INTRODUCTION
Training in industry infuses among students a sense of
critical analysis ofthe whole production system and
different situations arising in an
organisation. Trainings are bold attempts to bridge the gap
between the world of work and the knowledge at the
institutions. It enables us to see ourtheoretical knowledge in
operation. It helps us make better professionals and learn
the practical knowledge of the production system. Our
training at RSWM LTD, MANDPAM was no different it helped
us gain the practical knowledge of the textile
manufacturing. The process of production extending for
spinning of fibre, their conversion to fabric.
Textile manufacturing is one of largest business operations
taking place in India. It gives employment to a very large
population of the country nest onlyto agriculture. For a
student yarn manufacturing is based completely dependent
on the textile manufacturing. Our sixty days long internship
gaveus the through knowledge of the textile manufacturing.
It gave us the knowledge about the processes taking place in
spinning of the fibre. This internship, we hope will help in
developing us as better yarn manufacturing professional as
the knowledge of textile is pivotal in making good yarn
manufacturing professional. This internship has given us the
required confidence to face the various situations arising in a
work place.
This report is a written account of what we have observed and
learnt during our Sixty days long internship at RSWM
MANDPAM, BHILWARA.
OBJECTIVE
To study the organisational
structure of anintegrated
textile mill.
To study the process of Fibre
dyeing, spinning oftextile.
To study the equipment &
machineries installed atthe textile
mill.
To study the guidelines
established for variousdivisions
of textile manufacturing unit.
To study the testing of different
sample in SQC.
To study the latest development in
this industry.
PRODUCT OF MANDPAM, BHILWARA
Lycra blend yarn
Neppy Yarn
Syro Yarn
Injection Slub
Normal Slub
Fancy Yarn
Blend Yarn(P/V, P/A, P/C, V/C, V/A )
CESS SEQUE
NCE IN SPINNIN
G
* MIXING & BLENDING *
The process of combining two or more kinds of fibres.
Fibres in required ratio are taken, opened and blended in blenders.
The mixing is blended once or twice to ensure proper blending to thefibres.
During the blending process we use lubricant as TEXOL.
2156- is use for the purpose as finishing agent.
2146- is use for the purpose as antistatic agent.
Normal water are also use in this lubricant.
Texol V 100% P100% P/V P/A
2156 0.05% 0.06% 0.10% 0.10% 0
.
0
5
%
2146 0.75% 0.28% 0.40% 0.38% 0
.
7
5
%
Water 4.5% 4.5% 4% 5.5% 5
Finally blend material get out in blow room bin. Bin 1&2 are
kept 24hours for better conditioning.
Name of the part of Blender
Sr. No Name of parts of Blender
01 Conveyor Belt
02 Feed Lattice
03 Inclined Lattice
04 Delivery Roller
05 Evener Roller
06 Creeper roller
07 Stripper Roller
BLOW ROOM
OBJECTIVE
To ensure proper opening of bales.
To ensure proper blending.
To reduce the tuft size.
Removing dust.
Formation of uniform lap sheet.
To create laps to be fed in the carding
machine.
Wastage in Blow Room
Dropping (0.10%)
Dust (0.10%)
Filter waste
UNIMIX
Mixing & Blending checking
point
Mixing Checking
Layer checking
Moisture checking
Gauge checking
Lot cleaning checking
Finish checking
Lap CV % checking
Lap weight checking
CARDING
OBJECTIVE
Opening to individual fibres
Removing of impurities
Removing of dust
Disentangling of neps
Action in Carding
Combing action
Carding action
Stripping action
Doffing action
CARDING MACHINE
lap Roll Take-up Roller
Feed Plate Cross Roller
Feed Roller Top & Bottom Roller
Licker-in Calendar Roller
Cylinder Coiler
Doffer
lats
CARDING LC 300A- V3
Technical parameters of LC 300A – V3
Diameter of lap roll :- 162mm
Diameter of feed roll :- 80mm
Diameter of licker in :- 253mm
Diameter of cylinder :- 1290mm
Diameter of doffer :- 680mm
Diameter of calendar roll :- 80mm
Speed of different moving parts
Lap roller = 2.15 rpm
Feed roller = 4 rpm
Licker-in= 1050 rpm
Main cylinder = 450 rpm
Doffer = 30rpm * Draft constant for LC
300A – V3 = 2.23
🞂
Stop motion for LC 300A – V3
• Limit switch for lap tool – it stops the card in case
of shortage of lap.
• Limit switch over feed roll – it stops the card
if the feeding of double laptake place.
• Limit switch at front panel – it stop the cylinder if
the front panel is opened.
• Limit switch over crush tool – it senses the lapping
of the crush tool.
• Full can change motion – when the can full of
slivers the machine stops andthe can is changed
either by tender or automatically.
1. LC 1/3
2. LC 300A
Carded Sliver Can 38
Wastage in carding machine
NON-USABLE
USABLE
Card dropping-0.20%
Lap Ends – 0.20%
Flat Strip -1.30%
Card Sliver -0.30%
Fan Fly -0.20%
Sweeping – 0.10%
Carding checking points
Neps checking
U% checking
Stop motion checking
Flat brush checking
Randomisation checking
Delivery Speed checking
Lots cleaning checking
Wrapping checking
3.14*D*N*60*8*efficiency%*(100-waste extension%)
840*36*2.2*sliver hank
D= dia of doffer(27 inch)
N= doffer rpm (45 rpm)
DRAW FRAME
Objectives:
To parallelize the fibres of card
sliver and align them tothe axes of
the sliver through drafting process.
To improve the regularity in sliver
weight per unit lengththrough
doubling of sliver.
To mix different slivers to give a
homogenous blended
sliver.
To straighten out the fibre and
improve the fibre extent.
To improve uniformity and
evenness so that the finalsliver
become more regular resulting
uniform yarn.
DRAWING
Breaker draw frame
During this process 6 to 8 slivers
produced by carding machine are
paralleled to produce one sliver.
Finisher draw frame
To improve uniformity and
evenness so that the final sliver
become moreregular resulting
uniform yarn.
GEARING DAIGRAM OF DRAW FRAME
DRAW FRAME DIAGRAME
NAME OF THE PARTS OF DRAW FRAME
Guide
Creel Roller
Sliver Guide
Tensioner Roller
Condenser Roller
Condenser Tube
Scan Roller
Back Roller
Middle Roller
Front Roller
Condenser Tube
Trumpet
STOP MOTION FOR LDO-06
Electric creel stop motion: If
broken sliver passes throughthe
pair of the drawing frame, the
drawing frame will automatically
stop.
Full can stop motion: If pre-
set length of sliver is
delivered in the can drawing
frame will automaticallystop.
If the door open during running
the machine will
automatically stop.
Calendar roll lapping stop
motion: In case of sliver
lapping over the calendar
roll the machine will stop.
AUTOLEVELLER
OBJECTIVE
To measure and monitor the
variation in sliver thickness
continuously and to change the
draft accordingly
More draft will be applied to thick
places and less to thinplaces so that
the resultant sliver delivered will be
more regular
Improve production and better
productive efficiency
Even sliver appearance
Fewer ends breakages in subsequent
process
Less wastage
Lower count CV% can be expected
TYPES OF AUTOLEVELLER
Open Loop System
Open loop system generally use
in draw frame. Open loop auto
leveller, sensing is done at the
feeding end and the correction is
done by changing draft. This is
very effective levelling system as
compared to close loop because in
open loop system the correction
length in open loop system is time
smaller than close loop system.
However, in close loop system,
delivered sliver is of required liner
density. In case of open loop
system, as the delivered material
is not sensed for its liner density
to know whether the correction
has made or not.
In close loop system, the delivered
sliver is sensed for its liner density
and correction is done by changing
total draft. Closed loop auto levellers
are mainly used on carding machine.
But the modern carding machine have
sensing at the feed rollers as well as
the calendar rollers.
Hand Requirement:
No. of M/c Person
04 01
04 01
Delivery 01
Total 03
Production Calculation:
3.14*D*N*8*60*efficien%
Sliver hank*840*36*2.2
D= Front roll dia
N= Front roll rpm(550 mpm)
550mpm*1.1*8*60*efficiency/sliver
hank*840*36*2.2
Checking points:
Stop motion should be check on daily
basis
Lot on change
U% checking
Top roll change per two hours
Can randomization
Speed checking
Can length
Wrapping checking on two hours
Cut checking
Can report
AL & SM checking( auto leveler and
sliver monitor)
Problem during process on Draw
frame:
Sliver evenness
Sliver breakage
D/F gauge D/F
wrappi
ng
8 Py 55/60 0.103
10 Py 55/60 0.103
18 Py 55/60 0.103
18 P/v 50/58 0.103
20 Py 55/60 0.103
20 V 46/50 0.103
28 P/v 50/58 0.103
30 P/v 50/58 0.110
40 P/v 50/58 0.110
40 Py 55/60 0.110
50 P/V 50/58 0.145
60 P/V 50/58 0.145
Speed frame
Simplex is an intermediate process in which
fibres are converted into low twist lea
called roving. The sliver which is taken from
draw frame is thickerso it is not suitable for
manufacturing of yarn. Its purpose is to
prepare input package for next process.
This package is to prepare on a small
compact package called bobbins.
Objects/ Functions of Speed
Frame:
Attenuation of drawn sliver to form roving of
required count by drafting.
Insert small amount of twist to give required
strength of roving.
Wind the twisted roving on to the bobbin.
Build the roving in bobbin such a
form which will facilitate handling,
withdrawing &transfer to the next
process.
Draft Range :- 7 to 20
Roving Hank :- 1 to 1.2
SPEED FRAME
Parts name of speed frame
Creel
🞂 Front Roller
Creel
🞂 bar Clearer
Sliver
🞂 Bar Twist Multiplier
Condenser
🞂 Sliver Flyer
Bar
Back
🞂 Roller Flyer Arm
Middle
🞂 Roller Spindle
Apron
🞂 Bobbin
Cradle
🞂
Spacer
🞂
Nose
🞂 Bar
Stop Motion:
Creel Stop motion
Automatic tension control
Bobbin Safety
Sliver back Stop Motion
Checking Point:
Daily cots checking
Wrapping checking
U% Checking
Half Lea Checking
Tension Checking
Speed Checking
Stop Motion Checking
Production Calculation of Speed Frame
3.14*D*N*8*60*efficiency
840*36*2.2*Roving Hank* no of spindle
FRS =spindle speed /840*TPI
Hank = FRS/ 20
20=3.14*1.1 inch*8*60/840*36*2.2=0.05
1/20=0.05so we take the constant 20 and
divided withFRS so we get hank.
Now, Kg = hank/2.2* roving hank* no of
spindle
RING FRAME
Spinning of roving bobbin into yarn of
required count and twist and make a
yarn. It is capable of producing yarns with
wide ranges of linear density and twist
from a great variety of fibre materials. It
is also used for doubling and twisting
multi fold and cabled yarns. These
combinations meant that the potential
maximum speed of ring spinning was
raised from about 8500 to 20500
revolutions per minute
OBJECTIVES:-
To produce required count of yarn
from the suppliedroving by the
drafting.
To insert sufficient amount of twist to
the yarn. To windthe yarn onto the
bobbin.
To build the yarn package properly.
Parts of Ring frame
PASSAGE OF MATERIAL IN RING FRAME
Name of Parts of Ring Frame
Creel
Tension Bar
Roving Guide
Front Roller
Middle Roller
Nose Bar
Apron Roller
Tensioner Bar
Front Roller
Bobbin Ring
Spindle
Ring Traveller
Spindle Barb
Spindle Bolster
TECHNICAL SPECIFICATION OF RING FRAME
Machine Model LR6/
S
Manufacturer LMW
Total no of machine 24
Drafting System 3
over
3
Top Roller Diameter 32.5
mm
Bottom Roller Diameter 30m
m
Pressure 7 kg
Motor Pulley 152
-
187
mm
Total Spindle 624
Spindle Speed 850
0-
205
00
Spindle tape Driven Front Roller Speed 245
rpm
CREEL
TENSION BAR
ROVING GUIDE
DRAFTING ZONE
TWISTING
WINDING
Ring traveler
Schedule checking
Lot change, cleaning
TPI checking
Contamination checking
Count & CSP checking
U%
Partition checking
Spacer checking
Lot setting
Spindle vibration checking
Bottom & Top apron checking
Calculation in Ring Frame
Production 3.14*D*N*60*8*efficienc
(kg/shift) y/840*36*Cou
nt*2.2*T.P.I
Twist per 25.34*B*D/A*C
inch
C+D=137
Front roller Spindle
speed speed/840*T.P.I
Break draft:
Total draft of a ring frame is
limited. Since the main draft
should not exceed its limit, a
additional draft is implied in the
back zone (between back and
middle roller). This draft
facilitates the main draft and
known asbreak draft.
Normally twisted roving and
total drafts up to 40: breakdraft
should be 1.1-1.4 Strongly
twisted roving: break draft
should be 1.3-1.5 When total
draft exceeds 40, break draft:
1.4-2.
Count (Ne)-Synthetic T.M (Twist
yarn Multiplier)
10-20 2.9-3.2
AUTO CONER
Winding is one of the most
important operation, which is
mainly occurred in spinning
section. The creation of large yarn
packages that can be easily
unwound, is called winding. This
makes using the yarn on
subsequent machines both easier
and more economical. To prepare
the bigger package from ring
bobbin. To remove spinning
faults. To wax the material. To
improve thequality of yarn.
Objective
To remove the objectionable
faults present in original yarns.
To warp the forming on a
systematic manner or to transfer
yarn from smaller package to
larger package.
NAME OF THE PARTS OF AUTO CONER
Auto Feed
Splicers schlafhorst
Waxing device
Electronic cleaner
Detaching head
FX sensor
One doffer & empty tube loader
Magazine:- 6 each spindle
Technical Specification
Spindle gauge 320mm
Count Range 10 to 60 Ne
Cone Weight 2 to 2.50 Kg.
Drum speed 1400 rpm
Cone Dia 200 to 225 mm
Empty Cone Weight 30 to 35 gms
Magazine Creel capacity 8 Cops
Drum Diameter 95 mm
Count wise winding speed
Type Count Winding
Speed
Coarse 15-20s 1450 m/min
Medium 20-40s 1400 m/min
Fine 40s and above 1350 m/min
Conditioning
Before packing the yarn produced
are subjected to a treatment in the
conditioning room to increase the
moisture content of the cone to
according to requirement. It increase
the weight of cone marginally.
Packing
In packing department the cones
produced by Autoconer checked and then
packed in bags. There are 5checkers and
a large number of packers for this
purpose.
The defects, which are checked during
packing, are:-
Mixing of cones
3-ply
High twist /low twist
Contamination
Snarling
Winding defect (ribbon formation)
Types of packing :-
Cartoon packing
Pilot packing
Bora packing
Waste Report
There are various types of wastages which are
found in spinning mill during the processing of
raw cotton. About 12-13% wastages are
produced for card process and 25-30% wastage
are produced for combed process. The names of
different wastages are given below:
Blow room (waste= 3%) i. Dropings-2 ii. Lap waste
etc.
Carding (waste= 4%) i. Dropings-1 ii. Sliver
waste iii. Vacuumwaste.
Draw frame (waste= 0.5%)i. sliver waste
Lap former (waste=0.5%) i. lap waste ii.
Sliver waste iii.Vacuum waste
Comber (waste= 12-18%) i. Noils ii. lap waste iii.
Sliver waste
Simplex (waste= 0.5%) i. Roving waste ii. Sliver
waste
Ring Frame (waste= 2-3%) i. Pneumafil
ii. Hard wasteii.Sweeping iv. Vacuum
waste
Winding section(waste=1%) i. Hard waste
Usable Waste
Types of Waste Waste in %
Lap end 0.20
Card slier 0.30
Draw sliver 0.40
Roving 0.40
Bonda 1.20
Total(A) 2.50%
Unusable Waste
Types of Waste Waste in %
B.R Dropping 0.10
Card Dropping 0.20
Flat Strip 1.37
Fan Fly 0.16
Sweeping 0.40
Ring Frame 0.15
Finishing 0.91
Hard waste 0.12
S.Q.C 0.02
Total 3.25%
QUALITY ASS URANCE DEPARTMENT
NAME OF INSTRUMENT OBJECTIVE PARAMETERS
TESTED
Warp reel To Determine yarn Lea weight &
count Count
USTER evenness To Check the U% & CV%,
unevenness of foreign
sliver,roving,yan matter,hairiness,t
hick ,thin places
etc
USTER CLASSIMATE To check imperfection Slubs, thick &
QUANTUM thin place
Lea strength tester To test CSP Lea strength
Twister Tester To Determine twist & TPI & TM
TM in yarn
USTER TENSORAPID 5 To test tenacity, Strength
breaking force,
elongation
USTER AFIS PRO 2 Neps, length,maturity Individual fiber
ration of fibers study
USTER CLASSIMATE QUANTUM-
Uster classimate quantum system is digital maicroprocessor controlled
yarn fault classing system.Its based on structural components of the
uster classimate quantum .Capacitive mesausring heads with built in
sensor for foreign fiber detection are used.
Detecting disruptive thick and thin places
Detecting yarn count variations .
Detecting foreign matter contaminations .
Technical specifications
No of measuring heads-1-12
Yarn speed -100-2000m/min
Mesurement principle- capacitive measurement of yarn mass and
measurement of reflection of the determination of foreign fibers.
AFIS (Advanced fiber instrument system)-
AFIS is modular device intended for testing and anaysing 100% cotton
Samples in the from of bale, opened and cleaned material( card
mat.), Sliver and Roving.
It is based on the aeromechanical fiber processing similar to opening
and carding followed by electro optical sensing and than by high
speed microprocessor based computing and data reporting.
Basic AFIS Schematic
A fiber sample is introduced in to the system and is processed
through a fiber individualizer which aero mechanically separates the
Sample in to three components consisting of cleaned fiber, micro
dust and trash.
Each of these components is transported in a separate pneumatic
path and may be analysed electro optically or by other means.
The data Processing and Reporting are handled by an individualized
PC.AFIS Provides Basic Single fiber Information and is distinguished
from earlier and existing Methods by Providing Distributions of the
Basic Fiber Properties .
THANK YOU
