Interny Report Raw

Report on Industrial Attachment in Sinha Rotor Spinning Limited
CHAPTER VII
MAINTENANCE OF MACHINES
BANGLADESH UNIVERSITY OF TEXTILES
Maintenance
Maintenance points in Blow Room:
MACHINE
NAME
Unifloc A11
MAINTENANCE
POINTS
Chasis
Take off Unit
Take off roller
Retainer roller
Conveyor belt
Uniclean B11
Unimix B 7/3
Uniflex B 60
Jossi
Waste opener
B 2/5
Mono cylinder
B 4/1
Mix bale opener
B
Sensor
Control cabinet
Cleaning cylinder
Cleaning grid
Airlock cylinder
Gear and drive motor
Sensor
Chamber
Upright lattice
Blending roller
Take off roller
Sensor
V-belt pulley
Lamellar chute
Perforated roller
Opening &cleaning
cylinder
Cleaning grid
Gear and drive motor
Sensor
Tube light
CCD camera
Sensor
Upright lattice
V-belt and pulley
Beater
Upright lattice
V-belt and pulley
Sensor
WORK TO BE DONE
Clean properly by compressed air.
Check & clean properly by
compressed air.
compressed air.
compressed air.
Lenses to be cleaned by soft cloth.
Clean by skilled person..
Properly clean & check any damage.
Check any damage & position.
Check & clean properly.
Clean properly.
Clean, check belt & chain tension.
Cleaned by soft cloth & compressed
air.
compressed air.
Check any damage & position.
Clean properly.
Clean by soft cloth.

Maintenance carried in Blow Room:

Periodic maintenance : After 7 to 10 days
Maintenance Period
: From 8a.m. to 5p.m.
No of men in maintenance of Blow room to carding machine

are ten
Maintenance Assistance
Maintenance Helper
:3
:7
Schedule maintenance
: After two weeks
Preventive maintenance
: 1 month or 3 months.
Maintenance Tools for blow room to carding machine:
Adjustable range
Screw driver
Hammer
Spancer etc.
Lubrication schedule:
1 month, 3 month, 6 month, 1 year, 1 and a half year.
Duration of maintenance for carding machine
Duration of maintenance for blow room
: 2.5 to 3 hrs.
: 3.5 to 4 hrs.
Maintenance procedure:
At the beginning of the maintenance operation, all the covers of the
machines are opened and the machine is cleaned with a cloth internally. This is
called as general cleaning. Inside the machine the conveyor belt tension (if
present) is checked and wooden lattice is also cleaned and conveyor belt is
cleaned if needed. Jam in the two sides of spiked lattice is opened and under
cover of spiked lattice is opened and cleaned. Jam in the sides of bearing house
of evener roller with oils or lubricants as instructed by the manufacturer. China
box is checked and jam is cleaned if necessary. M/C parts are checked
conveniently and or changed if necessary.

Examples of maintenance procedure instructed by the

manufacturer :
Name of the machine
: Uniflock
Maintenance and Lubricating schedule : Every month

Item
Plucker roller
Head slewing
Traverse
Flexible pipe
Internal structure comb
Actoin
Inspect for sign of damage
Ensure clean
Inspect and clean cowl plate grille
check condition
Ensure clean
Maintenance and Lubricating schedule : Six month

Item
Plucked roller
Plucked roller drivers
Head lifting drive
Head slew drive
Transport fan drive
Action
Check condition of the teeth
V-belt drive check
Duplex drive chain-chain tension
Drive belt check tension
Maintenance and Lubricating schedule: One year

Item
Bearing for plucker roller
Cutting head
Tower support head
Action
Replenish lubricant using shell
Alvania-3 or equivalent
Do
Lubrication of head drive unit:
Mobil synthetic oil ED62/230 viscosity class VG680 or equivalent.

Lubrication of head slewing drive unit:
Shell BP mineral oil viscosity class VG220 or equivalent.
Lubrication of traverse drive unit:
Shell BP mineral oil viscosity class VG220 or equivalent.
Name of the machine: Unimix

Maintenance and lubricating schedule: Every three
month.
Item
Action
Variable speed for feed rollers

Variable speed for beater rollers
Conveyor belts

Duplex drive chain lubricant using,
gear box check oil levels and replenish
if necessary.
Duplex drive chain to roller lubricating
used.

Maintenance check list of carding m/c :

MAINTENANCE AREA
MAINTENANCE POINTS
Aero feed
Opening roller
Lap roller
Feed roller
Licker in
Flat
All Flat belts
Card C 51
Doffer
Detaching roller
Cross roller
Delivery roller
Calendar roller
Pneumatic system
All suction points
Cylinder
Control cabinet
Feed roller to licker-in
Gauge
Licker-in to cylinder
Cylinder to doffer
Cylinder to flat
Coiler
Doffer to stripping
roller
Coiler calendar roller
Rotary plate for can
Drive for rotary can
plate
Can changer
WORK TO BE DONE
Check and clean.
Check and clean.
Check and clean.
Check and clean.
Check and clean.
Clean properly & check
sharpness of the wire.
Clean, check tension &
adjust if required.
sharpness of the wire.
Check and clean.
Check and clean.
Check and clean.
Check and clean.
Clean & check condition.
sharpness of the wire
Clean properly
Check gauge & adjust if
required
required
required
required
required

Maintenance points
Frequency
Suction points and hoses

2 weeks
Interior of the coiler
2 weeks
Detaching unit
2 weeks
Check the doffer
2 weeks
Clean flats reversing points & the space
Inside the flats
2 weeks
Empty condenser
3 months
Check the tension & condition of the belts
2 weeks
Check the condition of the flat bar
6 months
Clean & check carding profiler
3 months
Check the tension of the flat belt
2 weeks
Cylinder inside & Cylinder gasket
6 months
Check the stripping knives
3 months
Check the bottom of the coiler & coiler tube
3 months
Check setting
6 months
Maintenance of draw frame, comber & simplex:
Nine person are involved in D, C, S maintenance.

Number of maintenance assistant 4
Number of maintenance helper 5
Schedule maintenance After 2 weeks
Preventive maintenance 1 month, 2 month, 3 month
Maintenance check list of Breaker drawing:

MAINTENANCE
AREA
Outer surface
Drafting zone
MAINTENANCE POINTS
WORK TO BE DONE
Outer surface of the whole

machine
Pressure bar, dead weight,
condenser, trumpet.
Top roller
Clean properly by
compressed air.
Clean properly check its
condition.
Cleaning by washing powder
Bottom roller
Gear box
Planetary gear box
Electrical parts
Motor, fan, creel light barrier
Nut-bolts
Top roller lock, pulley nutbolt, creel nut-bolt, drafting

zone nut-bolt
Flat belt, V-belt, timing belt
Belt tension and

condition
Suction system
& grinding after 5000 hour.

Clean & check its gauge,
reset if required.
Check oil level & put oil if
required.
Clean & check by electrical
person.
Check tightness & make
perfect tightness if required.
Clean all the belt, check

tension adjust if required.
Filter box, filter screen, fan
Clean properly filter & blade
blade
condition.
Can Changer
Can plate
Power cylinder
Maintenance procedure of lap former:

At first, the great box is opened and grease is applied to all
gears. Top and bottom rollers are opened and cleaned with spirit. Top roller, feed
roller, calendar roller, sliver table, sliver guide, counter shaft, conveyor belt,
guide roller, lap plate, lap drum, bobbin box, bobbin feeder, creel parts are
cleaned. In all the bearings and gearings of the above parts lubrication is carried
out. All the nuts and bolts are checked. If any parts of the m/c is damaged, it is
either changed or repaired. Then the whole m/c is set sincerely and the m/c is
started experimentally to watch if the m/c is running smoothly.
Maintenance checklist of Lap former:

Maintenance
Area
Suction Unit
Drive motor
Sliver feed
frame
Table calendar
Maintenance Points
Work to be done
Waste suction pipes, motor

knives.
Filters
All belts and chains
Clean & check suction

properly.
Clean, check tension, greasing
& apply grease if required.
setting.
Clean & check its physical
condition.
Clean & check gauge reset if
required.
Clean & check gear, vibration,
abnormal sound etc.
Clean all sensor unit by soft
cloth.
Guide rolls, sliver guide
Drafting system
Top cleaning device & bottom

cleaning device
Top and bottom roller
Gear units
Setting gear
Sensors
All sensors unit
Safety Device
Nut and bolt
Electrical
function
Lubrication
Safety switch, pneumatic

switch
Main gear box, drafting gear
box, lap plate etc.
Main motor, electronic board,
connection board etc.
Main gear box, drafting gear
box and all greasing point
Check safety device.

Tightness check & make
correct if required.
To be cleaned & checked by
electrical function.
required, also check greasing.
Maintenance procedure of comber:

According to the schedule maintenance of particular
m/c is done. First gear box is opened, then all the gears are cleaned and grease
is applied to gears and cover is set again. Top detaching roller, bottom detaching
roller, top drafting roller, bottom drafting roller are opened and spirits is served
to clean these rollers are set to the machine. Sliver table, sliver guide, top comb
nipper, cushion plate, feed roller, lap roller, cylinder, cylinder brush, wastage
suction pipe, coiler box and can wheel cover are opened and cleaned and grease
is applied to every bearing and gearing. Then all the nuts and bolts are checked.
In bottom detaching roller corium 157 is used. If any part of the m/c is damaged,
it is changed or repaired. After this, machine is started.
Maintenance checklist of Comber:

Maintenance Area
Drafting system
Gauge points
Belt tension and

physical condition
Delivery unit
Maintenance points
Top bottom and stripping
roller
Top comb and circular comb
setting and condition.
Nipper feed plate, nipper
gauge, bottom detaching
roller
V-belt, timing belt and flat
belt.
Feed table, table funnel,
calendar roller and trumpet
Nipper, nipper level on in
feed side, circular comb
brush
Feed roller, nipper lips, top
detaching roller, guide plate,
top delivery roller and lap
Work to be done
Clean Properly & check
physical condition if
required.
Gauge check & adjust if
required.
Gauge check & adjust if
required.
tension & adjust if required.
Clean & check condition if
required.
Clean & check condition if
required.
Clean & check condition
gauge, adjust if required.
plate.
All gear
Gear box
Oil level in gear box

Electrical parts
Can changer
Greasing points
Nut Bolts
Motor, switch, connection

board, electronic board,
motor fan
Chain tension on turn table
Belt tension roll axles and
other greasing points.
Beating bush of the top
detaching roller
Drafting roller, stripe nipper
frame, lower delivery and
table calendar
Top roller pressure, main
gearbox, top comber nipper,
all pulley, index wheel, coiler
wheel, lap feed plate, lap
roller nut-bolt, circular comb,
can wheel.
Check gear condition &

Check oil level and apply oil
if necessary
Clean & check by electronic
person.
Clean & check condition,
adjust if required.
Clean & check grease if
required.
required.
required.
Check tightness and make

Maintenance parts of comber E-62 by Rieter :
Cylinder comb
Nipper
Top comb
Detaching roller
Bottom feed roller
Bottom top roller
Brush
Drafting rollers
Noil % control system :
Top comb setting change
Ecartment setting change
Lubrication points :
Drafting system
Bottom detaching rollers
Top detaching rollers
Rush
Nipper
Gear box
Circular comb
Table calendar roller drive shaft
Spare parts life :

Parts
Top comb
Cots
Bearing
Life time
1-1.5 years
2-3years
6 years
Maintenance procedure of draw frame:

First gear box is opened and cleaned finally with cloth. Then grease
is applied to gears. Roller part is opened and cleaned with spirit. In all the
bearing of cover is opened and cleaned. In the bearing gears, grease is applied.
All the settings, nuts and bolts are checked. If necessary any parts of the
machine can be changed.
Maintenance check list of Breaker drawing:

MAINTENANCE AREA
Outer surface
Drafting zone
MAINTENANCE POINTS
Outer surface of the
whole machine.
Pressure bar, dead
weight, condenser,
trumpet.
Top roller
Bottom roller
WORK TO BE DONE
Clean properly by
compressed air.
Clean properly check its
condition.
Cleaning by washing
powder & grinding after
5000 hour.
reset if required.
Gear box
Planetary gear box
Electrical parts
Motor, fan, creel light

barrier
Top roller lock, pulley nutbolt, creel nut-bolt,
drafting zone nut-bolt.
Flat belt, V-belt, timing
belt
Filter box, filter screen,
fan blade
Can plate
Power cylinder
Nut-bolt
Belt tension and

condition
Suction system
Can changer
Gear

required.
Clean & check by
electrical person.
perfect tightness if
required.
Clean properly filters &
blade condition.
Check & clean meshing
condition, vibration,
abnormal noise etc.
Maintenance check list of Finisher drawing:

MAINTENANCE AREA
Outer surface
Auto leveler
Drafting zone
MAINTENANCE POINTS
whole machine
Funnel, scanning roller,
contact roller
Pressure bar, dead
weight, condencer,
trumpet.
Top roller
WORK TO BE DONE
Clean properly by
compressed air.
Clean & check their
condition adjust if
required.
Clean & check their
condition adjust if
required.
Cleaning by washing
Bottom roller
Gear box
Planetary gear box
Electrical parts
Motor, fan, creel light

barrier
Top roller lock, pulley nutbolt, creel nut-bolt,
drafting zone nut-bolt.
Flat belt, V-belt, timing
belt
Filter box, filter screen,
fan blade
Can plate
Power cylinder
Gear
Nut-bolt
Belt tension and

condition
Suction system
Can changer
powder & grinding after

5000 hour.
reset if required.
required.
Clean & check by
electrical person.
perfect tightness if
required.
Clean properly filters &
blade condition.
Check & clean meshing
condition, vibration,
abnormal noise etc.
Spare parts life :

Parts
Cots
Belts
Timing belts
Cans
Bearing
Life time
6-8 years
3-4years
10 years
6 years
6 years
Maintenance procedure of simplex:

At first the machine is opened and a general cleaning is done.
Greasing done to all outer bearings. Gear box is opened according to the
authorized booklet of the machine. Top and bottom rollers are opened and
cleaned with spirit and then acid treatment is done. Cotton aprons are opened
with jet powder and then acid treatment is done. Collector, condenser, sliver
guide, top and bottom cleaner, roller stand, roller beam, top arm, lifter rack,
building part, creel part and each flyer and bobbin rail cover are cleaned. At the
last every nuts and bolts are checked. Thus routine maintenance in the simplex
machine is carried out.
Maintenance checklist of Simplex:

MAINTENANCE AREA
Back side
MAINTENANCE POINTS
Creel
Sensor
Balancing spring and
chain
Creel chain
Rack groove
Grease level in the
grease pump
Top and bottom roller
Condenser assembly
Drafting zone
Traverse bar and sliver

guide
Neck bearing of bottom
roller
Cradle unit
Pressure arm
Top and bottom apron
Yarn cleaner
Flyer rail
Flyer cap
Flyer and its gear
Bobbin rail
Shaft
Bobbin rail and seal
Outer surface
Auto doffing

machine
Auto doffing in machine
WORK TO BE DONE
Clean & check bearing
condition.
Clean by soft cloth.
Clean & check greasing.
Check grease level &
apply grease if required.
Clean & gauge check &
adjust if required.
Clean & check assembly
& adjust if required.
Clean & check setting.
Clean & check & replace
if required.
Clean & check & replace
if required.
Check height gauge &
readjust if required.
Clean properly by
detergent & replace if
required.
Clean by brush replace if
required.
Clean set properly.
Clean & check gearmeshing condition.
Clean & check the gear
condition.
Clean the outer surface
properly.
Auto doffing system is
clean by compressed air.
Maintenance procedure for Ring frame:

First machine cover is opened. All the top aprons and bottom aprons are
opened with Surf ultra. Here acid treatment is done. It is also with ammonia. In
all the middle bearing, necessary amount of grease is applied. Ring plate is taken
down and the ring caps are cleaned with corium 97. After cleaning all the gears,
sufficient amount with corium 97.
If any part of machine is damaged or rough, it is changed or repaired. In this

way, all the works of maintenance is done successfully.
Maintenance checklist of Ring frame:

MAINTENANCE AREA
Cog belt tension
Bottom apron tension
bracket
Type tension roller
condition
All type of timing belt
condition for head stock &
tail stock
ROBO doff, lifting rod, drive
Brushes of servo discs
Cot roller
Cradle
Top & bottom apron
Spindle & spindle break
Pneumatic line, mono
meter & pressure regulator
Pressure hose condition
Gripper membranes
condition
Filter box, filter cloth, seal
of filter drum
Suction tube gauge 1mm
Sensors
Ring cup, balloon control
ring & lappet guide
Ring rail, lappet bar setting
gauge
Spinning traveler cleaner
gauge
Auto doffer, beam &
conveyor belt centre
Roller eccentricity &
MAINTENANCE PONTS
Cleaning & checking condition
required.
required.
required.
required.
if
WORK TO BE
DONE
30 days
if
30 days
if
30 days
if
30 days

required.
required.
required.
required.
required.
required.
required.
required.
required.
required.
required.
required.
required.
required.
required.
required.
if
30 days
if
30 days
if
30 days
if
30 days
if
30 days
if
30 days
if
240 days
if
30 days
if
30 days
if
240 days
if
30 days
if
30 days
if
120 days
if
120 days
if
120 days
if
90 days
if
730 days
bearing condition check

(back & middle roller
Front roller eccentricity,
bearing condition
Driving shaft eccentricity &
bearing condition check
Machine leveling
required.
Cleaning & checking condition if
required.
required.
required.
365 days
730 days
730 days
Maintenance of ring frame:
Twenty three persons are involved in ring frame maintenance

No of maintenance assistance 6
Grade 1=2
Grade 2=4
No of maintenance helper 17
Schedule maintenance : after one month
Cleaning, checking and lubrication are included in ring frame maintenance
Lubrication schedule : 6 months (spindle oil), grease(driving shaft), 1 year
(gear oil),
1 month (bottom roller)
Maintenance of ring frame:

MAINTENANCE AREA
MAINTENANCE POINTS
Waxing shaft
Pressure fork
Waxing device
Yarn trap
Guide plate
Splice cutter
Prism and its cover
Splice unit
Tension device
Untwist nozzle
Clamping guide
Feeder guide
Rubber sleeve
Sensor
Cuter
Lower end sensor
Package adapter
Cradle holder
Sliding part (cradle)
WORK TO BE DONE
Cleaning & checking any
damaged (cwf)
Cleaning & checking any
damaged (cwf)
Remove the yarn
accumulation
Cleaning the wax properly
Cleaning and apply RS-400
Cleaning the prism by
compressed air
Clean/wash by petrol &
brush, checking the position.
Cleaning by cloth.
Checking the position.
Cleaning & checking.
Cleaning carefully & adjust if
required.
Cleaning and apply RS-400
Cleaning the sensing area.
Check for unobstructed
rotation.
Cleaning and apply silicon
oil.
Cradle sensor
Check its cover and screw.
Circular magazine
Check, clean and refixing.
Chute
door
Cleaning and centering
Magazine
check.
Elector
Cleaning and movement
check.
Bobbin peg
Cleaning.
Conveyor belt
Tensioning device
Remove cover from the belt
tensioning device of the
conveyor belt & remove yarn
jam if required.
Deflection roller
Remove loose yarn ends
from the deflection rollers.
Maintenance procedure for Autoconer:
Ten persons are involved for winding m/c maintenance

No of maintenance assistance 3
Grade 1=1
Grade 2=2
No of maintenance helper 7
Schedule maintenance is done for winding m/c
60 drums consist in a winding m/c
Everyday except Friday 12 drums maintenance
Maintenance schedule for a winding m/c
: 45 days
Frequency of each drum maintenance
: 45 days
Cleaning, checking, lubricating are done in winding m/c maintenance.
Lubrication schedule:
Sliding part of gamo, cradle
- 6 months
Driving part inside winding unit
- 3 months
Winding unit outside cam drives and cassette type gear 1 month
Line shaft driving chain
- 2 months
Bearing centre for (right side)
: 6 months
Bearing centre for (left side)
: 6 months
Line shaft gear motor
: 6 months
Cam shaft bearing
: 3 months
Blower shaft
: 1 month
Cassette type joint gear cover
: 1 month
Maintenance checklist of Rotor:

MAINTENANCE POINTS
Rotor
Nozzle
WORK TO BE DONE
Cleaning by dishwasher.
Cleaning by detergent.
INTERVAL
15 days
15 days
Opening roller
Rotor chamber
Belt, pulley
Electrical function
Gear units
Sensor
Robot
Magazine
Cleaning by compressed air.

Cleaning by compressed air.
Clean all the belt, check tension & adjust
if required.
To be cleaned & checked by electrical
function.
Clean & check gear, vibration, abnormal
sound etc.
Clean all sensors unit by soft cloth.
Check & cleaning by compressed air.
Check & cleaning by compressed air.
15 days
15 days
15 days
15 days
15 days
15 days
15 days
15 days
List of Maintenance equipments for general purpose:

1.
2.
3.
4.
Dial Gauge
: used measure roller eccentricity.
Tightening tools
: used to tight bottom roller.
Thickness gauge
: to measure thickness.
Straightening gauge
: used to measure straightness of bottom
roller after joining.
5. Grease pump
: use to apply grease.
6. Stropping pliers
: to open or close the ring.
7. Spring piece for level plate
: for leveling parts of m/cs.
8. Bobbin rail jack
: use to level the bobbing rail.
9. Weight gauge
: use to alignment of the arm pressure.
10.Carding gauge
11.Outside calipers
: use to measure the dia.
12.Roller setting gauge
: use to set roller to roller distance.
13.L-key
14.Ring spanner
15.Spindle gauge
: use to set spindle at the center of the
ring.
16.Double end spanner
: use to open the nut bolts.
17.Soft hammer
18.Puller
19.Oil can
20.Grease gun
21.Nose pliers.
CHAPTER VIII
UTILITY SERVICES
Utility service
The utility department undertakes the following units:
1. Power supply
6. Workshop services
2. A/C Plant
7. Water treatment & water supply
3. Water collection plant
8. Civil works
4. Chiller
9. Fire-fighting system
5. Boiler
Power Supply (Generator)
Sinha spinning mill generate its own power. It has six generator in SRSL and
three generator in SSL. The generator specifications are given below:
Generator of SRSL:
Name: JENBACHER Engine
Model: JGS 320
Country of origin: Austria
Year of manufacturing: 2000
Necessary information:
Number of Generator: 6 (5 generator runs for power supply and 1 stand by)
Capacity: 1006 Kw
Production requirement: 60-70% of capacity
Type of Generator: Gas Generator
Synchronizing system: Auto synchronizing system
Controlling system: PLC (Programming Logic Control) Controlling system
Number of cylinder per generator: 20
Gas source: TITAS Gas
Gas line pressure: 14.5 PSI

RPM: 1500
Voltage: 415
Frequency: 50Hz
Gas consumption per day: 18000-20000m3
Price of gas: 4.18taka/m3
Island parallel operation:

Cylinder Exhaust Gas temperature:
Average : 542oC
Maximum : 552oC
Minimum : 534oC
Return water temperature: 63.6oC

Jacket water temperature: 81.6oC
Jacket water pressure:
1.11 bar
Engine oil temperature:
79.0oC
Engine oil pressure:
4.2 bar
Generator of SSL:
Name: JENBACHER Engine
Model: JGS 320
Country of origin: Austria
Year of manufacturing: 2006
Necessary information:
Number of Generator: 3
Capacity: 1064 Kw
Production requirement: 60-70% of capacity
Type of Generator: Gas Generator
Synchronizing system: Auto synchronizing system
Controlling system: PLC (Programming Logic Control) Controlling system
Number of cylinder per generator: 20
Gas source: TITAS Gas
Gas line pressure: 10 PSI

RPM: 1500
Voltage: 415
Frequency: 50Hz
Price of gas: 4.18 taka/m3
Boiler:
Number of boiler: 1
Capacity: 10 Kg/hour
Production: 5.6 Kg/hour
Source of heat: Exhaust of generator
Temperature raised: 550oC (Maximum)
Steam pressure: 405 Kg/cm3
Manufacturer: Hurst Boiler, India
Serial no: BA.BO. 2332
Compressor
Compressor 1
Manufacturer: Comp Air Drucklufttechnik GmbH, Germany
Type: L160-9A (Delcos 3000)
Voltage: 400V
Year of Manufacture: 2002
Serial no: 349020/0206
More information:
Capacity: 26.10m3/min
Motor: 160KW
Suction pressure: 1bar
Speed: 1500rpm
Stage pressure: 9bar
Compression medium: Luft/Air
Receiver:
Manufacturer: Lohenner GmbH & CO, Germany
Serial no: 81857
Date of Manufacture: 26.08.2002
More information:
Capacity: 2000 L
Working pressure: 11 bar (maximum)
Working pressure: 0 bar (minimum)
Test pressure: 15.8 bar
Compressor 2
Manufacturer: Comp Air, England
Model: 6220N8A
Serial no: F146/0827
Year of manufacture: 1997
More information:
Capacity: 29.10m3/min
Maximum pressure: 8 bar
Motor (KW input): 199.1 KW
Motor RPM: 1480
Voltage: 415V
Phase: 3Ph
Frequency: 50Hz
Compressor 3
Manufacturer: Atlas Copco
Model: GA 75
Serial no: 473279
Year: 2001
Country of origin: Belgium
More information:
Maximum working pressure: 7.5 bar
Free air delivery: 1/s=236
Nominal shaft power: 75Kw
Rotational shaft speed: 300.0
Gross weight: 1600 Kg
Compressed Air Dryer:

Model: Js-100Ac
Date of manufacture: 29.08.2001
Capacity: 14.4 Nm3/min
Maximum inlet temperature: 70oC
Maximum inlet pressure: 10 Kg/cm2
Amp: 7
Voltage: 415V
Phase: 3
Frequency: 50Hz
Compressor 4
Manufacturer: Atlas Copco
Model: GA 75
Serial no: 472583
Year: 2001
Country of origin: Belgium
A/C plant:
The factory consists of five A/C plants in SRSL and the two A/C plant in SSL.
The A/C plant in SRSL for
Blow room
Carding
Simplex
Rotor
Ring
AC Number
1
2
3
4
5
Use for the Area

Blow Room
Carding& drawing (Rotor side)
Carding, drawing, comber & simplex
Ring (East & West side)
Rotor & Auto cone
The A/C plant in SSL is for
Rotor
The manufacturer of A/C plant for SRSL & SSL is BEST AIR.
The main task of A/C plant is to maintain specific humidity in the factory in
the shed, for this it circulates the cooling air. A/C plant without chilling helps to
maintain only the RH% without much difficulty. They can be classified generally
as either unitary or central station. Central system is the most widely used in the
textile industry.
The systems principal components are:
1. Air moving devices-fans.
2. Mixing devices for air and washer i.e. Air washers.
Air moving devices are always two types:
1. Return Air fans
2. Supply Air fans
The return air fans return the air to the plant room from where it may circulate or
exhausted in the mill.
The supply of air to the mill from plant room.
Air washer is a device for intimately mixing water and air. The mixing water and
air supply by nozzle.
Number of fans in different AC:

Name of fans/pump
Return Fan
Supply Fan
Waste water pump
Main suction fan
Disk-pre separator
Material transfer fan
Fiber compactor
Duct Evacuations fan
Rotary air fan
AC 1
1
1
1
2
2
5
2
1
1
AC 2
1
1
1
2
1
1
1
1
AC 3
3
3
2
2
2
2
2
2
2
AC 4
6
6
3
AC 5
3
2
1
2
1
4
4
3
1
2
2
The following components are a must in an A/C plants:
Return Air and Supply Air fans.

Air washer
Return Air floor grills.
Exhaust damper
Fresh air damper
Supply air ducts and grills
Face and bypass dampers on the air washer
Control panel for Automatic control the RH and Temperature.
The fresh air come from outside, air is sucked by fan. Then the air humidified
in the washer room. In the washer room air and water is mixing then it supply
by nozzle through the supply air fan. Supply air fan supply the cooling air
through the air floor grills. The invisible waste is separated by filter and fresh
air sucked by return air. Then the air is circulating again in the washer room. It
is continuous process.
The humidity and temperature controlling depend on the machine
performance, machine life and on personnel.
A/C plant is must needed for textile industries mainly spinning shed- if A/C
plant will run smoothly then the operators will feel comfortable and
performance will be optimum.
Otherwise all these will suffer.
Supply and Return Air Fan capacity:

Suction
Carding
Drawing
Lap former
Comber
Simplex
Ring
Auto cone
Rotor
Supply air capacity

74000 CMH
70000 CMH
70000 CMH
70000 CMH
70000 CMH
452000 CMH
70000 CMH
106000 CMH
Return air capacity

17180 CMH
237820 CMH
237820 CMH
237820 CMH
46700 CMH
436640 CMH
67900 CMH
100020 CMH
Number of Air Change Cycle per hour:

Suction
Carding
Drawing
Lap former
Comber
Simplex
Ring
Auto cone
Rotor
Air Change Rate (per hour)

29.7
11.9
11.9
11.9
11.8
40.4
20.8
27.3
Importance of RH% and Temperature:

The atmospheric conditions with respect to temperature and humidity play
very important part in the manufacturing process of textile yarns. The
properties like dimensions, weight, tensile strength, elastic recovery,
electrical resistance, rigidity etc of all textile fiber whether natural or
synthetic are influenced by moisture regain.
Moisture regain is the ratio of the moisture oven-dry weight of the material
expressed as percentage. Many properties of textile materials very
considerably with moisture regain, which in turn is affected by the ambient
Relative Humidity (RH) and Temperature. If a dry textile material is placed in a
room with a particular set of ambient conditions, it absorbs moisture and in
course of lime, attains equilibrium.
Some physical properties of textile materials which are affected by RH is

given below:
Strength of COTTON goes up when R.H.% goes up

Strength of VISCOSE goes down when R.H.% goes up
Elongation% goes up with increased R.H.% for most textile fibers
The tendency for generation of static electricity due to friction
decreases us RH goes up
At higher levels of RH, there is also a tendency of the fibers to slick
together
Temperature alone does not have a great effect on the fibers- However the
temperature dictates the amount of moisture the air will hold in suspension and
therefore, temperature and humidity must be considered together.
ISO Standard # 139 defines Standard Atmospheric Conditions:
Temperature of 68
Relative humidity 75%
RELATIVE HUMIDITY & TEMPERAURE FOR DIFFERENT

DEPARTMENT:
Section
R.H.%
Temperature
o
C
F
38.5
101.3
37.9
100.22
37.5
99.5
37.7
99.86
38.0
100.4
39.0
102.2
39.1
102.38
o
Blow Room
Carding
Comber
Simplex
Ring
Auto coner
Rotor
49.6
54.5
55.0
60.2
58.3
63.0
59.8
Chiller:
The main purpose of chiller is to supply chilled water to the A/C plant. Here three
chiller in SRSL and one chiller in SSL.
Chiller 1
Manufacturer: Thermax Ltd, India
Type: DE
Model: EW 770V
Serial no: 18
Manufacturing date: August, 2000
Other information:
Capacity: 770 TR
Cooling system: Steam heated vapor absorption cooling system
No. of cooling tower: 2
Steam pressure: 8.0 Kg/cm2
Temperature of the cooling water: 23oC (it should be> 10oC)
Voltage: 415V
Phase: 9Ph
Frequency: 50Hz
Chiller 2
Type: Hot water
Model: THW-LT/16
Serial no: 2
Manufacturing date: October, 2000
Other Information:
Capacity: 160 Nom. RT (Nominal Refrigeration of tons)
Cooling system: Hot water
Temperature of hot water: 67oC
Voltage: 415V
Phase: 3 Ph
Frequency: 50Hz
Chiller 3(it does not work)

Type: Hot water
Model: THW-LT/42
Serial no: 3
Manufacturing date: March, 2000
Other information:
Capacity: 425 Nom. RT (Nominal Refrigeration of tons)
Cooling system: Hot water
Temperature of hot water: 87oC
Voltage: 415V
Phase: 3 Ph
Frequency: 50Hz
Fire Fighting System:

Cotton fiber catches and spreads fire very rapidly. So any kind of accidents
related to fire generation can turn into a devastating calamity in cotton spinning
mill. That is why the factory has a well-equipped firefighting system. Water lines
are spread throughout the factory. External and internal fire fighting groups are
always ready to action. Some workers practice to go out quickly from the factory
during fire alarm is start. It helps to make any action against fire and reduce any
kind of injury.
Number of fire fighters:
Shift
P/A
P/B
P/C
SRSL
20
20
20
SSL
16
16
16
SRSL
59
25
2
10
6
6
7
SSL
24
10
6
5
5
3
4
Fire extinguisher:
Name of fire extinguisher
ABC Power Box
CO2
Foam
Exit Box
House Cabinet box
Smoke Detector
Fire Alarm
Safety against fire hazard:

Automatic fire door
One pair between Blow room and pre-spinning

One pair between pre-spinning and spinning
One pair between spinning and finishing
Firefighting equipment:
Section
No. of fire exit
No. of water drum
Blow Room
Pre-spinning
Spinning
Yarn finishing
Power sub station
Store & godown
Generator house
Total
6
13
20
5
3
3
2
52
5
9
4
4
22
Water in each
bucket
10
10
8
8
36
Hose pipe points:

Location of points
North-west of Blow room
South-west of Blow room
Simplex gate Generator
East of yarn finishing section
Power supply & Power consumption:
Main power source: Generator
Substitute: DESA
DESA Line:
Supply: 1415 Volts

No. of step down transformer: 3
Transformer capacity: 1500KVA
No. of low tension distribution board: 14
Fluctuation: 2-5%
No. of point
2
1
2
1
Humidification Plant
Country of origin: Singapore
Total no. of machine: 5
Machine Presentation:
For Back section: 1
For Ring section: 2
For finishing section: 1
Comber and Simplex: 1
No. of air change (Filtration): 30 times per hour
Air spreading system: by different duel line
Relative Humidity in Different Section:

Back Process: 45%
Ring Section: 52%
Finishing Section: 65%
Comments:
Sinha Rotor Spinning Mills Ltd. try to maintain proper humidity required
for different section. So less problem is occurred in processing materials from
back to finishing section. There is no system for temperature controlling system
by slightly controlling the humidity.
CHAPTER IX
STORE & INVENTORY CONTROL
Store & Inventory control

Raw materials:
Import processing by head office

Physical received by stock spare LC or invoice as bale or Kg.
The raw materials are provided for lay down according to lay down plane
given from Q.C Department.
The inventory systems are divided into four groups:

1.
2.
3.
4.
Raw cotton inventory

Finisher yarn inventory
Wastage yarn inventory
Spare parts & materials inventory
The inventory is maintained in first in first out system. When store keeper receive
some goods, they write a note in the receive book. They also inform inventory
related department. Then the department made MRR (Material Receiving
Report). They made BIN card which contain its name, amount and other
necessary information. Then the materials are stored in the store.
If any department requires any item, they prepare a SR (Requisition Slip) for the
particular item and send it to store. The store then checks its availability and
delivers as required.
1. Raw cotton inventory:
In case of raw cotton inventory, QAD department sampling every bale and
numbering the bale according to micronaire value.
2. Finished yarn inventory:
Different lots of finished yarn are given to the production department by Transfer
Memo. The store produces its daily, monthly production report based on the
yarns are delivered to order of the marketing department, the yarns are
delivered to the buyers.
3. Wastage yarn inventory:
Different wastage produces from different department. Such as hard waste,
pneumafil, FS, dropping etc. They are measured even day and transferred to
store same procedure.
4. Spare parts and materials inventory:
Different type machine parts are stored in the store. When any kind of machine
parts broken, damage etc then this machine parts collect from store.
Finished Yarn: 1) Received from production department
2) Delivered to customer
3) Count, Lot or LC
Engineering stock or spare:

All kind of spare parts are received and stocks are maintained.
At first received by reporting system
Stock purchase required
Material receiving report (MMR)
Posting to bin card
Issue
Balance position
N.B: Gate pass is required for receiving or delivery.
Quality certify by the following items:
SPR no.
MRP no.
Chalan no.
User name.
Reference
Remarks: Sinha Spinning mill tries to maintain proper stock report required for
different section. So less problem is occurred in processing materials from back
to finishing section. The store department & inventory control system of this mill
is well organized.
CHAPTER X
STUDY OF YARN COSTING

&
MARKETING ACTIVITIES
Study of yarn costing

Type of cost: There are three types of cost mainly related to the yarn costing.
These are given below:
Manufacturing cost
Selling cost
Marketing cost
Product Cost:
Product cost consists of the following costs:
Cost of raw materials:
L/C price
C & F Value
Landing cost
Transport cost
Carrying, Loading & Unloading cost
Conversion cost:
Bale management cost

Wastage cost
Machine cost
Machine depreciation
Fuel cost
Lubrication cost
Power cost
Spare cost
Manpower cost
Salary & Wages
Bank interest
Establishment cost
Packing cost:
Paper cone
H.D.P.E bag
P.P bag/ Hosiery bag / Cartoon
Label
Jute twine
Wrapping
Formula of various cost:
Marketing cost= Manufacturing cost + Selling Cost + Distribution Cost

Selling Cost= Manufacturing cost + certain amount of profit
Gross profit= Selling cost Manufacturing cost
Net profit= Gross profit (Bank charge + All sorts Taxes)
Yarn Prizes:
Yarn prize depends on the following factors.
Raw material cost --------60-70%

Spare cost ------------------2-2.5%
Financial charge ----------12-17%
Wages & Salary -----------3-10%
Power cost -----------------3-4%
Others ----------------------1.3-2%
Marketing Activities
Brand name:
1. Sinha Rotor Spinning Ltd.
2. Sinha Spinning Ltd.
Buyer of Product:
1. Denim:
Hamim Denim Ltd.

Pacific Denim Ltd.
Chittagong Denim Ltd.
Royal Denim Ltd.
Sinha Denim Ltd.
2. Textiles:
Sinha yarn dyeing Ltd.

Sinha knitting Ltd.
Adnan textile Ltd.
Asian dyeing Ltd.
Dacca Dyeing Ltd.
Radiance group.
Mascot group.
Shirazgonj Check
Reja Fabrics
Padma textiles
All tex
Bengal textile
Competitors:
a.
b.
c.
d.
e.
f.
g.
h.
i.
Square textile
Shamim textile
Ages cotton
Akij textile
Thermax textile
Sayham textile
Nasa textile
RK textile
Al-Haj Karim Textile
Foreign buyers:
H&M
Mark Kough
Synergies
Lee & Fung
AMC
VF Asia
TCP
Hanes
GAP
Conclusion:
Technical education and its adoption in practical field we involved
inextricably. Without the implementation of the knowledge gathered in technical
education its success bound to suffer. Therefore, this two months long industrial
as a partial fulfillment of our B.Sc. in textile engineering course helped us

accomplish the gap between the theoretical and practical knowledge by
providing an elementary idea about industrial environment processing machines,
tools, equipment production system and maintenance, administration and
management system.
Our selected SINHA ROTOR SPINNING LIMITED may be regarded as the

pioneer of modern spinning mill in our country. It was established a few years
ago with latest model of efficient machinery. Within a very short time it earned
name and fame at home and abroad for its quality in production and
administrative facilities. It is now not only providing knitted yarn to the local
market, but also exporting them to foreign countries at a stationary level. It
mainly uses online process control and its qualify control department helped us
to achieve a profound knowledge about spinning mills production sequence
maintenance, quality control & assurance as well as its organization structure.
We tried our best to gather all necessary information but it is true that
within this short period it is quiet impossible to achieve 100% success as a whole
this industry training was a satisfactory. Once again we should like to thank the
authority of SINHA ROTOR SPINNING LIMITED as well as honorable teachers for
their altruistic help and advice.
----------------------------------------------------------------------------------
THE END

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Report on Industrial Attachment in Sinha Rotor Spinning Limited

BANGLADESH UNIVERSITY OF TEXTILES

Report on Industrial Attachment in Sinha Rotor Spinning Limited

BANGLADESH UNIVERSITY OF TEXTILES

Maintenance carried in Blow Room:

No of men in maintenance of Blow room to carding machine

: After two weeks

Maintenance Tools for blow room to carding machine:

BANGLADESH UNIVERSITY OF TEXTILES

Examples of maintenance procedure instructed by the

Maintenance and Lubricating schedule : Every month

Maintenance and Lubricating schedule : Six month

Maintenance and Lubricating schedule: One year

Lubrication of head drive unit:

Mobil synthetic oil ED62/230 viscosity class VG680 or equivalent.

Name of the machine: Unimix

Variable speed for feed rollers

Duplex drive chain-chain tension

BANGLADESH UNIVERSITY OF TEXTILES

Maintenance check list of carding m/c :

BANGLADESH UNIVERSITY OF TEXTILES

Suction points and hoses

Maintenance of draw frame, comber & simplex:

Nine person are involved in D, C, S maintenance.

Maintenance check list of Breaker drawing:

Outer surface of the whole

Planetary gear box

Motor, fan, creel light barrier

Top roller lock, pulley nutbolt, creel nut-bolt, drafting

Belt tension and

& grinding after 5000 hour.

Clean all the belt, check

Maintenance procedure of lap former:

Maintenance checklist of Lap former:

Waste suction pipes, motor

Clean & check suction

Guide rolls, sliver guide

Top cleaning device & bottom

All sensors unit

Safety switch, pneumatic

Check safety device.

Maintenance procedure of comber:

Report on Industrial Attachment in Sinha Rotor Spinning Limited

Maintenance checklist of Comber:

Belt tension and

Oil level in gear box

Motor, switch, connection

Check gear condition &

Check tightness and make

Report on Industrial Attachment in Sinha Rotor Spinning Limited

Maintenance parts of comber E-62 by Rieter :

Noil % control system :

Top comb setting change

Ecartment setting change

Spare parts life :

Maintenance procedure of draw frame:

Maintenance check list of Breaker drawing:

Planetary gear box

Motor, fan, creel light

Belt tension and

Check oil level & put oil if

Report on Industrial Attachment in Sinha Rotor Spinning Limited

Maintenance check list of Finisher drawing:

Planetary gear box