BY BAGADI NIKHIL L. 08 TEXT 02 BUCHADE SACHIN G. 08 TEXT 05 CHAVAN HRISHIKESH V. 08 TEXT 07 DAMLE RAVIRAJ V. 08 TEXT 12 PATNAWAR SHREYAS M. 08 TEXT 36 UNDER THE GUIDANCE OF Prof.A.U.Awasare Prof.S.D.Mahajan D.K.T.E SOCIETY’S TEXTILE AND ENGINEERING INSTITUTE, ICHALKARANJI 2011 - 2012
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‘ASSESSMENT AND CONTROL OF HARD WASTE IN SPINNING MILL’
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BY
BAGADI NIKHIL L. 08 TEXT 02BUCHADE SACHIN G. 08 TEXT 05CHAVAN HRISHIKESH V. 08 TEXT 07DAMLE RAVIRAJ V. 08 TEXT 12PATNAWAR SHREYAS M. 08 TEXT 36
UNDER THE GUIDANCE OFProf.A.U.AwasareProf.S.D.Mahajan
D.K.T.E SOCIETY’S
TEXTILE AND ENGINEERING INSTITUTE,ICHALKARANJI
2011 - 2012
Yarn realization Types of waste Economics
Causes of Hard Waste Ring cops Winding Ring Doubling and Two For One Twisters (TFO) Open End Spinning Material Handling & Poor House Keeping Length of yarn taken to piece a break
1) Estimation Of Overall Expected Hard Waste %
= (∑ PW ) / T . P = Production in Each Process. W= expected waste as per norms. T = total production in Kg.
2) Hard Waste Index (HWI) = (actual hard waste %) /
(expected hard waste %) * 100
Maintaining low breakage level at all operations Reducing ring cop defects Correct work practices Maintain cop rejection in winding at low level Backwind should be less Improve house keeping Maintain proper records
Ring cut Improper built Less clearance at top and bottom Stained and oiled bobbin Slough off Defective empty bobbin Soft built
Improper Built
Less clearance at bottom
Defective empty bobbin
Contaminated bobbins
Wild Yarn
Rubbed yarn
Avg. yarn content of improper built
bobbin( gm )
Avg. yarn content of full bobbin
( gm )
% reduction in wt.
37 53 30
40 52 23
39 50 22
38 54 29
Reduction in wt of bobbin due to improper built for LR 6/S
Avg. yarn content of improper built
bobbin( gm )
Avg. yarn content of full bobbin
( gm )
% reduction in wt.
42 53 20
40 50 20
41 50 18
44 54 19
Reduction in wt of bobbin due to improper built for KTTM
Results for defective bobbinsMake and Machine No
KTTM ( No 4 )
LR 6/S (No.17)
LR 6/S (No.15)
KTTM ( No.1)
LR 6/S ( No. 15)
LR 6/S ( No. 19)
Count 32 s Ne 32 s Ne 32 s Ne 32 s Ne 32 s Ne 30 s Ne
No Of Spindles Tested
1104 1104 1104 1104 1104 1104
Defect Type Ring Cut 7 12 2 0 9 2Less Clearance At Top
MIXING OF WASTE WITH GOOD BOBBINS WHICH LEADS TO CONTAMINATED OR SOILED BOBBIN
BABBIN FALL ON GROUND
IMPROPER MATERIAL STORING SYSTEM
BAD WORK PRACTICE - DOING DOUBLE GAITING AT WINDING OF RING BOTTOM WHICH LEADS IN COP REJECTION IN WINDING
MIXING OF DIFFERENT COLOR BOBBINS - NO CODING
BROKEN MATERIAL HANDLING DEVICESBROKEN MATERIAL HANDLING DEVICES
BROKEN MATERIAL HANDLING DEVICES
BOBBIN MIX UP AND LABOUR ABSENTISM
USE OF DIFFERENT TOP ROLLER (ORANGE)
IMPROPER STORAGE OF MATERIALTO BE PROCESSED
IMPROPER STORAGE OF MATERIAL TO BE PROCESSED
POOR HOUSE KEEPING
ENTANGLEMENT
WASTE ENTANGLED WITH OHTC
•Loepfe clearer produces more hard waste than UQ2.•Mill has proper control on winding process.•In ring cops, defects like less clearance at bottom, improper built and defective empty bobbins are to be controlled to reduce hard waste.•In case of backwind length, NF speed of ring rail & the time at which ring rail comes down at the time of doff should be controlled.•Optimized machine cleaning schedule and traveler change schedule should be followed to reduce end breaks at ring frame and winding cuts.•Another major reason of hard waste generation i.e. bad work practices, improper material handling, poor house keeping etc. should be avoided.
•Process control in weaving By Kimothi & Paliwal (ATIRA)•Studies on ring frame to reduce Winding Cuts, Spinning Textiles, June 2010•Yarn waste control in textile mills, by BTRA•‘Impacts of hard waste on profitability of spinning mills’ By G. Kathirvel Pandian, D. Shanmuganandam (T.I.T.J.,MAY1996)•‘Measures to control hard waste in spinning mill’ By G.Kathirvel Pandian, D.Shannmuganandam (A.T.J.,1996)•‘Quality requirements of ring cop in modern cone winding’ - (I.T.J.,MAY2008)•‘Process control in weaving’ By Paliwal •‘How to improve Yarn realization and control wastes?’ By D.Shanmuganandam•Lappage James,End breaks in spinning and weaving of weavable single yarns, textile research journal, June 2005•www.fiber2fashion.com