Project Of Air

Consumption On Air
Jet Weaving Machine

SUBMITTED BY: k
u
Agrata Gupta s
Km. Khusboo h
w
aha Abhishek
SUBMITTED TO:
Tripathi
Dr. J.P. Singh
OBJECTIVE:
To study the consumption of air in
air weaving machine
Specific Objective:
Reduction in the consumption of
air on existing machines
 ACKNOWLEDGEMENT

I take immense pleasure to acknowledge the most

important role played by Dr. J.P. Singh (Training and
Placement officer), UTTAR PRADESH TEXTILE
TECHNOLOGY INSTITUTE
in successful completion our project. His enthusiasm, support
and keen interest helped us in completing this
project.We extend our profound sense of gratefulness
for their great encouragement, belief and precious
guidance in carrying out this project.We express our
sincere gratitude to all the staff members of Alok
Industry and special thanks to Mr. Ajay Sir whose co-
operation and good wishes helped us in completing
this project.
 ABSTRACT

As it is well known, power consumption due to compressed air is

the main disadvantage of Air jet loom when compared to rapier
and projectile looms. This is making air jet less preferable where
energy cost is the problem, despite their high production speeds.
Studies which have been taken to reduce them, included
manufacturing of different parts i.e. researches have been taken
place on the manufacturing levels. But, we decided to reduce the
consumption of air which may be due to some wrong settings,
ignorance, etc. without any investment which can give profits to
the mill by reducing the consumption of air. A decrease of air
consumption by 18% was accomplished in a weaving mill by just
changing the process parameters consisting mainly by the
opening and closing time of nozzles and by improving work
practices.
 INTRODUCTION TO AIRJET
For the weft insertion mechanisms of air jet looms, the profile reeds with
sub- nozzle systems are the most advantageous in terms of improving
high speed weaving and wider cloth width. Not only the airflow from the
main nozzle and sub- nozzles but also the airflow in the weft passage is
closely related to the flying state of the yarn at the time of weft insertion
in this system. In order to manufacture high quality textiles with air jet
looms, it is necessary to establish optimum weaving conditions. These
conditions include the supply air pressure and air injection timing for the
main nozzle and sub-nozzles according to the kind of well yarn. Energy
saving is the most important of the technical subjects related to air jet
looms today. Research about the improvement in performance of main
nozzles and sub-nozzles, which plays an important role for weft insertion,
has been performed by various researchers. Intensive efforts have been
made by researchers and air-jet loom makers to overcome this problem
and achieve a dramatic reduction in air consumption without any
decrease in loom performance and fabric quality, but due to faulty mill
practices and ignored settings, air consumed by looms is on higher side.
So, our project aims to reduce the air consumption significantly, by
optimizing some loom parameters. These parameters, includes inly the
relay nozzles because they consume 80% of the pressed air produced.
 Filling Feeding System

The air jet loom feeds the filling as in Figure 1. The filling length is measured
according to the width of the fabric by 1 rotation of the loom.
It is accelerated by the main nozzle at a specific timing, and is inserted into the air
guide of the reed. Groups of sub-nozzles are located across the whole width. Each
group jets compressed air in a specific order to feed the filling tip to the right end of
the fabric. The compressed air is supplied from the compressor, its pressure is
adjusted by the regulators for the main nozzle and the sub-nozzles, and it is stored
in the proper tank. The control system of the loom opens and closes the electro-
magnetic valve, and sends the compressed air to the nozzles.
LAYOUT OF AIR JET WEAVING
MACHINE
COST EFFECTIVENESS OF SHUTTLE LESS LOOM

Shuttle less looms have numerous advantages over

shuttle looms Some of these are:
• Increase in loom productivity.
• Increase in weaver productivity. •Improvement in the quality of fabric,
• Longer lengths and wider widths fabrics can be produced,
• As many as 16 colours of yarn in the weft can be used without sacrificing the
speed of the machine,
• Increase in versatility
• Use of weft accumulators, which reduces average tension on weft
during insertion of equalizes yarn tension caused by the diminishing
diameter of weft supply package avoid snarls in the weft and gives
fewer weft breakages
• Reduces cost of production due to higher productivity and better value
realization due to improved fabric quality.
OPTIMISATION OF COMPRESSED AIR

Compressed air cost can be minimised broadly in two ways.

One, by minimising wasteful consumption of compressed air
i.e. by preventing compressed air leakages and
secondly by improving the efficiency of compressors.
Ways and means for both these aspects are
discussed.
 AIR LEAKAGES MAZOR POINTS

▶ Volve Direct
▶ Volve leakages
▶ Sub nozzles pipe leakage
▶ Main volve and Tendom volve leakage
▶ Elbow worn out or leakage
▶ Housepipe damage leakage
 PREVENTING AIR LEAKAGES

Leakages usually occur in small openings; but the cumulative effect

is great. Some tips for preventing the air leakage are given here
with
• Standardise on good hose clamps
• Inspect steam packing of valves in the system periodically, Repack when
necessary.
• Replace/repair leaky shut-off valves.
• Install condensate separators with automatic traps to eliminate the need for
operators, opening the manual valve to clear water, thereby wasting air.
• Use good quality air hoses to avoid breaks and leaks.
Improving Volumetric
Efficiency Of Air Compressors
Volumetric efficiency of an air compressor has a significant bearing on the
operational cost of air compressors. Low volumetric efficiency results in
higher per unit cost of compressed air. The main contributing factors for
low efficiency are:
• clogged air inlet filters.
• obstruction at the inlet valve.
• piston ring leakage.
• hot inlet air.
• inter cooler working inefficiently.
• increase in impeller-diffuser clearance in case of centrifugal compressors.
It is therefore, necessary to check the volumetric efficiency periodically and
if it falls below stipulated value the compressor should be checked and
attended.
Cost Reduction Opportunities

Cost reduction opportunities that were explored

include reuse of plant air, compressor motor
selection, optimizing compressor control schemes,
recovering the heat of compression, ensuring that
the distribution lines are properly configured and
free of leaks, and determining the minimum
pressure and flow requirements at the end use.
 AIR INTAKE (Compressor
Department)

Typically, the air being compressed is taken from outside the plant, from air at
ambient temperature and relative humidity. This creates wide varieties of
conditions that the compressor has to be adjusted to meet. During the summer
months, the compressor is under the greatest load. The volumetric flow rate of
the inlet must be higher (around 10%) to provide the same SCFM (standard
cubic feet per minute) during the summer months as in the winter.After air is
used at its point of operation, it is added to the air already in the plant. This
additional volume of air must leave the plant somehow, i.e. open doors, cracks
in door and window frames, etc. This air that is being leaked from the plant
would have much lower moisture content than the outside air. The air inside
the plant will also have a higher density in the summer months due to a lower
temperature. The implementation of a system that recovers the conditioned
plant air may prove to be useful in reducing air compression costs. The
potential energy savings from reusing this already dry air could be significant
when the conditions outside the plant are extremely hot and humid. Certain
geographic locations would benefit more than others from this reuse which has
extremely hot and humid summer months. The installation cost of such a
system can be very high for an existi plant, but this option should be
considered when a new pla designed.
 Compressor Motor Efficiency

Improvements in motor design have led to

increased energy efficiency in motor operation.
New motors that are suitable for textile
manufacturing plants operate at an efficiency of
95%, comparing to motors designed 15 years ago
at 90% or less. Over time, the efficiency of the
motors may be reduced. It is not uncommon for
the efficiency to drop several percentage points
after 10 years of operation. High efficiency new
motors should be considered when a replacement
or major maintenance is needed on the motors.
 Compressor Controls

Centrifugal compressors typically use inlet guide vanes to control the airflow
through the compressor. This throttling is beneficial in that the efficiency is
not reduced significantly with this method of control. The typical throttle
range is down to around 80% of maximum airflow capacity. The highest
efficiency is reached when the compressor is operating at 100% capacity. If
air is not being used on the demand side as fast as it is being produced, the
pressure will rise in the air receiver. A compressor (or multiple compressors)
must be throttled to prevent this. All of the compressors should be operating
at full capacity except for the one(s) being throttled. If the total compressor
output is still greater than the demand after the compressor(s) has been
throttled to their limit, air must be exhausted from the system through the
blow-off valve. An appropriate control scheme can reduce or eliminate this
wasteful blow-off. A precise compressor control scheme with little pressure
variation is desired. The compressor does not need to produce air at a
higher pressure than the minimum pressure required for proper plant
operation. The typical pressure output by a compressor tends to fluctuate
somewhat throughout the day. A good control scheme would minimize these
fluctuations.
 Distribution Lines

The distribution system represents a great source for energy savings.

There are pressure drops associated with the flow through all equipment
in the line, even in the piping itself. The pressure drop from the point of
use and from the output of the compressor should be as low as possible.
Equipment should be properly sized to give a minimum pressure drop.
End use equipment should be evaluated so that it is using the lowest
possible pressure and flow. The ultrasonic detector is able to focus the
sensor at a specific point, making it suitable for detecting leaks while
machinery is in operation. Escaping air produces the highest noise levels
at a frequency around 40 kHz, well beyond the human audible frequency
range. The device measures the loudness level at this frequency.
Estimates of the amount of air can be obtained from the dB reading.
 AIR COMPRESSOR UNIT

Atlas Copco
air
compressor
FLOW CHART OF DISTRIBUTION LINE
 FUNCTION
▶ IGV – Inlet Guide Valve
▶ Impeller 1- compress the air Low pressure , volume low ,
Temprature high
▶ Cooler 1- Decrease the temperature of impeller 1
▶ Impeller 2 – Compress the air
▶ Cooler 2 – Decrease the temperature of impeller 2
▶ Impeller 3 – compress air under high pressure
▶ Cooler 3- Decrease the temperature of impeller 3
▶ BOV –Blow of valve (blow the excess air)
▶ Header – common point of all compress air
▶ Dryer – Remove mositure and oil from air
 Basic details of air compressor
▶ Number Of compressor – 5
▶ Capacity of compressor – 9200CFM
▶ Compress air supply to – 9A,9B,9C,9F
▶ Machine average CFM
– 1.Normal width – 35-40
CFM 2.Wider width – 55
to 60 CFM
▶ No of machine in unit 7 – 190
▶ Average CFM of 9B looms – 3360 CFM
▶ Compressor Motor – 1600KV
▶ Standard pressure –
1.6Bar – Shirting
2.7-8.5Bar – course/lycra/textured yarn
Head Impell
er
er

Water Cooler
Measure steps to reduce air
consumption
▶ Ultra Sonic Cleaning:
Cleaning of main nozzle, relay nozzle, air filter, hose pipes etc. ultra sonic cleaning is
important to maintaining the efficiency of weaving. It should avoid the damaged or
error portion of the surface so such condition of deposition is micro fiber can drop
the Pressure of air blowing through it so these can be avoided due to these
cleaning.

▶ Opening and Closing Time of Nozzle:

Correction made by delaying opening time and early closing of Nozzle
settings it will help in reducing the air consumption. Improper opening &
closing timing of valves lead to undue stress on yarn thereby leading to
break. After proper adjustment the no. of end breaks can be reduced. The
air consumption can be reduced up to 8-10%
▶ Pressure On The Nozzle:
Pressure on nozzle has more impact on the m/c performance. Improper
pressure adjustment will causes the weft stop during working so quality &
productivity can be minimized. To avoid the problem, proper setting of pressure
can be required. These can be adjusted according to count, rpm, width of m/c.
Proper combination between main & relay nozzle will reduce the air
consumption.
SETTING OF NOZZLES:

1- Distance between two nozzles – Improper setting between to relay

nozzle will cause to variation in air pressure and will cause m/c performance to
be in decreasing the air consumption will be unnecessary increases.

2- Nozzle height – Proper height setting of relay nozzle will causes reduction
in air pressure during weft insertion & air consumption can be reduced.
Proper setting of the nozzle height will provide the uniform displacement of
yarn during insertion.

3- Nozzle angle- For uniform weft insertion of yarn during insertion proper
nozzle angle will reduce air consumption. Pressure required for insertion can
be reduced.
Multi hole versus single hole
The multi hole relay nozzles guarantee a very stable blowing angle at different
pressure levels. This is recommended for style changes that require different
relay nozzle pressure settings. The single-hole nozzles need to be adjusted by
hand whereas multi- hole nozzles keep their blowing angle stable and do not
need any adjustment or fine tuning. Due to the pre-given horizontal and
vertical jetting angles, the multi-hole nozzle requires less space between the
warp yarns, which prevents nozzle marks in your fabric..The multi hole pattern
allows also a more efficient air stream, thus delivering a better performance
over single hole nozzles, giving up to 15% higher yarn speed for the same air
consumption. Single-hole nozzles are recommended in case of a dusty
environment or low air quality.
The perfect nozzle jet loom for
any air Jet loom
Over 40 years ago, Te Strake Textile revolutionized weaving with the introduction of its
unique air jet weaving system. Today, Te Strake Textile is worldwide recognized as the
trendsetter and innovator in air insertion technology. With their complete range of
relay nozzles, Te Strake Textile delivers the perfect relay nozzle for your needs, no
matter which loom type you are using.

Innovation for better weaving performance:

D-type relay nozzle-
Based on their extensive experience in air insertion technology, Te Strake Textile takes another step
in air jet weaving with its innovative D-type nozzle. This D-type nozzle incorporates unique
characteristics to outperform any other model in terms of:
•Reduced weft stops
•mproved machine performancebod
•Extra stability of nozzle body
• Prevention of nozzle marks
• Reduction of air consumption
•Increased lifeline
Unique body design:
The new design makes the D-type nozzle the most robust and stable nozzle
currently available, with up to 45% higher resistance to deformation. This
stronger nozzle requires an absolute minimum of adjustments for higher
productivity.

New nozzle head

With the successful experience of a round or convex nozzle head, the D-type
nozzle head has been further optimized for better fabric quality. Filamentation,
nozzle marks or having your warp yarns staying on top of the nozzle, belong
now to the past.
Different hole patterns:
The D-type nozzle is available with different hole patterns (1-7 16-19
holes) to suit your specific need. The highest performance is given by
the 16 hole nozzle, offering you specific benefits.

Different types of nozzles:

Insertion time:

With the revolutionary 16-hole pattern, the air stream is now perfectly
parallel to the warp yarns, thus making maximum use of the insertion
time. As a result, higher weaving speed for increased productivity or a
gentler yarn passage for better fabric quality is guaranteed.
Higher performance :
The D-type 16 hole nozzle can offer you significant cost savings. This nozzle can
generate the same yarn speed with less air consumption in some cases up to 15-
20% depending on the weaving condition. Either, with the same air consumption,
you are able to increase the yarn speed.

DLC Coating
The D-type nozzles are exclusively coated with Diamond-Like carbon
coating which is superior to any other coating. It increases life time up to 5
times and avoids wear and yarn cuts. DLC coating is therefore specially
recommended for abrasive warp yarns.
Control of Sub -Nozzle

Control of sub-nozzles by increased groups conventionally, as in Fig. 02;

sub- nozzles are arranged in groups of 4 nozzles. An electro-magnetic
valve is attached to each group and the sub nozzles of the same group
jet simultaneously. Tsudakoma’s new arrangement, as in Figure 3, has
an electro-magnetic valve with a smaller inner volume so that it
matches to 2 sub-nozzles. The control of valve is improved, and extra
jetting time is reduced.
 Improvement of nozzle for
feeding the filling and reed

The main nozzle pulls the filling with compressed air and guides it to the air guide of the reed
as in Figure 4. A Laval-type nozzle: the interior is wider at one end than the other. The
nozzle’s pulling force is increased by 30%, and air consumption of the main nozzle is
reduced by 10. (Compared with the cylindrical nozzle) In addition, the sub-nozzles use
almost all of the air consumption in the air jet loom because of their number. Tsudakoma
invented a new sub-nozzle. The part aroundaving the jetting outlet of the new sub-nozzle is
hollowed (See Figure 5), and the flow speed is increased by 10%. Because the filling does
not touch the edge of the jetting outlet, damage to the filling is lowered. For the reed, the
air guide of the reed for feeding the filling is narrowed, and the air flow speed is raised.
ACTION PLAN:

▶ Selection of machines working with same fabric qualities.

▶ Study of air consumption on selected machines.
▶ Factors responsible for variation in air consumption.
▶ Air leakages and it’s effect on air consume
▶ Check points
1. Distance of machine from compressor
A] Leakages
B] Bends in pipe
2) Settings:
A] Shedding
1.Shed height
2. Shed angle
B]Picking
1. Nozzle settings
2. Opening & closing time
3. Distance between the nozzles
4. No of nozzles
5. Weft insertion rate
EXPERIMENTAL STUDIES:
▶ We have studied about four loom (i.e. 1288,1284 ,1293,1309)which having different sorts and running with different settings.

LOOM NO.-1288
SORT NO-32104
CONSTRUCTION
Warp- 2/60 PC (65:35)
Weft- 27 PC (65:35)
Reed-58/2
Reed Space -
59inch
Beam(m)- 3930
Weave- Plain
Picks-60
Total Ends -
3426 Grey
Width -57inch
Insertion- 1
 ICS Setting

• WARP:
WEAVE PATTERN:
1/1 MATERIAL:
Spun PC YARN
COUNT: 2/60
DENSITY : 56
• WEFT :

COLOUR 1 COLOUR 2
MATERIAL Blended Poly+Cotton Blended Poly+Cotton
COUNT 27den 27den
MEASURING BAND B(175mm) B(175mm)
To-Tw 70°-235° 70°-235°
ABS ON ON
STRECH NOZZLE OFF OFF
DENSITY 59/inch 59/inch
MACHINE:
RPM- 880
DRAW WIDTH -1709mm
BEAM DIA(BOTTOM BEAM) -
1000mm HARNESS FRAME – 2
MECHANICAL SETTING :
BACK REST - +2
DROP BOX -0
EEASING CROSS- 300°
SHED ANGLE– 160°-
149° EEASING
SCALE -2mm SIM
SETTING – 4mm
FRAME HEIGHT – 1st-140mm, 2nd -139mm
EFFICIENCY – 81%
TENSION- 130 kgf
 IFC SETTINGS
COLOUR 1 COLOUR 2
TARGET 235 TARGET 235
SAMPLING 1000 SAMPLING 1000
STD 5.62 STD 2.98
To 85 To 83
Tb1 88 Tb1 85
Tb2 142 Tb2 142
Tb3 183 Tb3 184
Tb4 0 Tb4 0
Tb5 0 Tb5 0
Tb6 0 Tb6 0
Tb7 0 Tb7 0
Tb8 0 Tb8 0
Tbw 224 Tbw 225
Tw 228 Tw 228
Tw-Tbw 4 Tw-Tbw 3
 PRESSURE SETTINGS

SUB NOZZLE – 5.47

MAIN NOZZLE 1 -2.32
MAIN NOZZLE 2 -
2.18 STRETCH
NOZZLE – OFF
MAIN BRIDGE -1.12
CUTTING BLOW -1.1
 VALVE SETTINGS
▶ NOZZLE SETTINGS:

Nozzle setting COLOUR 1 COLOUR 1

PIN(OPEN) 60° 60°
ABS ON ON
ABS(RELEASE) 60° 60°
ABS(BRAKE) 205°-255° 205°-255°
ABS(PULL BACK) 350° 350°
MAIN 80°-200° 80°-200°
TANDEM 100°-200° 100°-200°
CUTTER 35°-205° 40°-210°
CUTBLOW 10°-50° 10°-50°
▶ SUB NOZZLE SETTINGS:

Sub Nozzle COLOUR 1 COLOUR 2

SUB 1 87°-137° 87°-137°
SUB 2 111°-161° 111°-161°
SUB 3 129°-179° 129°-179°
SUB 4 147°-197° 147°-197°
SUB 5 165°-280° 165°-280°
SUB 6 184°-300° 184°-300°
SUB 7 202°-300° 202°-300°
SUB 8 0-0 0-0
▶ EXHAUST SETTINGS:

COLOU
COLOUR 1 COLOU
COLOUR 2
STRECH
STRECH NOZZLE 0 0-0 0 0-0
STRECH
STRECH BLOW 0 0-0 0 0-0
MAIN 0 0
MAIN EXHAUST 0-0 0-0
SUB EXHAUST (E) 300°-340° 00°-
SUB EXHAUST (E) 300°-340° 300°-340°
SUB EXHAUST(E-1)
SUB EXHAUST (E- 300°-340°
300°-340° 300°-340°
00°-
1)

• CFM :

LEAKAGE CFM – 7.8 * 0.585 = 4.5 (more leakage)

RUNNING CFM – 65*0.585 = 38.025
 OBSERVATION & CHANGES
• VALVE SETTING

Nozzle setting COLOUR 1 COLOUR 1

PIN(OPEN) 60° 60°
ABS ON ON
ABS(RELEASE) 60° 60°
ABS(BRAKE) 205°-255° 205°-255°
ABS(PULL BACK) 30° 30°
MAIN 85°-180° 85°-180°
TANDEM 90°-170° 90°-170°
CUTTER 25°-205° 30°-210°
CUTBLOW 10°-50° 10°-50°
• SUB NOZZLE SETTINGS:

Sub Nozzle COLOUR 1 COLOUR 2

SUB 1 87°-137° 87°-137°
SUB 2 111°-161° 111°-161°
SUB 3 129°-179° 129°-179°
SUB 4 147°-197° 147°-197°
SUB 5 165°-260° 165°-260°
SUB 6 184°-280° 184°-280°
SUB 7 202°-290° 202°-290°
SUB 8 0-0 0-0
• PRESSURE SETTINGS:
▶ SUB NOZZLE – 5.50
▶ MAIN NOZZLE 1 -2.98
▶ MAIN NOZZLE 2 -2.98
▶ STRETCH NOZZLE – OFF
▶ MAIN BRIDGE -0.58
▶ CUTTING BLOW -0.94
• FILLER SETTINGS:

COLOUR 1 COLOUR 2
WF1 SENSITIVITY 4 4
WF2 SENSITIVITY 6 6
ARRIVAL Tw 1 1
FEED FEELER OFF OFF
WF1 DEFECT ANGLE 215°-310° 215°-310°
WF2 DEFECT ANGLE 190°-340° 190°-340°
 NEW CONSUMPTION OF AIR AFTER CHANGING THE
SETTINGS AND BLOCKING THE
LEAKAGES

OLD CFM NEW CFM

LEAKAGE CFM 4.5 0
RUNNING CFM 37.025 34.98

IMPLEMENTATION :

• % Decrement in CFM : 24.75%

• STD - 1.64-1.70
 LOOM NO.-1283
SORT NO-
111391
CONSTRUCTI
ON
Warp- 40 comb
Weft- 2/30 comb
Reed -92/2
Reed Space -
72inch
Beam(m)- 4600
Weave- oxford
Picks-48
Total Ends -
6624 Grey
Width -68inch
Insertion- 1
 ICS SETTINGS
• WARP:
WEAVE PATTERN:
1/1 MATERIAL:
Spun PC YARN
COUNT: 2/60
DENSITY : 56

• WEFT:

COLOUR 1 COLOUR 1
MATERIAL SPUN COTTON SPUN COTTON
COUNT 30 30
MEASURING BAND B(175mm) B(175mm)
To-Tw 80°-235° 80°-235°
ABS ON ON
STRECH NOZZLE OFF OFF
DENSITY 48/inch 48/inch
MACHINE:
RPM- 825
DRAW WIDTH -1811mm
BEAM DIA(BOTTOM BEAM) -
1000mm HARNESS FRAME – 4
MECHANICAL SETTING :
BACK REST -
0 DROP BOX
- -1
EEASING CROSS-
300° SHED ANGLE –
149°-115° EEASING
SCALE – 3mm SIM
SETTING – 2mm
FRAME HEIGHT – 1st-139mm, 2nd -138mm ,3rd -137mm ,4th – 136mm
EFFICIENCY /SHIFT – 59%
TENSION- 250 kgf
 IFC SETTINGS
COLOUR 1 COLOUR 1
To-Tw 78°-240° 78°-240°
STRECH 0-0 0-0
SUB 8 213°-300° 213°-300°
SUB7 197°-300° 197°-300°
SUB 6 182°-280° 182°-280°
SUB 5 156°-260° 156°-260°
SUB 4 150°-190° 150°-190°
SUB 3 134°-174° 134°-174°
SUB 2 118°-158° 118°-158°
SUB 1 97°-137° 97°-137°
MAIN 80°-180° 80°-180°
TANDEM 85°-170° 85°-170°
PIN(OPEN) 70° 70°
ABS(BRAKE) 205°-245° 205°-245°
STD 2.80 2.71
 PRESSURE SETTINGS

SUB NOZZLE 1– 5.4

MAIN NOZZLE 1- 2.73
MAIN NOZZLE 2 –
4.5 STRETCH
NOZZLE – OFF
MAIN BRIDGE –
4.69 CUTTING
BLOW – 2.5
 VALVE SETTINGS
▶ NOZZLE
SETTINGS:

Nozzle setting COLOUR 1 COLOUR 1

PIN(OPEN) 70° 70°
ABS ON ON
ABS(RELEASE) 70° 70°
ABS(BRAKE) 205°-245° 205°-245°
ABS(PULL BACK) 350° 350°
MAIN 80°-180° 80°-180°
TANDEM 85°-170° 85°-170°
CUTTER 10°-205° 15°-210°
CUTBLOW 10°-50° 10°-50°
▶ SUB NOZZLE SETTINGS

Sub Nozzle COLOUR 1 COLOUR 2

SUB 1 97°-137° 97°-137°
SUB 2 118°-158° 118°-158°
SUB 3 134°-174° 134°-174°
SUB 4 150°-190° 150°-190°
SUB 5 166°-260° 166°-260°
SUB 6 182°-280° 182°-280°
SUB 7 197°-300° 197°-300°
SUB 8 213°-300° 213°-300°
▶ EXHAUST SETTINGS

COLOUR 1 COLOUR 2
STRECH NOZZLE 0-0 0-0
STRECH BLOW 0-0 0-0
MAIN EXHAUST 0-0 0-0
SUB EXHAUST (E) 300°-340° 300°-340°
SUB EXHAUST (E-1) 300°-340° 300°-340°

• CFM:

LEAKAGE CFM – 9 * 0.585 = 5.6(more leakage)

RUNNING CFM – 76.5 *0.585 = 44.75
 OBSERVATION & CHANGES
• VALVE SETTING

Nozzle setting COLOUR 1 COLOUR 1

PIN(OPEN) 70° 70°
ABS ON ON
ABS(RELEASE) 70° 70°
ABS(BRAKE) 210°-260° 210°-260°
ABS(PULL BACK) 350° 350°
MAIN 85°-170° 85°-170°
TANDEM 80°-160° 80°-160°
CUTTER 10°-205° 15°-210°
CUTBLOW 10°-50° 10°-50°
▶ SUB NOZZLE SETTINGS

Sub Nozzle COLOUR 1 COLOUR 2

SUB 1 97°-127° 97°-127°
SUB 2 118°-147° 118°-147°
SUB 3 134°-167° 134°-167°
SUB 4 150°-187° 150°-187°
SUB 5 166°-250° 166°-250°
SUB 6 182°-270° 182°-270°
SUB 7 197°-280° 197°-280°
SUB 8 213°-290° 213°-290°
• PRESSURE SETTINGS

▶ SUB NOZZLE – 5.08

▶ MAIN NOZZLE 1 – 4.28
▶ MAIN NOZZLE 2 – 4.25
▶ STRETCH NOZZLE – OFF
▶ MAIN BRIDGE – 1.51
▶ CUTTING BLOW – 1.51

• FILLER SETTINGS

COLOUR 1 COLOUR 2
WF1 SENSITIVITY 2 2
WF2 SENSITIVITY 6 6
ARRIVAL Tw 2 2
FEED FEELER ON ON
WF1 DEFECT ANGLE 210°-310° 210°-310°
WF2 DEFECT ANGLE 180°-340° 170°-340°
 NEW CONSUMPTION OF AIR AFTER CHANGING THE
SETTINGS AND
BLOCKING THE LEAKAGES

OLD CFM NEW CFM

LEAKAGE CFM 5.6 0
RUNNING CFM 44.75 38.31

IMPLEMENTATION

• % Decrement in CFM : 36.55%

• STD – 3.30-3.39
LOOM NO.-1293
SORT NO- 111099
CONSTRUCTION
Warp- 30comb
Weft- 20OE + 20K (70D)
Reed – 64/4
Reed Space -
72 Beam(m)-
3080 Weave-
4/1 Picks- 68
Total Ends -
9278 Grey
Width - 70
Insertion- 1
 ICS SETTINGS
• WARP:
WEAVE PATTERN:4/1
MATERIAL: Spun Cotton
YARN COUNT: 30
DENSITY : 128

• WEFT

COLOUR 1 COLOUR 1
MATERIAL SPUN COTTON SPUN COTTON
COUNT 20 20
MEASURING BAND B(175mm) B(175mm)
To-Tw 80°-235° 80°-235°
ABS ON ON
STRECH NOZZLE ON ON
DENSITY 68/inch 68/inch
MACHINE:
RPM- 755
DRAW WIDTH - 1903
BEAM DIA(BOTTOM BEAM) -
1000mm HARNESS FRAME – 6
MECHANICAL SETTING :
BACK REST - +1
DROP BOX - 0
EEASING CROSS-
300° SHED ANGLE –
155°-125° EEASING
SCALE – 1mm SIM
SETTING – 2mm
FRAME HEIGHT – 1st-144mm, 2nd -143mm ,3rd -142mm ,4th – 141mm ,5th – 140mm , 6th -
139mm
EFFICIENCY /SHIFT – 81%
TENSION- 400kgf
 IFC SETTINGS
COLOUR 1 COLOUR 2
To-Tw 80°-237° 80°-237°
STRECH 215°-300° 215°-300°
SUB 8 208°-280° 208°-280°
SUB7 193°-280° 193°-280°
SUB 6 178°-270° 178°-270°
SUB 5 162°-260° 162°-260°
SUB 4 147°-187° 147°-187°
SUB 3 132°-172° 132°-172°
SUB 2 117°-157° 117°-157°
SUB 1 97°-137° 97°-137°
MAIN 90°-160° 90°-160°
TANDEM 95°-150° 95°-150°
PIN(OPEN) 70° 70°
ABS(BRAKE) 195°-240° 195°-240°
STD 5.33 4.69
 PRESSURE SETTINGS

SUB NOZZLE 1– 5.29

MAIN NOZZLE 1- 1.56
MAIN NOZZLE 2 –
3.89 STRETCH
NOZZLE – 2.41
MAIN BRIDGE – 2.49
CUTTING BLOW –
3.56
 VALVE SETTINGS
▶ NOZZLE SETTINGS

Nozzle setting COLOUR 1 COLOUR 1

PIN(OPEN) 70° 70°
ABS ON ON
ABS(RELEASE) 70° 70°
ABS(BRAKE) 195°-240° 195°-240°
ABS(PULL BACK) 350° 350°
MAIN 90°-160° 90°-160°
TANDEM 95°-150° 90°-170°
CUTTER 35°-205° 30°-210°
CUTBLOW 10°-50° 10°-50°
▶ SUB NOZZLE SETTINGS

Sub Nozzle COLOUR 1 COLOUR 2

SUB 1 97°-137° 97°-137°
SUB 2 117°-157° 117°-157°
SUB 3 132°-172° 132°-172°
SUB 4 147°-187° 147°-187°
SUB 5 162°-260° 162°-260°
SUB 6 178°-270° 178°-270°
SUB 7 194°-280° 194°-280°
SUB 8 208°-280° 208°-280°
▶ EXHAUST SETTINGS

COLOUR 1 COLOUR 2
STRECH NOZZLE 215°-300 215°-300
STRECH BLOW 50°-150° 50°-150°
MAIN EXHAUST 0-0 0-0
SUB EXHAUST (E) 280°-340° 280°-340°
SUB EXHAUST (E-1) 280°-340° 280°-340°

• CFM
LEAKAGE CFM – 6.6 * 0.585 = 3.86(more leakage)
RUNNING CFM – 74.5 *0.585 = 43.58
 OBSERVATION & CHANGES
• VALVE SETTTING

Nozzle setting COLOUR 1 COLOUR 1

PIN(OPEN) 70° 70°
ABS ON ON
ABS(RELEASE) 70° 70°
ABS(BRAKE) 205°-235° 210°-260°
ABS(PULL BACK) 350° 350°
MAIN 85°-160° 85°-170°
TANDEM 90°-150° 85°-160°
CUTTER 30°-205° 25°-210°
CUTBLOW 10°-50° 10°-50°
▶ SUB NOZZLE SETTINGS

Sub Nozzle COLOUR 1 COLOUR 2

SUB 1 97°-127° 97°-137°
SUB 2 117°-137° 117°-157°
SUB 3 132°-147° 132°-172°
SUB 4 147°-167° 147°-187°
SUB 5 162°-250° 162°-260°
SUB 6 178°-260° 178°-270°
SUB 7 193°-280° 193°-280°
SUB 8 208°-280° 208°-280°
▶ PRESSURE SETTINGS

▶ SUB NOZZLE – 5.1

▶ MAIN NOZZLE 1 – 3.8
▶ MAIN NOZZLE 2 – 3.89
▶ STRETCH NOZZLE – 1.2
▶ MAIN BRIDGE – 1.7
▶ CUTTING BLOW – 2.0

• FILLER SETTINGS
COLOUR 1 COLOUR 2
WF1 SENSITIVITY 4 4
WF2 SENSITIVITY 6 6
ARRIVAL Tw 2 2
FEED FEELER ON ON
WF1 DEFECT ANGLE 215°-310° 215°-310°
WF2 DEFECT ANGLE 170°-340° 190°-340°
 NEW CONSUMPTION OF AIR AFTER CHANGING THE
SETTINGS AND BLOCKING THE
LEAKAGES

OLD CFM NEW CFM

LEAKAGE CFM 3.86 0
RUNNING CFM 43.58 40.014

IMPLEMENTATION

• % Decrement in CFM :18.12%

• STD –4.89-3.21
LOOM NO.-1309
SORT NO- 19944B
CONSTRUCTION
Warp- 20 OE
Weft- 16 OE
Reed – 48/4
Reed Space –
67inch Beam(m)-
2950 Weave-
Dobby Picks- 56
Total Ends - 6430
Grey Width – 65 inch
Insertion- 1
 ICS SETTINGS
• WARP:
WEAVE PATTERN:4/1
MATERIAL: Spun Cotton
YARN COUNT: 30
DENSITY : 128

• WEFT

COLOUR 1 COLOUR 1
MATERIAL SPUN COTTON SPUN COTTON
COUNT 16 16
MEASURING BAND B(175mm) B(175mm)
To-Tw 80°-230° 80°-230°
ABS ON ON
STRECH NOZZLE OFF OFF
DENSITY 56/inch 56/inch
MACHINE:
RPM- 830
DRAW WIDTH - 1702
BEAM DIA(BOTTOM BEAM) -1000mm
HARNESS FRAME – 4
MECHANICAL SETTING :
BACK REST - +2
DROP BOX - 0
EEASING CROSS-
300° SHED ANGLE –
147°-120° EEASING
SCALE – 3mm SIM
SETTING – 2mm
FRAME HEIGHT – 1st-143mm, 2nd -142mm ,3rd -141mm ,4th – 140mm
EFFICIENCY /SHIFT – 58.7%
TENSION- 218kgf
 IFC SETTINGS
COLOUR 1 COLOUR 2
To-Tw 80°-227° 80°-227°
STRECH 0-0 0-0
SUB7 199°-300° 199°-300°
SUB 6 183°-300° 183°-300°
SUB 5 167°-280° 167°-280°
SUB 4 151°-211° 151°-211°
SUB 3 134°-194° 134°-194°
SUB 2 118°-178° 118°-178°
SUB 1 97°-157° 97°-157°
MAIN 80°-190° 80°-190°
TANDEM 90°-180° 90°-180°
PIN(OPEN) 70° 70°
ABS(BRAKE) 185°-245° 185°-245°
STD 2.74 5.87
 PRESSURE SETTINGS

SUB NOZZLE 1– 5.36

MAIN NOZZLE 1- 2.16
MAIN NOZZLE 2 –
2.97 STRETCH
NOZZLE – OFF
MAIN BRIDGE – 1.8
CUTTING BLOW –
1.19
 VALVE SETTINGS

▶ NOZZLE SETTINGS

Nozzle setting COLOUR 1 COLOUR 1

PIN(OPEN) 70° 70°
ABS OFF OFF
ABS(RELEASE) 70° 70°
ABS(BRAKE) 185°-245° 185°-245°
ABS(PULL BACK) 350° 350°
MAIN 80°-190° 80°-190°
TANDEM 90°-180° 90°-180°
CUTTER 35°-205° 35°-205°
CUTBLOW 10°-50° 10°-50°
▶ SUB NOZZLE SETTINGS

Sub Nozzle COLOUR 1 COLOUR 2

SUB 1 97°-157° 97°-157°
SUB 2 118°-178° 118°-178°
SUB 3 132°-194° 132°-194°
SUB 4 151°-211° 151°-211°
SUB 5 167°-280° 167°-280°
SUB 6 183°-300° 183°-300°
SUB 7 199°-300° 199°-300°
SUB 8 199°-300° 199°-300°
▶ EXHAUST SETTINGS

COLOUR 1 COLOUR 1
STRECH NOZZLE 0-0 0-0
STRECH BLOW 0-0 0-0
MAIN EXHAUST 0-0 0-0
SUB EXHAUST (E) 300°-340° 300°-340°
SUB EXHAUST (E-1) 300°-340° 300°-340°

• CFM

LEAKAGE CFM – 6.4 * 0.585 = 3.78(more leakage)

RUNNING CFM – 63.3 *0.585 = 37.03
 OBSERVATION & CHANGES
• VALVE SETTINGS

Nozzle setting COLOUR 1 COLOUR 1

PIN(OPEN) 70° 70°
ABS OFF ON
ABS(RELEASE) 70° 70°
ABS(BRAKE) 185°-245° 200°-250°
ABS(PULL BACK) 350° 350°
MAIN 85°-170° 85°-170°
TANDEM 85°-160° 85°-160°
CUTTER 35°-205° 40°-210°
CUTBLOW 10°-50° 10°-50°
▶ SUB NOZZLE SETTINGS

Sub Nozzle COLOUR 1 COLOUR 2

SUB 1 97°-137° 97°-137°
SUB 2 118°-147° 118°-147°
SUB 3 134°-167° 134°-167°
SUB 4 151°- 187° 151°- 187°
SUB 5 167°-260° 167°-260°
SUB 6 183°-270° 183°-270°
SUB 7 199°-290° 199°-290°
SUB 8 199°-300° 199°-300°
▶ PRESSURE SETTINGS
▶ SUB NOZZLE – 5.3
▶ MAIN NOZZLE 1 – 2.1
▶ MAIN NOZZLE 2 – 2.4
▶ STRETCH NOZZLE – OFF
▶ MAIN BRIDGE – 1.8
▶ CUTTING BLOW –1.1

• FILLER SETTINGS
COLOUR 1 COLOUR 2
WF1 SENSITIVITY 3 3
WF2 SENSITIVITY 6 6
ARRIVAL Tw 2 2
FEED FEELER ON ON
WF1 DEFECT ANGLE 215°-310° 215°-310°
WF2 DEFECT ANGLE 170°-340° 190°-340°
 NEW CONSUMPTION OF AIR AFTER CHANGING THE
SETTINGS AND BLOCKING THE
LEAKAGES

OLD CFM NEW CFM

LEAKAGE CFM 3.78 0
RUNNING CFM 37.03 33.77

IMPLEMENTATION

• % Decrement in CFM :23.44%

• STD – 3.17-7.41
FACTOR AFFECTING
INCREASEAND DECREASE IN
THE AIR CONSUMPTION
▶ Opening time of the relay nozzles & main nozzle.
▶ Air pressure on relay nozzles & main nozzle.
▶ Power fluctuation.
▶ Coils on pre-winder.
▶ Proper alignment of 270°.
▶ Pin setting- more space is less pressure.
▶ Yarn tension- yarn turns on guide.
▶ Nozzle height & angle
▶ Waste present on reed support.
▶ Filter cleaning.
▶ WBS setting.
▶ Increase in the yarn tension, increases the pressure,
 CONCLUSION
This study showed that the weaving mills could obtain considerable saving in
energy cost by just improving the workpractices and by avoiding ignorance in
settings. We could reduce
air consumption by about 18% on a loom by achieving shortestpossible blowing
time of various nozzles, and optimizing this setting by trial and error method
without affecting theperformance of loom and quality of fabric.
Performance of Yarns in Air-jet insertion

Air-jet weaving machines are ideal for cost effective production of bulk fabrics with
a wide range of styles. Air-jet machines can handle both spun yarns and continuous
filamentyarns. Textured yarns are especially suitable for air-jet weaving due to high
propelling force.
However, monofilament yarns are not suitable for airjet weaving because of low
friction betweenair and yarn which is due to smooth surface of the monofilament
yarn. A wide range of fabrics from gauze fabrics to dense, heavy cotton fabrics, from
patterned dress fabrics to ribbon fabrics can be woven on airjet weaving machines.
Since the force required to move the yarn mass is provided exclusively by air friction
against the yarn surface, it is largelydependent on the yarn structure, the yarn and
fibre surface, and relative motion of air and yarn. The propulsive force is largely
independent of the fibre material. Minute disturbances in the flow field can also
lead to undesirable deviation of the yarn tip that result in faults or machine stops.
The air consumption of the main jet dependsyar the yarn type and denier. Spun
yarns and coarse yarns (with a certain hairiness) have higher air resistance
coefficients than find and smooth materials. This explains why monofilament yarn
cannot be inserted with air-jet. The factors that essentially determine whether a yarn
is suitable for pneumatic are its count, structure and twist.
 EFFECT OF YARN STRUCTURE

High twist, large denier, long staple high fibril cohesion increase the
standability of spun yarns to air-jet, giving longer yarn breaking time.
More air is needed to weave continuous filament fabrics than spun
fabrics due to less frictional force between yarn surface and air flow.
Yarn velocity in the insertion channel increases with the number of
filaments due to the larger yarn surface that is in contact with the
air.Yarns having a larger diameter require increased air pressure for
filling insertion. This is because the mass of the yarn increases in
proportion with the square of the yarn diameter, whereas the yarn
surface area increases linearly with the diameter.Since a high twist
coefficient makes the yarn more compact and smoother, it reduces the
yarn velocity and increases the insertion time. Increase in yarn count
increases the velocity of the weft yarn led through the tube.
 FUTURE SCOPE OF THIS
PROJECT

In this sectors owner don’t know or they don’t think about the cost of
air, wasting a lot of compressed air and money behind that. They don’t
think about small leakages & extra opening timings of different types of
valves, extra pressure etc. They think what is it going to cost to them,
and they neglect it. But if we convince them & make aware about the
cost of the compressed air and go practically & save the compressed air
which can give lakhs of profits to the owner and also less consumption
of energy. By this, fabric cost will also be reduced.