caused many accidents.
Schedule 12 and .19 u/r 102, GFR should be followed while handling acids, alkalis and
other chemicals. Rule 68D should be followed for using hot oil circulation in stenter etc. through
thermic fluid heaters.
8.2 Bleaching Process :
Purpose is to whiten the cloth or yarn (threads). Normally chlorine, sodium hypochlorite or
hydrogen peroxide are used as bleach liquors. Their concentration should be within safe limits. They
should be stored in minimum quantities. Transfer from bulk storage to small containers should be safe.
Flexible connections must be checked for safety. Emergency kit to handle chlorine leak should be kept
ready. Proper respirator, eye goggles and gloves should be worn while working near chlorine gas or
hydrogen peroxide fumes. Addition of chlorine in caustic solution to make sodium hypochlorite should
be in closed and safe system. See Part 8.6.1 of Chapter-18 for chlorine safety.
Open bleaching tanks should have fencing to prevent fall inside.
Bleaching machine should have fume exhaust device. Bleaching range should have nip guard on
rolls.
8.3 Processing Machines (Dyeing, Printing etc) :
Purpose is to wash, dye (colour), print, dry, heat, press, stretch, carbonise, mercerise, sunforise
and fold the cloth etc.
Water is used in large quantities in processing machines. Reverse Osmosis (RO) Plant should be
used to remove hardness as well as total dissolved solids (TDS) if the water available is hard and saline

(salty). Such soft and salt less water decreases rate of corrosion and increases life of the vessels/
machines.
Safety measures for some processing machines are stated below.
1. Washing machine : Purpose is to wash the cloth in open tub (i.e. no pressure) (i) Nip Guards on
rollers (ii) Catwalk and platforms to reach and work at the required places with sufficient
handhold and foothold (iii) Guard on moving flappers, (iv) Distance guard, belt and chain guard
(v) FRP and acid-proof lining if acid/alkali is used. (vi) Clean overflow "pipe with water tank (vii)
Nip guard on draw nip (viii) Air regulator for pneumatic loading of rolls (ix) Guards on chain
drives of nip rolls (x) Doors on soap tanks (xi) safely of steam lines and (xii) Guard on chain drive
of a plaiter. (xiii) Nif guard on padding mangle.
2. Washing Tanks : Purpose is to wash the cloth (i) Railing near hot water tanks to prevent
falling into it (ii) Drain pipes and valves to drain hot water from the tank. Simple hole, cotton plug
(stopper) and bamboo use is an unsafe practice.
3. Hydroextractor : Purpose is to remove water from wet cloth, (i) Interlock basket cover (ii) Fixed
guard on pulley-belts (iii) Brake to stop basket.
(a) (b)
Hydro extractor - (a) Hazard due to no basket cover (b) Basket cover with electrical enterlocking.
4. Jigger machine : Purpose is to colour the cloth in open tub (i.e. no pressure), (i) Nip guards on
rollers and gears (ii) Splash guards should be provided on each of such machines to minimise
chances of chemicals and colour solutions splashing on persons, (iii) Aprons and chemical
goggles should be given to workers (iv) Periodic inspection and maintenance of the floors. They
should be free from water and solution so as not to keep it slippery, (v) Pneumatic valve to control
steani flow (vi) Cover on motor pulley belt drive and gearbox (vi) Roll motion controller.
5. Calendar machine : Its function is to give fine finish (ironing) by passing the cloth through
calendar rolls or bowls, (i) Auto temperature control to prevent over heating (ii) Nip guards on in-

running nips (iii) Guards on main motor drive and reduction gears, (iv) Heavy rolls should be
handled mechanically (v) Contact with hot rolls may cause burn injury. Care should be taken
while working at heights (vi) When steam pressure is above atmospheric pressure. Rule 61 GFR
should be complied with. All safety devices should be properly maintained.
6. Drying machines : Purpose is to dry cloth, (i) Nip guards on rotating rolls and mangle rolls.
Guards on chain, bevel gears, winch drive and stack drive, (ii) Platform, foothold and handhold to
work at heights (iii) Hot cylinders of drying range may cause burn injury. Care and effective
supervision (iv) For pressure control, follow Rule 61, GFR.
7. Kiers and Agers : Purpose is heating by steam pressure, (i) While tightening the eye bolts of kier,
bars used should be of such construction that they hold the eye bolt securely and do not slip off.
(ii) Catwalks and platforms to work on the top of the Kier (iii) Care form coming into contact
with the hot parts of the kier (iv) Pressure reducing valve, safety valve, pressure gauge, stop valve
etc. should be properly maintained for the safe working pressure inside. Safety valve and pressure
gauge should be provided on jacket also (v) Hydraulic pressure test at every two years (vi) Chain
pulley block or hoist to lift heavy parts.
8. Stenter machine : Purpose is to dry cloth by passing it through heat chambers. Padding mangle,
feeding zone, heating zone (chambers), batching and plaiting are main divisions (i) Nip guard between in-
running rolls and rollers of the padding mangle, guard on
uncurler nip, main drive and bevel gears (ii) Catwalks or
platforms for working at heights, (iii) Temperature control
devices (iv) Effective exhaust hood and chimney for removal
of fumes from the machine, (v) Effective and sufficient
exhaust fans in the workroom (vi) Scouring process i.e. oil
removal from fabric before feeding it to the stenter machine
to reduce the oil fumes, (vii) Textometer to detect moisture
content, (viii) Covers on roll drive chain box, overfeed chain
drive, batching and plaiter drive (ix) 3-way pneumatic oil
flow control valve where oil heaters are used.
9. Pladding machine : (i) Nip guard on in-running rolls and padding mangle (ii) Guard on main
drive, roll chain drive and gear drive (iii) Pressure regulator for pneumatic loading of rolls. drive,
roll chain drive and gear drive, (iii) Pressure regulator for pneumatic loading of rolls.
10. Jet Dyeing machines -.Purpose is to colour the cloth under steam pressure, (i) PRV or pressure
regulator in pressure feed line (ii) Adequate safety valve
and rupture disc - both of at least .1.5 inch (dia) size and
in parallel on the top of the vapour cell (iii) High
pressure alarm and automatic or manual de-pressure
(venting) device to operate at that alarm (iv) Use of

heatexchanger for indirect heating and cooling (v) Periodical hydraulic tests and NDT for
corrosion effects (vi) Non-corrosive metal, joints and body parts (vii) Flap guard near filter cover
at the bottom and internal disc to restrict outflow (viii) Temperature gauge near the pressure
gauge on the vessel (ix) Water, steam and air control valves (x) Manhole cover interlocked with
depressure device (xi) Maximum pressure indicator and automatic pressure controller (xii)
Trained operator (xiii) Effective supervision and auto programming.
11. Drum washer : It is a washing machine under steam pressure, (i) Fixed guards on belt and chain
drive (ii) Pressure Reducing Valve, Safety Valve, rupture disc, proper nut bolts and fitting or
welding, proper material of construction and Pressure Gauge on steam supply line (iii) Drum
motion fixing device (locking) while loading and unloading. Internal drum should not rotate while
loading or unloading it. It should be mechanically locked. Power should also be deenergised at
that time.
12. Expander machine : (i) Nip guard on rollers and between the cloth in process and the rollers (ii)
Parts of machine should be periodically examined to detect defective conditions such as
protruding nails.
13. Stitching and sewing machine : (i) Gap between the needle and the machine table should be
guarded to 'prevent access to this zone. (ii) Electric earthing should be proper and ELCB should
be provided in power supply line.
14. Printing machine : Purpose is to print the cloth by machine. Various types of machines are in
use. (i) Nip guards on the printing roller, cloth roller and on the lapping and a roller (ii) While
removing a heavy roll from the machine, care should be taken' or the mechanical handling should
be used. (iii) Care should be exercised while changing a design roller otherwise a hand may be
caught between the design roller and control roller (iv) Care should be taken while turning a
handle to apply pressure to the printing rollers otherwise a worker may slip and fall from height
(v) The doctor blade of the machine should be removed carefully otherwise it may slip and its
sharp edge may cause injury. (vi) Fixed guards on pulley-belt drive, sector, connecting (eccentric)
rod, repeat-setting device and under table rollers (vi) Safety while cleaning blanket.
15. Stretching machine : Nip guard between running cloth and roller.
16. Polymerising or curing machine : See part 3.3 and 9 of this Chapter.
17. Gas/Electrical Singeing machine : See part 9 of this Chapter.

18. Shearing and Cropping machine : (i) Rotating cutters should be interlocked by a transparent
cover, (ii) Guards on main drive, suction blower and dust chamber and (iii) Metal detector are
necessary.
19. Sanforizing and Palmer machine : Its function is to give final finish (ironing) to the cloth.
(i) Nip guards and side guards on in-running rolls and trip wire near cylinder (height < 1.7 mt) to
stop the motion (ii) Pneumatic controls and roll drives guards (iii) Steamline safety (iv) Plaiter
drive guard.
20. Mercerising machine : Nip guard on mangle rolls, guards on main drive coupling, chain drive,
bevel gears, mangle roll gears, chain return wheel, squeeze roll belt drive, squeeze rolls,
impregnator nip between float roll and top roll, stabilizer-tension roll and top roll nip and splash
guard on caustic tank are necessary.
21. Carbonising unit : Its function is carbonising i.e. acid burning of cotton fibre of the blended
cloth. (i) Acid bath (70% H,SO„) should have safe overflow device and splash, guards on both
sides (ii) Nip guard on squeeze rolls (iii) FRP tray and acid-proof flooring, PVC valves for acid
use and use of PPE and safety shower by workers.
22. Folding machine : (i) The crank-wheel and reciprocating arm should be guarded to prevent hit
injury, (ii) Fixed guard on main drive.
23. Towel cutting machine : Cutting edge should be guarded at the feeding end of towel.
In addition to above textile machine guarding, general safety measures for metal working
machinery, lifting machines, material handling, hand tools, hand trucks, chemicals, flooring, fire and
health hazards, must also be provided and maintained. Welfare facilities of canteens, lunch/rest room,
ambulance room, creche, welfare and safety officers should also be provided. See Part-3 for statutory
provisions.
9 FIRE AND EXPLOSION HAZARDS AND CONTROLS
A booklet 'Fire Prevention in Textile Industry, Instructions for Supervisors' published by the Loss
Prevention Association of India Ltd., Mumbai - I (Gujarati copy is also available), IS:3079 and 2190 are
most useful to understand and control fire/ explosion hazards in textile industry.
Cotton dust is not fine enough to cause dustexplosion but it may certainly cause fire if any spark
is available. Explosion hazard lies with polymerising or curing machine where flammable liquids are

used and therefore explosion relief are required. Fire hazard is more in blow-room and spinning sections
due to loose and flying cotton and in processing department due to solvents and, chemicals.
The main cause of fire in textile mills can be attributed to the failure of electrical equipment,
sparks from foreign material carried along with cotton stock, friction, hot bearings due to inadequate
oiling and attention, presence of excessive quantities of fly and dust in the department and the use of
flammable liquids and processing of cloth at high temperatures.
Building Construction : Textile mill buildings are classified as 'fireproof; 'non-fire proof and
'inferior'. In order to minimise the risk of fire, all mill processes and storage buildings must be of fire
proof construction of at least 6 hours grading. The behaviour of a structure when subject to fire stresses
must be taken into account at the design stage.
Godowns for cotton and finished products shall be essentially single storey structures and
located at least 30 mt away from the spinning department. In textile mills, the departments that requires
separation by perfect party walls in order to reduce the fire loads are : (a) Baled cotton warehouses,
cotton mixing and blowing rooms; willow and thread extractor rooms; waste opening rooms; carding
rooms; speed and ring frames; mule spinning department; preparatory sections and loom sheds, cloth
processing houses with fire walls around special hazard processes such as 'singeing' and 'cloth raising',
(b) Boiler houses and firing places must be separated from all process and store buildings except the
engine rooms and the like. (c) Electric generating stations and transformer houses must be cited at least
10 mt away.
Cotton and yarn drying chambers must be constructed of incombustible materials and .fitted with
thermostat controls in order to cut off the source of heat supply at predetermined temperatures.
Warehouses and Stores : (a) Breakage of cotton bale hoops causes sparks and subsequent fires
(b) Faulty electrical equipment, both for lighting and bale stackers may cause fire; (c) Lots of baled
cotton must be stacked in an orderly manner away from godown walls to prevent spread of fire arid assist
fire fighting and salvage operations, (d) Adequate drainage of godown floors is necessary in order to
prevent excessive water damage of lower layers.
All sources of ignition like mechanical sparks due to friction, electrical spark, spark from welding
or cutting, prismatic effect of sunrays from glass window on cotton bales, use of naked flames, heated
lamp or metal parts, oil dripping and electrical loose wiring or electrically heated metal parts, should be
avoided by prompt supervision. Fire hydrants should be kept nearby.
Cotton Mixing and Blow Rooms : (a) Generation of sparks from foreign matters, particularly
pieces of metal carried along with cotton stock through metal rollers and spiked lattices of opening and
blowing lines. Loose rivets and short ends of hoop iron are the main causes which could be eliminated by
providing suitable magnetic separators which should be cleaned during each shift, (b) Machines with high
speeds are more prone to fires. Machines with higher capacities are exposed to large quantities of loose
cotton and hence fires in such machines are carried faster and at longer distances (c) All cotton opening
and cleaning machines with spiked lattices and rollers must be sprinkled.
Carding Department : Cotton in the carding machines being still in the loose stage is susceptible
to fire due to friction between metallic parts, particularly fillets, licker-ins and grinds.
Spinning Frames : (a) Frequent fires occur due to heated spindle bearings of those of the rollers
driving them (b) Lint and fly cleaner units of spinning frames cause fire due to improper conductor or
collector shoe contacts with the open bus bars running the entire length of the machines. The uneven

contacts of the collector shoes cause sparking which ignite the fluff collected around the buses, (c)
Generation of static electricity is generally encountered in the spinning of rayon yarn particularly in the
card room and it is safer to ground all machines and to provide suitable humidification system to
eliminate static charges.
Loom Shed : The picking mechanism usually gets jammed due to accumulation of fluff which
causes fire spreading and droppings below the loom or at times to the warp beams.
Processing Department:
1. Cloth and Yarn Singeing (burning by fuel fire): Due to the presence of open flames and
flammable gases, fires are frequent in singeing rooms but these could be avoided by the use of
proper electrical equipment and electrical interlocked sequence in order to prevent the machine
being started up before the exhaust and gas blower fans are brought into operation. All control
gear in such case must be mounted externally with vapour-proof lighting fixtures.
Solenoid valve on the fuel line is essential to stop fuel supply in the event of power or m/c
failure. This will prevent stationary fabric undergoing singeing and from being ignited.
LPG and air pipelines should be colour coded. NRV to prevent flash back, gas burner
control, no smoking notice and ready fire extinguishers are required. LPG safety rules should be
followed.
Fuel (petrol) control valve on carburettor (petrol vaporiser), temperature control on air
heater, suction hood, duct and dust chamber, flameproof electric fitting, guards on nip rolls and
batch drive, brush rolls and roll drive, water cooling of the guide rolls near burner and safety
ladder to fuel tank are also important.
2. Electrically heated Yarn Singeing Machines : An interlocking arrangement is necessary to

ensure that the heating elements cannot be switched on while the yarn is stationary in the
machine. Only water washed fabric should pass. Solvent may cause hazard.
3. Polymerising or Curing Machines : Its function is to dry (by heating) the printed cloth. Several
explosions and fires have occurred in polymerising machines in textile mills due to the mixture of
organic solvents in the printing pigments.
Precautions to eliminate accidents are : (1) Predrying of printed fabric over drying ranges
to remove most of the solvent outside the machine. (2) Lock the exhaust openings in top of curing
machine at least 2/3 full opening. (3) Electric heaters must be provided with thermostat controls
and synchronised with the exhaust fan and machine main drive so that in the event of accidental
failure of exhaust fan motor, the entire machine stops along with the heating elements. (4)
Provision of safety flaps on the tops of polymerising machines which would open out
automatically in case of explosion. (5) Air circulation fan filter gauze must be regularly cleaned as
poor circulation would cause localised pockets of solvent vapour. (6) Exhaust duct must be
regularly cleaned every week and extended outside the work room. (7) Interlocking of exhaust fan
with fabric motion so that the fans will start before fabric is fed into the chamber.
See Part 3.3 for Rule 68C GFR.
Steam curing is safer.
4. Cloth Raising Department : Here fires are frequent due to passage of foreign materials between
filleted rollers and it is necessary that the cloth be inspected before passing through the machine.
The machine must be regularly cleaned of fluff accumulation.

5. Electrical Installation: Electrical equipment must comply with Electricity Act and Rules (See
Part 2 of Chapter-28), relevant Indian Standards and installed and maintained in safe condition.
Lighting fixtures in places where considerable dust and fluff accumulate and godowns must be of
dust-proof type, wired in screwed conduits and switchgear must be mounted externally. Stop
motion devices on machines must be dust-proof, wired in conduit and checked regularly.
Overhead electric lines in compounds should also be cleaned regularly.
6. Fire Extinguishers:
Fire fighting arrangements consisting of portable appliances, water hydrants and automatic
sprinklers must be designed and laid in accordance with relevant IS Specifications.
The automatic sprinkler system discovers fire, sounds alarm and extinguishes the smallest
fire. In sprinkled building, water damage will be less because the amount of water necessary for
extinguishing is smaller, hence all mill buildings must be 'sprinkled'. Such installations are
expensive but their worth is justified. High pressure automatic sprinklers of special design must
be provided in generating stations, transformer houses and oil godowns. They should be used after
power is switched off. A trained fire fighting squad shall be maintained round the clock within the
mill premises.
7. General Safety Precautions :
Mill compounds must be regularly cleaned and housekeeping both inside as well as in the
yard should be of good order. Overhead structures in all departments must be regularly cleaned
and floors swept during each shift. Electrical equipment shall be satisfactorily maintained and
periodic check-up is necessary. Risk. of overheating can be reduced by providing efficient
lubrication and day-to-day maintenance of all machines, bearings and moving parts. Adequate
guarding for machines should be provided particularly on blowing and carding machines.
Smoking should be prohibited within 6 mt of process and storage blocks and it is advisable to
provide smoking booths.
10 HEALTH HAZARDS AND CONTROLS
Some important health hazards in a textile industry are as follows :
Accidents to fingers, hands and other body parts are due to a variety of textile machinery and their
hundreds of moving parts. Constant machine guarding is the best solution. Noise and vibration are
incidental hazards. Byssionosis is a lung disease due to prolonged exposure to high concentration of
cotton dust. Extraction and suppression is the best remedy. Sch. 27, Rule 102, GFR requires this. See Part
3.2.
Increased humidity and temperature cause discomfort to workers. Limits of dry and wet bulb
temperatures should be maintained. Well designed and maintained AC plants are more comfortable.
10.1 Health Hazards in Cotton Textile Industry :
1. Cotton Dust and Byssionosis : According one survey 20% (approx. 3 lakh) of the textile workers
in mills were found victim of byssionosis. It was 14% in carding section and 10% in spinning
and winding sections.

Measurement of cotton dust concentration in 8 units in India showed it from 3.4 to 5.6
mg/m" in blow room and 0.1 to 2.2 mg/m3 in card room. Another survey showed cotton dust level
as under:
At Kanpur - 7.85 mg/m3
At Delhi - 5.50 mg/m3
At Ahmedabad - 4.00 mg/m3
At Mumbai - 3.90 mg/m3
The threshold limit suggested is 0.2 to 0.75 mg/m 3 2nd Schedule of the Factories Act
prescribes 0.2 mg/m3 lint free raw cotton dust. ILO prescribed cotton dust values are as under:
TWA OSHA -
- 0.2 mg/ m3 in yarn manufacturing.

- 0.5 mg/m3 in other operations.
- 0.75 mg/ m3 in slashing and weaving.
STEL ACGIH - 0.6 mg/ m3 .

IDLH - 0.5 mg/ m3
Vacuum stripping and suction exhaust arrangement attached to carding machines, lint and dust
collectors and general exhaust ventilation are necessary to minimise the flying cotton dust. Proper dust
mask or cotton cloth should be given to workers.
Byssionosis is an occupational disease caused to many mill workers by the cotton -dust. This
name was given by Proust in 1877. It is a lung disease like TB or Asthma and reduces working capacity
of a worker. After working for 5 to 10 years in cotton dust area, respiratory problem starts. Initial
symptoms are cough or bronchitis, chest pain, breathlessness, emphysema and phlegm. Ultimately the
lungs are damaged. The victim gets exhausted soon by a small work. He feels energy loss and becomes
unfit to work. Its major hazard area is spinning department, though it can happen to winders and weavers
and also to flax, hemp or jute workers. Under section 89 and the Third Schedule of the Factories Act,
byssionosis is a notifiable occupational disease and the medical practitioner noticing this disease has to
report to the Inspector of Factories, otherwise he is liable for penalty.
For its diagnosis (1) Occupational history of the worker and (2) Lung function test are required.
The effected worker is examined on tKo-first day after his holiday and also at the"~nd of his shift after
working. His loss of working capacity is measured. Workman Compensation is available under WC Act
or ESI Act.
Factory Medical Officer should check such workers periodically. His workplace must be changed
soon after the first detection. X-ray and gradation reports should be maintained. There is no medical
remedy for this disease. Therefore its prevention is the only best solution. Local exhaust ventilation
attached with machine, room exhaust ventilation, water sprinklers and use of cotton dust mask or
respirator are the effective remedial measures.
Workers engaged in cleaning of cotton dust or in its high concentration must be provided with air
line respirator and hood or efficient face mask. Instead of broom-stick cleaning, vacuum cleaning
machine should be used to minimise the flying particles.
2. Heat and Humidity: Higher temperature due to closed operations and work rooms, humidity (to
reduce thread breakage), heat generating processes such as sizing, kiers, drying range, stenter,
hotdyeing, singeing, polymerising or curing, steam and oil heaters, hot air dryers, boilers etc.,
create higher temperature in spinning and processing departments which if exceeds 29.5°C (85°F)

(threshold or effective temperature), or humidity is increased, causes discomfort and fall in
productivity. Therefore the room temperature" must be, controlled @ 25.5 to 29.5°C (78 to 85°F)
by good natural and mechanical ventilation (See Chapter 10). Workers should be relieved at short
interval from high temperature zone. Air conditioning is desirable. Hot metal parts should be
insulated.
3. Noise : High noise in weaving and ring frame department causes mental stresses and may result in
a hearing loss which is an occupational disease under the Factories. Act. Permissible limit of 90
dB for 8 hr. working should not be exceeded.
One survey in a mill'at Bombay indicated the noise levels in Spinning Dept. - 96.5 dB,
Doubling machines - 97.6 dB, Winding machines - 98.5 dB, Auto loom shed - 99 dB and Non-
auto loom shed - 102 dB. Use of sound absorbing material is effective but expensive. Use of ear
muffs or ear plugs (glass wool) is the most practical remedy and the workers must be trained to
wear them. In Nigeria, it was observed that due to use of ear protection individual efficiency was
increased by 12% and overall production by 1%. The long term solution is the design of noiseless
looms.
Legally Sch. 23, rule 102, GFR is applicable.
4. Weaver's Cough : This is caused by inhalation of sizing materials, 50% of which comes out
during weaving. As the name suggests the workers of loom shed are prone to it. Good ventilation
dilutes the effect.
5. Cancer and Coronary diseases : These diseases like bladder cancer, chrome eczema or chrome
poisoning, dermatitis are caused due to the chemicals like lead chromate, potassium or sodium
bichromate, toxic solvents, titanium dioxide, hydrogen sulphide, sulphur dioxide and trioxide.
Local exhaust system near toxic fume generation, chemical respirators, gloves, aprons etc. are
useful. Non or less hazardous substitutes should be utilised. Medical health check-ups and advice
should be followed. Training and supervision will also help.
6. Machinery hazards : Foregoing parts 6 to 8 have classified and explained process-wise machine
hazards in textile industry. Newer machinery has reduced many of these hazards. The most
dangerous parts of textile machines are main motor and gear drives, head stock gearing of
spinning frames, revolving beaters of blow-room machines, card cylinder, flying shuttles and
loom gears, picking stick and in-running rolls of processing machinery. Specific hazards of jet
dyeing and other pressure vessels have also caused many accidents. The fixed guards, interlocked
guards, nip guards and other safety devices should not be tempered with or kept open while
machinery is in motion:
7. Material handling : Heavy rolls and other machine parts and bulk containers are to be handled in
textile industry. Excessive weights may cause health injuries, strain and pain. Mechanical aids
should be used to lift, carry and handle such heavy loads.
8. Poor lighting : Many textile processes require high standards of illumination, such as drawing in
threads through healds and reed, weaving and processing of coloured cloth, jacquard (design)
weaving, fabric defect checking, folding and packing etc. Poor lighting on such processes causes
eye strain. Poor lighting in passage ways, corners, stairs, platforms, confined spaces, tanks, pits
and vessels, unguarded machinery and slippery surfaces may cause accidents. Therefore in
addition to providing sufficient lighting (see Part 5 of Chapter-9), window glasses, lamps and
tubes should be regularly cleaned and local lighting should be provided where required.

9. Shuttle Kissing : Suction shuttles of ordinary (non-auto) looms need thread (weft) sucking by
mouth through shuttle eye (small hole) and pirn bobbin many times during a day. Dirt, dust or
broken fibre ends are drawn into the throat. The same shuttle may be used by different workers in
different shifts. Therefore this is unhygenic and infectious method. Non-suction shuttle or pirn
bobbin battery requiring no kissing by mouth is the only remedy.
10. Overtime work : Legal limit of 8 hours a shift is hardly followed in thousands of small and
medium scale textile industries. 12 hours a shift has become a routine working. This certainly
causes health hazards. This causes more harm to women and child workers. More working hours
cause physical, mental and nervous strain and result in more accidents and sickness rates. Full co-
operation of employers and employees can solve this problem.
11. Welfare provisions : Large scale factories have lunch room, rest room, canteen, ambulance
room, creche, washing facilities, free medical examinations, transport facilities etc. But
majority of small and medium scale factories do not have such facilities. This affects the health
and general well being of the workers.
12. Fire and Explosion hazards : Cotton is easily combustible material. Solvents used in processing
department can cause fire and explosion both. For details see part just following.
10.2 Health Hazards in other Textile Industry :
1. Manmade fibres (mmf) : Fire and explosion is the main risk from solvents and nitrocellulosic
materials. All flammable materials should be stored in specially designed separate' building and
its flow should be through closed system. All sources of ignition including static charge should be
eliminated. Electric fitting should be flameproof.
Toxic effects due to H2S, CS2, C6H6, acetic acid etc. should be reduced by local exhaust
ventilation. Workers should be given respirators.
Spillage of water and other solutions may cause slipping hazards. Protective clothing is
necessary for wet processes. Machine guarding to machineries is similar to cotton industry.
Glass wool manufacturing induces infrared emissions from molten glass. Heat absorbing
screen is required. Flying or breaking glass particles may cause skin penetration. Resins,
hardeners and accelerators may cause skin irritation. Protective clothing, good hygienic practices
and medical advice are necessary. Dust fumes need local exhaust ventilation.
Synthetic fibres are made from chemicals or petrochemicals. Nylon, polyester,

polyolefins, polypropylene, polyurethane etc. are well known. Machine guarding is required as in
case of other textile machines. The large quantities of solvent vapours given off during spinning
and extrusion pose fire, explosion and poisoning hazard and need local exhaust with safe
discharge and respiratory protection. Delivery of toxic and flammable substances through pumps
and pipes reduces hazards of manual handling and direct exposure. TLV, LEL and other safe
limits must be maintained. Sparks should be eliminated. Electric equipment should be flameproof.
Effective earthing to machines and vessels shall prevent dangerous spark. Static charge
eliminators to machines are necessary. Workers should wear footwear with rubber soles.
2. Flax & Linen industry : The fibres of flax plants are used to make linen cloth, towels, nets and
ropes. The fibre is light, strong and absorbent Its strength increases on wetting.

Machine guarding on rollers, pulley-drive; and other moving parts is essential. Flax dust
may cause Mill fever and Weaver's cough chronic bronchitis and byssionosis. An ILO report
(1965) gives following figures for flax dust levels and byssionosis prevalance :
Process Mean total dust concentration Byssionosis prevalence (% all

mg/m3 grades)
Pre-preparers 6.7 44.0
Prepares 2.7 30.0
Wet-finishers 0.6 3.6
Other finishers 1.4 0.7
Dust measurement at 6 months interval by a trained industrial hygienist is useful. Fine dust is
removed by passing air through canvas filter. Coarse dust is extracted by a cyclone extractor. Hackling
machines and carding engines need hood enclosure and exhaust system at the sources of generation.
For noise reduction, sound absorption treatment to walls, ceiling and floors and isolating mounts
to machines are necessary. Process segregation by separate rooms of heavy partition walls and ear muffs
to workers reduce noise problem.
3. Jute industry : See Part 5.2

4. Silk industry : Silkworms were reared in homes where CO poisoning was noticed in Japan. In
reeling raw silk, dermatitis was noticed. Handling raw silk may produce skin and respiratory
allergy.
Very good lighting is required in the weaving of coloured silk yarn. Temperature,
ventilation and humidity control are important at all stages. Reeling bath temperature should be
lowered to control skin effect Exhaust ventilation on bath and frequent replacement of water are
necessary. Machine guarding is required as in case of textile industry. See also Part 33 of Chapter-
23.
5. Wool industry : Like cotton textile machines/wool textile machinery also needs effective
machine guarding and spacing. Anthrax is possible to wool sorters. Chemicals used may cause
poisoning, eye burning, gassing etc. Selection of less harmful chemicals, local exhaust ventilation,
good washing facility, PPE and strict personal hygiene are necessary. Dust, temperature and noise
control are also necessary.
11 EFFLUENT TREATMENT AND WASTE DISPOSAL IN

TEXTILE INDUSTRY
Textile effluents are generally coloured and contain soluble (organic and inorganic) and insoluble
(suspended) impurities and possess high BOD and COD. Therefore their treatment and safe disposal are
necessary and statutory.
Effects of textile effluents :
(1) On Water courses :
S. No. Impurity Content Effect

1 Colour Dyes Colourification,
Photosynthesis is affected.

2 Suspended impurities Collodial & suspended Turbidity of receiving water.
particles
3 pH Alkalis Alkalinity disturbs aquatic
life.
4 Oils & Grease Mineral oils Form blanket and prevent O2
entry in water.
5 Dissolved minerals Inorganic sodium salts Increase salinity of water.
6 Toxic chemicals Chromium, sulphide, chlorine Toxic effect to fish and
and aniline dyes microbial organisms.
7 Oxygen depletion Starch, dextrin, sulphide, Demand O2 from water and
nitrite etc. affects aquatic life.
(2) On Land:
The excess content of sodium and boron of textile wastes adversely affects crops. High sodium
alkalinity combined with salinity impairs the growth of plants. Suspended solids and sodium prevent root
penetration in land and soil texture is spoiled.
(3) On Air:
Continuous addition of CO2 and other particles due to fuel (coal, LDO, gas) burning in boilers and
stenters, and toxic fumes of chlorine, acids, H,O, and flammable vapours from volatile solvents pollute
the air and surrounding environment.
Effluent generation flowchart is as under -

Reduction of Pollution Load :
To reduce costs and complexity of treatment, it is first necessary to reduce pollution load of the
effluents. It also results in saving of costly materials. Good housekeeping, controlled and efficient use of
dyes and chemicals and closer process controls are essential for this purpose. Some important methods
are as under :
1. Waste segregation.
2. Recovery and reuse.
3. Substitution of low pollution load substances.
4. Judicious use of chemicals.
5. Process changes.
6. Economical water use.
Treatment Methods:
Three stage treatment methods of textile effluents is as tabulated below :

Other inetilodsure
1. Colour removal.
2. Recovery and reuse of waste water.
3. Conservation- and reuse of water.
For details of these methods, books on pollution control methods should be referred. Please see
reference No.7 at the end of this chapter.
Diagram of effluent treatment plant in textile processing industry is given in Fig. 21.11

Tolerance Limits:
IS 2490 (Part I to 10) and Schedule I & VI u/ r 3 & 3A of the Environment (Protection) Rules,
1986 prescribe tolerance limits applicable to textile effluents.
Characteristics of raw (untreated) effluent and required parameters of process houses are shown ii
the table.
Process House Effluent Characteristics
No. Parameter Before Treatment Required after Treatment

1 pH 6.6-8.0 6.5-8.5
2 Color 1000-1500 unit 100 unit
3 Suspended Solids 600-900 ppm 100 ppm
4 Total Dissolved Solid 10000-14000 ppm 2100 ppm
5 Oil & Grease 20-25 ppm 10 ppm
6 BOD 500-600 ppm 30 ppm
7 COD 1600-2200 ppm 100 ppm
8 Ammonical Nitrogen 0-5 ppm 50 ppm
EXERCISE
1. Explain, State, Mention or Discuss :

1. Need of safety in textile industry.
2. Statutory provisions for safety of textile machinery.
3. Flow chart of a composite textile processes.
4. Flow chart of spinning and weaving OR Finishing processes.
5. Flow chart of long staple finishing processes.
6. Flow chart of synthetic fibre manufacture.
7. Flow chart of Filament yarn (Nylon - 6)
8. Flow chart of Oriented yarn (LOY, POY etc.)
9. Manufacturing process of spun (oriented) Yarn ( POY, FOY etc.)
10. The merits and demerits of rotor spinning.
11. Hazards and safety measures of Blow room machinery.
12. Hazards and safety measures of Carding machines.
13. Hazards and safety measures of Sliver and Ribbon lap machines.
14. Hazards and safety measures of Combers and Draw frames.
15. Hazards and safety measures of Speed frames.
16. Hazards and safety measures of Ring frames.
17. Hazards and safety measures of Doubling machines (frame).
18. Hazards and safety measures of Winding machines.
19. Hazards and safety measures of Warping machines.
20. Hazards and safety measures of Sizing machines.
21. Hazards and safety measures of power looms.
22. Hazards and safety measures of Bleaching process.
23. Hazards and safety measures of Washing machines.
24. Hazards and safety measures of Jigger machines.

25. Hazards and safely measures of Calendar machines.
26. Hazards and safety measures of Jet dyeing machines.
27. Hazards and safety measures of Stenter machine.
28. Hazards and safety measures of Drum washer machine.
29. Hazards and safety measures of Printing machine.
30. Hazards and safety Carbonising machine.
31. Health hazards and controls in Cotton .textile mill.
32. Health hazards and controls in Silk and Wool industry.
33. Fire and Explosion hazards in Textile industry.
34. Effluent treatment flow chart of a textile mill. Explain by a diagram.
35. Types of effluent treatment methods in a tovUlp mill
2. Write short notes on :

1. Inference of accident case studies in a textile mill.
2. Types of fibres and their use.
3. Spinning preparatory OR Weaving preparatory process.
4. Spinning processes OR Finishing processes.
5. Jute Manufacture.
6. Rotor Spinning.
7. General Safety measures of textile processing (finishing) machines OR Safety devices
on a Singeing machine.
8. Hazards and controls of flying shuttles.
9. Picking stick assembly.
10. Hazards and safety aspects of a Washing tank.
11. Kiers and Agers.
12. Byssionosis OR Weaver's Cough.
13. Heat and Humidity problems in a textile mill.
14. Fire hazards in cotton go-downs.
15. Methods to reduce pollution load in a textile mill.
3. Explain the Difference between
1. Cotton and Man- made Fibres

2. Thermic fluid heater and Drier.
3. Ginning and Pressing.
4. Ring frame and Doubling frame.
5. Pirn winding machine and a Warping machine.
6. Bleaching and Dyeing.
7. Spinning and Weaving.
8. Fibre and Fabric.
9. Short staple fibre and Long staple fibre.
10. Gilling and Carding.
11. Ring spinning and Rotor Spinning.
12. Singeing machine and Curing machine.
13. Stitching machine and Folding machine.
14. Fire hazards and Explosion hazards in a cotton textile mill.
15. Primary and Secondary effluent treatment methods.
4. Comment on the following explaining whether it is true or false ?

1. Women or children can be employed toward delivery - end side of a cotton opener.
2. Section 30 (F.A) is not .applicable to hydro extractor.

3. Rule 61 (GFR) is applicable to drum washers.
4. Copper sizing cylinder is a thin wall pressure vessel.
5. PET fibres pose no health hazards.
6. PET fibres pose environmental hazards.
7. Beaters are most dangerous parts in below room machinery.
8. Rotor spinning machine cannot spin combed yarn.
9. Bleaching and dyeing of jute is not possible.
10. Trip cum distance guard is required on a Warping machine.
11. Rule 61 (8) for thin wall pressure vessels is applicable to sizing cylinders.
12. Vertical picking stick is less dangerous than horizontal picking stick of a loom.
13. Hydro-extractor does not need interlocked top lid.
14. Jigger machine needs splash guards.
15. Calendar machine needs safety valve.
16. Stenter machine needs exhaust fans.
17. Jet dyeing machine needs de-pressure device.
18. Drum washer needs PRV and safety valve.
19. Sanforizing .needs steam line safety.
20. Towel cutting machine needs guard on delivery end of towel.
21. High noise area in a textile mill is its cloth department.
22. Jacquard (design) weaving requires better lighting condition.
23. Mmf manufacture has toxic hazards.
24. In silk industry dermatitis is not possible.
25. Glass wool processing has dust hazard but no infrared radiation hazard.
26. Flax dust cannot cause Byssionosis.
27. Employment of Industrial hygienist is justified in a textile mill.
28. Explosion is possible in a polymerising machine.
29. Cotton mixing room does not pose fire hazards.
30. Solenoid valve is essential on fuel supply line of a singeing machine.
31. Flameproof electric fitting is required in a fuel fired singeing machine room.
32. Electric heaters should be interlocked with exhaust fan drive and cloth drive of a curing
machine.
5. Explain the following terms from safety point of view
1. Fibres from Animal origin.
2. Card OR Comber.
3. Kier.
4. In-running nip.
5. Head stock gearing.
6. Drying range.
7. Artificial humidification.
8. Byssionosis.
9. Cotton opener.
10. Polymerising machine.
11. Yarn singeing machine.
12. Sanforizing.
13. Texturising.
14. Bobbin shield.
15. Knee brake.
16. Duck bill and Hitter.
17. Weaver's cough Shuttle kissing.
18. Tolerance limits of effluent.
19. Padding mangle.

20. Scouring process
21. Hinged swing door.
22. Micro switch.
23. Lap rod.
24. Beam flange.
25. Drafting zone.
26. Etching of copper roller.
27. Dust chamber.
28. Flutted roller.
29. Licker in.
6. Match the words in column 'A.' with appropriate words from column 'B' from safety point
of view -
A B
Fibres from –
Vegetable origin Acrylic fibres
Natural polymer Synthetic fibres
Petrochemical origin Viscose rayon
Polyvinyl derivatives Cotton
Wool
Asbestos
Carding machine Dyeing of cloth
Roving frame Gray cloth
Ring frame Weft for shuttle
Pirn winding machine Drawn warp
Warping machine Combed yarn
Draw frame Cone of yarn
Loom Sliver
Jigger machine Twisted yarn
Rove yarn
Warper’s beam
Cotton opener Cylinder doors
Carding machine Beater
Silver lap m/c Coiler and draw box
Comber m./c Gears
Slubber frame Nip guard
Inter frame Rotating flyers
Ring frame Bever whell guard
Rotor spinning Knot-free yarn
Knee brakes
Ring travelers
Warping machine Nip guards
Sizing machine Photo electric device
Loom Fume exhaust
Bleaching machine Shuttle guard
Doffer wheel
Washing Tank Chemical goggles
Hydro extractor Heavy rolls
Calendar machine Railing on hot water tank
Jigger machine Brake

Drying Range Use of chain pulley block
Ager machine Chain drive guard
Stenter machine Rupture disc
Jet dyeing machine Exhaust hood and chimney
Drum washer Crank-wheel guard
Stitching machine Locking device
Shearing machine Acid proof flooring
Carbonising unit Metal detector
Folding machine ELCB
Repeat setting device
Cotton dust To reduce thread breakage
Noise Sizing material
Weaver’s cough H2O2
Humidity Byssionosis
Bleaching process Explosion hazard
Shuttle kissing Loom shed
12 hours shift Pirn bobbin battery
Anthrax Fire hydrant
Yarn singeing machine Wool industry
Storage of cotton bales LPG Safety
Illegal
7. Give probable causes and controls of the following -

1. Accidents in blow room OR Loom shed
2. Accidents in Sizing OR Carding m/c.
3. Accidents in Dyeing OR Bleaching m/c
4. Accidents in Printing m/c. .
5. Bursting of drying cylinder.
6. Broken shields of bobbins.
7. Processing chemicals.
8. Stentering machines.
9. Ring spinning OR Winding m/c.
10. Carbonising of polvester.
Reference and Recommended Reading
1. The Factories Act and Rules.

2. BIS Handbook.
3. Encyclopaedia of Occupational Health and Safety, ILO, Geneva.
4. The Course Material of the Central Labour Institute, Sion, Mumbai-22.
5. Synopsis of the Gujarat Factories (Amendment) Rules, 1995, by K.U. Mistry, Siddarth Prakashan,
Ahmedabad.
6. Rotor Spinning - by Dr. Eric Dyson, The Textile Trade Press, Stockport, England.
7. Treatment of Textile Processing Effluents by N Manivasakarn, Sakthi Publications,
Coimbatore-21.
8. An Introduction to Spinning by Morton & Wray.
9. Repair and Adjustment of Textile Machines by T granousky.
10. Gujarati Booklet : Byssionosis Control, UnnaH Vikas Shikshan Sansthan, Gl/200, Azad Society,
Ahmedabad - 380014, or PRIA, New Delhi – 110062.

Safety in Textile Industry: Chapter - 21

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CHAPTER – 21

Safety in Textile Industry

1. Need of Safety in Textile Industry 6.6 Ring (Spinning) Frames

1. NEED OF SAFETY IN TEXTILE INDUSTRY

Fundamentals of Industrial Safety and Health 21- 1 Safety in Textile Industry

NIC Code (for Textile) Working Factories Average Workers

Accidents Fatal 67, Nonfatal 33047, total 33114

Type of Accidents 1996 1997

Fundamentals of Industrial Safety and Health 21- 2 Safety in Textile Industry

Year 1984 1985 1986

1. Weaving 111 6. Bleaching, Finishing 23

1. Striking against objects 103 6. Fall from height 24

S. N Department Accidents Percent

Fundamentals of Industrial Safety and Health 21- 3 Safety in Textile Industry

S. N Agency Accidents Percent

2 TYPES OF TEXTILE INDUSTRY

A classification of various types of the fibres is as follows :

Fundamentals of Industrial Safety and Health 21- 4 Safety in Textile Industry

Fundamentals of Industrial Safety and Health 21- 5 Safety in Textile Industry

Section 15 (Artificial humidification), 27 (Cotton openers) and 31 (Pressure plant) of the

Chapter-3 (Health), 4(Safety),5(Welfare), 6(Working hours), 7(Employment of young persons)

3.2 Health Provisions :

Fundamentals of Industrial Safety and Health 21- 6 Safety in Textile Industry

Rules 19 to 29 prescribed u/s 15, require other details as under :

3.3 Safety Provisions:

Fundamentals of Industrial Safety and Health 21- 7 Safety in Textile Industry

3.4 Welfare Provisions :

Fundamentals of Industrial Safety and Health 21- 8 Safety in Textile Industry

3.5 Cotton Ginning and Pressing Factories Act and Rules :

From a variety of IS on textile machinery, some are given below :

5 FLOWCHARTS OF TEXTILE PROCESSES

5.1 Composite (Textile Mill) Flowchart:

Fundamentals of Industrial Safety and Health 21- 9 Safety in Textile Industry

Fundamentals of Industrial Safety and Health 21- 10 Safety in Textile Industry

Artificial humidification is employed in carding, spinning and weaving departments to reduce

Now we shall see the flowcharts of different types of fabrics.

Fundamentals of Industrial Safety and Health 21- 11 Safety in Textile Industry

To understand flowcharts of fabric manufacturing it is necessary to understand sequence or

Short and Long staple Fibres :

Process flowcharts are shown from Fig 21.3 to

Fundamentals of Industrial Safety and Health 21- 12 Safety in Textile Industry

5.2.2. Process Flowchart of Long Staple (i.e. Worsted Wool) Spinning :

Fundamentals of Industrial Safety and Health 21- 13 Safety in Textile Industry

Sorting, selection and blending to suit type of yarn required

Opening-out and loosening of fibre packages

(in sliver form) Carding (in sliver form)

Backwashing (scouring) Condensing

Gilling Spinning on mule

Drawing and doubling

Fig. 21.5 : Process Flowchart of Wool spinning.

Fundamentals of Industrial Safety and Health 21- 14 Safety in Textile Industry

5.2.3. Process Flowchart of Viscose Rayon and Synthetic Fibre Manufacture :

Fundamentals of Industrial Safety and Health 21- 15 Safety in Textile Industry

5.2.4. Process Flowchart of Spun and Filament Yarn :

(A) Manufacture of Nylon - 6.

Fundamentals of Industrial Safety and Health 21- 16 Safety in Textile Industry

Polyethylene Terephthalate (PET) is a fibre of great commercial significance, useful in cordage,

Manufacturing and Processing:

Fundamentals of Industrial Safety and Health 21- 17 Safety in Textile Industry

Fundamentals of Industrial Safety and Health 21- 18 Safety in Textile Industry

Safety and Environmental Factors :

Fundamentals of Industrial Safety and Health 21- 19 Safety in Textile Industry

A block diagram of above mentioned process i «ihnwn in Pip- 21 9.