A

REPORT
ON
INPLANT – TRAINING
A
ALOK INDUSTRIES LTD. SILVASSA

DURING
26/11/2018 TO 22/12/2018

PREPAREDBY
1) Mr. Sanket J. Chavan
2) Mr. Aniket R. Hujare
 ACKNOWLEDGMEMENT
We like to thanks Alok Industries Ltd.Silvassa for giving us an opportunity for Inplant
Training to take the knowledge of industry and process activities followed in the industry. We
have taken it seriously and got good knowledge and support from the staff members. We are
also thankful for giving us good guidance for our carrier.

We would like to thank Mr.RadheshyamNayak Sir, and all the HOD’S

INDEX
Sr.No Content
1. Industry Profile
2. Introduction to Alok Industries
3. Process Flow
4. QAD
5. Luwa
6. Maintenance Schedule
7. Packing System
8. Waste

INDUSTRY PROFILE
Bench marking standard speed innovation technology quality, consistency and punctuality
Alok offers world class Integrated Textile Solutions. Keeping abreast with the International
trends in fabrics fashions and technology Alok possesses vertically integrated, state of art of
production facilities for home textiles, woven & knitted apparel fabrics, garment &polyster
yarns.

Alok has today emerged as one of the India’s leading textile group.

INTRODUCTION TO ALOK INDUSTRIES LTD

 Incorporated in state of Maharashtra as a private limited company on 12 March 1986
in the name of “ALOK TEXTILE PRIVATE LIMITED”.
 Alok began with the texturizing of yarn and steadily expanded to weaving, knitting,
processing, home textiles and readymade garments.
  Its first share cost was 10 rupees per unit and total share released by company was 20
lakhs 50 thousands.
 Name of company was changed to “ALOK INDUSTRIES PRIVATE LIMITED”
on 17 November 1992 and then converted into public limited company on 11
February 1993.
 Subsequently on 8 November 2000 name of company was changed to “ALOK
INDUSTRIES LIMITED”

ALOK’S VISION
To be the world’s best integrated textile enterprise driven by research & innovation. With a
leadershipposition across& stakeholder expectations.

ALOK’S MISSION
We will:

 Be a knowledge leader &an innovation in our business.

 Maximum people:development initiatives.
 Optimize use of all resources.
 Become a process driven organisation .
 Exceed complains and global quality standards.
 Actively explore potential marker and products
 Offer innovation customized and products .
 Be an ethical , transparent and responsible global organisation.

ALOK’S VALUES
 CUSTOMER SATISFACTION:
We will be attuned to market needs , wherever possible, we will anticipate market
needs, we will respond quickly to the changes in the customer requirements , we will
completely focused on quality , and we will keep delivery commitment on time and
every time.
 PASSIONATE ABOUT EXCELLENCE

Excellence is non-negotiable in every aspect of our business process superior quality

of performance is critical to our business growth and success .we will constantly
strive to exceed expectations: be it internal or external.

 DEVELOP HUMAN CAPITAL

We will empower ,energize and inspire our people to perform beyond the best, we
will respond quickly to the changes in the customer requirements, we will completely
focused on quality, and we will keep delivery commitment on time and every time.
 FAIR TO ALL
All our actions will be determined by fairness, we shall be fair to our customers,
senders, shareholders, all our business partners and society at large. Fairness is not
 just sticking to the letter of the law or contract but appreciating its spirit and basing all
our actions being fair to the spirit of understanding.
 CONCERN FOR THE ENVIRONMENT AND THE COMMUNITY
We will take the utmost care of our environment and the communities in which we
operate; we shall nurture our environment and its natural resources and shall ensure
that none of our actions deplete or pollute them.

 SAFETY AND HEALTH

We will provide a safe workshop. We will promote the health and being of our people
and their families. We believe that working safety and protecting the health of our
people is working smart and creats greater and more sustainable wealth.

 RESPONSIBLE CORPORATE CITIZEN

We recognize that we have our responsibilities towards the society in which we
operate. We commit ourselves to be a responsible corporate citizen; our activities
should not only create shareholder wealth, but also huminity wealth.

SPINNING DIVISION
 Number of units:-9
 Spindle capacity:-411840
 Open end rotor :-5680
 TFO Drum :-12120
 Type of yarn produced:-Compact yarn, Rotor yarn, Lycra yarn, Slub yarn, Double
yarn, Double gassed yarn, 3-ply yarn,4-ply yarn.
 Major customer:-
Export:
Kmart, KOHL’S, VICTORIA’S SECRET, ALLTAYLOR, IKEA, WAL-MART
JCPenney, GAP, TARGET, NORDSTROME.

Domestic:
Raymond, Pantalooms, WILLS LIFESTYLE,
BRFL,COATS, ZODIAC, creative garment.
 INSTALLED CAPACITY OF SPINNING UNIT
Unit no. 1 2 3 4 5 6 7 8 9 Total
Spindle 57072 57696 58704 633024 56400 50400 68544 - - 411840
R/F
Spindle - - - - - - - 12120 12120
TFO
Rotors 936 - - - - 2856 - - 1888 5680

FUNCTION OF VARIOUS DEPARTMENTS

Spinning division itself comprises of a number of department .each department plays a valid
role in proper and continues functioning of entire division.

1. Production house

2. Maintenance

3. Quality assurance department

4. Engineering department

5. Human resource department

6. Accounts

7. Security

8. Store &purchase.

1) PRODUCTION HOUSE:

The production and planning department will set standards and targets for each section of the
production process. The quantity and quality of products coming off a production line will be
closely monitored. In business focusing on lean production quality will be monitored by all
employees at every stage of production, rather than at the end as is the case for businesses
using a quality control approach.

2) MAINTENANCE DEPARTMENT:

The main objective of maintenance department is to eliminate the break down’s maximum
utilisation of machine operating time, incorporation of new technologies and engineering
development in the basic design of the machine capability and optimum expenditure on
maintenance function and activities.

3) QUALITY ASSURANCE DEPARTMENT:

The function quality assurance department is to control the manufacturing process against
the standard of as directed by buyer been conveyed through p.p.c it deals with testing of
yarns , various process developments, maintenance quality policy , handling customer
complaints etc.

4) ENGINEERING DEPARTMENT:

The engineering department itself comprises of three departments:

Civil department:

This department deals with the layout of the company. That means whenever the new
machineries is introduced in the industry this department helps for making layout.

Mechanical department: This department deals with the power plant and the other
mechanical regions of the mill. Any mechanical breakdown with the machines is repaired by
the help of this department.

Electrical department:

This department deals with the all type of electrical works, breakdowns and lightening
system, supply of electricity of the whole company.

5) HUMAN RESOURCE DEPARTMENT:

Accounts: Accounts department is mainly responsible for generation of financial report and
book keeping. The main activities for which the accounts are responsible are book keeping,
payments (payment to supplier, salaries to employees etc.)

6) Security:-

It deals with providing security for the company’s properties, company information and
personal security. As and when a person enters the premises of Alok spinning he has to report
to the security cell, to define the purpose of visit and he is guided to the right person at the
first go. Security also performs the following function:-

 Fire safety
 Transportation
 Housekeeping
 Horticulture
 Postal services
 Maintenance of club
 Keeping pace with government and outside people.

7) STORE AND PURCHASE:

The main function of the store and purchase department is to procure all the
materials accept raw material like paking material, electrical material, machines
spare parts, oils and lubricants, fuel and building material, furniture and fixtures and
administration equipment.it helps in providing the various request made by the entire
department in an effective and efficient way so that there is no wastage of time.
UNIT – 7
By –
1 .Sanket JChavan
2 .Aniket RHujare

HOD –Mr. G .Sahoo

Maintenance Head –Mr. A.S.Murchitte
QAD – Mr. A.M.Patil
STUDY THE FLOW OF MATERIAL

Blow Room

Carding

Breaker Draw frame

Unilap

Comber

RSB – D D/F

Speed Frame

Ring Frame

Autoconer

Machine allocation of each section

BLOW ROOM
Blow room consists of numbers of machines used in succession to open and clean the cotton
fibre to the required degree . 40 to 70 % trash is removed in this section .
  Object of Blow room :
1. To open the fiber
2. To clean the fiber

Operation in Blow room : -

 Opening : To open the compressed bales of fibers and make the cotton tuft small as
far as possible .
 Cleaning : To remove the dust , dirt , broken leafs , stalks and other foreign materials
from the fibers .
 Mixing : To make good values of yarn & to decrease the production cost by mixing
different grade of fibers.

Action of Air current in blow room:-

During processing the movement of cotton from machine to machine is done by air
current. It also helps the segregation of lint & trash.

UNIFLOC
 Manufacturer – RIETER
 Model - A11
 S.NO – 40012822-00035
 Year – 2011
 Power – 3*400V50HZ
 Air pressure – 6 Bar
 Machine efficiency – 100% (4hrs)

The main function of UNIFLOC is to open the bale into small tuft. The working
procedure is controlled by microcomputer and is fully automatic.

SPECIFICATION OF UNIFLOC A11

 Normal take off depth – 1.6 mm
 No .of assortment – 1
 Main frequency – 0
 Traverse speed – 16 m/m
 Indication rest .Take – off time – 1hr
 Assortment sequence – direct lift up
 Assortment time – 12sec
 Take off – A not equal to B

Bale group 1A 2B
Nominal take –off depth 1.6 mm 1.6 mm
Pile additional layer 0.0 mm 0.0 mm
Run – in value(1hard/5soft) 3 3
Run – out value 2 2
 (1hard/5soft)

 Efficiency – Stop go ratio = 81%

 Machine efficiency – 100%
 MTBA – 41 HR 56MIN

Overview take– off Bale group 1a

Passage Total Remaining

Full 9 Take off 0 Takeoff
Decreasing 25 Take off 0 Takeoff
Normal 205 Time 195 Takeoff
Increasing 25 5hr 23 min 25 Takeoff

Overview height position-

 Height position – 1519.4 mm
 Maximum lift – 1519.4 mm

UNICLEAN
 Manufacturer – RIETER
 Model – B12
 Year – 2011
 Power – 3*400 V 50HZ 40A

Efficiency – 100% (4hr)

Cleaning intensity – 0.4
Assortment – In case of one assortment the machine will operate with only one type
of material
Relative waste rate – 5
MTBA -168 hr
 SET VALUE – No of assortment – 1

FUNCTION OF UNIOCLEAN:-
In this zone, basic function is to open the tuft to small size and to clean the tuft
removing big size of trash.

UNIMIX
 Manufacturer – RIETER
 Model – B72
 Degree of opening- 0.4
 Opening Intensity – 0.4
 Waste rate – 7%
 Opening roller speed – 69rpm
 Spiked lattice speed – 92rpm
 Conveyer Belt Speed – 0.11rpm
 Feed Roller Speed – 2.6rpm
 Second Opening Roller Speed – 500rpm
 Position of Grid Bars – 35/34mm
  Year – 2011

Detector (for removing colored and foreign material)

Model – Inspect 4 ED – 50 -1200

Year – 2011

It is fine cleaning machine. Mixed cotton is fed to this machine for intensive cleaning. The
tuft of cotton is converted into very small size and cotton is cleaned by removing impurities
like small leaves, sand, etc. without damage of fibers. The beater speed, no. of spikes and grid
bars setting plays important role for cleaning of cotton.

UNISTORE
 Manufacturer – RIETER
 Model – A79
 Beater Speed – 500rpm
 Opening Intensity – 0.5
 Waste Rate – 7%
 Production level – 17
 Feed Roller Speed – 0.19
 Opening Roller Speed – 500rpm
 Year – 2011
 Power – 3*380V 50HZ 40A
FUNCTION OF UNISTORE:-

The basic function of UNISTORE is to mix various types of material. The proper mixing is
achieved at UNISTORE.

The unistore A79 is used to storage ,dedusting and feeder machine in the blowroom , its main
purpose is to provide intermediate storage for material in order to ensure trouble –free
blowroom operation . long piping distance are frequently

GRAVITY BOX
The main function of gravity box is to separate the seed from cotton and seed fall into
component tray whereas cotton is fed to next machine.

TVS
 TVS is nothing but THE VISION SHIELD. The main function of TVS is to detect
colored impurities and removed it from tuft.

HENNATEX
The function of HEENATEX is to detect and remove heavy particles like stones, sand etc.
with the help of conveyor belt and suction motor.
 CONDENSER
 Manufacturer – RIETER
 Model – A21
 Feed Roller Speed – 2rpm
 Opening Roller Speed – 500rpm
 Position Of Grid Bar – 35mm
 Year – 2011
 Power – 3*415V50HZ 9A 6BAR

FUNCTION OF CONDENSER:-
The material is passed over perforated drum. The suction is present in perforated
drum. With the help of suction the dust is removed from tuft of cotton.
 CARDING
 Manufacturer – RIETER
 Model no – C70
 Opening Roller Chute Feed – 836rpm
 Lap Weight – 712gm
 Licker-in Speed – 1090rpm
 Cylinder Speed – 704rpm
 Flat Speed – 0.23m/min
 Production – 42kg/hr
 Year – 2011
 Power – 3*400V 50 Hz 33A 6BAR

OBJECTS OF CARDING –
 Opening to individual
 Impurities and dust
 Removing of neps
 Elimination of short fibers
 Fiber blending
 Fiber orientation
 Sliver formation

Carding action - If two surfaces have opposite wire direction and their speed
direction or relative motion is also opposite , then the action between two surfaces is
known as carding action .

 It occurred between licker – in & cylinder

 Wire direction is opposite
 Speed direction is opposite
Stripping action – When two close surfaces have same wire direction & their speed
direction or relative motion is also same then the action between two surfaces is
called stripping action

 It is occurred between licker – in & cylinder

 Same wire direction
 Same speed direction

Doffing action– When two close surfaces wire points are inclined in opposite
direction & their speed direction is same then the action between two surfaces is
called doffing action .

 Doffing action occurred between cylinder and doffer

 Wire direction is opposite but speed direction is same
 It is special type of carding
 Sliver formation – is done by this action

Gauge of Carding –
Feed plate to feed roller – 1.5 mm
Feed roller to licker –in – 0.9 mm
Licker –in to first knife = 0.35mm
Licker – in to second knife =0.45 mm
Licker –in to cylinder = 0.25mm
Stationary back to cylinder = 0.35mm
Flat to cylinder = 0.35/0.35/0.3/0.3/0.3mm
Front plate to cylinder = 1mm
Back top plate to cylinder = 1.2 mm
Front stationary to cylinder = 0.3/0.3
Front knife =0,3mm
Doffer to cylinder = 0.175 mm
Doffer to stripping roller = 0.15 mm
Stripping roller to delivery roller = 0.15mm
Delivery to delivery roller = 0.15 – 0.125 mm
Cleaning brush of flat = 0.15 mm
Licker in dia = 253 mm
Cylinder dia = 1290 mm
Doffer dia = 500mm

Model C50 C51 C60 C70

Brand RIETER REITER RIETER RIETER
Origin Switzerland Switzerland Switzerland Switzerland

Working principal of RIETER (C70) Carding machine –

Production actual values work elements –

 Cylinder rpm = 654

 Flat speed = 0.30 m/min
 Licker –in = 1209 rpm
 Opening roller rpm chute = 837 rpm

Production efficiency 9 (MTBA) –

 Machine efficiency = 90.4%

 MTBA = 2.23 hrs

Production shift data – shift 1

 Efficiency = 96.4 %
 Nominal production time = 2: 46 hr
 Number of stands stills = 3
 Number of can chances = 2

MAJOR SETTING POINTS OF CARDING

MACHINE-
1. Lap Guide to feed roller

 Settings = 3/4 - 1”
 Effect = It control the selvedge of web , higher distance make
 2.Feed Roller to licker – in –

 Setting – 9 -12 THIO

Effect – for higher staple , heavy lap , setting will be wider ,

Excessive impurities in lap setting will be closer .

3. Mote Knife to licker – in –

 Setting –
 Bottom – 12 – 15 thou ( closer setting for heavy dusts)
 Top - 10 thou ( wider settings for less impurities )

Effect – The setting should be sufficiently close to remove heavy impurities on the
licker – in surface. If the setting is too wide the mote The main object of draw frame
are given as follow –

BREAKER DRAW FRAME

The main object of draw frame are given as follow –
 To improve the evenness of the sliver and uniformity.
 To remove the dust and foreign material from the sliver.
 Make perfect blending of the component.

 Manufacturer:- RIETER
 Mixing :- DM-1 NEW
 Del. Can color:-White
 Model no. :-SB-D11
 Feed can color:- Blue
 No of doubling – 5
 Feed Sliver Hank – 0.12
 Sliver content:- 10000mtr

PRODUCTION:-
 Machine production:-1380.16kg(8hrs)
 Efficiency:-72.5%

Machine setting:-
 Delivery sliver hank:-0.13
 Break draft :-1.4
 Delivery speed :-350 rpm
  Creel tension:-1.02
 Doubling:-5

UNILAP

 Manufacturer – RIETER
 Model No – E32
 Year - 2011
 Power – 3*420V 5Hz 36A 7 BAR

MACHINE PARAMETER –

 Mixing – MCH –SPL

 Del gms/mtr – 62 g/m
 Spool marketing – black tape
 No ,of doubling – 24
 Feed can color – blue + yellow tape

Object of unilap –
The main object of this machine is to converted the sliver into lap sheet for the use of comber

Function of Unilap –
 1. Combining a number of sliver into lap that is ideal for the use in comber
2. Creating a batt with sufficient cohesion to ensure good lap winding.
3. Orienting the fibers to the point that they are optimal for both the lap condition and
combing action
4. Produce battin which the fibers are uniformly distributed in the batt cross section
5. Supply lap that will have good unwinding characteristics on the comber

Working principal –
Slivers are entered into drafting and over feed plate. The slivers are drafted in the drafting
system. The calendar roller draw the overlapping fleece into the loop formation head due to
the strong compression between the calendar roller, a lap sheet is formed. This then rolled
onto a tube via the top roller and lap disc, the exchange of lap from supply empty tube takes
place automatically.

Main feature of Unilap (E32) : -

1. 2 – zone drafting for ideal fiber drawing

2. 4 calender rollers and automatic regulation of the lap loading for a perfect lap build
up
3. High production rate and quality level by means of the VARIO speed
4. Improved running conditions bettrrealiability
5. Function design for grater ease for operation .

COMBER
 Manufacturer – RIETER
 Model no – E – 76
 Year -2011
 Power – 3*420V 50Hz
 Air pressure - 7 BAR

Machine parameter –

 Mixing – MCU – 5
 Sliver hank – o.130
 Can color – green + yellow tape
 Noil % - 20 %
 Feed lap gms / mtr – 62
 Spool marketing – plain
 Deliver content – 7000
 No of machine – 09
 No of can – 96

Operation of combing process –

 Elimation of a precisely predetermined quantity of short fiber .

Niol % = (weight of noilproduced )/ (total wt . of cotton fed ) * 100
 Elimation of the remaining impuritites.
 Elimination of neps in the fiber material .
 Formation of sliver having maximum possible fiber parallization .

There are four type of comber –

1. Rectillinear comber – Works with stationary or oscillating nippers

and is mainly used in the short staple spinning .
2. Circular comber – It is used in the English worsted process .
3. Rotary comber – It is used in the production of scahappe spun yarn .
4. Hackling machine – Used in the processing of blast fibers .
 FINISHER DRAW FRAME
Technical Data –
 Manufacturer – RIETER
 Model no – RSB – D45
 Year – 2011
 Power – 3* 415V 50Hz 22A
 Air pressure – 6BAR

Machine parameter settings –

 Mixing – MCU – 5
 Sliver hank – 0.130
 Break draft – 1.15
 Feed can hank – 0.130
 Sliver content – 4000 mtr
 Number of doubling – 6

Objective– This is the process by which the fiber or sliver is elongated by passing it
through a series of pair of rollers, each pair moving faster than the previous one.

The main object of draw frame are given as follow –

 To improve the evenness of the sliver and uniformity .
  To remove the dust and foreign material from the sliver .
 Make perfect blending of the component .

Recent development of Draw frame –

 Production rate is higher up to 1000 m/min delivery speed .

 Drafting system arrangement , such as
1 . 4 over 3 with pressure bar .

SPEED FRAME
OBJECTIVES OF SIMPLES:
1)Attenuation of slivers is the chief task of simplex machine.
 2) Insertion of protective twist in order to impart coherence to the resulting thin fibre strand
so as to hold the constituent fibres tighter.

3)Winding of the roving formed onto the bobbin packages that can be transported ,stored and
donned on ring spinning machine.

FUNCTIONS:
1. Drawframe slivers are presented to simplex in large consist in the creel some
arranged in several.
2. Driven transparent rollers are present above can which guide the slivers to the
drafting arrangement.
3. Attention of slivers takes place which delivers a very thin strand of fibres.
4. Winding of the roving formed takes place on account of the difference in the
peripheral speeds of flyer and bobbin which in kept constant to perform controlled
winding action in an effective manner.

GAUGE SETTING ON SIMPLEX

Back zone 55 mm

Front zone 46 mm

Spindle gauge 121.83 mm

SIMPLEX PRODUCTION

PRODUTIONINKG/SHIFT =

SPECIFICATION:
Mixing= MECH SPL JW

Sliver hank = 0.22

Feed can color= white +black tape

Roving hank = 2.50

Bobbin color= yellow,khaki,blue + black tape.

Bobbin Content= 5000mtr

TPI/TM = 1.97/1.25

Break Draft = 1.15

Quality check point
1. Daily checking of wrapping.
2. Weakly checking of stretch %
3. Stretch % must be less than 0.75

Ring frame:
1.To draw the roving to its final count in the drafting system.

2. To impart tenacity to the bundle of fibers by twisted it.

3.To wind up the resulting yarn in a suitable from for storage, transportation &downstream
processing.

Function:
1. The roving bobbins are inserted in holders on the creel.
2. Guide bars guide the rovings into the drafting system, where they are drawn to their
firmly
3. After the resulting thin ribbon of fibers lead the delivery roller,twist necessary
strength is provided by spindle rotating at high speed.
4. In the process, each rotation of the traveller on ring spinning produces twist in the
yarn takes up the yarn onto tube mounted on the spindle.
5. The rotation of ring traveller somewhat lags behind that of spindle due to relatively
traveler on ring and atmospheric resistance of traveller and thread balloon between
yarn and traveller.
6 . This difference in speed between yarn and traveller results in thread being
wound into cylindrical cop form by raising and lowering of rings of rings by ring
rail.

SPECIFICATION:-
 Mixing DM -1 NEW
 Roving Hank - 2.5
 Bobbin color - Grey, Blue, Violet
 Count – 100cwc
 Ring traveller – 18/OLRT
 TPI/TM – 44.0/4.4
 Break Draft – 1.14
 Spindle Speed – 18000

WINDING SECTION
 OBJECTIVES OF WINDING
1.To form the larger packages (cone packages)from smaller packages(ringframe
spindles
2. To remove faults such as thin places, neps,slubs, etc
3. To wax the yarn during the process.
4. To produce packages which enable feasibility in unwinding for the next
subsequent processes(such as warping).
5. to enhance the overall strength and quality of the yarn.

FUNCTION:
1. The ringframe spindles are placed in the magazine creel.
2. With the help of suction system,threads are guided towards the tensioning
and yarn clearing zone.
3. Combined type tensioner help in removal of weak places in the yarn.
4. Yarn faults such as uneven places,nepsslubs are removed or cleared off using
slub catchers.
5. After removing the faults ,the two ends one from final wound package and
one from creel zone are spliced pneumatically.
6. Yarn with faults cleared –off is wound on paper cones on the surface driven
winding principle.
7. Yarn traverses through the grooves of steel drum and gets wound on the cone
forming the final packages.

QUALITY ASSURANCE DEPARTMENT

INTRODUCTION:
Research and development deals with the raw material, final product and the
values intermediate products so that we get a quality final product .Apart from
this is also include various efforts done to further improve the quality of the
product . The testing laboratory included following testing equipment.

LIST OF TESTING EQUIPMENT IN QAD:

1.WRAP REEL.

2. USTER EVENESS TESTER.

3.USTER CLASSIMATE QUANTINUM.

4.LEA STRETGH TESTER.

5. TWIST TESTER.

6.R.K.M TESTER

7. YARN APPERANCE BOARD WINDER.

8.USTER HVI SPECTRUM.

9.USTER AFIS PRO.

10. MOISTURE METER.

11. TRASH ANALYSER.

12. VERNIER CALLIPER.

1. USTER TESTER 5
OBJECT:
UsterTeaster 5 is a multi-purpose instrument for testing yarn, roving and sliver .it
can measure hairiness.CV%,U% shape ,diameter density, optical
evenness,imperfection index(ipi),
Thick and thin place ,neps etc.
Principle
Capacitance based (capacitive sensor measure the mass variation not diameter).
Sample length:
 YARN 400 MT.
 ROVING 50 MT.
 SLIVER 50 MT.

 2. USTER CLASSIMATE QUANTUM

OBJECT:
 It is used to measure the seldom occurring yarn faults caused by
spinning preparation and spinning
Sample size =100km
Speed = 100m/min
Faults categories =A,B,C,D,E,F ,G (THICK FAULTS)
H&I(thin faults)
Classes:
th
7 class:-A4+B4+C3+C4+D2+D3+D4
8th class:- A2+B4+C2+C3+C4+D2+D3+D4
4th class:- D1+C2+B3+A3
5th class:- A1+A2+B1+B2+C1
16th class:- All addition
Long thick:- E+F+G
Long thin:- H1+H2+I1+I2

3. USTER HVI SPECTRUM

OBJECT:
Its main object is to find below characteristics-

 Strength
 Elongation
 Fineness
 Color value
 Micronaire
 Maturity index
 Length
 Uniformity
 Short fibre index
 Moisture regain%
 Trash%
PRINCIPLE: optical and air pressure.
The HVI spectrogram consists of 4 distinct modules to carry out different analysis:

1.Optical module

1. Length &strength
2. UV module
3. Fineness module.
 4. USTER AFIS PRO

OBJECT:
 NEPS SIZE
 NEPS/GRAM
 SEED CODE NEPS
 SHORT FIBER CONTENTS
 MATURITY RATIO

Principle Standard values:

Carding std: 70 neps/gm

Blow room std: 225neps/gm

After combing: 20-30 neps/gm

Short fiber contents (N)

5. TWIST TESTER(TPI METER):

OBJECTS:
 Twist/inch(TPI)
 Twist multiplier™
 TPI gives the twist level in the yarn.

6. YARN APPEARANCE BOARD WINDER:

Its main object is to:-
 Identifies the defect
 To grade the yarn as A,B,C&D

7. WRAP REEL
Wrap reel is used for making lea of 120 yard of yarn either ring yarn or cone yarn.

8. STATEX TRASH ANALYSTER:-

 To determine lint, trash &dust content within a sample of cotton fibre up to 100gms.
Also used to determine non fiber content of synthetic fibre and to open and clean
fibres for further testing.

LUWA

Manufacturer: Luwa Textile Air Engg. – Switzerland

Software used: Luwa DIGI 5 CONTROL

FUNCTION:
 Air conditioning in department
 Filtration
 Waste handling of each machine
 Control RH and temperature

WASTE:
 MBO : Dropping waste (gravity box)
 Licker-in: Dropping waste
 Flat : Flat waste
 Draw frame : Sliver waste, fan waste
 Comber: Noil waste
 Speed frame : Roving waste, pneumaphill waste
 Ring frame: Pneumaphill waste, thread waste.
 Winding : Hard waste

Usable waste: sliver waste, roving waste, pneumafil waste

Non-usable waste: Dropping waste, fan waste, hard waste

WASTE HANDLING FUNCTION:-
The waste is collected in rotary screen. The rotary screen rotates intermittently indepedence of
differential pressure above the rotary screen. The dust-laden exhaust air of the waste separator
must be subjected of a post filtering.

Due to feeding of the carrier air flow with textile waste the external side of rotary screen is
coated with fleece of coats. These coats are also capable to separate a large portion of existing
duct.

When rotary screen rotates the waste coats carried free of slippage by four racks positioned on
the screen in the range of cellular cylinder the racks are restarted via a cam. So the cellular
cylinder positioned below the rotary screen can remove the waste coats the separator against
the atmosphere.

BENEFITS:-
 Room temperature & RH controlled with single drive module.
 Smooth control of room temperature & RH as per setting.
 The material properties of the yarn are perfectly maintained with maintenance
of room temperature and relative humidity of plant.
 Waste handling is superior and the plant free from dust and waste.
 Drivers provide the use monitors for user setting of either temperature or RH.

ELECTRICAL DATA OF U-7:-

Tubelight = 2000

Tubelight current = 0.26A

Fan = 12

Consumption = 24 hours

1 day consumption of electricity = 1,10,000 units/day

1 unit = 4.7rs

UKG of yarn = 3.66rs

MAINTENANCE SCHEDULE:-
Name of m/c Cleaning Schedule
Blow room 15 Days
Carding 60 Days
Breaker Draw Frame 30 Days
Unilap 30 Days
Comber 30 Days
Finisher Draw Frame 30 Days
Speed Frame 30 Days
Ring Frame 30 Days
Autoconer 35 Days
TFO 30 Days

WASTE:-
The form, quality and its utilisation depends upon the machine from which it is generated.
The different machine generates different type of waste material, which may or may not be
further usable by company. The waste can be reprocessed, is used by company again and rest
of it is sold in market.

The waste in textile unit broadly classified into two groups:

1) Usable waste:
 Sliver
 Roving

2) Unusable waste:
 Sweeping
 Hard waste
 Fan fly
 Dirty cotton
 Blow room dropping
 Card dropping
  Flat
 Comber noil
 pneumafil

WASTE PERCENTAGE:
 Blow room:3%
 Carding :4%
 Breaker draw frame:0.5%
 Unilap:0.5%
 Comber:12-24%(20%)
 Finisher draw frame: 0.5
 Speed frame:0.5%
 Ring frame:1.5%
 Winding :3%

TOTAL WASTE:-33.5%