bsl training report

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M.L.V. Textile & Engg. College, Bhilwara (An Autonomous Engineering College of Rajasthan Govt.) NAME – RAVI KUMAR JAIN ROLL NO. - 06EMBTT050

PREFACETraining in business organization infuses among students a sense of critical analysis of the

real managerial situation to which they are exposed. Our institutions has given us

opportunity through training to be aware of and cope with fast rate changing technology,

management policies, quality and productivity etc. This is a bold attempt to bridge the gap

between the ‘world of work’ and ‘studies imparted in the institutions’.

This training enables us to apply theoretical knowledge to practical situations,

appreciate the sense of responsibility, importance of discipline, punctuality and the

psychology of worker and their habits which make us more professional and near to the

world of technology and team work. Industrial training brings out better citizens, better

technocrats and better diplomats out of us.

I was lucky to get an opportunity to work in one of the top limited sector

industries, i.e. BSL LTD, MANDPAM,BHILWARA .The purpose of this training was to

gain knowledge about the industry, how it works and also to see the environment of the

industry. I joined the training not only for these purposes, but also to learn something

about operation of the machines and construction of spinning machines.

I have worked in the concern for ONE MONTH and prepared my industrial training

report. Under the guidance of training officer, I analyzed various aspects of production.

This has helped me in boosting up my confidence and determination, which will help me

to face any situation in the years to come.

This report is a written account of what I learnt and experienced during this period. I wish,

those going through it, will not only find it readable but will also find useful information

for future references.

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ACKNOWLEDGMENTOur summer training in BSL LTD, MANDPAM , BHILWARA has been a great

experience for us. It has given us an opportunity to study the processes and machines used

in the conversion of FIBRE to YARN.

This training could not have been a success without the help and support of some people.

It gives us greatest pleasure to acknowledge out deepest gratefulness to them.

I would like to express our grateful thanks to MR. ARVIND VASHISHTHA, T.P.O.,MR. ARVIND VASHISHTHA, T.P.O.,

MLVTECMLVTEC to give a golden opportunity of being a part of BSL LTD, MANDPAM ,

BHILWARA. . towards fulfilling the requirement of summer internship. The helping

behavior and the co-operation which we accepted from this family was itself heating

experience

I would like to thank, ‘Mr. A. K. Mehta (V P)’ . We are thankful to ‘ Mr. H. S.

Rathore’ ( GM P&A) for allowing us to do our summer training in

BSL.ltd,mandpam,bhilwara. We are also thankful to ‘Mr. K.M. Kogata’,( Personnel

Manager), & ‘ A.K.JAIN ’ (Head of Spinning unit) our supervisor for guiding us at

each step.

I are also grateful to all the executives and the supervisors who have shared their

precious knowledge and time with us during our training.

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INTRODUCTION BSL LTD.MANDPAM, BHILWARA, a 2859 crore LNJ BHILWARA GROUP company, is today a leading manufacturer of fashion fabric and wool worsted yarn in India. Manufacturing of a diverse range of polyester/viscose blended fabrics, wool and blended fabrics, premium light weight fabrics, and treviera wool fabrics. BSL produces over 12 million meters of fabric per year. The company also produces a premium range of worsted suiting, including those in kashmiri mohair and angora and camel hair blends. Within a span of 33 years BSL has become a multimillion dollar company and has put Bhilwara on the international map of premium suitings, while its commitment to quality and exceptional product innovation which has enabled BSL to earn the coveted wool mark and ISO 9002 quality accolades.

BSL LTD subsidiary of LNJ group, is a spinning unit located in the heart of bhilwara city i.e. in Rajasthan.

BSL LTD is having a installed capacity of 33,696 spindles which may be categorised as 13,440 spindles in unit ‘A’,11,616 spindles in unit ‘B’ and 8,640 spindles in unit ‘C’. The total daily production is about 25 tons that can be referred to as around 9.0 tons for unit ‘A’ around 8.5 tons for unit ‘B’ and around 8.0 tons for unit ‘C’. Currently grey yarn is being spun in the mill in the count range of 6 s to 60 s (single yarns). The yarn produced is supplied to internal market though centres at bhilwara, Calcutta, Delhi and surat. While the yarn is also exported to Brazil, South Africa, Indonesia and Bangladesh.

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THE GROUP HIGHLIGHTS

The founder of the LNJ BHILWARA GROUP is SHRI LAKSHMI NIWAS JHUNJHUNWALA.

At the age of 19, LNJ set up a jute export company and within 3 years it had become one of the India’s top ten concerns. Diversifying into Iron & steel scrap & manganese & iron ore, the next few years was 3rd largest iron exporter.

In 1960, the man might have been gazing the stars, set a company that was to be his real future, his dream, Rajasthan Spinning & Weaving Mills Ltd.

The flagship of the LNJ Bhilwara Group starting from sunrise sector of textile, the group diversified from cotton to synthetic & worsted, woolen & knitted garments. Simultaneously, the group made major roads into Graphite, Electrodes, Sponge iron, Oil drilling, Hydropower & Financial services. Today the group is all set from a future with Petro chemical & Tele communications.

The LNJ Bhilwara Group as it stands today is a well diversified Rs.2000 crores multi-product conglomerate with over 20,000 strong work force, of which over 3000 are highly qualified personnel in technical and managerial fields. The Group has an outstanding distinction of having as much as 45% of its turnover coming from exports to both developed and developing countries.

The Group is India’s largest producer and exporter of polyester/viscose yarns. RSWM being the first to create a market in Europe polyester/viscose, blended yarn and amongst the first three to produce blend for the first time in the world.

HEG has the largest Graphite Electrodes manufacturing plant in whole of South East Asia & Middle East.

RSWM and Maral were India’s first composite textile and knitted textile units to get the coveted ISO 9002 certification. HEG, BSL, Bhilwara Spinners and Bhilwara Processors have also earned this certification. Bhilwara Melba De Witte Ltd. is ISO/TF 16949 certified.

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RSWM is the winner of SRTEPC Highest Export Award (Award instituted by Synthetic and Rayon Textiles Export Promotion Council) for polyester/viscose yarn exports for the last 11 consecutive years.

Maral is India’s fully integrated 100% EOU cotton knitwear unit and winner of TEXPROCIL Silver trophy in 100% EOU / EPZ category. Maral has also been awarded Silver Trophy by AEPC.

Maral is the recipient of Rajiv Gandhi National Quality Award for 1998.

HEG is the winner of CAPEXIL Highest Export Award for Graphite Electrodes for the last 17 consecutive years.

HEG –Graphite Division bagged National Export Award for the year 1997-98.

HEG –Rishabhdev unit bagged National Export Award for the year 1997-98. HEG Rishabhdev unit also bagged SRTEPC Excellence Award for highest production in export of 100% Polyester spun yarn in the year 1996-97.

BSL – received the National Certificate of Merit for the year 1996 for outstanding export performance.

RSWM has been accorded the “Golden Trading House” status. Maral and HEG have been accorded the Trading House” status.

BSL Ltd have been accorded the “Export House” status.

BSL Ltd. has been accorded the prestigious “Niryat Shree” – Certificate of Excellence for Outstanding export performance during 2000-01.

SOME WELLKNOWN BRANDS

Mayur Suitings, BSL Suitings La Italia Fashions Buddy Davis Geoffrey Hammonds Superfine Suitings

.

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DIFFERENT COMPANIES OF THE GROUP:

Rajasthan Spinning & Weaving Mills Ltd. (RSWM)

Plant Location Product Range1. Gulabpura (Rajasthan) Synthetic, Regenerated Cellulosic

Blended Dyed Yarns & Fabrics. 2. Banswara (Rajasthan) Synthetic , Regenerated Cellulosic

& Cotton Blended Grey Yarns.3. Mandpam (Rajasthan) Cotton Melange Yarns4. Rishabhdev (Rajasthan) Synthetic, Blended & Grey Yarns

HEG Ltd. (HEG)

Plant Location Product Range5. Mandideep (Madhya Pradesh) Graphite Electrodes6. Durg (Madhya Pradesh) Sponge Iron7. Durg (Madhya Pradesh) Waste Heat Recovery Power8. Tawa (Madhya Pradesh) Hydro Electric Power

Maral Overseas Ltd. (MARAL)

Plant Location Product Range9. Maral Sarovar (100% EOU) Cotton Yarns, Cotton Knitted

Fabrics & Cotton Knitwears10. Jammu (J&K) Cotton knitted fabrics & Knitwears11. Noida Knitwears and Sweaters

BSL Ltd. (BSL)

Plant Location Product Range12 Mandpam (Rajasthan) Yarns, Worsted & Synthetic

Fabrics, Readymades and Accessories

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Bhilwara Processors Ltd. (BPL)

Plant Location Product Range14 Mandpam (Rajasthan) Processing of Synthetic & Worsted

Fabrics, Tops Fibre Dyeing.

Bhilwara Melba De Witte Pvt Ltd. (BMD)

Plant Location Product Range15 Mordi – Banswara (Rajasthan) Specialised Automotive Fabrics &

Furnishing Fabrics

Malana Power Company Ltd. (MPCL)

Plant Location Product Range16 Malana – Kullu (Himachal Pradesh)

Hydro Electric Power

AD Hydro Power Ltd.

Plant Location Product Range17 Allian – Duhangan (Manali – Himachal Pradesh)

Hydro Electric Power

Indo-Canadian Consultancy Services Ltd.

Plant Location Product Range18 Noida (UP) Power Engineering Services

Maral Fashions

Plant Location Product Range19 New Delhi Readymade Garments Retailing

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Bhilwara Scribe Pvt. Ltd.

Plant Location Product Range20 Bhopal (Madhya Pradesh) IT Enabled Service

Corporate Office

Office Location21 Noida (Uttar Pradesh)

Regional / Marketing Offices:

Office Location22 Mumbai23 Kolkata24 Bangalore

Sales Depots:

Office Location25 Delhi26 Ludhiana27 Bhilwara28 Tirupur29 Mumbai

COMPANY PROFILE

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The D awn

In the days when the idea of manufacturing poly-viscose suiting was a unique concept in India, the second member of the LNJ Bhilwara Group, BSL Ltd., was born in the desert state of Rajasthan. The year was 1971 and the town where this happened was Bhilwara. Over the years, with the belief that there are no shortcuts to excellence, at BSL we haveMove from strength to strength . Today, as a multi-million dollar company, and having put the Group firmly on the international map of premium suitings, we are one of the prominent members of the US$ 363 million LNJ Bhilwara Group.

Experience

With over quarter of a century of experience in textile manufacturing, BSL is currently producing over 12 million meters of fabric every year. Product profile covers material ranging from wool, wool-blended and premium lightweight fabrics, to wool modal, Trevira wool and other specialised fabrics blended with Lycra, Silk, Linen, Tencel etc.

PRODUCTS

Yarns to Fashion Fabrics

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BSL is one of the leading manufacturers of fashion fabrics and yarns in India. We produce a wide range of polyester viscose fabrics and premium range of worsted suitings, including Cashmere, Mohair, Angora and Camelhair blends.

We use the finest Australian Merino wool for making woolen fabrics & the Low Pill Trevira polyester for making wool blends, which are imported from Hoechst, Germany. For making special fibre fabrics, we use silk imported from China.

The dyes and chemicals used for manufacturing fabric are procured leading companies like Clariant, BASF, Ciba, Bayer and Henkel. And, keeping up with the rapidly changing consumer behavior towards the readymade garments segment, BSL has made forays in this segment with ready-made trousers under La Italia brand name.

BSL Yarns

These are made from the finest Australian Merino wool that is spun to perfection on latest manufacturing systems. Meeting the most stringent international quality standards, yarns comprise a sizeable chunk of the company's export turnover. This is possible because of the company's stringent quality policy and attention to detail at every stage of production.

Polyester Wool Blended Suitings

BSL's polyester wool blended suitings offer a perfect blend of 100% Australian New Merino Wool ranging from 22.5 to 17 microns and Treviera/ Tergal polyester. This combination of natural and man-made fibers in 2/24 Nm to 2/100 Nm offers the best of both the worlds.

Polyester Viscose & Polyester Cotton Blended Suitings

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These exciting modern fabrics are created through blends of the finest quality polyester, viscose and Polyester cotton. Thanks to the most advanced weaving and processing technology, BSL presents a fabric with yarns of 2/15 Ne to 2/60 Ne that are impeccable and finest in finish.

Pure wool Suitings

Immaculate Pure wool Suitings is created from the purest of raw materials--Australian New Marino Wool in 22.5 macrons to 17 microns with yarns of 2/24 Nm to 2/80 Nm.

Readymade Garments

The Group boasts of some well known brands, which include Mayur Suitings, BSL Suitings, La Italia Fashions, Buddy Davis and Geoffrey Hammonds Superfine Suitings Leisurewear. These products are manufactured at various units spread across the country.

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DEPARTMENT DISTRIBUTION

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The functional areas are classified in following three heads:

a) technical : the areas under this head are –1. production

2. maintenance

3. engineering

4. SQC and research and development

b) commercial : the areas under this are –1. accounts

2. commercial

3. material and stores

4. purchase and supplies

5. management information system

c) personnel and administration –1. industrial relations

2. HRD

3. administration

4. public relations

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I.S.O.

ISO( INTERNATIONAL ORGANISATION FOR STANDARDISATION )

IntroductionISO is an independent organisation which provides certificates to the firms / organisations as the award of their better qualities as well as infrastructure

This is an organisation, which takes care of standardization of various systems all over the world. It basically came into existence because the Europeans were the most quality conscious class and demanded that the imports must have consistent quality. To assure the quality product to the customers and consumers, there came into existence the quality assurance mode.

It gives the award to a particular firm after observing the machinery, quality norms, consumer satisfaction, mill’s environment, facility provided to employees, situation of management & marketing areas.

In order to acquire the certification regarding ISO several rules and regulations are to be fulfilled by the organisation which is essential, provided by ISO in the form of elements. All the records and internal audits regarding company is judged by ISO after every six month so as to renewal the ISO certification. A group of members of ISO visit the organisation and it inspects all the assurance modals regarding ISO 9002 modals

ISO 9001

Quality assurance in design, development, production, installation and servicing. This model is stringent in the product design and after sales service and can not deviate from the patterns.

ISO 9002

Quality control in production, installation and servicing. This model has an imbibed flexibility in it, which assures that the producers can be lithe in making their designs. The inspections so provided are at the elementary shop-floor level.

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ISO 9003

Quality assurance in the final inspection and test.

ISO 9004

It provides guidelines for models to select.

COMPARISON OF ELEMENTS OF ISO 9001, 9002, 9003

ELEMENTS ISO 9000 MODALS9001 9002 9003

Management Responsibility 0 0 0Quality System 0 0 0Concept Review 0 0 0Design Control 0 # #Document & Data Control 0 0 0Purchasing 0 0 #Control of Customer supplied product

0 0 0

Product identification & Tracebility 0 0 0Process Control 0 0 0Inspection & Testing 0 0 0Control of Inspection & Measuring and Test Equipment

0 0 0

Inspection & Test Status 0 0 0Control of Non-conforming Product 0 0 0Corrective & Preventive Action 0 0 0Handling, Storage, Packaging Preservation and Delivery

0 0 0

Control of Quality Records 0 0 0Training 0 0 0Servicing 0 0 #Statistical Techniques 0 0 00 Requirement Present# Requirement Absent

SPINNING

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This is the first starting process. In this whole process fibre of different types are used as input and yarn of different types is taken as output. PROCESS :

RAW MATERIAL

Common raw materials in synthetic spinning are Polyester, Viscose, Acrylic,flex fibres. These are received in the form of bales in grey conditions.

MIXING

Fibres in required ratio are taken opened and blended in Blenders. During blending water and antistatic agents are sprayed on fibres. In grey mixing tinting colours are also mixed in the spraying solution to provide identification of the mixing, then material send to bin room. This mixing is toppled once or twice to ensure proper blending of the fibres.

BLOW ROOM

The mixing is further opened so wastes like hard chips are removed from the mixing, the tuft size is reduced and better blending of fibres is achieved. The mixing is converted into lap to be fed into Cards. In new process Chute feed (Aero feed) system the opened fibre is directly fed into Cards without lap formation.

CARDING

Feeding by lap or in opened stage from chute the fibres are individualized, hard chips short fibres and entanglements are removed in the form of droppings, fly and flat strip respectively. The product of this is Card sliver.

DRAW FRAME

The Card sliver is subjected to doubling and drafting process to parallelise the fibres, removes micro-dust and make a uniform sliver.

SPEED FRAME

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The Draw frame sliver is drafted, slightly twisted and wound on Speed frame bobbin, called roving.

RING FRAME

Spinning of roving into yarn of required count and twist is done here.

WINDING

Defect present in the spun yarn are cleared by Electronic Gauges and the cleared yarn is wound on cones. The yarn is jointed by knots or spliced for getting a knotless yarn.

CHEESE WINDING

Two or more yarns as required for plying are wound parallelly on cheeses.

DOUBLING

In doubling twist is imparted to the yarn wound on the cheeses. There are two processes.

(A) TFO: In this process twisting and winding on cones is done simultaneously to provide knot free yarn.

(B) RING DOUBLING: Here only twist is provided to the paralled wound yarn. This yarn is then wound on cones at Cone winding. At Cone winding the yarn is cleared of doubling defects.

PACKING

All cones after enough checking are packed in cartons or bags as per the established packing process and sent to yarn godowns.

Material passage: Godown (Bales)

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Blender Passage (Open Form)

Layering (Open Form)

Blender Passage (Open Form)

Blow Room (Lap)

Carding (Card sliver)

Draw Frame (D/F Silver)

Speed Frame (Roving)

Ring Frame (Single Yarn)

Autoconer (Cone)

Cheese Winding (Cheese)

T.F.O(cones) Ring Doubler(Ring Doubler Bobbin)

Cone Winding(Cone)

Packing DETAILS OF MACHINES:

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18 RINGFRAME LMW LR6/S 5480 2005 2005

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RAW MATERIAL:o POYESTER FIBREo POLYESTER FILAMENTo VISCOSE

The Polyester Fibre is supplied by:

S.No. Name of Industry Place

1. Reliance Industries-RECRON fibreBale of 375 Kg

HaziraPatalgangaBombayBarabunki

2. Indo-Rama IndustriesBale of 350 Kg

3. JCTBale of 325-350 Kg

Hoshiarpur

4. Orissa Synthetics – Jekester Orissa

5. Swadeshi Polytech – JaieeleneBale of 275 Kg

Ghaziabad

Polyester fibre is also imported from :1. Germany2. China3. Canada4. Indonesia

Viscose is supplied by GRASIM Industries, Nagda.

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The Polymer Filament is supplied by:

S.No. Name of Industry Place

1. Reliance Industries –RECRON filament

Hazira

2. DCL Polyester Limited Mouda(Nagpur)

3. Asia Polytex Silvassa

4. Silvassa Industries Pvt. Ltd. Silvassa

Fibres used:

Denier – 1.2, 1.4, 1.5, 1.75, 2.0, 3.0, 6.0 D.

1.5, 2.5, 3.0 D TBL

Length - 40 mm, 44 mm, 51 mm.

.

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SELECTION OF FIBRE (0N THE BASIS OF FIBRE FINENESS):

Average no of fibres in yarn cross section should be greater than 70 to produce a yarn.

To fulfill this requirement we select fibre on the basis of its fineness & try to maintain the cost of the yarn.

For example: 60s yarn

Polyester: 1.0 D * 44 mm - 16%

: 1.2 D * 44 mm - 49% Viscose : 1.5 D * 44 mm - 35%

Denier of yarn = 5315 / 60 = 88.6 Average denier of fibre = 100 / (16 / 1 + 49 / 1.2 + 35 / 1.5)

= 100 / (16 + 40.8 + 23.3)

= 100 / 80.1

= 1.248 D

Average no of fibre = 88.6 / 1.248

= 71.0

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BLENDING

In the blending process, we make a reproducible homogenous mixture of different fibres so as to get desired properties is the finished product while improving the functional properties of product, improving the process performance and maintaining the economy of product.

Practically blending process involves reopening, mixing, toppling and conditioning of the fibre along with addition of predetermined quantities of usable (soft) waste.

TINT: In the processing of grey yarn, we need to give different shades to the lots so that we can easily distinguish between them. We give different shades to fibres by tinting. Tint should have following properties:

1. it should not change physical or chemical properties of fibre.

2. it should have poor light fastness.

3. it should have uniform color i.e. color should not change from day to night.

4. it should not stain the machine.

5. it should be water soluble.

6. it should not “Set” during the steaming.

Tints are available in following shades:

1. violet

2. yellow

3. green

4. orange

5. scarletOther shades are made by combination of these tints. The fibre may tinted into light, medium or dark shade as required.

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Shade Percentage of Fibres tinted

Wt. Of tint

Light 5% 35 gms/1000Kg of fibresMedium 10% 100-130 gms/1000Kg of fibresDark 15% 250 gms/1000Kg of fibres

Some examples of Blendings are:

Count(Ne),Blend Denier * fibre length LV-40 2152P Water

Lap Weight * length

2/60s,p/v 65/35

1.4D*44mm / 1.5D*44mm 0.22% 0.08% 5% 18kg * 40mt

2/60s,p/v 65/35

1.2D*44mm / 1.5D*44mm 0.15% 0.06% 4.5% 13kg * 40mt

30s, poly. 100% 1.4D*44mm 0.03% 4% 16kg * 40mt20s,p/v 65/35

2D*44mm / 1.5D*44mm 0.25% 0.08% 5% 19kg * 40mt

2/10s,poly. 100% 2D*44mm 0.03% 5% 19kg * 40mt4/12s, poly.100% 2D*44mm 0.03% 19kg * 40mt

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MIXING

Different count produced 18s, 30s, 36s, 40s, 50s, 60s (Either single Double)

Different blend composition 65/35, 80/20, 67/33, 90/10, 48/52, 60/40 of P/V Blend yarn

ANTISTATIC FINISH:

Object: - To prevent Static charge generation as well as fly generation in case ofMan made fibres

Function of chemicals:

LV40 - Prevents static charge generation2152P - Prevents fly generation

TINTING: Tinting is done of 10% of total material of mixing (only Grey)

Colour: Orange, Blue, Red, Yellow, Green, Pink.

DESCRIPTION OF A PARTICULAR MIXING(FOR 2/30s ; P/V):

Fibre to be used:

1. Polyester: G.Poly RECRON 1D*51mm; 65%

2. Viscose: G. Viscose NAGDA 1.2D*44mm; 35% LV-40 = 0.12% 2152 P = 0.10% WATER = 5.0% Tint / Shade = Green + Orange Tint = 150gm for 1000 Kg Material

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Mixing of 7958.6 Kg of P/V

Polyester = 5173.1 Kg Viscose = 2785.5 Kg Lap Weight = 21.5 Kg Lap Length = 45 Metre LV-40 = 9.5 Kg 2152 P = 7.9 Kg Water = 398 Kg Tint (Green + Orange) = (1.2 Kg + 1.2 Kg)

BLENDER TRUTZSCHLER (Made by Trumac India)

FEATURES

Total No. of Motors 4 1st - for Creeper Lattice

2nd - for Feed Lattice & Inclined Lattice 3rd - Evener Roller & Stripper Roller 4th - Delivery Roller

After delivery upward passage to Bin Room.8 Bin Rooms are here and each bin room has capacity of 7-10 tons.

Feed Lattice Inclined Lattice

Evener Roller ce

Delivery Roller

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BLOWROOM

A blowroom line is employed for:

1. OPENING -: the raw material enters spinning mill in the highly compressed form to enable optimum transport and storage condition in blow room. The bigger tufts of fibers are made into smaller tufts with minimum damage to the fibers.

2. CLEANING -: to remove foreign seed particles leave from fibers. During opening and cleaning there is always loss of good fibers. So the blow room line is selected such that the optimum opening and cleaning is obtained with minimum loss of good fibers. The cleaning efficiency of cotton in blow room section is approximately 75 – 80%.

3. DUST REMOVAL -: to remove finer impurities like dust particles and very short fibers by suction units e.g. cages. As the opening of the material increases the dust removal capacity also increases.

4. BLENDING -: To mix the different varieties of cotton bales thoroughly. This will give a homogeneous distribution of fiber in the yarn cross section.

5. For providing feed material for carding either as lap or though aero feed.

Humidity: R.H. – 65% to 75%

Variations:

Standard intra lap CV %( max.) = 1.0 % * If it is more than 1.0% then lap will rejected.

Lap Parameters :

Count Wt. (in Kg) Length (in m) Ozs./ yd Lap hank

8s P/v 20.0 36 16.5 0.0011510-12s P 16.5 30 16.0 0.0011815-20s P/v 20.5 38 16.0 0.0011824s P/v 20.0 40 14.8 0.00128

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BLOW ROOM LINE:

MAKE YEAR

TRUTZSCHLER (TRUMAC) 2005

PASSAGE OF MATERIAL (LAP FEED)

PASSAGE OF MATERIAL (AERO FEED)

FEATURES :

No. of beating points - 2 Krishner Beater First Krishner Beater Speed - 825 rpm Second Krishner Beater Speed - 800 rpm First Fan - Speed - 1800 rpm Second Fan – Speed - 1500 rpm

Shell roll rpm - 11.5 rpmShell roll dia - 10.5”

Rack pressure - 0.5 kg / cm2 Calender roll pressure - 5-6 kg / cm2 (100% Poly.) - 4-5 kg / cm2 (P/V) - 1.5-2 kg / cm2 (Viscose) Lap rod weight - 1.4 kg

Blenders Lattice

Spiked Roller Feed Roll & Piano feed

Kirshner BeaterShell Roller Calendar Roller

Unimix (6 Blocks)Super Fine Opener

Saw Tooth OpenerTransporting DuctReserve Duct (Opener)

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SETTING:

Between 1st Beater & Feed roll - 10/32”Between 2nd Beater & Feed roll - 10/32”

Inclined lattice & evener roller - -5 to 30 mm (Normally 10 mm) Pedal & Feed roll - 0.125 mm

PRODUCTION:

Prod. = (3.14*D*η*n*60*8) / (H*36*840*2.2) Kg/8 Hrs.

Where, diameter of shell roller D = 10.5 inches Speed of shell roller n = 11.5 rpm Efficiency of line η = 80 % Lap hank H = 0.0013

Lap length = 40 mt. Lap weight = 20 kg. Prod. = (3.14*10.5*11.5*60*8*0.8) / (0.0013*36*840*2.2) Kg/8 Hrs.

Length of Lap produced at 80 % efficiency

π x shell roll dia x shell roll rpm x 60 x efficiency=

36

π x 10.5 x 11.5 x 60 x 0.80=

36

= 505.54 / yards/ hour

PRODUCTION = = 1683.45 Kg/8 Hrs.

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No. of Lap produced / hour

= Lap produced in yds / Hr.Length of single Lap

= 505.54 = 11.55 = 12 Lap approx.40 x 1.094

Lap doffing = 60/12= 5 min approx.

BLOW ROOM MAINTENANCE SCHEDULE

1. Krischner Beater legs changed : 6 months2. Calender Roller assembly overhauling : 1 year3. Cone Drum Overhauling : 1 year4. Krischner Beater Cleaning : 1 year5. Gauge Checking : 1 year6. All lattice cleaning : 15 days

7. Magnets of metal extractor are changed : 6 months

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CARDING

OBJECT:

Individualisation and partial parallelisation of fibres Fibre to fibre separation To affect thorough mixing of the Fibre Removal of remaining trash of B/R process Conversion of Lap or opened fibre into sliver

Humidity : R.H. 60% to 65 %

CARDING MACHINES

TECHNICAL PARAMETERS OF LC1/3

In inch In mmDia of Lap roller 6.37 162Dia of Feed roller 3.14 80Dia of Licker-in 9.96 253Dia of Cylinder 50.78 1290Dia of Doffer 26.77 680Dia of Detaching roll 4.72 120Dia of Crush roll 2.99 76Dia of Calendar roll 3.14 80Dia of T.C.R. 2.36 60Dia of C.C.R. 2.44 62

MAKE MODEL REMARKSLMW & L/R LC1/3 & LC1/2 Lap feed

LMW LA 1/2 Aero feed

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Number of flats - 110 Working - 46 Motor used - 3

(main motor, auxiliary motor for brush pulley,& for fan ) No.of Stop motions - 10 Can size - 24” x 42”

RPM OF DIFFERENT MOVING PARTS

Lap roller 1.725Feed roller 2.875Licker-in Cylinder 840Main Cylinder 360Doffer 30.32Flat Speed 6.5 – 8 inch / min.

Draft Constant for C1/3 = 2.23Draft Change Gear = 46 T

Draft = Draft Const x DCP= 2.23 x 46= 102.58

SETTINGS:

Licker-in to feed plate 18 THLicker-in to cylinder 7 THCylinder to flat 10, 10, 8, 8, 8 THCylinder to doffer 4 THDoffer to detaching roller 12 THDoffer to crush roll 6, 10, 4 THLicker-in to mote knife 10 TH, 12 THLicker-in to under casing 22 THLicker-in combing segment 16 TH

DRAFT = 102,58

PAGE NO.-


FRONT PLATE

Top plate Up – 68 THLow – 34 TH

Stationary plateUp – 6 THMid – 8 THLow – 10 TH

Bottom plate 22 TH

BACK PLATE

Top Plate 34 TH

Stationary plateUp – 15 THMid – 10 THLow – 18 TH

Bottom plate 22 TH

PRODUCTION CALCULATIONS

Doffer dia = 26.77Doffer rpm = 32tension draft = 1.32Sliver hank = 0.140

Production in Kg/hour at 85% efficiency

= π x doffer dia x doffer rpm x tension draft x 60 x effcy 840 x 36 x Sliver hank x 2.205

= 3.14 x 26.77 x 32 x 1.32 x .60 x .85 840 x 36 x 0.140 x 2.205

= 19.39 Kg/hour

= 19.4 Kg./hour approx.

PRODUCTION OF CARDING = 19.4 KG/HOUR

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SETTING TOOLS OF CARD:

1 = SETTING GAUGE FOR LICKER IN GRID ,COMBING SEGMENT & MOTE KNIVES 2 = CARD GAUGE3=WRENCH FOR FLAT SCREWS4=HAND CRANK FOR TURNING THE FLATS5=TORQUE WRENCH6=ANGLE GAUGE7=WRENCH FOR SHAFT NUTS ON DOFFER DRIVE8=TOOL FOR PRESSING NEEDLE BEARING IN &OUT ON THE FLAT DRIVE AT THE RIGHT9=GAUGE FOR ALINGING THE DOFER DRIVE

PAGE NO.-


STUDY ON % WASTE EXTRACTED :

Lap hank = 0.00125Actual Weight = 20 Kg.Lap running time = 59 min.Count of yarn to be produced = 30s

(a) Flat strips = 130 gm

% Strips = Waste in gm x 1001000 x Lap Weight

= 130 x 1001000 x 20

= 0.65%

(b) Undercasing Waste = 48 gm % UC Waste = 0.24 %

(c) Waste collected by fan = 80 gm % Waste = 0.40 %

(d) Sliver breakage = 50 gm. % Waste = 0.255%

Total waste collected = 130+48+80+50= 308 gm.

% Waste = 1.54 %

WIRE POINTS PARTICULARS

Make – LCC – Lakshmi Card Clothing Company Ltd.

PAGE NO.-


Organ Wire Points SpecificationCylinder R 2520 x 0.70Licker-in D 5505 x 1.2Doffer N 4030 x 0.85 RFlat PD 32/1

STUDY OF GRINDING

GRINDING OF MAIN CYLINDER:

Grinding schedule of cylinder & doffer = 6 monthsName of grinder used = Full width grinderRpm of main cylinder = 160-200Rpm of full width grinder = 800-1000Setting = 5 THGrinder revolution/ min. in one revolution of cylinder

= R.P.M. of Grinder R.P.M. of Cylinder

= 1000 = 5 200Cylinder should be rotated in opposite direction of the grinder while grinding.

GRINDING OF DOFFER:

Rpm of doffer = 50-60Rpm of grinder = 800-1000Grinder revolution / minute for one revolution of doffer

= 1000 60

= 12.67Doffer is rotated in the same direction of grinder while grinding. TOOL FOR GRINDING THE CYLINDRER & DOFFER:

2=AUXILLIARY BRACKET FOR DOFFER 3= EXTENSION PIN FOR DOFFER SHAFT

PAGE NO.-


4= EXTANSION PIN FOR

5= V BELT FOR DRIVING THE DOFFER

STUDY OF STRIPPING

Stripping schedule of cylinders / doffer = 1 WeekStripping duration = 2 Min.Cylinder rpm = 5 to 6 rpmDoffer rpm = 32Stripping roll = about 100Motion transfer = Just like grinding operation

ARRANGEMENT OF STOP MOTION OF LC1/3 CARDS

(1) Limit switch for lap roll :- It stops the card in case of shortage of Lap.

(2) Limit switch over feed roll :- It stops the card if the feeding of double lap takes place.

(3) Limit switch at front plate :- It stops the cylinder if the front plate is opened.

(4) Limit switch over crush roll :- It senses the lapping over crush roll.

(5) Photo cell over coiler head :- It is just above the coiler head to sense the passage of Material.

(6) Full can change motion: - When the can is full of sliver in lifts the coiler head and can is changed either by tenter or automatically.

(7) Stop motion in coiler head :- When coiler head is opened m/c stops.

(8) Limit switch for sensing the presentation of automatic can in automatic can changing

System.

PAGE NO.-


(9) Automatic sensor for backward movement of the can.

(10) For sensing forward journey of can. Cylinder doesn’t stop to more after sensing by any limit switch except front stationary plate sensing limit switch.

FAULTS OCCURRING IN CARD1. LOADING OF CARD

REASON(a) Improper antistatic finish(b) Damaged wire points at particular place causing loading and nep

generation; takes place. (c) Improper humidity and temperature.

2. CLOUDY WEB: - Unopened fibres or cluster of fibres coming out indicates poor carding.

REASON(a) Damaged and blunt wire points of cylinder & flat(b) Wide cylinder & flat setting(c) Improper back plate setting(d) Improper stripping by doffer

3. HOLES IN THE WEB: - A hole in the web means a thin portion when it is followed by a lump of materialREASON (a) Any rough surface in undercasing causes choking of

material results holes in web.

4. SLIVER CUTSREASON(a) Improper humidity and temp.

(b) Rough surface of calendar roller

5. IRREGULAR WEBREASON(a) Lateral movement of Licker-in

(b) Damaged side wire points of cylinder and doffer

6. CARD JAMMINGREASON(a) Labor negligence

Maintenance schedule:

PAGE NO.-


1. cylinder , doffer grinding : 6 months2. flat chain washing : 1 year3. licker-in wire change : 1 year4. doffer drive gear box oil change : 3 months5. cylinder, doffer stripping :15 days6. flat chain oiling : 15 days7. coiler tube, trumpet and pulley cleaning : 15 days

DRAWFRAME

OBJECT OF DRAWFRAME:(1) To parallelize the fibers of card sliver and align them to the axes of the sliver

through drafting process. So that in final stage of spinning they can contribute maximum towards yarn strength.

(2) To improve the regularity in sliver weight per unit length though doubling of sliver.

(3) To improve hooks from the card sliver.

(4) To mix different slivers to give a homogenous blended sliver.

(5) To straighten out the fibre and improve the fibre extent i.e., removal of hooks.

(6) To improve uniformity and evenness so that the final sliver become more regular resulting Uniform yarn.

STUDY OF LDO/25:FEATURES: MAKE - LR

Drafting system 3 over 5 drafting systemDia of bottom roll (in mm) 35, 25, 20, 28, 28 in mmDia of top roll (in mm) 40Dia of cal.roll (in mm) 50Top roll weighting Pneumatic weighting systemPressure of top roll 68 – 72 kg.Trumpet size 3 – 3.5 (for finer hank)Coiling technique Over coilingMotor power 5 HPMotor rpm 1440

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Drafting system 3 over 5 drafting systemMachine pulley 185mmSuction motor 2.5HP, 2880r.p.m.No. of heads 2No. of card sliver per head 8Can size 24 x 42”Maximum speed 250m.p.m

DRAFTING SETTING:

Fibre Length (mm) Front zone setting (mm) Back zone setting38 42 4644 48 5251 53 57

PRODUCTION:

Delivery speed = 190 m/min. Hank = 0.120 (For 30s PV)Production in Kg/ hour/head at 85% efficiency.

= Delivery speed (in m/min) x 1.094 x 60 x efficiency840 x Sliver hank x 2.205

= 190 x 1.094 x 60 x 0.85 Kg./hour/delivery 840 x 0.120 x 2.205

= 47.69 Kg. /hour Production per shift/2 head

= 47.69 x 8 x 2 = 763.04 Kg / shift/2 head

Count to be spun 18s 30s 50s

Std. D/F sliver hank 0.110 0.120 0.160

PRODUCTION =763.04KG/SHIFT/2HEAD

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Prod. in Kg/shift at 85% efficiency

884.5 765 573.5

STOP MOTION DETAILS:

(1) Electrical creel stop motion: - If broken sliver passes through pair of creel rollers then this stop motion senses electrically and stops the D/F.

(2) Top or bottom roller lapping stop motion : - If sliver lapping occurs either upon top roller or bottom roller the m/c is stopped.

(3) Calender roll lapping stop motion: - In the case of sliver lapping over calendar roller, m/c is stopped.

(4) Coiler choking stop motion : - In the case of sliver lapping over calendar roller, m/c is stopped.

(5) Full can stop motion : - If reset length of sliver is delivered in the can, m/c is stopped automatically.

(6) Except these stop motions there are three pairs of door cover sensing switches which stops the m/c if cover is opened in running condition.

STUDY OF LDO/6:FEATURES: MAKE - LMW

Drafting system 3 over 3Dia of bottom roll (in mm) 52, 28, 28Dia of top roll 38Dia of cal. Roll 62Lap roll weighting PneumaticPressure of top roll 2.3 Kg/cm^2 (For 2nd & 3rd top roll)Trumpet size 3 – 3.5 for finer hankCoiling technique Over coilingMotor powerMotor rpm

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No. of head 2No. of card sliver per head 8Can size 24 x 42”

DRAFTING SETTING:

Fibre Length (mm) Front Zone (mm) Back Zone (mm)38 61 6144 61 6151 61 61

PRODUCTION CALCULATION:

Delivery speed = 275 metre / min.D/F hank = 0.12 (for 30s PV)

Production in Kg./shift at 85% efficiency

= F.R. Del. (in metre/ min) x 1.094 x 60 x 8 x effcy 840 x Sliver hank x 2.205

= 275 x 1.094 x 60 x 0.85 Kg./hour/head 840 x 0.12 x 2.205

= 69.03 Kg./hour/head

= 1104.51 Kg./shift/DF

STOP MOTION: Stop motion arrangement of LDO/6 is exactly same to LDO/2S but m/c starts automatically after full can changing.

PRODUCTION = 1104.51KG/SHIFT/DF

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STUDY OF LRSB-851 (RIETER):

Drafting system 3 over 3 rollerTotal draft 8.02Dia of bottom roll (in mm) 40, 30, 30Dia of top roll 38Dia of calendar roll. 55Top roll weighting Spring loadedTrumpet size (mm) 4.6Coiling technique Over coilingMotor power (main) 7.5 KWNo. of head 1No. of card sliver fed 8Can size 20 x 40No. of motor 4Function of motors 1st – Main motor for driving m/c pulley

2nd – For fan3rd – For driving servomotor for auto leveller4th – For automatic can changing.

DRAFTING SETTING:-

Fibre Length (mm) Front Zone (mm) Back Zone (mm)38 42 4644 48 52/5551 58 65

PRODUCTION CALCULATION:Delivery speed in m/min. = 550Standard sliver hank= 0.161

PAGE NO.-


Production per shift

840 x Sliver hank x 2.20 = 550 x 1.094 x 60 x 8 x 0.85 x 1

840 x 0.161 x 2.205

= 823.23 Kg./shift/DF

STUDY OF STOP MOTION :

(1) Electrical creel stop motion: - If broken sliver passes through the creel roller then creel senses electrically and stops the m/c.

(2) Feed side photo cell: - In the case of sliver breakage in feed side photo cell senses and stops the m/c.

(3) Front roller lapping stop motion: - It stops the m/c in the case of Front roller lapping.

(4) Web guide panel stop motion: - If drafted web does not passes through web guide panel then this stops the m/c.

(5) Calendar roller lapping stop motion: - If lapping takes place on calendar roller, this stops the m/c.

(6) Coiler choking stop motion: - When choking of drafted material takes place in coiler region, then this acts.

(7) Full can stop motion: - After completion of predetermined length m/c stops.

(8) Can change stop motion: - After completion of can if the empty can is not present then further removal of full can does not take place and m/c remains stopped.

(9) Door opening stop motion: - In case of any opening, m/c is stopped.

FAULTS OCCURRING IN DRAW FRAME :

(1) Roller Lapping(a) Improper humidity and temperature(b) More front roller speed

PAGE NO.-


(c) Damaged cots(d) Improper antistatic finish

(2) Coiler choking(a) Improper antistatic finish(b) Improper humidity and temperature

(3) Sliver Cuts(a) Rough calendar roller surface(b) Improper humidity and temperature

DRAW FRAME PREVENTIVE MAINTENANCE SCHEDULE:

SCHEDULE FREQUENCY REMARKS1. Cleaning Twice in a month depending upon availability2. Overhauling 4 years + 90 days3. Coiler Overhauling 3 years + 60 days4. Cots buffing 1 month + 10 days5. Servo Motor oil 6 months + 30 days Change

PAGE NO.-


SPEED FRAME OBJECT:

1. To impart twist.2. Conversion of sliver into roving.

Machine Specification:

Make LMW Model LF 1400-A Year 1994 No. of spindles 108

NO of machine 1

Make LMW Model LFS 1660 Year 2004/2005 No. of spindles 120

NO of machine 3

Production-Cotton- upto 13m.p.m.Man made – upto 40m/minUnder favorable marginal conditions.

Count range- English – 0.5 to 3.0 Metric - 0.85 to 5.0 Tex -1180to1200

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Drafting arrangement:

Guide saddle drafting arrangement with roll, weighing arm for two spindles, double aprons , 36,43,50mm Cage condenser positive top and bottom clearing device. Weighing: 3 rolls pneumatic and hexagonal type.

Draft: with 3 roller drafting system 3.5-16 draft can be applied ,total draft should not be less than 6, otherwise the drafting will too high.

Production:

Prod. = (3.14*D*N*8*60*n*No. of spindles*TD) / (840*36*2.2*H)

= (3.14*1.18*180.9*60*8*108*0.90) / (840*36*2.2*1.94) = 531.32 Kg/shift/frame

Maintenance schedule :Maintenance Schedule:

S.No. ACTIVITY FREQUENCY

1 M/c Cleaning 20D ± 4D

2 Long Coller Cleaning 3M ± 15D

3 Bottom apron change 9M ± 3M

4 Top apron change 1.5Y ± 6M

5 Middle arbour greasing 1Y ± 2M

6 cots buffing 2M ± 15D

7 Bottom roll gauge checking

&

Top arm pressure setting

6M ± 1M

8 Spindle truning 6M ± 1M

9 Bottom roll truning 1Y ± 2M

PRODUCTION = 531.32 KG/SHIFT/FRAME

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RINGFRAMEOBJECT:

1. To impart twist2. Conversion of roving into single yarn.

Technical specifications of ring frame:

Make : LMWmodel : LR6/SDrafting system : 3/3 Fs 160Top roll dia : 32.5 mmbottom roll dia : 30 mmtotal spindles : 480 mmtop roller weighting system : pneumaticpressure : 20 kgmachine pulley dia :175,185,198,205,215,310 mmmotor pulley dia : 152-187 mmCP : 20-70TRW : 20-60

Speeds, drafts and constants :

1. front roller speed = (1450*187*22*46) / (175*80*80)

= 245 rpm (TRW=22 T TW=46T)

delivery rate = 3.14*30*245 / 25.4 = 908 inches/min.

2.spindle speed = (motor speed *motor pulley* tin roll dia) / (M/c

PAGE NO.-


pulley*wharves dia) = 1440*187*10 / 175

=15494.25 rpm 3 DRAFT:

1. back zone draft : When combination is 43/48 T =1.12 When combination is 48/43 T =1.4

2. front zone draft = 28.52 (when brw-110 cp=42)3. draft constant

When BRW DC

80 95291 1083100 1190110 1310

4. twist constant

=784.4(let 3% slippage) (7c=784.4*(1-3/100) =760.87)

5. twist per inch =TC/TW =760/41= 18.5 TPT6. production : for 30 count and 90% efficiency

= (3.14*D*N*60*8*no of spindles*eff) / (36*840*2.2*count)

where d- dia of front rollN – Bobbin speed (spindle)

Prod = (927.16*60*8*480*0.90) / (36*840*2.2*30) = 96.328 kg/shift/machine

Reasons of stoppage of R/F :

1. cleaning and gauging

PRODUCTION = 96.328KG/SHIFT/MACHINE

PAGE NO.-


2. repairs and maintenance3. count change4. electric defect5. power failure6. labour shortage7. empty shortage8. back stuff shortage9. miscellaneous

Maintenance Schedule:

S.No ACTIVITY FREQUENCY


2 Spindle oil Topping 4M ± 15D

3 Spindle oil change 1Y ± 2M

4 Bottom apron change 8M ± 2M

5 Top apron change 9M ± 3M

6 Middle Arbour Greasing 1Y ± 2M

7 Cots Buffing 3M ± 15D

8 Draft gear overhauling 6M ± 1M

9 Heart Cam Overhauling As& when required

10 J.P. Ball Brg. Greasing 1Y ± 2M

11 Bottom Roll Trueing 1Y ± 2M

12 Lapet Hook Change 2Y ± 3M

13 Lifting OH 2Y ± 6M

14 Spindle Gauge 8M ± 1M

15 Rings Change 2Y ± 6M

16 Spindle Change 10Y ± 2Y

PAGE NO.-


Specific terms used in ring spinning:

1. Hank loss: if m/c is stopped without reason, the time for which machine is stopped is calculated in % of total time is called hank loss.

2. idle spinning : it is the spindle which is stopped for a time greater than the time required for the worker to take a round around the m/c

POST SPINNING PROCESS

PAGE NO.-


STUDY OF POST SPINNING PROCESS

PAGE NO.-


AUTOCONER:OBJECT: To remove imperfection of spun yarn and to make big package in the form of Cone Package.

TECHNICAL DETAILS OF AUTOCONER(Savio Orion )

Make Savio Orion Model Orion Manufacturer Savio Machine Tessili SPA

Italy Year 2005 No. of cone 60

Technical Specifications: Drum speed 1300 rpm Cone weight (Full) 2-3 Kgs. Cone weight (Empty) 30-35 gms. Magazine Creel capacity 6 Ring tubes Drum dia. 3.14 “

Salient Feature: 1. Pneumatic disc type tensioner. 2. Splicer is used. 3. Capacitance type electronic yarn clearer (Uster Quantum-2) 4. Fully automatic.

COUNTWISE WINDING SPEED

Type Count Winding Speed (M/Min.)

Coarse 15-20s 1200Medium 15-40s 1400Fine above 40s 1600

Machine Sequence:

PAGE NO.-


Ring Tube → Tensioner → Waxing Device → Splicer → Yarn Clearer

→ Winding Drum → Cone

PRODUCTION CALCULATION FOR AUTOCORNER:

Count : 18sNo. of Drums : 50Winding Speed : 1200 m/min.Efficiency : 92%

Production in Kg. /shift

= Winding speed x 1.094 x No. of Drums x 60 x Efficiency x 8 840 x Count x 2.205

= 1200 x 1.094 x 50 x 60 x 0.92 x 8 840 x 18 x 2.205

= 871.41Kg / shift

SPECIAL FEATURES OF AUTOCONER:

(i) Autoconer is fed by Magazine containing 6 reserve ring bobbins and one running bobbin.

(ii) Automatic cutting of thick and thin places and splicing and restarting of winding drum.

(iii) Its efficiency is upto 95%.

Maintenance Schedule:

PAGE NO.-



1. M/c Cleaning 1M ± 7D

2. Cleaning of base adoptor 3M ± 15D

3. Winding head cleaning & oiling 3M ± 15D

4. Suction arm setting 3M ± 15D

5. Gripper arm setting 3M ± 15D

6. Yarn trap OH 4M ± 15D

7. Splicer servicing 4M ± 15D

8. Magazine cover cleaning 6M ± 1M

9. Cradle setting 6M ± 1M

10. Bobbin peg overhauling 4M ± 15D

11. Duct cleaning 6M ± 1M

12. Suction arm OH 1Y ± 2M

13. Clutch OH 1Y ± 2M

14. Splicer OH 1Y ± 2M

15. Tension disc Cleaning, setting &

oiling

6M ± 1M

16. Tension assembly cleaning & oiling 12M ± 2M

PAGE NO.-


. CHEESE WINDING

OBJECT:

To wind two or more threads from cone to cheese with out inserting any twist.

PS Mettler

Make PS Mettler Model F.M.K.S. Manufacturer Peass Industrial Engg. Pvt. Ltd.

Navasari (Gujrat) No. of M/c 2

Technical Specification:

Cheese Capacity 120 Drum Dia. 3.14 ” Drum rpm 400-450 Motor Power 5 H.P

Machine Sequence:Cone

Yarn Guide

Slub catcher

Tensioner

Stop Motion

Guide roller

Yarn Guide

Winding drum

Cheese

Salient Feature:

PAGE NO.-


1. Fix blade mechanical type slub catcher. 2. Dead weight type disc Tensioner. 3. Electrical stop motion. Maintenance Schedule:


1 M/c Cleaning with upper & lower guide pulley

oiling

15D ± 4D

2 Drum shaft bearing greasing 6M ± 1M

3 Yarn path setting 3M ± 15D

4 Adopter greasing & drum cradle setting 3M ± 15D

T.F.O.

OBJECT:

To impart two twist in one rotation of the spindle

Machine Specification:

1. Veejay Lakshmi Make Veejay Lakshmi

Model VJ-150-HS Year 2004

No. of M/c 13 No. of cones 144 - 10 M/c 2. Prerna

Make PrernaModel PRN-225Manufacturer Prerna Textile Industries Ltd.

Year 1998/2000No. of M/c 2No. of cones 144 cones

PAGE NO.-


PRODUCTION CALCULATION:

Count of yarn : 2118sSpindle speed : 10100T.P.I. : 12.2No. of Spindles : 132Efficiency : 92%

Production in Kg./shift

= 2 x Spindle speed x 60 x 8 x Efficiency x No. of Spindle36 x T.P.I. x 840 x Count x 2.205

= 2 x 10100 x 60 x 8 x 92 x 132 36 x 12.2 x 840 x Count X 2.205

= 161.20Kg/Shift

Technical Specification :

Spindle rpm ` 9000-10000 Traverse Length 152 mm TPI according to count Vary acc. To count)

COUNT TPI18 ‘s 1230 ‘s 1740’s 20.550’s 22.5

Machine Sequence :

Cheese

Yarn Guide Traveler

Spindle

Yarn Guide

PAGE NO.-


Stop Motion

Pre take up roller

Traverse Guide

Winding Drum

ConeMaintenance Schedule :



2 Spindle oil topping 2M ± 15D

3 Spindle oil change 1Y ± 2M

4 Gear oil change 1Y ± 2M

5 Stop motion, dropper setting 6M ± 1M

6 Adopter greasing 6M ± 1M

7 Spindle bearing greasing 1Y ± 2M

8 T.R & P.T.R greasing 6M ± 1M

9 Tin roll bearing greasing 6M ± 1M

10 Belt guide roller greasing 6M ± 1M

11 Thread guide setting 6M ± 1M

12 Cradle, drum setting 6M ± 1M

13 Jockey pulley greasing 1Y ± 2M

14 Gear overhauling 1Y ± 2M

15 Pig tail setting 1Y ± 2M

DOUBLING

PAGE NO.-


Maintenance Schedule :

SCHEDULE/ ACTIVITY FREQUENCY REMARKS

1. Doubling O.H. 5 years + 30 days Depending upon the availability of machine2. Doubling spindle gauging 5 months + 30 days3. Lappet Hook change 5-6 years4. Ring changing 5-6 years5. Cleaning Twice in a month

PACKING

In packing department the cones produced by Autoconer / T.F.O are checked & then packed in bags. There are 5 checkers and 12 packers for this purpose.The defects, which are checked during packing, are:-

1. Mixing of cones2. 3-Ply3. High twist / Low twist4. Contamination5. Snarling6. Winding defect (Ribbon formation)

The standard weight of cone is 2 kgs. Tolerance is ± 50 gms. In a bag 32 cones are packed that is the weight of packed bag is

approximately 64 kgs. 8-9 tons cone are packed per day.The cones which are stored in store room are treated with

moisture to maintain their weight. This is called loose packing.

PAGE NO.-


WASTES:

The wastes produced in spinning have been classified into: 1. Usable wastes 2. Unusable waste

During mixing 5% waste is added in yarn for domestic consumptions. No waste is added in export yarn. The waste is opened 2 times and is then run with polyester fibre. The usable waste is added during the mixing. It includes:

1. Lap end2. Card Sliver3. Draw Frame Sliver4. Roving5. Bonda

The unusable waste can not be reused. It includes:1. Blow room droppings2. Card droppings3. Flat Strip4. Fan fly5. Sweepings

Usable Unusable

Material Target Actual Material Target Actual

Lap Ends - - B/R 0.05 0.04Sliver(cards) 0.20 0.19 Card 1.15 1.20Sliver D/F 0.40 0.44 Sweeping 0.25 0.25Roving 0.30 0.33 Hard waste 0.63 1.34Bonda 1.37 1.48Total 2.23 2.24 Total 2.68 2.01

* All data are in percentage

PAGE NO.-


Statistical Quantity Control Department( SPINNING)

The work of the SQC dept is to control the quality of product being manufactured through extensive testing during intermediate processes and of final product to give quality assurance to the buyer and to maintain company standards.

The daily jobs performed by this dept are checking of naps, count, hank, U%, CV%, thin and thick places in silver, roving and yarn (as applicable), lea strength, twist and degree of shade achieved in dye house.

Various machines and their description:1. Evenness testerMake – star testerNo of m/c = 2

As the name indicates the evenness tester gives details about the evenness of yarn i.e. CV, U% and thin thick places.

It is based on capacitance principle. The material is passed between the plates of a capacitor, due to the dielectric component of the material. The change in capacitance is directly proportional to mass or thickness of the material. A change is detected as a result on display unit. A printer and a spectrogram are also attached to provide reports.

2. Hairiness tester:Hairiness tester gives details about the fibres called hairs based on the photoelectric principle. The tester gives no. of hairs per unit length and classifies them according to length.

3. Lea strength tester:Model – kamal metal industries.

It provides information about average your strength which is used to calculate CSP.Lea of 123 yard is prepared and is tested on the tester. The strength can be ‘read off’ from axial scale.

4. Wrap block : no. of machines -2It is used to prepare hanks for testing

PAGE NO.-


5. Yarn appearance board : It is cardboard having white sermica coating. Yarn is wound with traverse like on wrap reel. It may have more than one yarn, each yarn having a few layers. The board is placed horizontally and unevenness in yarn is observed through eye i.e. manually. These are then ranked by comparing with standard boards. 6. Physical balance :no. of instruments -2It is used for weigh lea’s etc. for count calculations.

7. Classifault – 6 drumno. of m/c – 1Model – KIESOKIit is attached with a 6-drum miniature cheese winding machine. The classification has 6 sensors heads with cutters. It classifies the faults in groups according to their diameter and length. The fault classification has fixed diameter, in some faults with adjustable length limits and in remaining faults with parameters are adjustable.

8. Twist tester: no. of machines -2 i) star STTii) KAYCEE industries Ltd. To test yarn, yarn is gripped in two jaws, one of which is fixed and the other can rotate. The rotating jaw is connected to a motor and a control unit. We feed the maximum amount of turns required to untwist a yarn in the control unit .We feed the minimum amount of turns required to untwist the yarn in the control unit along with the direction of twist in starting the test, the feed no. of rotations of jaw. The other type of tester based on twist manually. 9. Stelo-meter:no. of instruments – 1it is used to check the strength of raw materials as well as of fibre after mixing/blending to check the blend homogeneity.

10.Electronic balance: no. of equipment – 1 The balance has been attached to a computer and gives the count/hank of material directly i.e. no. of cumbersome.

M.L.V. TEXTILE & ENGINEERING COLLEGE

PAGE NO.-


PROJECT REPORT

On

“Finding Faults & Remedies of Autoconer winding Machine”

In

BSL LIMITED MANDPAM, BHILWARA

Classification Diagram:

PAGE NO.-


LENGTH

Classimat Defects Classification

A1 Faults:This fault is having cross section 100% greater than the normal and fault length is shorter

than 1cm.

Causes:1. Bad condition of carding and blow room.2. Trash in yarn.

Remedies:1. All blow room machines and carding machine should be properly maintained.2. No trash should remain in yarn

A2 Faults:

PAGE NO.-


This fault is having cross section 150-250% greater than the normal and fault length is shorter than 1cm.

Causes:1. Bad condition of carding.2. Blow room condition is not good3. Trash in yarn4. Short thick places.

Remedies:1. All blow room machines and carding machine should be properly maintained.2. No trash should remain in yarn

A3 Faults:This fault is having cross section 250-400% greater than the normal and fault length is shorter

than 1cm.

Causes:1. Neps ,fluff, foreign matters2. Dirty drafting zone.

Remedies:1. No foreign matter and neps should remain.2. Drafting zone should be clean.

A4 Faults:This fault is having cross section greater than 400% than the normal and fault length is

shorter than 1cm.

Causes:1. Ring front zone dirty.2. Fly waste in trumpet etc.

Remedies:1. Keep the ring front clean.2. Good suction system.

B1 Faults:

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This fault is having cross section 100% greater than the normal and fault length is 1-2cm.Causes:1. Fibers damage in process .2. Spindle without aprons.3. Short thick places.

Remedies:1. Fibers should be handled carefully.2. Machine settings should be correct.

B2 Faults:This fault is having cross section 150-250% greater than the normal and fault length is 1-2cm.

Causes:1. Fibers damage in process.2. Spindle without aprons.3. Short thick places.

Remedies:1. Fibers should be handled carefully.2. Machine settings should be correct.3. Spindles with aprons should be placed.

B3 Faults:This fault is having cross section 250-400% greater than the normal and fault length is 1-2cm.

Causes:1. Fluff in travellers.2. Unsuitable travellers.3. Bad piecing.

Remedies:1. No fluff should remain in traveler.2. Suitable ring and traveler arrangement is to be selected.3. Piecing should be proper.

B4 Faults:This fault is having cross section greater than 400% than the normal and fault length is 1-

2cm.Causes:1. Slub from ring department.2. Some unacceptable faults.Remedies:1. Ring department should have proper settings so that no slubs are allowed in further processing.

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C1 Faults:This fault is having cross section 100-150% greater than the normal and fault length is 2-4cm.

Causes:1. Bad piecing in cans.2. Sliver entanglements.

Remedies:1. Piecing should be proper in cans.2. No sliver entanglements.


Causes: 1. Bad piecing in cans. 2. Sliver entanglements.

Remedies: 1. Piecing should be proper in cans. 2. No sliver entanglements.


Causes: 1. Ring piecing is not proper.

Remedies: 2. Piecing should be proper

C4 Faults:This fault is having cross section 400% or more than the normal and fault length is 2-4cm.

Causes:1. Floating fibers.2. Fly and slub are also causes of this type of fault.

Remedies:1. Drafting system should be properly adjusted.2. Fly and slubs should be controlled.3. Aprons should be properly adjusted.

D1 Faults:

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This fault is having cross section 100-150% greater than the normal and fault length is 4-8cm.Causes:1. Floating fibres are main cause of this type of faults.

Remedies:1. Floating fibres should be removed by proper drafting system and apron arrangement.

D2 Faults:This fault is having cross section 150-250% greater than the normal and fault length is 4-8cm.

Causes:1. Simplex gauge problem.2. Spacer problems.

Remedies:1. Gauge should be properly adjusted.2. Spacers should be selected carefully.

D3 Faults:This fault is having cross section 250-400% greater than the normal and fault length is 4-8cm.

Causes:1. More fluff in ring department.

Remedies:1. Fluff in ring department should be controlled.2.

D4 Faults:This fault is having cross section 400% or more than the normal and fault length is 4-8cm.

Causes:1. More fluff in ring department.

Remedies:1. Fluff in ring department should be controlled

E Faults:

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This fault is having cross section 100% or more than the normal and fault length is 8cm and above.

Causes:1. Double yarn is the main cause of E type fault.

Remedies:2. Yarn entanglement should be avoided.

F Faults:This fault is having cross section 45-100% greater than the normal and fault length is 8-32cm.

Causes:1. Bad piecing in ring simplex and back process etc.2. Long thick places.

Remedies:1. Piecing should be proper.

G Faults:This fault is having cross section 45-100% greater than the normal and fault length is greater

than 32cm.

Causes:1. Bad piecing in ring simplex and back process etc.2. Long thick places.

Remedies:1. Piecing should be proper.

H1 Faults:This fault is having cross section 30-45% less than the normal and fault length is 8-32cm.

Causes:1. Mostly eccentric bobbins of simplex and ring.2. Ring eccentric spindles etc.

Remedies:1. Bobbin shape should be proper.2. Spindles shape should be proper.

H2 Faults:

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This fault is having cross section 45-75% less than the normal and fault length is 8-32cm.Causes:1. Poor handling of material during processes.Remedies:2. Material handle should be proper.

I1 Faults:This fault is having cross section 30-45% less than the normal and fault length is above

32cm.

Causes:1. These types of faults are produced by separation of sliver or roving prior to spinning.

Remedies:2. Sliver or roving should not be separated out. They should be uniform.

I2 Faults:This fault is having cross section 45-75% less than the normal and fault length is above

32cm.

Causes:1. These types of fault are produced by separation of sliver or roving prior to spinning.

Remedies:2. Sliver or roving should not be separated out. They should be uniform.

OBSERVATION:We observe the machine for 5 hr.Delivery Speed of Autoconer Winding Machine is 1380 mt/minEfficiency is 90%Count 40/1In 5 hr yarn deliver is

= 1380*60*5*0.90 mt = 372.6 Kmt

In 372.6 kmt yarn contain 45 unacceptable faults.

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CONCLUSION

The first phase of practical training has proved to be quiet fruitful. The controlled working way of whole plant make the student realize that engineering is not just learning the structured description and working of various machines, but the greater part is planning of proper management. It provides opportunities to learn low technology used at proper place and time can save a lot of labour. It is recommended that there should some project specially made for students where presence of authorities should be ensured. There should be strict monitoring of the performance of students and system of grading be improved on the basis of work done. However training has proved to be quite fruitful. It has allowed an opportunity to get an exposure of the practical implementation to theoretical fundamentals.

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RINGFRAME

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CARDING

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SPEEDFRAMESPEEDFRAME

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PASSAGE FOR T.F.O :

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There are three department in bhilwara in BSL LIMITED , MANDPAM-1 Worsted department2 Polyester viscose 13 polyester viscose 2RAW MATERIAL-1 IOCL poly, Mumbai2 jayshree wool, west bangal3 Grasim ,nagada,(viscose)

Row material are in tops form Defelter-gill box-comber-auto leveler-finisher- roving machine –rubbing machine-ring frame-autoconer-cheese winding-tfo

DEFELTER- NSC - GN6 - 2GILLBOX-NSC-GN6-4COMBER-NSC-PB3ILF -6AUTOLEVELING-NSC-GC15 -4GC30-NSC-GC30-2FINISHER-NSC-6V11-3ROVINGM/C-NSC-BM15N-1RUBBING M/C-NSC-FM-1RINGFRAME-IDEA COGNEX,SPAIN-4AUTOCONER-SAVINO ORION-2AUTOCONER-SCHLAFHORST-1CHEESE WINDING-METTLER-1TFO-PEERNA-PRN225-4

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INDEX

bsl training report

Documents