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Newsletter - Volume-16, Issue-2, AUGUST-2016  

Replies from the readers

Why Start up breaks found higher in Compact spinning when compared to normal spinning? What are the remedies to overcome the same?

Mr.T.Paulraj, Executive-Prodn & Maint, GTSI, Madura Coats Private Limited, Madurai, Tamilnadu

"Causes of higher startup end breaks in Compact Spinning and ways to control"

1. A very long snarl is created at the time spindle stoppage and the snarl cannot be removed by start up program and it gets cut at the Traveller during start up, because of prolonged running of
spindle in slow speed due to inertia – brake not applying or applying too late. To overcome it, the brake should be applied at the appropriate RPM of front roller set estimated Nf speed (or) reduce.
2. The yarn comes out during start up due to insufficient bottom bunch coils, and during start up the bottom bunch slips of from seal band. Also there is more hard waste on seal band and the
bottom bunch doesn’t have grip, In this case bottom bunch timer should be set T54 and the seal band should be cleaned.
3. Balloon collapses during start up due to yarn tension too low due to lighter Traveller, low start up speed and ring rail down speed during start up low. Here Traveller number to be made heavier,
increase in no speed - recommended 70 - 75% of maximum speed and increase start program down speed is required to control this
4. Yarn is coming out of Traveller during spindle stop due to the yarn is very slack, lighter Traveller and the ring plate moves more than required to remove long snarl. To over come this, increase
yarn tension when spindle stops by adjusting 1st move up position, using of heavier Traveller and reducing 2nd move up position will help
5. Yarn becomes slackened during start up at 2nd move up due to the acceleration to no speed is slow, it can be settled by increase in ACC1 & ACC2 and increase in T46 acc rate change
6. Initial coils slips off the bobbin due to heaving operation improper. To overcome this set T58 (2nd up delay) & T57 (main motor delay) to ensure that few coils are formed at 2nd move up before
Ring rail starts moving down to winding start recommended
values T 58 – T 57 > 1 Sec
7. Yarn is not cut by cutter during doffing due to the angle of yarn to cutter is very low – due to more barrel winding and the bottom bunch is formed very near to cutter. To over come this, reduce Nf
speed Increase Ringrail down speed during end program and set bottom bunch position as 4 to 5mm from cutter

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Mr.S.Suresh Kumar, Factory Manager, Avaneetha Textiles(P) Ltd, Kaniyur, Tamilnadu

"Causes of higher startup End breaks in Compact Spinning"

Less hairiness in yarn, so that yarn slips out easily during spindle stopping. In General, yarn with high hairiness obstructs the Traveller speed at the time of spindle stopping due to high friction.
Secondly there is no delay draft mechanism.
Remedies:
1. Reducing the spindle speed especially at final doffing length. It should be approximately 12000 RPM.
2. In manual doffing, cops should be removed carefully so that the residual lappet yarn portion should not be disturbed.
3. Maximum speed of Compact motor can be achieved before front roller rotation.
4. After doffing, lappet tilting will be smooth and the angle of lappet stopping distance should be 45° from beam.
5. Lappet movement should be set above 95 mm.
6. Motor restarting cam position should to b33 sensor distance will be maintain 70 MM.
7. Damping cylinder movement will be smooth.
8. Low bow Traveller profile should be used.

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Mr.S.Ganesan, Spinning Master - Maintenance, Sri Jayajothi Textile Mills Pvt.Ltd, Rajapalayam, Tamilnadu

The following are the major reasons for start up breaks found higher in Compact Spinning:
1. More chances of yarn coming out of Traveller during doffing sequence because of less hairiness
2. Traveller lagging during restarting due to in sufficient lubrication between ring and Traveller due to less hairiness
3. Change in spinning angle due to extra attachment of Compact rollers

Remedies to overcome the start up Breaks:

1. Selection of Traveller profile and Traveller number is very important to prevent yarn coming out of Traveller during doffing sequence
2. The ring rail movement should be changed from double stroke to single stroke
3. The status of snarl should be checked before start of new doff and accordingly the first movement of ring rail should be set from under-winding position to upper reversing point
4. The main motor on time and the spindle drive should be started with the first down ward movement of the ring rail
5. The spindle should not rotate when the main motor stops. Checking should be done in the condition of Tin roller coupling for any play
6. Correcting of the start and stop sequence of ring frame main motor and Compact suction motor should be done
7. During restarting the Compact suction motor should be started before the main motor starts.
8. During doffing main motor should be stopped before Compact suction motor stopped.

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Mr.P.Suresh Babu, Production Manager, NSL Textiles ltd, Pulivendula, Andrapradesh.

Reason for more startup breaks in Compact Spinning: BACK TO

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1.In Compact there is no delay drafting functioning, spindle and drafting system the both are activated at a time while M/c restart sequence in that time startup breaks will increase.
2. Improper setting of suction motor delay timing.
3. Improper suction Pascal level.
  4. Worn out intermediate wheels and cylindrical pin in Elitops.
5. Damaged lattice aprons. 
6. Lack of proper cleaning of the Mango tubes and Lattices aprons.
7. Unsuitable Traveller profile.
8. Mixed Traveller profile.

Remedies:
1.Long snarl setting should be optimum. (Ring rail up and down starting sequence setting)
2. Optimum spindle speed than that requires for the initial speed.
3. Fan on Delay timing.
4. Back and under winding.
5. Balloon stability too slowly built up.
6. Optimum Start and initial Speed.
7. Optimum startup sequence settings after doff.
8. Cleaning must be done carefully and properly.
9. Meshing of gears are not proper.
10. Uneven Spinning tension should be avoided
11. Too long running time of Traveller should be avoided
12. Adjust blower nozzles

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Mr.Adinarayana M, AGM, Mohanspintex India Ltd,Unit-1,Veeravalli, Andra Pradesh

Tips to control of more restating breaks in Compact Spinning

1. In Compact yarn ring and Traveller has no Lubrication when compare with normal yarn that is why we go to close Traveller with low bow Traveller to control of restarting breaks.
2. Keep optimum starting speed at restarting time, keep bobbin bottom gap 12 MM compare to 10MM normal yarn gap.
3. Keep vacuum pressure setting maximum time only machine will start mainly central suction machines (24 to 27)
4. Keep Traveller clearer setting must be close one step compare with normal yarn
5. RH% and temperature should be maintained perfectly, because drafting fibers are open condition with help of lattice aprons temp - 36-38, RH% -48-50 for better working and avoid restarting
breaks.
6. Use special design over head cleaner nozzles for Compact machine. The air blow should be allowed at fiber path on lattice apron. OHTC must stop before going doff, (all ways stop OHTC
machine idle position and restarting)
7. Keep snarl removing mechanism must be close (better removing) compare with normal yarn
8. In Compact yarn traverse is minimum and lower than normal yarn buffing time 0.3mm need to buff and also frequency need closer normal yarn-45 days, Compact yarn-30 days
9. Keep Chase length minimum in Compact yarn 36mm to 38mm
10. Traveller must be changed one or two days before than the normal yarn

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Mr.K Murugan, Chief Manager (Works), Rajapalayam Mills Ltd, RAMCO GROUP, Rajapalayam, Tamilnadu

Reasons for startup breaks found higher in Compact Spinning when compared to normal Spinning
The well known fact, that Compact Spinning yarn is more even, less hairy and more Compact due to less spinning triangle and the fibres are well condensed before twisting than normal Spinning
yarn. The parallel formation of fibres before twisting in Compact Spinning imparts optimum twist and minimizing the weak yarn during delivery. Hence, the doubt of weak place breaks is eliminated
during start up breaks in Compact Spinning.
The Compact yarn Spinning start up breaks is higher due to yarn slippage from ring Traveller i.e. yarn coming out from Traveller and the reasons are Compact yarn having more even and Compact
(near round) shape of yarn while using regular ring Traveller like EL1 UDR or U1 EL UDR type. The second reason is lower lubricating act over ring due to less hairy, condensed / parallel shape of
yarn.
Compact Spinning with LEL type Traveller is minimizing the start up breaks due to less slippage of yarn during start up. We may also reduce by decreasing the speed of ring rail.

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Mr.N.Thangaraj, Asst.Manager (Maintenance), Sangeeth Textiles (P) Limited, Annur, Tamilnadu

The following points are the reasons for restarting breaks in Compact Spinning:
1. Bye pass of delay drafting system in Compact Spinning.
2. Due to low hairiness the yarn get slipped from Traveller while restart.
3. In Compact the yarn body gets even, due to this also yarn gets slipped from Traveller.
4. If Compact suction fan off before M/c stopped and on after machine start it will cause more restarting breaks.
Remedies:
1. Correct Traveller selection should be need.
2. Restarting ring rail speed should be optimized.
3.suction fan on / off timing to be set properly.

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Mr.Rm.Lakshmanan, Technical Adviser, Sri Nagammai Cotton Mills, Vikravandi, Tamilnadu

"Reasons for higher Start up breaks in Compact Spinning and the remedies"

Significance of Rings & Travellers in Start-up Breaks at Compact Spinning: Compact Spun yarn, in view of its low degree of hairiness in the yarn and the subsequent under lubrication, the contact
area of the Travellers with Rings, misses heavily the continuous regenerated filmy coating of natural lubrication from the fibre as in the case of normal spinning. In Compact Spinning , this
phenomenon impose and insist a spinner to use Travellers with very lower “sliding friction” with superior finish for facilitating excellent gliding on the rings with the highest “wear and Tear “
resistance to rid of the start up breaks considerably.

Extended usage of Rings and Travellers: The extended usage of both Rings and Travellers enhance the start up breaks as the sliding friction of Travellers goes on increased. The cut off date for
replacement has to be customized when the start up breaks exceeds the limitations. The replacement in time is a must for minimizing start up
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Profile of Rings and Travellers: The area of contact between Rings and Travellers also matters start up breaks. The exorbitant heat developed at the time of spinning, a portion of the same
absorbed by the rings and Travellers and the rest let into the air in the ambience. Hence a smaller area of contact leads higher and faster burning of Travellers and makes unstable and strained
gliding and end up in higher start up breaks. For good heat dissipation and diffusion Anti wedge Ring with UDR profile Traveller with deeper yarn passage may be matched to minimize the start up
breaks.

Department Humidity: Keeping the whole Spinning shed for the Relative Humidity between 55 to 60 % shall resist the quicker vulnerability of Ring and Travellers and in-turn keeping the start up
breaks in control.

Moisture level and fineness of Cotton: The cotton preferred for Compact Spinning better to have lower Micronaire value (say around 3.5) with moisture content about 7.0%. Higher Mic value and
lower moisture could enhance the intra fibre friction- between fibre and metal to happen for higher start up breaks

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Volume-16, Issue-2, AUGUST-2016

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