Production Process Chart for Spinning : -

Mixing

Blow Room Line

Carding

Draw Frame

Airjet Twin Spinner Speed Frame

Ring Frame

Autoconer or Winding Single Yarn Packing

Assembly Winding

Ring Doubling TFO

Winding

Double Yarn Packing

1) Mixing:-

Mixing is first and important process done with full care because next processes depends
on mixing.
Blends are PV at various percentages, 100% Poly, 100% Viscose
First fiber is open and after weighing.
Mixing of polyester and viscose fiber is done in layer .
As per the blend the mixing layers are place over one another.
Anti static agent is spread on the polyester layer in order to neutralize static charge
produce during processing.
Tint is given for identification.
After conditioning, hand toppling is done.
Layers are put in horizontal plane and cut into vertical planes so that mixing should be
even.

2) Blow Room Line: -

After hand Toppling M/c toppling is done.

Main aim is to make mixing even and uniform.
Through blow room line fiber is transferred to carding m/c by using air pressure.

3) Carding: -

Main objective is to open the fiber.

Dust and waste are removed .
Fiber are made parallel.
Out put is in the sliver form.

4) Draw frame:-

Sliver from Carding is input to draw frame.

Drawing process is done in two stages
i) Breaker
ii) Finisher
6 slivers of carding are run through breaker draw frame and converted to single sliver.
6 slivers of breaker converted to single sliver in finisher.
Fibers in sliver are made more parallel and straight in this process.

5) Speed Frame

I/p – Sliver
O/p – Roving
Process – Sliver is twisted and converted to Roving and wounded on Roving bobbin.
There are 120 spindle per m/c
6) Ring Frame:-

I/p- Roving
O/p- Yarn
Process- Roving is twisted by the motion of spindle and ring traveler to yarn and
wounded on bobbin.
Doffing – Process of removing full bobbin and putting new bobbins on spindle.
There are 1008 spindles per m/c.
Production of the m/c depends on the count to be manufactured.
Fine count- low production
Coarse count – high production

7) Winding :-

I/p – R/f Bobbin Yarn

O/p – Cone form

Autoconer RJK
Yarn is joined by automatic Yarn is joined manually by knotting.
by splicing.
Various faults are removed
Like neps, slub, thin thick
Places

Yarn is used for single yarn Generally yarn is send for doubling.
For sale as well as for double
Yarn.

8) Assembly Winding :-

I/p – cone (single yarn)

O/p- cheese (double yarn untwisted)

Process:- two single yarns are wounded on one cheese in parallel form without
twisting.

9) Doubling :-

I/p – cheese
O/p – double twisted yarn

Process is like Ring frame, yarn from cheese is twisted and wounded on bobbins by
the motion of ring traveler and spindle.
There are 480 spindles per m/c.

10) Winding: - same as single yarn winding.

11) TFO: - two for one.
I/p: - Cheese
O/p: - Cone
It is called TFO because for one rotation of cheese spindle two twists are given to
yarn. The advantage is we get single knotless yarn of uniform quality.
Yarn from the cheese is twisted as well as winded on the cone.

12) Packing:-

As per the market requirement packing is done depend on that carton packing or bag
packing, wt of packing are decided.
Ring Frame yarn Production in Kgs/Spindle/ shift:-

Count = No of Hanks of 840 Yards yarn in one Pound Wt.

Twist per inch = Twist Multiplier x Sq root (Count)

Yarn Delivery in inches/ minutes = Spindle Speed / TPI

Production in Kg/spindle/ shift = Yarn Del”/Min x 60 x 8 in Kg

------------------------------
36 x 840 x 2.204 x Count
60-to convert to Hr
8-shift Hrs
36-inches to Yards
840- Yards to pound
2.204- pound to Kg

Production in gms per spindle per shift=spindle speed x 7.202

-------------------
TPI x Count

Ex.
Spindle speed=17500 rpm
TM= 3
Count = 36
TPI= TM x sq root (count)
= 3.0 x sq root (36)
=18
Yarn Del/Min =17500/18
Production in Kg/spindle/shift = 17500/18 x 60 x 8
-----------------------
36 x 840 x 2.204 x 36
=0.194 Kg/spindle/shift
= 194 gms/spindle/shift

This is 100% production there are various losses in the production like doffing loss,
Twist contraction, breakages. Generally Ring Frame is operated at 94-92%.

Like wise production for the Draw frame, Speed frame, carding can be calculated.
Production Planning for Ring frame:-

Production planning is done on the basis of past experience and past production data.
Past figures shows that what is the maximum production achieved for a particular count.

A) On this basis Target production is taken =per spindle per shift.

B) Production per m/c per shift= Prod per spindle x No of spindle per M/c (ie 1008)

C) Production per m/c per day=Production per M/c per shift X 3 shifts

Ex.
Count Should be Production per shift per day
Per spindle Per shift Per m/c per m/c
20 320 gm 322kg 966 kg
21 310 312 936
30 234 235 705
36 180 181 543
40 156 157 471
60 85 85 255

Example:
If the order is of 15 Tone of 21s count yarn, time given 10 days.

Based on above calculations

For 21s count

Production per spindle per shift = 310 gms
Prod per m/c per shift = 312 Kg
Production per day per m/c=936Kg
Days Required = 15000/936
For 1 m/c =16 days
Target is within 10 days.
So we will use 2 m/c and complete the production in 8 days.
Production of Draw frame:-

Production per shift for Draw frame = Delivery speed in mt/min x 1.093 x 60 x 8
----------------------------------------------------- Kg
Count X 840 x 2.204

= Delivery speed Mt/min x 0.2834

---------------------------------------- Kg
Count
1.093 for Converting meter to Yard
This is 100 % production
Efficiency of Draw Frame is 85 to 90 %

Example:-
For a draw frame Sliver Delivery 600 mt/min Warping 0.120 count, find Production in
Kg/shift?
Production per shift for Draw frame = 600 x 1.093 x 60 x 8
-------------------------------- Kg
0.120 x 840 x 2.204
= 1416.9 Kg/shift for 100 % eff.
= 1416.9 x 0.85 for 85 % eff
= 1204.37 Actual prod/ shift
Production planning for single Yarns of different counts:-

Sr. No Count Required Prod/ day

1 30s 7000 Kg
2 40s 5000 Kg
3 24s 3000 Kg
Total 15000 Kg

For Ring Frame Production:-

Count 30 40 24
Avg Spindle Speed 18000 19000 15500
TPI 16.0 18.5 14.5
Std Efficiency of R/F = 90 %

count Should be Per shift per Per day per No of m/c

Production/spindle/ m/c(gms x 1008) m/c Required
shift gms X3
30 243 gms 245 kg 735 kg 9.5 = 9.5
40 166 gms 167 kg 502 kg 9.96= 10
24 288 gms 290 kg 871 kg 3.4 = 3.5

On this basis Target production per spindle per shift.= spindle speed x 7.202
----------------------------
TPI x Count

=18000 x 7.202
------------------- x 0.90
16 x 30

=243 gms
B) production per m/c per shift= Prod per spindle x No of spindle per M/c (ie 1008)

C) Production per m/c per day=Production per M/c per shift X 3 shifts

count Should be Per shift per Per day per No of m/c

Production/spindle/ m/c(gms x m/c Required per
shift gms 1008) X3 day
30 243 245 kg 735 kg 9.5 = 9.5
40 166 167 kg 502 kg 9.96= 10
24 288 290 kg 871 kg 3.4 = 3.5
For Speed frame:

No of spindle per m/c= 120

30 40 24
Spindle speed 850 850 800
TPI 0.84 1.0 0.7
Count 1 1.25 0.8

A) Production per spindle per m/c= Spl speed x .007202

---------------------------
TPI x Count
= 850 x 0.007202
----------------------
0.84 x 1
= 7.28 Kg

B) production per m/c per shift= Prod per spindle x No of spindle per M/c (ie 120)
= 7.28 x 120
= 873.6 Kg

C) Production per m/c per day=Production per M/c per shift X 3 shifts
= 873.6 x 3
= 2620.8 kg This is 100 % eff.
=2361 kg at 90 % eff. Actual Prod.

In speed frame waste is 0.5 %

So production planed for 100% + 0.5%
Production for speed frame= 7000 + 0.5% of 7000
=7035 kg

Should be Per shift per Per day per No of m/c

count Production/spindle/ m/c( x 120) m/c at 90% eff Required per
shift in kg X3 day
30 7.287 874kg 2361 kg 7210/236 =3m/c
40 4.9 587 kg 1586kg 5150/1586=3.24
= 3 m/c
24 10.29 1235 kg 3334 kg 3090/3334=0.92
= 1 m/c
For Draw frame (RSB):-

Delivery speed =500 Mt/min

Count = 0.120
Waste= 0.5%
Eff=90%
Production per shift for Draw frame = Delivery speed Mt/min x 0.2834
---------------------------------------- Kg
Count
=500 x 0.2834
-------------------
0.120
=11808 kg
Production per day for Draw frame = 11808 x 3 shift
= 35424 kg for 100 % eff.
= 3188 kg for 90% eff
In draw frame waste is 0.5 %
So production planed for 100% + 0.5%
Production for speed frame= 7210 + 0.5% of 7210
=7246 kg

count Production Per Per day per No of m/c

shift per m/c m/c at 90% eff Required per
X3 day
30 11808kg 3188 kg 7246/3188=2.27
40 11808kg 3188kg 5176/3188=1.6
24 11808kg 3188 kg 3106/3188=0.97
= 1 m/c
Carding Production:-

Delivery speed = 150 Mt/min

Count= 0.120
Waste= 2%

Production per shift per card = Delivery speed Mt/min x 0.2834

---------------------------------------- Kg
Count
= 150 x 0.2834
-------------------
0.120
=354 kg
Production per day for Card = 354 x 3 shift
= 1062kg for 100 % eff.
= 956 kg for 90% eff
In Carding waste is 2 %
So production planed for 100% + 2%
Required Production for carding= 7246 + 2% of 7210
=7391 kg

count Production Per Per day per No of m/c Total m/c

shift per m/c m/c at 90% eff Required per Required
X3 day
30 354kg 956 kg 7391/956=7.7
40 354kg 956kg 5279/956=5.5 17
24 354kg 956 kg 3168/956=3.3

Summarize Plan:-

Count Ring Frame Speed Frame Draw frame Carding

Production M/c Production M/c Production M/c Production M/c
30 7000 10 7210 3 7246 2.5 7391 7.7
40 5000 10 5150 3 5176 1.5 5279 6
24 3000 4 3090 1 3105 1 3168 3.3
Total 15000 24 7 5 17
Lot No.

From Lot No we can know following parameters:-

Ex. 1 30 2 4 97 .5

Type count Blend Blend% Sr.No Unit

Single 30 PV 65/35 97 Wani

1st Digit 2nd & 3rd 4th 5th 6th & 7th 8th
Type Count Blend Blend % Sr No. Unit
1-Single 0-PC 0-100 From 10 To 99 1-RSR
Combed
2-Double 1-PC Carded 1-15/85 2-Gima
Hgt
3-Air Jet Double 2-PV 2-40/60 3-Gima
Wani
4 –Airjet TFO 3-100% Vis 3-
50/50,52/48
5-CoreSpun 4-100% P 4-65/35,
Lycre 67/33, 70/30
6-Multiple Yarn 5-Dyed 5-85/15
7-Core spun fill 6-Melange 6-60/40
8 -SlubYarn 7-CV 7-80/20
9 -RingTFO 8-100%C 8-35/65
9-Other 9-20/80
Yarn Faults

1) Classimate faults
The faults produce in the yarn are classified on the basis of length and yarn
diameter.
Length of fault in cm.
Diameter of fault is taken in percentage of std diameter.
Faults are measured for per 100 km of yarn.
Faults upto 8 cm length are short faults and more than that are long faults.

Types of faults
A – 0.1 to 1 cm length
B – 1 to 2 cm length
C – 2 to 4 cm length
D – 4 to 8 cm length
F- 8 to 32 cm length
G – more than 32 cm length
E –more than 8 cm length having diameter more than +100%

0- Diameter 75 to 100 % more than Std Diameter

1- Diameter 100 to 150 % more than Std Diameter
2- Diameter 150 to 250 % more than Std Diameter
3- Diameter 250 to 400 % more than Std Diameter
4- Diameter more than 400%

A1- 0.1 to 1 cm length and Diameter 100 to +150 %

A2- 0.1 to 1 cm length and Diameter +150- to +250 %
A3 -0.1 to 1 cm length and Diameter +250- to +400 %
A4 -0.1 to 1 cm length and Diameter 400 % more.

B1 -1 to 2 cm length and Diameter 100 to 150 %

B2 - 1 to 2 cm length and Diameter +150 to 250 %
B3 -1 to 2 cm length and Diameter +250 to 400 %
B4-1 to 2 cm length and Diameter 400 % more

C1 -2 to 4 cm length and Diameter 100 to 150 %

C2 - 2 to 4 cm length and Diameter +150 to 250 %
C3 -2 to 4 cm length and Diameter +250 to 400 %
C4-2 to 4 cm length and Diameter 400 % more

D1 -4 to 8 cm length and Diameter 100 to 150 %

D2- 4 to 8 cm length and Diameter +150 to 250 %
D3 -4 to 8 cm length and Diameter +250 to 400 %
D4 -4 to 8 cm length and Diameter 400 % more
 F - 8 to 32 cm length and Diameter +45to 100 %
G- 32 cm more length and Diameter +45to 100 %
E – 8 cm more length and Diameter above 100 %
H1- 8 to 32 cm length and Diameter –30 to -45 %
H2- 8 to 32 cm more length and Diameter –45 to -75 %
I1 - 32 cm more length and Diameter –30 to -45 %
I2 - 32 cm more length and Diameter –45 to -75 %

Short Thick Places:-

A1, A2, A3, A4, B1, B2, B3, B4, C1, C2, C3, C4, D1, D2, D3, D4

Long Thick Places:-

E, F, G

Long Thin Places:-

H1,H2, I1, I2

Non Objectionable Faults:-

A1, A2, A3, B1, B2, B3, C1, C2, D1, D2.
Objectionable Faults:-

A4, B4, C3, C4, D3, D4

2) Imperfections:-
Imperfections are the number of thick places, thin places and neps in yarn per 1
km length.

Imperfections are measured per 1000 m length of yarn.

Imperfections are of following types

Thin Places – Yarn Diameter is less than 50% of Std Diameter.

Thick Places – Yarn Diameter is more than 50% of Std Diameter.
Neps – Yarn Diameter is more than 200% of Std Diameter.

3) Uster Percentage:-

The unevenness present in yarn, measured per 1000 m length of yarn which are
non objectionable faults.

Good Quality – Uster % should be low.

CSP TESTING:-

CSP is Count Strength Product.

Yarn quality is decided by the CSP of the yarn.
For checking CSP of Yarn 120 yard Lea is taken as yarn sample.
First Lea is weighed for count checking and then Lea is put on strength testing m/c.
Count is No of 840-yard hanks of yarn per pound.
Strength is the ultimate stress that can be sustained by yarn in Pound.

CSP Testing is done for Yarn of Roving, Ring Frame bobbin yarn, final Cone yarn,
Ring double yarn, Final cone double yarn.

For Carding and Draw frame sliver only wrapping test is done.

The avg value of all the reading is taken as final result if readings are abnormal then the
report is immediately communicated to respective dept. after corrective action again CSP
Test is done.

The Count Variation should not be greater than 1.3% for Yarn
1% for Roving
0.4% for Draw frame sliver
4% for Card sliver.

TPI TESTING:-

TPI of single, double and open-end yarn can be found on the Statex Twist Tester.

TPI testing is done for the 20 cm of single yarn length, 15 cm length of double yarn, in
case of high twist yarn the test length is reduce to 10 cm.

20 tests are carried out for one sample. The avg. value of the all test result is taken as
final result.
High & Low TPI Neps, No of Plys and Hairiness Testing:-

From each lot 60 bobbins per M/c are bringing for testing.
The bobbins are checked for all above faults,
By visual inspection in sunlight,
the hairiness bobbins
Neppy bobbins
Three or four ply bobbins
High TPI bobbins
Low TPI bobbins
Are found and a report is prepared showing all above faults.

USTER % TESTING:-

This test done for the checking unevenness present in the yarn.
It is found per km length of yarn.
Testing is done on USTER TESTER 4

U%- Irregularity (unevenness) of mass in yarn

Or variation in % from means mass of yarn.

CV:- Overall mass variation based on a cut length of 1 cm.

Index:- Shows how close a yarns actual CV is to theoretical CV.

Thin and Thick Places:- No of Thin (-50%) and Thick (+50%) places yarn imperfection
per 1 km of yarn.

Neps:- No of thick places having cross section diameter more than 200%.

Relative Count:- The mass variation of test length as compare to avg mass of all
samples.

Hairiness:- The ratio of the total length of protruding fibers per cm of yarn.

Sh:- std deviation of hairiness.