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 Pakistans largest textile processing capacity. The companys 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
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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 worlds 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:
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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 nations first power generation company in the private sector. Commercial production started in 1992 with three KRUPPMAK 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
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Standard moisture regain of different materials is given below:

Cotton Wool Viscose Silk Jute Polyester Acrylic Nylon

8.5 % 17 % 11 % 11 % 14 % 0.3--0.4 % 34 % 4.2 %

CONVERSIONS

Tex

590.6 / Ne
4

Denier Denier Grex Metric 1 mon 1 mon 1 lb 1 lb 1 lb 1 kg 1 oz 1 gram 1m 1m

= = = = = = = = = = = = = =

5315 / Ne tex 9 tex 10 1.693 English 82 lbs 40 kg 7000 grains 453.6 grams 16 oz. 2.2045 lbs 437.5 grains 15.43 grains 1.0936 yd 39.37 inches

English count = Number of hanks which weight one pound Count Cotton hank Worsted hank Linen hank Silk hank = = = = = hanks / Pound 840 yd 560 yd 300 yd 840 yd

SPIN PLAN
Spin planning is the job to control production and quality of end
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product i.e. yarns at various stages of spinning process. 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 = Final tuft size Jute picked daily Method of mixing = = = 220 bales 20-30 gm 250gm Mechanical

BLOW ROOM
Number of lines C.V. % Waste% Beating point Cleaning efficiency = = = = = 2 1% 5.6% 3 60%

CARDING
Total No. Of cards Grains/yd Mechanical draft = = = 40 67 98
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Actual draft Waste % Cleaning efficiency Production efficiency Production C.V. % U%

= = = = = = =

105 5.3 % 80 % 85 % 400 - 450 lbs / hr / card 3.5 % 4.5 %

DRAW FRAME BREAKER

Total number of frames Grains / yd Draft Doubling Delivery rate Efficiency No. of deliveries Production C.V. % U% = = = = = = = = = = 9 67 8 8 350 m / min 85 % 2 340 lbs / hr / frame 2% 3.5 %

DRAW FRAME FINISHER

Total number of frames Grains / yd Draft = = = 8 67 8
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Doubling Delivery rate Production efficiency No. Of deliveries Production C.V. % U%

= = = = = = =

8 700 m / min 85 % Single 340 lbs / hr / frame 1% 2%

SIMPLEX
Total number of frames Hank roving Flyer speed Total draft Delivery rate Twist per inch Production rate C.V. % U% = = = = = = = = = 9 0.98 1050 rpm 7.2 25 m/min 1.12 320 lbs / hr / frame 2.5 % 4.5 %

RING FRAME
Count Total No. of frames Draft T.P.I = = = = 20 s/ 1 carded hosiery 60 25.09 17.4
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Delivery rate Spindle speed O.P.S. calculated Production efficiency C.V. % U%

= = = = = =

21 m / min 14750 rpm 10.75 80 % 2% 10 %

WINDING
Total No. of machines Winding rate Cone weight Tolerance limit Efficiency Production = = = = = = 12 1000 m / min 4.16 lbs + 20 gm 68 % 160 lbs / hr / frame

PACKING
No. of cones / bag Net weight of bag = = 24 100 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
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stations of the Punjab like Bahawalpur Bahawalnagar Hasilpur 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
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 Honey Dew Moisture % age Net bale weight = 160-170 kg 165 kg 2.0 2.5 kg

Average bale weight = Tare weight =

TARE WEIGHT INCLUDES:

Wire weight Strip weight = = 0.6-0.7 kg 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

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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 W1 M Then M = W W1 = = = Sample weight Dry sample weight Moisture content

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.
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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:

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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

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 Temperature R.H. %

3 20 - 23oC 60- 65 %

Acceptable limits in Nishat Textile Mill Unit No.7 for the selection
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of cotton are: Neps Mice Rd +b Gm / Tex Length Elongation : : : : : : : 150 - 250 /gm 3.5 - 5 65 - 75 7.5 20 - 24 1.04 - 1.9 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. 3. Homogeneous mixing can minimize ends down rate. 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 No. of lots present No. of bales taken / lot Net weight of bale Bale dimensions Bale volume Bale density

= = = =

140 bales 44 lots 1-7 bales / lot 153-170 kg

H = 45, W = 20.5, L = 31.5 = = 16.93 ft3 9.74 kg / ft3

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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

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It is also included that some roving, sliver and pneumaphil waste are also added in the plucker along with bales in the following quantity; Sliver Roving Pneumaphil 50 kg 15 kg 50 kg

TECHNICAL DATA:
Name M/C model No. of Machines Out put Beater rpm No. of Motors Time taken Dia of rail Main Motor speed = = = = = = = = Automatic Disk Plucker FA002 11 1800 kg/hr 800-900 3 35 s/rev 5200mm 960 rpm

CONDENSER
Fan speed Cage speed Leather beater speed Suction pressure = = = = 1600 rpm 90-110 rpm 250-300 rpm 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 Type of beating
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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. Uniclean has a single cylinder with special type of pins on its surface.

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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 Speed Production Waste % age Length Width = = = = = = 750 mm 480 - 980 rpm Up-to1200 Kg / h card sliver Up-to 6 % 2200 mm 1040 mm
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Height Material

2000 mm = 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 Beater dia Beater speed Length of beater No. of grid bars Power consume = = = = = = Porcupine 490 mm 800 rpm 1060 mm 36 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) Porcupine RN-1 Porcupine RN-2 Scutcher Total beating points = = = = = 1/2 1 1/2 1 3

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Waste calculations in Blow room

Waste Trash Waste % = = = Lint - Trash Foreign matter only (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 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 Company Model Temp. RH% 40 Crosrol MK 4 30 oC 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
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Elimination of short fibres 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

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b. Maximum speed ratio difference c. Setting between two surfaces

Brushing and Raising

a. Back to back action b. Speed difference ratio c. Setting between the two surfaces SPECIFICATION OF WIRE POINTS FOR TAKER-IN
Type Height Angle Thickness Wire points/inch2 = = = = = Interlock 5 mm 80o 1.1 mm 36

FOR CYLINDER
Type Height Angle Thickness Wire points/inch2 = ECC = 2mm = 50o = 0.85 mm = 800

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FOR DOFFER
Type Height Angle Thickness Wire points/inch2 = ECC = 4 mm = 600 = 0.85 mm = 400

FOR TOP SET

Type Height Angle = KBS-450 = 8 mm = 75o

LIFE OF CLOTHING
Doffer clothing life Taker-in clothing life Cylinder clothing life Flats clothing life Stationary flats life = = = = = 2 years 1 year 2 years 2 years 2 years

TYPES OF WASTE ON CARD

There are five points where waste is separated from fibres on the card. These waste points are:
30

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
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 Dia Cylinder Dia Doffer Dia Flats Delivery speed No. of moving flats = = = = = = = = = 1200 rpm 10 inch. 519 rpm 51 inch. 96 rpm 27 inch. 10 inch/min. 155m/min. 101 5
31

No. of stationary flats =

OBSERVATIONS AND CALCULATIONS

CYLINDER
RPM of cylinder S.S of cylinder = = = = 519 DN 51519 83112.66 inch/min

TAKER IN
RPM of taker in S.S of taker in = = = 1200 120010 37680 inch/min

DOFFER
RPM of doffer S.S of doffer = = = 96 rpm 9627.55 8307.40 inch/min

FEED ROLL
RPM of feed roll S.S of feed roll = = = 5.2 rpm 5.27.08 115.60 inch/min

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DRAFT CALCULATION
Major draft between roller and doffer = = = S.S of doffer/ S.S of feed roll 8307.40/ 115.60 71.86

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

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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 83112.66/8307.40 10.04

CARD MAINTENANCE STAFF

Foreman Maintenance supervisor Fitter Helper Total = = = = = 1 1 3 1 6

PRODUCTION STAFF
M / C operator Helper Floor cleaner Supervisor Total = = = = = 20 2 2 1 25

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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 Trash in lap 100

The cleaning efficiency of cards is to be judged together with waste extracted. 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. ii. iii. Type of mixing Trash in lap Type of cards

PRODUCTION

Actual Production = Doffers.speed Tension Draft Efficiency

35

36

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.
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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.
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Total No. of frames Company Model No. of frames Make Model No. of frames Make Model No. of frames

17 Rieter RSB-D30 8 TOYODA DX-8 5 TOYODA DYH-500C 4

ABOUT RSB-D30
Length of machine Height of machine Width of machine Drafting system Draft range Delivery speed Can dimension No. of deliveries No. of doublings Length of sliver in cane = = = = = = = = = = 1800 mm 2000 mm 2410 mm 4/3 with pressure bars 4 - 12 400 m / min 20 42 inches single 8 5000 yards

DIAMETER OF DIFFERENT ROLLERS

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Back bottom roller Middle bottom roller Front bottom roller Top roller

= = = =

30 mm 30 mm 40 mm 38 mm each

SETTING OF DRAFTING ROLLER Back zone

Roller gauge Nip to nip setting = = 6 mm 41 mm

Middle zone
Roller gauge Nip to nip setting = = 5 mm 40

Front zone
Roller gauge Nip to nip setting = = 6.5 mm 41 mm

FACTORS ON WHICH SETTING WILL DEPEND

1. 2. 3. 4. Hank sliver Shorter fiber %age Staple length Level of draft

Top roller weighting / pressuring

Pressure system Color of spring used = = Spring pressure Red
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Amount of pressure used

On front and IV roller On 2nd and back roller On pressure bar Life of cots = = = = 40 kg on each side 30 kg on each side 10 kg on each side 2 Years

Rotary speed calculations

Motor speed Motor pulley dia Machine pulley dia = = = 1450 rpm 167 mm 100 mm

Calendar roller
Rotary speed of machine pully = Surface speed of calendar roll = = = Front roller Rotary speed = = 2421.5 44 48 49 30 3479.05 rpm = 1450 167/100

2421.5 rpm DN 3.1451/10002421.5 387.78 m/min

Surface speed of front roll

= =

3.143479.0535/1000 382.34 m/min

2nd roller
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Rotary speed

= =

2421.5 23 71 77 81 634.008 rpm

Surface speed

= = =

DN 3.1435/1000634.008 69.71 m/min

3rd roller Rotary speed = 2421.5 23/77 71/81 37/59 47/30 = Surface speed 622.904 rpm = = = Back roller = 2421.5 44/75 68/59 37/114 44/52 = Surface speed = = = 449.65 rpm DN 3.14 35/1000 449.65 49.44 m/min DN 3.14 35/1000 622.904 68.49 m/min

DRAFT CALCULATIONS
Draft b/w 3rd and back roller
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D1

= = =

Surface speed of 3rd roll Surface speed of back roll 68.49 49.44 1.385

Draft b/w 2nd and 3rd drafting roller D2 = = = S. speed of 2nd 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

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= = Draft constant D.C. = = =

1.385 1.018 5.48 1.014 8.01

Draft D.C.P 8.01 33 264.99

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

= = =

387.78 x 39 60 67 8 0.85 36 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. 3. A motion stops m/c in case of roller lapping. M/C stops automatically when said length is completed in the can.

CAN CHANGE MOTION

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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 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
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 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 Relative humidity = = 96oF 58%

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47

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 300500. 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.

48

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 Company 9 Toyoda FL-16

Observations:
Total no of machines No. of spindles per frame Model Make Mfg. Year Spindle speed Delivery rate Production efficiency = = = = = = = = 9 120 FL-16 Toyoda 1991 model 1050 rpm 24 m/min 85 %
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TPI Drafting System Range of draft Applied draft Twist range Twist applied (T.P.I) Rail balancing method Temperature R.H. %

= = = = = = = = =

1.02 4/4 arrangement 5-25 7.5 0.7 - 1.5 1.02 Dead weight 96Fo 58 %

SETTING ON SPEED FRAME

Front zone setting Roller gauge Nip to nip setting Middle zone setting Roller gauge Nip to nip setting Back zone setting Roller gauge Nip to nip setting = = 21 mm 50 mm = = 20 mm 49 mm = = 6 mm 35.0 mm

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FACTORS ON WHICH SETTING WILL DEPEND

Hank sliver Short fibre % age Staple length Level of draft Top Roller Pressure

Pressure system Pressure on front roller Pressure on second roller Pressure on third roller Pressure on Back roller Spacer:

= = = = =

spring pressure 10 kg 21 kg 14 kg 14 kg

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

STOP MOTIONS
Condition Machines is at rest Sliver breakage at creel by photocell Roving breakage by photocell Indication of doffing Color Red light Green light Yellow light White light

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CALCULATIONS
Motor speed Motor pulley dia Drive pulley dia Twist change gear Total draft change gear Back draft change gear = = = = = = 960 rpm 190 mm 222 mm 43 T 46 T 60 T

Spindle speed

Motor rpm 190 47 47 222 54 32

960 190 47 47 222 54 32 = 1050.325 rpm

Front roller speed

Motor rpm 190 82 72 T.C 222 91 91 91 960 190 82 72 43 222 91 91 91 276.797 rpm Motor rpm 190 82 72 43 20 222 91 91 91 21 960 190 82 72 43 20 222 91 91 91 21

= = 2nd roller speed =

= =

263.616 rpm

3rd roller speed = Motor rpm190827243264633 60 222 91 91 91104 83 61 26 = 47.88 rpm

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Back roller speed = Motor rpm 190 82 72 43 26 46

222 91 91 91104 83

= 38.35 rpm
Draft Calculations

D1

front zone draft = Surface speed of F.R Surface speed of 2nd roll = 276.79 D 263.616D = 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

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T.P.I

Spindle rpm Surface speed of front roller 1050.325 D N (inch/min)

= 1050.325 975.19 = 1.0765 T.P.I. T.C.

Twist constant = = = T.M. =

1.0765 43 46.29 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 = = Efficiency of simplex So actual production = Total no of spindles = = 1050.325 60 8 1.0765 36 8400.98 15.80 lbs / shift / spindles 85 % 15.80 85 100

13.43 lbs / shift / spindle = 120 / frame

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Total production

= =

13.43 120 1611.6 lbs / shift / frame

MAINTENANCE STAFF Drawing (Breaker and Finisher) and simplex Foreman Supervisor Fitter Assistant fitter : : : : 1 1 2 1

PRODUCTION STAFF

Jobber Double simplex tender Drawing tender Doffer Floor cleaner

: : : : :

1 3 2 3 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
55

 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 Checking of top and bottom aprons Grinding of top roller and changing of grease

56

57

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
58

The ring-spinning machine is designed to; 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 Company Model No. of spindles per frame Total No. of spindle = 60 = Toyoda = EJM 168 = 480 = 28800

DIAMETERS OF DIFFERENT ROLLERS Dia of front drafting roller Dia of middle bottom drafting roller Dia of back bottom drafting roller Top roller dia Cots dimensions Top apron life Bottom apron life = 25 mm = 25 mm = 25 mm = 28 mm = 19 28 26 = 2 years = 1 years.

DRAFTING ROLLER
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Front zone Back zone PRESSURE ON TOP ROLLERS Pressure on front top roller Pressure on middle top roller Pressure on back top roller

= =

44 mm 46 mm

= = =

18 kg 16 kg 14 kg

ATMOSPHERIC CONDITIONS Temperature Relative Humidity Machine data (EJM 168) Length of machine Width of machine Type of drafting Ring dia Type of ring Flange No. Flange width Life of ring Traveler No. Life of traveler Spindle type Spindle driving system Spindle gauge = = = = = = = = = = = 18800 mm 760 mm 3/3 apron drafting 42 mm HY (Chinese) 1 3.2 mm 1 year I/0 1 week blade type (Chinese) = = 94oF 60 %

= Tape and pulley drives 4 spindles = 70 mm

60

Bobbin dia inner Bottom Middle Top Bobbin length Ring rail lift Balloon height

= = = = = = =

17 mm 25 mm 21 mm 20 mm 230 mm 8 inch 9 inch 45 mm Yellow (3.3 mm)

Dia of balloon control ring = Spacer color =

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 T.M. T.P.I. Ends down % age = = = = 20 CD 3.89 17.40 3.5 %

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SPEED CALCULATIONS

Motor rpm Motor pulley Dia Driven pulley dia Belt thickens

= = = =

1460 rpm 196 mm 185 mm 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 = 274.0174 36 41 43 33 38 87 84 104 69 28 = 14.85 rpm

Speed of middle roller

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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 D1 = Surface speed of middle roller Surface speed of back roller (25+(1.1 2 0.8) 14.85 25 10.914 1.456 0.8 is the 80% thickness of apron

= Note:

Main draft b/w middle roller and front roller

D2

= 25+274.0174 (25+ (1.12.8)) 14.85 = 17.239 = = = D1 D2 1.456 17.239 25.09

Total mechanical draft M.D.

Total M.D = =

Surface speed of front roller Surface speed of back roller 25+274.0174 25 10.914 25.10
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Draft constant ACTUAL DRAFT

T.M.D. D.C. = 25.09 43

= 1078.87

Count delivered Hank roving A.D. = =

= = 20 0.83 24.09

20 0.83

TWIST CALCULATION AS T.M. Count T.P.I. = = = = 3.89 20 T.M. Count 17.396

Also T.P.I. = = Spindle r.p.m. Front roller delivery (in/min) 14750.8 . 25 274.0174 17.4 .

PRODUCTION CALCULATIONS

64

Spindle speed changes during building of package so we take Spindle speed = T.M. T.P.I = = 14750.8 rpm 3.89 17.4 = = 60 480

No. of ring frames for 20 CD/H No. of spindles per frame

So Calculated production Lbs/shift/spindle = spindle speed 60 8 T.P.I. 36 840 count = = = Efficiency of ring Actual production 14750.8 60 8 . 17.4 36 840 20 0.67 lbs/shift/spindle 10.765 OPS/shift = = = Total production of 20 CD/H = = = = Where weight of each bag = 80% 10.765 80 100 8.61 OPS 8.61 60 480 16 15498 lbs/shift 46494lbs/day 465 bags / day 100 lbs
65

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. 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 Irregular roving feeding Remedies improve regularity of roving

66

Excessive twist in roving Fly accumulation on creel guides Damaged bobbin hanger

decrease T.M. at simplex clean the creel and guides replace bobbin hanger with a new one

Drafting Faults Incorrect setting of rollers Incorrect draft distribution Improper pressure on top rollers Worn out rollers Damaged cots Broken system teeth of gears of

Remedies Correct the setting Correct the draft distribution Correct the top pressure. replace the rollers Grind the cots or replace them drafting replace such gears.

67

SPINDLE, RING AND TRAVELLER REGION FAULTS

Drafting Faults Incorrect setting of lappet guide Spindle eccentric Less or no oil in spindle tube Spindle bearing worn out Wrong setting of traveler clearer Worn out ring Wrong setting of traveler clearer Loose tapes Vibrating bobbins Excessive tension

Remedies Correct it Correct it Correct it Fill the spindle tube with out Replace it Replace them with new ones Correct it according to count Correct them by jockey pulley Incorrect bobbin size be corrected Check traveler no.

FAULTS DUE TO RELATIVE HUMIDITY Bottom roller lapping Top roller lapping More fly in the department REMEDY Less R.H. % age. More R.H. %age

68

Accurate department.

R.H%

age

should

be

maintained

in

the

69

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.

70

INFORMATION ABOUT DEPARTMENT No. of machines Company Model No. of spindle per machine Winding speed Winding range 12 MURATA 21-C 60 1000 m/min 800 - 1200 m/min

Winding shape (transverse of yarn) 152 mm Blower cleaner Blower exhaust air Balloon breaker Doffing method Slubs catcher Magazine Tensor Suction mouth top Tensor spring Drum dia Bs type down Triangular (MKC-15) Length doffing from counter Uster D-4 6 bobbins (75 mm dia) positively driven disc type Comb type 0.9mm thickness with red color 90 mm (nose side) 100 mm (cradle side) Length of drum RPM of drum Air for spicing Grooves on drum 170 mm 1000 rpm 6 kg 2.5
71

Dia of full cone Rate of breaking Package weight Paper cone weight No. of joining/min. R.H. % age of department Efficiency MAINTENANCE STAFF Foreman Fitter Assistant fitter PRODUCTION STAFF Supervisor Winder Picker

180-220 mm 70 % 1938 gms 48 gms (40 - 50) 15 65 % 68 %

= = =

1 1 1

= = =

1 14 7

PRODUCTION
Delivery speed of winding drum Efficiency No. of spindles for 20 CD/M = = = 1000 m/min 68 % 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

72

Total production of 20CD

= = =

31.25 60 1875 lbs/ shift/ machine 5625 lbs/day/ machine 68 % 5625 68 100 3825 3825 100 38.25 bags 460 bags lbs/day/ machine

Efficiency Production

= = =

No. Of bags/day/machine

= Total production of 12 machines = 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

73

SIX MONTHLY One compressor head complete overhauling after 6 months ANNUALLY Head bearings & fan shaft bearing cleaned and greased.

74