Summer Training Report

VMT SPINNING COMPANY Ltd.

Baddi , Himachal Pradesh

(A Unit of Vardhman Textile Limited)

Training Period- 28 may to 23 July ,2018 Guided by – Mr. Vibhor Mangal

2018 ( Chief Manager)

Submitted to – H.O.D Submitted by- Manish Kumar Negi

JNGEC Sundernagar (Mandi) 10BTD5090018

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 **ACKNOWLEDGEMENT**

I would like to express my sincerest gratitude towards VARDHMAN Textiles Ltd. for
providing me the best facility & good working environment during my training period, at their
esteemed organization. I am grateful towards each and every employee of the VMT
SPINNING MILLS, Baddi (HP) for providing me their valuable time & experience.

It is indeed a great pleasure for me to express my profound and sincere thanks to Mr. VIBOR
MANGAL (Production head) for his co-operation. I would like to thank Mr MR. RAJESH
KUMAR (Astt. Executive Production) for giving their valuable time & attention during my
training. Their instructions proved to be quite beneficial during the training period.

I pay my special thanks to Mr.Beem Raj Singh (R&D Head), Mr. Gaurav
Sharma(Maintenance Head), Mr. Akshay Singh Dod, Mr. Abhisheak Mishra , mr. Sauvik
Karmakar & Vivek Loyal (Shift officers), for acting as my guide & mentor during the
training period. All of them shared their valuable time, co-operation, guidance and experience
with me & made my theoretical & practical learning even more enhanced.

MANISH KUMAR

TEXTILE ENGINEERING

B. TECH FINAL YEAR

J.N.G.E.C SUNDER NAGAR (H.P)

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 PREFACE

This report is the outcome of my endeavor in the industrial training program pursued by me at
the prestigious VMT SPINNING MILLS LIMITED, BADDI (H.P.).

The importance of practical training cannot be ignored in any field. After three years of study
at my institute (JAWAHRLAL NEHRU GOVT. ENGG. COLLAGE SUNDERNAGAR H.P.),
I sensed this importance and after training of 54 days at VMT SPINNING MILL BADDI
(VARDHMAN GROUP), I realized how many benefits practical training has in its store. I was
ushered into a totally new world with modern machineries around me. My practical knowledge
augmented during the training period and then I could realize the theories which I studied in
the period of three years. Exposure to real condition of the mill cleared many concepts and
doubts which got accrued in my mind.

I was instructed to join VMT SPINNING MILLS, BADDI (VARDHMAN GROUP), the
training starting from the 28nd May.

After the completion of my allotted tasks I left, with a magnificent learning experience, with
actually seeing a unit, such big in production, and also lots of memories of the place and the
people there.

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 INDEX

Sr. No. Topic Page no.

1. Vardhman history 4

6. Group unit 6-7

7. Vardhman mission 6

8. Business profile 6

9. About VMT Spinning unit 7

11. Mixing 8

12. Blowroom 12

13. Carding 18

14. Breaker D/F 27

15. Omega Lap 30

16. Comber 31

17. Finisher D/F 41

18. Roving 37

19. Ring Spinning 45

21. Winding 51

22. Packing 55

24. Humidification plant 57

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VARDHMAN HISTORY

Vardhman is a leading Indian conglomerate in the world of textiles having a turnover of around 2,000 Crs. It
started its operations in 1965 under the name of Vardhman Spinning And General Mills Ltd. at Ludhiana, since
then the group has expanded manifold and today is perhaps the largest spinning conglomerate in India.

Shri S. P. Oswal, a gold medalist in M.Com who is the Chairman and Managing Director of the group, heads
Vardhman group. Vardhman started in a humble way in 1965 with a spinning capacity at Ludhiana having an
installed capacity of 14,000 spindles. Today the spinning unit of the group is over 5, 00,000 spindles, the largest
in India. Vardhman has a Rs. 5,000 million structured expansion program that focus on forward & backward
integration to transform the group into a composite textile manufacturing company. Today, Vardhman products
have a strong presence in some of the most quality conscious markets of the world due to its TQM orientation,
state-of-the-art technology and technical tie – ups with specialists worldwide.

The group has 18 operation plants spread across Punjab, Himachal Pradesh, Madhya Pradesh and Gujarat having
a growth rate of about 15 % per year of the turnover over the few years. The group identified exports as a thrust
area and set foot in the international market in mid 1980’s. Since, then the group has attained global standards of
quality in terms of product and services. Vardhman today has become a global citizen with presence practically
in all continents, currently exports to more than 100 customers spread in more than 25 countries, with a share of
more than 6 % of the total exports of the country.

GROUP UNITS
• Vardhman Spinning and General Mills Ltd.
• Vardhman Spinning and General Mills Ltd. Ludhiana.
• Auro Spinning Mills Baddi H.P.
• Auro Dyeing Baddi H.P.
• Auro Weaving Mills Baddi H.P.
• Auro Textile Baddi H.P.
• .V.S.G.M. 100% E.O.U. Baddi H.P.
• V.S.G.M. Unit 2 Ludhiana
• .V.S.G.M. Unit 3 Ludhiana
• Mahavir Spinning Mills Ltd.
• Mahavir Spinning Mills Ltd. Hoshiarpur.
• Arihant Spinning Mills Malarkotla.
• Anant Spinning Mills
• Vardhman Special Steel Ludhiana Punjab.
• M.S.M.L. Sewing Threads Unit 2 Ludhiana Punjab.
• Arisht Spinning Mills Baddi H.P.
• Arisht Spinning Mills 100% E.O.U. Baddi H.P.
• Vardhman Polytex Ltd.
• Vardhman Polytex Ltd. Bhatinda, Punjab.

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 • Anshupati Textiles Ludhiana Punjab.
• V.M.T. Spinning Co. Ltd. Baddi H.P.
• Vardhman Acrylic Ltd. Bharuch (Gujarat).
• Vardhman Threads Ltd. Baddi H.P.

VARDHMAN MISSION

Vardhman aims to be world-class textile organization producing diverse range of products for the global textile
market. Vardhman seeks to achieve customer delight through excellence in manufacturing and customer service
based on creative combination of state-of-art technology and human resources. Vardhman is committed to be
responsible corporate citizen.
“Our quality is the result of state-of-the-art technology and in house R & D efforts. We continue to move towards
exploring new horizons.”
S.P. Oswal
(Chairman, Vardhman Group)
BUSINES

YARNS

Vardhman group is largest exporter of yarn from India. The total export of Cotton yarn of the group is about 6%
of total export of cotton yarn from the country. It has a wide range of specialized grey, dyed & a variety of blended
yarns in cotton, polyester, acrylic, Lycra, silk, wool & Tencel.

SEWING THREADS

Vardhman has Licensing agreement with American & Efird, Inc. USA for manufacturing & distribution of the
famous A&E branded sewing threads. Second largest brand of specialized threads in the country.

The product range includes:

- Apparel Sewing Threads

- Specialty Threads

- Textile Crafts

- Kite Flying

ACRYLIC FIBER

World class wet spun technology with highly automated, microprocessor controlled systems. Products are
marketed under the brand name VARLAN©. It is used in manufacturing of hand knitted yarns, blankets, jerseys,
sweater, saris, upholstery, carpets etc. The acrylic fiber contributes for 8.1 {Rs 228 crore} of total turnover.

STEEL

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Manufactures Special and Alloy Steel. Application of products in automotive components, forging, ball bearings,
engineering applications, railways, defense, medico surgical, Rolling Mills and more.

The group supplies its products to some of the most stringent quality steel buyers like Maruti and Telco.

Steel business constitutes 14.1{Rs. 376 crore} of the group turnover.

FABRIC

Vardhman is recognized as a quality 100% cotton greige and polyester cotton fabrics used for shirting, bottom
weight, sheeting and dress material.

The group has created a state of-the-art fabric weaving and processing facilities in its plants at Baddi (H.P) &
Budhni (M.P).

The group has over 800 looms and a fabric processing capacity of around 90 mm annually.

Fabric business comprise of 17% (45 crore) of total turnover.

About VMT Spinning mill-

GENERAL INFORMATION OF THE MILL

Name of mill: - VMT spinning co. ltd.

Year of establishment:- 1996

No of spindles (total):- 46320 (Hall 1-28320, Hall 2-18000)

Yarn count spun: - 30 Ne, 32 Ne, 40 Ne, 60 Ne, 80 Ne upto

120 Ne

Products: - 100 % carded cotton, 100 % combed cotton, blended yarn.

Avg. ring frame Utilization/day: - 97%

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MIXING-

Various type of Natural fibres & Man-Made fibres used in VMT-

Natural fibres-

FIBRE NAME STATION Weight (k.g)

1. S-6 organic Gujrat 165 kg
2. Shankar-6 Gujrat 165 kg
3. Shankar-6 GN Gujrat 165 kg
4. MCU-5 Odhisa 165 kg
5. J-34 Haryana & Punjab 165 kg
6. Mech-1 Maharashtra
7. Pima U.S.A 230 kg
8. GIJA Egypt 300 kg / 244 kg
9. GIJA 88 300 kg
10. GCH – 32 org & Normal Orrisa / Maharashtra 165 kg

Man-made/Regenerated Fibres

Fibre Name Station Weight

1. Modal 320-322 kg
2. Viscose 240 kg
3. Birla modal Gujrat 240 kg

Various Fibre properties-

Fibre Name fineness Length Uniformity Trash % Strength Maturity Rd +b

Ratio
S-6 gn 4.53 29.64 82 2.67 30.3 .87
DCH-32 org 3.6 35.16 36 71.4 9.5
MCU-5 4.36 31.2 84.01 2.32 30.5 .87 74-80 8-9.5
J-34 4.74 28.08 82.17 4.08 29.98 .88 72.6 7.6
Suvin 3.35 37.37 36.85 76.3 10.2
Mech-1 4.58 29.9 82.4 2.97 29.6 .87 70-80 7.5-9
Maharani 3.3 35.86 37 76.58 9.5
PIMA 4.08 38.32 87.47 4.98 48.21 .87 71-75 9.5-11.5
GIZA-86 4.09 35.4 85.98 3.36 45.8 .86 70-72 7.8-8.9
GIZA-92 4.23 32.87 46 70-75 8-8.5
S-6 org 4.39 30.04 81.54 2.98 30.26 .86

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 S-6 4.35 29.4 2.47 3.18 29.3 .86 72-80 7.5-9
DCH 4.1 35 38 74-80 8-9.5

Testing Instrument used- HVI (High Volume Instrument)

Mixing Department-

Objective-

➢ To get the yarn of different counts & tenacity according to requirements of the customer.
➢ To have a uniform distribution of different types of cotton
➢ To give required characteristics to the end product.
➢ To Compensate for variations in the characteristics of raw material.
➢ To hold down raw-material costs.

Mixing is decided by following factors-

1. Mic value
2. Rd
3. +b

Type of cotton to be used for process or what mixing is required for different types of fibre is dependent on
properties required in resultant yarn.

Mic Value- Weight of the fibre per inch is termed as MIC Value. The higher micronaire value the fibre regarded
as coarser.

MIC Fineness
Upto 3.1 Very fine
3.1 to 3.9 fine
4.0 to 4.9 medium
5.0 to 5.9 Slightly coarse
6.0 to above coarse
Conversion factor: dtex= Mi * 0.394 ( heavily dependent on degree of maturity)

Rd- Brightness represents as Rd value against degree of reflection.

b+ - it is a yellowness of fibre.

Bale Management & Lot Management-

In lot management 10% of bale sof lot are tested for samples and its average give idea of all bale sin a lot. It is
generally preferred for Indian cotton.

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Bale Management is a process of testing , Mixing, sorting bales according to characteristics of fibre for
producing desired quality of yarn at minimum range of cost. In this average is taken. It is done on imported
cottons

Objective-

➢ It is used to meet the functions & end use requirement.

➢ It has done to compensate the variation in properties of raw material.
➢ It is use to control & reduce fabric barre.
➢ It has done to provide desired properties properties of the end product.
➢ It has done to achieve uniform yarn quality.
➢ It has done to achieve required quality of yarn.
➢ It is used to decrease shade variation of finished fabric.

LAYING METHOD FOR COTTON (50/50) :

Total no. of bales laid -40

Total no. of waste bale - 4

No. of Bales length wise -11

No. of Bales width wise -4

Mixing – Mech-1 & S-6 (50:50)

MIC 4.40 MIC 4.40 MIC MIC 4.40 MIC 4.41 MIC MIC MIC MIC MIC MIC
4.73 4.16 4.64 4.16 4.41 4.64 4.73 4.22 4.72 4.25 4.40 4.72 4.41 4.57 4.41 4.64 4.40 4.64 4.41 4.64 4.40 4.72
4.14 4.14 4.25 4.23 4.23 4.14 4.16
Mech-1 S-6 Mech-1 S-6 Mech-1 S-6 Mech-1 S-6 Mech-1 S-6 Mech-1
S-6 Mech-1 S-6 Mech-1 S-6 Mech-1 S-6 org Mech-1 S-6 Mech-1 S-6
(waste) (waste)
Mech-1 S-6 S-6 org S-6 Mech-1 S-6 Mech-1 S-6 S-6 S-6 Mech-1
(waste) (waste)
S-6 Mech-1 S-6 Mech-1 S-6 Mech-1 S-6 Mech-1 S-6 Mech-1 S-6

Types of contaminations in fibre & its sorting-

The unnecessary things which get mixed with the fiber either at the time of harvesting the fiber from the field or
at the time of ginning operation.

Type of contamination MCU-5 + S-6 org (50:50) S-6 org warp

C.T 130 18
Hair 125 12
Poly (w) 145 25

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 Poly ( c ) 138 15
Plastic (w) 340 20
Plastic ( c ) 350 30
Jute 230 12
Cloth 45 10
Paper 36 8
Feather 16 4
Total Contaminations 1555 151

SORTING of Contaminations :

Sorting is the procedure in which the compressed bales are broken into small tufts which is done in the mill
manually. In this process the contaminations are sorted out of the fiber material Types of contaminations in shift
-

Composition of various mixing & how do we decide it-

Mic value , Rd value & b+ value are the composition of various mixing & it is decided on the basis of Strength
& Count of the fibre.

Waste addition on mixing & its harm if added more-

Waste used = 360-400 kg

Bale weight= 161kg

Total no. of bales used = 40

No. of waste used = 4

Waste % used= (total weight of waste / wt. of bale * no. of Bales )*100

= (360/161*40)*100 =5.6 %

Harm if add more waste-

➢ Effects on Quality
➢ Cohesiveness reduce
➢ Effects on yarn Strength
➢ Effects on dying

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BLOWROOM-

The basic purpose of Blow room is to supply

✓ small fiber tufts

✓ clean fiber tufts
✓ homogeneously blended tufts if more than one variety of fiber is used to-

carding machine without increasing fiber rupture, fiber neps, broken seed particles and without removing more
good fibers.

For adequate running of the blow room following conditions are maintained.

Objective of blowroom-

➢ Opening
➢ Cleaning
➢ Mixing/Blending
➢ Dust Removal

Cleaning efficiency of Blowroom Line-1-

Mixing Material- MCU-5 & S-6 Org

Cleaning Efficiency= (Trash in feed- Trash in delivery)/trash

Blow room Trash in infragment(gram)
feed *100 Trash in Lint (gram)
M/C feed(gram) Deliver(gram)
SP-MF 1.411 0.129 1.253 48.162

CL-P 1.253 0.11 0.805 48.223

CL-C1 0.806 0.094 0.723 49.036

Machine Cleaning Efficiency

SP-MF 11.1977 %
CL-P 35.75 %
CL-C3 10.3 %
Cleaning Efficiency of Blow room 57.2477 %

Mixing in VMT-

MCU-5 + S-6 org (50:50)

Mech-1 + S-6 (50:50)

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 Birla Viscose 100 %

Alovera Viscose 100 %

Modal 100 %
S-6 org Warp 100 %
.

Machine specifications-

Machine Name Manufacturer Model Year of Manufacture

Blendomat BO-A Trutzschler BDT
Multifunctional Trutzschler SP-MF 2006
Separator
Pre-Cleaner Trutzschler CL-P 2006
Multimixer Trutzschler MX-I 2006
Clenomat Trutzschler CL-C3 2006
Dust Separator Trutzschler DX-385 2006
Multimixer Trutzschler MP-M8 2013
Clenomat Trutzschler CL-C1 2013

Operation of m/c-

1.Blendomat- It plucks the bale which is laying for mixing about __mm depth and transfer it to another machine.

The laydown consisting of bales of cotton or synthetic fibres, is worked off from BO-A by means of rotating
take off roller as it moves over bales. The material pneumatically to downstream machine.

Technical Data-

Make Trutzschler
Model BO-A-2300
Machine Height 1.7 – 2.90 m
Machine width 5.16 m
Machine Length 23.13 – 50.27 m
Speed of the toothed disc rolls 2.5 rpm
Speed of supporting rolls 12-36 rpm
Working length 5.18 – 45.41 m/min
Working speed 5-15 m/min
Lifting speed 0.85-7 m/min
Power consumption 12.6 kw

Objective-

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 • Bale Opening
• Blending
• Transfer of material to next machine

Machine parts-

• Suction Duct system

• Truck
• Suction Duct Covering
• Turret
• Operator console

2.Metal Separator SP-MF: It separate the metals from the fibre (material separation). It is a compact foreign
parts separator. It combine all revelent protection functions, including initial dust removal. Integrated micro-
computer control system control al

Principle- Work on Gravity Sepration

Objective-

• Remove the heavy impurities

• Fire sensor
• Intensive extraction of dust
• Metal detector

Machine Details-

Make Trutzschler
Model 2006
No. of Machine 01
Pressure 250kpa- 300kpa
Cleaning time Weekly 2 time

3.CL-P :It is a pre-cleaner, it reduces the cotton tufts & remove the heavy impurities.

Principle- Aerodynamic gravity Sepration

Objectives-

• Remove heavy impurities

• Reduces the cotton tufts

Operation performed-

• Cleaning
• Opening

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Machine Details-

Make Trutzschler
Model 2006
No. of machine 01
Type of beater Pin beater
Beating point 1
Ist beater speed 643 rpm
2nd beater speed 667 rpm
Dia of beater 605mm
Setting of grids 0 to 4

Machine parts-

• Feed chute
• Beating cylinder
• Grid bars
• Delivery chute

4.Clenomat Cl-C3: it remove the lighter impurity. It gives best cleaning of trashy cotton at lower power
consumption.

OPERATION:-

From the feeding machine the material is carried on the feed lattice beneath the pressure roll to the two feed
rolls. The feed rolls draw in the material and transfers it to roll 1. The roll has two mote knives. A carding
segment is installed after the 1st mote knife.Waste is extracted directly from the mote knives i.e. continuous
suction stream removes all impurities produced at the extraction points. Once separated any dust and waste
cannot drift anymore throughout the waste chamber and be drawn in again, but is immediately carried off by the
suction hoods.

WASTE SUCTION:-The waste from the mote knives of roll 1 is directly and continuously extracted and
disposed of via the suction hoods. The waste and dust are immediately carried off via the collecting box.

Principle- Gripping the material & remove the lighter impurity by aerodynamic principle.

Objective-

• Remove the lighter impurity

• Reduces cotton tufts

Machine details-

Make Trutzschler
Model

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 No. of Beater 3
1st beater rpm 655 rpm
2nd beater rpm 1040 rpm
rd
3 beater rpm 1491 rpm
1st beater type Pin beater
nd rd
2 & 3 beater type Wire beater
Beating points
Pressure on material 126 pa
Pressure on waste 789 pa
Feed roll to Beater setting 3 mm
Feed roll to pin beater setting 1.5 mm
Pin beater to 2nd roll setting 2mm
nd rd
2 roll to 3 roll setting 3mm

➢ Outstanding economic viability.

➢ Gentle cleaning technology.
➢ Adjustable computer-controlled cleaning efficiency.
➢ Intensive dust removal due to constant suction.

5.MP-M8: It is used to achieve extremely good homogenous and consistent blend of material.Multimixer used
for homogeneous mixing of different origin cotton within a bale

Principle: - the material fed into the chambers which is separated layers by partitions. The displacement of
layers between the material entry and exit yields blend.

➢ 8 chambers
➢ Light barriers in all chambers for minimum filling level monitoring.
➢ Pressure sensing through sensitive pressure transducer.
➢ Modifies system of trunk filling offers excellent homogenous mixing.
➢ Pneumatic central locking & Electronic door safeguarding system.
➢ Automatic flap cleaning facility prevents clogging in distribution area.
➢ Machine with microprocessor control with display commander.
➢ Connection with TKN possible.
➢ DC drives for delivery roller.

Make
Model
Pressure 320 pa

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6.CL-C1:With its open needle roll that is gentle on the fibres, it design to clean all type of cotton including extra
long.

Machine details-

make Trutzschler
model 2013
No. of beater 1
Beater types Pin beaters
No. of Beater 6048 pins
Feed roll to beater setting 3 mm

7.DX-385:

Principle- Air dynamic

It is a dust separator machine.It removes microparticles.

It remove micro-dust particles at the end of cleaning line installation.It improves the efficiency of downstream
process & ensure longer life of clothing & spinning compact, increase economic efficiency.

Material Suction pressure 700 kpa

Material feeding pressure 450 kpa
Dust extraction pressure 200 kpa

8. MX-I:

It is a multimixer m/C

Its having 6 compartments

Perfect & homogenious blend is achived by this m/c.

It is equipped with pressure sensing features.

Make Trutzschler
Model 2006
Pressure 350 pa
Speed (opening roll) 870rpm & 875 rpm
Settings of blowroom machines-

CL-P:

Grid bar setting=0 to 4

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For viscouse=0

For other fibre=3

CL-C3:

Feed roller to pin beater1= 1.5mm

Pin beater to wire beater= 2mm

Wire beater2 to wire beater3= 3mm

CL-C1:

Feed roll to beater= 3mm

Total Beating Points in Line 1 & line 2:

Line 1 Line2
CL-P ½&½ CL-P ½&½
CL-C3 1 & ½ & ½ Cl-C1 1
Total=3 Total = 2

CARDING

Carding is the heart of the spinning industry

Carding is carried out by passing entangled fibres between closely spaced surfaces of cylinder and flats covered
with sharp metal metal teeth .The surfaces are moved relative to each other and so the fibres are disentangle.

Task of the card-

➢ Opening to individual fibres

➢ Elimination of impurities
➢ Elimination of dust
➢ Disentangling of Neps
➢ Elimination of short fibres
➢ Fibre-blending
➢ Fibre orientation
➢ Sliver formation

MACHINE USED FOR CARDING-

Machine number Manufacturer Year Aerofeed model

1 to 10 Trutzschler TC-03
11 & 12 Trutzschler TC-10

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Setting of Different parts of Carding machine-

Machine Parts Gauge (Thou)

1.Feed roll to lickerin 40
2.Lickerin 1 to Lickerin 2 7
3.Lickerin 2 to Lickerin 3 7
4.Lickerin 3 to Cylinder 8
5.Back Botto p;ate 40
6.SFL(Stationary flat lickerin side) 18/16/14
7.Button Suction hood back 40/18
8.Middle Suction hood back 40/18
9.Top suction hood back 50
10.Back to plate 18
11.Flat to Cylinder 7/7/7/7/7/7
12.Front top plate 40
13.Top Suction hood front 14
14.Middle Suction hood front 35/14
15.Front SFD(stationary flat doffer side) 12
16.Bottom Suction hood front 35/14
17.Front bottom plate 22
18.Doffer to Cylinder 8
19.Doffer to takeup roll 8
20.cross roll to cross roll 5

Card Cleaning-

Type of Cleaning Time after (hr) Cleaning parts

1.Pressure Cleaning 48 General/Pipes
2.Hand Cleaning 8 FBK
2 Cylinder roll stripper
3.Stick Cleaning 2 Feed Roll
4.Cloth Cleaning 8 Machine Cover

Pulley Diameter of TC-03

Parts Diameter
Lickerin 1 175 mm
Lickerin 2 112 mm

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 Lickerin 3 85 mm
Lickerin motor pully 135 mm
Cylinder motor pully 210 mm
Doffer 127 mm
Take-up 47 mm

Gearing Diagram of TC-03-

Motor Squeeze Roller

Squeeze Roller

Stripping roller

Doffer

Motor

cylinder

Motor Lickerin 3

Lickerin 2

Lickerin 1

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ge Feed Roll
Pulley Diameter of TC-10

Parts Diameter
Lickerin 1 150 mm
Lickerin 2 96 mm
Lickerin 3 73 mm
Lickerin motor pully 87 mm
Cylinder pully 110 mm
Doffer 127 mm
Take-up 47 mm

Motor rpm-

motor Tc-03 Tc-10

Feed roll 391/m 1138/m

Lickerin 1493/ 499/m

cylinder 1471/m 499/m

Doffer 352/m

Calender roll 922/m

coiler 788/m

Dfk 834/m

Card Production in VMT Unit-11

Production (kg/hr)= (Delivery Speed (m/min) * Ktex * 60 * efficiency)/1000

Delivery Speed=169m/m

Hank=0.13

Tex=509.2/hank

Tex=0.001ktex

Ktex=4.538

Production(kg/hr)= 44.9282 kg/hr

Production(kg/Shift)=44.9282*8=359.4 Kg/Shift

Total Card M/C production in VMT Unit 11- (kg/Shift)= 329.4*12=4312.8 kg/shift

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Draft in Card Machine-

Feed roll speed=4.3 rpm

Feed roll dia=112mm

Feed roll speed in mpm=112mm*4.3*0.001*3.142

=1.5mpm

Delivery Speed=165mpm

Mechanical Draft= Deliver Speed/Feed Speed

Draft=110

If the waste % is taken into account , the actual draft can be calculated

Waste % in card=5.785 %

Actual Draft= (Total Draft * 100)/100-waste%

Actual draft will always be more than mechanical draft upto drawing stage due to waste extraction.

Cleaning Efficiency of Card

Cleaning Efficiency= (Trash in feed- Trash in delivery)/trash in feed *100

Trash in feed= 0.778 g Trash in Sliver= 0.093 g

Fragment=0.35 g Fragment=.51 g
Lint weight= 48.829 g Lint Weight=49.347 g

Cleaning Efficiency of Card = 88.046 %

Cleaning Efficiency of Card+ Blowroom=93.14%

Card Speed change method -

Speed of diffrents parts of card m/c can be change by changing pulleys of motor. This is because the rpm is
directly depend product of motor rpm & Pulley length .

Rpm=(motor rpm*pulley length)/ machine pulley

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Autoleveler in Card-

Function-

Function of autoleveller is to correct the linear density(m/l) of delivered Sliver.

Objective-

To measure & monitor the variations in sliver thickness continuously &

To change the draft according to that more draft will be applied to thick place & less to thin, so that result
delivered will more regular.

1.CORRECTACARD (CCD) • This serves for a long term levelling and monitoring of the sliver count. It is
present in calender roll. Long term autoleveller system measures sliver mass through senser in card sliver
trumpet & control control speed of feed roller accordingly.

This is the most commonly used principle of card autolevelling & serves to hold the sliver hank constant.
Measuring is performed by the sensor in the delivery.

2.CORRECTAFEED (ICFD) • This serves for levelling of the sliver count (CVvalue). The levelling system
works already from a sliver length of 1 m.It is present in feed sliver. For short term variation, SANSOFEED
constantly scan the thickness of the thick web & requirement adjustment in feed roll is made through card
control system.

Any variation in the delivered sliver CCD send feedback to ICFD. If D% is +ve then thicking increases &
viceversa.

Advantage-

➢ Improve production & better productive effect.

➢ Even sliver appearance.
➢ Fewer end-breakage in subsequent process.
➢ Less wastage
➢ Lower count C.V % can be expected.

Grinding of Clothing-

Machine parts frequency

Cylinder 40 min
Flat 35 min
Doffer 35 min

Grinding of the flats-

W.S.G grinding machine is used to grind flats.

Grinding of Cylinder-

23 | P a g e
T.S.G grinding machine is used to grind cylinder.

Resharping- (maintenance)

Frequency
st
1 (ton) 2nd 3rd 4th
Cylinder 140 120 100 100
Doffer 140 120 100 100
Flat 120 100 80 80

Detentions-

1. Electrical – motor trip problem ,Rotary can plate alarm ,current overflow problem.

2.Maintenance-DFK jam, Opening roll jam ,C.V alarm ,web cut problem, Thick spots.

3.Production-Lot change, Accumulation.

Card Clothing-

Card Parts Clothing Specification PPSI

Cylinder P2030*0.4 996
Doffer N4030*0.9 354
Flat top SPACE
st
1 lickerin PIN BEATER
2nd lickerin VK 5020 G16-8 160-210
rd
3 lickerin VK 5020B16-8 160-210
SFL FD-24
FD-32
SFP FD 55
Carding action increases if no. of wire points per fibre increases.

Thus SFL & SFD use to increase production.

Calculation of points per square inch-

Parts RPM :

Parts Rpm (mpm)

Feed roll 4.3
Lickerin 1 1152
Lickerin 2 1800
Lickerin 3 2372

24 | P a g e
 Cylinder 508
Doffer 42
Stripper 240
Calender roll 835
Squeeze roll 512
Delivery Speed 165

Motor Rpm Data:

Motor Rpm (mpm)

M1 834
Feed roll motor 391
Lickerin motor 1493
Cylinder motor 1471
Doffer motor 352
Calender motor 922
Coiler motor 788

PROCESS PARAMETERS RUNNING-

Delivery Speed 163 mpm

Sliver hank 0.113 Ne
Production 44.95 kg /hour
Chute pressure 197 pa.
Feed roller speed 4.3 rpm
Card draft 100-110
Cylinder speed 507 m/m
Flat speed 319 mm/min
Licker in speed 1149rpm
Cylinder Diameter 1295 mm or 51 inch
Licker-in Dia 170 mm
Doffer Dia 685.8 mm or 27 inch
No. Of flats 84
No. of working flats 36
Length of Sliver in can 1100 m

waste percentage in carding machine:Mixing: MCU-5 & S-6 org (50:50)

Waste point Waste in k.g Waste (%)

25 | P a g e
 1) Flat 0.434 2.04
2) L-in 1st & 2nd 0.284 1.37
3) L-in 3rd 0.024 0.11
4) BSH (top) 0.073 0.34
5) BSH (mid) 0.078 0.37
6) BSH (bottom) 0.038 0.18
7) FSH (top) 0.079 0.37
8) FSH (mid) 0.131 0.62
9) FSH (bottom) 0.085 0.40
Total 1.226 5.78
Waste percentage in carding m/c = 5.78 %

Carding waste- 4-5 %for foreign cotton

5-6 % for Indian cotton

26 | P a g e
Breaker Drawframe-

Although the fibres are separated up to individual state but they are in random disorganized manner in the card
sliver . Draw frame straightens and align the fibre along the axis of the sliver in order to have strong and even
spinning.

OBJECTIVES OF PRE-COMBING PROCESSES :-

➢ To give an even feed to the comber.

➢ To orient the fibres so that only the short fibres are removed in noil.
➢ To present the material in a direction that majority of hooks are presented as leading hooks.

STOP MOTIONS AND SAFETY POINTS

A. To stop the machine automatically when breakage in sliver with the help of creel stop motion
B. To stop the machine when the can will be full.
C. Drafting stop motion.

Roller inter changing:

Morning Shift Evening Shift Night Shift

Red, Green, Yellow, Blue 8 am 4 pm 12 am
Blue, Red, Green, Yellow 9 am 5 pm 1 am
Yellow, Blue, Red, Green 10 am 6 pm 2 am
Green, Yellow ,Blue, Red 11 am 7 pm 3 am
Red, Green, Yellow, Blue 12 am 8 pm 4 am
Blue, Red, Green, Yellow 1 pm 9 pm 5 am
Yellow, Blue, Red, Green 2 pm 10 pm 6 am
Green, yellow, Blue, Red 3 pm 11 pm 7 am

Suction system for drafting zone:

A. At Top and bottom of drafting zone.

B. At the end of sliver funnel .
C. At calendar rolls The integrated suction system ensures effective cleaning and removal of dust from
drafting zone.

27 | P a g e
Gearing Diagram-

PROCESS PARAMETER RUNNING-

SBD-2

Manufacturer Rieter
Model SB D-22
Year 2016
Sliver Hank 0.110s
Speed 856m/min
Drafting system 3/4
Material feed Card Sliver
Material delivery 6-8
Delivery Double

28 | P a g e
 Autolevler no
Draft 5
Production kg/hr 183.6 kg/hr
No. of doubling 6

SB-D22

Manufacturer Rieter
Model SB D-22
Year 2015
Sliver Hank 0.110s
Speed 856m/min
Drafting system 3/4
Material feed Card Sliver
Material delivery 6-8
Delivery Double
Autolevler no
Draft 5
Production kg/hr 183.6 kg/hr
No. of doubling 6

MAINTANENCE SHEDULE

1.Machine full cleaning 15 days

2.Cots buffing 1 month
3.Can plate opening 20day
4.Creel cover opening 20 days
5.Basic setting all gauge 3 month
6.Bottom roll twinge 3 month
7.Gear box oil change 6 month
8 .Coiler over having 1 year

29 | P a g e
OMEGALAP-

FUNCTIONS:

➢ The drawing sliver is conveyed to drafted systems via sliver feed units.
➢ Drawframe slivers are drafted in drafting system to produces fleeces.
➢ These are then drawn into lap head by calendar rolls which compares it strongly to form a lap sheet.
➢ This is then wound onto a tube by lap rolls and lap roller flanges. When the tube is full, it is
automatically ex- changed for an empty one.

Process parameter Running-

Make Rieter
model E-36
year 2017
No. of machine 1
No. of creel 24
Can use white
Spool color Black
Hole in spool 90
Pressure 3.7 bar
efficiency 76.5%
Delivery speed 201 m/min
Delivery 76 g/mtr
Draft 1.7
Production 696.12 kg/hr

Doff meter- how much length doff break

Calculation of draft:

For draft calculation we should know weight per unit length of lap produced. For this we do following
procedure .

1. Take a 1 meter length wooden board which is in shape of cross.

2. Take lap roll and place lap on ground.
3. Take 3 samples of 1 meter each and weight is calculated.

1st sample weight = 75.8 gram

2nd sample weight = 75.6 gram

3rd sample weight = 75.9 gram

Mean = 76 gram per meter= 0.0077 Ne

30 | P a g e
Feed sliver = 0.112 Ne

Number of doublings = 24

Draft = delivery (Ne) / feed (Ne) * 24

Manufacturer Rieter
Model E65
Year of manufacturing 2006
Total machines 07
0.0078 * 24 / 0.112 = 1.671

Lap licking: Due to lap licking, laps become difficult to unravel and stick between layers. If it occurs then draft
is reduced.

Reason-

➢ High or low air pressure

➢ No cleanliness
➢ Calendar roll jam
➢ Worker negligence

Maintenance cleaning schedule of UNILAP E -36:

Maintenance lap ejector opening cleaning - 15 days

Gear box oil change – 6 months

Bearing of tension pulley greases – 1 month

COMBER-Combing process removes predetermined level of short fibres from the group of cotton fibres.

The short fibres, shorter than 12mm do not contribute to the strength of the yarn,but in turn they increases the
hairiness of the yarn & adversely affect the appearance & other good properties of the yarns & the fabrics made
out of them.In combing operation , fibres shorter than length of fibres or certain fixed percentage of short fibre
are removed.Since the shorter cotton fibres are generally coarser, removing the shorter fibres leaves behind fibre
which are relatively finer.

Operation in combing process-

➢ Elimination of a precisely predetermined quantity of short fibres.

➢ Elimination of remaining impurities.
➢ Elimination of neps in the fibre material.
➢ Formation of sliver having maximum possible fibre parallization.

Factors affecting combing performance-

Properties of cotton:

31 | P a g e
 ➢ Fibre length & its uniformity
➢ Fibre Stiffness
➢ Moisture content
➢ Fibre fineness
➢ Foreign matter associated with the fibre

Material preparation-

➢ Fibre parallelization
➢ Sheet thickness
➢ Sheet evenness
➢ Orientation of hooks

Factor associated with the machine-

➢ Condition of combs
➢ Speeds
➢ Operation of combs
➢ Type of sliver forming elements
➢ Drafting arrangement
➢ Settings

Influence of machine components & settings on combing

➢ The feed amount per cycle

➢ Type of feed
➢ The Detachment Setting
➢ No. of points on the combs
➢ The depth of penetration of the top comb
➢ Piecing
➢ Ambient Conditions

Running Process parameters:

Mixing S-6 + MCU-5

Sliver Hank 0.12s
Roll Gauge 42/48
Nips/min 450
Feed/nips 5.20 mm
Gram per mtr 76
Noil Index 8.0
Top comb +0.5
Spool white
Production 516 kg/shift

32 | P a g e
 No. of ratchet wheel 18
Nipper assembly material Aluminum alloy
No. of heads 08
Noil % 15.635
efficiency 90 %
Can filling length 5700 mm
Total lap length 290 mm
Dia of full lap 580 mm
Sliver wt. 4.920 ktex
Feed batt tension 10 %
Feed distance moved per cycle 4.7 mm

Production=feed/nips * nips/min *lap wt. * no. of head * (1-Waste %) * 60

Comber Draft= 0.245* *8 *Seff. * g * (100-a) (100-P)/ b
Where S=feed amount/cycle

g= batt wt.

a=batt tension

p= noil %

Influence of m/c components & settings on combing performance

1.Type of feed-

1.Forward feed

2.Backward feed

Forward feed – It implies that feeding of the sheet into the nippers occurs while the nippers are moved toward
the detaching rollers.

Backward feed – It implies that feeding of the sheet occurs during return of the nippers. The triangular areas
represent stylized staple diagrams.NOIL PERCENTAGE – Noil extraction in comber For noil extraction place
a sheet to block noil travel in suction pipe Keep running machine at for 10 second Noil will collect at sheet
Note down noil weight for these 10 seconds production is noted at delivery.

The short fibres removed in the combing process is called as ‘noils’.

Weight of sliver=183.89 g

Wt. of noil =39.47 g

Weight of sliver + wt. of noil = 223.36

33 | P a g e
Noil % = noil * 100/ ( wt. of sliver + wt. of noil)

Noil%= 17.67%

Noil index: A scale with 40 graduations is attached to circular comb shaft. This scale is called an index. With
the help of index, the machine can be positioned at particular time in combing cycle. For example, index 24 is
front reversing point of combing nippers. For most setting jobs , the machine has to be positioned at certain
index. This is only way of performing the setting.

The machine stops at index 24.

Top comb: The extraction of husks and neps is affected by the penetration depth. Position of eccentric: +
1 + 0.5 0 -0.5 -0.75 If the detaching distance is smaller than the 7.5 and penetration
amount of depth of top comb to + 1, then machine will be in danger of collision. Either increase detaching
distance to 7.5 or reduce penetration depth to 0.5. The sliver is compressed again before deposited in can.

Method of operation: The sliver is compressed with calendar rolls and the delivery funnel. The fixed calendar
disc roll is driven by the conveyor belt. The spring calendar disk roll is idle. The calendar disc roll draw the
sliver through the funnel and compress it so that it holds together better in subsequent processing.

Trumpet coiler dia ranges from 6.0 mm , 4.0 , 4.4 , 4.8 mm

Table trumpet: 5.5, 5.75, 5.0, 5. 25, 4.5, 4.75, 6.5, 6.75, 6.0, 6.25

Gauge setting:

Nipper to Detaching roll 6.25 mm

Top comb 0.5 mm
Brush & Cykinder 12 mm
Nipper & feed plate 2.2 – 2.4 mm
Unicomb & nipper 0.3 -0.5 mm
Front to middle roll distance 42 mm
Middle to Back roll distance 48 mm
Nipper to Detaching roll 6.25 mm
Comber cleaning:

Production cleaning

➢ Top comb cleanliness -every batch

➢ Top roll cleanliness with water -in a shift
➢ Nipper clean with gun - 1 in a shift

Maintenance cleaning-

➢ Gauges are checked once in a year

➢ Proper cleaning of machine parts and greasing , oiling is done after 15 days .
➢ Brush cleaning is done or changed after 6 months

34 | P a g e
Stop motion:

➢ Feed roll jam

➢ Opening of any door cover
➢ Lap spool changing
➢ Can changing
➢ Opening of front glass cover
➢ Breaking of sliver in package
➢ Vacuum fault due to jam in noil drum
➢ Jam in detaching roller and thus end to end piecing is done

FINISHER DRAWFRAME-

RSB draw frame is known as the finisher draw frame . It gives finishing to th combed sliver .It prepare material
for the simplex process . It gives doubling and parallelization to the sliver.

OBJECTIVES OF FINISHER DRAW FRAME-

➢ It gives the parallelisation to the material .

➢ drafts the material.
➢ It gives doubling to the material
➢ To blend /if required
➢ To level

STOP MOTIONS AND SAFETY POINTS

1. To stop the machine automatically when breakage in sliver occurs.

2. Stop the machine when the ca is full.

MACHINE USED-

Machine Model Make year No. of Machine

RSB-D 22 Rieter 2013 1
RSB-D 24 C Rieter 2015 1
RSB-D 40 Rieter 2006 2
LD/6 Rieter - 1

Machine no. 1-RSB-D 22

Hank 0.120s
Saddle Gauge 44/46
Roll gauge 38/42
Draft/Break Draft 8/1.30

35 | P a g e
 Trumpet 3.80mm
Scanning Roll 6.9/7.2/7.0
Speed 472 m/min
Efficiency 66.6%
C.V % 1.70
A% -0.6
Can color Red , Green, White
Production 92.4 kg/hr
No. of Delivery 2

Machine no. 2- RSB-D 40

Hank 0.120s
Saddle Gauge 44/46
Roll gauge 18/42
Draft/Break Draft 8/1.30
Trumpet 3.80mm
Scanning Roll 6.9/7.2/7.0
Speed 363 m/min
Efficiency 68.1%
C.V % 1.57
A% 1.1
No. of Doubling 08
Can color Red , Green, White
Production 72.86 kg/hr
No. of Delivery 1

Machine no. 3 -RSB-D 40

Gearing Diagram-

Hank 0.120s
Saddle Gauge 44/46
Roll gauge 38/42
Draft/Break Draft 8/1.30
Trumpet 3.80mm
Scanning Roll 6.9/7.2/7.0
Speed 423 m/min

36 | P a g e
 Efficiency 72.4%
C.V % 1.98
A% 1.3
No. of Doubling 08
Can color White
Production 94.9 kg/hr
No. of Delivery 1

Machine no. 4- RSB-D 24 C

4-A

Hank delivered 0.100s

Hank feed 0.12
Saddle Gauge 44/46
Roll gauge 38/42
Draft/Break Draft 7.2/1.30
Trumpet 4.20 mm
Scanning Roll 8.9/9.2/9.0
Speed 349 m/min
Efficiency 71.2 %
C.V % 2.31
A% 0.1
No. of Doubling 06
Can color Red , Green, White
Production 98.8 kg/hr
No. of Delivery 2

In VMT unit 4B is used as Breaker Drawframe.-4-B

Hank delivered 0.110s

Hank feed 0.13
Saddle Gauge 44/46
Roll gauge 38/48
Draft/Break Draft 5.07/1.70
Trumpet 4.20 mm
Scanning Roll 6.9/7.2/7.0
Speed 371 m/min
Efficiency 71.2 %

37 | P a g e
 C.V % 2.17
A% -0.8
No. of Doubling 08
Can color Red , pink band
Production 85 kg/hr
No. of Delivery 1

Machine no. 5 LD/6

No. of Delivery 2
Creel 8
Scanning roll no

Machine no. 6 SBD 22

Mixing Lenzing Viscose + Cotton (30/70)

Hank 0.120s
Saddle Gauge 44/46
Roll gauge 42/52
Draft/Break Draft 5.65/1.70
Trumpet 1.70 mm
Scanning Roll 8.9/9.2/9.0
Speed 349 m/min
Efficiency 71.2 %
C.V % 2.31
A% 0.1
No. of Doubling 06
Can color Red , Green, White
Production 98.8 kg/hr
No. of Delivery 2

Function of break draft: The break draft prepares the slivers feed for flawless main draft. It influences yarn
quality , mainly thick and thin places.

Function of main draft: To control the fibre means : holding the amount of fibes without control (floating fibres)
To control fibres and avoid any fibre damage by roll settings too closed.

Break draft roll setting: Setting depends on:

38 | P a g e
 ➢ Maximum and average staple length.
➢ Degree of fibre parallelization.
➢ Draft resistance.

Suction system for drafting zone:

➢ Top and bottom of drafting system

➢ End of sliver tube
➢ Sliver funnel
➢ Calendar rolls

Pressure drafting setting:

Depth of pressure bar = 3mm Pressure bar deflects the material in main drafting zone. The depth of pressure bar
expresses the deflection in mm. Flat spring mounted on weighing arms apply pressure to pressure bar. Top
rollers are pressure loaded against the bottom roller to ensure transport of fibres. The pressure load is
transmitted to fibre material in vertical and horizontal direction. The load compresses the fibre material and
creates fibre to fib re friction for fibe control. This system enhances the uniformity of drafting process.Gearing
Diagram

Delivery speed: Delivery speed depends on material used , its type , its melting point , static charge of fibre

39 | P a g e
Type

Combed cotton: 300 – 500 m/min

Combed cotton / synthetic blend: 350 – 500 m/min

Cotton carded: 400 – 500 m/min

Synthetic: 300 – 500 m/min

Trumpet: Distance of trumpet to front top roller is 1 mm. Condenser roll- used for bulky and coarse material
Diameter is 55 mm. It ensures a continuous forwarding An intensive compression of sliver.
Most demanded blends from customer are:

➢ 40/60
➢ 52/48
➢ 30/70
➢ 45/55
➢ 33/67
➢ 65/35
➢ 20/80

Auto leveler:

A drawframe can be fitted with an autoleveller to control short & medium term variation.

Principle- Open loop , Closed loop & combined loop

The thickness of the entering sliver is continuously monitored at the m/c entrance, by a pair of sensing rollers.
One of the two rollers is movable & get deflected to a varying extent depending upon the variation in sliver
thickness. These movements converted into electrical signal is stored into a memory. After suitable delay, the
signal is sent for comparison with reference value already set & depending upon the nature.(i.e positive &
negative). & extent of deviation , a draft change is initiated in the main draft field by altering the speed of
middle roller via a planetary gear train connected to a servo motor. The speed of feed roller & sensing rollers are
also changed proportionately so that draft or tension in break draft zone & between sensing & feed roller do not
get changed. The system thus ensures constant delivery speed. The autoleveller therefore works mainly on the
principle on ‘ Open loop’ & ‘close loop ‘system.

40 | P a g e
Levelling Intensity- indicates amount of correction to be done & it decides amount of draft change required to
correct feed variation.

Levelling action point-corrective correction should be done on corresponding defective place. Time required for
defective material to reach correction point should be known.It depends in Break Draft ,Main Draft setting &
delivery speed.

Roller inter changing:

After 2 hours roller interchanging take place.

Morning Shift Evening Shift Night Shift

Red, Green, Yellow, Blue 8 am 4 pm 12 am
Blue, Red, Green, Yellow 10 am 6 pm 2 am
Yellow, Blue, Red, Green 12 pm 8 pm 4 am
Green, Yellow ,Blue, Red 2 pm 10 pm 6 am

ROVING FRAME-

Objectives:-

➢ Attenuation of sliver
➢ Protective twist insertion
➢ Winding roving on suitable package
➢ Conversion of sliver to roving

Total number of roving frames machines – 5

STOP MOTIONS AND SAFETY POINTS OF THE SIMPLEX FRAME

To stop the machines automatically with the help of photocell when sliver breakage occurs.

41 | P a g e
Parameters of speed frame:

➢ Loading = pneumatic
➢ Weight of empty bobbin=0.300 kg
➢ Wt. of full bobbin=2.380 kg
➢ Wt. of roving in bobbin=2.080 kg
➢ No. og grooves in Twist Master=18
➢ Fluted middle roller dia=27 mm
➢ Front roll dia=30mm
➢ Back roll dia=30 mm
➢ Spindle wharve dia=18.5 mm
➢ Break Draft Standard=1.19
➢ For viscose B.Draft=1.28
➢ Maintainance time- after 1 month

PROCESS PARAMETERS-

Machine 1- Mixing : Mech-1 & S-6

Make Zinser
Type FL-681
Model 2006
Roving Hank .80s
Roll gauge 50/60
Saddle gauge 55/58
Spacer/B.draft 6.4/1.19
TPI / Tm 1.21/1.35
Floated condenser 15mm
Bobbin
Can White + Black Band , Green + yellow band
Draft System 3/3
No. of Spindles 120
Lift 400
Voltage/Frequency 415/50
Air pressure maximum 7-10 bar

Machine 2 & 3- Mixing : Mech-1 & S-6

Make Zinser
Roving Hank .80s

42 | P a g e
 Roll gauge 50/60
Saddle gauge 55/58
Spacer/B.draft 6.4/1.19
TPI / Tm 1.21/1.35
Floated condenser 15mm
Bobbin
Can Red & Green + yellow Band,White + Black band
Flyer Speed 1100 rpm
Delivery Speed 23.09 m/min

Machine 4- Mixing -Viscose 100%

If proportion of Viscose of synthetic fibres is more, then low value of TM is required. It is because length of
synthetic fibres is higher and thus require low twist.

Make Zinser
Roving Hank 0.80s
Roll gauge 50/60
Saddle gauge 55/58
Spacer/B.draft 6.4/1.29
TPI / Tm .90/1.9
Floated condenser 17mm
Bobbin pink
Can yellow
Flyer Speed 1188 m/min
Delivery Speed 23.84 m/min
Nw/D15 39/162
Nv/Wv 40/28

Machine 5- Mixing : Mech-1 & S-6

Make Zinser
Type FL-681
Model 2007
Sliver Hank 0.12
Roving Hank .80s
Roll gauge 50/60
Saddle gauge 55/58
Spacer/B.draft 6.4/1.19

43 | P a g e
 TPI / Tm 1.21/1.35
Floated condenser 15mm
Bobbin
Can White + Black Band
Draft System 3/3
No. of Spindles 120

Cleaning Instructions-

Front pair 8hr operator gun

Back pair 8hr operator gun
Roll Stand 8hr operator gun
Bottom apron 48hr operator stick
creel At batch operator cloth
Back side 8hr operator gun
rail 8hr operator cloth
Below creel floor - operator
Fan cleaning 8hr operator Hand

MAN POWER DEVELOPMENT:

Total no. of worker-4

Operator=3

Bobbin-1

Doffing Method – Manual

Coats Specicication-

M/C Name Size Max./Min. Hard Degree Frequency Cut Life in days
Zinser All top cots 19*30*39 30/29 83 90 0.2 450

44 | P a g e
Gearing Diagram-

Draft = 4.848 * D15/NW

Draft Constant= 4.848

RING FRAME- B.Draft= 0.831 * N.V/W.V

Ring spinning is the last state of conversion of fibre to yarn completely. Ring frame is the last machine in the
B.Draft Constant= 0.831
spinning section .

RINGFRAME-

OBJECTIVES OF RING FRAME

-to make good quality yarn from roving with the help of drafting arrangement , twisting and winding.

Total no. of machines- 15 , LR6/A -14 & LR9/AX -1

Total no. of Compact Spinning-3 m/c no. – 13,14,15

Apron:

Machine no. top Bottom

1 to 12 41.5*28*1.05 73*30*1.05
13 to 15 38.1*30*1.05 73*30*1.05

45 | P a g e
Spindle Tape:

Machine no. Tape Size

1 to 12 2371*11H55
13 to 15 2371*11 W-8 finger

Lubrication:

Machine no. Place Lubricant Frequency

1-15 Spindle oil Servospin EE-10 10 months
2-15 Oil tank gear oil Servomesh 220 2 months
2-15 Gear box oil Servosystem 100 2 months
2-15 Damping Cylinder Servosystem 100 2 months
1-15 Bearing Mobilus EP-2 2 months
1-15 Micro fog. Servospin EE-10 2 months

Running R-tr:

M/C no. Company

1 R*F 7/0
2 ONYX C1 Ul udr 6/0
3 ONYX 6/0
4 ONYX 6/0
5 ONYX 6/0
6 ONYX 6/0
7 ONYX 6/0
8 ONYX 6/0
9 ONYX 6/0
10 ONYX 6/0
11 ONYX 6/0
12 ONYX 6/0
13 C1 MM udh 5/0
14 C1 EL udr 6/0
15 C1 EL udr 6/0

46 | P a g e
Gearing Diagram:

Total Draft=10.52* H/G

Draft Constant=10.52

B.Draft=67.05/ BDCP
47 | P a g e Break Draft Constant=67.05
 TPI=28.14 *(B*D/A*C)
Twist constant= 28.14

Winding Length= 3.19 *(F gear/ E gear)

Tm= TPcm *(Tex)1/2

Tm(ne)= TPI / (ne)1/2
Tm (metric) = TPM / (Nm)1/2

Twist Contraction=(yarn count at front roller- yarn count at bobbin) *100

yarn count at front roller

Production-
Kg/shift/machine= D.S (m/min) *60*8*efficiency* no of spindles
Count * 840 * 2.205 * 0.91

48 | P a g e
 Running M/c Details- mixing- Mech 1 + s-6 & viscose 100%

m/c TPM/TM Count Roving CP/BRW/ A/B C/D E/F RW Spacer/

no. Hank BDCP B.Draft

1. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

2. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

3. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

4. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

5. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

6. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

7. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

8. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

9. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

10. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

11. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

12. 828/3.72 32 CH .80s 27/110/59 78/87 82/55 50/63 24/2P 4.0/1.14

13. 690/3.20 30s 1.0s 33/04/62 85/80 82/55 50/63 24/2P 3.50 m/
kwc 3.51 1.08

14. 984/4.43 32 kwc .80s 27/112/54 83/82 72/65 50/03 24/2P 3.75/
1.24

15. 984/4.43 32 kwc .80s 27/112/54 83/82 72/65 50/03 24/2P 3.75/
1.24

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MACHINES USED IN RING SPINNING :

No of machines 15

Make Lakshmi

Model LR 6/A & LR 9/AX

Spindle capacity 1200

Total spindle capacity in ring frame 18000

EFFICIENCY LOSSES:

➢ Doffing losses
➢ Pneumafil waste
➢ Twist contraction
➢ Idle bars

Traveler ISO no. = weight in grams of 1000 travelers

UDR – ultra demi round

Types of travelers:

LRT –domestic use – Lakshmi – coimbatore ( UIMLUDR )

R & F – Germany - ( ELIHDEM )

FINISHES IN TRAVELLER ;

o Hitech ( silver , without colour – mostly used in INDIA )

o Saffire

o Ruby

o Pyrite

Yarn broken frequently on spindle because of :

➢ Cots damage
➢ Eccentric ring
➢ Apron broken
➢ Wrong traveller

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ULTIMO- Data of Shift

Count 32.54
kg 3054.08
gpss 173.33
tpi 21.2
Lb/100sh 3.87
Seb/a/100s 2.83
Min/doff 2.5
Stop min 173.7
Pneu waste 0.99
% idle loss 0.35
Rogue % 0.24
Slip Spindle 0.20
AEF % 94.6
Idle spindle – if yarn is broken in spindle and not knotted within 30 minutes then this spindle is idle spindle.

Rogue spindle- end breakage rate is very high for that spindle.

Slip Spindle- A spindle will be recorded as slip spindle if its traveller speed observed less then limit set 13-51 %
for more then the no. of time set.

Winding-

Objectives of winding-

➢ To remove yarn faults.

➢ To improve the quality of yarn.
➢ To wax the yarn during winding process.
➢ To make bigger package from ring bobbin in order to get continuous length of yarn on cones for
weaving/Knitting processes.

Manpower in winding-Total worker- 16

Operator 9
Bobbin cleaner 2
Doff carrier 1
Reliver 1
Material checking 2
Floor Cleaner 1

Parts of Autoconer-

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Bobbin Holder: It is a disk type wheel. Its functions is to hold the filled bobbins for unwinding process.

Bobbin plate: The function of plate is to rotate the bobbins one by one.

Bobbin Magazine: This is the main component of the Autoconer machine. Its function is to hold the cops for
winding. Its capacity lies up to 9 cops.

Yarn tensioner & waxing unit: Yarn tensioner provides sufficient tension to the yarn during unwinding from
cop to winding on to cones. Wax motor runs wax bush/roll continuously. Waxing makes the surface of the yarn
smooth by sticking hairy fibres. Waxing is applied especially to the yarn intended for knitting.

Yarn splicer: Mach Splicer – It overlaps the yarn ends from package & bobbin sides , twist them together
using compressed air, & splices them together without a knot.

Perfect spliced joints are one of the most important quality features of Autoconer packages. These are
guaranteed by the unique, flexible and easy-to-operate splicing technology, based on the successful pneumatic
splicing principle. The splicing mechanism performs the knot free joining of the two yarn ends after yarn
breakage.

Retie pipe: It take the yarn end from bobbin toward splicing mechanism.

Yarn Cleaner:(Uster Quantum 3) Its function is to remove the faults such as thin and thick places, neps,
hairiness according to the set value.

Yarn faults-

YF Yarn fault
YJ Yarn jam
YB Yarn Breakage
N Neps
S Slubs
L Long Thick Place
T Thin place
Cp Count plus
Cm Count minus
CCp Continuous Count plus
CCm Continuous Count minus
Pf Periodic fault
Jp Joint Splice plus
Jm Joint splice minus
FD Foreign Matter
PP Poly propylene

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Cradle: Its function is to provide setting to cone having package holders. It lies on upper part of machine on
drum.

Winding drum: It is a metallic drum and its surface is polished .It has cut marks or grooves cut in to it at its
surface to help the cross winding of packages.

Waste suction pipe: During yarn cutting and splicing it sucks the waste yarn.

Suction mouth: When ever yarn breaks during winding the package move in opposite direction with slow speed
during that time it sucks the broken yarn end from the package and take it for splicing.

Display Panel: It displays various operating machine parameters like speed, production, Count of yarn etc.
Understand the details in the display panel and work accordingly

MACHINE SPECIFICATIONS :

Drum- pac 21 ( 2.0 w & 2.5 w possible (6-inch traverse) )

No. of drums on the machine 60

No. of Machine 7
No. of bobbins on one creel

Drum speed 1500 m/min

Splicing Mach type

Tensioner Perla – A type
Magazine capacity 9

Yarn clearer Uster Quantum 3

Drum dia. 100 mm

Drum length 172 mm

Traverse length 108 mm (4 inch)

152mm (6 inch)
Winding Angle 4” 20’
Package Conveyer max. load 180 kg
Wax type Jama / Janta
Hairiness reducing device Perla A- Hairiness reducing nozzle type
Perla D- Friction nozzle type
Package weight ( for cotton) 2.55 kg

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 (for viscose) 1.60 kg
Winding speed 471 m/min

Different winding parameters for different count :

Yarn count & type 30 CH 32 CH 20 CH

Yarn Speed 1500 m/min 1500 m/min 1400 m/min
Package wt. 2549 g 2574 g 2176 g
Package length 129500 m 139500 m 73700 m
Bobbin Yarn length 2540 m 2710 m 1693 m
Bobbin yarn Wt. 50 g 50 g 50 g
Bobbin length 200 mm 200 mm 200 mm
Yarn strength 350 cN 330 cN 450 cN

Housekeeping & Cleaning Schedule:

M/C cleaning After 7.5 hr With air pressure & cloth

Blower After 7.5 hr With air pressure & cloth
Blower suction After 1 hr Cleaner by floor cleaner
Hard waste After 4 hr Clean by worker
Package belt After 2 hr Clean with cloth by reliver
Bobbin conveyer belt brush After 4 hr Clean by feater

Material Handling system:

Count Mix (50:50) Bobbin Cone Tip Wax

32 CH Mech-1 & S-6 Pastel green , Mehandi , green Black Star Janta
30 Kwc 100 % Birla viscose Jamuni, Blue Black Zebra none
34 CH Mech-1 & S-6 Pista , Chocolaty Green Star Janta
30 CH Mech-1 & S-6 grey Yellow Star Janta

ULTRA VOILET CHECKING:In this we check the packages in ultraviolet light.We check that if there any
mixture of material in package and we reject it.Each cone undergoes through UV check for shade variation and
other defects.

CONDITIONING:

➢ Conditioning is done to allow to gain water.

➢ It is done to make packages to work in smooth conditions in subsequent processes
➢ It is done to cover invisible loss.

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 ➢ It improves yarn quality.
➢ Strength of yarn is increased.
➢ Weight of package is increased.

The machine is intended exclusively for the treatment and conditioning of yarn by steam.Conditioning of the
cones is done by manual conditioning method (room conditioning). The moisture % in the yarn comes out to be
7.4 % in the cotton yarns. The material after conditioning remains for 15 -20 minutes outside the conditioning
room and then conditioning is done by XORELLA conditioner. The process takes place in following situations:-

XORELLA CONDITIONING PARAMETERS:

Program no. Cycle no. Temp. Vaccum Handling Time

Warp 1st 65’c 170 mb 10 min
2 nd
75’c 200 mb 15 min
Housery 1st 55’c 110 mb 5 min
2 nd
59’c 110 mb 60 min
Pima 1st 65’c 170 mb 10 min
Housery 2nd 75’c 200 mb 60 min
H.T.M 1 st
70’c 180 mb 10 min
cycle 2nd 100’c 270 mb 60 min
2/80 z/c 1st 90’c 160 mb 5 min
nd
H.T.M 2 95’c 150 mb 30 min

PACKING-
After conditioning, the material is packed according to the customer's demand. There are two ways of Packing:-

1.Carton Packing -
Cone wt. 2.65 kg
Cone tip Black star
angle 4”20’
Total no. of cone 18
Yarn wt. in cone 47.7
Oll over wt. 50.3
Carton Size 655 X 460 X 506 mm
Export to India

2.Pallet Packing -
Net wt. 688.28 kg
Gross wt. 740.6 kg
Cone tip Black Zebra

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 Cone angle 4”20’
Cone wt. 1.6 kg
Dimension 1145 X 1145
Total layer 12
Cone in one layer 36

PACKAGE FAULTS
1.Out yarn
2.Multi tanent
3.Extra yarn
4.Dirty cone
5.Heavy cone
6.Soft cover
7.Cut yarn
8. Bulge winding
9. Ribbon/patterning
10. Stepped winding
11. Slough off
12. Without tail package
13. Stained cones
14. Deformed cones

Package Tolrence limit:

S.No Number of cones Tolrence limit Range Customer

1. 18 ( 2.65 kg) -250 gm 48.210 kg (min) Export Market
+100 gm 48.561 (max)
2. 432 (1.6 Kg) + 7.0 gm (Actual wt. from Auro weaving
-7.0 gm System)
3. 18 2.65 kg) -100 gm 48.36 kg (min) For Domestic
+150 gm 48.61 kg (max)
Lot no.- E2IA1/C134222

E2- VMT Hall

I-Year

A1-Carded

C1-Combed

34- Count 201 – lot no.

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 HUMIDIFICATION PLANT

The basic objective of a H-plant in a textile mill is to condition the air so that the fibers can be processed easily by
supplying the conditioned air to the department. The hot air laden with dust and fly from the department is carried
out by underground suction ducts through exhaust fans. The fibers are sucked on the surface of the cylinder covered
with a special type of blanket and finally the fibres are removed by stripping. The H-plant is of LUWA company. In
winter season, the air is reintroduced in the department for maintaining the required temp. The fresh air is sucked
form the outer through the supply fans to cool down the department. Sometimes the water droplets are mixed with
the supply air for maintaining the humidity between 55-60%. Bigger droplets are taken out by the eliminator plate
before sending humid air to department.

RANGE OF HUMIDITY

Department Humidity Temperature

• Blowroom 55-60% 32 C

• Carding 52-56% 34 C

• Preparatory 52-56% 34 C

• Ring Frame 54-56% 34 C

• Winding 62-65% 32 C

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