INTRODUCTION

 Training in industry infuses among students a sense of

critical analysis ofthe whole production system and
different situations arising in an
organisation. Trainings are bold attempts to bridge the gap
between the world of work and the knowledge at the
institutions. It enables us to see ourtheoretical knowledge in
operation. It helps us make better professionals and learn
the practical knowledge of the production system. Our
training at RSWM LTD, MANDPAM was no different it helped
us gain the practical knowledge of the textile
manufacturing. The process of production extending for
spinning of fibre, their conversion to fabric.
 Textile manufacturing is one of largest business operations
taking place in India. It gives employment to a very large
population of the country nest onlyto agriculture. For a
student yarn manufacturing is based completely dependent
on the textile manufacturing. Our sixty days long internship
gaveus the through knowledge of the textile manufacturing.
It gave us the knowledge about the processes taking place in
spinning of the fibre. This internship, we hope will help in
developing us as better yarn manufacturing professional as
the knowledge of textile is pivotal in making good yarn
manufacturing professional. This internship has given us the
required confidence to face the various situations arising in a
work place.
 This report is a written account of what we have observed and
learnt during our Sixty days long internship at RSWM
MANDPAM, BHILWARA.
 OBJECTIVE
 To study the organisational
structure of anintegrated
textile mill.
 To study the process of Fibre
dyeing, spinning oftextile.
 To study the equipment &
machineries installed atthe textile
mill.
 To study the guidelines
established for variousdivisions
of textile manufacturing unit.
 To study the testing of different
sample in SQC.
 To study the latest development in
this industry.
 PRODUCT OF MANDPAM, BHILWARA

 Lycra blend yarn

 Neppy Yarn
 Syro Yarn
 Injection Slub
 Normal Slub
 Fancy Yarn
 Blend Yarn(P/V, P/A, P/C, V/C, V/A )
CESS SEQUE

NCE IN SPINNIN
G
 * MIXING & BLENDING *
 The process of combining two or more kinds of fibres.

 Fibres in required ratio are taken, opened and blended in blenders.

 The mixing is blended once or twice to ensure proper blending to thefibres.

 During the blending process we use lubricant as TEXOL.

 2156- is use for the purpose as finishing agent.

 2146- is use for the purpose as antistatic agent.

 Normal water are also use in this lubricant.

Texol V 100% P100% P/V P/A

2156 0.05% 0.06% 0.10% 0.10% 0

.
0
5
%
2146 0.75% 0.28% 0.40% 0.38% 0
.
7
5
%
Water 4.5% 4.5% 4% 5.5% 5
 Finally blend material get out in blow room bin. Bin 1&2 are
kept 24hours for better conditioning.
 Name of the part of Blender
Sr. No Name of parts of Blender

01 Conveyor Belt
02 Feed Lattice
03 Inclined Lattice
04 Delivery Roller
05 Evener Roller
06 Creeper roller
07 Stripper Roller
 BLOW ROOM
OBJECTIVE
 To ensure proper opening of bales.
 To ensure proper blending.
 To reduce the tuft size.
 Removing dust.
 Formation of uniform lap sheet.
 To create laps to be fed in the carding
machine.

Wastage in Blow Room

 Dropping (0.10%)
 Dust (0.10%)
 Filter waste
UNIMIX
 Mixing & Blending checking
point
 Mixing Checking
 Layer checking
 Moisture checking
 Gauge checking
 Lot cleaning checking
 Finish checking
 Lap CV % checking
 Lap weight checking
 CARDING

OBJECTIVE
 Opening to individual fibres
 Removing of impurities
 Removing of dust
 Disentangling of neps

Action in Carding
 Combing action
 Carding action
 Stripping action
 Doffing action
CARDING MACHINE
 lap Roll Take-up Roller
 Feed Plate  Cross Roller

 Feed Roller  Top & Bottom Roller

 Licker-in  Calendar Roller

 Cylinder  Coiler
 Doffer
 lats
CARDING LC 300A- V3
Technical parameters of LC 300A – V3

 Diameter of lap roll :- 162mm

 Diameter of feed roll :- 80mm
 Diameter of licker in :- 253mm
 Diameter of cylinder :- 1290mm
 Diameter of doffer :- 680mm
 Diameter of calendar roll :- 80mm

Speed of different moving parts

 Lap roller = 2.15 rpm

 Feed roller = 4 rpm
 Licker-in= 1050 rpm
 Main cylinder = 450 rpm
 Doffer = 30rpm * Draft constant for LC
300A – V3 = 2.23
🞂
Stop motion for LC 300A – V3

• Limit switch for lap tool – it stops the card in case

of shortage of lap.
• Limit switch over feed roll – it stops the card
if the feeding of double laptake place.
• Limit switch at front panel – it stop the cylinder if
the front panel is opened.
• Limit switch over crush tool – it senses the lapping
of the crush tool.
• Full can change motion – when the can full of
slivers the machine stops andthe can is changed
either by tender or automatically.
1. LC 1/3
2. LC 300A
Carded Sliver Can 38
Wastage in carding machine

NON-USABLE
USABLE
 Card dropping-0.20%
 Lap Ends – 0.20%
 Flat Strip -1.30%
 Card Sliver -0.30%
 Fan Fly -0.20%
 Sweeping – 0.10%
Carding checking points

 Neps checking
 U% checking
 Stop motion checking
 Flat brush checking
 Randomisation checking
 Delivery Speed checking
 Lots cleaning checking
 Wrapping checking
3.14*D*N*60*8*efficiency%*(100-waste extension%)
840*36*2.2*sliver hank
D= dia of doffer(27 inch)
N= doffer rpm (45 rpm)
 DRAW FRAME

Objectives:

 To parallelize the fibres of card

sliver and align them tothe axes of
the sliver through drafting process.
 To improve the regularity in sliver
weight per unit lengththrough
doubling of sliver.
 To mix different slivers to give a
homogenous blended
sliver.
 To straighten out the fibre and
improve the fibre extent.
 To improve uniformity and
evenness so that the finalsliver
become more regular resulting
uniform yarn.
 DRAWING

Breaker draw frame

During this process 6 to 8 slivers
produced by carding machine are
paralleled to produce one sliver.

Finisher draw frame

To improve uniformity and
evenness so that the final sliver
become moreregular resulting
uniform yarn.
GEARING DAIGRAM OF DRAW FRAME
DRAW FRAME DIAGRAME
 NAME OF THE PARTS OF DRAW FRAME

 Guide
 Creel Roller
 Sliver Guide
 Tensioner Roller
 Condenser Roller
 Condenser Tube
 Scan Roller
 Back Roller
 Middle Roller
 Front Roller
 Condenser Tube
 Trumpet
 STOP MOTION FOR LDO-06

 Electric creel stop motion: If

broken sliver passes throughthe
pair of the drawing frame, the
drawing frame will automatically
stop.
 Full can stop motion: If pre-
set length of sliver is
delivered in the can drawing
frame will automaticallystop.
 If the door open during running
the machine will
automatically stop.
 Calendar roll lapping stop

motion: In case of sliver

lapping over the calendar
roll the machine will stop.
 AUTOLEVELLER
OBJECTIVE
 To measure and monitor the
variation in sliver thickness
continuously and to change the
draft accordingly
 More draft will be applied to thick
places and less to thinplaces so that
the resultant sliver delivered will be
more regular
 Improve production and better
productive efficiency
 Even sliver appearance
 Fewer ends breakages in subsequent
process
 Less wastage
 Lower count CV% can be expected
 TYPES OF AUTOLEVELLER
Open Loop System
 Open loop system generally use
in draw frame. Open loop auto
leveller, sensing is done at the
feeding end and the correction is
done by changing draft. This is
very effective levelling system as
compared to close loop because in
open loop system the correction
length in open loop system is time
smaller than close loop system.
However, in close loop system,
delivered sliver is of required liner
density. In case of open loop
system, as the delivered material
is not sensed for its liner density
to know whether the correction
has made or not.
 In close loop system, the delivered
sliver is sensed for its liner density
and correction is done by changing
total draft. Closed loop auto levellers
are mainly used on carding machine.
But the modern carding machine have
sensing at the feed rollers as well as
the calendar rollers.
 Hand Requirement:
No. of M/c Person
04 01
04 01
Delivery 01
Total 03

Production Calculation:

3.14*D*N*8*60*efficien%
Sliver hank*840*36*2.2
D= Front roll dia
N= Front roll rpm(550 mpm)
550mpm*1.1*8*60*efficiency/sliver
hank*840*36*2.2
 Checking points:

 Stop motion should be check on daily

basis
 Lot on change
 U% checking
 Top roll change per two hours
 Can randomization
 Speed checking
 Can length
 Wrapping checking on two hours
 Cut checking
 Can report
 AL & SM checking( auto leveler and
sliver monitor)
Problem during process on Draw
frame:
 Sliver evenness
 Sliver breakage
 D/F gauge D/F
wrappi
ng
8 Py 55/60 0.103
10 Py 55/60 0.103
18 Py 55/60 0.103
18 P/v 50/58 0.103
20 Py 55/60 0.103
20 V 46/50 0.103
28 P/v 50/58 0.103
30 P/v 50/58 0.110
40 P/v 50/58 0.110
40 Py 55/60 0.110
50 P/V 50/58 0.145
60 P/V 50/58 0.145
 Speed frame
 Simplex is an intermediate process in which
fibres are converted into low twist lea
called roving. The sliver which is taken from
draw frame is thickerso it is not suitable for
manufacturing of yarn. Its purpose is to
prepare input package for next process.
This package is to prepare on a small
compact package called bobbins.

Objects/ Functions of Speed

Frame:
 Attenuation of drawn sliver to form roving of
required count by drafting.
 Insert small amount of twist to give required
strength of roving.
 Wind the twisted roving on to the bobbin.
 Build the roving in bobbin such a
form which will facilitate handling,
withdrawing &transfer to the next
process.
Draft Range :- 7 to 20
Roving Hank :- 1 to 1.2
SPEED FRAME
 Parts name of speed frame

 Creel
🞂  Front Roller
 Creel
🞂 bar  Clearer
 Sliver
🞂 Bar  Twist Multiplier
 Condenser
🞂 Sliver  Flyer
Bar
 Back
🞂 Roller  Flyer Arm
 Middle
🞂 Roller  Spindle
 Apron
🞂  Bobbin
 Cradle
🞂

 Spacer
🞂

 Nose
🞂 Bar
 Stop Motion:

 Creel Stop motion

 Automatic tension control
 Bobbin Safety
 Sliver back Stop Motion

Checking Point:
 Daily cots checking
 Wrapping checking
 U% Checking
 Half Lea Checking
 Tension Checking
 Speed Checking
 Stop Motion Checking
 Production Calculation of Speed Frame

3.14*D*N*8*60*efficiency
840*36*2.2*Roving Hank* no of spindle

FRS =spindle speed /840*TPI

Hank = FRS/ 20
20=3.14*1.1 inch*8*60/840*36*2.2=0.05
1/20=0.05so we take the constant 20 and
divided withFRS so we get hank.
Now, Kg = hank/2.2* roving hank* no of
spindle
 RING FRAME

Spinning of roving bobbin into yarn of

required count and twist and make a
yarn. It is capable of producing yarns with
wide ranges of linear density and twist
from a great variety of fibre materials. It
is also used for doubling and twisting
multi fold and cabled yarns. These
combinations meant that the potential
maximum speed of ring spinning was
raised from about 8500 to 20500
revolutions per minute
OBJECTIVES:-
 To produce required count of yarn
from the suppliedroving by the
drafting.
 To insert sufficient amount of twist to
the yarn. To windthe yarn onto the
bobbin.
 To build the yarn package properly.
Parts of Ring frame
PASSAGE OF MATERIAL IN RING FRAME
 Name of Parts of Ring Frame
 Creel
 Tension Bar

 Roving Guide

 Front Roller

 Middle Roller

 Nose Bar

 Apron Roller

 Tensioner Bar

 Front Roller

 Bobbin Ring

 Spindle

 Ring Traveller

 Spindle Barb

 Spindle Bolster
 TECHNICAL SPECIFICATION OF RING FRAME

Machine Model LR6/

S

Manufacturer LMW

Total no of machine 24

Drafting System 3
over
3
Top Roller Diameter 32.5
mm
Bottom Roller Diameter 30m
m
Pressure 7 kg

Motor Pulley 152

-
187
mm
Total Spindle 624

Spindle Speed 850

0-
205
00
Spindle tape Driven Front Roller Speed 245
rpm
 CREEL

TENSION BAR

ROVING GUIDE

DRAFTING ZONE

TWISTING

WINDING
 Ring traveler
 Schedule checking
 Lot change, cleaning
 TPI checking
 Contamination checking
 Count & CSP checking
 U%
 Partition checking
 Spacer checking
 Lot setting
 Spindle vibration checking
 Bottom & Top apron checking
 Calculation in Ring Frame

Production 3.14*D*N*60*8*efficienc
(kg/shift) y/840*36*Cou
nt*2.2*T.P.I
Twist per 25.34*B*D/A*C
inch
C+D=137
Front roller Spindle
speed speed/840*T.P.I
 Break draft:
 Total draft of a ring frame is
limited. Since the main draft
should not exceed its limit, a
additional draft is implied in the
back zone (between back and
middle roller). This draft
facilitates the main draft and
known asbreak draft.
 Normally twisted roving and
total drafts up to 40: breakdraft
should be 1.1-1.4 Strongly
twisted roving: break draft
should be 1.3-1.5 When total
draft exceeds 40, break draft:
1.4-2.
Count (Ne)-Synthetic T.M (Twist
yarn Multiplier)
10-20 2.9-3.2
 AUTO CONER
 Winding is one of the most
important operation, which is
mainly occurred in spinning
section. The creation of large yarn
packages that can be easily
unwound, is called winding. This
makes using the yarn on
subsequent machines both easier
and more economical. To prepare
the bigger package from ring
bobbin. To remove spinning
faults. To wax the material. To
improve thequality of yarn.
Objective
 To remove the objectionable
faults present in original yarns.
 To warp the forming on a
systematic manner or to transfer
yarn from smaller package to
larger package.
 NAME OF THE PARTS OF AUTO CONER

 Auto Feed
 Splicers schlafhorst
 Waxing device
 Electronic cleaner
 Detaching head
 FX sensor
 One doffer & empty tube loader
 Magazine:- 6 each spindle
 Technical Specification
Spindle gauge 320mm
Count Range 10 to 60 Ne
Cone Weight 2 to 2.50 Kg.
Drum speed 1400 rpm
Cone Dia 200 to 225 mm
Empty Cone Weight 30 to 35 gms
Magazine Creel capacity 8 Cops
Drum Diameter 95 mm

Count wise winding speed

Type Count Winding
Speed
Coarse 15-20s 1450 m/min
Medium 20-40s 1400 m/min
Fine 40s and above 1350 m/min
 Conditioning
 Before packing the yarn produced
are subjected to a treatment in the
conditioning room to increase the
moisture content of the cone to
according to requirement. It increase
the weight of cone marginally.
 Packing

 In packing department the cones

produced by Autoconer checked and then
packed in bags. There are 5checkers and
a large number of packers for this
purpose.
The defects, which are checked during
packing, are:-
 Mixing of cones
 3-ply
 High twist /low twist
 Contamination
 Snarling
 Winding defect (ribbon formation)
Types of packing :-
 Cartoon packing
 Pilot packing
 Bora packing
 Waste Report
 There are various types of wastages which are
found in spinning mill during the processing of
raw cotton. About 12-13% wastages are
produced for card process and 25-30% wastage
are produced for combed process. The names of
different wastages are given below:
 Blow room (waste= 3%) i. Dropings-2 ii. Lap waste
etc.
 Carding (waste= 4%) i. Dropings-1 ii. Sliver
waste iii. Vacuumwaste.
 Draw frame (waste= 0.5%)i. sliver waste
 Lap former (waste=0.5%) i. lap waste ii.
Sliver waste iii.Vacuum waste
 Comber (waste= 12-18%) i. Noils ii. lap waste iii.
Sliver waste
 Simplex (waste= 0.5%) i. Roving waste ii. Sliver
waste
 Ring Frame (waste= 2-3%) i. Pneumafil
ii. Hard wasteii.Sweeping iv. Vacuum
waste
 Winding section(waste=1%) i. Hard waste
 Usable Waste
Types of Waste Waste in %
Lap end 0.20
Card slier 0.30
Draw sliver 0.40
Roving 0.40
Bonda 1.20
Total(A) 2.50%
Unusable Waste
Types of Waste Waste in %
B.R Dropping 0.10
Card Dropping 0.20
Flat Strip 1.37
Fan Fly 0.16
Sweeping 0.40
Ring Frame 0.15
Finishing 0.91
Hard waste 0.12
S.Q.C 0.02
Total 3.25%
 QUALITY ASS URANCE DEPARTMENT

NAME OF INSTRUMENT OBJECTIVE PARAMETERS

TESTED
Warp reel To Determine yarn Lea weight &
count Count
USTER evenness To Check the U% & CV%,
unevenness of foreign
sliver,roving,yan matter,hairiness,t
hick ,thin places
etc
USTER CLASSIMATE To check imperfection Slubs, thick &
QUANTUM thin place
Lea strength tester To test CSP Lea strength
Twister Tester To Determine twist & TPI & TM
TM in yarn
USTER TENSORAPID 5 To test tenacity, Strength
breaking force,
elongation
USTER AFIS PRO 2 Neps, length,maturity Individual fiber
ration of fibers study
 USTER CLASSIMATE QUANTUM-

Uster classimate quantum system is digital maicroprocessor controlled

yarn fault classing system.Its based on structural components of the

uster classimate quantum .Capacitive mesausring heads with built in

sensor for foreign fiber detection are used.

Detecting disruptive thick and thin places

Detecting yarn count variations .

Detecting foreign matter contaminations .

Technical specifications

No of measuring heads-1-12

Yarn speed -100-2000m/min

Mesurement principle- capacitive measurement of yarn mass and

measurement of reflection of the determination of foreign fibers.

 AFIS (Advanced fiber instrument system)-

 AFIS is modular device intended for testing and anaysing 100% cotton
Samples in the from of bale, opened and cleaned material( card
mat.), Sliver and Roving.
It is based on the aeromechanical fiber processing similar to opening
and carding followed by electro optical sensing and than by high
speed microprocessor based computing and data reporting.

Basic AFIS Schematic

A fiber sample is introduced in to the system and is processed

through a fiber individualizer which aero mechanically separates the
Sample in to three components consisting of cleaned fiber, micro
dust and trash.

Each of these components is transported in a separate pneumatic

path and may be analysed electro optically or by other means.

The data Processing and Reporting are handled by an individualized

PC.AFIS Provides Basic Single fiber Information and is distinguished
from earlier and existing Methods by Providing Distributions of the
Basic Fiber Properties .
THANK YOU