Professional Documents
Culture Documents
BDZ Projerct
BDZ Projerct
ZENEBE ASSEFA................................ITR/1071/03
BEDASA ABEBE................................ITR/179/03
DEJENE JOTE.....................................ITR/295/03
Our acknowledgement is first to the Almighty God for his governess internal life to write
the full of this document.
I wish to express our sincere thanks to The Management of Kombolcha Institute of
Technology, Wollo University for providing the necessary infrastructure facilities for
carrying out my project work successfully.
We express our sincere thanks to ETUR Textile Factory for giving permission as we do
our internship in their company.
Also we express great gratitude to the company manager Mr. Galip Yarar, who
assigned us as supervisor starting from the day we enter the company up to the end of our
internship program.
Also we would like to express our gratitude particularly to Ms. Nigat Belete (Industrial
Engineer), Mr. Adisu Negese (HRM), staff and all of the workers in each department.
At the last, but not the least, we express our gratitude to Mr. Getenah, Department of
Textile Engineering for his guidance, encouragement, assistance and suggestions during
our internship training.
ABSTRACT
This project works which focus on minimizing the effect of high end breakage on rotor spinning
machine. The document includes many topics like introduction, back ground, review of related
literature, methodology, result and discussion, conclusion and recommendation. The causes of
high end breakage and the remedial actions which have to be taken are included on this
document. The result of observation before and after remedial action taken is also briefly
discussed on this project work.
TABLE OF CONTENT
Table page
CHAPTER ONE
1.1 Introduction.................................................................................................................
1.2 Back ground.................................................................................................................
1.3 Statement of the problem...........................................................................................
1.4 Objective of the project...............................................................................................
CHAPTER TWO
2 Review of literature.........................................................................................................
2.1 Rotor spinning machine....................................................................................................
2.2 Important points about rotor spinning............................................................................
2.3 Factor affecting the degree of opening of opening roller...............................................
2.4 Advantages of rotor spinning machine...........................................................................
2.5 Causes of yarn breakage in rotor spinning machine........................................................
CHAPTER THREE
3.0 Methodology..........................................................................................................................
3.2 Materials.................................................................................................................................
3.3 Equipment...............................................................................................................................
CHAPTER FOUR
4.1 result..................................................................................................................................
4.2 Discussion...........................................................................................................................
CHAPTER FIVE
5.1 Conclusion.............................................................................................................................
5.2 Recommendation..................................................................................................................
6reference..................................................................................................................................
CHAPTER 1
1.1 INTRODUCTION
Many problems found in ETUR PLC which can hinder the company from achieving its goal and
accomplishing its mission. But when we ask the company owners and Turkish workers about
thus problems their answer is we have no any problem, our machine is new. The only problem
found in our company is poor work habit of Ethiopian workers.
But as we examine as textile engineering students there is so many problems which they are not
interested to raise it.
Frequency of yarn breakages per a given lengths is higher, in open end machine during spinning.
Higher breakage rate is lead to reductions in production and less quality of yarn.
There are many problems which causes high yarn breakage in open-end machine. This problem
is the main problem which hinders the company from its mission.
Fire problem
High trash content of raw material
Low yarn uniformity
Higher waste generation
Lack of quality testing instrument
Air conditioning problems
Poor waste system
1.2 BACK GROUND
This project is attentively focuses on how to minimize yarn breakage in rotor spinning machine.
Yarn breakage is the main problem which reduce the efficiency of spinning machine and
deteriorate the quality of yarn that will produced.
Yarn breakage cause yarn unevenness and affect the appearance of the fabric produced from it.
Yarn breakage deteriorates the quality of yarn produced.
Yarn breakage cause yarn unevenness and affect the appearance of the fabric produced from it.
Yarn breakage deteriorates the quality of performance of the next process like warping, sizing,
weaving and knitting. The problem of yarn breakage is caused due to machine problem
(including machine parameters) and material problem.
End breakages have to be reduced to increase machine efficiency, to improve quality of yarn
produced and the fabric which will be produced from it. The quality of yarn cannot be improved
unless yarn quality is improved. The problem of end breakage is deteriorates good appearance of
knitted and woven fabric. This problem is also increase cost of production by reducing machine
efficiency, consuming high energy without work and requiring large number of labors. Hairiness
is increased if there is yarn breakage and may cause uneven shade during dyeing process. Rotor
spinning is a well established high speed yarn manufacturing process but there are problems
which have to be solved to exploit the full potential of this spinning method. For example, rotor
spinning is restricted to coarse and medium yarn count. All foreign materials in fibers assembly
such as neps, bolls, dust, human hair, plastics, etc are deposited and pressed by centrifugal force
collected against surface of the rotor
The density of these impurities is often greater than that of fibers. It happens that they stay on the
collecting surface after the ribbon of the fibers has been withdrawn by open yarn end. The
increased mass of impurities due to centrifugal cannot be overcome by the torque of rotating
yarn end. The continuity of fiber flow is interrupted and so yarn breaks. But if yarn count is
coarser or the size of impurities are small as compared to that of fiber assembly, the yarn torque
overcome the increased mass off impurities and at the same time the impurities may
accommodated inside yarn structure, so the process will continue. In rotor spinning end breakage
can be classified into three broad groups depending on broken ends collected from the yarn
package and also by observing the rotor groove after breakage. Tension yarn breaks, spinning
yarn breaks and breaks due to interference factors outside the spinning box, (yarn breaks in
consequence of sliver breaks) are the three groups of yarn breaks. Tension yarn break is occurs
on already spun yarn, normally between take of nozzle and take up rollers. The yarn ends on the
yarn package have blunt appearance, and short broken yarn ends are In general found in rotor
groove. On the other hand the spinning yarn breaks occurs in the peel-off zone in the rotor
groove when continuous fiber spin is interrupted. The end breakage due to interference factors
outside spinning box can be easily controlled by proper maintenance and good work practice.
End breakage stand from effect of different factors such as residual trash in draw frame sliver,
rotor speed, opening roller speed and the yarn count. In general the problem of end breakage is
caused due to machine and material problem. There is high frequency of end breakage and low
machine stop for long period of time, due to low quality of raw material.
The yarn which is manufactured by rotor spinning has better appearance as compared to ring
spun yarn. Abrasion resistance is also improved by 30% on the average which increases fabric
life proportionately. In addition to the above said improvements rotor spun yarn has better
uniformity as compared to ring spun yarn of the same count and the number of imperfection per
unit length is almost comparable to the combed qualities ring yarn.
The west breakage of rotor spun yarn during continuous weaving on shuttle less loom are lower
than ring spun yarn by about 20% and the warp breakage 40% lower in warping and 50% lower
in weaving.
Another advantage of rotor spinning is processing low grade and less expensive raw materials
which reduce the cost of production. It is possible to produce more bulker yarn than ring spun
yarn.
Although rotor spinning machine has many advantages, but there is some problems which raised
with rotor spinning process such as processing only medium and coarse count and the problem
high yarn breakage.
High yarn breakage can alter the rate of productivity of rotor spinning machine. So, we were try
to found the solution which can minimize the problem of end breakage found in this rotor
spinning.
The general objective the project is to minimize the percentage of end breakage in rotor spinning
machine which can affect the productivity of the machine and decrease the cost of production by
decreasing the number of faults on the yarn.
Increasing productivity.
Reducing cost of production
Improving the quality of the yarn
Reducing number of end breakage per yarn length
Improving sustain able use of raw –material
To reduce extra labor requirements
2. REVIEW OF LITERATURE
2.1 ROTOR SPINNING MACHINE
In rotor spinning a rotor (a cup like machine element) is used to collect the fibers on its wall and
to rotate the open-end yarn by rotation of the rotor. The rotor rotates at the rates of about
100,000rev/min and above. The rotor, air is sucked from the opener roller end towards the rotor
end. The pressure gradient thus obtained increases the acceleration of fibers in the tube. The
rotor assembly needs to hermetically sealed (i.e. there should be no suction of air from unwanted
area).
The accelerated fibers are allowed to fall on the inclined rotor wall. The surface speed of the
rotor wall must be considerably higher than the speed of incoming fibers, so that fibers are laid
on the rotor wall in a longitudinal length wise form. The rotor runs at a very speed and the fibers
are subjected to tremendous centrifugal forces and they are held (attached) strongly to the rotor
inner surface.
The Fiber slides down to the rotor groove under the influence of centrifugal forces. Once the
fibers enter the grooves, they are held (attached) firmly to the groove. If the fibers are fed
continuously, the fiber will form a ring of the fibers in the groove.
Now, a yarn end is introduced into the rotor so that it touches the groove of rotor, the open-end
of the yarn is also subjected to the very high level of centrifugal forces and is firmly attached to
the rotor groove and the free end of the yarn rotates along with the rotor.
The free end of the yarn is withdrawn by a pair of take up roller. As the yarn is wit drawn, newly
arriving fibers get twisted by the brush like open structure of the open-end and continuous
spinning takes place. The withdrawn yarn is wound onto suitable package.
2, Opener roller has high cleaning potential and accordingly, suction arrangements are provided
to eliminate heavy trash neps/slubs etc however micro dusts escape this action.
3, Micro dust (very small damaged cellulose particles/dust, mineral matter/seed coat, fragments
coat particle etc) tend to be collected in the groove of rotor as sticky material. This prevents
uniform deposition of fibers in the groove of rotor. Non-uniform deposition of fibers tends to
uneven yarn and ultimately to the yarn break. So the sliver feed to the rotor must have a very
minimum amount of micro dust.
4, Sliver is opened to individual fibers states by the opener roller; this could be considered as the
first draft in the spinning machine. The converging tube (the feed tube to rotor) accelerates the
movement of fibers and this is the second draft that is given to the fibers. The rotor wall rotates
at the faster rate than the incoming fibers and fibers are deposited in the wall. This is the third
draft.
5, The mouth of the yarn withdrawal tube is called naval and it has a great influence on the yarn
properties and yarn formation.
6, Each revolution of rotor generates one turn of twist (assuming there is no slip between open-
end and the rotor).
7, A region in which the open end grasps and binds and forms a new yarn is called “binding-in
zone”. The length of binding-in zone is critical factor in obtaining the continuous twist.
8, Rotor spun yarn has a characteristic or distinctive feature called ”wrapper fibers”.
3. METHOLOGY
To the causes of high yarn breakage and to find the method which minimize it, we were utilizes
different data collection methods.
We have been used both primary and secondary data collection method.
Although getting data is difficult, but we have been try continuously to get data from different
sources.
Most of data which we have been used for this project work is secondary data. A brief discussion
of data collection methods which we have been used is listed below
INTERVIEW
Although the absence of textile professionals in ETUR textile plc, we have collect the data by
interviewing experienced Ethiopians workers and Turkish by using sign language to overcome
the limitation of communication with them.
In addition to company workers, some experienced individuals we come to the company for
different objectives are helps us by sharing their knowledge for the success of our work.
OBSERVATION
The main data collection method which we used for our work is observation method by relating
it with what we have been learnt in the last sixth semesters.
We can identify the causes of high yarn breakage in ng the rotor spinning machine by observing
the process flows materials used and machine setting in spinning machine starting from blow-
room and recycling machine up to rotor spinning machine.
INTERNET SERVICE
In addition to interview and observation, internet services play a valuable role in assisting us by
providing abroad information about rotor spinning process and machine.
We obtained some data about causes and methods to minimize high end (yarn) breakage in rotor
spinning machine. Internet is the most useful information area to get the exact information about
the process and arrangement of the machine which determine the productivity of the machine.
UNPUBLISHED LITERATURES
Unpublished literatures are also one of the important data collection methods which help us to
accomplish our work.
Lecture notes and other short notes and other short notes from handout which is given in the
class are contributes a great role for this work. Especially lecture notes of Professor Manoharan
about rotor spinning process and other related lecture notes helps us for success of our work.
3.2 MATERIALS
DRAW FRAME SLIVER
To identify the causes of breakage and to minimize it, we have been observed the process by
using different raw-materials.
Specification
Yarn count=6-14 Ne
Temperature; 26+2
Humidity: 68%
Rotor: 42,000 rev/min
Opening roller speed: 8,000rev/min
We have been try to observe the different in end breakages rate by using raw-materials from
different sources and by varying the speed of opening roller , delivery speed and rotor speed.
3.3 EQUIPMENT
Spinning machine
Carding and blow room sections are the most important section in which high impurities are
removed. The degree of cleaning is depending up on machine setting such as machine speed and
gap between parts. So, the speed of machine and gap between parts in carding and Blow room
machine have to be properly set to obtain good quality of yarn. Embedded foreign materials are
also removed by good cleaning. The gap between drafting roller in draw frame machine is also
properly set to obtain even sliver. Properly set machine part is important to obtain even sliver
which fibers are properly arranged.
PROPER OPENING OF FABRIC INTO FIBER
In ETUR Textile plc a piece of fabric is recycled and use as a raw material for rotor
spinning machine. The yarns which are form a fabric have to be properly opened into fiber.
Unopened long yarns are uncomfortable for spinning by rotor machine.
So opening cylinder in opening machine has to be properly set to improve good opening. We
have been trying with Turkish workers and as we test by observation good result was obtained.
Too much rotor speed is the cause for high yarn breakage, because of Increase tension in yarn.
SO proper setting of rotor speed is one of the methods to minimize high yarn breakage.
In ETUR textile plc due to lack of textile professionals on some machine they use unmatched
opening roller speed and rotor speed.
Rotor No.
Deliver Running Theoretica Actual
M/ N T/ Speed Of Eff.
y Speed Time(Min l Productio
C e M Rev/Mi Roto (%)
M/Min ) Production n
n r
1 10 630 52000 83 220 484 519 288.8 56
2 9 6oo 45000 75 280 481 663 292.6 44
3 9 600 45000 75 280 481 663 288.8 44
total 233 780 1446 1845 870.2 47.16
Table no. 1
From the data we gathered before taking measurements we calculate production loss.
Applying all remedial was difficult for us, because of lack of professionals who may help us and
lack of basic quality improvement facilities. However we try to apply some of the remedial and
we have been obtained the following results per the same machine and the same material after
the remedial has been taken.
No.
Deliver Theoretica Actual
Of Running Rotor
M/C Ne T/M y l Productio Eff.(%)
Roto Time(Min) Speed
M/Min Production n
r
1 10 630 83 220 484 52000 519 296.4 57
2 9 600 75 280 481 45000 663 539.6 81
3 9 600 75 280 481 45000 663 357.2 54
Tota 233 780 1446 1485 1192.4 65
l
Table no. 2
For machine 1
Theoretical production = 519 kg
Actual production = 296.4kg
Eff.(%) = (296.4/519) x 100 = 57%
For machine 2
Theoretical production = 663 kg
Actual production = 539.6 kg
Eff.(%) = (539.6/663) x 100 = 81%
For m/c 3
Theoretical production = 663kg
Actual production = 357.2kg
Eff.(%)= (357.2/663) x 100 = 54%
Now the total efficiency of the machine is calculated as follows.
Total theoretical production = 1845kg
Total actual production =1192.4kg
Production loss = theoretical-actual
= 1845-1192.4
= 652.6kg
Which is less than the previous one (974.8kg)
Cost loss in this case is = (652.6kgx95birr) / 2.5 = 24799 birr is loss.
But when we compare this value with the previous one there is some improvement. We can save
(37042-24799) =12243 birr for the company per day.
CHAPTER FOUR
4.0 RESULT AND DISCUSSION
4.1 Result
Before taken the measurements
Loses of money= 37042 birr/day/3m/c
After taken the measurement
Loses of money =24799 birr/day/3m/c
4.2 Discussion
From above result we can calculate the amount of money that we have been saves for the
company per three machines per day.
We know that total loss before taking remedial action is 37042. But it is reduced to 24799 after
remedial action have been taken. Therefore 37042=100%
24799=?
Then loss after is (24799x100)/37042=67%
The percentage of money loss is reduced by 33%. From result we observe that the amount of
money lost is reduced after remedial action is taken. In addition the amount of product is also
increased. That means the company is became more productive due to remedial action is taken.
The company will become more productive if all needed remedial actions are fully applied.
CHAPTER FIVE
5.1 CONCLUSION
As we has been try to discuss at the beginning of this document, there are many problems which
should be solved to eliminate the factors which hinders the company from achieving its goals as
per required.
During our intern ship program we have been try to found the ways to minimize the affect of
high end breakage. High end breakage is the problem which can reduce productivity and the
efficiency of the rotor spinning machine.
Rotor spinning machine has high speed, but in ETUR Textile plc spinning factory the efficiency
of the machine is affected due to lack of some basic requirements of quality improvement.
Efficiency and productivity of rotor spinning machine can be improved by fulfilling the basic
requirements like improving quality of raw materials and by using properly set machine. Even
though eliminating the problem is impossible but minimizing the affect of the problem by taking
some remedial is possible. Generally high end breakage is the main problem that limit the
company from achieving its goal as per required and it can be minimized by taking some
measurements.
5.2 RECOMMENDATION
As we has been try to discuss above yarn breakage is the factor which can reduce the profit and
production capacity of textile factory. ETUT Textile plc is also affecting by this problem due to
lack of proper maintenance, lack of proper air conditioning system, workers carelessness,
machine problem and material problem.
By taking those problems into account and taking some remedial that is possible in our level we
could improving the productivity by some quantity. If taking more remedial actions properly the
company will become more productive and save the cost. So we went to recommend the
company to be work more on this problem by educated professionals and fulfilling the basic
requirements for solving the problem.
ETUR Textile plc has no educated textile professionals and the basic requirements of quality
improvement. The problem of high end breakage is becoming the main factors which can affect
the efficiency of rotor spinning machine and the quality of its product.
We have been try to found the ways to minimize high end breakage. But due to lack of quality
tasting materials and some other needs we are not so much successful. But if there is availability
of required materials and the educated professionals the problem can be fully minimized as per
required. So we went to recommend the company to employ professionals and to fulfill the
required facilities.
References
1 lecture note
2 htt:/rotor spinning.com
3 hand out and short notes