SUMMER TRAINIG REPORT ON

BIRLA TEXTILE MILL

[ In partial fulfilment of required for the award of diploma in “ textile
technology”]

SUMITTED BY :- SUMITTED TO :-

Richa Verma E18301235100013 MRS. ANUBHA GUPTA

Ekta Prajapati E18301235100009 H.O.D.
Ansh Mishra E18301235100039 TEXTILE TECHNOLOGY GOVT.
Srajan Patel E18301235100022 POLYTECHNIC KANPUR
Himanshu Rajput E18301235100047
Buddha Prakash E18301235100023
 ACKNOWLEDGEMENT

We are very thankful to whole BIRLA TEXTILE MILLS for providing the best facility and good
environment during the training period. We express our gratitude to each and every employee of
BIRLA TEXTILE MILLS for their co-operation and their most valuable time.
We should like to express our gratitude to Mr. R.K. SHARMA, Vice President (Tech.) for his co-
operation. We pay our thanks to Mr. SUNIL KUMAR MISHRA, General Manager (Production).
We are very thankful to Mr. SANTOSH VERMA (Production Manager) and all other staff member for
their support and motivation.

RICHA VERMA
ANSH MISHRA
SRAJAN PATEL
EKTA PRAJAPATI
HIMANSHU RAJPUT
BUDDHA PRAKASH
 CERTIFICATE

This is to certify that following students of TEXTILE TECHNOLOGY 2018 batch of GOVERNMENT
POLYTECHNIC KANPUR has completed their one Month Industrial Training in "Birla Textile Mill"
Baddi (H.P.) report in his genius work.

I wish for their success in future.

Richa Verma E18301235100013

Ansh Mishra E18301235100039
Srajan Patel E18301235100022
Himanshu Rajput E18301235100047
Ekta Prajapati E18301235100009
Buddha Prakash E18301235100023

MRS. ANUBHA GUPTA

H.O.D.
TEXTILE TECHNOLOGY GOVT. POLYTECHNIC KANPUR
 About BIRLA TEXTILE MILLS
BIRLA TEXTILE MILLS is a part of the CHAMBAL FERTILIZERS AND CHEMICALS LTD. and has the pride
of establishing India's one of the largest and most modern spinning unit under one roof.

The group is built on a firm belief in the values of innovation, quality & services. These concepts
have successfully guided the company's fortune.

BTM is a $110 million venture of the Chambal Fertilizers. The division is one of the largest spinning
mills under one roof in India The plant is located in the town of Baddi in Himachal Pradesh, near
Chandigarh, in the foothills of the Himalayas, in close proximity of the growing belt in northern
India. The plant is considered to be one of the most modern spinning mills in India.

BTM entrusted overall coordination to leading consultancy firm Gherzi Eastern, specialist in textile
Industry. The result the most modern and single spinning unit comprising of 83376 spindles and
dyeing unit with an investment of $ 110 million to produce different type of premium quality yarns
viz, 100% combed cotton, Polyester/Cotton Combed blend, and 100% polyester yarns. Beside Gray
yarn BTM product range also includes Gas Mercerized, Bleached ,Melange and dyed yarns.

The plant becomes operational in 1999, and has a total production capacity of 23,400MT per
annum. The plant is fully automated and all the processes in the plant are fully integrated. The
company is ISO 9002 and is currently working on the ISO 14000 certification. Apart from this the
company also trying to implement Six-Sigma, Total Productivity Management, 5's and Gemba
Kaizen Management Initiatives- the first for any spinning company in India
 BIRLA TEXTILE MILLS AT A GLANCE

➤ India's most modern spinning plant.

➤Production commenced in 1999.
➤83376 spindles & a Fibre dyeing unit.
➤Total production is 23400 MT/annum. >Export upto 40% of total production.
►Our export destinations are in all 5 continents. Equipped with most modern machines.
drawframe
➤ Blowroom,cards,comber and drawframe from LAKSHMI MACHINERY WORKS(LMW).
➤Ring frame with auto doffer MTMM from ITALY.
➤Autoconers from SAVIO.
➤ Best work practices as an ISO 9000-2001 certified
company.
➤ Fully computerized and integrated from raw materials
to finished goods with bar coding.

Features of BTM (That Attract You on First Sight)

 Modern machinery Excellent House Keeping

 Excellent Fire Control System General Services along With Human Resource
Development.
 Computer Added Yarn system.
 Communication system like Intercom, LAN, Intranet.
 SAP system

Products

UNIT NO-1

•100% Polyster & Polyster viscose blend.

• Count range 20 Ne to 40 Ne.
•Daily production 20.50 MT (avg).
•Single/two ply.

UNIT NO-2

Polyester/viscose blended or 100% polyester grey and dyed yarn

100% Viscose grey yarn.

•Count range 20Ne to 40Ne.

•Daily production 11MT (avg).
• Normal blends are.
52% PET/48% viscose
65% PET/35% viscose.
Waxed/unwaxed for knitting/weaving end usage

MACHINE PARK AT BTM

sr Machine name Unit no. 1 Unit no. 2 Unit no. 3 Unit no.4 Unit
no.5

1 Blow Room Line 4 2 2 3 2

2 Card 26 14 14 22 22

3 Draw Frame 8 4 4 7 7

4 Lap Former 2 3

5 Comber 11 15

6 Speed Frame 8 4 4 7 7

7 Ring Frame 30 20 20 19 20

8 Autoconer 9 6 6 8 8

9 Tfo 30 24 25 6 6

10 Cheese Winding 5 3 5 2 2
UNIT NO-3

Polyester/ blended ring span yarns. In count range 19-40Ne

Daily production 23MT(Avg).
Normal blends are
 52% PET/48% combed cotton.
 65% PET/35% combed cotton
 60% PET/40% combed cotton
 Waxed/unwaxed for knitting/weaving end usage

UNIT NO-4

Types of materials:

100% Grey cotton combed and carded yam, slub yarn, compact yarn,100% grey viscose, 100% grey
polyester, cotton blanded yarn like P/C, V/C

UNIT NO-5

100% Grey cotton combed and carded yarn, slub yarn and compact yarn,

Humidification Control
Humidity: -
Degree of dampness in the air.
Measured by:
Eminent temperature sensor by Digivent.

Process of control: -
Regulation is through controlled flow of air through the department.
which is operated electronically.
Path of air: -
A constant flow of return air is sucked from the room through floor grids and
directed to the filtration cabins by means of return channels.
After it has been cleaned by filters return air passes through return fans and reaches
return chambers then according to the respective position of the dampers.

 A part of return air is exhausted through exhaust damper

 The rest air enters the mixing chamber through recirculation damper. It is then mixed with fresh air
damper and sucked by fan which has two functions::

1. Pulverizing water through centrifugal atomisizer in order to humidify

2. Blowing the air into ducts.
RH% maintained different Department

Deptt B/R CDG D/F CBR RSB S/F R/F A/C PKG
RH% 56% 56% 56% 56% 56% 56% 56% 65% 70%

MIXING

Objects

1. To even out the differences in fibre properties such as: staple length,
fibre fineness, maturity, dye affinity etc.
2. To control cost & quality of that product.
3. To apply antistatic agent to the material.

Types of Mixing Used in BTM

1. Batch System.
2. Tapering System

Batch System

Batch system is used in the unit no-4 because here the lot does not change for long time. For batch process
we make batch of those bales, which are in large quantity, daily we choose lor 2 bales from the lot. But this
process is not better than tapering because changeover is large. Here whole batch is changed
simultaneously, that's why change in process parameter is large
 Tapering System
Tapering process is used in unit no-5. In tapering process we go on adding the new bales to the previous lots,
but process parameter should not vary to the previous lots. Because here we add new bales to the previous
lots that's why changeover is small. But for tapering process we must have at least 25 bales in the lot. In
tapering process we need not to have large storage capacity, but for batch process we have to store large
quantity of bales, that's why this process required large storage capacity.

Raw Material:
Types of Cotton

1-H-4 Cotton
2-Shanker-6
3-1-34
Types of Polyesters
1- Reliance (1.2*32))

Parameters of Raw material used:

Cotton:
Type Micronair strength Length Uniformity elongation trash Moisture Moisture
value 2.5% ratio regain content

J-34 4.8 23.5 28.5 48.5 5.2 4.75 9.2 8.42

H-34 3.8 22 28.5 48.10 5.4 3 8.1 7.19

S- 6 3.6 22.8 28.2 47.2 6.2 3.2 8.22 7.6

STATIONS OF COTTON

J- 34 PUNJAJ, HARYANA
H-4 MAHARASHTRA, GUJRAT
S-6 MAHARASHTRA, GUJRAT
 QUALITY OF BALES

Weight of Bale- 165 to 184 Kg

Size of bale= 4x2x1.5

FIBRES PROPRITIES

FINENESS

* It is the measured as the cross section of the fibre

* The minimum fibres required for making a yarn are about 30, so if the fibre is fine yarn will also
be fine.
• Yarn from finer fibres should have more strength, more evenness. elongation and less hairy.

LENGTH

 It is a very important properity taken as first priority for better yarn

quality.
 Minimum length of fibre used for making yarn is 3 cm and above.
 Longer fibres used for yarn production have better uniformity, less hairiness, more strength.

UNIFORMITY

* Fibres should be uniform for production of uniform for production of uniform yarn and does not
vary so that it can vary yarn strength and lead to breakage of the yarn so uniformity ratio should be
less.

TRASH PERCENTAGE

It is responsible for the increase in cost of the yarn prepared because if the trash percentage is
more then number of machines required for the cleaning are more and hence the cost increases
and there will be less production.
TYPES OF CONTAMINATION

1. Jute 2. Hair
3. Plastic 4. Coloured Yarn
5. Polythene 6. Dry Grass
7. Cloth 8. stone
9. Metal 10. Rubber
11. Paper 12. Wood
13. Feather 14. Leather

LOT MANAGEMENT OR BALE MANAGEMENT

It is done as the name suggests that the raw material coming from the one truck is
considered to be of the same lot
As there are different lots in the company, so number of lots of same kind are mixed.

They are mixed by placing one lot then in 2 number placing another lot i.e. all the lots
are different, in this way lot management is done

LEVEL OF CONTAMINATION

It is the amount of impurities present in the raw material such as jute, plastic, cloth, hairs, woods,
leaves, sand, cotton seeds and stones

TYPES OF BALES

Bales may be of different types as their mic value, maturity level, length. ,uniformity, strength,
elongation, moisture, trash etc.

DIMENSIONS OF THE BALE:

Length of the bale -120cm

Breadth of the bale-60cm
Width of the bale - 40 cm

DENSITY:
Mass of the bale = 16000g
Volume of the bale =120x60x40 cm3
Density of the bale = mass/ volume
= 16000/
=55 g/centimeter
CONDITIONING TIME

It is the time in which the cotton bales are allow to remain in the atmospheric conditions to absorb
the moisture content the conditioning time is about 8hrs.

RELATIVE HUMIDITY PERCENTAGE (R.H%)

It is the ratio of moisture absorbed by the sample to the weight of the sample
It can be calculated by the difference in the temperature of the dry air and the wet air to the wet
air. R.H%= [Temp of dry air(Td)-Temp of wet air(Tw)] x 300/Temp of dry
air(Td) -98.4
In industry we take
Dry temp (Td) = 77° F and Wet temp(Tw)=65* F
So R.H% = (77-65)/77 x 300 -98.4
=55%

PRECAUTIONS TAKEN WHILE MIXING OR LAYING

1 No two bales of same kind are laid adjacently, they should be laid alternatively
2 R.H should be kept constant or according to the raw material fed.

WORKERS NEEDED

1 Two workers are required for laying, mixing

2 Two workers are required for cleaning during the bale plucking.
3 One worker for cleaning the fly fibres .So total workers required are 5.
 BLOW ROOM

Layout of Blowroom machine

Objects
1. To effect a through blending and opening with min. nep generation.
2. To remove any type of impurity as metallic or dust.
3. Removal of sort fibers
4. To convert mass of staple fibres to a chute feed for the carding zone.

Lightning system
Tube lights are used.

Transport of material
Through metallic pipes from the B.D.T.

Ducting in blow room

Different coloured of metallic pipes are used for transportation of material i.e.
cotton/polyster, contamination and microdust. These pipes are coloured in order to check which
pipe is damaged, if found.
White -material transport
Yellow -waste
Blue -micro dust

Red -fire waste out

MACHINE NAME MAKE BEATER
1. Bale plucker LMW spikes
2. Aerotec LMW NA
3. Vario clean LMW hooks beater
4. Unimix LMW saw tooth
5. Flexi clean LMW saw tooth
6. Poly sensor(Vetal scan) LMW v-type
Beater

IMPORTANT TERMS

Metal Detector
Main purpose of metal detector is to detect the iron particles in the particular raw material

PHOTO CELL
The purpose of photo cell is to stop the machine in case of any accident.

FIRE CONTROLSYSTEM
Its purpose to sense the material and protect it from going it to next machine in case of any
fire and send that burning material to be the water tank.

BEATER SPEED
Beater speed plays a very important role in cleaning of the raw material. The beater speed
depends on the quality of cotton.

Work Load - 1 Blow Room line / worker

Technological Data-

Beating point -2.5

Cleaning Efficiency - 55%
 Bale plucker (LA23)

Function
The LA23 serves as a dust free opening of bales of cotton. The working
procedure is controlled by microcomputer (Blend-Commander TKN-29) and is
fully automatic.

Working

The babes are laid directly on the floor with in the mark working area.
Then LA23 travels overt the bales with the detacher being lower to the surface
of bale the detacher has two toothed discs rolls working in opposite direction.
The teeth of the toothed disc roller plucks the tuft from the surface of the
bales bugling up and filling them into the air stream which remove them by
suction and carry them to the blow room line.

Specification of LA23

1. Traverse speed 12meters/min

2. Lifting motion (a)slow
(b)fast
3. Ventilator speed 2603
4. Run-in take-off depth 5.5mm
5. Max. ht. of arm 1800 mm
6. Prod rate in kg/hr 1250kg/hrs
7. Length of rail 30000mm
8. Advance 4mm(current)
9. Advance increase factor 2-10 (current=2)
10. Waste % 0.2-0.3%
11. Passage line 1-25 (current=10)

NOTE- Take -off roller always rotates in traverse direction.

 AEROTEC
Function
1. The pneumatic transport of the open tuft material through the
pipeline.
2. Intensive extraction of dust from the drawn in tuft.
3. Separation of the tuft material from suction air stream.

Specifications

1. Make Aerotec
2. Inner frame width 1000mm
3. Machine height 1000mm
4. Width 1464mm
5. Depth 1100mm
6. Dust cage speed 108-129rpm
7. Finned striper roller 357-428rpm
speed
8. Inlet dia 250-350mm
9. Outlet dia 250-350mm

10. Weight 580kg

E.M.A. (Electronic metal separator)

Function:

-A metal detector is located in the transport ducting.

-An eliminating arrangement is provided about 15 m after the detector

When a piece of metal of any kind pass through the detector the entry and exit
flaps are set so that material cannot fly straight through the duct, but must
pass through the eliminator. The end holds the raw material and metal back
while the air can flow through the flaps immediately return the normal flow
condition, the floor of collector chamber and the contents fall into the
container.
 Function

1. Interact material evenly from the bales/tufts

2. Open the material gently of equal
3. Open material top smaller flocks
4. Blend material
5.Permit putting together of a fibre blend from several components

VARIO CLEAN LB9/1

Function

It is first cleaning stage. It has two cylindrical rolls with cleaning

elements attached in a spiral fashion. The material enters the machine
through one side and streams trough other side.

The two rollers rotating in opt. Direction that gives an opening effect.
while grids are at bottom which gives a cleaning effect. In order to
prevent flocks being drawn straight through the machine the large
hood is divided in 3 chamber by guide plates in this was flocks are
made to circulate 3 times or the grid, this gives strong cleaning effect.

The LB9/1 relies on optimum exploitation of the inertia of the

material.

The cotton passes through the ema in the dotted transportation air
accelerated due to convergence duct and an addition air stream is
created by a fan in the region, having a sharp diversion the whole
stream under go upward.

With the relatively light cotton flocks can follow the change of
direction, heavier foreign particles fly through an opening the duct
beyond the region. into waste chamber.
 This is an extremely gentle cleaning technique but it requires foreign
matter to be quite heavier than the fibre.

SPECIFICATION

1. Make LMW
2. Model LB9/1
3. No. of Beatrers(Pin 02
type)
4. No. of plates 46
5. Beater roller dia 605mm
6. Beater roller speed 420rpm
440rpm
7. Grid bar setting 3-5
8. Material production 900kg/hr
9. Dia of stock inlet duct 300mm
10. Dia of stock outlet duct 300mm
11. Waste volume 7kg/hr
12. Angle of deflector plate 150
above the right hand
beater from the vertical
to the left.

Right hand beater revolves at a speed 3% less than the left one to maintain a
shift

Between two sets of beating points.

 UNIMIX
SALIENT FEATURE:-
 Machine working width is 1600mm
 Infinitely variable production upto 800 kg/hr without opening and
cleaning roller and upto 600kg/hr with opening and cleaning roller.
 Larger buffer volume.
 High throughput coupled with minimum space requirement.
Combined Blending and Cleaning:-
 Extremely good homogenous and consistent blend of material.
 Intensive three point blending.
 Saving of the power by the combined blending and cleaning.
Specification-
1. Make LMW
2. Model LB 7/4 R
3. Beater Speed 413 rpm
4. Storage Capacity 350-400kg
5. Material production 600kh/hr
6. Pressure 475 Pa
7. Beater Diameter 400mm

FLEXI CLEAN
MAKE & MODEL LMW LB 5/6

Function

In this machine material is feed by feeding device and is carried on the

feed lattice beneath the pressure roller to the two feed rollers.
The feed rolls draw the material and transfer it to the cylinder. It consists of three
cylinders (beaters), which carry out the cleaning process along the mote knives.

Every beater consists of at least one mote knife, which interacts with the beater and
performs cleaning operation. Wing is also provided with every cylinder, which
decides the amount of waste removal. Waste is extracted directly from the mote
knife and a continuous suction flow removes all contamination produced by the
separation.
The waste is not left there but is continuously removed via suction hoods if waste
removal is to be increased, then the wing setting is increased.
The machine has three types of beaters: -
I. Fully spiked roll.
2. Coarse saw-tooth roli
3. Fine saw-tooth roll.
This is the main cleaning organ of blow room line. The rpm of beaters increases from
spike to fine saw-tooth roll. Below the beaters wing are provided which are moved
apart or closer to have more or less waste.
Specification
S. No. Name of the Beater Dia. Beater Speed Wing Setting
Roller (mm) (rpm) (degree)
1. Fully Spike 250 1100 25
Roll
2. Coarse Saw- 250 1900 35
tooth Roll
3. Fine Saw- 250 2900 50
tooth Roll
 Carding

Object
 To carry further process of fibre opening to a stage of fibre individualization.
 To remove neps, tiny lumps of fibre and fused fibre used.
 To deliver a continuous silver for further process.
Function
 To open the tuft web coming from tuft feeder into a fibre web.
 To parallel the fibres.
 To extract the waste particles from the fed lap into a silver and to feed this to
the coiler for being deposited in can.
Transportation of material
Cotton from Blow Room is fed to card by chute feed is fitted with a beater which
further opens up the cotton tufts and then allow the cotton tufts to fall between the
rollers to form the lap ,which is continuously fed to the card.

Machine Used
Make : LMW
Model : LC300A – V3
Main Components of LC300A-V3 :
1. Feed table
2. Feed roll
3. Deflector blades, mote knives, with suction hoods and carding segment.
4. Licker -in.
5. Pre carding Segments and suction hoods and mote knives.
6. Flat cleaning device.
7. Cylinder covering segments with suction hoods and mote knives.
8. Revolving Flats.
9. Cylinders
10. Two suction hoods with mote knives and post carding segment i.e. web clean.
11. Doffer
12. Cleaning roll for stripper roll.
13. Stripper roll.
14. Web speed.
15. Calendar roll.
16. High-speed coiler KH or KHC.
Technical Data-
1. Feed Roll Dia. :100mm
2. Licker-in speed :992 rpm
3. Cylinder rpm (Cotton) :450
4. Cylinder rpm (Manmade) :410
5. Doffer speed :20m/min
6. Flats (Total) :94
7. Flats (Working) :28
8. Flats (Speed) :12inch/min
 9. Delivery rate :143m/min
10. Cleaning Efficiency 98%

Gearing Diagram of M/C

Setting & Parameters for Cotton:-

S no. SETTINGS COTTON(mm)
1. Licker in to Cylinder 0.2
2. Feed plate to Licker in 0.75
3. Cylinder to back bottom plate 0.75
4. Cylinder to top plate 0.65
5. Cylinder to flats 0.3,0.3,0.25,0.25,0.25
6. Cylinder to top front plate 0.75
7. Doffer to Redirecting roll 0.125
8. Redirecting roll to cross 0.125
9. Stationary Flats 0.4,0.375,0.35
10. Cylinder to front bottom plate 0.55
11. Cylinder t Doffer 0.125
12. Doffer to Redirecting Roller 0.125
13. Combing segment (1st &2nd) 0.5,0.45
14. Feed sensing roll of sensing plate 0.1
15. Cyinder to under casing 0.85,1.5,1.3,2.6,6
16. Licker in to Licker in grid 0.55
17. Mote Knives 0.35,0.4

S. No. PARAMETERS COTTON

1. Fineness 135
2. Standard spped(10-50m/min) 20
3. Fast speed(0-294m/min) 140
4. Draft(60-130fold) 115
5. Can length 10,000
6. Target pressure(1-999pa) 280
7. Doffer motor rpm 1180
8. Feed roll 9.3rpm
9. Cylinder rpm 450rpm
10. Licker in rpm 992rpm
11. Flats(speed) 12inch/min
12. Production 280kg/shift

The Card Sliver Leveling:

CORRECTA CARD DEVICE (CCD-Std. Equipment)
The CORRECTACARD (CCD) serves for a long term regulations and
monitoring of sliver count. In the sliver trumpet, the calendar unit is fitted
with a measuring lever which is linked with a displacernent detector. This
measuring lever measures the thickness of card sliver and converts the
information via the displace detector into an electrical signal which is
transmitted to the control system. On the basis of pre-selected target value
and the measured value of the sliver count, the speed of the feed roll drive
is allied by the controller.

CORRECTA FEED DEVICE (CFD)

For measuring length of sliver as short as Im upward The web thickness is
measured at the web between fixed feed roll and the measuring plate in
feed table. The measuring plates are provided with displacement detector,
which measures via pedal lever variation in the thickness of the tuft web.
The displacement detectors convert these variations of thickness in to
electronic signal and correction of the feed roll speed froin there the
addition control of there drive takes place by means of a controller

Special Features of Card:

→ Centrally Chute feed system for the entire Card.

→ Larger cans (40x 48") are employed to accommodate more

length of sliver.

Automatic Can Changer.

* Suction pipes (under the machine cover) are provided to prevent
the fly.

* Total covered body of cards, and use of Synthetic Gear belts

* Very less noise pollution, and very less fly generation in the
atmosphere.

* Card Commander is provided for feeding the required data.

* Card Character Device (CCD) for better control of sliver variation.

Materia Positio Ppsi Heig Angle Rows/in Pitc Rib

l n ht ch h
Cotton Cylinde 865 2 30 1.5 0.5
r wire
365 4 25 1.95 0.9
520 7.5
41 5 10 8 5
140
640
60

Change places of Card LC300A-V3:

1. (a) Draft between delivery roll FBK (F80) and feed roll (F100)
=VI. (b) Change wheel for V1-FBKW.
(c) Increasing the no. of teeth of FBKW decreases the amount of
feed per unit and this consequently reduces production but
increases the draft.
2. (a) Draft between doffer and stripper roll-V2. (b) Change wheel
for V2-AW. (c) Increasing the no. of teeth of AW increases the
draft.
3. (a) Draft between stripper roller & squeezing roller V3. (b)
Change wheel for V3-AWW. (c) Increasing the no. of teeth of
AWW, increasing the shaft.
4. (a) Draft between squeezing roller and calendar roller-V4. (b)
Change wheel for V4-MW. (c) Increasing the no. of teeth of MW,
increasing the draft.
5. (a) Draft between calendar roller and press roller-V5. (b) Change
wheel for V5 KW.

Running gears :
FBKW 23T
AW 81T
AWW 30T
KW 37T
MW 19T
Cleaning of Card

Full eleuning of Card is done after 10 days

Cleaning is done for following reasons

* For life of machine
* For high efficiency of machine,
*For fine quality of firal product

This cleaning is done with the help of compressed air pipe and some parts
are cleaned with different methods.

FBK Cleaning:- It is done with the help of vacuum cleaner & one time in
each shift

Feed roller & Calender roller - It is done with the help of compressor
air pipe after each 2 hrs.

Cylinder, Licker-in- lt is done by opening stationary flats & auction hoods

& then by compressor air pipe.

Doffer :-It is done by hand brush & sir pipe & this hand brush is cleaned
by air pipe.
TECHNOLOGICAL DATA
Production rate 80Kg/hitat100ff)
Sliver count range 7.38 to 3.28 Nm 0.30
Draft 60 to 300
Total waste. 2-10%
Weight of feed for chute feed 400-750/gm

COMPRESSED AIR SUPPLY

System pressure Operating 6 bar minimum (87psi)

pressure

Operating pressure 4-5bar (58-72psi)

Air consumption 0.71nm cube/hr

With waste removal 1.31 nm cube/hr

Connecting pipe diameter 12mm

WEIGHT OF MACHINES AND ITS COMPONENTS:-

Total weight erected 750

completed about
Cylinder 990kg
doffer 360kg
Licker in 110kg
 Detaching device 190kg
Cylinder bends 215kg each
Can coiler complete 500kg
Charge

FAN
Fan diameter 490mm across blades

EXHAUST AIR
Exhaust air rate 1.1m cube/sec

FILTER BOX
The exhaust air extraction system and fan must be able to handle
this air flow with this air flow with a minimum of 5-10mm.
CENTRAL SUCTION
The central suction system should extract air at the rate of 0.83m
cube/sec at bars 100WG ofv vaccume when card is served.
Work load - 22machine/worker

MAINTENANCE SCHEDULE

Half setting (cleaning,greasing,oiling) after 15-20toe material or 15

days
Clothing of cylinder 100tone(hoisery)
 700tone(export quality)
Flat ,doffer,cylinder Simultaneously
Licker in 180tone
General cleaning Daily by air pressure

PRODUCTION CALCULATION

Production of card machine /8 hour in KG = (Delivery speed

*8*60*1.09* efficiency)/(2.205*840*wrapping)

PASSAGE OF MATERIAL THROUGH CARD:-

Material feed by clute
↓
Feed roll
↓
Licker in
↓
Flat chain
↓
Cylinder
↓
Doffer
↓
 Detaching roll
↓
Crush roll
↓
Delivery roll
↓
Steeping roll
↓
Guide roll
↓
Coiler
↓
Calender roll
↓
On to the chain

QUALITY PARAMETERS

Neps/gm in silver -62/gm

Trash% in silver -0.1%
U% -3.0-4.0%
Cv(1m)-2.5-3.0
 DRAW FRAME LDO/6(BREAKER)

1 Sliver funnel Broken sliver

Delivery roliers Broken belt
Desired site of
fracture
2 Yellow h 50 Sliver monitor Stop since set value
3 Flashimg light H 41 Can changer
Pre signal for the can changer and can chanhe in progress
 PASSAGE OF MATERIAL THROUGH FINISHER DRAW FRAME

Can creel
↓
Between feed roll
↓
Through guide lines
↓
Through calander roller
↓
Between scanning rollers
↓
Through sliver tube
↓
Coiler
↓
Can

PRODUCTION CALCULATION

Production of machine/ 8 hour in KG = (Delivery speed x 8 x 60 x 1.09 x No. Of

delivery x efficiency)/(2.205 x 840 x wrapping)

Work Load 6 machine/ worker

Quality Parameters

U%-1.8-2.2(COMBED)
-2.0-2.4(CARDED)

Cv(1m)-0.50.65%
 Speed frame

Object :-
The work oif simple into a number of separate operations. These operations are
follows :-

Drawing - To reduce the size of strand (sliver to rove)

Twisting - To give the necessary strength
Laying - To put the coils on the bobbin in a regular arrangement.
Winding - To put the successive layers on the roving.
Building - To shorten successive layers to make conical ends on the
packages of the roving

Specification

MAKE Zinser Saurer

MODEL ZINSER68i
PARAMETERS OF ZINSER 68i RUNNING

PARAMETERS COTTTON
1 Spindle Speed 110 rpm
2 T.P.I 1.28
3 T.M 1.36
4 Hank 0.90
5 Bottom roll Gauge 48.5/60mm
6 Saddle Gauge Spacer 53.5/58mm
7 Spacer 6.5 mm
8 Top Arm Pressure 12/20/15/15kg
9 Draft 7.33
10 Break Draft 1.19
11 No. of spindles 120
12 Bobbin 48X452mm
13 Flyer Size 146X406mm
14 Spindle Gauge 121mm
15 Bobbin truf lift 406mm
16 Twist master 12 grove

Motors Used

1 Main Motor(inverter drive) 11KW

2 Motor with magnetic brake for bobbon rail 0.2KW
3 Motor for returning core drum belt 0.2KW
4 Suction and blower motor 3KW

Clearers
1. Top clearer cloth
2. Bottom clearer cloth
3. Pneumatic suction under the clearer to collect the bottom clearer waste.
4. Pneuma suction system is continuous.
5. Pneuma collected system is standard.
Driving System

1. Flyer-shaft driven by timing belt.

2. Bobbin-shaft driven by timing belt.
3. Flyer and Bobbin driven by Helical gears.

Top motions

1. Box-of-tricks arrangement.
2. Cone drum belt returning device.

Electric Stop-Motions

1.Feeding Part (Green)

indicates sliver breakage by photoelectric cell
2.Flyer top Part (Yellow light)
Indicates roving breakages before the roving enters the false twister
Detection is by photocell.

3 Full Bobbin stop motion actuated by manual reset counter (White light).

Top Rolls Buffing

1.Once in 6 months.

2. Cots used for Zinser 681.

19*28*39mm, ALU, core, shore hardness-83

Where

19 - inner dia.
28 - outer dia. Unit: (mm)
39 - length of cot
Automation for High Quality Production

1.Sensor based automation tension control.

2.Roving irregularity prevention 3.3 over 3 drafting roller.
device.
4. Optional creel type tension fine adjustment mechanism.
5. Automatic oil supply for flyer & Bobbin gearing.
6. Automatic travelling suction clearer.
7. Stop motion upon breakage at middle part of package.
8. Cross flow fan type dust collection.

MAINTENANCE PARAMETERS

1 Full cleaning - 15 day

2 Top and bottom path - 15 day
3 Bottom roller gauge change - 1 year
4 Top apron change - 2 year
5 Creel cover opening - 3 months

PASSAGE OF MATERIAL THROUGH THE ROVING FRAME

Sliver can feed material

On to creel

Roving guide

Drafting zone

Twist master guide

 Flyer

On to roving bobbin

IMPORTANT POINTS

#Twist is inserted with the help of the flyer

# In bobbin leading bobbin speed increases as its diameter increases and

flyer remains constant

PRODUCTION CALCULATION

Production of machine/ 8 hour in KG = (Spindle speed x.0254 x 8 x 60 x 1.09

x No. Of delivery x efficiency)/(2.205 x TPI x 840 x wrapping)

Work load

Tenter - 2 m/c worker

Doffer load - 1200 Bobbin/doffer

Quality Parameters
U%-3.03.5%(combed)
-4.25-4.5%(carded)

Cv(1m)-1.5-1.65%
 Ring Frame

Objects :-

1. Drafting : to reduce the bulk of strand to get the desired size.

2. Twisting: Causing the fibres to spiral around each other and bind themselves
together to give the desired strength.

3. Winding: To coil twisted standard of yarn around the bobbin rapidly as it is

delivered by drafting rolls.

4. Building: To regulate the pattern of yarn to give a package of a desired shape and
size to suit the requirement of the use of the yarn

Specifications:
 MAKE LMW
MODEL LR6/S
NO. of machines 39
NO. of spindles 1104 SPINDLES PER RING FRAME
BUFFING OF COTS
Front cots- once in a month
Back cots – once in three month

GREASING
Front cots in four months
Back cots in six months
Aprons Used
Bottom apron endless inner lengh thikness dia.
Bottom apron 38.8*39.8*1.4mm
Top apron endless 37.0*39.8*1mm

Ring Change at Ring Frame:-

Trvlr chng time
1st change Start of doff after ring change
2nd change At 75% of 1st doff
3rd change At 75% of 2nd doff
4th change At 75% of 4th doff
5th change At 75% of doff next day
6th change At 75% of doff after 2 days
7th change At 75% of doff after 4 days
8th change At 75 % of doff after 6 days
 Buffing
 *Buffing process is done for grinding the top cots rollers of R/F, S/F,RSB,Super
lap.DYH,DT,Comber (draw box) & detaching rollers (Rieter).

 *The buffing is done on Buffing m/c.

 *In this the cots come in contact of a revolving cylindrical stone which rubbs
cots for definite time After buffing we check the eccentricity / tapering of the
cots. If there is tapering in the cots then we again buff the cots with suitable
setting until they are untapered. Tapering is tested on taper tester m/c.
 *Berkolising m/e in which rollers are kept in heated region (Temp.-120 Deg.)
for 5 minutes.
 *Except R/F cots we don't apply berkolising process for remaining cots
 but they are Liquimixed in two liquids in 1:3 & then dried for 48 hrs.
 After berkolising R/F cots are ready for operation.
 *For greasing of Arbours of R/F & S/F we use Greasing m/c.

 *Greasing of front cot arbour after 6 months

 Greasing of back cot arbour after 1 year
 Greasing of middle cot (SKFG grease) after 5 year.

 *New cots diameter - 28 mm.

 *Dia. Of cots after last buffing-26.5 mm.
 Buffing time:
 *Front cols-2 months for Cotton
 4 months for Polyester.
o -45 days for P/C blend
 *. Back cots - 2 months.

 Greasing time

 *Front cot arbour 6 months

  *Middle cot arbour - 1 year
 Back cot arbour 5 year

 Types of Apron :

 *Top apron - (a) Hoshukin

 (b) Arcotex

 *Bottom Apron- (a) Précitеx

 (b) Inarco
 *Dia of bottom apron 37.3 mni
 Dia of top roller = 37.0 mm
 *Thickness of bottom & top apron = 1.2 mm
 Breath of bottom & top apron = 30 mm

 *AS we spin course count the height of spacer increases.

Doffing:

*For doffing of spindles auto doffing is used in which electronic puises in terms of
length are filled in CPU (Central Processing Unit) which gives the message to PCB
(Programming Card Board) to move the doffer in relative direction after definite
time.

Features of auto doffer S.C.D. :

* Fully automatic operation from withdrawal of full up to the loading of

empty bobbin.
*Adoption intermediate peg system that requires no ring dia.
*Doffing process takes about only two minutes & contribute much to
improve the product of high production.

Power consumption in R/ F:

*Main motor 45kw

*Fan motor 3.7kw
*Servo motor 2.2kw
*Doffer motor 1.5/0.75 kw
*Conveyor motor (2 in nos.): 25 w each
*Conveyor filling 25kw
*Blower (a) Fan 2.2kw
(b) Drive 40kw
*Lappet motor 40kw

Work load :

*One operator for 2 m/c.

* One helper for a 10 R/F
*Doffer- 7000 Bobbin /Doffer
*One Jobber for 20 R/F
*One clg boy for 6 R/F
* creel boy -900 bobbin/
 PASSAGE OF MATERIAL THROUGH RING FRAME:

ROVING MATERIAL
↓
ROVING GUIDE
↓
DRAFTING ZONE
↓
THROUGH LAPPET
↓
RING TRAVELLER
↓
AROUND BOBBIN

QUALITY PARAMETERS:-

30CH 24CH 20CH 30CH 30P/C 40P/C

U% 9.0-9.5 8.8 8.0 12-12.5 10-10.5 10.5-11.0
Cv(1m) 3.97 3.97 3.5 6.5 3.5-4.0 4.0
Thin 0 0 0 5-10 0-5 0-5
place-50
Thin place 10-15 5-10 0-5 50-60 40-50 50-60
+50
Neps+200 40-50 30-40 20-30 250-300 50-70 60-80
Hairiness 6.0-6.5 6.5-7.0 6.5-7.0 5.5-6.0 6-6.5 5.5-6.0
Classimate 100-120 100 80-100 250-300 100 100-150
fault
 AUTOCONER

OBJECTS:-

*To improve the uniformily of yarn by removing its objectionable faults.

* To improve the strength of yarn.

*To obtain package (cone) containing more lengh of yarn.
*To improve the lusture of yarn.
*To preduce a final compact package with minimum decterioration in quality.

Machine used-
*Make & Model – Savio Orion ,Savio Polar

Specification :-

Sr. No. Particular Value

1. M.P.M 1400
2. Efficiency 81%
3. Cots/100km 35,40,45
4. Pre clearer setting 1
5. Disc tension setting 3

Special features:-
*Max.winding speed = 1575 mpm.
* Individual inverter control.
*Tension manager & balloon control ensures high productivity.
* An extremely flexible fully automatic for all winding needs.
*Multiple yarn counts on one m/c. & automatic bobbin transport from
*winder. A simple sorting & distribution system.
*Bobbin option.
*Mixed yarn detector. Sloughing preventer.
*Doubled yarn detector.
*Tail clip device.
*Splice monitor.
*Photoelectric feeder.
* Automatic faulty bobbin alarm reset.

Machine specification:-

S. No. Parameter setting

 1 Count Range 20*s -30*s
2 Package Weight 3
3 Machine Orientation Left/Right
4 No. of reserve bobbin 6&8
5 Yarn joining method Splicer
6 Tensor Gate
7 Blower Centralized
8 Package Length 104000m
9 Drum Drive Individual
inventer
10 Slip coefficient 1.05
11 Residual yarn detector photoelectric

Work load

 1 winder /2 m/c

 I Wdg Cone checker/5.2 m/e

TENSOR

 Minimum Pressure - 16
 Running Pressure-26
• Anti-Wrap Sensor = 145

VSS PARAMETERS:

VSS%-90%

Maximum Speed Reduction – 20

 CHEESE WINDING

It acts as a pre preparatory m/c for T.F.O. In this m/e yarn forms the cone made on
autoconer is rewound in cheese from the yam would on the cheese is in the form of
double yarn.

Specification :

Make : RJK MACHINE PRODUCTS

Tension wt. : 32.60 gms.

Cheese wt : 68 gms. (empty) & full cheese1228 gm

No. of m/c :2

Speed of machine : 350-400 rpm

T.F.O. TWO FOR ONE TWISTER

T.F.O. is an advance doubling machine & the supply package is cheese.
It does both doubling & twisting. This m/c is called T.F.O. because it imparts 2 twist per
rotation of its spindle This m/e is used for making plied yarn.

MAKE AND MODEL:- Veejay Lakshmi VJ-120-M

For T.F.O.:

The twist given to the double yarn is 80% of the single yarn twist

PACKING
 The nain object of packing is to protect the material from dust & damage & to
transport the material at its required place.
 In packing the material is collected to trolley from A/C or T.F.O. & taken to UV
region where it is checked that there should not any type of raixing different
qualities or different lots.

 After UV region the material is kept in the marked area. After here the material
is taken to HW Conditioner for conditioning the material. Here the material is
kept for 4 hrs.

 The moisture content of material before conditioning is 4 - 5 % & after

conditioning material regains the moisture & it becomes 9 % (In just hot
condition). Now the material is kept for 20 min. at room temp. (now M.C.
becomes 8 %) then it is taken to Commander room where it is kept for 8 hrs
(Single yarn) & double yarn for 12 hrs. then after 16-20 hrs packing is start.

 Packing is done in polythene (Size 17 x 18 inches ie width x length) & gauge 40

(+)(-) 5 mic mtr.

 Now packed material is kept in Cartons of different size

 There are two types of cartons.

1.Small size carton :- (a) 645 x 425 x 505 (+X-) 5 mm {for domestic}
(b) 640 x 425 x 505 (+)(-) 5 mm { For export }

It contains 18 cones of heavy wt.

2. Big size carton :- (a) 770 x 385 x 510 (+)(-) 5 mm { For domestic }
(b) 770 x 3/85 x 510 (+)(-) % mm For export It contains 24 cones of less wt.

Weight of cones :

 Empty cone wt.: 48 gms

 Full cone wt.- 1.57 kg. & 1.93 kg. (Domestic)

 Full cone wt. :- 2.23 kg. & 2.32 kg (Export)

 Wt. of 18 cone with carton (gross wt) - 44.500 kg

 Net wt. 42.300 kg.

 Wt of 24 cone with carton (gross wt)- 48.360 kg.

 Net wt. = 45 kg.

Maintainance Cleaning Schedule

Machine Frequency

Blowroom:

LA 23
Full cleaning 10 day
Motor gear box 365 day
 Oil change
Metal rope 30 day
Lubrication

VARIO CLEAN:
Cleaning 10 day

ASTA cleaning 10 day

FAN cleaning 30 day
LVSA cleaning 10 day
Check & Lubricate 6 months
Fan shaft bearing
Stripper roller & Dust cage

LC300A-V3

Full cleaning 20 day

Full setting 90 day

LDO/6

Cleaning 7 day
Buffing 30 day
Gearbox oil change 180 day

LRSB 851

Cleaning 7 day
Buffing 3 day
Gearbox oil change 180 day

COMBER LK54

Cleaning 20 day
Top roller grinding 60 day
Gearbox oil change 180 day
One way clutch gearing 180 day

LAP FORMER

Full setting 10 day

Top roller grinding 60 day
Gear box oil change 180 day

SPEED FRAME ER68i

Full cleaning 20 day

Top arm pressure 180 day
Cleaning
Bottom roll eccentric 180 day
Check
Buffing of top roller 180 day
Check saddle & 180 day
Bottom roller guage
Gearbox oil change 180 day
 RINGFRAME LR6/S
Cotton P/C
Cleaning 30 day 45 day
Top roller grinding 30 day 45 day
(front/back cots only)
Checking
Bottom roller eccentricity
Check block guage &
Spindle gunge
Drive shaft bearing
Tin pulley shaft bearing
Tape tension pulley
Screw shaft lifting gear
SCD setting checking
Overhauling

TFO

Cleaning
Spindle bolster oil change
Cam box oil change
Spindle bearing greasing
Tension pulley greasing
CHEESE WINDING

Cleaning

Reduction gear box oil

Change
Drum shaft bearing greasing
Cradle bearing & Guide roller
bearing greasing

RESEARCH & DEVELOPMENT

The R & D lab contains following types of instruments.

Eureka-lea - tester:

Type EVO -3
Range 0-200 lbs
Motor rpm - 1440
Dry oven model - QVO - D
Moisture meter

Paramount twist tester:

Type-C 126/121 DB
Y.A. m/c
Model S.P.M
 U.V.cabinet

Uster tester-3
 Neps/km
 Hairiness
 Thick & Thin Places
 Evenness/ Im & 10 m

Uster fibro sampler - 192:

 Used for making the sample.

 Uster HVI-900:
 Yellowness & Whiteness
 Micronaire Value
 Mean Fibre Length
 Short Fibre Index
 Maturity Percentage
 Immature Fibre Content.

Uster AFIS:

Used for card and combed sliver for

 Neps
 Maturity ratio
 Short fibre content

Uster Classimate :

 Yarn fault/100 km can be shown.

 Uster tensojet
 Used to find out tenacity & resistance per km (R.K.M.)