Rana Training Report of Nishat #7

INTRODUCTION

Nishat Mills Limited (NML), commenced business in 1951 as a

partnership concern, which was converted into a private limited

company in 1959. In 1961, the company went public and was

listed on the Karachi Stock Exchange.

NML has 176,500 spindles, 458 weaving machines and

Pakistan’s largest textile processing capacity.

The company’s production facilities comprise of spinning,

weaving, processing, stitching and power generation.

Pakistan ranks 5th in cotton production of the world and is one of

the major exporters of yarn. There are many industries in

Pakistan but NISHAT group of industries is one of the most

prominent groups of Pakistan. In this way, it is earning valuable

foreign exchange for the country. There are many industries of

this group, but some prominent mills of this group are listed as

under:

Nishat Mills Limited Fsd.

Nishat Mills Limited Chunian.

Nishat Mills Limited Lahore.

However, the present practical training was conducted in Nishat

textile mills Faisalabad. Its brief introduction is below.

This mill is situated on Sheikupura road Faisalabad (the city

seems with textile factories and popularly known as

1

“Manchester” of Pakistan).

It has:

Seven Ring Spinning Units

One Open End-Spinning Unit

Weaving unit

One Garment Section

Power Generation Plant

There are approx. 3000 workers, working in the various

departments of this mill. The daily production of yarn is near

about 1200 bags daily.

SPINNING:

The spinning section, with 176,500 spindles, is operationally

organized into even units. Entire spindleage, supplied by world’s

renowned manufacturers from Germany, Japan, china and the

Untied Kingdom, is located at one premise in Faisalabad.

NML produces ring-spun cotton and blended yarn of coarse,

medium and fine quality counts and commands a premium in

local as well as overseas markets.

NML exports more than 50% of its products mainly to the

Far East, Europe and the United States, where it is trusted for its

product quality and timely delivery.

PROCESSING:

2

The processing section at NML has bleaching, dyeing and

printing facilities for processing 160,000 meters of cloth per day.

It has continuous bleaching, thermosol dyeing and three rotary

printing machines along with allied processing facilities like

mercerizing, sanforizing, raising and emorizing. Entire equipment

has been imported from established European manufacturers,

ensuring high quality standards.

POWER GENERATION:

The power generation unit, formerly known as Nishat Tek

Limited, was nation’s first power generation company in the

private sector.

Commercial production started in 1992 with three KRUPP-

MAK engines with generating capacity of 5.5 MW each. Capacity

at Faisalabad has since been increased to 27 MW, supplying

power generating unit of 6 MW at Sheikhupura to supply power to

Sulzer Unit 2 and Tsudakoma Unit 3. It started commercial

operations in September 1995.

CALCULATIONIONS

3

Standard moisture regain of different materials is given below:

CONVERSIONS

Tex = 590.6 / Ne

Denier = 5315 / Ne

Cotton 8.5 %

Wool 17 %

Viscose 11 %

Silk 11 %

Jute 14 %

Polyester 0.3--0.4 %

Acrylic 3—4 %

Nylon 4.2 %

4

Denier = tex × 9

Grex = tex × 10

Metric = 1.693 × English

1 mon = 82 lbs

1 mon = 40 kg

1 lb = 7000 grains

1 lb = 453.6 grams

1 lb = 16 oz.

1 kg = 2.2045 lbs

1 oz = 437.5 grains

1 gram = 15.43 grains

1 m = 1.0936 yd

1 m = 39.37 inches

English count = Number of hanks which weight one pound

Count = hanks / Pound

Cotton hank = 840 yd

Worsted hank = 560 yd

Linen hank = 300 yd

Silk hank = 840 yd

SPIN PLAN

Spin planning is the job to control production and quality of end

product i.e. yarns at various stages of spinning process.5

Factors on which “SPIN PLAN” will depend

Type of raw material

Production capacity of mill

Capacity of each machine

Counts to be spun and their quantities

Number of machines available.

Number of qualified personals.

MIXING

Number of bales used daily = 220 bales

Final tuft size = 20-30 gm

Jute picked daily = 250gm

Method of mixing = Mechanical

BLOW ROOM

Number of lines = 2

C.V. % = 1 %

Waste% = 5.6%

Beating point = 3

Cleaning efficiency = 60%

CARDING

Total No. Of cards = 40

Grains/yd = 67

Mechanical draft = 98

Actual draft = 105

Waste % = 5.3 %

6

Cleaning efficiency = 80 %

Production efficiency = 85 %

Production = 400 - 450 lbs / hr / card

C.V. % = 3.5 %

U % = 4.5 %

DRAW FRAME BREAKER

Total number of frames = 9

Grains / yd = 67

Draft = 8

Doubling = 8

Delivery rate = 350 m / min

Efficiency = 85 %

No. of deliveries = 2

Production = 340 lbs / hr / frame

C.V. % = 2 %

U % = 3.5 %

DRAW FRAME FINISHER

Total number of frames = 8

Grains / yd = 67

Draft = 8

Doubling = 8

Delivery rate = 700 m / min

Production efficiency = 85 %7

No. Of deliveries = Single

Production = 340 lbs / hr / frame

C.V. % = 1 %

U % = 2 %

SIMPLEX

Total number of frames = 9

Hank roving = 0.98

Flyer speed = 1050 rpm

Total draft = 7.2

Delivery rate = 25 m/min

Twist per inch = 1.12

Production rate = 320 lbs / hr / frame

C.V. % = 2.5 %

U % = 4.5 %

RING FRAME

Count = 20 s/ 1 carded hosiery

Total No. of frames = 60

Draft = 25.09

T.P.I = 17.4

Delivery rate = 21 m / min

Spindle speed = 14750 rpm

O.P.S. calculated = 10.75

Production efficiency = 80 %

8

C.V. % = 2 %

U % =10 %

WINDING

Total No. of machines = 12

Winding rate = 1000 m / min

Cone weight = 4.16 lbs

Tolerance limit = + 20 gm

Efficiency = 68 %

Production = 160 lbs / hr / frame

PACKING

No. of cones / bag = 24

Net weight of bag = 100 lbs

RAW MATERIAL

STUDY OF RAW MATERIAL

Raw material used in Nishat Textile Mills Unit NO. 7 is cotton of

variety MNH-93, GIZA 86, 88, 89, and also Indian Cotton. Mainly

second pick is preferred. Cotton is purchased from different

stations of the Punjab like

Bahawalpur

Bahawalnagar

Hasilpur

9

Lodhran

Mailsi

Garha Morr

Vehari

Rahimyar Khan

Chistian

Haroonabad

Ahmedpur

Major characteristics involved in the evaluation of cotton quality are

Fibre Length

Uniformity ratio % age

Short fibre % age

Fibre Fineness

Fibre Maturity

Fibre Strength

Fibre Elongation % age

Fibre Cleanliness % age

Color Grade

Honey Dew

Moisture % age

Net bale weight = 160-170 kg

Average bale weight = 165 kg

Tare weight = 2.0 – 2.5 kg

TARE WEIGHT INCLUDES:

10

Wire weight = 0.6-0.7 kg

Strip weight = 2-2.5 kg

For quality assessment, the following instruments are available in

the cotton-testing laboratory.

Fibrograph 910

Shirley Analyzer (AAK-2)

Fineness maturity tester (FMT)

Shirley Moisture meter

Uster tester (UT-3)

HVI 900

AFIS

Pressley bundle strength tester

11

12

QUALITY LAB

Quality lab has following instrument for testing quality

parameters of cotton fibre, yarn and fabric. Polyester is also

tested.

Mahlo or texto moisture meter:

This moisture meter is used for measuring moisture

content of cotton. Samples from lot are tested by this meter and

reading of moisture content is noted from three different places

and then takes its average for accurate reading of moisture

content.

Oven for moisture:

This is also used for moisture measurement. Weight of

cotton sample before and after heating in chamber of oven is

noted and then moisture is calculated.

If

W = Sample weight

W1 = Dry sample weight

M = Moisture content

Then

M = W – W1

Trash analyzer:

It is also called Shirley analyzer. It is used to determined

amount of trash in raw cotton. Sample of cotton is weighted

before and after trash drop out and so amount of trash is

calculated by difference of weight.

13

UV Meter:

It is also called as ultra violet meter. It is used for testing

color fastness of polyester. A sample is tested from four sides by

UV meter and then average of four readings is calculated for

accurate results. As reading is high polyester is of good quality

and vice versa.

HVI Spectrum:

HVI Spectrum is used to determined micron air value,

maturity, length, uniformity, amount of fibres, short fibre

index(SFC), strength, elongation, moisture, Rd value, +b value,

color grade, trash count, trash area and trash grade. Moisture and

maturity are two additional properties of HVI spectrum as

compared to HVI 900.

HVI 900:

HVI 900 is used to determined micron air value, length,

uniformity, amount of fibres, short fibre index(SFC), strength,

elongation, Rd value, +b value, color grade, trash count, trash

area and trash grade.

AFIS:

AFIS is used for advance fibre integration system. This

instrument is used for nep testing, length and maturity testing

and trash classification testing. Three testings can also be done

separately. A sliver of weight 0.4-0.6gm with length 30 cm is used

for accurate determination of neps, trash and fibre count.

Hairiness tester G 566:

14

Hairiness of yarn is determined by this tester. Sample of

yarn is fed to the suction hole of the tester and hairiness is

measured.

Uster Tester-3 (UT-3):

It is used to determined uniformity, CV% at 1m, CV% at

3m, CV% at 10m, thick places and thin places of yarn. After

passing over yarn guide yarn sample is fed to the suction hole of

the uster and then results are noted.

Nishat Textile Mills has a combined “Cotton Testing

Laboratory” which tests raw material for whole group. This

laboratory is situated in Unit NO. 5

Laboratory Incharge:

M.M Quality Hafiz Mumtaz (M.Sc. Fibre Tech.)

Laboratory Technician 3

Temperature 20 - 23oC

R.H. % 60- 65 %

Acceptable limits in Nishat Textile Mill Unit No.7 for the selection

of cotton are:

15

Neps : 150 - 250 /gm

Mice : 3.5 - 5

Rd : 65 - 75

+b : 7.5

Gm / Tex : 20 - 24

Length : 1.04˝ - 1.9˝

Elongation : 4 - 8

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MIXING

Mixing is done to thoroughly mix the fibres with each other as

they have different physical parameters. The natural fibres

always differ from each other in the following properties i.e.

length, maturity, strength cleanliness, moisture, shade, etc. so.

1. Uniform mixing is very essential to achieve uniform yarn

results

2. Homogeneous mixing can minimize ends down rate.

3. Higher production rate can be achieved. Some times

different varieties of cotton are mixed for these purposes.

a. To achieve the required results of yarn

b. To minimize the cost

METHOD OF MIXING IN NISHAT TEXTILE MILLS UNIT NO. 3

No. of bales blended daily = 140 bales

No. of lots present = 44 lots

No. of bales taken / lot = 1-7 bales / lot

Net weight of bale = 153-170 kg

Bale dimensions H = 45˝, W = 20.5˝, L = 31.5˝

Bale volume = 16.93 ft3

Bale density = 9.74 kg / ft3

17

In Nishat Textile Mills Unit No.7 mixing is done mechanically by

means of 11 Auto Pluckers. 20 bales are placed in each Plucker.

140 bales are fed in all Auto Pluckers and time taken to open and

mix all the bales is 24 hours.

Condenser takes the material from Auto Plucker. Two condensers

are used for 3 Auto Plucker. From condenser material is passed to

a conveyer lattice. From here feeding of cotton is done on the

feed lattice of Bale opener. The entire condensers are fitted with

the yellow color pipes that are used to carry waste to the filter

bags.

AUTO PLUCKER

The function of this machine is to pluck the cotton, medium

length fibre and synthetic fibres.

It consists of following parts.

1. Telescope pipe

2. Carriage

3. Plucking beater

4. Center axle

5. Inner round frame

6. Outer round frame

7. Rail

It is also included that some roving, sliver and pneumaphil waste

are also added in the plucker along with bales in the following

quantity;

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Sliver 50 kg

Roving 15 kg

Pneumaphil 50 kg

TECHNICAL DATA:

Name Automatic Disk Plucker

M/C model = FA002

No. of Machines = 11

Out put = 1800 kg/hr

Beater rpm = 800-900

No. of Motors = 3

Time taken = 35 s/rev

Dia of rail = 5200mm

Main Motor speed = 960 rpm

CONDENSER

Fan speed = 1600 rpm

Cage speed = 90-110 rpm

Leather beater speed = 250-300 rpm

Suction pressure = 300-350 Pa

19

20

BLOW ROOM

Blow room is a collection of various machines working on different

principles to achieve different objectives. Almost all the machines

associated with blow room work with air currents hence this unit

of machines is called Blow Room.

OBJECTS OF BLOW ROOM

Pre opening

pre cleaning

mixing or blending

fine opening

de-dusting

Regulation

Drafting

To prepare fed for card, material is led to card by lap

feeding.

PRINCIPLE OF WORKING

Following are the principles on which different machines of blow

room work.

No of opening machines

Type of beater

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Type of beating

Beater speed

Amount of trash in the material

Type of trash in the material

Temperature and relative humidity in the blow room

department

BLOW ROOM LINE

Sequence of machines

Auto Blander

Uni-clean (B11)

Porcupine beater

Porcupine beater (Fully spiked)

Loptex

TV Fan 425

3-Hopper feeder

3-Scutcher

UNI-CLEAN:

Uniclean is an efficient cleaning and dedusting machine, which is

used immediately after Auto Blander.

22

Uniclean has a single cylinder with special type of pins on its

surface.

The material is fed to uniclean and passed mechanically seven

times over the cleaning grid on special pins. In the process raw

material is guided over the integrated dedusting filter, where

dust, fibre fragments & paper trash are stripped off mechanically.

The cleaning process takes place undisturbed by air currents and

thus in a controlled and effective manner.

The trash removed drops into the waste chamber and is fed to

the waste removal system by an air lock cylinder.

MAIN FEATURES

Production up to 1200 kg/h card sliver

Optimum raw material utilization

High cleaning performance

Low air and space requirements

Low maintenance requirements

TECHNICAL DATA

Cleaning cylinder dia = 750 mm

Speed = 480 - 980 rpm

Production = Up-to1200 Kg / h card sliver

Waste % age = Up-to 6 %

Length = 2200 mm

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Width = 1040 mm

Height = 2000 mm

Material = Cotton, Cotton waste

PORCUPINE BEATER (RN-I&RN-2)

Material after passing from B-11, comes under the influence of

RN-I & then RN-2. A condenser (cage) is mounted on the upper

side of the machine which takes material from back and fall it to

the hopper feeder. Hooper feeder consists of a photocell that

keeps the material quantity always constant. A stripper roll is

present in hopper that stops when a sufficient amount of material

is collected in hopper. A porcupine beater has ability that it is

suitable for the low-grade cotton and use in many opening &

cleaning lines.

TECHNICAL DATA:

Beater type = Porcupine

Beater dia = 490 mm

Beater speed = 800 rpm

Length of beater = 1060 mm

No. of grid bars = 36

Power consume = 7.55 kw

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LOPTEX:

Loptex is used for detection of

foreign matter in cotton. It

works on the principle of

optical sensing. The sensors

detect foreign matter and

separate them.

ARGUS (AD-50) METAL DETECTOR:

It detects any metal part in blow room line.

There are tow metal detector

in two blow room lines of unit

#7.

Beating points in blow room

Uni-clean (B11) = 1/2

Porcupine RN-1 = 1

Porcupine RN-2 = 1/2

Scutcher = 1

Total beating points = 3

25

Waste calculations in Blow room

Waste = Lint - Trash

Trash = Foreign matter only

Waste % = (input-output) x 100 Input

CLEANING EFFICIENCY:

Cleaning efficiency of the machine is the ratio of the trash

removed by the machine to that of total trash fed to the machine,

expressed as percentage

CLEANING EFFICIENCY %

Trash % in mixing - Trash % in lap х 100 Trash % in mixing

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CARDING

The word carding is derived from a Latin word “Cardous” which

means a state of single fibre separation. On card machine we

obtain a state of material where each individual fibre is separated

from there fibres.

Experts explain carding as the heart of spinning process. This is

because; it is the last stage for removal of Impurities and neps.

Moreover, once an irregularity is introduced in the material, it

would be further drafted in the subsequent processes of spinning.

DETAILS ABOUT CARDING DEPARTMENT

Total Number of cards 40

Company Crosrol

Model MK 4

Temp. 30 oC

RH% 50 %

OBJECTS OF CARDING

In short the objects of carding are:

To open the lap into individual fibres

Elimination of impurities

Reduction of neps

Elimination of dust

Elimination of short fibres

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Fibre blending

Fibre orientation

Sliver formation

PRINCIPLES OF CARDING

Point to point

The point of wire end of one surface faces the point of wire end of

other surface. These results in opening of fibres into single fibre

state which causes cleaning of material.

Point to back

The point of wire point of one surface faces the back of wire point

of other surface. This results in transfer of material from latter to

the former surface.

ESSENTIALS OF CARDING

Carding

a. Point-to-point action

b. Maximum speed is very high as compared to that of flats

c. Setting between the two surfaces

Stripping

a. Point to back action

b. Maximum speed ratio difference

c. Setting between two surfaces

Brushing and Raising

a. Back to back action

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b. Speed difference ratio

c. Setting between the two surfaces

SPECIFICATION OF WIRE POINTS

FOR TAKER-IN

Type = Interlock

Height = 5 mm

Angle = 80o

Thickness = 1.1 mm

Wire points/inch2 = 36

FOR CYLINDER

Type = ECC

Height = 2mm

Angle = 50o

Thickness = 0.85 mm

Wire points/inch2 = 800

FOR DOFFER

Type = ECC

Height = 4 mm

Angle = 600

29

Thickness = 0.85 mm

Wire points/inch2 = 400

FOR TOP SET

Type = KBS-450

Height = 8 mm

Angle = 75o

LIFE OF CLOTHING

Doffer clothing life = 2 years

Taker-in clothing life = 1 year

Cylinder clothing life = 2 years

Flats clothing life = 2 years

Stationary flats life = 2 years

TYPES OF WASTE ON CARD

There are five points where waste is separated from fibres on the

card. These waste points are:

1. Mote knife separation

2. Taker-in under-casing

3. Cylinder under-casing

4. Flats waste separated by stripping roller

5. Cylinder wire waste separated by stationary flats

30

A suction system collects all the falling waste at one end of card.

From there they are conveyed to the filter room, in which fibres

are separated from dust and other material on a special machine

called fibre separator.

The fly waste is also sucked by vacuum pipes and carried to filter

room by a separate duct.

CARD -MK 4

Taker in = 1200 rpm

Dia = 10 inch.

Cylinder = 519 rpm

Dia = 51 inch.

Doffer = 96 rpm

Dia = 27 inch.

Flats = 10 inch/min.

Delivery speed = 155m/min.

No. of moving flats = 101

No. of stationary flats = 5

OBSERVATIONS AND CALCULATIONS

CYLINDER

RPM of cylinder = 519

S.S of cylinder = Π DN

31

= Π × 51×519

= 83112.66 inch/min

TAKER IN

RPM of taker in = 1200

S.S of taker in = Π ×1200×10

= 37680 inch/min

DOFFER

RPM of doffer = 96 rpm

S.S of doffer = π×96×27.55

= 8307.40 inch/min

FEED ROLL

RPM of feed roll = 5.2 rpm

S.S of feed roll = Π ×5.2×7.08

= 115.60 inch/min

DRAFT CALCULATION

Major draft between roller and doffer

= S.S of doffer/ S.S of feed roll

= 8307.40/ 115.60

= 71.86

32

Total mechanical draft = 13.58 /.1531

= 88.75

Actual draft = wt/yd fed wt /yd delivered

= (14/.1531)

= 91.43

Note: In cotton card actual draft is always greater than

mechanical draft due to waste removal.

Draft constant = Mechanical draft × DCP

= 88.75 × 25

= 2218.75

CARDING RATIO OR POWER

CP = Surface speed of cylinder Surface speed of flats

= 83112.66 7.87

= 10560.69

STRIPPING RATIO OR TRANSFER RATIO

T.R. = S.speed of cylinder/ S.speed of taker in

= 83112.66/37892.28

= 2.193

CONDENSATION FACTOR

C.F. = S.speed of cylinder/S.speed of doffer

33

= 83112.66/8307.40

= 10.04

CARD MAINTENANCE STAFF

Foreman = 1

Maintenance supervisor = 1

Fitter = 3

Helper = 1

Total = 6

PRODUCTION STAFF

M / C operator = 20

Helper = 2

Floor cleaner = 2

Supervisor = 1

Total = 25

CLEANING EFFICIENCY

Select at least 4 cards per-mixing for each group of card of same

type. Estimate trash in lap and the sliver by using a trash

analysis.

Cleaning Efficiency = Trash in lap - trash in sliver Х 100 Trash in lap

The cleaning efficiency of cards is to be judged together with

waste extracted.

34

Process at least one lap on each of 4 cards now collect the waste

region wise and weigh it. The total collected wastes at a card

expressed as a percentage of the weight of waste %age at each

region taker-in (Dropping) and flats (fly). The %age waste

depends upon

i. Type of mixing

ii. Trash in lap

iii. Type of cards

PRODUCTION

Actual Production = Doffer’s.speed Х Tension Draft Х Efficiency

35

DRAW FRAME

NECESSITY OF DRAW FRAME

From a purely commercial viewpoint the draw frame is of little

significance. It usually contributes less than 5% to production

costs of the yarn. However, its influence on quality, especially

evenness, is advantage of this. Further If the draw frame is not

perfectly adjusted there will also be effects on yarn strength and

elongation.

There are two main reasons for the considerable influence of the

draw frame on evenness. First, within the sequence of machines

in the cotton-spinning mill, the draw frame is definite

compensation point for eliminating errors. The yarn can never be

of good quality without draw frame passage.

TASK OF DRAW FRAME

i. Lay the sliver income with uniform coil forming a central

hole.

ii. Thorough mix different type of fibers so as to gives a

homogeneous blending.

iii. Improve the regularity in weight per unit length over a

considerable length of the material through doubling of a

number of slivers from different cards.

36

iv. Remove the hooks of the carded fibers and straighten the

fibers by gliding them over one another during drafting.

v. Parallelize the Criss-Crossed fibers of the card silver with

one another and align them to the axis of the sliver through

the process of drafting.

vi. Cross canning is used to traverse blends

The factors that affect the yarn qualities are

The total draft

No. of draw frame passages

Break draft

No. of doublings

Grams/meter of sliver fed to the draw frame

Fibre length

Fibre fineness

Delivery speed

Type of drafting

DRAWING DEPARTMENT OF UNIT # 7

In Unit No 7 of Nishat Textile Mills, there are total 17 drawing

frames. 9 drawing frames are used as breaker, 8 as finisher.

Total No. of frames 17

37

Company Rieter

Model RSB-D30

No. of frames 8

Make TOYODA

Model DX-8

No. of frames 5

Make TOYODA

Model DYH-500C

No. of frames 4

ABOUT RSB-D30

Length of machine = 1800 mm

Height of machine = 2000 mm

Width of machine = 2410 mm

Drafting system = 4/3 with pressure bars

Draft range = 4 - 12

Delivery speed = 400 m / min

Can dimension = 20 × 42 inches

No. of deliveries = single

No. of doublings = 8

Length of sliver in cane = 5000 yards

DIAMETER OF DIFFERENT ROLLERS

Back bottom roller = 30 mm

Middle bottom roller = 30 mm

38

Front bottom roller = 40 mm

Top roller = 38 mm each

SETTING OF DRAFTING ROLLER

Back zone

Roller gauge = 6 mm

Nip to nip setting = 41 mm

Middle zone

Roller gauge = 5 mm

Nip to nip setting = 40

Front zone

Roller gauge = 6.5 mm

Nip to nip setting = 41 mm

FACTORS ON WHICH SETTING WILL DEPEND

1. Hank sliver

2. Shorter fiber %age

3. Staple length

4. Level of draft

Top roller weighting / pressuring

Pressure system = Spring pressure

Color of spring used = Red

Amount of pressure used

On front and IV roller = 40 kg on each side

On 2nd and back roller = 30 kg on each side

39

On pressure bar = 10 kg on each side

Life of cots = 2 Years

Rotary speed calculations

Motor speed = 1450 rpm

Motor pulley dia = 167 mm

Machine pulley dia = 100 mm

Calendar roller

Rotary speed of machine pully = 1450 × 167/100

= 2421.5 rpm

Surface speed of calendar roll = ΠDN

= 3.14×51/1000×2421.5

= 387.78 m/min

Front roller

Rotary speed = 2421.5 × 44 ×48 49 30

= 3479.05 rpm

Surface speed of front roll = 3.14×3479.05×35/1000

= 382.34 m/min

2nd roller

Rotary speed = 2421.5 × 23 × 71 77 81

= 634.008 rpm

Surface speed = ΠDN

40

= 3.14×35/1000×634.008

= 69.71 m/min

3rd roller

Rotary speed = 2421.5 ×23/77 × 71/81 × 37/59 × 47/30

= 622.904 rpm

Surface speed = ΠDN

= 3.14 × 35/1000 × 622.904

= 68.49 m/min

Back roller

= 2421.5 × 44/75 × 68/59 × 37/114 ×44/52

= 449.65 rpm

Surface speed = ΠDN

= 3.14 × 35/1000 × 449.65

= 49.44 m/min

DRAFT CALCULATIONS

Draft b/w 3rd and back roller

D1 = Surface speed of 3 rd roll Surface speed of back roll

= 68.49 49.44

= 1.385

Draft b/w 2nd and 3rd drafting roller

41

D2 = S. speed of 2 nd roll S. speed of 3rd roll

= 69.74 68.49

= 1.018

Draft b/w front roll and 2nd drafting roller

D3 = S. speed of front roll S. speed of 2nd roll

= 382.34

69.71

= 5.48

Draft b/w front and calendar roller

D4 = S. speed of calendar roll S. speed of front roll

= 387.78 382.34

= 1.014

Total draft of drafting system

D = D1 × D2 × D3 × D4

= 1.385 × 1.018 × 5.48 × 1.014

= 8.01

Draft constant

D.C. = Draft × D.C.P

= 8.01 × 33

= 264.99

42

Production Calculations

Actual production = S. speed of C.R. (inch. /min) × 60 × 67 ×8 ×85Lbs / shift. 7000 100

= 387.78 x 39 ×60× 67 ×8 × 0.8536 x 7000

= 1640.53 lbs / shift / delivery

= 3281.06 lbs/ shift / D.F.

STOP MOTION

1. Photo-cells are mounted at creel which sense the

absence of any sliver

2. A motion stops m/c in case of roller lapping.

3. M/C stops automatically when said length is completed in

the can.

CAN CHANGE MOTION

When one can is filled, it is replaced by empty can and machine

starts automatically.

MAINTENANCE SCHEDULE OF DRAWING FARME DEPARTMENT

DAILY

Cleaning of coiling section of all frames

Oiling of gearing heads

43

Checking of stop motions completely

One draw frame is opened for checking

Cleaning of auto can changer completely

Checking of drafting roller

Monthly

Drafting zone

Checking of bearing

Checking of coiler side, creel and calendar roller section

After 3 months

General over hauling of one draw frame

Top roller grinding

Complete over hauling of auto can changer

Signal Lamps

On creel for indication of sliver absence

On delivery end for indication of absence of can is can

changer

For doffing indication.

Atmospheric Conditions

Temperature = 96oF

Relative humidity = 58%

44

45

ROVING FRAME

NECESSITY OF ROVING FRAME

The draw frame produces a sliver that already exhibits all the

characteristics required for the creation of yarn namely an

ordered, clean strand of fibers laying parallel to one another. It is

a fair question to ask why this sliver is not used as in feed

material for the ring spinning machine, instead of being

processed in an expensive manner to create a roving as feed for

spinning. The roving machine itself is complicated, liable to faults,

causes defects, adds to production costs and delivers a product

that is sensitive in both winding and un-winding. Use of the

machine is forced upon the spinner as a necessary evil for two

principal reasons.

The first reason is related to the required draft. Sliver is a

thick, untwisted strand that tends to be hairy and to create fly.

The draft needed to covert this to yarn is in the region of 300-

500. The drafting arrangements of ring spinning machines, in

their current forms, are not capable of processing this strand in

single drafting operation to create a yarn of short-staple fibers

that meets all the normal demands on such yarn. The fine,

twisted, roving is significantly better suited to this purpose.

46

The second reason is that draw frame cans represent the

worst conceivable mode or transport and presentation of feed

material to be ring spinning frame.

TASKS OF RONGVING

Attenuation of the sliver

Insertion of twist in order to hold small number of fibers

together

Winding of roving into package that can be transported,

Stored and processed on the ring-spinning machine.

SIMPLEX DEPARTMENT

Simplex frames 9

Company Toyoda FL-16

Observations:

Total no of machines = 9

No. of spindles per frame = 120

Model = FL-16

Make = Toyoda

Mfg. Year = 1991 model

Spindle speed = 1050 rpm

Delivery rate = 24 m/min

Production efficiency = 85 %

TPI =1.02

47

Drafting System = 4/4 arrangement

Range of draft = 5-25

Applied draft = 7.5

Twist range = 0.7 - 1.5

Twist applied (T.P.I) = 1.02

Rail balancing method = Dead weight

Temperature = 96Fo

R.H. % = 58 %

SETTING ON SPEED FRAME

Front zone setting

Roller gauge = 6 mm

Nip to nip setting = 35.0 mm

Middle zone setting

Roller gauge = 20 mm

Nip to nip setting = 49 mm

Back zone setting

Roller gauge = 21 mm

Nip to nip setting = 50 mm

FACTORS ON WHICH SETTING WILL DEPEND

Hank sliver

48

Short fibre % age

Staple length

Level of draft

Top Roller Pressure

Pressure system = spring pressure

Pressure on front roller = 10 kg

Pressure on second roller = 21 kg

Pressure on third roller = 14 kg

Pressure on Back roller = 14 kg

Spacer:

For 1st hank roving black spacer is used which cause 7 mm apron

nip.

STOP MOTIONS

Condition Color

Machines is at rest Red light

Sliver breakage at creel by photocell Green light

Roving breakage by photocell Yellow light

Indication of doffing White light

CALCULATIONS

Motor speed = 960 rpm

49

Motor pulley dia = 190 mm

Drive pulley dia = 222 mm

Twist change gear = 43 T

Total draft change gear = 46 T

Back draft change gear = 60 T

Spindle speed = Motor rpm × 190 × 47 × 47 222 54 32

= 960 х 190 × 47 × 47 222 54 32

= 1050.325 rpm

Front roller speed = Motor rpm × 190 × 82 × 72 × T.C 222 91 91 91

= 960 х 190 × 82 × 72 × 43

222 91 91 91

= 276.797 rpm

2nd roller speed = Motor rpm × 190 × 82 × 72 × 43× 20 222 91 91 91 21

= 960 х 190 × 82 × 72 × 43 × 20 222 91 91 91 21

= 263.616 rpm

3rd roller speed = Motor rpm×190×82×72×43×26×46×33× 60 222 91 91 91×104 83 61 26

= 47.88 rpm

Back roller speed = Motor rpm × 190 × 82 × 72 × 43× 26 × 46 222 91 91 91×104 83

= 38.35 rpm

50

Draft Calculations

D1 = front zone draft = Surface speed of F.RSurface speed of 2nd roll

= 276.79× D × Π263.616×D×Π

= 1.05

D2 = draft b/w 2nd&3rd rolls = Surface speed of 2nd roller Surface speed of 3rd roller

= 263.616 47.88

= 5.50

D3 = Break draft = Surface speed of 3rd roller

Surface speed of back roller

= 47.88 38.35

= 1.25

Total draft = D1 × D2 × D3

= 1.05 × 5.50 × 1.25

= 7.22

Draft constant = Total mechanical draft × TDC

= 7.22 × 46

= 332

T.P.I = Spindle rpm Surface speed of front roller

= 1050.325

Π D N (inch/min) 51

= 1050.325 975.19

= 1.0765

Twist constant = T.P.I. × T.C.

= 1.0765 × 43

= 46.29

T.M. = T.P.I.

√ Hank

= 1.0765 0.9899

= 1.09

PRODUCTION

Calculated production (lbs/shift) = spindle rpm × 60 × 8 T.P.I × 36 × 840 × count

= 1050.325 × 60 × 8 1.0765× 36 ×840×0.98 = 15.80 lbs / shift / spindles

Efficiency of simplex = 85 %

So actual production = 15.80× 85 100

= 13.43 lbs / shift / spindle

Total no of spindles = 120 / frame

Total production = 13.43 × 120

=1611.6 lbs / shift / frame

MAINTENANCE STAFF

Drawing (Breaker and Finisher) and simplex

52

Foreman : 1

Supervisor : 1

Fitter : 2

Assistant fitter : 1

PRODUCTION STAFF

Jobber : 1

Double simplex tender : 3

Drawing tender : 2

Doffer : 3

Floor cleaner : 2

MAINTENANCE SCHEDULE

DAILY

One machine dismantled for cleaning.

Top and bottom cone drum bearing jack box bearing

gearing head, bobbin wheel shaft, and head bearing.

Checking and oiling of every part of the machine.

Quarterly

One machine complete dismantled

Top rail, bottom rail, spindle rail and spindle shaft check

completely

Jack box, building motion checking and adjustment

The remaining parts are checked and over hauled

Half yearly

53

Checking of top and bottom aprons

Grinding of top roller and changing of grease

54

55

RING FRAME

An American, Thorpe invented the ring spinning frame in the

year 1828. In 1830 another American jack, contributed the

traveler rotating on the ring. Now more than 150 years have

passed since that time, the machine has experienced

considerable modification in detail, but the basic concept has

remained unchanged.

Further developments on large scale appear unlikely because of

the traveler, the amount of heat developed in the traveler at high

speeds is considerable, and it is extremely difficult to conduct this

heat away in the short time available, the traveler speed is thus

limited.

In spite of this ring spinning frame is most widely used from of

spinners because;

It is universally applicable i.e. any material can be spun to

any required fineness.

It delivers a yarn with optical characteristics (especially with

regard to structure and strength).

It is uncomplicated and easy to master.

It is flexible as regards quantities (blend and lot sizes)

TASKS

The ring-spinning machine is designed to;

56

Attenuate the roving until the required fineness is achieved.

To impart strength to the fibre strand by twisting it.

To wind the resulting yarn in a form, suitable for storage,

transportation and further processing.

Ring department of Unit # 7

Total No. of frame = 60

Company = Toyoda

Model = EJM 168

No. of spindles per frame = 480

Total No. of spindle = 28800

DIAMETERS OF DIFFERENT ROLLERS

Dia of front drafting roller = 25 mm

Dia of middle bottom drafting roller = 25 mm

Dia of back bottom drafting roller = 25 mm

Top roller dia = 28 mm

Cots’ dimensions = 19 × 28 × 26

Top apron life = 2 years

Bottom apron life = 1 ½ years.

DRAFTING ROLLER

Front zone = 44 mm

Back zone = 46 mm

57

PRESSURE ON TOP ROLLERS

Pressure on front top roller = 18 kg

Pressure on middle top roller= 16 kg

Pressure on back top roller = 14 kg

ATMOSPHERIC CONDITIONS

Temperature = 94oF

Relative Humidity = 60 %

Machine data (EJM 168)

Length of machine = 18800 mm

Width of machine = 760 mm

Type of drafting = 3/3 apron drafting

Ring dia = 42 mm

Type of ring = HY (Chinese)

Flange No. = 1

Flange width = 3.2 mm

Life of ring = 1 year

Traveler No. = I / 0

Life of traveler = 1 week

Spindle type = blade type (Chinese)

Spindle driving system = Tape and pulley drives 4 spindles

Spindle gauge = 70 mm

Bobbin dia inner = 17 mm

Bottom = 25 mm

Middle = 21 mm58

Top = 20 mm

Bobbin length = 230 mm

Ring rail lift = 8 inch

Balloon height = 9 inch

Dia of balloon control ring = 45 mm

Spacer color = Yellow (3.3 mm)

PNEUMAFIL ARRANGEMENT

This arrangement is attached with the ring frame with the help of

a suction fan at one end of the frames. If thread breaks and

workers are not attentive it piles on the floor and also touches the

neighboring threads and breaks them. Therefore, quality

deteriorates this is why pneumatic pipe is attached with ring

frame.

OBSERVATIONS

Count to be spun = 20 CD

T.M. = 3.89

T.P.I. = 17.40

Ends down % age = 3.5 %

SPEED CALCULATIONS

Motor rpm = 1460 rpm

Motor pulley Dia = 196 mm

Driven pulley dia = 185 mm59

Belt thickens = 4 mm

Spindle speed at start of package = 1460 × 185+4 × 200+0.5 196+4 20.5+0.5

= 13172.85 rpm

Spindle speed at middle of package =1460 × 196+4 × 200+0.5 185+4 20.5+0.5

= 14750.8 rpm

Spindle speed at end of package = 13172.85 rpm

Speed of main driving shaft= 1460 × 196+4 185+4

= 1544.97 rpm

Speed of front roller = 1460 × 39 × 63 × 38 × 36 67 97 81 36

=274.0174 rpm

Speed of middle roller = 274.0174 × 36 × 41 × 43 × 33 × 38 87 84 104 69 28

= 14.85 rpm

Speed of back roller = 274.017 ×36 × 41 × 43 × 33 × 32 87 84 104 82 27

= 10.914 rpm

DRAFT CALCULATIONS

Break draft b/w back roller and middle roller

60

D1 = Surface speed of middle roller Surface speed of back roller

= Π ×(25+(1.1 × 2 × 0.8) × 14.85 Π × 25 × 10.914

= 1.456

Note: 0.8 is the 80% thickness of apron

Main draft b/w middle roller and front roller

D2 = Π ×25+274.0174 Π × (25+ (1.1×2×.8)) ×14.85

= 17.239

Total mechanical draft = D1× D2

M.D. = 1.456 × 17.239

= 25.09

Total M.D = Surface speed of front roller Surface speed of back roller

= Π ×25+274.0174 Π × 25× 10.914

= 25.10

Draft constant = T.M.D. × D.C. = 25.09 Χ 43 = 1078.87

ACTUAL DRAFT

Count delivered = 20

Hank roving = 0.83

A.D. = 20 0.83

61

= 24.09

TWIST CALCULATION

AS

T.M. = 3.89

Count = 20

T.P.I. = T.M. √ Count

= 17.396

Also T.P.I. = Spindle r.p.m. .

Front roller delivery (in/min)

= 14750.8 .Π × 25 × 274.0174

= 17.4

PRODUCTION CALCULATIONS

Spindle speed changes during building of package so we take

Spindle speed = 14750.8 rpm

T.M. = 3.89

T.P.I = 17.4

No. of ring frames for 20 CD/H = 60

No. of spindles per frame = 480

So

62

Calculated production Lbs/shift/spindle = spindle speed × 60 × 8 T.P.I. 36 × 840 × count

= 14750.8 × 60 × 8 .

17.4 36 × 840 × 20

= 0.67 lbs/shift/spindle

= 10.765 OPS/shift

Efficiency of ring = 80%

Actual production = 10.765 × 80 100

= 8.61 OPS

Total production of 20 CD/H = 8.61 ×60 × 480

16

= 15498 lbs/shift

=46494lbs/day

= 465 bags / day

Where weight of each bag = 100 lbs

RING MAINTENANCE SCHEDULE

Daily one machine for overhauling (4 hours)

Daily two machines for cleaning (2 hours each)

Daily eight machines spindle bolster cleaning

Daily blower cleaning and checking.

Spindle gauge, lappet, snail wire, and traveler clearer gauge

on every third overhauling.

63

Gear head checking, outer and main shaft checking on

every third overhauling.

Drafting zone, pendulum arm, pressure gauge after six

months

Drafting zone gauge and bobbin hanger cleaning after one

year.

Main shaft bearing, shaft checking + replacement after

three months.

Gear head checking + bearing replacement after three

months.

RIGN FRAME FAULTS

Creel Faults Remedies

Irregular roving feeding improve regularity of roving

Excessive twist in roving decrease T.M. at simplex

Fly accumulation on creel guides clean the creel and guides

Damaged bobbin hanger replace bobbin hanger with a new

one

Drafting Faults Remedies

Incorrect setting of rollers Correct the setting

Incorrect draft distribution Correct the draft distribution

Improper pressure on top rollers Correct the top pressure.

64

Worn out rollers replace the rollers

Damaged cots Grind the cots or replace them

Broken teeth of gears of drafting system

replace such gears.

65

SPINDLE, RING AND TRAVELLER REGION FAULTS

Drafting Faults Remedies

Incorrect setting of lappet guide Correct it

Spindle eccentric Correct it

Less or no oil in spindle tube Correct it

Spindle bearing worn out Fill the spindle tube with out

Wrong setting of traveler clearer Replace it

Worn out ring Replace them with new ones

Wrong setting of traveler clearer Correct it according to count

Loose tapes Correct them by jockey pulley

Vibrating bobbins Incorrect bobbin size be corrected

Excessive tension Check traveler no.

FAULTS DUE TO RELATIVE HUMIDITY

Bottom roller lapping More R.H. %age

Top roller lapping

More fly in the department Less R.H. % age.

REMEDY

Accurate R.H% age should be maintained in the

department.

66

67

WINDING

INTRODUCTION:

“Winding is the process which result in producing a good package

of long length and fault free yarn.”

Most of the spinning mills use automatic winding machines.

Quality of yarn and package and winding machine production are

improving day by day.

The requirement of yarn from the ring department comes in the

small packages (Ring Bobbins). This yarn is full of defect i.e., thick

and thin places etc. these defects are removed on the winding

machines. The objects of winding are:

To prepare a bigger package having sufficient length of yarn

on it.

To remove spinning faults i.e. thick and thin places.

To improve the quality of the yarn

AUTO CONER

The development of automatic winding has reduced the labor

requirement of winding and along with the development of

electronic yarn clearer has been a major factor leading to the

most universal adoption of single yarn winding and cleaning.

68

INFORMATION ABOUT DEPARTMENT

No. of machines 12

Company MURATA

Model 21-C

No. of spindle per machine 60

Winding speed 1000 m/min

Winding range 800 - 1200 m/min

Winding shape (transverse of yarn) 152 mm

Blower cleaner Bs type

Blower exhaust air down

Balloon breaker Triangular (MKC-15)

Doffing method Length doffing from counter

Slubs catcher Uster D-4

Magazine 6 bobbins (75 mm dia)

Tensor positively driven disc type

Suction mouth top Comb type

Tensor spring 0.9mm thickness with red color

Drum dia 90 mm (nose side)

100 mm (cradle side)

Length of drum 170 mm

RPM of drum 1000 rpm

Air for spicing 6 kg

Grooves on drum 2.5

Dia of full cone 180-220 mm

69

Rate of breaking 70 %

Package weight 1938 gms

Paper cone weight 48 gms (40 - 50)

No. of joining/min. 15

R.H. % age of department 65 %

Efficiency 68 %

MAINTENANCE STAFF

Foreman = 1

Fitter = 1

Assistant fitter = 1

PRODUCTION STAFF

Supervisor = 1

Winder = 14

Picker = 7

PRODUCTION

Delivery speed of winding drum = 1000 m/min

Efficiency = 68 %

No. of spindles for 20 CD/M = 60

Calculated production = spindle speed × 60 × 8 lbs/shift/drum 840 × count

Production = 1000 × 1.0936 × 60 × 8 lbs/shift/drum 840 × 20

= 31.25 Lbs/shift/drum

Total production of 20CD = 31.25× 60

= 1875 lbs/ shift/ machine

70

= 5625 lbs/day/ machine

Efficiency = 68 %

Production = 5625 × 68 100

= 3825 lbs/day/ machine

No. Of bags/day/machine = 3825 100

= 38.25 bags

Total production of 12 machines = 460 bags

MAINTENANCE SCHEDULE

DAILY

12 spindles are over hauled daily.

WEEKLY

Greasing of head bearing and main shaft bearing.

Oiling of cone holder, chain of conveyer and greasing of head

chain.

MONTHLY

a. Greasing of head bearing, main shaft bearing and blower

pulley bearing.

b. Checking of drum speed

c. Pressure in pipes

SIX MONTHLY

One compressor head complete overhauling after 6 months

71

ANNUALLY

Head bearings & fan shaft bearing cleaned and greased.

72