industrial attachment of noman weaving mills limited

Noman Weaving Mills Ltd

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INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTNoman Weaving Mills Limited


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Acknowledgment

“In the name of Allah, the most merciful and beneficent”

All praise to Almighty Allah, the most Gracious and compassionate. Who created theuniverse and bestowed mankind with the knowledge and blessings of Allah be upon theHoly Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran andSunnah, the everlasting source of guidance and knowledge for humanity.

At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted inNoman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their wholehearted cooperation and cordial support in providing information and assisting our training activates.Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, NomanGroup for giving us opportunity to performing our internship of their reputed industry. We alsothankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his specialguidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuablediscussion during the training period. It has been a great opportunity to be a trainee under hissupervision.

Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering ofSoutheast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering,Southeast University have made our efforts for training & report writing successful.

During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us veryhonestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md.Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, SectionalWarping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. ArifHassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical).Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us theirvaluable time on the very busy schedule.

Finish but not yet we are thankful to all the staffs whose name is not listed but without their help thistraining and ultimate success could not come out a good result.


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Acknowledgment








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Acknowledgment








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TABLE OF CONTENTS

Acknowledgement

Project Description

Introduction

Objectives

Duration of study

Location of factory

General information of the factory

Units of Noman Group

Layout plan

Product mix

Different departments of factory

Manpower Management

General organ gram

Manpower setup

Machine Description

Specifications of the machines

Layout plan of weaving section

Information’s of raw materials

Research & Development

R & D department

Production Planning, Sequences & Operation

Sequence of operation

Winding

Yarn path diagram of winding


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TABLE OF CONTENTS

Acknowledgement

Project Description

Introduction

Objectives

Duration of study

Location of factory



Layout plan

Product mix


Manpower Management

General organ gram

Manpower setup

Machine Description





R & D department



Winding



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TABLE OF CONTENTS

Acknowledgement

Project Description

Introduction

Objectives

Duration of study

Location of factory



Layout plan

Product mix


Manpower Management

General organ gram

Manpower setup

Machine Description





R & D department



Winding



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Warping

Calculations of high speed warping

Calculations of sectional warping

Sizing

Machine specification

Control system of sizing

Size chemicals & their costing

Calculation of sizing

Drawing & Denting

Loom

Basic mechanism of power loom

Weft path diagram of air jet loom

Machine specification of air jet

Compressor air quality

Loom piping system

General operation of air jet

Rapier loom

Specification of picanol

Basic mechanism of rapier

Setting of rapier

Projectile loom


Operation procedure

Quality Assurance System

Quality assurance system

Inspection system

Quality standard


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Warping



Sizing





Drawing & Denting

Loom





Loom piping system


Rapier loom



Setting of rapier

Projectile loom


Operation procedure



Inspection system

Quality standard


5

Warping



Sizing





Drawing & Denting

Loom





Loom piping system


Rapier loom



Setting of rapier

Projectile loom


Operation procedure



Inspection system

Quality standard


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Maintenance

Maintenance of machine

Maintenance procedure

Utility Services

Utility services

Available utility facilities

Store & Inventory

Inventory

Cost Analysis & Marketing Activities

Cost analysis

Marketing activities

Conclusion

Conclusion

Limitations

Suggestions


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Maintenance



Utility Services

Utility services


Store & Inventory

Inventory


Cost analysis


Conclusion

Conclusion

Limitations

Suggestions


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Maintenance



Utility Services

Utility services


Store & Inventory

Inventory


Cost analysis


Conclusion

Conclusion

Limitations

Suggestions


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Chapter -01

Project description


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Chapter -01

Project description


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Chapter -01

Project description


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Introduction:

Industrial training is an important part of a student of textile engineering. Internship helps a student toget practical knowledge about the whole process of textile technology. After the 11 th semester offour year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finishedour internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry isconcerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we havetried our best to perform our duty perfectly. The authority of this factory helped us a lot to performour duty very freshly. For that reason we got the required data very shortly. Every employee towardsthis factory tried to help us honestly from their position and busy schedule. This internship helped usto minimize the gap between theoretical and practical knowledge. We think this idea will help to ourfuture practical work.

Objectives:

The main purpose of our entire training schedule is to know about the differencebetween the theoretical and practical on different processing of textile.

To know about the whole sections of the industry To get a very strong about the processing of textile product. To be able to handle the weaving section and production To know about the activities of mechanical & electrical sections To know about the inventory & costing on different purpose To gather the maintenance & various utility services To know about the quality parameters of the product

Place of study:

We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna,Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very muchsincere about the quality level so this is a very perfect place for industry.

Duration of study:

The total duration of training period was eight week

Method of study:

We worked here as trainee and our working method was Auto Instruction


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Introduction:


Objectives:



Place of study:


Duration of study:


Method of study:



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Introduction:


Objectives:



Place of study:


Duration of study:


Method of study:



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Noman Weaving Mills

MawnaBazar

Tangail Joydebpur

Dhaka

CandanaGazipur

Maymensing NNoman Weaving Mills Ltd

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Noman Weaving Mills

MawnaBazar

Tangail Joydebpur

Dhaka

CandanaGazipur

Maymensing NNoman Weaving Mills Ltd

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Noman Weaving Mills

MawnaBazar

Tangail Joydebpur

Dhaka

CandanaGazipur

Maymensing N


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GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD

Name of the factory : Noman Weaving Mills Ltd.

(An enterprise of Noman Group)

Location : (kewa westside), Mawna, Sreepur, Gazipur.

Business Type : 100%Export Woven Factory

Status : Private Ltd. Company.

Head office (Corporate Office) : Adamjee Court (5th &6th Floor), 115-120,

Motijheel C/A, Dhaka-1000.

Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282

History of the project development:

Land purchase : June 2006

Machine setup : December 2006

Year of production : January 2007

Total area of land : 25 Bigha

Production floor:

(a) Airjet floor : 47581 sft(b) Sizing shed : 44762 sft(c) Sectional warping : 18036 sft(d) Picanol floor :11620 sft

No. of machine:

(a) Toyota air jet loom : 128 pcs(b) Picanol loom : 40 pcs

Production capacity:

(a) Toyota airjet loom : 45000 Mtr(b) Picanol loom : 9000 MtrTotal production : 54000 Mtr

Per month production : 1404000 Mtr


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Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282






Production floor:


No. of machine:






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Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282






Production floor:


No. of machine:






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Man power:

Officer Staff Workera) Male : 41 Male : 93 Male : 418b) Female : 01 Female : 02 Female : 144

Total manpower of the factory : 699 people

Toilet:

a) Officer/staff : 13 pcsb) Male worker : 08 pcsc) Female worker : 05 pcs

Fire Extinguisher:

a) DCP : 99 pcsb) CO2 : 55 pcsc) Water : 20 pcsd) Foam : 06 pcs

Dormitory:

a) Officer/staff & F.Q : 01 pcsb) Worker : 01 pcs

Emergency gate : 01 pcs

Units of Noman Group: Sufia fabrics ltd.

Talha Tex pro Ltd.

Artex Fabrics Ltd.

Noman Fabrics Ltd.

Nice Denim Mills Ltd.

Marium Textile Mills Ltd.

Zaber Spinning Mills Ltd.

Talha Spinning Mills Ltd.

Noman Weaving Mills Ltd.

Sufia cotton Mills Ltd.

Zarba Textile Mills Ltd.


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Man power:



Toilet:


Fire Extinguisher:


Dormitory:




Talha Tex pro Ltd.

Artex Fabrics Ltd.

Noman Fabrics Ltd.









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Man power:



Toilet:


Fire Extinguisher:


Dormitory:




Talha Tex pro Ltd.

Artex Fabrics Ltd.

Noman Fabrics Ltd.









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Noman Terry Towel Mills Ltd.

Yasmin Textile Mills Ltd.

Talha Fabrics Limited

Ismail Spinning Mills Ltd.

Zubair spinning mills Ltd.

Noman Textile Mills Ltd.

Zaber Zubair Fabrics Ltd.

Noman Spinning Mills Ltd.

Yasmin Spinning Mills Ltd.

Saad Saan Textile Mills Ltd.

Zaber &Zubair Accessories Ltd.

Noman composite Textile Ltd

Ismail Anzuman –Ara Fabrics ltd.

Saad Saan Apparels Ltd.

Noman Fashion Fabrics Ltd.

Zarba Rotor Spinnimg Mills Ltd.


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WEA

VIN

GSH

ED

SIZ I

NG

SHED

DIG

IC

LOTH

STO

RE

FOLD

I NG

&IN

S PEC

TIO

ND

EPT

GENERATORCHIILLER

WORK

SHOP W

AR

PIN

G

OFFIC

E

A/C STATION

GA

TE0 1

SEC

UR

I TY

SEC

UR

I TY

POST

NO

MA

NW

EAV

I NG

MIL

LSLT

D

GA

TE01

SEC

UR

ITY

AIR VESSELSECURIT

YWASTAGE

STORAGE

BOILER

CANTENE FOR WORKER

OFFICE ROOM

TOILET

MA

ING

ATE

SEC

UR

I TY

PER

SON

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MAYMENSING DHAKA HIGH WAY

NLAY-OUT PLAN OF THE FACTORY


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WEA

VIN

GSH

ED

SIZ I

NG

SHED

DIG

IC

LOTH

STO

RE

FOLD

I NG

&IN

S PEC

TIO

ND

EPT

GENERATORCHIILLER

WORK

SHOP W

AR

PIN

G

OFFIC

E

A/C STATION

GA

TE0 1

SEC

UR

I TY

SEC

UR

I TY

POST

NO

MA

NW

EAV

I NG

MIL

LSLT

D

GA

TE01

SEC

UR

ITY

AIR VESSELSECURIT

YWASTAGE

STORAGE

BOILER

CANTENE FOR WORKER

OFFICE ROOM

TOILET

MA

ING

ATE

SEC

UR

I TY

PER

SON

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13

WEA

VIN

GSH

ED

SIZ I

NG

SHED

DIG

IC

LOTH

STO

RE

FOLD

I NG

&IN

S PEC

TIO

ND

EPT

GENERATORCHIILLER

WORK

SHOP W

AR

PIN

G

OFFIC

E

A/C STATION

GA

TE0 1

SEC

UR

I TY

SEC

UR

I TY

POST

NO

MA

NW

EAV

I NG

MIL

LSLT

D

GA

TE01

SEC

UR

ITY

AIR VESSELSECURIT

YWASTAGE

STORAGE

BOILER

CANTENE FOR WORKER

OFFICE ROOM

TOILET

MA

ING

ATE

SEC

UR

I TY

PER

SON

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Product mix: Plain

Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.

Twill 2/1s twill, 3/2 S twill

Satin 5 ends satin, stripe satin

poplin Voile Matt

Canvas Oxford stripe fabric


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Product mix: Plain




poplin Voile Matt



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Product mix: Plain




poplin Voile Matt



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Check fabric 2/1s twill 3/2 S twill

5 ends satin Stripe Satin

Different Department:

Administration dept. Accounts dept. Store dept. Security dept. Mechanical dept. Electrical dept Quality dept. Mending &folding dept Utility dept. Workshop dept. Preparatory dept.(sizing & warping ) R&D dept. Production dept.


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Chapter- 02Manpower Management


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D


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Manpower setup in different shift:

Administration dept.

Shift General Shift“A”

Shift“B”

Shift“C”

Short

Manpower 26 06 03 01 -04

Accounts dept.


Shift“B”

Shift“C”

Short

Manpower 03 -02

Store dept.


Shift“B”

Shift“C”

Short

Manpower 37 01 01 01 -04

Security dept.


Shift“B”

Shift“C”

Short

Manpower 02 22 22 22 -17

Mechanical dept.


Shift“B”

Shift“C”

Short

Manpower 18 19 19 19 -34

Electrical dept


Shift“B”

Shift“C”

Short

Manpower 09 05 05 05 -15

Quality dept.


Shift“B”

Shift“C”

Short


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Shift“B”

Shift“C”

Short

Manpower 26 06 03 01 -04

Accounts dept.


Shift“B”

Shift“C”

Short

Manpower 03 -02

Store dept.


Shift“B”

Shift“C”

Short

Manpower 37 01 01 01 -04

Security dept.


Shift“B”

Shift“C”

Short

Manpower 02 22 22 22 -17

Mechanical dept.


Shift“B”

Shift“C”

Short

Manpower 18 19 19 19 -34

Electrical dept


Shift“B”

Shift“C”

Short

Manpower 09 05 05 05 -15

Quality dept.


Shift“B”

Shift“C”

Short


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Shift“B”

Shift“C”

Short

Manpower 26 06 03 01 -04

Accounts dept.


Shift“B”

Shift“C”

Short

Manpower 03 -02

Store dept.


Shift“B”

Shift“C”

Short

Manpower 37 01 01 01 -04

Security dept.


Shift“B”

Shift“C”

Short

Manpower 02 22 22 22 -17

Mechanical dept.


Shift“B”

Shift“C”

Short

Manpower 18 19 19 19 -34

Electrical dept


Shift“B”

Shift“C”

Short

Manpower 09 05 05 05 -15

Quality dept.


Shift“B”

Shift“C”

Short


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Manpower 3 2 2 2 -2

Mending &folding dept


Shift“B”

Shift“C”

Short

Manpower 130 16 20 -46

Utility dept.


Shift“B”

Shift“C”

Short

Manpower 12 9 14 14 -15

Workshop dept.


Shift“B”

Shift“C”

Short

Manpower 10 2 2 -3

Preparatory dept.(sizing & warping)


Shift“B”

Shift“C”

Short

Manpower 6 27 27 27 -55

Production dept.(loom)


Shift“B”

Shift“C”

Short

Manpower 11 59 59 59 -35


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Manpower 3 2 2 2 -2



Shift“B”

Shift“C”

Short

Manpower 130 16 20 -46

Utility dept.


Shift“B”

Shift“C”

Short

Manpower 12 9 14 14 -15

Workshop dept.


Shift“B”

Shift“C”

Short

Manpower 10 2 2 -3



Shift“B”

Shift“C”

Short

Manpower 6 27 27 27 -55



Shift“B”

Shift“C”

Short

Manpower 11 59 59 59 -35


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Manpower 3 2 2 2 -2



Shift“B”

Shift“C”

Short

Manpower 130 16 20 -46

Utility dept.


Shift“B”

Shift“C”

Short

Manpower 12 9 14 14 -15

Workshop dept.


Shift“B”

Shift“C”

Short

Manpower 10 2 2 -3



Shift“B”

Shift“C”

Short

Manpower 6 27 27 27 -55



Shift“B”

Shift“C”

Short

Manpower 11 59 59 59 -35


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Specification of machineries:

List of the machine: Number of m/c Brand name Origin RPM

Winding machine: 3 Tangsi TextileMachinery Co.

Chine 1120

Warping machine: 4 Benninger /hacoba Switzerland 1200

Chapter -03Machine description


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Chine 1120




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Chine 1120




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Sizing machine 2 Benningersucker muller

Switzerland 160

Picanol loom 40 OptimaxGamma

Belgium 700/500

Air jet loom 128 Toyota JAT 710 Japan 800

Projectile loom 156 sulzer Switzerland 250

Desk loom 1 Bangladesh

Knotting m/c 5 Staubli Switzerland

Lay out plan of weaving section:


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Switzerland 160


Belgium 700/500







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Switzerland 160


Belgium 700/500







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Information about yarn source and product mix:

Important Yarn

Receive From Count Blend Ratio

Chapter -04Raw Materials


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Important Yarn




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Important Yarn




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(Name of spinning mills)

Nahar (India) 80s/1,60s/1,40s/1 CB/CP 100%

Local Yarn

Receive From

(Name of spinningmills)

Count Blend Ratio

Zaber 30s/1 BC 100%

Zaber 40s/1 CW 100%

Zaber 50s/1 Comb 100%

Zubair 30s/1,40s/1 CW 100%

Zubair 40s/1,50s/1 CB/CP 100%

Talha 16s/1,20s/1,24s/1 CTN 100%

Talha 30s/1 KW 100%

Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50%

Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100%

Yasmin 45s/1,46s/1 TC 65%+35%

Yasmin 40s/1,45s/1,50s/1 CVC 60%+40%

Yasmin 49s/1 Comb 100%

Sufia 19.5s/1,45.5s/1 CTN 100%

Sufia 30s/1 KC 60%+40%

Sufia 45s/1 CVC 100%

Ashik Comp. 9s/1 CTN 100%

Ashik 16s/1 CTN

Double Yarn


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Local Yarn

Receive From


Count Blend Ratio

Zaber 30s/1 BC 100%

Zaber 40s/1 CW 100%


Zubair 30s/1,40s/1 CW 100%


Talha 16s/1,20s/1,24s/1 CTN 100%

Talha 30s/1 KW 100%

Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50%

Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100%

Yasmin 45s/1,46s/1 TC 65%+35%

Yasmin 40s/1,45s/1,50s/1 CVC 60%+40%


Sufia 19.5s/1,45.5s/1 CTN 100%

Sufia 30s/1 KC 60%+40%



Ashik 16s/1 CTN

Double Yarn


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Local Yarn

Receive From


Count Blend Ratio

Zaber 30s/1 BC 100%

Zaber 40s/1 CW 100%


Zubair 30s/1,40s/1 CW 100%


Talha 16s/1,20s/1,24s/1 CTN 100%

Talha 30s/1 KW 100%

Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50%

Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100%

Yasmin 45s/1,46s/1 TC 65%+35%

Yasmin 40s/1,45s/1,50s/1 CVC 60%+40%


Sufia 19.5s/1,45.5s/1 CTN 100%

Sufia 30s/1 KC 60%+40%



Ashik 16s/1 CTN

Double Yarn


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Receive From


Count Blend Ratio

Z&Z Fab 10s/2,16s/1 CTN 100%

Z&Z Fab 36s/2 CVC 60%+40%

Noman Tex 30s/2 CW 100%

Noman Tex 40s/2 CB/CP 100%

Zaber 32s/2 CW 100%

Spuare 20s/2 CTN 100%

Mytas 20s/2 CTN 100%

R.k. Spg 20s/2 TC 35%+65%

R.k. Spg 60s/2 CB/CP 100%

R.k. Spg 20s/2 CTN 100%

R.k. Spg 39s/2 CW 100%

MIMTEX 40s/2 Comb 100%

MIMTEX 60s/2 CB/CP 100%

TAMIJ 80s/2 CB/CP 100%

Dyed Yarn (For sample making)

Receive From

(Name ofspinning mills)

Count Blend Ratio Color

Paramount 40s/1 CVC 60%+40% Opt.White

Paramount 20s/1 CVC 60%+40% Beige

Paramount 40s/1 PC 50%+50% Opt.white

Paramount 20s/1 CTN 100% Opt.white

Paramount 40s/1 CB/CP 100% Navy blue


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Receive From


Count Blend Ratio

Z&Z Fab 10s/2,16s/1 CTN 100%

Z&Z Fab 36s/2 CVC 60%+40%



Zaber 32s/2 CW 100%



R.k. Spg 20s/2 TC 35%+65%


R.k. Spg 20s/2 CTN 100%

R.k. Spg 39s/2 CW 100%





Receive From









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Receive From


Count Blend Ratio

Z&Z Fab 10s/2,16s/1 CTN 100%

Z&Z Fab 36s/2 CVC 60%+40%



Zaber 32s/2 CW 100%



R.k. Spg 20s/2 TC 35%+65%


R.k. Spg 20s/2 CTN 100%

R.k. Spg 39s/2 CW 100%





Receive From









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Paramount 40s/1 CVC 60%+40% Sky blue

Paramount 20s/1 CVC 60%+40% Black

Paramount 40s/1 PC 50%+50% Blue

NOOR 30s/1 Comb 100% Black

NOOR 30s/1 Comb 100% White

Raw material for Sizing:

Chemical Name

Kollatex 05

Penetrose 50

Glysofill soft

Elastex

Tape

Pinitex

PVA

Quick solan SPR


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Chemical Name

Kollatex 05

Penetrose 50

Glysofill soft

Elastex

Tape

Pinitex

PVA

Quick solan SPR


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Chemical Name

Kollatex 05

Penetrose 50

Glysofill soft

Elastex

Tape

Pinitex

PVA

Quick solan SPR


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Chapter -05

Research & development


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Chapter -05



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Chapter -05



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R&D Department:

Sample analysis:

Fabric construction analyses from given sample Identify the fabric type e.g. yarn dyed or grey fabric Identify the weave structure of sample Find out yarn count, EPI, PPI etc. Measured the yarn consumptions according to the order quantity Make warp and weft pattern. During sample making some parameters are considered-

Cover factor Reed selection

Cover Factor: Cover factor is important part during production like as loom running. It indicates thefabric consumption. Is it possible or not to go to production. Expressed as

British method:

EPI PPIC.F

count count

Germany Method:

K1EPI

count

K2PPI

count

EPI PPI

countK1 K2

28C.F

count


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R&D Department:

Sample analysis:




British method:

EPI PPIC.F

count count

Germany Method:

K1EPI

count

K2PPI

count

EPI PPI

countK1 K2

28C.F

count


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R&D Department:

Sample analysis:




British method:

EPI PPIC.F

count count

Germany Method:

K1EPI

count

K2PPI

count

EPI PPI

countK1 K2

28C.F

count


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Reed selection:

Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabricconstruction & storage of reed.

Construction:

124 9640 40

58**

Total ends 124 * 58

7192

Reed count EPI *Width of cloth

Reed Width

Reed Width Fabric With100

*100 + % regain

58 **100 + 12

10064.96"

Reed Count 124 *58

64.96110.7

Or

Reed count = Finished EPI × 0 .9

= 124× .9

= 111.6


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Reed selection:


Construction:

124 9640 40

58**

Total ends 124 * 58

7192


Reed Width


*100 + % regain

58 **100 + 12

10064.96"

Reed Count 124 *58

64.96110.7

Or


= 124× .9

= 111.6


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Reed selection:


Construction:

124 9640 40

58**

Total ends 124 * 58

7192


Reed Width


*100 + % regain

58 **100 + 12

10064.96"

Reed Count 124 *58

64.96110.7

Or


= 124× .9

= 111.6


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Reed Width= Total endsReed Count

7192111=

= 64.7

Contraction mesurment:

Warp contruiction = EPI *3

Warp count

= 124 *340

Weft contruction= *PPI 3Weft count

= 96 *340

= 9.3

7.2=

Total Contruction = (9.3 +7.2) * .85

= 14.02

Suppose, fabric required = 5000mtr

Tape Length= Required length + (contruction % * .85) + 30mtr wastage

5000 + (14.02 * .85) + (30=

=

* 2) [Here, no of beam = 2]

5074


30


7192111=

= 64.7



Warp count

= 124 *340


= 96 *340

= 9.3

7.2=


= 14.02



5000 + (14.02 * .85) + (30=

=


5074


30


7192111=

= 64.7



Warp count

= 124 *340


= 96 *340

= 9.3

7.2=


= 14.02



5000 + (14.02 * .85) + (30=

=


5074


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Fabric wt calculation system:

Oz/Yds² = 1.03 1.05 0.685e e

EPI PPIN warp N weft

GSM = 1.03 1.05 23.25e e


eN = L wW l

Wt calculation =39.37 1000width GSMlength

Warp wt in lbs (yarn consumption):

EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %)+20% waste of the total warp weightNe warp × 840

Weft wt in lbs

EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15%waste of the total warp weightNe weft × 840


31


Oz/Yds² = 1.03 1.05 0.685e e


GSM = 1.03 1.05 23.25e e


eN = L wW l




Weft wt in lbs



31


Oz/Yds² = 1.03 1.05 0.685e e


GSM = 1.03 1.05 23.25e e


eN = L wW l




Weft wt in lbs



32

Design identification:

Fig: plain weaves (1/1) Fig:2/1 z twill

Fig: 5 end satin Move-3 Fig: 2/2 Matt

Fig: Dobby design


32




Fig: Dobby design


32




Fig: Dobby design


33

Chapter -06Operation procedure


33



33



34


Yarn from spinning (Cone)

Winding

Weft (Cone form)Warping

Sizing

Drawing KnottingAnd

Denting

Inspection

Mending

Folding

Packing

Unwind the fabric from the cloth roller

Looming

Weaving

warp weft

Introduction of winding:


34



Winding


Sizing

Drawing KnottingAnd

Denting

Inspection

Mending

Folding

Packing


Looming

Weaving

warp weft



34



Winding


Sizing

Drawing KnottingAnd

Denting

Inspection

Mending

Folding

Packing


Looming

Weaving

warp weft



35

Winding is the process of transferring yarn or thread from one type of package to another to facilitatesubsequent processing. The rehandling of yarn is an integral part of the weaving process. Not onlymust the package and the yarn itself be suitable for processing on the next machine in the productionprocess, but also other factors such as packing cases, pressure due to winding tension must beconsidered.

Objectives:

To know about the winding process To get knowledge of different parts of the winding machine. To calculate the hardness of the cone To measure the winding angle of the package To get exact winding rate To acquire perfect knowledge about winding and apply it in future.

Purpose of winding:

To remove objectionable faults from the yarns To produce good package containing long continuous length of yarn. The winding package should facilitate smooth operation of the subsequent

process To make the suitable package for warping To control the exact tension of the package

Types of winding:

Actually winding is divided into three types:

Parallel wound package Near parallel wound package Cross wound package

Winding faults:

Yarn faults

Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter,Adhered loose fiber.

Package faults

Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls.

1Machine Specification:

Cone winding machine

Model : GA014MD- 120

Origin : China

Spindle : 120

High speed cone/ Cheese windingmachine

M/c serial no : 1817

R. P .M : 1720

Spindle : 120


35


Objectives:


Purpose of winding:



Types of winding:



Winding faults:

Yarn faults


Package faults





Origin : China

Spindle : 120



R. P .M : 1720

Spindle : 120


35


Objectives:


Purpose of winding:



Types of winding:



Winding faults:

Yarn faults


Package faults





Origin : China

Spindle : 120



R. P .M : 1720

Spindle : 120


36

Yarn path diagram of winding:

Winding packageYarn clearer

Traverse Tension device

Guide rod

Bobbin holder

Yarn package

Fig:Yarn path in winding2

Hardness of cone:

Hardness = wt. of package/ volume of packageD

d

H


Model : GA014MG

Origin : China

Tangsi Textile Machinery Co. Ltd


36




Guide rod

Bobbin holder

Yarn package


Hardness of cone:


d

H


Model : GA014MG

Origin : China



36




Guide rod

Bobbin holder

Yarn package


Hardness of cone:


d

H


Model : GA014MG

Origin : China



37

We know,

Volume of package = πR2H /4

Where,

R2= D2-d2

=142-42

= 180cm

So, volume = 3.1416*180*17/4

=2403 cm3

Hardness of cone = 1600/2403 gm/cm3

=0.6658 gm/cm3

Standard range of hardness:

For soft cone …………………..0.350--0.500 gm/cm3

For hard cone ………………….0.550—0.700 gm/cm3

Winding angle and Winding length calculation:

Winding angle,

Ѳ =2 tan-1 (t / π*d*n)


37

We know,


Where,

R2= D2-d2

=142-42

= 180cm

So, volume = 3.1416*180*17/4

=2403 cm3


=0.6658 gm/cm3





Winding angle,

Ѳ =2 tan-1 (t / π*d*n)


37

We know,


Where,

R2= D2-d2

=142-42

= 180cm

So, volume = 3.1416*180*17/4

=2403 cm3


=0.6658 gm/cm3





Winding angle,

Ѳ =2 tan-1 (t / π*d*n)


38

Where,

Travers length, t= 150 mm

Scroll number, n= 2

Bobbin dia, d = 5cm

So winding angle,

Ѳ=2 tan-1(150/3.1416*50*2)

=51.068 ◦

Winding length = 2t/ sin Ѳ/2

=2*150/sin 51.068/2

= 695.97mm

Requirements for winding:

The fault level in the yarn must be reduced to an acceptable level. The yarn must not be damaged in any way in the winding process. The yarn must be wound in such a way as to permit unwinding in the

following. process with minimum difficulties at required speed. The package size, shape and build must be most technologically suitable for

particular end use. The package size should be controlled to meet the particular economic

requirement. The device must be reliable. The device must not introduce difference in count. It must be easily cleaning. The operating surface must be smooth.

Introduction:

The preparation of warp yarn is more demanding and complicated than that of the weft orfilling yarn. So correctly warping (Beaming) is very important for weaving and sizing(slashing). It depends on some aspects as different condition.

What is warping?

Warping is transferring many yarns from a creel of single end package forming a parallelsheet of yarns wound onto a beam or section beam.


38

Where,


Scroll number, n= 2

Bobbin dia, d = 5cm

So winding angle,

Ѳ=2 tan-1(150/3.1416*50*2)

=51.068 ◦


=2*150/sin 51.068/2

= 695.97mm






Introduction:


What is warping?



38

Where,


Scroll number, n= 2

Bobbin dia, d = 5cm

So winding angle,

Ѳ=2 tan-1(150/3.1416*50*2)

=51.068 ◦


=2*150/sin 51.068/2

= 695.97mm






Introduction:


What is warping?



39

Depending on the kind of intermediate carrier used, the industrial warping process can becarried out according to two different technologies:

Sectional warping ( indirect or conical drum or dresser warping) Beam warping or direct warping (preparatory beam warping)

Objectives:

To know about different warping systems and machines. To get knowledge of various parts of the warping machine. To calculate the different terminology for exact production. To minimize the machine breakdown time.

Purpose of warping

To accelerate the next process. To remove flies, dust, dirt particles from the yarns. To find thin, weak place, large knots and modify. To make the yarns uniform and control the yarn tension. To increase the productivity and decrease the wastage of the yarns To build a suitable package for the perfect sizing and weaving.

Direct or high speed warping:

Direct Warping Denotes the transference of yarns from single-end yarn packages, woundpackages, directly to a beam in a one step process. This means that there are an equal numberof packages in the creel area as there are ends on the beam, except in the case of a magazinecreel. A magazine creel connects the tail of one wound package to the beginning of a newwound package for an easy package transfer, from the wound packages in the creel.

Direct warping can be used to directly produce the weavers beam in a singleoperation. That is use for strong yarn such as mono filament or multifilament yarnthis is also called direct beaming.

In direct warping system there is a several method which is called intermediatebeams. This beam is used in sizing then it wind in weavers beam. If the weaversbeam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 endseach.


39



Objectives:


Purpose of warping







39



Objectives:


Purpose of warping







40

Operation procedure of direct warping:

The direct warping section each and every works are done accordingly. From creel towarper’s beam the yarn are passes continues in a systematic device. Firstly input the cone into the cone stand in creel according to weight or length wise that can be measured previously.Every stand contains nine package holders. The yarn are continues passes by the sensoryguide which can measure the tension of yarn and identify the yarn. In this guide there has asuctioning system which cleans the device continuously. In Benninger warping machine thecreel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred fromcreel to warping machine by passes to the v-reed. The top of the machine contains v-reedwhich separates each yarn eventually. Then the yarn is passing upon pre roller and windingthe warper beam. The warpers beam gets a pressure from pressure roller at the bottom of themachine. The pressure roller supported the warper beam continuously and keeping the yarnparallel.

M /C specification:

Modern- Conventional-

Name of the m/c: Benninger Name of the m/c: hacoba

Name of origin: Switzerland Name of origin: China

Creel capacity : 1224 Creel capacity : 720

R P M : 1200 R P M : 600

Beam width : 2400 mm Beam width : 2400mm


40



M /C specification:





R P M : 1200 R P M : 600



40



M /C specification:





R P M : 1200 R P M : 600



41

Diagram of direct warping:



41




41




42

Total ends =7000

PPI =70

Warp length =1200

Creel capacity =875

40*40

120*70

Construction:-

Beam required =8

solution:

Each beaming time at 100% efficiency =1200

800= 15 min

waste times are ---Creeling =60 minknoting =40 min

Beam change =16 min

Breakage time =80 min

Total = 196 min

wastes time for each beam =196

8= 24.5 min

With waste per beaming time = 15 +24.5

= 39.5 minutes

For one shift,/8 hours production =480

39.5= 12 beam

So efficiency, = 1239.5 *100

=37.9746 %

58 inch

suppose,finish construction

Indirect or Sectional warping system:


42

Total ends =7000

PPI =70

Warp length =1200

Creel capacity =875

40*40

120*70

Construction:-

Beam required =8

solution:


800= 15 min


Beam change =16 min


Total = 196 min


8= 24.5 min


= 39.5 minutes


39.5= 12 beam


=37.9746 %

58 inch




42

Total ends =7000

PPI =70

Warp length =1200

Creel capacity =875

40*40

120*70

Construction:-

Beam required =8

solution:


800= 15 min


Beam change =16 min


Total = 196 min


8= 24.5 min


= 39.5 minutes


39.5= 12 beam


=37.9746 %

58 inch




43

Sectional warping is one of the most important and complicated section than high speedwarping. Because it contain varies types of section or repeat which is directly input in sizingand weaving. In sectional warping total number of ends are added together then it sized.Every repeat is important for producing accurate width of the fabric and perfect cloth. So itwill depend on good sectional warping, which is impossible in direct warping. For thesereason it’s called sectional warping. By sectional warping we can produce cheek and stripefabric.

The sectional warping depends on some parameters such as:

Head stock Control device. Creel arrangement.

Operation procedure of sectional warping:

In the sectional warping system the yarn path is same like as direct or high speed warping.But it has some dissimilarity from high speed warping that is pattern drum, eye reed.Headstock, and control device. The drum and other control equipment are totally different.Firstly should have to calculate the repeat size, width and set the other parameters perfectly.Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eyereed into a guide that contain some weight disk, because of getting parallel, separation anduniform tension of yarn. In there is some lease rod that is helps to separate the yarns fromdifferent creel. For winding purposes it passes in to v-reed, and then get the section widthand wound in drum perfectly. The movements of drum and head stock are constant, thatvalue is input into the device with respect to the repeat width. After finished the total length istransferred to the sized beam.

M/C Specification:

Name of the m/c: Benninger supertronic

Name of origin: Switzerland

V-reed capacity: 650

Eye reed capacity: 650

Creel capacity: 576

R. p. m : 800

Components of sectional warping:


43






M/C Specification:





Creel capacity: 576

R. p. m : 800



43






M/C Specification:





Creel capacity: 576

R. p. m : 800



44

Indirect Warping process:


44



44



45

40*40

102*70

Total ends =5900

Reed density/inch = 46

Reed cound =92

Reed width =64.1

PPI =70

Warp length =1300(1300+118)

Order quanty =1100

Pattern chart of warp & weft

Construction:-

Warp pattern

Navy

Optical white

Total

6

7

13

Weft pattern

All optical white

In warp

Color

Navy

Optical white

Total

Ends

6

7

% of color Required warpin kg

per colorreq. in kg remarks

46.15

53.85

116

116

54

62

116

% of color Requiredwarp in kg

picks per colorreq. in kg remarksColor

White 1 100 84 84

In weft


45

40*40

102*70

Total ends =5900


Reed cound =92

Reed width =64.1

PPI =70

Warp length =1300(1300+118)

Order quanty =1100


Construction:-

Warp pattern

Navy

Optical white

Total

6

7

13

Weft pattern

All optical white

In warp

Color

Navy

Optical white

Total

Ends

6

7



46.15

53.85

116

116

54

62

116



White 1 100 84 84

In weft


45

40*40

102*70

Total ends =5900


Reed cound =92

Reed width =64.1

PPI =70

Warp length =1300(1300+118)

Order quanty =1100


Construction:-

Warp pattern

Navy

Optical white

Total

6

7

13

Weft pattern

All optical white

In warp

Color

Navy

Optical white

Total

Ends

6

7



46.15

53.85

116

116

54

62

116



White 1 100 84 84

In weft


46

Why sectional warping is different?

In sectional warping dyed yarns are used for making the sections according to theconstruction and repeat size also the total number ends that the number of colored yarns isrequired for completing the sections. Actually sectional warping is to done for check or stripefabric production. It is very different from high speed warping. Only gray yarns are used forhigh speed warping so it has fewer hazards. For that reason check or stripe fabric is costlythan solid dyed fabric.

The computerized sectional warping can automatically calculates the following:

1. Number of sections on the beam and width of each section.2. Constant warp tension regulation for uniform buildup3. Automatic stops for predetermined length4. Automatic stops for leasing5. Constant warp tension over the full warp width6. Memory of yarn breakage during warping for beaming

Faults in warping

1. Practically for winding2. Machine fault3. Operator misconception4. Low quality yarn5. others

Problems in warping

a. Overlapping problemb. Soft yarnc. Incorrect form of beamd. Loose selvedge (depends on tension)e. Incorrect warp lengthf. Big knot

Checking have to done during warping:

1. Lot mixing2. Count mixing3. Color variation


46





Faults in warping


Problems in warping





46





Faults in warping


Problems in warping





47

Calculation of sectional warping:

Construction:

40*40

102*7057

Reed dents per inch =46Reed count =92

Reed width =64.1PPI =70winding angle = .8

Total ends =5900

Solutions:

Total ends *10

warp widthMesured phase or e/cm =

Number of ends = Fabric width *EPI

Number of section =Total ends

Repeat size

Fabric width =Total ends

EPI

Warp density=d tex * total ends * 0.8

400 * warp width(mm)

d tex =5905

Ne= 147.625

=5900 *10

1900= 31.052 cm

= 57*102 = 5814

5900

13= = 453.846

=5900

102= 57.843

=147.625*5900*0.8

400*1900= 0.91mm


47


Construction:

40*40

102*7057



Total ends =5900

Solutions:

Total ends *10




Repeat size


EPI



d tex =5905

Ne= 147.625

=5900 *10

1900= 31.052 cm

= 57*102 = 5814

5900

13= = 453.846

=5900

102= 57.843

=147.625*5900*0.8

400*1900= 0.91mm


47


Construction:

40*40

102*7057



Total ends =5900

Solutions:

Total ends *10




Repeat size


EPI



d tex =5905

Ne= 147.625

=5900 *10

1900= 31.052 cm

= 57*102 = 5814

5900

13= = 453.846

=5900

102= 57.843

=147.625*5900*0.8

400*1900= 0.91mm


48

Required weight of yarn per cone in creel,

SupposeCone weight =2000gm

Count = 30

Creel capacity =512

Length of one cone = 1.6933*30*2000

= 101598 mts

Number of cone =200

* 200

=20319600 mts

=22221514.56 ydslength per creel stand =22221514.56/512

= 43401.3956 yds

=43401.3956

840*30

=1.72227 lbs

Following terms should be considered

1. Floor temperature 28-32 degree ( 65 degree Farenhight)2. For warping light should be 10 lumen per square feet3. Warping efficiency 60%4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5%

What is sizing:

The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing.This is the most important operation to attain maximum weaving efficiency. Especially for blendedand filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness,frictional resistance. Sizing consists of impregnating the yarn with particular things which form on theyarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequentweaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems thetensions and the rubbing caused by weaving.

Purpose of sizing:

To improve the weave ability of the warp yarn To maintain good fabric quality by reducing hairiness, weakness and by increasing

smoothness, strength of yarn. To increase the tensile or breaking strength for cellulose yarn.


48



Count = 30

Creel capacity =512


= 101598 mts

Number of cone =200

* 200

=20319600 mts


= 43401.3956 yds

=43401.3956

840*30

=1.72227 lbs



What is sizing:


Purpose of sizing:




48



Count = 30

Creel capacity =512


= 101598 mts

Number of cone =200

* 200

=20319600 mts


= 43401.3956 yds

=43401.3956

840*30

=1.72227 lbs



What is sizing:


Purpose of sizing:




49

To increase the elasticity To remove the protruding/floating fibers To reduce electrostatic formation for synthetic or blended yarn

Sizing Technique:

All beams previously wound on the beam warper are mounted on a special beam creel. The threadsare taken off in sequence from all beams and introduced into a vat containing the proper size. Thewarp enters then a drying unit, where the water contained in the threads is evaporated, this result isobtained by direct contact of the threads with cylinders having decreasing temperature having steamline. These last are a real innovation and operate as follows: the electromagnetic field generated byradio-frequency permits to extract the water contained in the glue, without heating the threads. Byavoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemicaland physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It isimportant to take care that during sizing the threads do not stick together, but remain separate in ordernot to create problems during the downstream processes. The drying unit is followed by a waxingdevice which is aimed at increasing the threads smoothness. The process concludes with the windingby an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between thedrying unit and the end frame there are lease rods: these are available in the same number as thebeams under process minus one and have the function of keeping the threads separate and ofpreventing that they get entangled and are not wound up with the correct sequence.

A recent variation to the traditional system carries out sizing during beam warping and thereforeassembles already sized beams. The advantage is the possibility of sizing beams, each with a warprate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’sbeam.

Reason for different sizing recipe:

Sizing is a complementary operation which is carried out on warps formed by spun yarns withinsufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing isnecessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soonas warping is completed, to the sizing machine where they are assembled.

There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizingmethods depend on the type of weaving machine used, the construction of fabric, on the yarn typeand count, on the technician’s experience and skill, but all kinds of material in progress. The onlycommon consideration of the various sizing materials is that they have to be easily removable afterweaving in order to allow carrying out without any problems for the selected finishing cycle. Thesubstances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, whena particularly thick size is required.

Machine specification:


49


Sizing Technique:








49


Sizing Technique:








50

Scematric diagram and control system of sizing m/c:

Shade-02

Machine Name : Sucker MullerBrand :HacobaOrigin : SwitzerlandR.P.M :60 each rollerCylinder : 12V-reed : 1450Lease : 14Beam capacity : 16Winding pressure : 4500 barPress tension : 3500 barLease tension : 2000 bar (Maximum)Cylinder temperature : 145 degreesProduction capacity/day : 30000 meters

Shade-01

Machine Name :BenningerOrigin : SwitzerlandR.P.M :160 MaxCylinder : 14Lease : 29Beam capacity : 32V-reed : 1372Cylinder Temperature : 145 degreeWinding pressure : 1800 NCreel tension : 700 NProduction capacity/day : 40000-45000 Max


50


Shade-02


Shade-01



50


Shade-02


Shade-01



51

Factors for warp sizing:

Warp sizing is an essential process to coat warp yarns with elastic films and bind fibers of yarns aslowering fluff or hairiness so that yarns may be so strong that resist the mechanical strain in weavingprocess, and maintain or improve weaving efficiency. Quality of warp sizing generally evaluated bythe following factors

Cohesive strength: Total strength including elasticity of sized yarn to resist such mechanical strainsin weaving process as tensing, bending, rubbing, shedding, etc

Fluff binding: Very important factor to prevent yarns from clinging among yarns. It is particularlyrequired in weaving a high-density fabric or by a high-speed air jet loom. Sized yarns without fluffmay be shed smoothly in weaving loom.

Size pickup (SPR): The amount of size picked up by yarns. An ideal size pickup is pre-determinedaccording to yarn/fabric construction, by which you can formulate a size recipe and set squeeze rollpressure and other mechanical condition. Size must be picked up by yarn sheet evenly.

Smoothness & Softness: Another important factor of sized yarn as well as cohesive strengthparticularly in weaving high-count yarns into a high-density fabric by a high-speed air jet loom.

Size cooking condition: Determine the quality of size solution in terms of viscosity, particle size, etc.In other words, a good size solution can be prepared in a good cooking process.


51









51









52

Size machine condition: In terms of size box temperature, squeeze pressure, draft, dry cylindertemperature, etc. This may determine the quality of the above factors.

Basics of ideal SPU (for regular cotton woven cloth)

Yarn count 10/S 20/S 30/S 40/S 50/S 60/S 80/S

SPU(±1.0%)

8.0 9.0 10.0 12.0 14.0 15.0 16.0

[SPU: Size concentration × Squeezing ratio]

90-120% by polyester/ cotton blends100-150% by 100% cotton120-170% by 100% rayon100% or less by 100% polyester

(Depending on machine and squeeze roller condition)

Basically,For cotton : 2.5 KN

Pc : 2.0 KN

Ideal amount of moisture for sized yarn:

For 100% cotton 6.5-7.0%100% rayon 9.0-9.5%100% polyester 1.0-1.5%35/65 polyester/cotton 3.0-3.5%

Sizing chemicals and their costing:

Chemical Name Cost/kg

Kollatex 05 54.96 TkPenetrose 50 35 TkGlysofill soft 160 TkElastex 44 TkTape 50 TkPinitex 194.52 TkPVA 173 tkQuick solan SPR 108 Tk


52




SPU(±1.0%)

8.0 9.0 10.0 12.0 14.0 15.0 16.0





Pc : 2.0 KN







52




SPU(±1.0%)

8.0 9.0 10.0 12.0 14.0 15.0 16.0





Pc : 2.0 KN







53

Size ingredient and their function:

During sizing there used different types of size chemicals. Those chemicals are mainly categorized by

Adhesive or Starch Softener Binder

Adhesive or Starch: It is the main ingredient of solution preparation. It is two types-

Natural starch Synthetic starch

Natural starch: Natural starches are generally made from potato, maize, wheat, corn, sago. Those arenative starch. Some native starches are-

Name Country Brand Viscosity Solid %Penetrose Pakistan Low modified 75-80Tape Thailand Apple Low modified 75-80

Synthetic starch: Synthetic starches are made from different chemical composition. Those aremodified and highly modified starch. Some modified starches are-

Name Country Brand Viscosity Solid %PVA Singapore PVA 217 High modified 98-99Kollotex Holland Avebe Medium modified 85-90SPR Holland Avebe High modified 90-96

Functions: To make coating on the yarn To improve yarn strength To increase smoothness To increase elasticity and stiffness.

Softener: It is the second main ingredient of size solution preparation. Some softening agent’s are-Pinitex (Holland), Glysofill softener.

Functions: To make the yarn soft and slippery To smoothen the yarn and To reduce stiffness

Binder: It is another essential ingredient of size solution preparation, has some impacts duringsizing. The binding agent’s are-

Size CA (Indonesia) Elastex (Pakistan)


53
















53
















54

Pinitex (Pakistan) Acry size (Pakistan)

Possible uses percentages of size chemicals:

Starch : 85%Softener : 3%Binder : 12%

During size solution preparation those percentages may be 2-3% adding or reducing.

Recipe for Sucer Muller sizing machine:

Construction 30×30 × 58”110×70

Set length 5000meter

Solution:

Total ends×100Cover Factor =

√count × beam width

6380×100=

√30×2400= 48

It is possible to running one size box.

Total ends= 110×58= 6380

6380×5000Weight of yarn=

1.6933×30= 62796 gm=627kg

Liquored required = 627+ 35%= 627+219= 846kg

Total liquor required= 846+ 300 [Here, 300kg required for size box]= 1146kg

Chemical׃ Water׃1 5


54








Solution:



6380×100=

√30×2400= 48


Total ends= 110×58= 6380


1.6933×30= 62796 gm=627kg





54








Solution:



6380×100=

√30×2400= 48


Total ends= 110×58= 6380


1.6933×30= 62796 gm=627kg





55

Water = 600leterPVA =10kgPenetrose =70kgKollotex =25kgSize CA =12kgPinitex =3kg

Total volume = (120+600) + 12 %( steam)= 806kg

Solid percentage of chemicals:

PVA =.97×10= 9.7Penetrose =.75×70 = 52.5Kollotex =.85×25 = 21.25Size CA =.30×12 =3.6

Total = 87.05

87.0Refraction value= ×100

806=10.7 %

Recipe for Beninger sizing machine :( shed 01)

40×40Construction × (61”+61”)

124×96Set length=10000meter

Solution:

Total ends = 124×122= 15128

Total ends×100Cover Factor=

√count× beam width

15128 ×100= [Here, used 2size box]

√40 × 2400 ×2= 49.86


55





Total = 87.05


806=10.7 %




Solution:

Total ends = 124×122= 15128




√40 × 2400 ×2= 49.86


55





Total = 87.05


806=10.7 %




Solution:

Total ends = 124×122= 15128




√40 × 2400 ×2= 49.86


56

15128×10000Weight of yarn= 1.6933× 40

=2233.50kg

Liquored required = 2233.50+35%=3015kg

Total liquored required: = 3015+300 [Here, 300kg used for 2size boxes]= 3315kg

[Chemical: Water]1:5

Recipe:Water : 600literPVA : 30kgPenetrose : 73kgSize CA : 14kgPinitex : 3kg

Total volume = (600+120) +12 %( steam)= 806kg

Solid percentages of chemicals:

PVA =.97×30=29.1Penetrose =.75×73=54.75Size CA =.30×14=4.2

Total = 88.05

Solid %Refraction value = total volume

88.05 ×100= 806

= 11%


56

15128×10000Weight of yarn= 1.6933× 40

=2233.50kg








Total = 88.05


88.05 ×100= 806

= 11%


56

15128×10000Weight of yarn= 1.6933× 40

=2233.50kg








Total = 88.05


88.05 ×100= 806

= 11%


57

Size mixing curve:

2 Minaggetate

900 C

Steam

PVA

Cooking time

30 minute

Fig: Sizing Cruve

Add Another chemical

Viscosity of size solution:

For better warp sizing, it is important to maintain ideal viscosity of size solution. If size has extremehigh viscosity, it may permeate in warp yarns well which might be rough and hard handling touch,and be bound as a tape. On the contrary, if size solution without enough viscosity is applied in warpyarns, their fluffs may not be laid down well, and/or SPU may be lower than expected because sizemay be easily squeezed out. In general, ideal viscosity is between 10 and 20 seconds by 6- mmviscosity cup.


57

Size mixing curve:

2 Minaggetate

900 C

Steam

PVA

Cooking time

30 minute

Fig: Sizing Cruve





57

Size mixing curve:

2 Minaggetate

900 C

Steam

PVA

Cooking time

30 minute

Fig: Sizing Cruve





58

Introduction to Loom:

Introduction:

Weaving is a mandatory part of textile, mainly the physical textile. To set up a weaving project a lotof preparation is required. So, this is a very big investment project, but this technology is related toour culture. Now days some weaving industry is established in Bangladesh. Weaving is a mechanismthrough which two sets of yarns are interlaced together to form fabric by the machine called loom.One set of yarn is called warp and another set is weft. Weaving is done on a machine called a loom.All the weaves that are known today have been made for thousands of years. The loom has undergonesignificant modifications, but the basic principles and operations remain the same. Warp yarns areheld taut within the loom, and weft yarns inserted and pushed into place to make the fabric. At thefirst time the shuttle loom is used for making fabric. Actually shuttle is a kind of weft insertingelement used previous time. During the industrial revolution mass production high speed looms weredeveloped. Today the industries uses modern looms like projectile, rapier, air jet, water jet looms.These looms are high speedy and production capacity is very high. The modern loom consists of twobeams, a warp beam and a cloth or fabric beam, Kolding the warp yarns between them. Warp yarnsthat sufficient for length, width, and density of the fabric to be woven are wound carefully onto awarp beam.

Objectives:

To know about the different weaving machine. To get knowledge about the projectile mechanism for weft insertion also the projectile loom. To gather knowledge of rapier loom and the rapier driving mechanism. To know about the different parts of rapier loom and rapier set for picking the filling yarns. To know of cam adjustment of rapier loom for various construction depending on it the heald

shaft movemet. To know about air jet loom and different parts of air jet loom. Carefully evaluate the weft insertion system of air jet loom. To get knowledge of the valves and nozzles and know about the required amount of air to run

a machine for exact construction.

Basic Mechanisms of Power Loom:

In order to interlace wrap and weft threads to produce a fabric, the following mechanisms arenecessary on any type of loom:

Primary mechanisms Secondary mechanisms Auxillary mechanisms


58


Introduction:


Objectives:








58


Introduction:


Objectives:








59

Primary Mechanisms:

These are fundamental or essential mechanisms. Without these mechanisms, it is practicallyimpossible to produce a fabric. It is for this reason that these mechanisms are called ‘primary’mechanisms. The primary mechanisms are three in number.

a. Shedding mechanismb. Picking mechanismc. Beat-up mechanism

a. Shedding mechanism

The shedding mechanism separates the warp threads into two layers or divisions to form a tunnelknown as ‘shed’

b. Picking mechanism

The picking mechanism passes weft thread from one selvedge of the fabric to the other through theshed by means of a shuttle, a projectile, a rapier, a needle, an air-jet or a water-jet. The inserted weftthread is known as “pick”.

c. Beat-up mechanism

The beat-up mechanism beats or pushes the newly inserted length of weft thread (pick) into thealready woven fabric at a point known as “fell of the cloth”. These three mechanisms namelyshedding, picking and then beat-up are done in sequence.

Secondary Mechanisms

These mechanisms are next in importance to the primary mechanisms. If weaving is to be continuous,these mechanisms are essential. So they are called the ‘secondary’ mechanisms. They are:

a. Take-up motionb. Let-off motion.

a. Take-up motionThe take-up motion withdraws the cloth from the weaving area at a constant rate so as to give therequired pick-spacing (in picks/inch or picks/cm) and then winds it on to a cloth roller.

b. Let-off motion.The let-off motion delivers the warp to the weaving area at the required rate and at constant tension byunwinding it from the weaver’s beam. The secondary motions are carried out simultaneously.

Auxillary Mechanisms

To get high productivity and good quality of fabric, additional mechanisms, called auxiliarymechanisms, are added to a plain power loom. The auxiliary mechanisms are useful but not absolutelyessential. This is why they are called the ‘auxiliary’ mechanisms. These are listed below.

Warp protector mechanism


59

Primary Mechanisms:


















59

Primary Mechanisms:


















60

Weft stop motion Temples Brake Warp stop motion (Predominantly found in automatic looms)

a. Warp protector mechanism

The warp protector mechanism will stop the loom if the rapier gets trapped between the top andbottom layers of the shed. It thus prevents excessive damage to the warp threads, reed wires andshuttle.

b. Weft stop motionThe object of the weft stop motion is to stop the loom when a weft thread breaks or gets exhausted.This motion helps to avoid cracks in a fabric.

c. TemplesThe function of the temples is to grip the cloth and hold it at the same width as the warp in the reed,before it is taken up.

d. BrakeThe brake stops the loom immediately whenever required. The weaver uses it to stop the loom torepair broken ends and picks.

e. Warp stop motionThe object of the warp stop motion is to stop the loom immediately when a warp thread breaks duringthe weaving process

AIR PREPARATION STAGE

1. Receive2. Filtration3. Compress the air (dew point 10ᵒC and 6 bar pressure)4. Drying5. Separation.6. Micro-filtration7. Reserved (pressure 7-8 bar)

AIR COMPRESSOR TYPES

Type Oil free/oiling Water/ air cooling

ReciprocatingOil free Water cooling

Oiling Water cooling

ScrewOil free Water/ air cooling

Oiling Water/ air cooling


60

















60

















61

TurboOil free Water cooling


Weft path diagram of air jet:

Package

Ballon breaker

tensoner

Guide

Pirn winder

ballon breaker

PFT

Fixed Nozzle movable Nozzle Cutter

First end of fabric

Relay nozzle

Weft yarnLast end of fabric

FD1FD2Selvedge yarn

Fig. Passage diagram of air-jet loom filling yarn

Weft parameters of air jet:

Balloon breaker Tensioner Pre-winder PET Fixed nozzle Movable nozzle Filling cutter Relay nozzle FD1

FD2


Name of the machine : Toyota

Brand : Toyota JAT 710

Origin : Japan


61




Package

Ballon breaker

tensoner

Guide

Pirn winder

ballon breaker

PFT


First end of fabric

Relay nozzle


FD1FD2Selvedge yarn




FD2




Origin : Japan


61




Package

Ballon breaker

tensoner

Guide

Pirn winder

ballon breaker

PFT


First end of fabric

Relay nozzle


FD1FD2Selvedge yarn




FD2




Origin : Japan


62

RPM : 800

Solenoid Valve : 15 use 14

Tuck-in : 03 no.

Temple : Ring

Shedding : Tapped & Dobby

Weft insertion : By Air

Required pressure : 5.5 Bar

Operating system : Computerized

Weavers beam

Back restDroper

Heald shaft

reedFall of the cloth

take uproller

Guide

cloth roller

Fig. Passege diagram of warps in loom


62

RPM : 800


Tuck-in : 03 no.

Temple : Ring





Weavers beam

Back restDroper

Heald shaft


take uproller

Guide

cloth roller



62

RPM : 800


Tuck-in : 03 no.

Temple : Ring





Weavers beam

Back restDroper

Heald shaft


take uproller

Guide

cloth roller



63

Compressor Air Quality:The compressed air for weft insertion should be as high quality in order to run the air-jet loomefficiently some important factors is given.

Moisture:a. Liquid should be completely removed.b. Moisture in air should be removed. The dew point of the moisture should be 10ᵒC or lower.c. If moisture is not removed from the compressed air then,

1. Metallic part of the equipment and piping corrode.2. Dust and other impurities will adhere in the pipe. Passage resistance as presence will

increase. And pin holes made in the pipe wall result in air leakage.3. The need will soil, this will produce faulty fabric.

Grease:a. Oil, aerosol (0.8-0.01 micron) particle and larger grease should be removed.b. If remove is incomplete then,

1. The metallic part of the equipment and piping will corrode.2. Foreign particle will adhere in the compressed air pipe.3. Woven cloth will soil.4. Operational environment will not hygienic.

Foreign particle and carbon:a. 0.3 micron or larger foreign particle and carbon should be removed.b. If they are not removed then,

1. Nozzle efficiency will reduce and valve will not work properly.2. Particle mixed with moisture grease will spoil the reed and cause equipment mal

functioning.

Causes of warp breakage:

Loose yarn/ weak yarn. Crossing of warp. Sticky end. Back rest position. Low sized yarn. Friction in different part.

Loom piping system:


63









functioning.



Loom piping system:


63









functioning.



Loom piping system:


64

3"

3"

2"

Figure A Piping Example

3"

3"

Figure B Piping example

General operation of air jet:

The operation principle is the following: the thread, prepared in a given length (corresponding to thereed width) by pre-measuring weft carriers is launched through the shed by a jet of compressed air.The air jet weaving machines require air ducts capable of maintaining an effective air flow on thewhole weaving width. To obtain this, the machine manufacturers prefer today to use the system withprofiled reed, in which the air and the thread are guided through a tunnel-shaped reed The weft isplaced in the groove formed by the reed’s profiled dents, in which it remains until the reed stroke. Inthe air jet weaving machines, the impulse causing weft launch is provided by a main nozzle but the jetof compressed air, being blown in a room of same kind, looses very quickly its own energy.Consequently, if the weft has to be transported along reasonable widths, the use of additional gears,that is of secondary or auxiliary (or relay) nozzles is necessary; these, besides pushing the weftforward, have also the task of keeping it inside the guide channel. The auxiliary nozzles are stationedalong the whole reed width and operate according to the relay principle, the nozzle holder blocks are


64

3"

3"

2"


3"

3"





64

3"

3"

2"


3"

3"





65

connected group wise to the distributors of compressed air by means of flexible pipes. The multi-holerelay nozzles applied on modern air jet weaving machines accelerate the weft motion in the best way,at the same time reducing the stress on the yarn and helping towards increasing machine yield andperformance. The manufacturers are increasingly installing on the weft delivery side of the shed asuction nozzle which has the function of maintaining stretched the weft pending the stroke of the slayand the consequent weft binding in the fabric. This ensures a perfect stretching of the weft inside theshed with any kind of yarn, even with the most critical yarns. Among the various optional devicesoffered by some manufacturers, we point out in particular the auxiliary main nozzle; the combinationof an auxiliary main nozzle with the main nozzle accelerates the weft motion but under low pressure,thus avoiding damaging the yarn. A particular characteristic of the last models of weaving machines isthe automation and the supervision of the machine with the aid of microprocessors. An automaticregulation system optimizes the air pressure in the machine, adjusting it to the variations of yarn

Machine Indicator Light:

·► Green Light : Normal Stop

·►Yellow Light : Weft Stop

·► Red Light : Warp Stop


65







65







66

·► White Light : Technical Problem

·► Red + Yellow Light : Warp + Weft Stop

·► Green + Red Light : Selvedge + Wastage Stop

·► Green + Yellow Light : Bobbin Breakage

CAUSES OF WEFT BREAKAGE

1. Package position.2. Entanglement of yarn with machine parts.3. Worm tension.4. Low pressure in

a. Pre-winderb. Fixed nozzlec. Movable nozzled. Relay nozzle

5. High pressure ina. Pre-winderb. Fixed nozzlec. Movable nozzled. Relay nozzle

6. High speed of pre-winder7. Mal functioning of magnet pin8. Clogging of yarn in pre-winder9. Wrong passage of filling yarn.

Rapier weaving machines:

The rapier weaving machines are the most flexible machines on the market. Their application rangecovers a wide variety of fabric styles. Their present weaving speed of about 600-700 strokes/min is


66













66













67

the result of the use of a state-of-the-art construction technique, characterized by the use of gear setswithout plays and by minimum vibrations of the reed, the slay and the heald frames.

Picanol:


Name of the Machine : Picanol

Optimax Gamma

Origin : Belgium

R.P.M : Optimax-650

: Gamma 8R-500

Loom type : Rapier

Rapier : Double end rapier

Shedding system : Tappet &Dobby

Rapier insertion system:

The weft, which is under constant proper control, remains connected to the cloth as a consequence ofthe previous insertion (or it remains blocked under the temple in the other cases) (fig. 36). At the rightmoment the selection gear acts in a way, that the end of the weft is caught by the bearing rapier 1mounted on a flexible tape or on a rod and at the same time is cut by shears on the selvedge side. Theweft, after adequate braking, is transported to the center of the shed, where the bearing rapier meetsthe drawing rapier 2, which takes over the weft thread and, while holding it by its end, transports itback to the opposite side, where the rapier leaves it free, thus completing the insertion. The weftexchange between the two rapiers in the middle of the shed can take place in two different ways, thatis:

Negative system Positive system.


67


Picanol:



Optimax Gamma

Origin : Belgium

R.P.M : Optimax-650

: Gamma 8R-500

Loom type : Rapier







67


Picanol:



Optimax Gamma

Origin : Belgium

R.P.M : Optimax-650

: Gamma 8R-500

Loom type : Rapier







68

Driving gears for rapier belts:

To transform a uniform rotary motion into an alternating motion, all kinds of gears are used. Amongthese gears, the cam motion system is the most used as it is possible to study the cam profile in orderto obtain an accelerating movement of the rapiers which permits the most delicate handling of theyarn. This fact is particularly important during the critical moments of the thread clamping at thebeginning of the cycle, during the rapier exchange in the middle of the shed and during the release ofthe weft at its exit from the shed at the opposite side. In all these cases the weaver tries to operate atthe lowest possible speed rates.Fig. 39 Floating guideWe give hereunder some examples driving systems for flexible rapiers. A manufacturer uses in hismachines the following disk cam system with complementary cam profile the rotating shaft 1 carriesfixed a couple of disk cams with complementary profile 2 (the other couple of cams serves to movethe reed) which transmits, through a roller cam follower 3, a swinging movement to a lever withadjustable arm (not visible in the figure), which lever is linked to the connecting rod 4. This lasttransmits the swinging motion to the block 5, mounted eccentrically on shaft 6, which by a system ofside gears and planet wheels converts the movement into the alternating rotary movement of a crownwheel with pinion 7 and of the toothed wheel 8. The flexible rapier belt, which is driven by thiswheel, moves on a straight level and transforms the alternating rotary motion into a straight rotarymotion. Of course a similar gear carries out the control of the other rapier.


68




68




69

Fig. Driving system by double conjugated cam

Projectile weaving machinesThe projectile weaving machine made its appearance in the market at the beginning of the50’s andis today still used in the whole world. Thanks to its steady renovation and to the use ofadvancedelectronic systems as well as of microprocessors for the supervision and the control of thevariousdevices, this machine is characterized by a good productivity level (450 rpm and 1050 m/minofinserted weft) and by high operational reliability. It is established especially in the field ofmachines with high reed width.

M/C SPECIFICATION:

General operationIn this weaving machine the weft insertion is carried out by small clamp projectiles (fig. 45),which number depends on the weaving width and which with their grippers take out the weftyarnfrom big cross-wound bobbins and insert it into the shed always in the same direction.The projectiles work in sequence, that is they are launched in succession. They run thereforeoneafter the other, describing in the space a continuous, endless route, as if they would be stuckon a


69



M/C SPECIFICATION:



69



M/C SPECIFICATION:



70

conveyor belt.The first projectile takes and holds in its back the weft in form of a tail; then, pushed by therelease of the projectile thrower, it passes through the shed and deposits the weft inside thewarp;subsequently the projectile falls and is collected by a device which, by passing under thearray ofthe warp threads, takes it at reduced speed back to the starting point. Here the projectile goesup totake up a new weft; meanwhile the other projectiles have run after each other making thesameoperation.Fig. 45 shows the projectile conveyor chain (shuttle return chain), the projectile (shuttle)with itsback clamp to seize the yarn (thread grippers), the cutting tool (scissors) to separate theinsertedweft from the bobbin and the strap which, through twisting, launches the projectiles

Projectile guideThe limited weight and the reducedvolume of the projectile make aprojectile guide necessary (fig. 47).The projectiles therefore do notcome into contact with the threads,but run inside a sort of channelcomposed of the thin prongs of a


70




70




71

rake, which form reminds a semiclosedhand. This rake goes up fromunder the threads at the moment ofthe projectile launch and has ofcourse to fall back lowering itself atthe slay stroke. To enable thismovement, the rake is secured onthe slay and is positioned very closeto the reed; the rake’s laminas arenot in contact with the warp, ortouch it very lightly because thereed opens them the way.The latest models of the projectilemachine have been equipped withnew types of guide dents, which aredivided and placed in alternate position, in order to reduce the stress on weft and warpthreads.This permits to use in warp even very delicate yarns as for instance untwisted or entangledyarnsand at the same time to cope with high quality requirements


71



71



72

Chapter – 07Quality Assurance system

Quality : The totality of features and characteristics of the product or services that bear onits ability to satisfy stated or implied needs.

Quality assurance & Fabric Inspection system:


72





72





73

Quality assurance is defined as all those possible planned and systematic actions necessary toprovide adequate confidence than a product or service will satisfy given requirements forquality. The Quality Assurance Department is assigned to maintain consistently uniformquality of the material in process and various stages of manufacturing.

Objects of Quality Control:

Specification test Raw material control Process control Process development Product testing Research

Finish Fabric Inspection:

Purpose:

To ensure that an acceptable quality fabric is used for producing garments and properquality of shipment is received from the supplier.

Procedure:

Store in charge will check the received fabric with the report length and typeof fabric with the stated shipment document quantity and the actual orderquantity.

The finding will be recorded in inventory report and discrepancy regardingfabric type, color and length will be notified to the AGM/ ASTT Manager.

For in house product quality control officer will guide all over inspection. Quality inspector ( fabric) will check 100% receive fabric for quality. He will

identify any defect, hole or stain in the fabric and make calculating below-

Four Point System:

Defect area Point

0 to 03 inch 1

3 to 06 inch 2

06 to 09 inch 3

Above 09 inch 4

For any hole in fabric 4


73





Purpose:


Procedure:





Four Point System:

Defect area Point

0 to 03 inch 1

3 to 06 inch 2

06 to 09 inch 3

Above 09 inch 4



73





Purpose:


Procedure:





Four Point System:

Defect area Point

0 to 03 inch 1

3 to 06 inch 2

06 to 09 inch 3

Above 09 inch 4



74

If point grade is 40 or below than the fabric is ok. If the result is more than 40 points,then inform it to AGM or respective Manager.

The fabric is also checked for shedding defect in side by side and length. Any non-conformities/ shedding will be noticed to asst. manager using reports. Roll wise coloruniformity card is maintained for identification of shade variations.

During the fabric inspection if the yardage of any roll is reported more or less by thefabric inspection machine then the one specified in the roll, the roll will be measuredmanually using measuring tape. Only calibrated measuring tape should be used.

The result of fabric inspection will be recorded in fabric inspection report.

The quality assurance system followed by this factory is given below:

Inspection

Mending

Recheck

Folding

List of the equipments:

Mending table Glass box Thread cutter Comb Nipper Correction pen Pocket box Inspection Machine Electronic balance

Inspection Procedure:

The grey fabric produced from different loom shed is collected by thequality inspector and thoroughly inspected in front of a white board light. During inspectiondifferent types of fault happened during weaving like holes, oil spot, reed mark, temple mark,miss pick, double pick, starting mark, broken pick, shade variation in case of yarn dyed fabricis checked. Then fabrics transferred to the mending section for some adjustment done throughhand. Then fabric is rechecked and finally folding is done for storage.


74






Inspection

Mending

Recheck

Folding






74






Inspection

Mending

Recheck

Folding






75

Quality Standard:

For quality standard this factory follows 4 point system. The acceptable quality gradesdepending on the buyer’s requirements are:

Grade-A: Maximum 10 point in 100 meter fabric is considered for first grade.

Grade-B: Maximum 11-15 points in 100 meter fabric are considerable for second grade.

Grade-C: Maximum 16-20 points are considerable for 100 meter fabric in third grade.

Following Table shows common faults and response by inspection section at NomanWeaving Mills ltd:

No Faults Response1 Reed Mark Uneven warp & weft tension2 Miss Pick Uneven weft yarn tension3 Snarl Uneven air pressure4 Hole Uneven knotting5 Slubs Yarn fault6 Thick thin place Uneven tension7 Weft Wrong weft yarn supply8 Double end Wrong denting9 Wrong denting Double end10 Double pick Wrong air tension11 Wrong drawing Operator fault12 Loose warp Wrong beam winding13 Tight warp Do14 Oil line/ Stain Carelessness15 Crease mark Do16 Uneven tension Wrong operational setup

Faults & points:

Starting Mark 4 point Miss pick 4 point Half pick 4 point Double pick 4 point Running pick 3 point Cut pick 2 point


75

Quality Standard:







Faults & points:



75

Quality Standard:







Faults & points:



76

Mesh 4 point

Daily grey inspection report:

SlNo

Construction Width(Meter)

Loom Shift Dam: Mtr. Name of faults

A B1 30*30/ 72*64 64 146 30 34 64 Temple cut

2 30* 30/ 72*52 98 15 118 100 218 Starting mark

3 30*30/ 77* 68 60 93 50 40 90 Starting mark,running pick

4 16*10/ 48*44 96 130 30 40 70 Starting mark,half pick

5 40*40/ 110*80 63.5 153 98 57 155 Temple cut

6 30*30/ 72* 44 98 113 08 36 44 Starting mark,miss pick

Folding: 24033 meter

Inspection: 21393 meter

Calculations of points is done by-

Actual point × 100

Inspected Total Yard

Shift Total fabric inspection(meter)

Percentage (%)

A 14608 68.28%

B 3164 14.79%

C 2351 10.99%

Inspection Waste 62 0.28%

Folding waste 77 0.35%


76

Mesh 4 point


SlNo



A B1 30*30/ 72*64 64 146 30 34 64 Temple cut

2 30* 30/ 72*52 98 15 118 100 218 Starting mark



5 40*40/ 110*80 63.5 153 98 57 155 Temple cut





Actual point × 100



Percentage (%)

A 14608 68.28%

B 3164 14.79%

C 2351 10.99%




76

Mesh 4 point


SlNo



A B1 30*30/ 72*64 64 146 30 34 64 Temple cut

2 30* 30/ 72*52 98 15 118 100 218 Starting mark



5 40*40/ 110*80 63.5 153 98 57 155 Temple cut





Actual point × 100



Percentage (%)

A 14608 68.28%

B 3164 14.79%

C 2351 10.99%




77

Chapter-08

Maintenance of Machinery


77

Chapter-08



77

Chapter-08



78

Maintenance:

Maintenance is the actions taken to prevent a device or component from failingor to repair normal equipment degradation experienced with the operation of the device tokeep it in proper working order. Machine, building, & facilities are subjected to deteriorationdue to their use & exposure to environmental condition. Process of deterioration ifunchecked, culminates in rendering these service facilities unserviceable & brings them to astandstill. In industry therefore has no choice but to attend them from time to repair &recondition them so as to elongate their life to extent it is economically & physically possibleto do so.

Objectives of maintenance:

To keep the factory plants, equipments, machine, tools in optimum working order. To ensure accuracy of product & time schedule to delivery customers. To minimize downtime of machine. To prolong the useful life of factory plant & machine. To modify or improve productivity of existing machine to meet the need for

production & thus avoid sinking of additional capital.

Reactive / Break down maintenance:

Reactive maintenance is basically the “ run it till it breaks” maintenance mode. No actions orefforts are taken to maintain the equipment as the designer originally intended to ensuredesign life is reached.

Preventive maintenance:

Preventive maintenance can be define as action performed on a time or machine run basedschedule that detect, preclude or mitigate degradation of a component or system with the aimof sustaining or extending its useful life time to an acceptable level.

Routine maintenance:

Maintenance of different machines is prepared by expert engineer of maintenancedepartment. Normally in case of weaving machine is done after every 07 days for completechecking of different important parts are done.

Maintenance procedure of different machine:

Warping machine Sizing machine Weaving machine


78

Maintenance:














78

Maintenance:














79

Warping Machine:

To check the motor and motor belts To check all the gear and gear boxes To examinant all the sensors of the warping machine Lubrication should be done to the lubrication points of the machine. Cleaning of different parts which are covered by fiber and dust To verify tension devices and guides.

Sizing Machine

Maintenance Points:

Gear & gear box Motor & motor belt Different sensor Lubrication Cleaning of various parts which are covered by flies and dust

Maintenance in the Weaving section

For proper running of the machine it is necessary to maintain the machine. This isdone by cleaning the machine after every 15-20 days. This is basically the servicing of themachine. This is done because

- To maintain the quality of the fabric- To reduce the fabric fault- Removal of dust from the machine- Cleaning of different parts of the machine

During servicing the following things are checked weather they are in good conditionor not. These are cleaned and also replaces if necessary. These are

Relay nozzle Stress nozzle Cam box Filling detector Reed


79

Warping Machine:


Sizing Machine

Maintenance Points:








79

Warping Machine:


Sizing Machine

Maintenance Points:








80

Drop wire PFT Pre winder Full body

Cleaning points:

Draw roller Tension roller

Guide roller Size box

Immersion roller Squeezing roller

Delivery roller Separating roller

V-reed Measuring roller

Spreading roller Eliminate laps from the warping beam

Size material pipe Air blast nozzle

Oiling & Greasing points:

All roller bearing squeezing roller bearing

Cylinder roller bearing All gear boxes

Health & Safety :

Noman Weaving Mills Ltd have a separate sounding fire alarm, that is distinct &audible in all parts of the workplace & that can be rung from various pointsthroughout the facility.

Emergency evacuation routes are marked on floors. Workers are trained in emergency procedures. NWML provides one first aid kit per 100 employees. First aid kits are fully stocked. NWML provides eating areas that are separate from the main work area, clean,

protected from the weather & with enough seating for all workers on break at once. Safe drinking water is available for all workers at all time. NWML have functional & clean toilets for worker use. Work areas are ventilated. NWML have adequate temperature & humidity control. Workers wear footwear to avoid foot injury. Chemicals are stocked & used in designated areas which are adequately ventilated. Electrical boxes are covered & switches are labeled. Doctor is available.


80


Cleaning points:











Health & Safety :





80


Cleaning points:











Health & Safety :





81

Chapter -09Utility services


81



81



82

Utility:

It is a complete department. Its purpose is to deals with air, gas, electricity required for the factory torun the production and facilitate the all power related factors.

It has some sections that are-

Power plant Boiler Chiller/ Compressor/Humidifier/ AC plant

Power plant:

Capacity : 5.15 MW

No. of generator : 5

Capacity of each generator : 1030 KW

Generator type : Gas generator

Maximum generation is 80% depending on the use

Gas required/ month : 332492 m3 × pressure factor (constant)

= 671068 m3

Per unit price : 3.74 tk

Total cost : 671068 × 3.74 taka

= 2509796 taka

Boiler:

Boiler type : Fire tube (02)

Gas consumption / month : 47252 × pressure factor m3/hr

47252 × 2.0183

95368.2 m3

Per unit price : 5.86 taka

Total cost : 95368 × 5.86


82

Utility:




Power plant:

Capacity : 5.15 MW






= 671068 m3



= 2509796 taka

Boiler:



47252 × 2.0183

95368.2 m3


Total cost : 95368 × 5.86


82

Utility:




Power plant:

Capacity : 5.15 MW






= 671068 m3



= 2509796 taka

Boiler:



47252 × 2.0183

95368.2 m3


Total cost : 95368 × 5.86


83

= 558860.65 taka

Chiller:

Pressure for loom : 6.00 bar

Pressure for weaving shed : 7.00 bar

In chiller natural air is generated

Specification of Utility machines

SL NO Name ofMachine

ManufacturerName

Country of origin Quantity (nos)

1. Generator Cattrrpiller U.S.A 5

2. Chiller L.S Koria 1

Carrier (Old fromTongi)

U.S.A 1

3. Compressor Atlascopco Belgium 7

4. Dryer Atlascopco Belgium 7

5. Boiler Schnelder Germany 2

A/C Plant Dae Lim Koria 2

6. Overhead Luwa Switzarland 3

7. Electrojet spain 16


83

= 558860.65 taka

Chiller:






ManufacturerName





U.S.A 1








83

= 558860.65 taka

Chiller:






ManufacturerName





U.S.A 1








84

Chapter -10Store and Inventory


84



84



85

Inventory:

Physical inventory: Physical inventory is a kind of inventory the material that is necessary available atthe store.

Two types of physical inventory:

Fast Moving Item Slow Moving ItemPaper office file Plug connection 8630215Ball pen Air jack base plateRolling paper Water meterFile box Interface module 8760182Duplicating book Sizing belt P# 7462023Correction pen Air pressure regulator P# 774702202Envelop 11" × 5" Reed switch P# 780301021Envelop 10" × 12" Encoded cupping P#7491318Measurement book Proximity switch p# 8360005White paper 9" × 12" Limit switch 240 VFile box plastic Wax level sensorStaff officer attendance register Module P# 8760196Textile marker classic Pneumatic cylinder P# 780108301Staple pin big size Pneumatic valve P# 743601806Lithium battery 3.6 V Squeezing roller side protection P# 7086007Steel scale 01 meter Lighting wire P# 7423028Aromatic soap Turn bucketSteel Roller 01 meter Load cell P# 8200183Shampoo 200 ML Motor A/C P# 801205202

Specification of Inventories Godown:

Yarn go down: 02Volume of one go down: 50' × 80' × 10'Volume of another go down: 80'× 80' × 10'

Main spare parts: 40' × 50' 10' Chemical go down: 50' × 60' ×10' Wastage go down: 40 '× 50 '× 10' Fabric go down : 50' × 80' × 10'


85

Inventory:








85

Inventory:








86

Chapter -11Marketing activities & Cost Analysis


86



86



87

Marketing:

Marketing is main department for a industry where setting all of the the production depend. By thecauses of product demand and price. They decide where product sale, product price and quality ofproduct.

Sequence of Marketing Activities

Order taken from buyer

Counter sample

Approved sample

Cost analysis for bulk production

Bulk Production

Quality Inspection

Shipment

Analysis the sample or swetch

Name of Buyer:

Ikea

Hemtex

Spring Canada

C & A / H & M

Iusaka

Promod Ltd.


87

Marketing:




Counter sample

Approved sample


Bulk Production

Quality Inspection

Shipment


Name of Buyer:

Ikea

Hemtex

Spring Canada

C & A / H & M

Iusaka

Promod Ltd.


87

Marketing:




Counter sample

Approved sample


Bulk Production

Quality Inspection

Shipment


Name of Buyer:

Ikea

Hemtex

Spring Canada

C & A / H & M

Iusaka

Promod Ltd.


88

Padma Ltd.

Lidle

Carre four

Ia re doute

Joine max

La balance

Van dillen

Costing:

Sum of expenditure incurred in making a product or service available at a point from where it is tobe sold is known as costing.

1. Required yarn calculation2. Identify the yarn cost3. Sizing cost4. Weaving cost5. Dyeing cost

Construction: 40×40 = 58"

133×100

Total ends = 133×58

= 7714


88

Padma Ltd.

Lidle

Carre four

Ia re doute

Joine max

La balance

Van dillen

Costing:




133×100


= 7714


88

Padma Ltd.

Lidle

Carre four

Ia re doute

Joine max

La balance

Van dillen

Costing:




133×100


= 7714


89

Weight of warp = 0.26 lbs/yds

Weight of weft = 0.21 lbs/yds

Total weight = (0.26+0.21) lbs/yds

= 0.47 lbs/yds

Price of yarn = 233.38 tk/lbs

So, yarn cost = 233.38* 0.47

= 110 tk

Sizing chemical cost = 3.05 tk/lbs

M/C cost + overhead cost

Weaving cost = tk/yds

Total production per M/C/day

9300

= tk/yds

394

= 23.60 tk/yds

So total manufacturing cost = (23.60+110.00+3.05+22) tk/yds

= 158.65 tk/yds


89




= 0.47 lbs/yds


So, yarn cost = 233.38* 0.47

= 110 tk





9300

= tk/yds

394

= 23.60 tk/yds


= 158.65 tk/yds


89




= 0.47 lbs/yds


So, yarn cost = 233.38* 0.47

= 110 tk





9300

= tk/yds

394

= 23.60 tk/yds


= 158.65 tk/yds


90

Chapter-12Conclusion


90



90



91

Introduction:


Objectives:



Place of study:


Duration of study:


Method of study:



91

Introduction:


Objectives:



Place of study:


Duration of study:


Method of study:



91

Introduction:


Objectives:



Place of study:


Duration of study:


Method of study:



92

Conclusion:

Findings:

As a textile everybody should perform industrial attachment and project report. Undoubtedly thisindustrial training was very helpful to learn about textile technology, production process, textilemachineries, industrial management, match with industrial environment. It was the first opportunity towork on the industry.

Limitations:

Because of secret act, the data of costing and marketing activities have not been supplied. It is not possible to in compass the whole process in such a small frame as this report. Some of the points in different chapters are not included as these were not available We did not get enough supervision from the responsible persons of different sections due to

their busy schedule. So, there may some limitations of data of different section in this report. We had a very limited time. In spite of willingliness to study in more details it was not

possible to do so.

Suggestions:

Due to shortage of technical persons (Textile Engineers) sometimes quality level drops whichneed to be minimize by employing technical person. Especially at night.

During our training period, most of the time the product were not first time right and need tobe reprocessed, increasing the production cost these problems has to be overcome.

We observed that there is lack of understanding between top level personnel and floor levelworkplace, weakening the chain of command.

Supervisor or in- charge did not follow the program. So sometimes operators deviate from theset procedure which may hamper the quality of the product.

Weaving production needs to increase as well as technical persons need to employ there. The machine stoppage time should be analyzed and minimized. The maintenance should be

carried out regularly. More skilled labor should be used in the project to improve productivity.


92

Conclusion:

Findings:


Limitations:



possible to do so.

Suggestions:








92

Conclusion:

Findings:


Limitations:



possible to do so.

Suggestions:





