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    Spin Plan For Carded Yarn

    Uploaded by

    Santosh
    The document discusses the production parameters and calculations to determine the required number of machines in a spinning mill process to meet a target production level. It provides the process parameters and formulas used to calculate the production rates and required inputs and outputs at each stage of the ring spinning process from blowroom to cards to draw frames to ring frames. The calculations determine that 7 carding machines, 3 speed frames, 3 finisher draw frames, 1 breaker draw frame, and 10 ring frames are required to produce the target output of 1320kg from the 12,000 spindle ring frame process.

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    © All Rights Reserved
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    Spin Plan For Carded Yarn

    Uploaded by

    Santosh
    5K views6 pages
    The document discusses the production parameters and calculations to determine the required number of machines in a spinning mill process to meet a target production level. It provides the process parameters and formulas used to calculate the production rates and required inputs and outputs at each stage of the ring spinning process from blowroom to cards to draw frames to ring frames. The calculations determine that 7 carding machines, 3 speed frames, 3 finisher draw frames, 1 breaker draw frame, and 10 ring frames are required to produce the target output of 1320kg from the 12,000 spindle ring frame process.

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    Original Title

    Spin Plan for Carded Yarn

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    The document discusses the production parameters and calculations to determine the required number of machines in a spinning mill process to meet a target production level. It provides the process parameters and formulas used to calculate the production rates and required inputs and outputs at each stage of the ring spinning process from blowroom to cards to draw frames to ring frames. The calculations determine that 7 carding machines, 3 speed frames, 3 finisher draw frames, 1 breaker draw frame, and 10 ring frames are required to produce the target output of 1320kg from the 12,000 spindle ring frame process.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    5K views6 pages

    Spin Plan For Carded Yarn

    Uploaded by

    Santosh
    The document discusses the production parameters and calculations to determine the required number of machines in a spinning mill process to meet a target production level. It provides the process parameters and formulas used to calculate the production rates and required inputs and outputs at each stage of the ring spinning process from blowroom to cards to draw frames to ring frames. The calculations determine that 7 carding machines, 3 speed frames, 3 finisher draw frames, 1 breaker draw frame, and 10 ring frames are required to produce the target output of 1320kg from the 12,000 spindle ring frame process.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    Annexure: Basic conversion charts

    395

    Production program ring spinning


    Assuming that the installed capacity of the spinning mill is 12,000 spindles
    comprising of 10 Ring Spinning Frames (1200 spindles/machine), the daily
    production will depend upon the production program.

    Process parameters for production balancing


    S. No. Department Process Parameters

    1 Ring Frame Count – 40s


    Spindle speed – 18,00 rpm
    Machine Efficiency – 93.5%
    TM – 4.35
    TPI – 27.51
    Waste – 2%

    2 Speed Frame Hank – 1.2


    Spindle speed – 1100 rpm
    Machine Efficiency – 85%
    TM – 1.25
    TPI – 1.37
    Waste – 1%

    3 Finisher Draw frame Hank – 0.13


    Delivery speed – 350 mpm
    Machine efficiency – 80%
    Waste % – 0.5%

    4 Breaker Draw frame Hank – 0.13


    Delivery speed – 500 mpm
    Machine efficiency – 80%
    Waste % – 0.5%

    5 Carding Hank – 0.13


    Delivery speed – 130 mpm
    Machine efficiency – 90%
    Waste % – 7%

    6 Blow room Diameter of Lap Roller – 9”


    Speed of Lap Roller – 15 rpm
    Linear density of Lap – 400 g/m,
    Lap length – 40 m
    Efficiency – 85 %
    Hank of Lap – 0.0015

    © 2016 by Woodhead Publishing India Pvt. Ltd.


    396 Process control and yarn quality in spinning

    Ring frame
    Ring frame production / spindle/8 hrs
    7.2 × Spindle speed ( rpm ) × Machine efficiency ( % )
    =
    Count × TPI × 100
    7.2 × 18000 × 93.5
    =
    40 × 27.51 × 100
    = 110 g / spindle / 8 h × No. of spindles
    = 110 × 12000
    Ring frame Actual Production = 1320 kg / 10 machines
    Actual production
    Ring frame (Required Input) =
    (100 – std waste% ) /100
    1320
    =
    (100 – 2 ) /100
    = 1347 kgs

    Simplex frames
    On the basis of the foregoing assumptions, the number of Simplex frames
    required to supply roving to be ring shed are calculated as follows:
    7.2 × Spindle speed ( rpm ) × Machine efficiency ( % )
    Speed frame production / spindle / 8 hours =
    Count × TPI × 100000

    7.2 × 1100 × 85
    =
    1.2 × 1.37 × 100
    = 4.09 kg / spindle / 8 hours × No. of spindles
    = 4.09 × 120
    Speed frame Actual Production = 490.8 kgs/machine
    Ring frame input required
    No. of Speed frame required =
    Speed frame production

    = 1347 / 490.8
    = 2.74 ∞ 3 machines
    Total speed frame production = 490.8 × no. of machines
    = 490.8 × 3
    = 1472.4 kg / 3 machines

    © 2016 by Woodhead Publishing India Pvt. Ltd.


    Annexure: Basic conversion charts 397

    Actual production
    Speed frame (Required Input) =
    (100 – std waste% ) /100
    1472.4
    =
    (100 – 1) /100
    = 1487.27 kg

    Finisher draw frame


    Draw frame production /delivery/8 hrs
    0.2835 × delivery speed ( mpm ) × m / c efficiency ( % )
    =
    Sliver hank × 100
    0.2835 × 350 × 80
    =
    0.13 × 100
    = 610.6 kg / delivery / 8 hrs
    Draw frame Actual Production = 610.6 kgs / machine
    Speed frame input required
    No. of Speed frame required =
    Draw frame production
    = 1487.27 / 610.6
    = 2.43 ∞ 3 machines
    Total speed frame production = 610.6 × no. of machines
    = 610.6 × 3
    = 1831.8 kgs / 3 machines
    Actual production
    Finisher draw frame (Required Input) =
    (100 – std waste% ) /100
    1831.8
    =
    (100 – 0.5) /100
    = 1840.95 kg

    Breaker draw frame


    Draw frame production /delivery/8 hrs
    0.2835 × delivery speed ( mpm ) × m / c efficiency ( % )
    =
    Sliver hank × 100
    0.2835 × 500 × 80
    =
    0.13 × 100
    = 872.3 kg / delivery/8 hours × no. of deliveries
    = 872.3 × 2

    © 2016 by Woodhead Publishing India Pvt. Ltd.


    398 Process control and yarn quality in spinning

    Breaker Draw frame Actual Production = 1744.6 kg / machine


    Finisher Draw frame Input required
    No. of Breaker Draw frame required =
    Breaker Draw frame production
    = 1840.95 / 1744.6
    = 1.05 ∞ 1 machines
    Total Breaker Draw frame production = 1840.95 kg / machine
    Actual production
    Breaker draw frame (Required Input) =
    (100 – std waste% ) /100
    1840.95
    =
    (100 – 0.5)/100
    = 1850.15 kgs

    Cards
    Card production / spindle/8 hrs
    0.2835 × delivery speed ( mpm ) × m / c efficiency ( % )
    =
    Sliver hank × 100
    0.2835 × 130 × 90
    =
    0.13 × 100
    = 255 kg / card / 8 hours
    Breaker Draw frame Input required
    No. of card required =
    Card production
    = 1850.15 / 255
    = 7.25 ∞ 7 machines (2 machine cushioning = 9
    machines)
    Total card production = 255 × no. of machines
    = 255 × 7
    = 1785 kg / 7 machines
    Actual production
    Card (Required Input) =
    (100 – std waste% ) /100
    1785
    =
    (100 – 7 ) /100
    = 1919.3 kg

    © 2016 by Woodhead Publishing India Pvt. Ltd.


    Annexure: Basic conversion charts 399

    Usually 2 extra cards will be installed to add flexibility to the carding


    process and take care of stoppage of any card for replacement of old wire.

    Blowroom
    Daily production required from Blow Room Line @ 7 % waste at the carding
    stage is 1919.3 kg Production required per hour = 240 kg/h
    If Chute Feed System is not provided, number of scutchers required is
    calculated as follows:
    Production/scutchers/8 hrs (kg)
    0.2835 × delivery speed ( mpm ) × m / c efficiency ( % )
    =
    Lap hank × 100
    0.2835 × ( 3.14 × 9” × 0.0254 × 15 ) × 85
    =
    0.0015 × 100
    = 1730 kg / scutchers
    Card required input
    No. of scutchers required =
    Blow room production
    = 1919.3 / 1730
    = 1.1 ∞ 1 scutcher
    Total blow room production/day = 1730 × no. of scutchers × no. of shifts
    = 1730 × 1.1 × 3
    = 5709 kg / day

    Cotton required
    The quantity of cotton required per day can be calculated is shown:
    Cotton required per day @ 3 % waste in Blow Room = 5709 × 1.03
    = 5880.27 kg
    Number of cotton bales required (170 kg each) = 5880.27 / 170
    = 35 bales / day

    Summary
    Process wise number of machines calculated above for achieving production
    balance is summarized below:

    © 2016 by Woodhead Publishing India Pvt. Ltd.


    400 Process control and yarn quality in spinning

    1. Ring Spinning Economic Unit = 12,000 spindles, 10 Ring Spinning


    Frames, 1200 spindles each
    2. Simplex Frames = 3 Roving Frames, 120 spindles each
    3. Finisher Drawing Frames = 3machines (single delivery)
    4. Breaker Draw frame = 2 (twin delivery)
    5. Carding Machines = 9 machines
    6. Blow Room = 2 scutcher line

    © 2016 by Woodhead Publishing India Pvt. Ltd.

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