JUTE BATCHING

Flow chart of jute yarn manufacturing:

Batch:
A blend of different types of jute is made up to suit the particular class of yarns being spun. This blend is known
as ‘the batch’.
To produce 8lbs/spindle Hessian warp yarn following batch component is taken under consideration.
White C-40%...........................40bales
White X-40%...........................40bales
Tossa-20%...............................20bales
Total-100%...............................100bales
Batching:
All the processes starting from batch selection up to carding of jute is called batching. It is primary stage of jute
yarn processing.

Importance of Batching
 To help fibre move freely during processing
 To get expected dampness and flexibility
 To remove hardness and stiffness of jute fibres
 To intermix the batch component effectively
 To reduce loss due to wastage
 To control and reduce yarn cost

JUTE BATCHING EMULSIONS

Jute batching emulsions are of a simple nature, usually containing only the mineral oil, water, and an
emulsifying agent. An emulsion is an intimate mixture of two immiscible liquids, one dispersed in droplet form
inside the other.
Oil and water are usually immiscible but if the oil can be split up into minute drops which are prevented from
coalescing then they can be dispersed throughout the water-this is then called an emulsion.

General recipe:
Water -73%
Oil -25.4%
Emulsifier-1.6%

Emulsion preparation machine:

OD Automatic Batch Mixer:

‘OD’ Batch Mixer is a simple automatic m/c for producing stale batching emulsion for jute.
Procedure:
 The percentage of emulsion, oil and water accurately and automatically measured by volume.

 The percentage of oil and emulsifier can be adjusted easily by setting the pointers on oil and emulsifier
scale. When adjusted, the machine automatically adds the required percentage of water to complete 1000
L.

 Once the required percentages are set, the machine will automatically continue to measure and mix these
percentages each time.

 After all the ingredients are added, the agitator or paddle starts to rotate at a high r.p.m. Then emulsion
is formed which is then stored to the storage tank under the mixing tank.
Jute spreader machine

The fibre bundles are laid by hand on the feed sheet of the spreader, the root end of one fibre bundles
overlapping the crop end of the previous one. This is the point where the separate and individual reeds of jute
are assembled into a continuous sliver.

The fibre bundles pass between a pair of fluted feed rollers and on to the pins of the slow-moving pinned lattice
known as the slow chain; above the slow chain there are two or three lantern rollers to press the jute firmly
down on to the pins.

Halfway along the machine the material is transferred from the pins of the slow chain to those of a similar
chain having a higher surface speed. Because of the greater linear speed of the fast chain the jute is combed and
drawn out, i.e. drafted, at this transfer point.

Jute softener
The softener is a long machine comprising 64 or 72 pairs of cast iron fluted rollers, the lower of the pair being
driven from a side-shaft and the upper, spring-loaded one by contact with the lower of the pair. Figure shows a
diagrammatic view of a softener.

The jute is flexed between each pair of rollers and is made softer, some of the loose dust and dirt falls off, and
pieces of bark and stick become broken, making their removal at later stages easier. About two-thirds of the
way along the rollers the emulsion is dripped on to the jute.

As the jute is not fed to this machine in a continuous manner as it is on the spreader, there are gaps in the
material and some of the emulsion falls straight through between the rollers; in addition it can drip from the jute
itself as it proceeds towards the end of the machine.

In order to collect this excess emulsion there is 2 sump beneath the machine. From here the excess is pumped
back to storage through various filters to extract all the dirt and waste which inevitably finds its way into the
sump.
 Problem-(01):
If raw jute receives an application of 20% emulsion of which 15% is absorbed. Find out the weight of a
batch of 12bales Raw jute (4000lbs = 1bale):
Solution:
Wt. of 12 bales = 4000 ¿ 12 = 48000 lbs.
100 lbs raw jute after batching wt. = 115 lbs
115
1 lbs raw jute after batching wt. = 100
115×48000
48000 lbs raw jute after batching wt. = 100
= 55200 lbs (Ans)

 Problem-(02):
If an emulsion is prepared as follows: Oil = 24%, Water = 74.5%, Emulsifier = 15%.
If raw jute receives an application of 20% emulsion of which 15% absorbed. Find out the absorbed amount oil,
water and emulsifier of raw jute (A batch containing 12bales, 4000lbs/bales)
Solution:
Wt of 12 bales = 4000 ¿ 12 = 48000 lbs.
100 lbs emulsion contains = 24 lbs oil
24
1 lb emulsion contains = 100
24×15
=3. 6
15 lbs emulsion contains = 100 lbs oil

100 lbs raw jute absorbs = 3.6 lbs

3.6
1 raw jute absorbs = 100
 3 . 6×48000
48000 lbs raw jute absorbs = 100
= 172.8 lbs.

Water:
100 lbs emulsion contains = 74.5 lbs water
74.5
1 lb emulsion contain = 100
74. 5×15
15 lbs emulsion contain = 100
= 11.175 lbs
100 lbs jute absorbs = 11.175 lbs.
11.175
1 lb jute absorbs = 100
11.175×48000
48000 lbs jute absorbs = 100
= 536.4 lbs
536 .4
= 9 gallon.

Emulsion:
100 lbs emulsion contains = 1.5 lb emulsifier
1.5
1 lb emulsion contain = 100
1.5×15
15 lbs emulsion contain = 100
= 3.225 lb emulsifier

100 lbs raw jute absorbs = 3.225 lb emulsifier

3 .225
1 raw jute absorbs = 100
3 . 225×4800
48000 lbs raw jute absorbs = 100
= 10.8 lb emulsifier.

 Problem-(04):
Find the production in lbs/hr of S. M/c delivered speed = 60 yds/min, Draft = 12, Efficiency = 80%,
emulsion applied = 20%. Wt of feed material = 6 lb/yds.
Solution:
6 100+20
×60×60× ×0 .8
Production in lbs/hour = 12 100
= 1728
 Problem-(05):
Production of spreader M/C have dollop wt = 36lbs, Clock length = 6yds, delivery speed = 60yds/min,
M/C draft = 12, emulsion applied = 12%
Solution:
Production of spreader machine in lbs/hour =
 36 100+12
60×60× ×
= 12×6 100
= 2016 Yds/hr.