A Report on Spinning Process

Prepared By
Engr. Saad Ahmed Salman
Table of Contents
Introduction:...............................................................................................................................4
Objectives: .................................................................................................................................4
Terminology Used in Textile Industry:......................................................................................4
Count:.....................................................................................................................................4
Tex: ........................................................................................................................................5
Denier:....................................................................................................................................5
Pounds/ spindle: .....................................................................................................................5
English Count: .......................................................................................................................5
Metric system:........................................................................................................................5
Coefficient of Variation CV%: ..............................................................................................5
The Irregularity U%:..............................................................................................................5
Twist per inch (TPI):..............................................................................................................5
Thin Place: .............................................................................................................................5
Thick Place: ...........................................................................................................................5
Neps: ......................................................................................................................................6
Micronaire (Mic.) – fineness: ................................................................................................6
Process Work Flow Diagram of Spinning: ................................................................................7
Production Machineries and Their Functions: ...........................................................................8
Blow Room: ...........................................................................................................................8
1. Control unit ....................................................................................................................9
2. Channel for cable chain .................................................................................................9
3. Fly duct ..........................................................................................................................9
4. Swiveling tower .............................................................................................................9
5. Control box ....................................................................................................................9
6. Take off unit...................................................................................................................9
7. Suction duct ...................................................................................................................9
8. Traversing rails ..............................................................................................................9
9. Bale lay down area.........................................................................................................9
10. Chassis .........................................................................................................................9
In figure (B), the main part of a uniclean machine has been shown, where;.....................9
1. Double pin beater...........................................................................................................9
2. Grid bar ..........................................................................................................................9
3. Waste chamber...............................................................................................................9
Carding:................................................................................................................................14
Breaker & Finisher Drawing:...............................................................................................15
Lap Former: .........................................................................................................................16

2
 Comber:................................................................................................................................17
Simplex Frame/Roving Frame:............................................................................................18
Ring Frame: .........................................................................................................................18
Winding: ..............................................................................................................................19
Rotor Machines:...................................................................................................................21
Heat Set Machine:................................................................................................................23
Utility Machineries and Their Functions: ................................................................................24
Compressor& Dryer:............................................................................................................24
Power Generator: .................................................................................................................26
Boiler: ..................................................................................................................................27
Chiller: .................................................................................................................................28
Figure: A schematic diagram of a vapor absorption chiller.................................................28
Air-conditioning Plant: ........................................................................................................29
Different Types of Attachment: ...............................................................................................30
Slub: .....................................................................................................................................30
Inject: ...................................................................................................................................30
Siro:......................................................................................................................................30
Lycra: ...................................................................................................................................30
Sample Production Calculation: ..............................................................................................31
Required Winding Machine:................................................................................................31
Required Ring Machine: ......................................................................................................31
Required Simplex Machine: ................................................................................................32
Required Finisher Drawing:.................................................................................................32
Required Comber Machine:.................................................................................................33
Required Unilap Machine:...................................................................................................33
Required Breaker Drawing: .................................................................................................33
Required Carding Machine:.................................................................................................34
Consumable Spare Parts of Machineries & their life: .............................................................35
Conclusion: ..............................................................................................................................37

3
Introduction:
Spinning is the process where yarn is Produced from raw cotton. Severel process and
machineries are involved with this industry. Spinning is the initial process for fabric or ready
made garments production. Yarn that has been produced in spinning mill will be sent to the
Knitting or Weaving factory. Here, fabric will be produced and send to the garments factory
for garment production.

Objectives:
A spinning mill is space consuming industry. From raw cotton to yarn processing, lot of
machineries are involved. Numbers of machineries has been used in each step for yarn
processing. Objectives of this report has given below:

 Get technical knowledge of spinning mills.

 Understanding yarn manufacturing process from cotton.
 Enhancing knowledge about spinning machineries and function.
 Learn about maintanance and planning.
 Get knowledge about consumable spares and how frequently the are needed.

Terminology Used in Textile Industry:

Every industry has their own terminology that has been widly used in same industry. Textile
industry is not an exception. Terminology that is widely used in Textile industry has been
described below:

Count:
The count of Yarn is a numerical expression which defines its fineness. It is a numbers
indicating the mass per unit length or the length per unit mass of yarn. Count is denoted by
Ne. There are two systems for denoting count:
Direct System:
Count is mass per unit length. Thus, higher the count coarser the yarn.
Wxl
Ne = -----------
wxL

Where, W = Wt of the sample

w = Unit of wt of the system
L = Length of the sample
l = Unit of the length of yarn.

Indirect System:
Count is length per unit mass.In this system higher the count finer the yarn.
Lxw
Ne = -----------
lxW

Where, Ne= Count.

4
 L= The length of the sample.
W=The wt. of the sample at the official regain
w = Unit of the wt of the system.
l= The Unit of length of the system.

Tex:
Count is the Tex system is the wt. in gm of 01 km of yarn. i.e. wt/1000m.

Denier:
It is the wt in gm of 9000m of yarn. i.e. lycra, PET.

Pounds/ spindle:
It is the wt in pound of 14400 yd of yarn (for Jute count)

English Count:
It is defined as no. of hank (840yds) per lb. For example, If 1 pound of yarn contains 20
hanks of 840 yards, then English cotton count will be 20Ne .1 hank=840yds.

Metric system:
It is defined as no of hank (1000m) per kg. Example If 01 kg of yarn contains 40 hanks of
1000m, Then Metric system Yarn count will be 40Nm

Coefficient of Variation CV%:

The coefficient of variation CV is a well known value for the determination of the evenness
of slivers, roving’s and yarns. The Coefficient of Variation (CV) is the standard deviation
(SD) expressed as a percentage of the mean. Each process in a spinning mill contributes a
part to the evenness.
CV % = (SD ÷ mean) x 100

The Irregularity U%:

It is the percentage mass deviations of unit length of material and caused by uneven fibre
distribution along length of strand. The irregularity U% is proportional to the intensity of the
mass variations around the mean value. The U% is independent of the evaluating time or
tested material length with homogeneously distributed mass variation.

Twist per inch (TPI):

This value is only measured over one inch (1inch=2.45cm). This term is used commonly to
express twist level of the yarn.

Thin Place:
Thin places are places in the yarn that are thinner than 50% or more than the average
diameter of the yarn. There is no limitation in the length of the thin place. Better yarn has less
thin place.

Thick Place:
Thick places are determined where the yarn diameter is in excess of 50% of the average yarn
diameter and the length is 8-12mm.

5
Neps:
It has to be made a differentiation in the two faults - thick places and neps.
Frequently-occurring thick places exhibit a length that corresponds with the mean staple
length of the fibre. A nep is a very short thick place in the yarn, a small fault having a length
of 2mm diameter of 3 times or more at a standard setting of 200%. It can either be a fiber
nep, a seed coat nep or a trash particle. It can be thicker than 200% of the average yarn
diameter. The increase for neps is calculated to a reference length of 1mm. They can be a
bunch of entangled fibres commonly not bigger than pin ball head.

Micronaire (Mic.) – fineness:

A measure of mass per unit length expressed in micrograms per inch for cotton. A fiber
sample of constant weight is measured by passing air through the fibers and measuring the
drop in pressure. The micronaire scale has been established empirically with a standard set of
cottons and is not linear. Other factors such as fineness and maturity have an influence on
micronaire results.

6
Process Work Flow Diagram of Spinning:
Spinning is conversion of fibers into yarn. These fibers can be natural fibers (cotton) or
artificial fibers (polyester). Final product of spinning is yarn. Spinning is the foundation
process and all the subsequent value added processes such as Weaving, Knitting, Garments
and Denims are depend upon it. Any variation in quality of spinning product directly affects
the entire value chain.

UNIfloc MBO

Carding

Breaker

Breaker
Unilap
Normal
Comb
Process
Process
Comber Finisher

Finisher

Simplex Rotor

Ring

Ring process Open End

Winding Heat Set
Process

Heat Set

Packaging Packaging

Figure: Work flow chart of spinning process

7
Production Machineries and Their Functions:
Different types of machineries have been used for the conversion of fibers into yarn and their
functions are different. A brief discussion of function of the major machineries used in
Square textile Complex has been described below:

Blow Room:
Blow room is the starting of the spinning operation. It is the section where supplied
compressed bale is turn into a uniform lap of particular length. The basic functions of blow
room are opening, cleaning, dust removal, blending and evenly feeding the material on the
card. The machineries required to carry out these functions are:

1. Cotton Bale
2. Unicleane or
Cleaning Machine
3. Unimix or Mixing
Machine
4. Fine Cleaner
5. Condenser
6. Carding
7. Coiler

Figure: Work flow diagram of Blow room

Bale Opener:
Bale Opener Machine is the first major machine in the Blow Room. It could be automatic or
manual. The functions of a bale opener machine are open the tuft of cotton, mix & blend the
fiber, remove a considerable amount of trash from fiber which is taken out by fan to FDP and
act as a reservoir for the next machine. Unifloc is an automatic bale opener machine that
plucks raw cotton in lump form and sends these to clean through air transportation for coarse
cleaning.

(A) (B)

8
Figure: Unifloc machine plucking cotton from Lay-down (A) and identification of major
parts of automatic bale opener (B).
From Figure (B), the major parts of automatic bale opener are:
1. Control unit
2. Channel for cable chain
3. Fly duct
4. Swiveling tower
5. Control box
6. Take off unit
7. Suction duct
8. Traversing rails
9. Bale lay down area
10. Chassis

Cleaning Machine:
Cleaner machine is an important machine in spinning for opening and cleaning impurities
from cotton. This machine is set normally after Bale Opener machine. It main functions are to
open & clean the cotton by combinations of opposite spike & the beating action. It also
removes the impurities such as leaves, stalk, motes & sand without damaging the fiber.

1 2 3
(A) (B)
Figure: Uniclean machine of blow room (A) & (B)

In figure (B), the main part of a uniclean machine has been shown, where;

1. Double pin beater

2. Grid bar
3. Waste chamber

9
Mixing Machine:
This is a process of mixing the same or different category of fibers to get desired properties
and cost effectiveness. Mixing is done after the study of the essential properties of fiber like
staple length, tensile strength, fineness, uniformity etc. Fibers actually stored in six chambers
and mixed up by beating.

6 Chambers

Figure: Unimix machine of blow room

In figure above, major parts of unimix machine has been indicated and they are:
1. Storage Section 9. Material exit
2. Separating Vanes 10. Stripper roller
3. Conveyor Belt 11. Take-off roller
4. Top exhaust air exit 12. Spiked feed lattice
5. Partitions 13. Opening and cleaning unit
6. Downwards exhaust air 14. Waste chamber
7. Intermediate section 15. Conveyor belt drive
8. Delivery section

10
Fine Cleaner:
Traditional methods use more number of machines to open and clean natural fibers. In this
section fine cleaning is done through beating and waste products are separated. Mechanical
action on fibers causes some deterioration on yarn quality, particularly in terms of neaps.

Figure: Fine cleaning or uniflex machine and identification of their major parts
From figure above the major part of fine cleaner machine:
1. Inlet duct 7. Feed roll
2. Ventilator 8. Trough
3. Dust cage 9. Grid bar
4. Plain drum 10. Waste box
5. Cleaned cotton outlet duct 11. Laminar chute
6. Laminar chute

11
Contamination Separator:
In every steps of blow room, the main function is cleaning. The most effective protection
here consists of two stages: One for the separation of metals, heavy parts and burning
material at the start of the cleaner line and one for the specific separation of foreign parts
(foreign fibers) at the end of the cleaning line. The wide range of special contamination
separator machines makes it possible here to find the ideal configuration for each line:

Figure: JOSSI Contamination Sorter in blow room

12
Condenser:
The condenser are de-dusting duct remove from chute material by suction air. This chute
material sends to the carding machine for further processing via chute line.

Figure: Rieter condenser unit in blow room

From figure above, the major parts of a condenser are:
1. Material feed 7. Fan
2. Feed funnel 8. Guide plate over take-off roller
3. Perforated drum 9. Take-off roller
4. Protected cover 10. Switch
5. Exhaust air outlet 11. Material delivery
6. Inspection glass

13
Carding:
The carding machine mainly removes the naps, short fibers and remaining impurities in the
cotton fiber and forms carded sliver. Mainly impurities are removed at the intake and the
naps and short fibers are removed by action between the cylinder and flat. It is called the
heart of cotton spinning because the quality of a yarn is greatly dependent upon the carding
machine. In carding machine, cotton converted into sliver, which is deposited in sliver can.

Figure: Carding machine and its major parts.

From the figure above, the major parts of a carding machine are:
1. Aero feed 8. Carding profile 15. Waste removal
2. Material distribution device 9. Detaching device
3. Carding profile 10. Fleece pick-up by cross apron
4. Flat cleaner 11. Stepped rollers
5. Flat 12. Doffer
6. Cylinder 13.Bottom part of the machine
7. Complete covering 14. Licker-in

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Breaker & Finisher Drawing:
Carded Slivers are fed into the Breaker draw-Frame. Here, slivers are stretched/Straightened
and made in to a single sliver. Also fiber blending can be done at this stage. Some other tasks
of this draw frame are drafting, parallelizing, blending, dust removal etc. Usually, it takes 12
sliver can as input and give one sliver can as output.
Breaker Drawing and Finisher Drawing looks similer but the main difference between these
two is Finisher Drawing has Auloleveller. Auloleveller is a online monitering system in
spinning process and an integral part of the process for better yarn production. Slivers
collected from carding have high degree of uneveness and contains infamous piecings.
Autoleveller adjust the draft continuously and maintain consistent hank of sliver. It will
provide hiher efficiency in further process. So, for obtaining good quality yarn autoleveller is
must.

Figure: Draw frame and its sectional view.

From the figures above, the major parts of a draw frame are:

1. Input sliver can

2. Feed roller
3. Drafting zone
4. Tube
5. Calendar discs
6. Sliver passage
7. Tube gear in to a can
8. Creel

15
Lap Former:
Its a precombing operation. In this machine, laps are prepared for combing process. After
first drawing when the fibers are partially parallelized and more regularized, they are
combined together, up to 48 ends on sliver lap machine and a small lap is produce with a
predetermine weight/yd & length. This is the preparatory machine for the comber. Usually, it
takes 24 sliver can from breaker drawing and makes a lap.

Figure: Sectional view of a Unilap E32

From figure above: the parts of Inilap machines are,
1. Lap roller 6. Lap
2. Lap head 7. Lap roller flanges
3. Calendar roller 8. Fleeces
4. Sliver Feed units 9. Drafting System A
5. Drawing Sliver 10. Drafting System B

16
Comber:
The process of straightening and parallelizing of fibers and the removal of short fibers by
using combs and this combs assisted by brushes. This processes carried out in order to
improve the quality of the sliver coming out of the card. It also removes naps and residue
impurities. It takes 8 laps from lap former and make a single sliver can.

1
2
3
4

5
6

Figure: Comber of a blow room

Major parts of a comber machine has been listed below,

1. Lap
2. Head Stock
3. Combing Zone (circuler comb, top comb, detaching roller, delivery roller,
calender roller etc)
4. Drafting Zone (Top Roller, bottom roller etc)
5. Coiler Zone
6. Deposited Sliver Can

17
Simplex Frame/Roving Frame:
In yarn manufacturing system, simplex frame is situated after the drawing frame. The sliver
which is produced from the draw frame that is thicker and it is not suitable to feed into the
ring frame directly to produce yarn. For this reason, drawn sliver is treated before entering
into the ring frame. There are three basic steps in the operation of the roving frame – drafting,
twisting and winding. In this process drawn sliver is input and fine Roving is output. The
roving is feed into ring frame for yarn production. It is noted that, simplex is essential for the
production of cotton yarn in case of ring spinning system.

Figure: Symmetric view of a Roving Frame

Ring Frame:
Roving produced in roving frame used in ring frame to obtain the desired yarn. Main function
of ring frame is to draft the roving until the required fineness is achieved, then twist the
drafted yarn to form yarn of required count and strength. Finally, wind the twisted yarn on
the bobbin for further processing. In ring frame, any type of fiber can be spun and wide range
of count can be processed. Higher yarn strength can also be achieved through ring frame.

Figure: Symmetric view of a Ring Frame

18
Winding:
Winding is one of the most important operation, which is mainly occurred in spinning
section. The ring-spinning operation produces a ring bobbin containing just a few grams of
yarn, which is unsuitable for the further processing. This necessitates the preparation of a
dense and uniform yarn package of sufficiently large size. The packages prepared in winding
are normally cross-wound, containing several kilograms of yarns. Clearer device is also
installed in each spindle of winding machine. The clearer for winding machines is a
sophisticated sensor which is able to eliminate disturbing thick places, thin places, foreign
fibers and separate bobbins which do not fulfill the conditions with respect to evenness,
imperfections, hairiness, count deviations, etc.

1. Headstock
2. Bobbin Transport system
3. Machine Body
4. Winding Head
5. Control station
6. Cleaning Unit

Figure: Symmetric view of a Savio Winding Machine

1. Box housing of the mechanical,

electrical and pneumatic driving components.
2. Tensor and antiwrap device
3. Clearer
4. Package yarn suction
5. Economiser
6. Yarn Splicer
7. Yarn accompanying Leaver
8. Bobbin Yarn Suction
9. Yarn Tensioner
10. Waxing Unit
11. Yarn Detection Feeler
12. Pre-clearer
13. Scissors Unit
14. Yarn Guide
15. Unit Control Panel

Figure: Winding Heads Middle Unit

19
 1. Rotating Package
2. Yarn Guide
3. Drum & Package chute pallet
4. Package Cradle
5. Cradle support & package chute
6. Cradle support & adjustment screw
7. Mobile Nozzle
8. Chutters
9. Clearer
10. Bobbin Slide
11. Bobbin Slide Drive
12. Bobbin Ejector
13. Bobbin Magazine
13

Fifure: Symmetrical View of a winding head

20
Rotor Machines:
The rotor spinning machine is unlike any other machine in the short staple spinning mill in
the range of tasks it has to perform, namely all the basic operations:
 Sliver feed: A card or draw frame sliver is fed through a sliver guide via a feed roller
and feed table to a rapidly rotating opening roller.
 Sliver opening: The rotating teeth of the opening roller comb out the individual fibers
from the sliver clamped between feed table and feed roller. After leaving the rotating
opening roller, the fibers are fed to the fiber channel.
 Fiber transport to the rotor: Centrifugal forces and a vacuum in the rotor housing
cause the fibers to disengage at a certain point from the opening roller and to move
via the fiber channel to the inside wall of the rotor.
 Fiber collection in the rotor groove: The centrifugal forces in the rapidly rotating
rotor cause the fibers to move from the conical rotor wall toward the rotor groove and
be collected there to form a fiber ring.
 Yarn formation: When a spun yarn end emerges from the draw-off nozzle into the
rotor groove, it receives twist from the rotation of the rotor outside the nozzle, which
then continues in the yarn into the interior of the rotor. The yarn end rotates around its
axis and continuously twists-in the fibers deposited in the rotor groove, assisted by the
nozzle, which acts as a twist-retaining element.
 Yarn take-off, winding: The delivery shaft and the pressure roller through the nozzle
and the draw-off tube and wound onto a cross-wound package continuously take off
the yarn formed in the rotor. Between takeoff and package, several sensors control
yarn movement as well as the quality of the yarn and initiate yarn clearing if any pre-
selected values are exceeded.

Figure: Symmetrical view of a Rotor machine

A- Drive Unit B- Machine Section
C- End Unit E- Starter Winder
F- Automatic Piecer Carriage G- Package Doffer
K- Spin Box L- Spinning Position

21
 Figure: Different parts of rotor head
1. Cover 6. Opening Roller Housing 17. Clamping Leaver
2. Adapter 7. Feed Tray 18. Rotor Housing
3. Navel 8. Condenser 19. Rotor
4. Opening Roller Brake 9. Opening Roller 22. Pre-condenser
5. Feed Clutch 10. Pressure ventilation

22
Heat Set Machine:
After winding process, the yarn cones are sent to heat setting section. In this chamber, yarn
packages are heated by steam generated from boiler for several hours. This process reduces
the hairiness of the yarn, will give the yarn better shape and will increase the strength of the
yarn. During heat setting, yarn packages can gain weight up to 2%. After heat settings yarn
packages are sent for packaging.

Figure: Xorella Heat setting Machine

23
Utility Machineries and Their Functions:
Apart from the production machineries, the machineries which are used to support the
production process are utility machineries such as boiler, compressor, generator, air
conditioning plant etc. Utility machineries and production machineries are subsidiary to each
other. List of utility machineries and their functions has been described below:

Compressor& Dryer:
Air compressors are one of the indispensible equipment in industries. Most of the production
machineries of spinning mills need compressed air to run accordingly. The compressed air
produced by the compressors are not suitable to use in any machineries directly. This air
contains water vapour which is harmfull for any machineries. Dryers are used to remove this
water vapor. So, compressed air produced by the compressor has to be transfered to the
machineries via Dryer.

Figure: Rotary screw compressor

The rotary screw compressor uses two rotors (helical screws) to compress the air. There’s a
‘female’ rotor and a ‘male’ rotor. The rotors are of different shape, but fit each other exactly.
When the rotors start turning, air will get sucked in on one side and gets ‘trapped’ between
the rotors. Since the rotors are continuously turning, the air gets pushed to the other end of
the rotors (the ‘pressure side’) and new fresh air gets sucked in.
Because this is a continuous process, this kind of compressor doesn’t make a lot of noise; it
runs quiet and smoothly. The screw compressor will run 24/7 and 365 days a year without
any problems. The capacity (liters of air per second) of screw compressors are generally
much bigger compared to piston-type compressors.
This type of compressor is usually the best choice for industries where lot of compressed air
is required.

24
 Figure: Dryer connected to the compressors
Dryers are connected at the end of compressors. Compressed air may contain water vapor
which is not suitable for the production machineries. Compressed air produced by the
compressor passed through the dryer to the machineries. Dryer used refrigeration cycle and
condensed water drain out.

25
Power Generator:
Generators are useful appliances that supply electrical power during a power outage and
prevent discontinuity of daily activities or disruption of business operations.

An electric generator is a device that converts mechanical energy obtained from an external
source into electrical energy. Generator uses the mechanical energy supplied to it to force the
movement of electric charges present in the wire of its windings through an external electric
circuit. This flow of electric charges constitutes electric current supplied by the generator.
Generator works on the principle of electromagnetic induction discovered by Michael
Faraday in 1831-32. Faraday discovered that flow of electric charges could be induced by
moving an electrical conductor, such as a wire that contains electric charges, in a magnetic
field. This movement creates a voltage difference between the two ends of the wire or
electrical conductor, which in turn causes the electric charges to flow, thus generating electric
current.

Figure: Different parts of an electric generator

Main components of an electric generator can be broadly classified as follows:

1. Engine 2. Alternator
3. Fuel System 4. Voltage Regulator
5. Cooling and Exhaust Systems 6. Lubrication System
7. Battery Charger 8. Control Panel
9. Main Assembly / Frame

26
Boiler:
The heart of an industrial boiler system is a hot water or steam boiler operated with a certain
kind of fuel. The boiler heats up or evaporates the water inside it, which is then transported to
the consumers via pipe systems. In case of steam the transport is based on inherent pressure.
The cooled water or the condensed steam returns to the boiler where it can be heated again.
Loss of water must be compensated by treated fresh water to avoid corrosion. Flue gases
created by combustion are discharged into the atmosphere through a chimney.

Figure: Cross-sectional view of a fire tube boiler

The Boilers used in Square Textile Complex are Fire Tube Exhaust Gas Boiler (EGB).
Exhausts of the generator are used here to produce steam in the boiler. The hot flue gas
(Temperature 480°C-550°C) coming from the generators used to pass through the tubes of
the boiler and these tubes are surrounded by the water. Water at the outside of tubes is heated
by hot tubes, so there is heat transfer between hot gases inside tubes and water outside tubes.
Thus water will gain temperature from the tubes and converted into steam. Produced steam is
used in Heat Set machine as well as in vapor absorption chiller.

27
Chiller:
Absorption type chiller is simple heat exchanger operating at different pressure. It does not
have any moving parts hence less noise and vibration. Waste heat normally utilized and fully
automatic driven hence minimal number of human intervention required.

Figure: A schematic diagram of a vapor absorption chiller

28
Air-conditioning Plant:
Air conditioning is the process of treating air also as to control simultaneously its
temperature, humidity, cleanliness and distribution to meet the requirements of "conditioned
space". An air conditioning system may use heating, cooling, humidifying, de-humidifying
and filtering units and combination of these depending upon the outside weather.
Air conditioning plant is very important in spinning industry. To get better quality yarn,
temperature and relative humidity need to be maintained properly.

6
1 1. Protection grill / Outside air
intake
2. Fresh air damper
3. Return air damper
4. Mixing chamber
5. Air straightner
6. Spray bank
7. Water eliminator
8. Supply air fan
9. Automatic rotary air filter
10. Suction fan / dust bag
11. Return air fan
12. Exhaust air damper

Figure: Central Air-conditioning plant

The basic task of the Luwa Central Air Conditionino Plant is :

a) Air conditioning
b) Air conveyance
c) Purification of the room air

The volume offresh air drawn through the weather proiectlon louvers and outside air intake
depends on the position of the fresh air dampers (2), which are linked with the return air
dampers (3) in such a way that the air volume tlowing through the mixing chamber (4) is
always 100%. Depending on the outside atmospheric conditions and the heat accumulation in
the room, an air heater may be requires in front of the return air damper. The air straightener
(5) governs the air flow in such a manner that its speed and direction are at any point of the
washer's cross section uniformly distributed. This eveness is necessary to obtain the best
possible economic etfect from the humidification by means of the spray bank (6), and also to
enable the water.eliminator (7) to eliminate large water droplets as uniformly as possible. The
conditioned air is then blown by the supply air fan (8) into the duct system. A return air fan
(11) evacuates the heated and dust and fibre charged air from the production room. On ihe
other hand, the dust and fibres floating in the return air is held back by the rotary air fiiter (9).
The accumulated dust and fibres are usually evacuated and dumped automatically (10) or
must be removed by hand. Depending on the requirements, the purified exhaust air is either
recycled into the system (12) or blown through the exhaust air dampers to the open air.

29
Different Types of Attachment:
Different types of attachments are attached to the ring machine such as slub, inject, siero and
lycra according to the requirements. But in rotor machine only slub attachment is possible.
Combination of inject plus slub and lycra plus slub are attached in some machines. Unit-2 is
free of any type of attachment.

Slub:
Slub is a process where external attachment is attached to the ring or rotor machine which
consists of servo motor and encoder. Since the servo motor gives additional speed to the
back roller in reguler interval, the yarn diameter increased than the normal yarn diameter in
same interval. So the yarn will get thick places for certain distance in a regular interval.

Inject:
Inject is a process where roving sliver is injected to the normal yarn during ring process in a
regular interval. So the yarn will get thick places for certain distance in a regular interval as
like slub processs. Different colored roving sliver can be injected to create multi colored
yarn.

Siro:
It is a process of combining two yarn twising together and make single yarn in the ring
process. Differet colored yarn can be achieved from this process.

Lycra:
Lycra is a process where some equipment are attached to the ring frame such as lycra roller,
roving stopper, sensor, servo motor, PCB etc. During this process, lycra from roller and sliver
from roving twisted together and make yarn. Lycra is elastic material so the lycra yarn has
the elastisity.

30
Sample Production Calculation:
Calculation for machineries requirement to produce 30,000 Kg of yarn per day has been
shown below:

Let,
Yarn Production = 30,000 kg/Day Here,
Yarn Count = 30 Ne 1 Yards = 0.9144 m
Calculation for Winding Machine, 1 Kg = 2.2046 lb
No of dram = 60
Machine speed = 1500 m/ min
Machine Efficiency = 65

Required Winding Machine:

∗ . ∗ / ∗
Production / Machine/ Day =
∗ ∗ 0.9144 ∗ 2.2046

1500 ∗ 60 ∗ 60 ∗ 24 ∗ 0.65
=
840 ∗ 30 ∗ 0.9144 ∗ 2.2046

= 1658.26 kg

30,000
No of required winding machine = = 18.09 ≈ 19
1658

Required Ring Machine:

. ∗ . .∗ / ∗
Production / Machine/ Day =
∗ ∗ ∗ 2.2046 ∗ 36

17000 ∗ 1008 ∗ 60 ∗ 24 ∗ 0.94 TPI (Twist Per Inch)= TM√Count

= TM (Twist Multiplier)= 3.6
840 ∗ 30 ∗ 19.7 ∗ 36 ∗ 2.2046 TPI = 3.6 * √ 30 = 19.7
Sp. Speed = 17,000 rpm
= 588 kg
No. of Sp. = 1008
Efficiency = 94%
Production loss during winding operation is 1% (Assumption).

30000 ∗ 1
So, Total Ring production has to be = 30,000 + = 30,300 Kg
100

30,300
No of required Ring machine = = 51.53 ≈ 52
588

31
Required Simplex Machine:
Production / Machine/ Day
. ∗ . .∗ / ∗
=
∗ ∗ ∗ 2.2046 ∗ 36
TPI (Twist Per Inch)= TM√Hanks
1100 ∗ 120 ∗ 60 ∗ 24 ∗ 0.70 TM (Twist Multiplier)= 1
= Roving Hanks = 0.75
840 ∗ 0.75 ∗ 0.87 ∗ 36 ∗ 2.2046 TPI = 1 * √ 30 = 0.87
Sp. Speed = 1100 rpm
= 3058.72 kg No. of Sp. = 120
Efficiency = 70%

Production loss during Ring operation is 3% (Assumption).

30300 ∗ 3
So, Total Roving production has to be = 30,300 + = 31,209 Kg
100

31,209
No of required Roving machine = = 10.20 ≈ 11 Machine
3058.72

Required Finisher Drawing:

Production loss during Simplex operation is 2% (Assumption).

31209 ∗ 2
So, Total Roving production has to be = 31,209 + = 31,833.18 Kg
100

∗ / ∗
Production / Machine/ Day = X KTex
1000
Speed = 450 m/min
450 ∗ 60 ∗ 24 ∗ 0.75 Efficiency = 75%
= X 4.9 KTex =4.9
1000

= 2381 Kg

31,833.18
No of required Drawing machine = = 13.37 ≈ 14 Machine
2381

32
Required Comber Machine:
Production loss during drawing operation = 0.5%
So, Input of Comber Machine = 31,833 + (0.5*31833)/100 = 31,992.17

∗ ∗ . .∗ ∗ ∗ KTex ∗
Production / Machine/ Day =
1000 ∗ 1000 Nips = 350 m/min
Feed/Nips= 4.7mm
350 ∗ 4.7 ∗ 8 ∗ 24 ∗ 60 ∗ 0.83 ∗ 80 ∗ 0.85 Efficiency = 85%
= Number of Head=8
1000 ∗ 1000 Noil=17%
Lap KTex =80

= 1069.56

Number of Comber Machine Required = 31,992 / 1069.56 30 Machine

Required Unilap Machine:

Waste of Comber machine = Noil 17 % & Lap waste 1%
So, input of Unilap machine = 31,992 + (31992*18)100 = 37,750.56

∗ KTex .∗ / ∗
Production / Machine/ Day =
1000 Efficiency = 70%
= 8870 Kg Delivery Speed=110 m/min
Lap KTex =80

Number of Comber Machine Required = 37750 / 8870 = 4.26 5 Machine

Required Breaker Drawing:

Waste of Unilap Machine = 0.5%
So, Input of Breaker Machine = 37750 + (37750*0.5)100 = 37,938.75 Kg
∗ / ∗ Speed = 650 m/min
Production / Machine/ Day = X KTex Efficiency = 75%
1000 KTex =4.9

650 ∗ 60 ∗ 24 ∗ 0.75
= X 4.9 = 3439.8 Kg
1000

37938.75
No of required Drawing machine = = 11.03 ≈ 12 Machine
3439.8

33
Required Carding Machine:
Waste of Breaker machine = 1%
So, Input of Carding Machine = 37938.75 + (37938.75*1)/100 = 38,318.14 Kg

∗ KTex .∗ / ∗
Production / Machine/ Day =
1000
Speed = 165 m/min
165 ∗ 4.9 ∗ 24 ∗ 60 ∗ 0.9 Efficiency = 90%
KTex =4.9
=
1000
= 1047.816

38318.14
No of required carding machine = = 36.57 ≈ 37 Machine
1047.816

34
Consumable Spare Parts of Machineries & their life:

Ring and Roving Frame

Parts Name Brand Origin life time Remarks
Hokushin/Kureha Japan 2 to 2.5 years
Goldtex Taiwan 8 to 10 months
Top Apron
JKS Germany 1 to 1.5 years
Accotex Germany 1.5 to 2 years
For short apron life will be same as top apron same brand.
Bottom Apron
For long apron Life will be 6 month more than top apron same brand.
Breaker(Titan) CH 8 years
Ring cup R&F DE 5 to 6 years
Laksmi India 3 to 4 years
Snail wire - - 8 Years
Novibra Germany 13 to 17 years Auto doffing
Novibra Germany 10 to 14 years Manual doffing
Spindle
SKF Germany 13 to 17 years Auto doffing
SKF Germany 10 to 14 years Manual doffing
Roving KHK Japan 10 to 12 years
holder Autotex India 5 to 6 years
Rubber cot both
Goldtex Taiwan Minimum dia back & front Should
Rubber cot be same
27mm
manufacturer.
Accotex Germany
Compact
1 Year
Spare
Cleaning
4 Year
Roller
Spacer 4 Year
Comber/Unilap/Drawing
Circular
comb brush Reiter Germany 02 years
Circular
comb Graf Germany 1100 to 1200 ton
Top comb Graf Germany 900 to 1000 ton
Detaching
roller brush Reiter/ Alternative 2 years
Cot Roller Max dia 39mm &
for Unilap Min dia 36mm

Cot Roller Max dia 38mm &

for Drawing Min dia 36mm

35
 Carding
STxL Unit-1&2 Ring STxL Unit-2,3 Open end SYL Mélange SYL PC,CVC
line line line line
Cylinder, Flat tops, Front stationary will be GRAF wire
800 ton 1000 ton 800 ton 800 ton
Licker-in will be Bekert/Graf wire
400 to 450 ton 450 to 500 ton 400 to 450 ton 400 to 450 ton
Doffer will be Bekert/Graf wire
1600 to 2000
1500 to 1700 ton 1500 to 2000 ton 1500 to 1800 ton ton
Under licker-in segment, Back stationary will be Graf wire
400 to 450 ton 450 to 500 ton 400 to 450 ton 400 to 450 ton

Parts Name Life Time Machine Name

Mechanical splicer
1.5 years
spare Winding
Scissor 6 years
Piston 3 years T.F.O
Rotor 24000-30000 hrs/ 2.5 years
Opening roller 24000-30000 hrs/ 2.5 years
Adapter 2 years
Supporting Disk 24000-30000 hrs/ 1.5 years
Drive roller 24000-30000 hrs/ 2 years
Flexible coupling 2 years
Naval 30000-40000 hrs/ 3 years Rotor & Autocoro
Resilient mounting 5 years
Spec. washer 1.5 years
Torque stop 5 years
Roller 1.5 years
Damping cylinder 3 years
Toothed wheel 3 years

36
Conclusion:
Square entered into textile business in 1997 with a single unit. Since then it has been
expanding on a regular interval with modern technologies. Now, Square Spinning Complex
consists of four units equiped with modern machineries. Someother latest machineries are yet
to append to enhance its strength in yarn manufacturing.

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