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Jute Spinning Process Raw jute in the form of bales are processed in jute mills to produce hessian, sacking, jute yarn, bags, and other useful products. Raw jute bales from jute fields or suppliers, carried by trucks are unloaded are stacked in the jute mills gowdown. Selection: In the selection process, raw jute bales are opened to find out any defect and to remove the defective portion from the mora by experienced workers.
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Page 1: Jute Spinning Process

Jute Spinning Process

Raw jute in the form of bales are processed in jute mills to produce hessian, sacking, jute yarn, bags, and other useful products. Raw jute bales from jute fields or suppliers, carried by trucks are unloaded are stacked in the jute mills gowdown.

Selection: In the selection process, raw jute bales are opened to find out any defect and to remove the defective portion from the mora by experienced workers.Raw jute bales are of two types i.e. 150 kg weight and 180 kg weight with or without top portion cutting.

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The bales are assorted according to end use like Hessiean weft, Sacking wrap, Sacking weft etc. After selection, jute bales are carried to softning section by workers called Gariwala and Bajawala.

Softening In softening process jute morrahs are made soft and pile able. Two methods are used for softening; use of softening machine and use of jute good spreader. Generally an emulsion plant with jute softener machine is used to lubricate and soften the bark and gummy raw jute. The emulsion plant consists of gear pump, motor, vat, jet sprayer, nozzles, emulsion tank and the jacket. In this softening process jute becomes soft and pile able and suitable for carding.

Carding 

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Carding is a combining operation where jute reeds are splitted and extraneous matters are removed. Jute fibres are formed into ribbon called “sliver”.There are three different carding sections:(i) breaker carding(ii) inner carding and(iii) finisher carding

Breaker Carding In the Breaker carding machine soften jute after piling is feed by hand in suitable weight. The machine by action with different rollers turns out raw jute in the form of jute sliver for finisher carding. In this process root cutting is necessary before feeding the material to the hand feed breaker carding machine.

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Finisher Carding  Finisher carding machine make the sliver more uniform and regular in length and weight

obtained from the Breaker carding machine. Finisher carding machine is identical to the Breaker carding machine, having more pair of

rollers, staves, pinning arrangement and speed.

Nearly 4 to 12 slivers obtained from Breaker carding machine is fed on this machine.

The material thus obtained is send to drawing section.

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Drawing Drawing is a process for reducing sliver width and thickness by simultaneously mixing 4 to 6 sliver together. There are three types of Drawing Frame machine. In most mills 3 Drawing passages are used in Hessian and 2 Drawing passages are used in Sacking.

First Drawing The slivers obtained from finisher carding machine is fed with four slivers on to the first drawing frame machine. The first drawing frame machines makes blending, equalising the sliver and doubling two or more slivers, level and provide quality and color. This machines includes delivery roller, pressing roller, retaining roller, faller screw sliders, check spring, back spring, crimpling box etc..

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Second Drawing In second drawing, the Second Drawing Frame machine obtain the sliver from the First drawing machine and use six slivers and deliveries per head. The Second Drawing machine makes more uniform sliver and reduce the jute into a suitable size for third drawing.

Third DrawingIn the third drawing, the Third Drawing frame machine uses the sliver from second drawing. The Third Drawing machine is of high speed makes the sliver more crimpledand suitable for spinning. The comparison of the three drawing process:

  Drawing Process   Efficiency Range(%)   Productivity Mt/mc/shift

  1st  Drawing   55 – 73   1.75 – 2.2

  2nd Drawing   64 – 74   1.62 – 1.9

  3rd Drawing   67 – 70   1.31 – 1.4

Spinning

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 Spinning is the process for producing yarn from sliver obtained from Third drawing.The jute spinning frame machine is fitted with slip draft zone and capable of producing quality yarns at high efficiency with auto-dofting arrangements also.

Common defects found in jute

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Specky Jute:If the Jute Fibers are not rotted and washed properly; the barks of jute adhere to the fibers and causes them speck. Speck in jute is a major defect which lowers the quality of Jute fibers.

Rooty Jute:This kind of Jute Defects occurs due to various reasons such as under retting of the root ends of Jute fibers and if the root portion is not completely under water during ratting.

Croppy Jute:If the top end of the fibers is rough, black and hard then stripping is insufficient which causes croppy jute.

Knotty Jute:This kind of knotty jute defects is caused by insect bite in the jute plants.

Hunka:This type of Jute is hard and barky caused by insufficient removal of hard bark from jute.

Mossy Jute:Mossy grows in stagnant of water. The mosses adhere to the Jute fibers causing Mossy Jute.

Glossy Jute:Highly lustrous jute fiber sometimes creates problems. This kind of highly lustrous jute fiber is named as Glossy Jute.

Flabby Jute:Hairy Jute fiber defects are created due to over retting and careless stripping of Jute.

Runners:Long hard and broken ribbon like fibers caused careless stripping and washing.

Dazed Jute Fibers:

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The Jute fibre which has lost it’s strength and luster due to over retting or excessive moisture in it.

Heart Damage:This kind of defects caused for badly damage rotten or tendered fibers.

Weak fibers:Over retting is the main cause of weak fibers, also due to under drying and sorting in moist condition.

Sticky or Woody:In the top end at the jute plant is not stripped properly from the fiber, the brow pieces of the plant remain the fiber ceurecl this defect. It is due to over retting of lower part of the plant is under retting of lower part of the plant is under retting of the top end.This all about the Jute Fiber Defects or Faults and reasons.

  Technology  

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Jute Technology

    Technology

    

Jute Manufacturing  in Jute Mills

Raw jute in the form of bales are processed in jute mills to produce hessian, sacking, jute yarn, bags, and other useful products.  Raw jute bales from jute fields or suppliers, carried by trucks are unloaded are stacked in the jute mills gowdown.  The production of jute goods from raw jute processing involves the following steps:

 Selection :

In the selection process, raw jute bales are opened to find out any defect and to remove the defective portion from the mora by experienced workers.  Raw jute bales are of two types i.e. 150 kg weight and 180 kg weight with or without top portion cutting.  The bales are assorted according to end use like Hessiean weft, Sacking wrap, Sacking weft etc.  After selection, jute bales are carried to softning section by workers called Gariwala and Bajawala.

  Jute   Processing Chart

  Selection,   Softening   &   Piling,   Carding

  Drawing &     Doubling, Spinning, winding, Beaming/Dressing

  Weaving, Damping & Calendering, Lapping,   Cutting etc.

  UNDP and Govt. of India - National   Jute   Development Program

 

Productivity Improvement in Jute Industry - Report by I. I. T Kharagpur, 2000

  Rice Bran Oil (RBO) Technology - Food Grade Bags

 

Jute Composites

Advance Jute Testing Equipment

Softning :

In softning process jute morahs are made soft and pileable.  Two methods are used for softning; use of softning machine and use of jute good spreader.  Generally an emulsion plant with jute softner machine is used to lubricate and soften the bark and gummy raw jute.  The emulsion plant consists of gear pump, motor, vat, jet sprayer, nozzles, emulsion tank and the jacket.  In this softning process jute becomes soft and pileable and suitable for carding. Piling and pile Breaking :

The main function of pile breaker is to break the pile and serve it to the carding machines.  The softner machine out put material carried by pilemen through a bile to the pile place for pilling.  During piling a superficial moisture penetrates inside fibre and "Thermo fillic" action take place which softner the hard portion of the root.  After piling for nearly 24 hours the pile breakers carry the material to the carding machine.

Research in Jute Related Fields

   

 

   

     

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Generally root cutting is done after piling near the hand feed breaker carding machine.  The root weight varies from 5 to 7% of the total weight of jute.

Carding :

Carding is a combining operation where jute reeds are splitted and extraneous matters are removed.  Jute fibres are formed into ribbon called "sliver".  There are three different carding sections: (i) breaker carding (ii) inner carding (iii) and finisher carding

Breaker Carding :

In different jute mills the carding operations has been carried out in two ways:    a. Hand feed breaker carding    b. Rool feed breaker carding

     

     

     

     

     

     

     

     

Drawing :

Drawing is a process for reducing sliver width and thickness by simultaneously mixing 4 to 6 sliver together.  There are three types of Drawing Frame machine.  In most mills 3 Drawing passages are used in Hessian and 2 Drawing passages are used in Sacking. 

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First Drawing : 

The slivers obtained from finisher carding machine is fed with four slivers on to the first drawing frame machine.  The first drawing frame machines makes blending, equalising the sliver and doubling two or more slivers, level and provide quality and colour.  This  machines includes delivery roller, pressing roller, retaining roller, faller screw sliders, check spring, back spring, crimpling box etc..

Second Drawing :

In second drawing, the Second Drawing Frame machine obtain the sliver from the First drawing machine and use six slivers and deliveries per head.  The Second Drawing machine makes more uniform sliver and reduce the jute into a suitable size for third drawing.

Third Drawing :

In the third drawing, the Third Drawing frame machine uses the sliver from second drawing.  The Third Drawing machine is of high speed makes the sliver more crimpled  and suitable for spinning. The comparison of the three drawing process:

Drawing Process Efficiency Range (%) Productivity Mt/mc/shiftIst Drawing 55 - 73 1.75 - 2.2

IInd Drawing 64 - 74 1.62 - 1.9IIIrd Drawing 67 - 70 1.31 - 1.4

Spinning :

Spinning is the process for producing yarn from sliver obtained from Third drawing.  In the spinning process slivers are elongated and fibres are twisted into yarn to impart strength.  spun yarns in the spinning process are wound onto Bobbins.  after to fill the empty bobbins with yarn machine is stopped, replace these bobbins by empty bobbins.  The entire time is called an average cycle time.  The time for replacing the bobbins full of yarn by empty bobbins is called softing time.

The jute spinning frame machine is fitted with slip draft zone and capable of producing quality yarns at high efficiency with auto-dofting arrangements also. A 4', pithch slip-draft sliver frames available of 20 spindles 100 spindles, having a production range 8 uls to 28 uls with a flyer speed of 3200 to 4000 RPM. Spinning of several types of yarn is processed by

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spinning frame machine usingdifferent kinds of bobbins, such as: Food Grade HCF, Sacking Wrap, Hessian Wrap, Hessian Weft. 

The jute spinning frame machine is fitted with slip draft zone and capable of producing quality yarns at high efficiency with auto-dofting arrangements also. A 4', pithch slip-draft sliver frames available of 20 spindles 100 spindles, having a production range 8 uls to 28 uls with a flyer speed of 3200 to 4000 RPM. Spinning of several types of yarn is processed by spinning frame machine usingdifferent kinds of bobbins, such as: Food Grade HCF, Sacking Wrap, Hessian Wrap, Hessian Weft. 

Winding :

Winding is a process which provides yarn as spools and cops for the requirement of beaming and weaving operations.  There are two types of winding :             (i) Spool Winding               (ii) and Cope Winding

(i) Spool Winding                                                       

In Spool Winding yarn is produces for warp (the longitudinal yarn).  Spool winding machine consists of a number of spindles.  There is wide variation in the number of spindles per machines from one make to another.  Productivity of spool winding depends on the surface speed of the spindle and machine utilisation.

Spool winding machine uses the bobbins contain smaller length of yarn.  This machine wound the yarn into bigger packages known as 'spool'. The Spool are used in making sheets of yarn to form warp portion used during interleecment of weaving.

(ii) Cop Winding

Cop Winding  machine obtain yarns from the spinning machines.  The spinning bobbins is placed on a suitable pin on top of the cop machine and yarn tension is  maintained by means of a small leaver.  The yarn on the bobbins are cnverted into hollow cylindrical package said to be cop.  The cop is used to form Transverse thread during interlacement of weaving.  Generally a cop winding machines consist 120 spindles.

Beaming :

Beaming process is follows after spool winding.  In Beaming operation yarn from spool is wounded over a beam of proper width and correct number of ends to weave jute cloth.  To increase the quality of woven cloth and weaving efficiency, the wrap yarns are coated with

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starch paste.  Adequate moisture is essential in this process.

Quality characteristic of a beam is width of beam - number of ends and weight of stand and there is a continuous passage of yarn through starch solution from spools to the beam.

Strach solution in water contains tamerine kernel powder (TKP), antiseptic - sodium silica fluride (NaSiF4) and its concentration varies with the quality of yarn.

Weaving :

Weaving is a process of interlacement of two series of threads called "wrap" and "weft" yarns to produce the fabric of desired quality.  There are separate looms for hessian and sacking in weaving section.  The Hessian looms, shuttle which contents cops (weft yarn) is manually changed.  The sacking looms are equipped with eco-loader to load a cop automatically into the shuttle.

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Dumping :

Dumping is the process in which the rolled woven cloth is unrolled and water is sprinkled on it continuously to provide desired moisture.  Each roll is generally104 yards or 95.976 meters.  Damping is done manually.

Calendering :

Calendering is a process similar to ironing of fabric.  After damping the damped fabric passes through pairs of heavy rollers rendering threads in fabric flattened and improve the quality and appearance.

Lapping :

Lapping is the process in which Hessian fabrics are folded into the required size used in "Bale press" operation on the lapping machine.

Cutting :

Cutting is the process where the sacking cloth is cut to the required length for making bags for different size such as A-Twill bags and B-twill bags of 100 kg capacity.

Hemming :

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In Hemming process, the raw edges of sacking cloth cut pieces are shown by folding it with sewing machine.

Herackele Sewing :

In Herackele sewing the sides of sacking cloth cut pieces are shown to make a complete bag.

Bailing :

Bags or Bale processing cloths are pressed compactly according to buyers need.

Composite

Jute is an attractive natural fibre for use as reinforcement in composite because of its low cost, renewable nature and much lower energy requirement for processing. The scope for

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using jute fibres in place of the traditional glass fibres in different forms partly or fully as reinforcing agents incomposites stems from the higher specific modulus and lower specific gravity of jute (~ 40 Pa and 1.29 respectively) compared with those of glass(~ 30 GPa and 2.5 respectively)

The major drawback of natural fibre reinforced composites is due to its affinity for moisture. Many experimental studies have shown that compatible coupling agents are capable of either slowing down or preventing the de- bonding process and hence moisture absorption even under severe environmental conditions, such as exposure to boiling water. Jute fibres/fabrics can be modified chemically through graft co-polymerisation and through incorporation of different resin systems by different approaches. 

Natural fibre composites enjoy excellent potential as wood substitutes in building industry in view of their low cost, easy availability, saving in energy and pollution free production. In order to improve upon the laboratory-industry linkages towards application development & commercialisation, the Advanced Composites Mission launched the projects on jute composites such as 'Jute-Coir Composites Boards’, 'Jute-glass composite components for railway coaches’, ' Thermoplastic composites based synthetic wood’ and others.

IntroductionThe composite technology of a polymeric matrix reinforced with man- made fibres such as glass, Kevlar, carbon etc. has come of age especially with the advances in aerospace applications since 1950s. The developments in composite material after meeting the challenges of aerospace sector have cascaded down for catering to domestic and industrial applications. Composites, the wonder material with light-weight, high strength-to-weight ratio and stiffness properties have come a long way in replacing the conventional materials like metals, woods etc. The material scientists all over the world focused their attention on natural composites reinforced with jute, sisal, coir, pineapple etc. primarily to cut down the cost of raw materials.

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Eastern India has been bestowed with abundant cultivation of jute. The production of processed jute fibre in India has touched 1.44 million tonnes in 1998-99. Jute as a natural fibre has been traditionally used for making twines, ropes, cords, as packaging material in sacks & gunny bags, as carpet-backing and, more recently, as a geo-textile material.

         

But, lately, a major share of its market has been eroded by the advent of synthetic materials, specially polypropylene. In order to save the crop from extinction and to ensure a reasonable return to the farmers, non-traditional outlets have to be explored for the fibre. One such avenue is in the area of fibre-reinforced composites. Such composites can be used as a substitute for timber as well as in a number of less demanding applications.

Jute fibre due to its adequate tensile strength and good specific modulus enjoys the right potential for usage in composites. Jute composites can thus ensure a very effective and value-added application avenue for the natural fibre. Interest in using natural fibres as reinforcement in polymer matrices and also in certain applications as partial replacement of glass fibres has grown significantly in recent years for making low cost composite building materials. Thus, new alternative materials have emerged that could partially meet the demands of conventional materials especially wood in buildings.