Yarn Division

TEXTILE INTERNSHIP
REPORT
YARN DIVISION
TECHNOCRAFT
INDUSTRIES PVT. LTD.
Submitted By:
Gopal Dixit
Snigdha Patel
TECHNOCRAFT INDUSTRIES PVT. LTD

YARN DIVISION
NATIONAL INSTITUTE OF FASHION TECHNOLOGY,

NEW DELHI

YARN DIVISION
CERTIFICATE
This is to certify that this Textile Internship
Report based on our research work, conducted
under the guidance of Ms. Bhavna Verma, has
been completed.
All the material that was borrowed has been duly
acknowledged

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ACKNOWLEDGEMENT
At the outset, we wish to express our gratitude to
everybody who has assisted in the formulation of this
report. There are many to whom expression of gratitude is
inevitable, but there some special people who have to be
given prominence, without whom we would not have
reached the conclusion of this project so quickly and so
efficiently.
We are grateful to Dr. V. Senthil for guiding us throughout the
internship. We would like to thank our mentor Ms. Bhavna
Verma for her constant support. Also, we would like to thank
our Course Coordinator, Ms. Girija Jha, who has always
added to our buoyancy with her tremendous efforts.
At Technocraft, we would like to thank the HR Manager, Mr.
Amit Salian, Spinning Manager, Mr. Shiva Barimani; our
industry mentor and the Quality Head, Mr. Anil Upadhyay;
and the factory manager, Mr. Ketan Oza. Also, we would like
to express a special gratitude to the company for being
excellent hosts.
We take this opportunity to express our affection towards our
parents for their consistent faith and support.
Gopal Dixit
Snigdha Patel

YARN DIVISION

YARN DIVISION

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INDEX

YARN DIVISION
1. TECHNOCRAF
T INDUSTRIES:
INTRODUCTION

YARN DIVISION
1.1. INTRODUCTION
The foundation of the Technocraft Group was laid in the
year 1972 by two siblings Mr. Sharad Kumar Saraf and Mr.
Sudarshan Kumar Saraf both graduates from the prestigious
Indian Institute of Technology, Bombay under the leadership
and able guidance of their father Mr. Madhoprasad Saraf
with a humble beginning and on a small budget of Rupees
Ten Thousand, capped with a vision to manufacture
sophisticated technological tools for the industries.
Technocraft Group is one of the leading manufacturer &
exporter of Drum Closures, Steel Pipes, Tubes and
Scaffolding Systems, 100% cotton yarn, garments,
providing engineering software solution services.
Today Technocraft is the second largest producer of Drum
Closures around the globe having global patent under its
belt for GRT Flanges, Octagonal Clinched Drum Top and
many more are pending registration. It has its immense
marketing capabilities through its Subsidiaries in United
Kingdom, Poland, Hungry, Germany, warehousing facilities
in The United States of America catering to the North
American markets.
Their head office is located in Mumbai (India) & overseas
offices & Warehouses in Manchester (U.K.), Lodz (Poland) &
Budapest (Hungary); Chicago (U.S.A.) & Houston, Hilden
(Germany), China, Australia.
The dominant feature for the success of its products
around the world has been due to long term trustworthy

YARN DIVISION
relationship based on unmatched impeccable ethical
principles with our Business Partner all over the globe; they
have been instrumental in pitching our products against the
best in the world.
The manufacturing operations of the group are located in
the industrial belt of Thane District some 90 Kms away from
the port city and the financial capital of the country Mumbai
(formerly Bombay), backed by state of art infrastructure
encompassing 50000 Square Meters of Land, powered by
the passionate zeal of more than 1400 quality conscious
leaders, skilled technician and workmen.
1.1.1.
COMPANY OBJECTVE
On the textiles front, Technocraft envisions to be one of the

leading cotton yarn producers in India and one of the largest
fully integrated textile producers in the country.
1.1.2.
COMPETITIVE STRENGTHS OF THE
COMPANY
In house capability to design and manufacture special
purpose machines, tools, accessories and development
process, thereby resulting in world class manufacturing at
low costs.
High technological base in its manufacturing units, which
results in optimum raw material utilization.

YARN DIVISION
Located close to Mumbai, there is abundant availability of
cheap and skilled labour.
Manufacturing units are located close to JNPT port, which
results in very low shipping costs.
The installation of a Captive Power Plant in the Textile
division has resulted in lower cost of power.
Efficient and modern effluent treatment plant with
recycling of water.
Technocraft has its own marketing companies with
warehouse and showrooms, thereby resulting in a far wider
reach in the international markets.
Exports to over 60 countries and covering all the
continents (except Antartica)
Labour Management - In the past years the company, has
not had any major Labour Disturbance resulting in any
production loss.
Markets its products worldwide through its subsidiaries in
UK, Hungary, Poland and Germany.
Fully owned subsidiary engaged in developing CAD, CAM
and CAE software solutions, the subsidiary company extends
high end technology inputs and support for continuous
upgradation and take up challenging new areas.
1.1.3.
COMPANIES UNDER TECHNOCRAFT INDIA
PVT. LTD.
1. Drum Closures:

YARN DIVISION
Today Technocraft is the second largest producer of Drum
Closures in the world with a production of over 20 Million
sets of Drum Closures annually. Their drum closures are
now exported in millions to safety conscious customers in
Europe, USA, Middle East, South East Asia and the Asia
Pacific region.
2. Yarn Division
Yarn Division is into manufacturing & exporting of 100%
Cotton Ring Spun Yarn. The plant is equipped with
production capacity of 1000 kg/hr and 61,100 spindles in
count range. From NE 20 to NE 40, Carded and Combed
variety of Cotton Yarn is produced. The Spinning mill is
equipped with world class Swiss, Japanese, German,
Spanish and other equipments. The Cotton Yarn Unit is a
Certified ISO 9001:2000. It also has a Captive power
generation plant to cater to its power requirements.
3. Garment Division
Manufacturing premium quality active wears products and
provides superior service making it one of the leading
textile and apparel manufacturers in India. Products are
custom knit, dyed, finished, cut, sewn, decorated, packaged
and distributed with names Danube Fashions.Being part of
a diverse group, it has access to the latest trends in the
European markets, thus enabling to offer high quality and
latest fashions with Indian prices in a very short lead-time.
The motto of the brand is to offer quality right from the
cotton yarn to the clothes.
4. Technosoft

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It is the engineering Services Subsidiary. It provides total
solutions in the field of CAD / CAM / CAE. Technosoft is the
business partner with leading software companies in the
CAD/CAM/CAE field. We market and support RADAN and
Strand7.
Fellow Subsidiaries
5. CAE Systems Gmbh.(Germany)
The Company was incorporated on September 1, 2005 and
its main business is to carry out software development and
other related services. The basic operations are to cater to
the European market.
6. Impact Engineering Pvt Ltd (USA)
The Company was incorporated on 11th June 1993 and its
main business is providing an integrated line of engineering
services including services related to mechanical design
and engineering, product simulation, technical staffing,
systems integration and related consulting to
manufacturers. Technosoft Information Technologies (India)
Limited, a subsidiary of Technocraft Industries (India)
Limited, acquired this company on 31st August 2006. Its
registered office is situated at Milwaukee, Wisconsin, USA.
7. Swift Engineering Inc
A company headquartered in Calgary, Canada, which is in
the business of providing Engineering, Procurement and
Construction Management services to the oil and gas
industry in Alberta, British Columbia and Saskatchewan,
since 2003.
Foreign Subsidiaries:
8. Technocraft International Limited, U.K.

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Incorporated on 2nd of April 1993 and its main business is
to trade in goods manufactured by Technocraft.
9. Technocraft Trading Spolka, Poland
Incorporated on 14th of May 1998 and its main business is
in to trading of yarn, drum closures and Scaffolding, sale of
product made by Technocraft in Poland and neighboring
countries.
10.Technocraft Australia Pty Ltd.
Incorporated on 29th of March 2006 and its main business
is to trade in goods manufactured by the Technocraft.
1.1.4.
THE YARN DIVISION
In 1997, Technocraft diversified into manufacturing of Cotton

Yarn. The Unit was accorded a 100% EOU status. The cotton
yarn division is into Manufacturing & Exporting of high
quality 100% Cotton Ring Spun Yarn. From NE 20 to NE 40,
the spinning mill is equipped with world class Swiss,
Japanese and other equipment. The cotton yarn division
employs highly trained technical experts in all aspects of
yarn spinning. It also has a Captive power generation plant
in the yarn division to cater to its power requirements.
Today technocraft is a leading manufacturer and exporter of
100% Cotton ring spun Yarn. The cotton yarn division has
forward integrated its operations by production & export of
Garments through its subsidiary. Technocraft has been
constantly upgrading its capacity & improving its standards
to meet the ever increasing expectations of its customers.

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The strategy adopted by the company comprises of growth
through constant innovation, enter new categories, and
focus both on domestic as well as foreign markets.
There are two units in the yarn division; Unit 2 was
established in 2007.
Located just 90 kms from Mumbai and only 50 kms from the
Port.
Captive power generation.
Production capacity of 1000 kg/hr
On 61,000 Spindles approx in count range from NE 20 to NE
40, Combed
Government of India Recognized Trading House
ISO 9002 Certified Company
Employing Over 1500 Trained Workmen and Qualified
Technicians.
Almost 100% of the Companys production is exported to
about 60 Countries worldwide.

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1.1.5.
CORPORATE SOCIAL RESPONSIBILITY
As a part of corporate social responsibility, Technocraft has

promoted an Institute of Higher Education in the name of
NTTF Training Centre (NTC). NTC offers Diploma Course in
Mechatronics and Tool & Die Design Engineering initially and
further courses will be added in due course. NTC is located
on a lush 9 acres landscaped site in Murbad, Dist. Thane,
about 90 km from Mumbai, Maharashtra, India.
NTTF Training Centre is a trust run by Technocraft Industries
promoters, tied up with Nettur Technical Training Foundation
(NTTF) to bring the esteemed institute in Maharashtra for the
first time. NTTF is the living symbol of Indo-Swiss cooperation aimed at promoting a purposeful technical
education for the youth in India.
1.1.6.
COMPETITION
In the domestic market they face competition from both the

organised and unorganised sectors. Even with a diversified
product portfolio, quality approach, manufacturing flexibility
and modern technology they face intense competitive
pressures. Countries such as Mexico have the advantage of
being located in proximity to our main markets of the US and
EU. These countries can shorten the lead time required by
being able to deliver products to the customers in shorter
time. They also face competition from manufacturers in
other cost efficient supplier countries, which have low labour

YARN DIVISION
costs.
They intend to meet this competition through product
differentiation, whereby they offer value added, design
based products in the respective segments.
1.1.7.
ORGANISATIONAL STRUCTURE -
DEPARTMENTS
There are 5 departments in the unit:
Raw material department - This department is responsible
for the sourcing and storage of raw material (i.e. cotton).
Production department - The department takes care of all the
production related activities from planning to processing.
Maintenance department - This department takes care of all
the machinery and cleanses the machinery at regular
intervals.
Quality Assurance department - The department is
responsible for checking the quality levels and maintaining
them throughout the process.
Human Resource department - They take care of all the
working personnel of the factory from a machine operator to
the manager.
1.1.8.
1972
1977
1979
1980
1993
1994
MILESTONES
Started manufacturing Drum Closures
Launched Export Drive
Recognized as a Export House
Expanded Drum Closure Capacity
Setup its first Foreign subsidiary in United Kingdom
Acquired Maharashtra Steel Tubes Limited Pipe Division

YARN DIVISION
1994 Merger of Technocraft Fabricators (Bombay) Limited
and Eskiedee Metal Crafts Private Limited
1997 Started 100% EOU Yarn Unit1998 - Setup Subsidiary in
Poland
2000 Setup Subsidiary in Hungary
2000 Awarded the National Award for Export Excellence
by Ministry of Commerce and Industry, Award Presented by then
Prime Minister of India Shri. Atal Bihari Vajpayee
2000 Started Technosoft Information Technologies India Limited
Engineering Software and Design Services Company.
2001 Awarded Export Excellence Award for all steel products by
Engineering Export Promotion Council Maharashtra
2003 Started Garmenting through - Danube Fashions Limited
2004 Awarded 3 Star Export House Certificate
2004 Achieved the Export Targets set by Government of India in
the yarn Division under the Target plus Scheme.
2005 Setup a Subsidiary in Germany
2005 Launched Haute Chilli Brand in India through its
Subsidiary
2005 Achieved the export targets set by Government of India in
our Yarn Division2nd year straight
2006 Setup a Subsidiary in Australia2006 Filed the DRHP with
SEBI
2007 Got listed on the Mumbai Stock Exchange and the National
Stock Exchange
2008 Installation of 15MW power plant
2009 Establishing first manufacturing plant outside India

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1.1.9.
HIERARCHY
Chairman
Mr. M D Saraf
Director
Mr. Navneet
Saraf
M.D.
Engg Business
Mr. S M Saraf
Factory Manager
Mr. V P Kavatkar
(Yarn Division)
M.D.
Commercial
Mr. S K Saraf
President
Mr. Subhash
Khandelwal
Manager- Legal
Mr. Vikas
Patangia
Manager- Admin/
Purchase
Mr. Deepak
Mishra
Manager- Export
Yarn
Mr. Ketan Oza
ManagerPersonnel
Mr. Anand Singh
Yadav
ManagerAccounts
Mr. Vinod
Gadodia
Director
Mr. Ashish Saraf
Director
Mr. Subhrao S
Kole

YARN DIVISION
1.2. PLANT LAYOUT
1.3. PROCESS FLOW

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Blow Room
Carding
Pre- Drawing
Lap Formation
Combing
Finisher
Drawing
Speed Frame
Ring Frame
Winding
Yarn
Conditioning
Packaging

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2. THE
SPINNING
PROCESS

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2.1. RAW MATERIAL

The raw material (i.e. cotton) is obtained from various
companies throughout India. They also import some special
varieties of cotton from Egypt and Australia. They use
mainly the Shanker 6 variety of cotton bought from
Gujarat. Other varieties used are Mach 1 and LRA- 5166.
2.1.1.
PROCUREMENT
The company sources its cotton from a variety of

companies all over India. It sources mainly from the state of
Gujarat and South India. Below is a list of companies from
which Technocraft Industries is currently sourcing its cotton
from:
Aashirwad Cotton Corp., Ahmedabad

Dayal Cotspin Ltd., Akola
Pankaja Mills, Coimbatore
Moolchand Mannalal, Wardha
Sree Tirupathi, Amravati
Jalaram Ginning Factory, Dhrangadhra
Sri Bhagyodaya Cotton Company, Ahmedabad
2.1.2. STORAGE
The cotton bales arrive in the company via trucks. The bales
are usually of the weight range 160 kg- 170 kg. They are
stored in the godowns of the two units according to the

YARN DIVISION
amount required by each unit. The excess bales are stored
in the godown outside the units. The bales are unloaded on
the unloading porch using the forklift trucks. All the bales
arriving in the godown are duly weighed and proper logs are
maintained.
2.2. PRODUCTION DEPARTMENT

2.2.1. BLOWROOM
The blow room is the first stage or the first process in the
short staple spinning. The name Blow Room is given to this
stage because of the air currents that are commonly used
during the processing of fibres. the blow room the fibre
mass is progressively opened, cleaned and mixed. This is
done by using a large number of machines. In each of these
machines used in blow room if the actions are too severe of
sudden then fibre damage will occur.
Input: Bales of raw cotton
Output: Cleaned and homogenously mixed cotton in the
form of lap form or chute feed to the card
Functions:
1. Fibre Opening: The tightly packed fibre bales received from
the ginning mills have to be opened by converting the larger
fibre tufts into smaller ones and ultimately converting the
smaller tufts into individual fibre form.
2. Cleaning: All the natural fibres including cotton have
considerable amount of impurities in them which have

YARN DIVISION
to be removed to produce a clean yarn.
3. Mixing/Blending: The properties of the cotton fibres
differ from each other from bale to bale and from fibre
to fibre so in order to obtain a homogenous and
consistent quality yarn, they need to be thoroughly
mixed together. Sometimes in order to have a desired
quality at the right price high quality cotton fibres are mixed
with low quality fibres.
4. Preparation of feed for the next stage: The end product of
the blow
room should be compatible with the next stage of spinning
i.e. carding. The feed to the carding can be either given in
the form of lap or in direct chute form.
Basic concepts of Blow Room:
Opening in blowroom means opening into small flocks.
Technological operation of opening means the volume of the
flock is increased while the number of fibres remains
constant. i.e. the specific density of the material is reduced.
The larger the dirt particle, the better they can be removed.
Since almost every blowroom machine can shatter particles,
as far as possible a lot of impurities should be eliminated at
the start of the process. Opening should be followed
immediately by cleaning. The cleaning efficiency is strongly
dependent on the Trash %. It is also affected by the size of
the particle and stickiness of cotton. Therefore cleaning
efficiency can be different for different cottons with the
same trash %.
Cleaning is made more difficult if the impurities of dirty
cotton are distributed through a larger quantity of material
by mixing with clean cotton.

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If cotton is opened well in the opening process, cleaning
becomes easier because opened cotton has more surface
area, therefore cleaning is more efficient.
Due to machine harvesting, cotton contains more and more
impurities, which furthermore are shattered by hard ginning.
Therefore cleaning is always an important basic operation.
The higher the degree of opening, the higher the degree of
cleaning. A very high cleaning effect is almost always
purchased at the cost of a high fibre loss. Higher roller
speeds give a better cleaning effect but also more stress on
the fibre.
In cleaning, it is necessary to release the adhesion of the

impurities to the fibres and to give the particles an
opportunity to separate from the stock. The former is
achieved mostly by picking of flocks, the latter is achieved
by leading the flocks over a grid.

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Using Inclined spiked lattice for opening cotton in the initial
stages is always a better way of opening the cotton with
minimum damages. Of course the production is less with
such type of machines. But one should bear in mind that if
material is recycled more in the lattice, neps may increase.
Traditional methods use more number of machines to open
and clean natural fibres.
Mechanical action on fibres causes some deterioration on
yarn quality, particularly in terms of neps . Moreover it is
true that the staple length of cotton can be significantly
shortened.
Factors which affect the degree of opening , cleaning and
fibre loss :
o thickness of the feed web
o density of the feed web
o fibre coherence
o fibre alignment
o size of the flocks in the feed (size may be same but
density differs)
o the type of opening device
o speed of the opening device
o degree of penetration
o type of feed (loose or clamped)
o distance between feed and opening device
o type of opening device
o type of clothing
o point density of clothing
o arrangement of pins, needles, teeth

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o speeds of the opening devices
o throughput speed of material
o type of grid bars
o area of the grid surface
o grid settings
o airflow through the grid
o condition of pre-opening
o quantity of material processed,
o position of the machine in the machine sequence
o feeding quantity variation to the beater
o ambient R.H.%
o ambient temperature
Removal of dust is not simple. Dust particles are very light
and therefore float with the cotton in the transport stream.
Furthermore the particles adhere quite strongly to the fibres.
If they are to be eliminated they are to be rubbed off. The
main elimination points for adhering dust therefore, are
those points in the process at which high fibre/metal friction
or high fibre/fibre friction is produced.
Removal of finest particles of contaminants and fibre
fragments can be accomplished by releasing the dust into
the air, like by turning the material over, and then removing
the dust-contaminated air.
Release of dust into the air occurs wherever the raw
material is rolled, beaten or thrown about. Accordingly the
air at such positions is sucked away. Perforated drums,

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stationary perforated drums, , stationary combs etc. are
some instruments used to remove dust.

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Process Flow in Blowroom:
Opening of Bales
Trutzschler Blendomat BO-A & Trutzschler

Wastefeeder BO-R
Multifunction Mixer
Trutzschler SP-MF
Pre-Cleaning
Trutzschler CL-P
Mixer
Trutzschler MX-I
Fine Cleaner-I
Trutzschler CL-C3
Fine Cleaner-II
Vetal Scan Polysensor
Dedusting
Trutzschler Dustex SP-DX

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Machinery:
M
S
C
B
C
Po
S
Bale Conditioning:
The cotton fibres from the ginning factories are
received by the spinning department in form of highly
compressed bales that are wrapped by metal or plastic
straps. As the bales are received these straps are cut off and
the bales are allowed to condition for 24 hours in
controlled temperature and between 60% to 80% relative
humidity. For this purpose all the spinning mills allocate floor
space for conditioning purpose.
The conditioning allows the fibres to relax and maintain
a temperature and moisture equilibrium with atmosphere
and reduces the chance of fibre damage and inconsistency

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in quality.
Bale Lay Down:
After the bales are conditioned properly they are taken to
the blow room and placed in groups of special sequence for
the first processing stage. This group of bales is called as
bale lay down. The main aim of a proper bale lay-down is to
have fibres with similar properties and spinning attributes
from lay-down to laydown so that spinning machines can
be adjusted optimally and yarn of consistent quality may
be produced over a longer period of time.
1. Bale-Opening Machines
After proper bale lay-down the initial bale feeding is
done either by using a parallel set of machines called as
hopper feeders or by a single machine called as a top feeder.
Functions:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Extract material evenly form bales.

Open the material gently.
Open up to smallest tufts.
Form tufts of equal sizes.
Process as many bales as possible in a single charge.
Easily programmable.
Blend fibres at the start of the process.
Top Feeder: Trutzschler Blendomat BO-A

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The top feeders are travelling machines that move over and
past the bale layout and extract fibres from top to bottom.
They have great advantage that more than one bale can be
processed simultaneously to give a better long term blend.
These machines are fitted with computerized control
panels and they extract material from all the bales
evenly. The production rates of such modern bale openers
ranges from 750 kg/hour to 1000 kg/hour.

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The bales (1) are positioned along the machine. Light

barriers detect the position of the bales. The controller then
sets the doffer (2) to the right height accordingly. The drive
in the truck (6) moves the machine on rails (5) along the
bales.
Opening rolls (3) in the doffer draw the material though grids
(4) and pluck it from the bales. Support rolls (7) make sure
the doffer rests evenly on the bale and prevent them being
knocked over. If the working direction turns around, the
penetration inversion mechanism which is integrated into
the doffer, makes sure that he support rolls also rest evenly
on the bale in the new direction.
The bales are plucked upto a set height which is predefined

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by the controller. If the bales are being processed on the
right or left hand side of the machine it is possible to switch
to the other working area. The pivot drive in the turret then
rotates the doffer 180 degrees on the vertical axis.
Processing continues without the machine coming to a
standstill.
Hopper Feeder: Trutzschler Wastefeeder BO-R
The hopper feeders have stock supply compartments which
are either filled manually or by automatic machines. They
remain stationary while the raw fibres from the bales
can be fed manually or by automatic machines.

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The Waste Feeder AS is fed by the feed lattice (1). At the end
of the feed lattice a star roller is positioned which together
with a stripper delivers the material evenly to the feed table
(2) and affects a pre-opening of the material. The material
being opened is conveyed from the feed lattice (1) via the
feed table (2) to the sharply angled spiked lattice (6) whose
speed can be varied in a ratio 1:5 with a variable speed
motor. The evener roller (8), whose distance from the spiked
lattice (6) can be varied from -5 mm to +30 mm, determines

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the degree of opening of the material and, in conjunction
with the spiked lattice speed, the machines rate of output.
The material cast back by the evener roller in combined
action with the cleaner roller (7) falls against the deflector
panel and the guide panel back onto the feed table (2). The
height of the resulting reserve material in the baffle plate (4)
is determined by the adjustable light barrier (3). This light
barrier also controls the feed lattices variable speed motor,
requesting more material or stopping material feed to
prevent overfilling.
The stripper roller (9) collects the opened material from the
spiked lattice (6) and transfers it via the transfer trunk to the
next machine.
2. Multifunction Separator
Functions:
Mixing of flocks from the bale opener and waste feeder
To help in separation of heavy parts and metals
It also helps in separating burning or smoldering parts from

the material and extinguishes fire if any inside the machine.
Multifunction Separator: Trutzschler Multifunction
Separator SP-MF

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The multifunction separator consists of three parts:

ii. Heavy Part Separator: The heavy part separator serves for
separating foreign particles (seeds, dirt or other foreign
particles) from the raw material supplied. It works on the
principle of aerodynamics. The aerodynamic guiding profile
in connection with the constant current, helps in removal of
heavy parts while keeping the loss of good fibers down. After
having been separated, the particles are fully automatically

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discharged through a flap and dropped into a wheeled waste
container. The flap is opened by the machine control at
preset intervals. The process of discharging takes place
without leakage of air.
iii. Air separator: The purpose of the air separator is to adjust
the air volume of the main air current for the downstream
machine by splitting the air volume of the main air current
and discharging one part, depending on the intake capacity
of the downstream machine. The discharged dusty exhaust
air is usually led to a filter installation.
iv. Metal and spark separator: Two spark sensors in the airduct
downline of the heavy part separator and upline of the air
separator detects sparks and burning or smoldering
material. The burning or smoldering material is discharged
into a fireproof wheeled waste container via a quick closing
flap, if the material continues to burn, heat sensor present in
the container will cause it to be extinguished with CO2. A
metal sensor surrounds the duct which detects any kind of
metal in the material flow. When the sensor detects metal,
the quick closing flap is opened, and the metal is discharged
into the waste container.
3. Pre- Cleaner
The coarse cleaning machines directly gets it feed from
multifunction separator. The striking and beating
elements in this zone are widely spaced and hence the
opening of the fibres is also very minimal.
Functions:
The main purpose of these machines is to open up the mass

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of fibres into large tufts which are then converted into
smaller tufts by using more intense opening and
cleaning machines in the next zones.
Dual Roll Cleaner (Pre-Cleaning): Trutzschler Pre-Cleaner
CL-P
Two beater rollers of about 61 cm diameters are used. Both

of the rollers rotate in the same direction and have their
surfaces covered with spikes arranged in a spiral to
improve passage of the material.

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The tuft material enters the machine vertically and drawn

in between the first rotating beater (5) and the adjustable
grid.
The second beater (2), which rotates in the same direction

as the first beater roll, takes on the tufts and tosses them
upwards. This turns the tufts several times and brings them
into contact with the grid on all sides. This eradicates a large
part of any impurities. This process is repeated several times
until the tuft enters the output area.
Waste- The extracted impurities fall into the pockets of the

delivery roll (3) and then into the waste duct (4). The
impurities are sucked upwards through pipes, which are laid
inside the machines sheet- metal casing, and ejected from
the machine.The exit opening of the machine is kept higher
than the in-feed opening of the machine to ensure that only
the smallest tufts can pass straight through but the bigger
tufts due to weight falls down and are always subjected
to the beater action of the beater.

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4. Multiple Mixer
Functions:
The main function of this machine is opening and cleaning, though it is
also used for mixing.
Multiple Mixer: Trutzschler Mixer MX-I
MX-I
This is a very simple mixer that gives very good long

term blend. The machine is composed of several (6 - 8)
chambers. The fibre material is pneumatically fed from the
top. All the chambers are successively and
simultaneously filled and the material is removed from
the bottom through a single common duct.

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The material is charged by an exterior fan(1) through the

connection for material feed(5) into the trunks.
The downline machine which is linked mechanically to the

Multi-Mixer via the feed belt also drives the conveyor
belt(12). The material is drawn out of the trunks by the
delivery rolls (10) and thrown onto the conveyor belt (12) by
the continuously rotating opening rolls (11). The conveyor
belt feeds the material to the feed belt or pressure belt (13).
The feed belt feeds the material to the downline machine.
Collecting impurities are continuously drawn off via the
waste tray and discharged via the pipeline for dust exhaust.
The desired speed of the DC geared motor of delivery rolls

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can be set.
5. Fine Cleaning Machines
Functions:
The beater in fine cleaners thoroughly opens the fiber
material and transports it to the next stage by suction, while
the trash is also removed by the beating and opening action.
Fine-Cleaner 1: Trutzschler Cleanomat CL-C3

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It is designed to process cotton with medium soiling.

The material from the feeding machine is fed over the
feed lattice (1) to the pressure roller (2). From there,
two feed rollers (3) take on the material and convey it
further to the needle or fully spiked roller (4). It
passes the material on to the medium saw tooth roller
(5) which in turn passes it on to the fi ne saw tooth
roller (6). The cleaned material is conveyed to the
next machine by the suction unit (7).
The carding segments (1) are situated on the needle

or fully spiked roll and on the medium saw tooth roll.

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Mote knives (3), defl ector blades (2) and the waste
suction unit (4) are fastened to each roll. They free
the material of soiling. The defl ector blades are
adjustable by which waste quantity can be regulated.
Fine Cleaner 2: Vetal Scan Polysenso
It is one of the most eff ective ways of removing

foreign particles like feather, color cloth bits,

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discolored threads, yellow fabric pieces and high
density impurities like white/transparent
polypropylene, plastic, colored polythene bag
fragments. It is done by 96 line scan cameras and
using sonic acoustic/ultrasonic sensing. Detected
materials are ejected through high-speed nozzles by
pneumatic air jets.
6. Dedusting
Functions:
Helps in removing microdust or dedusting the fibre material.
Dedusting Machine: Trutzschler SP-DX

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The fibre material flow is drawn in by a transport fan (1) and

guided uniformly onto perforated plates (6) by distribution
flaps (5)
Due to their size, the dust particles in the fibre material flow
fall through the holes in the perforated plates (6), are drawn
in by a transport fan (7) and pass through the material outlet
(3) to the downstream machine.
The machine is equipped with a separate control in the

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control cabinet (2). It is operated by way of the display and
operating unit (8).

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2.2.2. CARDING
The carding is a one of the most important process of the
short staple spinning system. Carding is an operation
where the tufty condition of the fibres is converted into
an individual fibre form. The separation of fibres in
individual form is one fundamental operation of carding
while the other fundamental operation is the formation of
the card sliver. The carding is a very important
process because unless the fibres are separated into
individuals, they cannot be spun into smooth and uniform
yarns neither can they be blended properly with other
fibres.
Input: Uniform Lap feed from blowroom
Output: Carded Sliver
Functions:
1. Opening: As the blow room only opens the fibre mass from
larger tufts to small ones, the main objective of the carding
machine is to further open up the smallest tufts into an
individual fibre form.
2. Cleaning: The removal of impurities is also an important
objective carried out by the card. Since not all the impurities
are removed by the blow room, it is essential at the carding
to remove the remaining impurities. Modern carding
machines can remove about 85 to 95% of the foreign
matter present in the fed fibres. The overall degree of
cleaning achieved
by both blow room and carding room can be as high as 95 to
99%.
3. Mixing & Blending: As the fibres are processed in the

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carding machine, they are not only opened up to the extent
of the individual fibre form but also are thoroughly mixed
together. Sometimes blending of two or more different
types of fibres can take place at the carding machine.
The card can be a very good point of blending as with the
carding action an intimate fibre to fibre blending is
achieved.
4. Disentanglement of Neps: Because of the repetitive
beating and opening of the fibres, the number of neps
increases from machine to machine in the blow room
line. The carding machine due to its special action on the
fibres opens the majority of the neps and hence their
number is reduced considerably.
5. Removal of short fibres: The carding machine also removes a
very small quantity of short fibres. The amount of short
fibres removed at the carding process is not more than 1%.
6. Sliver Formation: The end product of the carding machine is
produced in a form of a cylindrical mass of fibres called as
silver. The sliver is the very first intermediate product of
spinning that start to resemble somehow like a yarn.
7. Fibre Orientation: Although not majority of the fibres in the
card sliver are parallel and aligned however with
formation of the card sliver, the fibres for the very first
time becomes slightly parallel and assumes some
longitudinal orientation. So the carding process also helps to
create partial longitudinal orientation of the fibres.
Revolving Flat Card: Trutzschler TC03; Trutzschler TC05

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Principles of Working:
The carding action refers to passing of fibre material in
between two moving wire surfaces. This typical action is
repeatedly carried out in the carding machine to
individualize the fibres. At various stages of the carding
machine the fibres are forced to pass through closely
spaced surfaces covered with sharp metal teeth. The use of
these sharp pointed surfaces gives rise to two types of
actions:
i.
Point to point action or Carding Action

The carding action is used to separate and individualize
fibres. This action takes place between:
(i)
Feed roller and taker-in

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(ii)
Cylinder and flats

Requirements of Carding Action
(a)There should be two moving wiry surfaces
between which fibres are subjected.
(b)The action between these two wiry surfaces should
be point to point.
(c)There should be a difference in the surface speed of
these two surfaces. Greater the speed difference more
carding power is achieved
Carding Power = Surface Speed of Cylinder / Surface
Speed of Flats
To achieve best carding power, the speed of the flats
should be kept as low as possible. The optimum running
speed of flats is about 4 to 6 inches per minute. To vary
the carding power the surface speed of the flats is
altered depending upon the opening and cleaning
required at carding.
(d)The distance between the two wiry surfaces should be
constant. For cotton fibres a gauge of 8/1000 to 10/1000
of an inch is used.
ii.
Point to back action or Stripping Action

The stripping action is used to transfer the material from
one place to the other. As the material is transferred by
this action, opening and cleaning also takes place.
(iii)
Stripping action takes place between:

(i)
Taker-in and cylinder
(ii)
Cylinder and doffer
Doffer and stripping roller
Requirements of Carding Action

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(a) There should be two moving wiry surfaces.
(b) The action between these two wiry surfaces must be
point to back.
(c)There should be a difference in the surface speed
of two surfaces. However the difference in the
surface speeds should not be as high as that in
carding action. The recommended difference ratio is 1:2
i.e. the surface to which the material is to be transferred
should have twice the surface speed.
(d)The distance between the two wiry surfaces should be
constant. For cotton fibres a gauge of 3/1000 to 7/1000
of an inch is used.
Operation of the Revolving Card:

The operation of the card can be divided into three main
areas:
(1)
(2)
(3)
Feeding
Carding
Doffing
(1)
Feeding Region:
Functions of the Feeding Region:
(i)
Feeding of fibres to the carding machine at a

controlled and predetermined rate according to the
(ii)
speed and productivity of the card.

Thorough opening of the fibres.

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(iii) Removal of impurities (cleaning).
(iv) Transferring the fibres from the taker-in to the main cylinder.
The Chute Feed System:
The output of the carding machine i.e. Card sliver should be
regular and free from faults so that the resultant yarn
made out of it can also be regular and consistent in
quality. This is only possible if feed given to card is
even and uniform. However the chute feed is more
sensitive and inconsistent. To obtain even chute feeding, the
fibres in the chute should be equally thick, evenly
distributed over the whole width of the card and should
have same density all over. In its simplest form the chute
feed to the card is shown below:
This simple arrangement is called as a single chute system.

Here the fibres are fed from the top. The fibres fall down
due to gravity. A pair of delivery roller at the bottom
discharge the fibre stock on to the card feed table.
This is a conventional system used in old machinery and

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has poor consistency. A better and modern version of
chute feeding system is the double chute system as
shown below:
Card Feeding Device

The fibre stock at a consistent rate is fed to the feed
assembly of the card. In its simplest form, feed assembly is
shown below:
This feed assembly comprises of a stationary feed table

with a feed plate (1). A feed roller (2) with a diameter of 80
to 100 mm is used that presses the fibres against the feed

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plate. The surface of the feed roller is covered with saw
tooth wire. The special design of the feed plate forces
the fibre mass towards the taker-in and the carding begins.
Taker-in and its Operation
The taker-in roller has a diameter of about 250 mm having
its surface covered with saw tooth. The speed of taker-in
roller ranges between 800 to 1500 rpm. Beneath the takerin an enclosure of grid elements for cleaning purpose
are used.
Working at 1000 rpm the taker-in provides 600,000 beating

points per second with a circumferential speed of about 50
km per hour and a draft of about 1000 is given. This severe
point to point or carding action of the taker-in does
majority of the fibre opening and about 50% opening of
the entire carding machine is achieved here.
Cleaning
The extensive opening of fibres at the taker-in allows the
removal of impurities with the help of cleaning aids placed
beneath the taker-in. The cleaning aid in the conventional
card includes 1-2 mote knives and a grid whose half of
the surface is perforated sheet and the other half is slotted

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sheet. The impurities are removed as the fibre mass at
high speed strikes the knives and the grid. In modern
cards to achieve high speeds instead of using grids
triangular carding segments are used.
Transfer of Fibres to Main Cylinder
Between the surfaces of the taker-in and the main cylinder
the condition of point to back action or stripping action
arises. Due to the stripping action, the fibre material is
transferred to the main cylinder. As the fibres are
transferred to the main cylinder, longitudinal orientation of
the fibres takes place here. This orientation depends upon
the ratio of the surface speed taker-in to cylinder, ideally
this ratio should be 1:2. i.e. a draft of slightly above 2 is
given at this point.
Use of Multiple Taker-in Rollers
The standard carding machine has only one taker-in roller.
At higher production rates to achieve good opening without
fibre damage some manufacturers have come up with a
technique of using two or sometimes three taker-in rollers.
For example Truetszchler TC-03 card as shown below utilizes
three taker-in rollers:

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Three taker-in rollers are used so that at very high speeds,
the opening of fibres may be done gradually. This is done by:
(i) Rotating all three taker-in rollers in opposition directions
to each other.
(ii)
Keeping the speed of the each succeeding takerin roller higher than the previous one (each roller runs
25% faster than the last one).
(iii)
Using finer tooth covering on each of three
succeeding taker-in rollers to ensure steady flow and
(2)
opening of material at high speed.

Carding Region
Functions of the Carding Region

(i) Intensive opening of the fibres into individual fibre form.
(ii)
Removal of the remaining trash and impurities.
(iii) Removal of short fibres
Carding Action
The major carding action takes place in the area between
the main cylinder of the card and revolving flats. As the
material is stripped off the taker-in towards the main
cylinder, the fibre mass is subjected to severe carding
action due to a significant difference in the surface speed of
the cylinder and flats.
The flats move at a speed of about 4 to 6 inches per
minute whereas the cylinder having a diameter of about 50
inches rotates at a speed of 150 to 600 rpm. The cylinder of
this diameter and speed produces a surface speed which is
about 10,000 times more than that of the flats. To alter the
carding power, only the speed of flats is changed while the
speed of the main cylinder remains the same. The direction
of movement of flats in old cards is kept towards the front of

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the machine while in modern cards it is kept towards the
back. The direction of motion of flats has no effect on the
carding power of the machine. For proper carding action,
the space distance between the flats and main
cylinder is very important. It should not neither be very
great where carding action is compromised nor very less
where fibre breakage may take place. For cotton fibres
usually spacing of 10/1000 is used.
Removal of Trash & Short Fibres
During the carding action between the flats and the main
cylinder the waste gets embedded into the interspacing
between the adjacent wires of the flats. The waste
includes mainly the short fibres, neps, trash particles
and dust. It is therefore very essential to clean off the
surface of the flats so that the carding action between the
main cylinder and the flats may not be affected. In old
carding machines manual cleaning was carried out by
stopping the machine after a specific period of time (4 to 6
hours). However in modern cards the waste removal off the
flats is carried out continuously with the normal operation.
Carding Power
The degree of carding or carding power achieved on a
carding machine can be expressed as:
Carding Power = Rotary Speed of Cylinder / Surface Speed of
Flats
Since the carding power does not only depend upon this
ratio, so instead the carding power of a card machine is more
effectively expressed in terms number of beating points

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presented per fibre. This can easily be found out by
averaging total number of fibres being fed in specific
time divided by the total beating points presented in that
same time.
Carding Power = Beating Points per unit time / Fibres Fed in
unit time
(3)
Doffing Region
Functions of the Doffing Region
(i) Transferring of fibres from the main cylinder on to the
doffer.
(ii) Stripping the fibre web from the doffer.
(iii) Gathering the fibre web into a twistless strand (sliver).
(iv) Condensing or calendaring the sliver.
(v) Depositing the sliver into the sliver can
The Doffing Operation
The cylinder is followed by a roller called as doffer. The main
purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form. The
diameter of the doffer is 24 to 27 and it rotates at a speed
of 20 to 60 rpm. The surface speed of the cylinder is about
20 to 25 times more than the surface of the doffer. This helps
to create a thick layer of fibres on the surface of the doffer.
The action between the cylinder and doffer surfaces is shown
below:
The Detaching Apparatus

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In old conventional card the detaching of the web from the

doffer is done by using an oscillating comb or doffer comb
that moves up and down at a rate of 2500 strokes per
minute. However in the modern high performance cards, the
web of fibres from the doffer is detached by using a
special detaching or stripping roller as shown in the figure
above because the reciprocating motion of the doffer cannot
be used at higher speeds.
The detached web is then passed between a pair of
calendar rollers or crush rollers placed on one another.
The surface of these rollers is smooth and a pressure is
applied in between these rollers. These rollers provide an
additional point of cleaning because any foreign matter
present in the fibres can be squashed and dropped off
at this stage. The crushed fibre web is finally subjected
to transverse belt sliver condenser. The opposite motions
of these transverse belts convert the fibre web into a
condensed strand of fibres commonly known as sliver.
Another way of converting the fibre web into a sliver
is by using a specially designed trumpet guide as shown

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below:
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver
form.
Depositing Sliver into Cans
The sliver produced by the card must be properly stored in
packages called as cans. Normally can used for sliver storage
are 48 inches with a diameter of 30, 36 or 40 inches. The
sliver coming from the transverse belt is passed through a
special spiral motion of the coiler calendar rollers which
helps to deposit the sliver in a spiral form.

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Draft
The degree of reduction in the linear density of the fibre
material is called as the draft. Draft can be expressed in two
forms:
(1)
Actual or Technical Draft
Actual Draft = Linear Density of Input / Linear Density of
output
(2)
Mechanical Draft
Mechanical Draft = Linear Speed of Output / Linear Speed of
Input
If the percentage waste removal during the carding
machine is (W) then the actual and mechanical draft are
related to each other as:
Mechanical Draft = Actual Draft (1 - W/100)
2.2.3. THE DRAWING PROCESS

The carding process is one of the most important process
in short staple spinning as it separates fibres into
individual form and also removes the remaining portion of
impurities left by the blow room. Despite of many
advantages of the carding process it has a big drawback of
producing variation and misalignment of the fibres within the
card sliver. The alignment and the slight parallelization
achieved at the carding region between the main cylinder and
flat largely disappears again because of the doffing action at
the doffer. During the transfer of the fibres from the cylinder to
the doffer hooked surfaces in the fibres arise. About 50% of the
fibres in the card sliver has trailing hooks, 15% fibres have
leading hooks and 15% of the fibres have double hooks and

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only a small portion (20%) of the fibres remain straight.
In order to produce a strong and uniform yarn it is necessary to
straighten and align the fibres and to improve the evenness of
the sliver. All of these objectives are achieved by the drawing
process carried out by a machine called as the draw frame. At
the draw frame a number of card slivers are drawn or
stretched between several pairs of rollers. As the fibres are
attenuated or drafted, the fibres are straightened and aligned
to the axis of the sliver in the direction in which they are
drawn.
Draw Frame:
Input: Sliver
Output: Regular Sliver
Finisher Draw Frame:
Input: Combed Sliver
Output: Regular Sliver
Functions:
1. To straighten the fibres and to make them parallel to the
central axis of the sliver. This is done by subjecting the sliver in
between several pairs of rollers with each subsequent pair of
rollers moving faster than the previous one. The drafting
tends to reduce the linear density of the sliver.
2. To improve the evenness of the sliver. This is achieved by
feeding more than one sliver at the draw frame and drawing it
together. The feed of multiple slivers is called as doubling. Most
commonly 6 to 8 sliver are fed to the draw frame and hence
a doubling of 6 to 8 is achieved. The doubling reduces the
mass variation of the sliver by averaging out the heavy and

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light sections of the sliver. The decrease in the linear density of
the sliver caused by drafting is balanced out proportionately by
combining a number of card slivers.
3. The doubling process at the draw frame in addition to
improve the evenness of the silver can also be used to blend
different origin of fibres. For example to obtain a 50:50 blend of
cotton and polyester fibres equal number of both cotton and
polyester card slivers must be doubled together provided
that the count of all card slivers is same.
4. To produce a proper weight of sliver required for the following
process. Doubling and drafting are the two main processes
employed at the draw frame. Drafting tends to decrease the
linear density of the sliver whereas doubling tends to cancel out
the effect of drafting. If drafting and double are of same
proportion then the drawn silver will have same linear density as
that of the card sliver. But if the drafting employed is more
than the doubling than the resultant drawn sliver will be finer
than the fed card sliver and vice versa. Therefore the degree
of drafting and doubling actually depends upon the required final
count of the yarn.
Draw Frame: Trutzschler TD 03-003 & Trutzschler TD-03-004
Main Parts of the Draw Frame

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The draw frames are built with one or two deliveries. The
single delivery draw
frame is more efficient and flexible but the double delivery draw
frames have the advantage of having twice the production
covering nearly the same floor area as that of the single delivery
draw frame. The double delivery draw frames also have a less
initial cost. A standard draw frame is divided into following
sections:
(1)
(2)
(3)
(4)
(5)
(1)
Creel Section
Drafting Section
Sliver Condensing Section
Coiler Section
Suction Section
Creel Section
Creel is the portion of the draw frame where the card sliver cans
are placed. The
cans behind the draw frame are placed in two most common
arrangements:
(i) The nested creel arrangement
(ii)
In-Line creel arrangement
In nested creel arrangement, the cans are placed in a
rectangular group. Such
an arrangement is exclusively used for single delivery draw
frames. On the other
hand the in-line creel arrangement has all the cans placed in a
straight line and
is mostly used for double delivery draw frames. Both the
arrangements are
shown below:

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The sliver coming out of each can is passed over a guide

plate and is fed to the main drafting rollers. The sliver is
either directly pulled by the drafting rollers or in order to
avoid unnecessary stretch it is pulled by power driven
rollers placed just above the cans. The creel also
sometimes has an automatic stop motion to detect sliver
breaks and on breaking of any sliver, the machine will be
stopped.
(2) Drafting Section
The drafting of the sliver at the draw frame is carried out
by roller drafting method in which the card sliver is passed
through two or more pairs of rollers. In modern draw frames the
top roller used are rubber coated and are called as cots while the
bottom rollers are steel rollers having fine flutes on their surfaces.
The cots exert pressure on the bottom rollers and their surface is
treated with antistatic material. The back cots exert less
pressure as compared to the next succeeding cot in the
drafting system.
The surface speed of each succeeding pair of roller is kept
more than the previous one. The slower pair of roller grips the
fibres whereas the next faster pair of rollers draws the fibres

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forward. This increases the length of the sliver and reduces its
linear density by a factor equal to the ratio of the surface speed
of the fast moving roller to the surface speed of the slow moving
roller. This ratio is called as mechanical draft.
The distance between the two pair of rollers is called as
drafting zone. The
distance between the nip lines of the two adjacent pair of rollers
is called the
roller setting. The first pair of rollers (at the feed end) is
called as the back
rollers and the last pair of rollers (at the delivery end) is
called as the front
rollers.
The roller drafting systems used on various draw frames are
of many types.
However every roller drafting system is named according to the
number of top
and bottom rollers it has. Draw frames are available with 4 over
4, 3 over 3, 4
over 3, 5 over 3 and 3 over 4 roller arrangements. All of these
arrangements
give good results when set appropriately. A 4 over 4 roller drafting
system is
shown below:

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The over 4 over 4 drafting system has four pair of rollers and
hence has three drafting zones namely the back zone, middle
zone and the front zone. The draft given in the back zone is called
as the break draft, the draft in the middle zone is called as the
middle draft and the draft given at the front zone is called as the
main draft. The break draft is always smaller than middle draft
and the main draft is always kept the greatest.
Break Draft = V2 / V1 Middle Draft = V3 / V2
Main Draft =
V4/V3
The total draft is the product of the individual drafts given in all
drafting zones.
Total Draft = Break Draft x Middle Draft x Main Draft Total Draft =
V2/V1 x V3/V2 x V4/V3 = V4/V1
Fibre Straightening During Drafting:
As the fibres are drafted out at the draw frame, the hooked
fibres are also straightened out. This is illustrated in below:

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In this example for simplicity three fibres are shown to be caught

between two pair of rollers. The roller pair (A) is moving at a
linear speed of 100 m/min whereas the roller pair (B) is
moving 5 times faster at 500 m/min. When the slower hooked
fibre (1) held by the nip of roller pair (A) comes in contact with
the faster moving fibres (1 & 2) held by the nip of roller pair
(B), the faster fibres (1 & 2) will tend to pull the slower fibre (1)
and the hooked end will be aligned with other fibres moving in the
same direction.
Roller Settings:
The roller setting which is the distance between the nip lines of
the two adjacent pair of rollers is mainly governed by the fibre
length. The roller setting is kept widest apart in the back zone
while it is narrowest in the front zone. This is due to the fact that
fibres in the back zone will have more hooks and a wider spacing
must be given in this zone to allow the fibres to attenuate and
grow. Since fibres reaching the front zone will have many of their
hooks removed by the previous zone so less wide roller spacing is
required here.
When adjusting roller settings, the distance between the
nips of the two adjacent rollers should be just wide enough to
let the longest fibre grow. If the spacing is too narrow, the longer
fibres will break. If the spacing is too wide then too many fibres

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will float in between the two draft zones. The floating fibres are
the ones which are not held by any pair of drafting rollers.
Floating fibres can bulge at a point to create thick and thin places.
The succession of thick and thin places along the sliver is called
as the drafting wave. Drafting wave may also be caused by worn
off cots and other machine imperfections.
(3) Silver Condensing Section
The flat fibre web (consisting of several card slivers) exiting the
drafting section
must be converted back into a web. The fibre web leaving the
front pair of
drafting rollers is passed through a converging tube and is guided
to a specially
designed condensing funnel called as the trumpet guide as shown
below:
The degree of condensing at the trumpet guide is essential for

providing a good fibre to fibre cohesion to hold them better
in a sliver. However if too much condensing is done then the
drawn sliver develops thick places.
After condensing of fibres at the trumpet guide back into a sliver
form, the sliver is passed through a pair of calendar rollers which
does a further compressing of the fibre mass and ultimately

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deposits the drawn sliver into a sliver can.
(4) Coiler Section
The drawn sliver coming out of the calendar rollers is passed
through a coiler tube fixed on a coiler plate. The coiler gears fixed
on the coiler plate help to rotate the coiler tube so that sliver can
be laid in the can in form of special coils.
The can rests on the rotating plate, with the rotation of the plate
that can also rotate. The rate of rotation of the can is kept slower
than the rate of rotation of the coiler tube. This helps in proper
deposition of drawn sliver in a spiral arrangement.
It is necessary to keep the sliver deposition rate slightly higher
than the sliver
delivery so that blockage of the sliver in the tube may be
avoided. However this
difference should not be too large where false draft may arise in
the sliver.
(5) Suction Section
As the fibres move swiftly over the surface of the drafting rollers,
dust and lint
may be dislodged into the air. The purpose of the suction system
on the draw
frame is to remove these particles so that they might not get
deposited on the
surface of the drafting rollers and also to maintain a dust and lint
free working
environment. The accumulation of the fibrous mass on the
surface of the rollers

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causes unevenness in drafting and sometimes also causes
sliver breakages
causing the machine to stop. A typical air suction system used on
the draw
frame is shown below:
2.2.4. THE COMBING PROCESS

Combing is an optional process in the processing of
short staple fibres necessary for the preparation of high
quality combed yarn. The process of combing is carried
out after carding and the combed sliver after passing
through the draw frame follows the regular path of yarn
formation.
The carded sliver still has some trash particles, neps and
short fibres in it. In addition to it, the individual fibres
in the card sliver are not well aligned longitudinally
and majority of them have hooked surfaces. The basic
purpose of combing is to remove short fibres and
remaining impurities and to make the fibres well
aligned and straight so that only long high quality long
fibres are used for yarn making a yarn. The carding

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process brings out following positive influence on the

yarn character:
(i)More uniform yarns and stronger yarns can be
made as compared to carded yarns.
(ii)
Owing to greater cleanliness and alignment of
the fibres, the combed yarns are much smoother and
have better lustre as compared to carded yarns.
(iii)
Combed yarns are less hairy and compact as
compared to carded yarns.
(iv)
Combed yarns can be spun into much finer counts
as compared to the carded yarns. Counts finer than
40 No are usually spun with combing where
uniformity and quality is required. However to make
stronger yarns, even coarse yarns are spun by combing.
(v)
The combed yarn requires less twist as
compared to carded yarns. So high quality knitted
fabrics are also made from combed cotton to have
better appearance and handle.
The combing process therefore results in an improvement in
the quality of the yarn and also enables the spinner to spin
finer yarn counts. However the above mentioned quality
improvements in the yarn are obtained at a cost of additional
machinery, additional process, extra labour and extra floor
space. This increases the cost of yarn production considerably.
Input: Lap
Output: Combed Sliver
Functions:
1. To separate the long fibres from the short ones. The longer fibres
are processed into a combed sliver whereas the shorter fibres

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are removed as a waste. Depending upon the quality of the yarn
required predetermined quantity of short fibres are removed
during the combing process.
2. To eliminate the remaining impurities and trash left by the
carding process. The amount of noil removed during combing
ranges from 5% to 25% depending upon the quality of the yarn.
3. Elimination of majority of the neps in the fibre material
4. To straighten and align the separated long fibres.
5. To create a combed sliver with maximum possible evenness.
Comber Lap Preparation

Since the main function of combing is to remove short
fibres, if the carded slivers are directly fed to the
combing machine, the waste extraction would be very
high and also lot of fibre breakage will take place. This is
due to the fact that fibre orientation in the card sliver is
very poor and also the card sliver has majority of
hooked surfaces. So it is desirable for the card sliver to
be prepared into such a form which is suitable for the
combing operation. For this reason a suitable lap with
straight and parallel fibres is formed which is
presented as a feeding material to the comber. The
majority fibres in the card sliver have trailing hooks
(about 50%). It has been established with experience
and experiments that better combing results are
obtained when majority of fibres presented to the
comber has leading rather than trailing hooks. This is
because the leading hooked fibres can be straightened
out better and they pass into the combed sliver

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whereas the trailing hooked fibres have less chances

of straightening and more chances of being removed as
a noil. In order to straighten and align the fibres and also
to convert the trailing hooks into leading position,
even number of machines must be used in the
preparation of a comber lap and most commonly
two machine processes are used. Straightening and
orientation of fibres is achieved by using roller drafting
method in both of the preparatory operations. The
total draft of both the machines ranges from 8 to 12.
Since the drafting tend to cause imperfections and
unevenness in the material, operation of doubling is also
carried out. The doubling not only helps to improve
the evenness of the material but also is necessary
to form a sheet of material which is converted into a lap.
Methods of Comber Lap Preparation
Commercially two systems of preparing the comber lap
are used:
(1) Lap Doubling System
(2) Sliver Doubling System
Lap Preparation Machine (Sliver Doubling
System): Toyota SL100 & Rieter E32

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Input: Regular Sliver

Output: Lap
In the sliver doubling process the carded sliver is given
first passage through a normal draw frame and then
series of drawn slivers are given second passage
through a sliver doubling machine.
The working principle of a modern sliver doubling
machine also known as the super lap machine is
shown below:

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The super lap machine has three feeding heads in the

creel portion with each head holding 16 to 20 draw sliver
cans. All the slivers coming from each feeding head is
passed through a vertically held 2 over 3 roller drafting
system. The lap sheet formed by the combination of
these drafted slivers are passed through a pair of
calender rollers and is ultimately wound on the lap tube
with the help of two working winding rollers.
Combing Machine(Rectilinear Comber): Toyota
VC5A & Rieter E76

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The rectilinear or cotton combers operate

intermittently because the short length of the fibres
does not allow continuous method of combing. One
end of cotton fibre bundle is combed with cylinder
comb or half lap having half of its circumference
covered with teeth while the other end is combed with
single row of needles called as the top comb. After
both ends of the cotton fringe has been combed
separately, the separated fringes are reunited by
a piecing unit. The standard parts of the comber are
shown in the figure below:

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The combing of the cotton fibres is carried out in

an intermittent cycle of operation called as the
combing cycle. In one combing cycle, the short fibres
are removed and the long fibres are passed forward into
a sliver. One combing cycle can be divided into many
phases:
(1) Feeding
The combing cycle begins with the feed of the lap. The
lap sheet is fed to the comber between the feed roller
and smooth cushion plate also called as the bottom
nipper. The top nipper or the nipper knife moves
down to fix on the bottom nipper (cushion plate).
Hence the lap sheet is gripped between the top and the
bottom nippers.

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(2) Cylinder or Half Lap Combing

As the lap is held by both the nippers, the half lap or the
cylinder comb rotates and the protruding fringe of
the fibres is combed with the help of needles
mounted on the cylinder comb. Any fibres not held by
the needles will be treated as short fibres and will be
removed as a waste during the rotation of the circular
comb. The waste (noil) is removed from the surface of
the needle with the help of a revolving brush mounted
just below the cylinder. The waste removed is then
collected by suction at the back of the comber.
(3) Piecing
As the half lap or circular comb has finished combing
and has cleared the fibre fringe, the detaching roller
remains stationary and does not rotate however only the
back top detaching roller rocks backward. At the same
time the top nipper is raised while the cushion plate
or bottom nipper rocks forward. Also the feed roller
rotates by a small and amount feeds a predetermined
length of lap. This increases the length of the lap fringe
and as the bottom nipper moves forward, the leading
edge of the lap fringe is entered into the nip of the

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detaching rollers and initiates piecing. During piecing

the top comb also starts descending.
(4) Top Combing

Just as the piecing has started, a top comb with one row
of needles is descended into the fibre fringe from the
above. As the combed web of fibres is pieced or
connected to the surface of the detaching rollers, the
detaching rollers now start
rotating forward and the combed web of fibres is pulled
through the top comb. As the fibres web is pulled
through the top comb, short fibres, neps and
entanglements not removed by the circular comb is
removed here by the top comb. As the bottom
nipper reaches its maximum forward position, the
detaching is completed because the detaching rollers
continue to move forward while the bottom nipper
begins to rock backwards. As detaching finishes the top
comb is withdrawn upwards.

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The feed roller again rotates and advances a new short

section of the lap to be combed by the bottom circular
comb and the same combing cycle continues.
On a modern comber the cycle of combing takes place 3

to 5 times in a second.
(5) Sliver Condensing & Drafting
The combed web taken by the detaching rollers is
delivered to the web pan having a trumpet guide on
its one side as shown below:
The combed web is pulled through the trumpet guide

with the help of a pair of calender rollers that converts
the web into a combed sliver. The combed slivers
coming from all the heads of the comber are laid side by
side and are passed through a draw box where a draft of
5 to 12 is given. Most commonly a 3 over 5 roller

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drafting is used where the rollers are inclined at an

angle of 60. The drafted slivers are coiled into
sliver cans. On modern combing machines, the sliver
cans are automatically doffed on completion.
2.2.5. THE ROVING PROCESS FRAME
The drawn sliver is composed of clean and straightened fibres
lying parallel to one another and to the axis of the sliver. These
characteristics of a drawn sliver are ideal for creation of a yarn.
However this is not possible because if the drawn sliver is to be
directly converted into a yarn it would require a mechanical
draft of a range of 300 to 600. But even on the most modern
machines technologically it is not possible construct a ring
frame that could give such high drafts in a single process. So
an intermediate stage of drafting is carried out using the
roving frame. The draft given at the roving frame reduces the
linear density of the drawn sliver into a less thick strand of
fibres suitable as an input to the ring frame. This roving which is
fed to the ring frame can then be easily converted into a yarn
by giving a draft of 15 to 40.
Another advantage of making roving is to have a better
package as an input to the ring frame. The roving frame
produces roving on compact small packages called as bobbins.
The bobbins are much more convenient to transport and have
less chances to get damaged as compared to the can sliver
mode of package.
Input: Uniform sliver/drawn sliver
Output: Roving

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Functions:
1. The basic function of the roving frame is attenuation or drafting
so that the mass per unit length of the sliver may be reduced
down to the extent which is suitable to be fed to the ring frame.
The range of draft given at the roving frame is 5 to 20.
2. After drafting the fine strand of fibres (roving) has very little
coherence and becomes unsuitable for further attenuation at
the ring frame. So a protective twist must be imparted to give
coherence to the fibres and to give strength to the roving. The
amount of twist given at the roving frame is low and ranges from
0.7 to 2 TPI.
3. The drafted and twisted roving has to be properly wound on a
package called as bobbin. This is done by the winding
operation at the roving frame. The winding operation is a
complex process which not only winds the roving on the bobbin
but also maintains a special built of the package.
Roving Machine: Rovematic AF

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A standard type of a roving frame has following sections:

(1) Creel Section
The creel is the area designated for the drawn sliver cans which
are positioned at the back of the machine. Just above the cans
number of independently driven guide rollers are provided

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that helps the sliver to move toward the drafting section.
Since the fibres in the drawn sliver have less coherence
so it is necessary to keep the surface speed of the guide
rollers equal to the surface speed of the back drafting rollers so
that any false drafting may be avoided that can damage the
sliver. Just before the drafting section a photo-electric stop
motion is used which detects the presence of the sliver and as
the sliver breaks it automatically stops the machine.
(2) Drafting Section
A typical drafting section of the roving frame is composed
of 3 over 3 roller arrangement. However some of the
machines also make use of 3 over 4 roller drafting
arrangement. Regardless of the type of roller arrangement the
bottom roller used is always a steel fluted roller while the top
roller is covered with some synthetic rubber covering. The top
rollers are pressed down with sufficient force on to the bottom
rollers to ensure proper grip of the fibres. A pressure of 100 to
250 N per roller is provided on the top rollers by using
mostly the spring pressure. However in addition to spring
pressure, pneumatic and magnetic weighting is also used by
some manufacturers. A simple 3 over 3 roller drafting
arrangement is shown below:

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Use of Condensers in the Drafting Section

Three specially designed trumpet guides or condensers are
used in the drafting section of the machine. First trumpet guide
also known as in-feed condenser is used just before the back
pair of drafting rollers and its purpose is to lead the sliver
properly into the drafting arrangement. The second trumpet
guide is used near the nip of the middle pair of rollers and the
third one is used just before the front pair of rollers. The main
function of the last two guides is to bring back the fibre mass
into a strand that tends to tear apart because of the drafting
action.

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The trumpet guides are usually mounted on a reciprocating bar
giving the sliver a traversing motion so that the wear of
the rollers may spread out gradually over the entire width of
the roller.
(3) Winding Section
The winding section comprises of a spindle and a flyer. A
spindle is a long steel shaft that acts as a support and a driving
element for the flyer. The flyer is a special component of the
roving frame that helps to insert twist in the roving. The spindle
is mounted at its lower end in a bearing which gets its drive
from the train of gears and transmits it to the flyer. Just around
the flyer a shaft is fixed around the spindle with a collar that
gets its drive independently from a separate set of gears. An
empty hollow package made of wood or plastic is mounted on
this shaft. The arrangement of a spindle and a flyer is shown
below:

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The winding portion of the machine with the help of the spindle
and the flyer meets the following two main objectives of the
roving frame:
(1)
Twisting
The sliver after being drafting out to form a roving

coming from the front delivery rollers have little fibre cohesion
among themselves and is weak to be wound on packages and
also may not sustain further drafting at the next stage of
processing i.e. the ring frame. So in order to give cohesion and
strength to the roving strand a small amount of protective
twist is given. The twist is imparted by using a flyer method
of twist insertion.
The roving coming out of the front delivery roller is threaded
through the top of the flyer, passes through its hollow leg
around the presser arm on to the bobbin. The presser arm
maintains certain tension on the roving which is necessary for
proper compact winding.
The flyer rotates with the spindle at a constant speed with each
revolution of the flyer inserting one twist in the roving strand.
The relation is given by:
Twist Per Inch = Flyer Rotary speed (rpm)/ Delivery Speed
(inches/min)
Since the rotary speed of the flyer is constant so the amount of
twist inserted per unit length depends upon the delivery rate of
the front delivery rollers. High values of twist cause production
loss along with difficulty in drafting at the ring frame. On the

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other hand very low twist makes the roving weak and it can
break during the package winding. The level of twist inserted
for cotton at the roving frame is about 0.7 to 2 TPI.
(2)
Package Winding
In order for the winding to take place on the surface of the

bobbin, the surface speed of the roving coming from the flyer
should be different from the surface speed of the bobbin. The
bobbin therefore is driven independently of the flyer and it
rotates with the collar around the spindle.
The Package Built
The roving coming out of the hollow leg of the flyer is
made to wind on a cylindrical package called as the bobbin.
The bobbin is either made of wood or plastic. The roving is
wound on the bobbin in such a way so that tapered ends on
both sides of the package are formed. The angle of taper
of the ends lies between 80 to 95 depending upon the
adherence of the material. By increasing the angle of taper,
larger packages are possible to make however the adherence
between the layers decreases. On the other hand low angle of
taper gives better adherence to the material but only smaller
packages are possible to make with it.

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Bobbin is an ideal form of a supply package to be fed to the ring

spinning frame because when full it can hold large length of
roving owing to its compactness and when empty it is light and
occupies small volume and is easy to handle and transport.
The Builder Motion
The above mentioned required package built is not easy to
construct. There are lots of complex mechanical
arrangements provided at the roving frame to achieve this.
Due to these special winding needs at the roving frame it
makes it a very complicated machine. The builder motion is
a device or series of mechanical arrangements necessary
to obtain a proper built of the roving bobbin. The builder
motion performs the following important tasks related to the
package built:
(1)
Controlling Bobbin Drive
During package winding with each new layer of roving wound

on the bobbin, the diameter of the bobbin increases which
causes the surface speed of the bobbin to increase as well.
However for a uniform package winding, it is absolutely

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essential to keep the difference in the surface speed of
the flyer and bobbin constant. Since the rotary speed of flyer
in a roving frame is kept constant so to keep this difference of
the surface speed constant, the rotary speed of the bobbin
is reduced proportionately with the increase in its diameter. The
reduction in the rotary speed of the bobbin originates from
a cone drum drive. With each new layer of roving wound on the
bobbin, the builder motion shifts the cone belt enough to
reduce the rotary speed of the bobbin so that its surface speed
may remain constant A simple arrangement of a cone drum
drive is shown in the figure below:
(2)
Controlling Lifter Motion of Bobbin Rail
The roving package is created by placing layer upon layer

of parallel coils of roving on the surface of the bobbin. The
built of the package is carried out in a precision manner where
each successive layer or coil of roving is laid in a precise
spacing to the previous coil. This can be achieved by
(i)
Raising and lowering of the flyer.

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(ii)
Raising and lowering of the bobbin
The flyer is never moved because by doing so the

unsupported length of the roving coming from the front
delivery roller to the top of the flyer will vary. Also the angle of
the roving from the front delivery roller to the flyer top will also
change. This can cause uneven winding tension and is not
suitable. So the only way to achieve a proper built of the
package is to move the bobbin up and down. For this purpose
the bobbins are supported by a movable rail that lifts and
lowers the bobbins as per requirement.
Since the package diameter is steadily increasing, the lift speed

must also be reduced by a small amount after the completion of
every layer. This is necessary because with a bigger diameter
of the package more length of roving will be
accommodated and the lifting and lowering of the bobbin
should be slowed down. To obtain this, the drive to the lifter
mechanism is also obtained from the same cone drum drive

YARN DIVISION
used for the bobbin. The lifter mechanism is also fitted with
a reversing mechanism so that the bobbin rail is alternately
raised and lowered so that the roving could be wound on the
entire length of the bobbin.
(3)
Formation of tapered ends
In order to form a special taper ends on the bobbin the height of

the lift through which the lifter motion is going to raise and
lower the bobbin is gradually reduced after each layer of
roving has been completed. For this the builder motion of
the roving frame is fitted with special micro switches that
perform this action.
Controlling the Roving Tension
The roving coming out of the lower end of the hollow leg of the
flyer passes over a presser arm. The presser arm has to guide
the roving from the lower exit of the flyer leg on to the
package. Before the roving could be wound on the package
it is wrapped two or three times on the presser arm.
The number of turns determines the roving tension. More

turns would mean greater roving tension and would result in a
harder and more compact roving package. However the tension
should not be kept so high where false drafts or roving
breakages may occur.
2.2.6. RING FRAME

YARN DIVISION
The ring spinning is the final operation in the formation of the

ring spun yarn. The basic purpose of the ring spinning frame is
to attenuate the roving until the required fineness of the yarn is
achieved. The ring spinning machine was first invented in 1828
in America. Since then a lot of modern modifications have been
carried out but the basic principle of operation and the
basic machine design remains the same. Even with the
introduction to new sophisticated spinning systems, the ring
spinning system is widely used and is the most popular form of
spinning system. The reason behind is the ability of this system
to produce very fine yarns which is not possible to obtain at the
moment with any other form of spinning systems. Only the rotor
spinning system provides good competition to the ring spinning
system which again cannot produce fine yarns of the order
produced by the ring spinning frame.
The initial and maintenance cost of the ring spinning is
quite high. The ring frame contributes about 60% towards the
final cost of production of the yarn. So every effort is being put
in to make modify the ring spinning machine to give more
productivity at a less cost.
Input: Roving
Output: Yarn
Functions of The Ring Spinning Frame
1. The basic function of the ring spinning frame is drafting.
Drafting is carried out to such an extent so as to achieve
desired fineness of the yarn. The drafting is carried out by
using a 3 over 3 roller drafting arrangement with double

YARN DIVISION
apron support. At the ring spinning frame a draft of 15 to 40 is
given (sometimes also up to 50).
2. The attenuated yarn formed by drafting is weak and lack
cohesion. In order to give strength to the final yarn, twist is
inserted. Twist is inserted at the ring spinning frame by
using the popular traveller method. The amount of twist
inserted in the yarn varies with the count of the yarn. To make
finer yarns, greater TPI is given and vice versa. The value of
Twist Multiplier (TM) at the ring spinning frame generally ranges
from 3 to 5.
3. The final yarn produced after drafting and twisting is
wound on special ring bobbins also called as cops. The
built of the package kept is such which is suitable for
storage, transportation and further processing.
Ring Frame: LUWA RXI240
Main Parts of The Ring Spinning Frame

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The ring spinning frames are double sided or double delivery
machines having up to 500 delivery points or spindles on each
side. Hence a single machine can have a capacity of up to 1000
spindles.
A typical ring spinning frame is divided into four zones:
(1)
Creel Zone
(2)
Drafting Zone
(3)
Twisting Zone
(4)
Package Winding Zone

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(1)
Creel Zone
The creel of the ring spinning frame is a simple device that
holds the roving. It is very important that the roving should
unwind properly and evenly to avoid any false drafts or roving
breakages. To facilitate proper unwinding the roving bobbins
are held vertically by inserting the roving bobbin on the bobbin

YARN DIVISION
holder placed at the upper portion of the frame. A typical
bobbin holder is shown in the figure below:
The upper end of the bobbin holder is suspended by a

bearing. The roving bobbin is pushed upward on to the bobbin
holder. Since the ring of the bobbin holder is attached to the
retainer device so as the bobbin is pushed upward, the ring will
also move upward causing the retainer device to grab the inner
portion of the roving bobbin tube.
As the roving is pulled forward by the drafting rollers, the roving
bobbin rotates and unwinding takes place. To avoid excessive
rotation to the bobbin, a brake arm is used to lightly press the
roving bobbin to restrict its motion.
(2)
Drafting Zone
Since the at the ring spinning frame greatest value of draft is

given, the drafting zone of the ring frame is the most important
part of the machine that directly influences the evenness and
strength of the yarn.

YARN DIVISION
All the modern ring spinning frame makes use of a 3 over 3

roller drafting with both the top and bottom middle rollers
covered with aprons. The bottom rollers are steel fluted and
are driven positively. The top rollers are covered with
synthetic rubber coating and are driven by the frictional contact
with the bottom rollers and are hence pressed down on the
bottom rollers with a considerable force. For this purpose the
top rollers are weighted by using spring, pneumatic or magnetic
weighting with the help of a pendulum arm. A total draft of 15
to 40 and in some cases even up to50 can be given at the ring
spinning frame. The distribution of draft in the back and front
drafting zone is very important as a proper draft distribution
helps to reduce the drafting wave problem. Practically the break
drafts should be given in the range of 1.1 to 1.5 and the
remaining draft is given in the main drafting zone. High
degree of drafting in the front zone will tend to create drafting
waves. To avoid this middle pair of drafting rollers is covered
with aprons. Aprons give support to the fibres throughout the
roller spacing between middle to front rollers not letting even
the shortest fibre to float. Apron systems are not perfect
but they help to drastically reduce drafting waves.

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Using Trumpet Guides
The strand of roving has few numbers of fibres in a crosssection and upon drafting even fewer number of fibres will
remain in a yarn. These fibres have hardly any cohesion
between themselves. Special fibre guiding elements are
therefore essential to carry out drafting without breaking
the strand. For this purpose specially designed trumpet
guides are used in the drafting zone to help keep the fibre
mass together and to avoid tearing apart of the strand.
Three trumpet guides or condensers are used one just before
the back pair of rollers, second in between the back and middle
rollers and the last just before the front pair of rollers. These
guides are mounted on reciprocating bar that oscillates
slowly so that the wear of the rollers may spread out gradually
throughout the entire roller width.
Overhang of Front and Middle Top Roller
As the twist is given to the yarn with the help of a traveller, the
twist must run back as close as possible to the nip line of
the front rollers. But it never penetrates completely to the
nip because at the nip the fibres are diverted inwards and
are made to wrap around the surface of the roller. So at the exit
point of the front pair of rollers there is always a small
triangular mass of fibres which remain without twist, this is
called as the spinning triangle. This triangle bundle of fibres will
remain without twist during twisting and create a weak point in
the yarn and hence breakage rate of the yarn during spinning
increases. The effect of spinning triangle is enhanced at the ring

YARN DIVISION
spinning frame where greatest draft along with greatest twist is
applied.
So in the ring spinning drafting arrangement the front top roller

is deliberately kept 2-4 mm forward relative to the bottom
front roller while the middle top roller is kept 2-4 mm
backward relative to the middle bottom roller. This type of
arrangement gives smooth running of the top roller and helps to
reduce spinning triangle and ultimately the breakage rate
during the spinning process is reduced.
To further enhance the flow of the fibre strand

through the drafting arrangement, the drafting roller instead
of being placed in a straight horizontal line as depicted from the
above figure, they are arranged at certain inclination.
(3)
Twisting Zone

YARN DIVISION
The yarn leaving the front pair of drafting rollers is threaded
through a guide also called as the lappet guide that is placed
directly over the spindle axis. The yarn then passes through a
traveller on to the yarn package (cop). The traveller is mounted
on the ring encircling the spindle. The cop is mounted on the
spindle and rotates with the spindle. When the cop rotates the
tension on the yarn pulls the traveller to rotate around the ring.
Due to the friction created between the traveller and the ring
and also due to the air drag created by the balloon
formation at the winding section, the rotary and surface speed
of the traveller is slightly less than that of the spindle and is
given by:
RPM of Traveller =RPM of Spindle - Delivery Speed / x
Package Dia
So in one rotation of the traveller one twist is inserted in the
yarn. Since the difference between traveller and spindle
rotary speed is very small so this difference is ignored.
Thus for calculating twist rotary speed of the spindle is
considered, mathematically:
T.P.I = Rotary Speed of Spindle (rpm) / Delivery Speed
(inches/min)
The ring/traveller arrangement and the spindle are also very
important elements of the ring spinning frame because it not
only helps to insert twist in the yarn but also helps in the

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winding of the package.

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The Ring
The rings are supported on the raisable and lowerable ring rail.
The ring should have a tough, hard and smooth surface. For this
purpose flame hardened steel, nitrided steel, carbo-nitrided
steel and chrome steel is used. The hardness of the traveller
should be less than that of the ring so that wear mainly occurs
on the traveller which is cheaper and easier to replace. On the
basis of working sides of the ring, rings can also be classified
as:
(i)
Single Sided Rings
(ii)
Double Sided Rings.
Double sided rings have the advantage of having two working

sides. When one side gets abraded the ring can be turned
over so that the other side can be used. Whereas when
single sided rings get damaged, they have to be replaced by
new ones. However double sided rings are not used anymore
because when it is time for the ring to be turned over, the other
side of the ring will become unstable due to corrosion and
rusting and cannot be used.
The Traveller
The traveller is an important element of the ring frame as it
imparts twist on the yarn and also helps in winding the yarn on
the cop. The traveller does not have a drive of its own but is
dragged along with the yarn as it gets wound on the cop due to
the rotating spindle. As the traveller moves at a high speed on
the ring it creates lot of friction that generates significant
amount of heat. So in order to cope up with such frictional

YARN DIVISION
forces the material used for traveller should exhibit the
following properties:
(i)
Generate as little heat as possible.
(ii)
Should dissipate heat quickly to the ring and the air.
(iii) Should be elastic so that it might not break.

(iv)
(v)
Should have high wear resistance.

Should have less hardness than the ring.
To meet these requirements, the traveller is made exclusively of

steel having its surface either electroplated with nickel and
silver or treated with chemicals to increase wear and reduce
friction.
Different types and varieties of yarns can not be spun
using a single type of traveller. Therefore travellers come in
many different varieties. The differences among travellers are
found in shape, mass, wire profile and yarn clearance (bow
height).
The traveller is shaped according to the ring so that single point

of contact with greatest possible surface area with the ring can
be achieved. The height or bow of the traveller should be as low
as possible to keep the centre of gravity low and to ensure
smooth running. However the bow should be not so small where

YARN DIVISION
the yarn starts getting abraded which can damage the yarn
hairiness.
Another important parameter of the traveller is its mass.
The mass of the traveller directly influences the frictional
forces between itself and the ring. The mass of the traveller is
selected according to the yarn count being spun. If the traveller
is too light for a specific yarn count then tension created on the
yarn will be low resulting in a loose softly wound cop and also
the size of the balloon increases. On the other hand, if the
traveller is too heavy then it causes excessive tension on
the yarn and cause frequent yarn breakages.
Limitations of Traveller/Ring Arrangement
The greatest limitation faced by ring spinning frame is its
incapability to further increase its productivity and speed. This
is mainly due to the use of traveller ring arrangement. At high
speeds the traveller generates significant amount of heat due
to friction with the ring. If the speed of the ring frame is to
further increase, owing to a very small mass and size of
the traveller, dissipation of heat generated by the traveller
is not possible. Thus the operating speed of the traveller
and the ultimately the entire machine is limited. Currently the
spindle of the ring frame is capable of running up to 30,000
rpm but the use of traveller permits the speed only to be raised
up to around 22,000 rpm. Another way of increasing the
speed of the ring frame is by using ring with smaller
diameter so that spindle speed can be further increased
without increasing the frictional forces on the traveller/ring.

YARN DIVISION
However by doing so smaller packages will be formed and they
will have to be doffed more frequently. This can decrease the
productivity of the machine. However this problem can be
rectified by using automatic doffing devices.
To put into a nutshell, there is a very small room as far the
speed advancement
in the ring spinning frame is concerned. However
measures like automatic doffing, use of precision
instruments and precision components (specially ring and
traveller), increase in the number of spindles per machine to
reduce cost per spindle and automatic linkage of ring frame
with the winding machines will help the ring spinning frame to
be economically viable to use for years to come.
(4)
Package Winding Zone
The yarn after being twisted by the traveller has to be properly

wound on the entire length of the package called as the cop. In
order for the winding to take place there should be a difference
in the surface speed between the spindle and the traveller. The
traveller has no drive of its own instead it is carried along with
the yarn which is being wound on the cop after passing through
the traveller. The frictional forces between the spindle and the
traveller and also the air drag because of the balloon
formation between the lappet guide and the spindle makes
the surface speed of the traveller less than that of the
spindle. This automatically fulfils the requirement of
winding. The traveller and the spindle cooperate with each
other to perform winding.

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In order for the yarn to be properly wound on the entire length
of the cylindrical ring bobbin (cop), the ring is raised and
lowered which is mounted on a longitudinal ring rail.
The Spindle
Spindle is a very important component of the ring frame, it not
only supports the cop and helps in winding of the yarn on it but
also gives motion to the traveller. The spindle and the traveller
therefore work in close cooperation with each other to perform
both twisting and winding.
A spindle is a metallic shaft that holds the yarn package or cop.
The spindle is divided into two main parts namely the upper
part and the bolster.The upper part is made of aluminium alloy
and is slightly tapered to firmly hold the package. The bolster or
the lower part is secured in a bearing to rotate freely and is also
connected to the ring rail by means of a nut. The drive to the
spindle can either be given with the help of tapes or belts in
group form or in individual form where one motor is supplied
per spindle.
The upper part is made of aluminium alloy and is slightly

tapered to firmly hold the package. The bolster or the lower part
is secured in a bearing to rotate freely and is also connected to
the ring rail by means of a nut. The drive to the spindle can

YARN DIVISION
either be given with the help of tapes or belts in group form or
in individual form where one motor is supplied per spindle.
Package Built of Ring Spinning Frame
A typical form of a package produced by a ring spinning frame
is called as the cop. The package is produced on a tube of
paper, card board or plastic material. About 10 mm of the tube
is left free of the yarn on both upper and lower ends. The tube
has a slight taper corresponding to the taper of the spindle so
that the package can be firmly secured on the spindle.
2.2.7. WINDING
The quantity of yarn on the ring spinning bobbins or cops
is very small as compared to the size of the package
required for efficient processing at the knitting and weaving
process. In addition to the small package size, the ring
bobbins are also full of spinning defects i.e. thick and thin
places.
So the process of winding involves unwinding of the yarn
from the spinning packages i.e. ring bobbins and winding it on
to a new bigger package. During the formation of the new
package, spinning faults i.e. thick and thin places are also

YARN DIVISION
removed. Two types of packages can be produced by
winding machine i.e. cheeses or spools (rectangular or
parallel side packages) and cones (tapered side packages).
But the type of package build within these two types of
packages can vary depending upon the end use of the package.
It appears that winding process is just a simple process
where the yarn is unwound from the ring bobbins and again
wound on the new package and it seems that winding has no
great significance but this is in fact not true. Suppose if we use
ring bobbins directly in the process of weaving or knitting,
then following problems may arise :(i) The ring bobbins will keep on exhausting very quickly and
lot of time will be wasted in replacing the empty bobbins
with new ones.
(ii)
The ultimate fabric produced by using ring bobbins
will have defects and a lot of time and resources will go
wasted.
(iii)
Because of the thin places in the yarn, threads will
break more frequently during the fabric formation and thus
efficiency and production will suffer.
(iv)
All these points make the winding process very
important. Even though it is an extra and expensive
process for the preparation of a suitable package for fabric
formation but still it proves its worth.
Inputs: Yarn
Outputs: Yarn on cone
Functions:
1. To prepare a bigger package having a sufficient length of yarn
on it.

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2. To remove spinning faults e.g. tick and thin places.
3. To improve the quality of yarn.
4. In some cases, the yarn is also treated with certain
chemicals or dyes during the winding process. Waxes are also
applied to the yarn to reduce the abrasion and friction during
the winding process.
5. To produce a package of required density and shape suitable for
the next stage of processing.
Winding Machine: Muratec Magazine Type Autoconer
Types of Winding Packages

Two types of packages can be produced by winding machines:(1)
Rectangular or Parallel Side Package.
Rectangular or Parallel side packages are called as cheeses or

spools. Cheeses or spools are produced by slow conventional
type of machines. Parallel side packages are also suitable
for fibres and for those yarns where the desirable length on
the package is not very long. This type of package is also
suitable when the package has to be dyed. The Parallel or
rectangular side packages may or may not have flanges.
(2) Tapered Side Package

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The tapered side packages are called as cones. Cones are
produced by high speed winding machines like the autoconer.
Components of Winding Machine

The old conventional winders are quite simple machines where
majority of the necessary mechanisms being of mechanical
type. On the other hand, the modern automatic winding
machines are equipped with variety of electronic devices
and computerized control panels to achieve high speeds of
winding at a better quality. Furthermore arrangement of
automatic bobbin creeling, automatic doffing and auto joining
of the broken threads are also provided on these modern
winders. Illustration of a high speed winding machine is given
below:

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Typically a modern high speed winding machine is divided into

following zones:
(1)
Creel Zone
Creel is the part on which ring bobbins are held. The creel is
designed so that
it should assist in continuous uniform unwinding of the
yarn at high machine speeds which in case of modern winders
can go up to 1500 metres per minute. Each creel also has some
sort of balloon controller which is made up of metal and does
not allow bigger balloons to get formed during unwinding.
The unwinding of the yarn from the package is called as the
withdrawal of the yarn or package
(2)
Tension Zone
Tension zone performs the following two main objectives:

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(i) To apply a uniform tension on the yarn so that
uniform package with required density can be obtained.
Greater the tension on the yarn,
more compact and
dense package can be obtained. However the

of
amount
tension to be applied on the yarn depends upon the
count.
(ii) The tension on the yarn helps to remove thin or weak
places in the yarn. To remove thin places, a sufficient
tension for a certain count of yarn is applied uniformly. This
tension will cause the thin or weak places in the yarn to
break however the regular yarn will not be affected. In this
way, these faults are removed. The amount of tension
applied should be about 10 to 15% of the single yarn
strength.
The tension on the yarn is applied by passing it through a
tensioning device or tensioner. Tensioners come in variety of
shapes and techniques however conventionally a disc type
tensioner is used in which the yarn is passed through two disc
plates and a sufficient pressure is applied to the plates. The
amount of tension produced in this case would be directly
proportional to the amount of pressure on the discs.
(3)
Clearing Zone
The purpose of the clearing zone is to eliminate yarn

defects such as thick places, thin places and slubs. In old
winding machinery mechanical clearers are used. These
clearers or slub removers are composed of fixed blade with
very little distance left for the yarn to pass beneath or over it.
As a thick place or slub comes, the blade cuts it off the

YARN DIVISION
surface of the yarn. Mechanical clearers are either flat blade
or ring blade type as shown below:
Mechanical clearers are very difficult to adjust; they are not

reliable and durable and make the yarn surface harsh and hairy.
Due to these limitations they are no longer used on modern
winder. Instead electronic clearers are used. The electronic
clearers either work on optical or capacitance principles.
These clearers are very efficient, reliable and durable as
compared to mechanical type and even the slightest of
variation can be detected and removed by them which is not
possible in mechanical type.
When optical principle is used then we use photoelectric cells. A
light source is generated by the emitter or the transmitter and
is passed through the yarn and received on the other end by
the receiver. The amount of light received after passing through
the yarn is translated into an electric current. For example, for
coarse yarn less light and for fine yarn more light will be
received. The Electronic clearer is set for a particular count of
yarn and if any slub or thin place comes on the yarn, it is
detected by variation in the light and hence it is removed by the
cutter.

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In case of capacitance type electronic clearer, the yarn is

passed over a capacitance device which constantly measures
the capacitance of the yarn and translates that capacitance into
an electric current. The capacitance of the yarn depends upon
the moisture in the yarn which in turn depends upon the
number of fibres in a cross-section i.e. for fine yarns,
capacitance will be low and for coarse yarns it will be high. The
clearer is set according to the count, when any variation in
capacitance that exceeds a certain limit is detected, the cutter
cuts the thread and in this way both slubs and thin places are
removed.
(4)
Yarn Joining Zone
During the winding process, breakage of threads may take

place. As the yarn breaks, the stop motion installed on the
machine causes the machine to stop immediately.
The modern winders make use of optical sensors for stop
motion. The yarn is passed through a pair of sensor having
a transmitter and a receiver. The transmitter transmits light
which can only be received by the receiver when there is
no yarn between them i.e. when the yarn breaks. As soon

YARN DIVISION
as the receiver starts receiving the light, the machine is
stopped immediately.
Whether the yarn is deliberately cut due to the action of clearer
or it accidentally breaks, the stop motion installed on the
machine will immediately stop winding. As soon as the machine
is stopped, the two broken ends of the yarn must be pieced or
joined together as soon as possible so that the machine
can be immediately started again. The piecing of the broken
ends can be carried out by following methods:
(a) Knotting
In this method, the two broken ends of the yarn are
knotted together by a regular knot. The knotting of the
threads may be carried out manually by hand or by automatic
knotting machines. One or more than one automatic knotters
may be used per winding machine. It is always desirable to use
each separate knotter for each spindle, but this increases the
machine cost considerably. So the general practice is to use one
knotter for 10-12 spindles. The knotter will move or patrol
these spindles in a reciprocating manner and whenever it
finds any spindle stopped, it repairs the broken ends by
knotting.
The method of knotting is considered to be an old method
and it has many drawbacks:
(i)
The presence of knot in the yarn will increase its diameter
at the point of a knot. This increase may be 3-4 times the actual
yarn diameter.

YARN DIVISION
(ii)
The knot sometimes makes it difficult to pass the threads
through various components of loom and needles of knitting

machine.
(iii) Knots can be clearly visible in the fabric degrading its
quality.
(iv)
These knots also reduce the life of knitting needles and
loom components through which the yarn is passed.

(b)
Splicing
Splicing is a modern method of joining the broken ends.

The machine component that does splicing is called as the
splicer. The procedure of splicing is as follows:
(i)
Both broken ends of the thread are collected by splicer
arms by means of air suction.

(ii)
Each broken end is untwisted by applying twist in the
opposite direction to the twist in the yarn.

(iii) Both broken ends of the yarn are placed on each other.
(iv)
They are joined together by twisting and slight stretching.
The use of splicing has many advantages over the knotting:

(i)
The diameter of the spliced yarn does not increase more
than 25% of the actual diameter.

(ii)
The splices in the yarn are less visible in both the yarn
itself and the fabric made out of that yarn.

(iii) The spliced yarn can easily pass knitting needles and loom
components without damaging or increasing the wear of these
components.
The most efficient system would have one splicer per spindle.
Such arrangement will make the cost of the winding
machine very high and also the cost of maintenance will

YARN DIVISION
increase. It is a general practice to have one splicer for small
group of spindles e.g. one splicer for 10-12 spindles. Either the
spindles move towards the splicer or the splicer moves
towards the spindles. Commonly the splicer moves in a
circular path or in a straight reciprocating path covering the
specific number of spindles.
(5)
Winding Zone
The yarn after being cleared from spinning faults has to be

wound on packages of suitable shape, size and built. This is
done at the winding zone. The winding packages can be either
in the form of cheeses (rectangular side packages) or cones
(tapered side packages). However within these two types of
packages, the package built can vary depending upon the end
use of the package. Two types of package builds are possible at
the winding machine:
(1)
Precision Package Built
The precision package built can be obtained by placing coils of

thread side by side parallel to one another and at a small
predetermined and precise distance. In order to obtain such
package built, it is necessary that the package should have
flanges on its sides; otherwise the package will not be stable
and would collapse. If the package does not have flanges, then
this package built can still be use by giving a small taper to the
package on both sides In order to place the successive layers of
thread parallel to each other on the package, a to and fro
movement must be given to the yarn by using linear
traversing guides. In each revolution of the machine, the
traversing guide moves by a very small precise distance so that

YARN DIVISION
the next layer of the thread may be wound parallel and close
to the last layer.
The distance between the two successive layers of thread

is called as the pitch or gain. The density of the winding
package depends upon the pitch. Minimum pitch would
give the maximum dense package. The pitch can be
determined and controlled by the linear movement made by the
traversing guide in each revolution. The winders that give
precision built to the package are also called as spindle driven
winder since drive to the package is directly obtained from
a rotating spindle.
(2)
Random Package Built
In this type of package built, the successive coils of the thread

are wound at a considerable helix angle so that the layers cross
each other to give stability to the package. Here the pitch
between the successive layers and the angle of wind of each
layer is considerably high. Also the packages used do not have
flanges on the sides. This high pitch and high wind angle does
not make the package unstable.

YARN DIVISION
The winders that give random package built are also called as
random winder. Since the random winders make use of grooved
drum for winding, they are also called as grooved drum
winders. The package on such winding machines is driven
by the frictional contact of the rotating drum with the
package. No traversing guides are used in this case because
the grooves in the drum cause the yarn to traverse on the
package.
Auto Creeling and Auto Doffing Devices
Removing of the supply package (ring bobbin) when it is
emptied and replacing it with a new full supply package
(ring bobbin) is called as the process of creeling. On old
conventional machines this process is carried out manually by
hand however on the modern winders, arrangements
are given that automatically does the creeling process.
The creeling arrangement does the following necessary
tasks:
(i)
Stops the machine when the supply package exhausts.
(ii)
Removes the empty bobbin tube and ejects it into a
special
compartment.
(iii) Inserts a new supply package from the creel.

YARN DIVISION
(iv) Performs the piecing of the thread.
(v)
Restarts the winding process.
Similarly removing the full wound package (cone or cheese)

when the required package size is obtained and replacing it with
a new empty one is called as the process of doffing. The
automatic doffing installed on the modern winders performs
the following functions:
(i)
Stops the machine when the required size of the package
is wound.
(ii)
Removes the full winding package and transfers to a
conveyer belt.
(iii) Places an empty tube into the cradle
(iv) Pieces up the yarn on the new package.
(v)
Restarts the winding process

YARN DIVISION
3. POSTSPINNING

YARN DIVISION
3.1. Yarn Conditioning

Conditioning plays a major role in determining both knitting and
weaving performance of the yarn. In knitting, conditioning helps
in maintaining the proper unwinding tension, reduce end breaks
through improvement in elongation and through considerable
reduction of fluff
liberation. Whats more, conditioning of the yarn gives the knit
fabric a soft, bulky feel.In weaving, size pickup improved after
conditioning implies high weaving efficiency andcontrolled
tension in positive weft feeders assures a minimum of 1-2%
increase in weftinsertion efficiency.
The normal moisture content of cotton is around 6-6.5%. After
converting to yarn, cotton has only 4% of moisture. A
conditioning machine by the name of imparts required amount
of moisture and strength to the yarns. It uses steam, high
temperature and pressure. Steam penetrates into the material
and increases the strength of the yarn. If conditioning of yarn is
not done, problems like snarling and end twists can occur.
Objective:
1. Increase weight and strength of the cone.
2. Increase absorption capacity of dyeing agents.
Yarn Conditioning Machine: Seiger YCP

YARN DIVISION
Sieger YCP Conditioning is carried out by Cold Saturated Steam

generated inside the plant. Steam is generated in accordance to
the vapour pressure curve of stream, to maintain homogeneity.
Material
Temp. 0C
Cotton Waxed 55- 60

Cotton Unwaxed
60- 80
Soak Time
25-30
20-25
min
o
o
o
o
Capacity: 350-400 kgs

Production/ Day: 7.5-8.5 tonnes
Heating options: Electrical/ Steam/ Dual
Material Loading: Manual
Advantages:
Optimum moisture gain

Additional weight realisation upto 2.5%
Fly and fluff liberation reduced upto 60%
Higher elongation and work capacity for yarn
Improved knitting and weaving performance
Reduced snarling
Total time
55 min
60

YARN DIVISION
3.2. INSPECTION
Final physical inspection by quality assurance personal of every
cone prior to packing with the aid of UV light is done.
The cones are brought in on the same cone trolley and taken
into the UV room which is completely veiled on all sides and has
various UV light sources. The UV room has a transparent
window-like arrangement from where the concerned operator
observes the variations, if any, present in the cones. The UV
light is utilized in checking for slubs and neps in the cone
package.
Only one operator per shift is present for the UV checking.
The UV room is conveniently located between the Yarn
conditioning facility and the packaging area. Being the
intermediate process and requiring very little space.

YARN DIVISION
The board outside the UV Checking room(left) and the view from outside in a
UV Checking room
3.3. PACKING
After yarn conditioning and UV checking, the cones which pass
proceed to be packed in order to be sent on for delivery. The
packing and transferring data is fed simultaneously into the
computer as processes occur. The packaged material is then
stacked into the storage, from where it is loaded onto trucks to
be taken for shipping out.
Sample Sticker on all Cones
Materials used:

YARN DIVISION
o Polythene bags
o Cartons
o Transparent Tape

YARN DIVISION
4. PROJECT

YARN DIVISION
4.1. PROJECT :
Variation in Quality by Changing the Tension of the
4.1.1.
Sliver in Finisher Draw Frame

ABSTRACT
Sliver has a huge impact on yarn quality parameter like

evenness, imperfection index, Cvm%, U% of yarn. The
study was performed on 0.12 hank card sliver which was
used to produce 26/1 Ne carded yarn. The position of cans
in the finisher draw frame were Normal (N), H shape and A
shape respectively. The paper is to find out whether the
change of position of can (i.e. variation in tension) has any
effect on yarn quality or to find out the suitable position of
the cans.
4.1.2.
INTRODUCTION
In processing in the spinning mill, the unevenness of the

product increases from stage to stage after the draw
frame. There are two reasons for this. Firstly the
number of fibres in the section steadily decreases.
Uniform arrangement of fibres becomes more difficult
because of their smaller number. Secondly each drafting
operation increases the unevenness. Each processing
stage is a source of faults. Drafting arrangements, in
particular increase unevenness considerably. In order,
finally, to achieve a stable yarn the process must include
operations that give an equalizing effect. These can be
doubling, levelling, and drawing. In general doubling

YARN DIVISION
means the increase in weight per unit length. Doubling
is a process used in yarn manufacturing by which a single
product is produced from a several intermediate feed
product. For example, sliver doubling where 4 to 8 slivers
are fed to draw frame and 1 sliver is delivered. On the
other hand, draft is to reduce the linear density of a
fibrous assembly by drawing. This process is called
drafting and drafting operation increases the
unevenness. The function of draw frame is to provide
doubling and drawing at the same time. The paper is to
find out whether the change i n t h e t e n s i o n of s l i v e r
has any effect on t h e u n e v e n n e s s o f t h e yarn.
4.1.3.
FINISHER DRAW FRAME
Draw frame is very important for equalizing. This means

well distribution of different fibres with their same or
different properties all along the length of the delivery
sliver. The main purpose of draw frame/finisher is blending
and elimination of mass variation of the delivery sliver Mass
variation is reduced if there are a few thick places and some
amount of thin places in the same zone. If this kind of set
up does not arise the task of elimination of mass variation
completely depends on the auto leveler. Thus a very good
blending of fiber can be achieved. When doubling and
drawing are combined, the input materials are
doubled
to reduce the long-term errors; however, new
errors of shorter wavelengths are added as a result of the

process of elongation. There is an exchange of relatively

YARN DIVISION
long-term for short-term error.
4.1.4.
MATERIAL AND METHOD
The carding machine produces card sliver. Then the card

sliver cans are fed to the breaker draw frame. The breaker
draw frame sliver cans are then fed to the finisher draw
frame. In finisher draw frame different position of cans
were used and for each sample roving in simplex machine
were made and finally yarn was made in ring frame. After
producing yarn we test the quality of yarn through Uster
Tester 4-SE and Uster CLASSIMAT 3 V2.10
4.1.5.
EXPERIMENTAL PROCEDURE
The target is to get finisher sliver made from 3 different

can position that is Normal, A and H shape. Those above
mentioned sliver from each set of finisher draw frame
sliver were prepared. Finally 30 cans finisher drawn sliver
of 3 different positions of can were achieved. Then one
Rovematic-AF was selected for roving. There are 3 samples
each having 10 cans. Spindle no 111 to 120 of RovematicAF machine were used for sample 1. For every sample
those same spindles of same Rovematic-AF machine were
used. 30 Spindles (approx 300 gms each) of each sample
were produced. In one particular ring frame LUWA RXI240,
from spindle no-01 to 30 the roving for each samples were
fed. Finally 180 ring bobbins in 3 different samples each

YARN DIVISION
sample has 60 bobbins (approx 50 gm each) were made.
Than tested those samples with the help of Uster tester-4SE. The bobbins were winded onto 7 cones of total 120
kms each sample and tested under Uster CLASSIMAT 3 ver
2.10 which requires 100 kms of each sample.
Different colour of can, spindles, bobbins and cones for
separate different position can, roving and ring yarn were
used.
(1)
Finisher Draw Frame- Trutzschler TD 03-003:
Different Position of cans:
NORMAL
Position
A Position

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H Position
(2)
Roving Frame- Rovematic AF
(3)
Ring Frame- LUWA RXI240

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(4)
Winding Machine- Muratec Auto Coner (Magazine
Type)
(5)
Test Methods:
(i) Uster tester-4-SE

YARN DIVISION
(ii)
4.1.6.
Uster CLASSIMAT 3 ver 2.10
DATA ANALYSIS
Process
summary:
Position
of Can at
finisher
draw
frame
Number
of finisher
cans
produced
Number
of roving
produced
(bobbins)
10
30
10
30
10
30
Number
of yarn
produced
(cones)
10
10
10
10
10
10
10
10
10

YARN DIVISION
Table 1: Uster tester result for 26/1 Ne carded ring spun
yarn:
Sample
Numbe
1
Can position in
finisher draw
frame
N
U%
Cvm%
8.2
8
8.3
2
8.2
6
10.5
0
10.5
0
10.4
3
Table 2: Uster CLASSIMAT 3 ver 2.10 result for 26/1 Ne

carded ring spun yarn:
Sampl
e
1
4.1.7.
Can position in
finisher draw frame
N
Total faults
43.9
29.9
32
OBSERVATIONS
Results Report: Annexure Attached*
During the production it was observed that the sliver

breakage increased as we changed the position of the
cans to A since the tension was high and the sliver is a
very delicate material. So irrespective of the variation in
quality it was not feasible for the production.
Position H had a slight increase in the sliver breakage
which could be handled by the same amount of staff
Yarn breakage during the last stage of production was
irrespective of the position of the can.
4.1.8.
CONCLUSION

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This experiment shows that sample no-3 means H

shaped can position is a good position in carded ring
yarn production. Considering U% and Cvm% sample-3
does not show the best result. The U% and Cvm% value
of other sample are very close to sample-3 value. But in
Classimate 3 results sample 2 and 3 showed good
results. Considering the fact that sample 3 i.e. Can
position H is easy to produce and is close to A so
sample 3 would be a good position for cans. Spinning
mill which is looking for very good quality yarn should
try this setup.

YARN DIVISION
REFERENCES
o Websites:
www.textilelearner.blogspot.com
www.cottonyarnmarket.net/OASMTP/Trutz
schler%20auto%20leveller%20Draw
%20Frame%20TD
%2003%20%E2%80%93%20Manual.pdf
o Operation Manuals
- Provided by Technocraft

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TEXTILE INTERNSHIP

TECHNOCRAFT INDUSTRIES PVT. LTD

NATIONAL INSTITUTE OF FASHION TECHNOLOGY,

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

On the textiles front, Technocraft envisions to be one of the

COMPETITIVE STRENGTHS OF THE

TECHNOCRAFT INDUSTRIES PVT. LTD

COMPANIES UNDER TECHNOCRAFT INDIA

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

THE YARN DIVISION

In 1997, Technocraft diversified into manufacturing of Cotton

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

CORPORATE SOCIAL RESPONSIBILITY

As a part of corporate social responsibility, Technocraft has

In the domestic market they face competition from both the

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

1.2. PLANT LAYOUT

1.3. PROCESS FLOW

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

2.1. RAW MATERIAL

The company sources its cotton from a variety of

Aashirwad Cotton Corp., Ahmedabad

Sri Bhagyodaya Cotton Company, Ahmedabad

TECHNOCRAFT INDUSTRIES PVT. LTD

2.2. PRODUCTION DEPARTMENT

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

In cleaning, it is necessary to release the adhesion of the

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

Trutzschler Blendomat BO-A & Trutzschler

Vetal Scan Polysensor

Trutzschler Dustex SP-DX

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

Extract material evenly form bales.

Top Feeder: Trutzschler Blendomat BO-A

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD

The bales (1) are positioned along the machine. Light

TECHNOCRAFT INDUSTRIES PVT. LTD

TECHNOCRAFT INDUSTRIES PVT. LTD