Arvind Spin Weav

8/8/2019 Arvind Spin Weav

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SPINNING

Ring Spinning:

In the Ring spinning, yarn is formed from cotton fibres that are twisted together after

being drafted by passing between a set of top and bottom rollers. The yarn then is

wrapped on a bobbin as it spins on a spindle by use of a traveller. The relationship

between roll speeds, traveller speeds and spindle speeds controls the amount of twist in

the yarn.

Flow Chart of spinning process:

Removal & Sliver Pr

BlowRoom

Cotton Tuft

Opening, Cleaning and Blending

Card

Sliver

Individualization of fibers, neps

Removal & Sliver Preparation

Pre Drawframe

BreakerSliver

Parallisation & Improvement in sliver

Unilap

Comber Lap

To prepare Lap sheet suitable for combing

Comber

Combed Sliver

Short fiber removal, individualization & Sliver

preparation


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Post Drawframe

FinisherSliver

Parallisation & Improvement in Sliver Quality

Speedframe

Roving Bobbin

To prepare a suitable Roving for Ringframe by inserting

twist

Ringframe

Yarn

To produce Yarn on smaller package

Random Winding

ClearedY

arn

To prepare bigger package after Removing faults

T.F.O

Double Yarn

To impart twist in assemble yarn & Produce bigger

acka e

Singeing

Singed Yarn

To remove the protruding fibers on the yarn surface

Assembly Winding

Assembled Yarn

To assemble the yarn


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BLOWROOM:-

Blowroom is the first step of yarn production in the spinning mills. Following are the

objective of objective of blowroom department

Opening

Cleaning

Mixing or blending

Microdust removal

Uniform feed to the carding machine

Recycling the waste

Flow chart of blowroom operation:

BLANDOMAT

SPARK DETECTOR

METAL DETECTOR

BALE OPENER

AFC

ASTA

LOPTEX

CVT4 CVT4


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BLENDOMAT

Opening of bales and transporting them to the downstream machine by suction

after blending,cutting and plucking of small tufts.The working process is controlled by a

microcomputer and is fully automatic. The bales are placed manually on the floor in the

marked working area. BDT 019 travels over the bales and holds back the material against thepull of the toothed disc rolls. The material protrudes between the bars of the grids. The

supporting rollers rotate at a peripheral speed, which is identical to disc rolls or grids.

The teeth of the toothed disc rolls pluck the bulging tufts from the surface of the bales and

fly them into the air stream, which removes the tufts by suction. Machine make:

Trutzschler (Germany)

Model no. : BDT 019/2300

Bale layout: Both sides (2 rows)

Number of bales: 50-60

Weight of bales: 110-167 kg

Mode of bale laying: Manual

Material in process: Cotton with seeds and impurities

BALE OPENER (BO)

Objective of this matchine is to clean cotton fibers.Material is fed by the

Feed Lattice and stored in the Reserve Tank and then transferred to the Feed Table that

supplies material to the Spiked Lattice, which then passes it o nto the Evener and Stripper

rollers. The Evener roller brushes the excess material of the spiked lattice and tosses it back

to the Mixing Chamber where a Cleaning roller is installed.Striper roller releases the material

from the Spiked Lattice.

Model no.: BOA 046

Major parts: Feed lattice, inclined spike lattice, perforated condense

Gauge: Distance b/w inclined lattice and opening roller is 20 mm.


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CLEANING AND MIXING:-

If cotton is opened well in the opening process, cleaning becomes easier

because opened cotton has more surface area, therefore cleaning is more efficient.

Due to machine harvesting, cotton contains more and more impurities, which furthermore

are shattered by hard ginning. Therefore cleaning is always an important basic operation.Incleaning, it is necessary to release the adhesion of the impurities to the fi bers and to give the

particles an opportunity to separate from the stock. The former is achieved mostly by picking

of flocks; the latter is achieved by leading the flocks over a grid.

DUST REMOVAL:-

Cotton contains very l ittle dust before ginning. Dust is therefore caused by

working of the material on the machine. New dust is being created through shattering of

impurities and smashing and rubbing of fibers. But dust removal is not simple. Dustparticles are very light and therefore float with the cotton in the transport stream.

Furthermore the particles adhere quite strongly to the fibers. Machines for this process

are:-

AXI-FLOW CLEANER

MULTIPLE MIXER

ASTA

LOPTEX

CVT


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AFC (AXI-FLOW CLEANER):

Objective of AFC is separation of heavy parts (impurities) from cotton.The

opened up mass of fiber rotates around two cleaning rollers (beaters) with cylinder steel pins

which beat the fiber material, allowing the coarse particles to be separated.The time (in

hours) of the passage of material can be regulated by a detector in the in-jet and thedeflector above the beater. The air volume of the extractor machine and the input time can

be regulated with a flash on screen at the outlet.The coarse particles drop through adjustable

grids and are made available by means of a wheel lock.The cleaned tufts are carried through

outlet pipes to the downstream machine with the help of air flow.

Machine details:

Machine make: Trutzschler (Germany)

Model: 052-2502

Pressure: 50-75 bar

Major parts: Two metallic perforated cylinders and waste collector

MPM 10 (MULTIPLE MIXER):

Objective 0f multiple mixer homogeneous mixing of cotton fibers .Material from different heights

are fed to ensure proper mixing.

Machine details:

Make: Trutzschler

Model: 10236

Motor speed: 1750 rpm

Opening rolls speed: 800-850 m/min

Number of chambers: 10

Output: 30-36%

Pressure: 350 bar

Major parts: This machine consists of material feed, reserve tank, reserve tank

flaps, optical sensor,delivery,rollers, and material suction funnel.


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ASTA

Objective of ASTA Heavy trash separation from cotton. The air

and material enters the separation tank in a stream via upper channel and strikes the

baffle plates. Heavy particles are removed away from the lighter fibers by negative

acceleration and the force of gravity. The lower channel generates an opulent air

stream in the area of baffle plates, which guides the fibers to the outlet.

Machine details:

Make: Trutzschler (Germany)

Model: ASTA 800

Principle: principle of aerodynamics

LOPTEX

Machine details:

CVT;-

Main operation is Separation of residual trash from cotton. From ASTA

the material is carrie twodifferent lines BS 1 and BS 2. The feedrollers throw the material and

transfer it to the first roller where the opening takes place less aggressively. The material isthen passed through other rollers sequentially which beat the cotton and hence remove the

residual trash.


Model: Optasonic t 120

Voltage: 415 v

Frequency: 50 Hz

Power: 1.5 KwA

Pressure: 0.6 to 0.8 M Pa


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Machine details:


Model: CVT-4 1600

No. of machines: 2

Cleaning efficiency: 18-30%


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Feeding process to card

There are two process to feed the raw material that is open fibre to carding machine

1. scutcher lap

Linear density of the lap is very good and it is easier to maintain(uniformity)

The whole installation is very flexible

Deviations in card output will be nil, as laps can be rejected

Investment cost and maintenance cost is less

Transportation of lap needs more manual efforts( more labour)

2. Flock feed system

High performance in carding due to high degree of openness of feed web

Labour requirement is less due to no lap transportation and lap change in

cards

Flock feeding is the only solution for high production cards

Linear density of the web fed to the card is not as good as lap

Installation is not flexible

Autoleveller is a must, hence investment cost and maintenance cost is more

Machine details:

Number of machines: 14


Model: DK 803

Humidity: 56.5%

Temperature: 33.3 degree Celsius

Production: 80 kg/hr.

Card cleaning efficiency: 62-67%

CV%: 1.2-1.7

Front Delivery speed: 210-240 meters per minute

Pressure: 325 pas


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Licker in:

Diameter: 102 mm

Speed: 1960 rpm

Cylinder:

Diameter: 1290 mm

Speed: 600 rpm

Doffer:

Diameter: 700 mm

Speed: 96 rpm


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COMBING:-

Combing is an optional process introduced into the spinning of finer and high -

quality yarns from finer cotton for great evenness, smoothness, fineness and strength. For

coarser cotton fibers, the combing operation is usually omitted. This operation combines several

card slivers which are drawn into the comber and, once again, spread into a web. The fibers

continue to be cleaned and straightened as the web is formed. Short fibers and all residual non -

lint materials are removed.

It influences the following yarn quality

Yarn evenness

Strength

Cleanness

Smoothness

Visual appearance

Objectives of combing:

Removal of short fibers

Removal of remaining impurities

3 .Removal of neps

FLOWCHART OF OPERATION IN A COMBER:-

Feeding of lap to machine

Through nipper griped by fed lap

Lap is combed by circular comb

Detatchin roller ri the combed la

Mean while top roller comes into action for further


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Machine details:

Make: Reiter

Model: Reiter E60

Input 8 laps

Output 2 cans

Machines 15

Feed cotton laps:

Width 300mm

Diameter 600mm

Fixed quantity of laps 60 - 70gsm

Length of cotton Spinning fiber: 25 - 51mm

Fixed output of combed strips: 3 - 6gsm

Pressure of compressed air: 0.6 - 0.8MPa

Air consumption: 1.5Nm3/h

Total power: 14.25 KW

Dimensions: 7,230 x 2,120 x 1,700mm

Lap

Roller

Comb

Combed sliver


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UNILAP

Objective of unilapis formation of laps. The laps produced in the

unilap machine are stored on creels which can be transported to the combing machines .

Machine details:

Make: Rieter

Model: E 30

No. of machines: 3

Major parts: Creel, Scanning roller, Drafting zone, Delivery roller and sliver deposit

Input cans: 26

Output laps: 1

Length of lap: 300 meter.

Speed: 650 m/min.

Efficiency: 75%

Temperature: 31 degree Celsius

RH%: 50%


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Drawframe

Drawing follows either combing or carding, depending on the

quality of yarn desired. Several strands of sliver (typically eight to ten) from different carding

machines are combined and conveyed to the drawing machine, where they are pulled

together and drawn out into a new sliver no larger than one of the original single slivers. The

loose, rope like strand of fibers resulting from this process is called drawn sliver. The purpose

of drawing is to make yarn more uniform by combing and elongating multiple slivers, thus

eliminating the randomly occurring defects.After drawing, rotor yarns go directly to the

spinning frame.

Objectives of drawframe:

Hooks created in the card are straightened

Through doubling the slivers are made even and results in homogenization.

Through draft fibers get parallelized

Through the suction ,intensive dust removal is achieved

From the cards the material passes to the draw frames, where the thick and thin areas are

removed, i.e. the sliver is smoothened. Sliver quality is improved and the sliver is doubled,

drafted, parallelized, and leveled. Here three or more slivers are blended and one sliver of

same diameter is formed.

Breaker draw frame:

Process is carried out after carding and mainly doubling of yarn takes place

Machine details:

Input 8 cans

Output 1 can

Mainly 50s count used

Machines used Reiter (7 m/cs)


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Doubling (6) Drafting (6)

Finisher draw frame:- Auto leveling as well as doubling takes place

Machine details:

Auto levelling as well as doubling takes place.

Input 6 cans

Output 1 can

Speed 250 mt. /min.

Machines used: Reiter (7 machines)

Model: RSB 1 draw frame

1 operator required for all the machines

Doubling (6) Drafting (6)

15 min

16 Cans from

card

Twin Delivery

3 min

8 cans from

breaker draw

frame

Single

Delivery


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SPEEDFRAME

Thedraw frame sliver is drafted into a thin material called Rove and a

minor amount of twist is imparted to it to withstand loads in further process . As the roving

strand is ready to leave the roving frame, a slight twist is imparted to hold the fibers

together. Roving machine is complicated, liable to faults, causes defects, adds to productioncosts and delivers a product that is sensitive in both winding and unwinding. This machine is

forced to use by the spinner.

OBJECTIVE OF ROVING FRAME:

Attenuation- drafting the sliver into roving

twisting the drafted strand

winding the twisted roving on a bobbin

Drafting is the process of elongating a strand of fibers, with the

intention of orienting the fibers in the direction of th e strand and reducing its linear density.

In a roller drafting system, the strand is passed through a series of sets of rollers, each

successive set rotating at a surface velocity greater than that of the previous set. During

drafting, the fibers must be moved relative to each other as uniformly as possible by

overcoming the the cohesive friction.

The factors affecting roving strength are as follows:-

the length, fineness, and parallelization of fibers

the amount of twist and compactness of the roving

the uniformity of twist and linear density.

Machine detail:

Machine : Toyota FL16

No. of machines: 13

Speed: 900 rpm

Efficiency: 82-87%

Power consumption: 5.5 kW


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RING FRAME

The two most widely used processes for making cotton yarn

are ring spinning and rotor spinning, ring spinning is used for high quality, smaller yarns

(shirtings); rotor spinning is typically used for larger yarns (denim).Most combed yarns are

ring spun. It is the process where the actual yarn formation takes place. Here the Rove

material is again drafted to a very thin strand and considerable twist is imparted to it to get

the final yarn.

Objective of ringframe:

To draft the roving until the required fineness is achieved

To impart strength to the fiber, by inserting twist

To wind up the twisted strand (yarn) in a form suitable for storage , transportation

and further processing.

Machine details:

Machine used: Laxmi LG551

No. of machines: 33

No. of spindles per machine: 512

Speed: 18500 rpm

Efficiency: 85%


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Winding

It is the process wherein the single small yarn package formed at Ring Frame stage is

converted into a big package called cone. In this conversion process, single yarn packages

from Ring Frame are taken and continuously unwound and wound on a package called cone

and during this winding process, faults in the yarn will be cleared . Winding process serves to

achieve additional objectives made necessary by the requirements of the subsequent

processing stages.

Objective of winding

Extraction of all disturbing yarn faults such as the short, long thick ,long thin,

spinners doubles, etc

Manufacture of cones having good drawing - off properties and with as long a

length of yarn as possible

paraffin waxing of the yarn during the winding process

introduction into the yarn of a minimum number of knots

achievement of a high machine efficiency i.e. high production level

T.F.O.

Two for one means there are two twist is inserted in one revolution. This is used for plying or

cabling yarns.

Machine detail:

Machine used: SaurerVTS-09 Volkman

No. of machines: 18(per machine 2200 spindle)

No. of cones: 200 per machine

Speed: 900 rpm

Efficiency: 96%

Power consumption: 30 kW


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YARN SINGEING

Singeing is a process applied to yarns and to produce an even

surface by burning off protruding fibers or hairs from the surface of yarn. This is

accomplished by passing the yarn over a gas flame at a speed sufficient to burn away the

protruding material without scorching or burning the yarn . The singeing of yarns is done on

special machines, on which singeing and winding are done simultaneously.

Machine detail:

Make: PEASS Industrial Engg. and SSM (Scharer SchweiterMettler)

No. Of machine: 1 PIE and 1 SSM

Speed : depends on count ranges from 1000 -1500mpm

No. Of spindle: 60 in PIE and 40 in SSM

Spinning related Defects:

Warp Slub

Weft Slub

Thick end

Coarse/fine weft Weft bar

Moir


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WARPING

Warping is the process of transferring multiple yarns from individual

yarn packages onto a single package assembly.

There are two types:

Direct

Indirect

In case of direct warping Normally, yarns are collected in a sheet form where

the yarns lie parallel to each other and in the same plane onto a beam, which is a

cylindrical barrel with side flanges. In indirect warping the yarns from the yarn packages

are wound onto an intermediate cylinder (mill) in many parallel groups with a specified

density, and then they are back wound onto the warp beam.

The main objectives of warping are :

To form a pre-determined number of single end package such as cone,pirn or cheese

or a continuous sheet of yarn of specified length and width.

The individual ends of sheets should be spaced uniformly across its full width.

All ends of sheet should be wound at uniform tension.

Machine details:

Make Benninzer,Vamatex & Ukil

Made in Germany,India& Italy

No. of machine 10 Benninzer,4 Vamatex & 1 Ukil

Creel capacity 720,700 & 800

Machine speed Upto 500 rpm


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Width 64-72 inch

Beaming tension 12-20 gm

Tentioner type Disk

Cone Length 1050mm

Cone Height 210mm

Beam Diameter max 32 can be used.


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SIZING

The process consists of laying warp yarn parallel and sizing the yarn

with a mixture to strengthen it to withstand the rigours of weaving. Warp yarn is

withdrawn in sheet from from warp beams which are placed at the back of the sizing

machine. The yarn is then passed through sow box. Size solution is applied by immersion.

After removing surplus solution that occurs at this state, the yarn is dried and arranged

on a loom beam.

Objectives of sizing:

To improve the weavability of warp .

To reduce hariness of the yarn.

To withstand the stresses and strains of weaving.This can be attained by improving

primarily the abrasion resistance of the yarn.this is achieved with the formation of a

film around the yarn along with size penetration o9f size ingredients.

To reduce generation of static charges for polyester blend yarns.

to improve the breaking strength of the yarn.

Machine detail:

Make Hokoba,SukerMuller

No. of machine 4 Hokoba& 1SukerMuller

Speed 35 rpm

Double saw box


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WEAVING

The object of weaving to produce the fabric by the interlacement

of warp & weft. The other object is to produce defect free fabric . The warp threads run

lengthways of the piece of cloth, and the weft runs across from side to side.

Three motion are involved in weaving:

Primary Motion

Shedding

Picking

Beating up (Battening)

Secondary Motion

Let off motion

Take up motion

Auxillary Motion

Warp protector motion

Weft protector motion

Shedding:-

Shedding is the raising of the warp yarns to form a shed through which the

filling yarn, carried by the shuttle, can be inserted. The weave pattern determines which

harness controls which warp yarns, and the number of harnesses used depends on the

complexity of the weave.

Picking:-

The filling yarn in inserted through the shed by a small carrier device called a

shuttle. A single crossing of the shuttle from one side of the loom to the other is known as a

pick.


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Beating up (Battening):-

With each picking operation, the reed presses or battens each filling yarn

against the portion of the fabric that has already been formed. The point where the fabric is

formed is called the fell.

Taking up and letting off:-

With each shedding, Picking, Battening operation, the new fabric must be

wound on the cloth beam which is called 'taking up'. At the same time, the warp yarns must

be released from the warp beam which is called 'letting off'.

Warp protection:-

The object of warp protector motion is to stop the loom , if shuttle fails to

reach the opposite side as a result of faulty pick or some obstruction in the warp shed or

breaking of picking strap

Weft protection:-

To detect the absence of weft yarn & stop the loom.

Classification of Weaving Machines:

Weaving machines are classified according to their filling insertion mechanism.

The classification is as follows:

1. SHUTTLE LOOM

2. SHUTTLE-LESS LOOM

Rapier

Projectile

Air-Jet

Water-Jet

AIR-JET WEAVING:

Air-jet weaving is a type of weaving in which the filling yarn is

inserted into the warp shed with compressed air. Air -jet system utilizes a multiple nozzle

systems and a profiled reed.Yarn is drawn from a filing supply package by the filing feeder


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and each pick is measured for the filling insertion by means of a stopper. Upon release of the

filling yarn by the stopper, the filling is fed into the reed tunnel via tandem and main nozzles,

which provide the initial acceleration. The relay nozzles provide the high air velocity across

the weave shed. Profiled reed provides guidance for the air and separates the filling yarn

from the warp yarn.

The advantages of air jet weaving machines are:

y High productivity.

y Low initial outlay.

y High filling insertion rates.

y Simple operation and reduced hazard because of few moving

parts.

y Reduced space requirements.

y Low noise and vibration levels

y Low spare parts requirement.

y Reliability and minimum maintenance

PROCESS FLOW CHART

WEAVERS BEAM

DRAWING IN

CREELING WEAVERS BEAM

BEAM KNOTTING / BEAM GAITING

LOADING THE EMPTY CLOTH ROLL

SETTING OF INFORMATION IN PANNEL

TYEING UP OF ENDS ON THE CLOTH ROLL


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STARTING OF THE MACHINE

MACHINE IS STOPPED AFTER COMPLETION OF REQ. LENGTH WOUND ON THE CLOTH ROLL

FABRIC IS CUT AFTER THE REQ. CLOTH LENGTH

UNLOADING THE CLOTH ROLL

WEAVERS BEAM CHANGE IS DONE WHEN THE BEAM GETS EMPTY

There are mainly two types of shirtings:-

1. CLASSIC SHIRTING

2. CASUAL SHIRTING

Machine detail:-

In Arvind mill ,classic shirtings are mainly manufactured on two types of machines

1. RAPIER LOOM

Machine name PICANOL GAMMA Length : 545 mtr

Count : 2/50s, 2/60s,2/84s etc

Total Ends : 8082

Reed Space : 64.50

Denting order : 3/4 dent


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2. AIR JET LOOM

Machine name PICANOL OMNI Length: 650-700 mtr

Count: 2/50s, 2/60s,2/84s etc

Total Ends : 8082

Reed Space: 64.50

Denting order : 3/4 dent

Defects and Faults commonly found after weaving:

Floats

Short pick

Defective shedding

False Stop

Breakage

Missing Ends

Knots, Pulls

Fluffs Starting mark

White patti

Pick finding

Tight end

Weft float

Bent pick

Knot


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Repaired warp

Double end

Weft patti

Size Residue

Start Marks


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INSPECTION

4-point grading system is used for inspection of fabrics and this includes:

Size of defect Penalty Points

3 or less 1 Point

3 to 6 2 Points

6 to 9 3 Points

More than 9 4 Points

Holes or Openings(Largest

Dimension)

1 or less 2 Points

More than 1 4 Points

At the beginning of the month the inspection department gets the production plan for the

entire month and they plan their procedures accordingly. The finishing department gives the

material transfer note to the inspection department where the material is checked for the

following defects:

Spinning related Defects:

Warp Slub

Weft Slub

Thick end

Coarse/fine weft

Weft bar

Moir

Weaving preparatory related defects

Knot

Slack end

Ball formation

Size patches


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Weaving related defects

Starting mark

White patti

Pick finding

Tight end

Weft float

Bent pick

Chira

Knot

Repaired warp

Double end

Weft patti

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Arvind Spin Weav