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FIBRE MANUFACTURE

PROCESS
M.B.O
BREAKER D/FRAME
LAP FORMER

SLIVER LAP M/C


RIBBON LAP

M/C

KINDS OF COTTON USED : INDIAN COTTON


IMPORTED COTTON
INDIAN COTTON TYPE
S-6

100%

S-6

ONGIN

S-6

ORGANIC

J-34

100%

DCH32

100%

DCH32

ONGIN

DCH32

ORGANIC

MCU-5

FAIR TRADE

MCU-5
MCU-5

100%
ORGANIC

IMPORTED COTTON
GIZA-86

EGYPT

GIZA-88

EGYPT

AKDLA

AUSTERLION

ULTIMA

U.S.A

PIMA

U.S.A

SICALA

DISCRIPTION OF M.B.O. :MANUFACTURE

MODEL
NO. OF M/C

LAKSHMI
-

LB3/4 (YEAR 1997)


1

OBJECT OF M/C : To make homogeneous mixture of different types of


fibers.
Opening & cleaning of the material.
Mixing & blending of the fibers.

Removal of dust as a percentage of dust content of the


fibers.

M/C PARTS: Feed lattice with conveyer belt,


Bottom feed lattice with conveyer belt,
Inclined lattice,

Stripper roller,
Evener roller,

Feed roller,

Saw tooth beater.

SUMMERING
OBJECT :To remove the contamination like hair, colour yarn,
jute plastic, polythin, sutli,etc.
PROCEDURE OF SORTING :FOR COTTON SORTING {PROCESS} 1.To hold the cotton in one hand & open the cotton slightly by
other hand.
2. Then, to separated the contamination like hair, pouch, sutli,
white plasti ,etc in different places.
3. Kept the contamination in different places.
4. And after this procedure count to the register.
This process is done by manually.
No. of worker or sorter required for process= 30-40.

PROCESS SEQUENCE BALE (TO BE SORTED)--M.B.O. (MIXING BALE OPENER)FIRST SORTING -SECOND SORTING -TUFT IS FED TO BALE
PRESS M/C
Sorting load acc. to mixing of cotton fibersMIXING

LOAD

90

60

45

35

30

NOTE:- Sorting load in kg/shift/ sorter.


CALCULATION:- If we have 32 sorter in a shift & work
load is 90kgs , then how to calculate the no. of bale.
No. of sorter = 32
Work load = 90kgs/sorter
Wt. of one bale = 170kgs
So, No. of sorter = no. of bale *wt. of one bale /work load
No. of bale = 32*90/170
=17 (approx.)

COTAMINATION SORTOUT IN 45KGS.


VARITY
J-34
S-6
S-6 OG
DCH32
MCU-5
MCU-5 SUPER
DCH32

TOTAL
123
149
105
255
461
234
178

STANDARD
131
169
114
271
495
252
189

EFFICINCY(%)
94
94
93
94
93
93
94

CONTAMINATION STANDARD IN KGS.


VARITY
J-34
S-6
S-6 OG
DCH32
MCU-5
MCU-5 SUPER
DCH32

TOTAL
113
135
101
237
405
208
154

STANDARD
131
169
114
271
495
252
189

EFFICINCY(%)
86
85
89
87
82
83
81

BLOW ROOM DEPTT.


OBJECT : Opening of the raw material.
Cleaning of the raw material.
Mixing of the raw material.
To achieve the uniform yarn quality.
To avoid lot to lot variation.
Removal of magnetic material.
MATERIAL PROCESS FLOW IN BLOW ROOM M/CsBLENDOMAT (BDT)
SP-MF
MAXI FLOW
MPM8
CVT-1
SP-F

MPM-8
CVT-1
SP-F

The Factors which influence the opening and cleaning


efficiency Position of m/c in blowroom sequence.
Penetration of opening spikes.
Angle of grid bars.
Speed of opening rollers.
Area of the grid surface.
Pre-opening of material.
Thickness of feed web.

TYPES OF PIPE USED IN B/R LINE Fire pipes


Material transfer pipes
Micodust pipes
Dropping waste pipes
& some ventilators

NO. OF WORKER IN blowroom = 3


Collection of waste from blow room =6%
Hygrometer type sensor is used in blowroom for
atmospheric conditions.
Relative Humidity (RH%)= 63*F
Temp. in blowroom

= 29*c

DESCRIPTION OF EACH M/C IN BLOW


ROOM LINE
BDT(BLENDOMAT)
Manufacture

Model
No of m/c

TRUTZSCHLER
-

BO-A-2300(YEAR-2005)
1

Operation Performed Bale opening


Blending
Transfer of material to next m/c
Machine Parts :
Suction duct system
Truck
Suction duct for system covering
Tarret
Light burries station
Operators console
Detacher

Working area safeguard system or safety system for


working area

TECHNICAL DATA :
M/C HEIGHT =2.90 mtr
M/C WIDTH

= 5.16 mtr

Working height =1.70 mtr


Working length =5.81-45.41 mtr
Working width

=1.60-2.20 mtr

Working speed =5-15 m/min.


Lifting speed

= 0.85-7.0 m/min.

Speed of toothed disc roll =1.5 rev./min.


Speed of supporting roll =12-36rev./min.
Suction duct unit has length = 2475 mm.
Air fan suction pressure =600-1050 Pa
No of sensor in m/c = 6
Wt. of machine = 2700kgs
Production of m/c =1000 kgs /hr.

The setting of BDT depending upon two factors :


Overall production of the unit,
Length of belt.

Suction duct

Truck :- It give way or it is help in moving to the machine


from left to right & right to left on laydown in straight
manner.
Suction duct covering consist
Cover belt
Wind up device
Cover belt : one end is fitted at suction station &
other end is on winding roller.
Wind up device it is fitted on the truck.
Turret :- In inner suction system ,transformation of tufts
from detacher to inner suction system.
Pressure =0.6 kpa
Two guide rollers,
Two disc tooth rollers,
Two grid bar used below disc tooth rollers.

SP-MF (MULTI FUNCTION SEPRATOR)


MANUFATURER

MODEL
NO. OF MACHINE

TRUSTZSCHLER
-

SP-MF(YEAR-2005)
1

OPERATION PERFORMED : The pneumatic transport of open tuft material through


pipe lines.
The intensive extraction of dust from draw in tuft material.
The separation of heavy material or particals from suction
air stream.

Separation of metal particals.


MACHINE PARTS : Frame
Sheet metal cover
Doors
Fan (BR-FD 500)Drive
Metal detector
Sensor
Fire sensor/ detector
CO 2 Extinguish system
Dust cage & finned stripper roller drive
Exhaust
TECHNICAL DATA :Inner frame width = 1000 mm
Machine width

= 1464 mm

Machine length

= 1100mm

Fan speed

= 1360-2960 rpm

Weight of machine = 580 kgs.

MAXI FLOW PRE-CLEANER


MANUFACTURER

MODEL
NO. OF MACHINE

TRUTZSCHLER
-

0532501 (YEAR-2005)
1

OPERATION PERFORMED
Removal of microdust particals.

Heavy impurities.
Removal of trash from fibers like seed, chaff(leaf
,stalk),dirt &dust,etc.
Removal of dropping waste.
MACHINE PARTS : Two beater (pin type) with drive
Grid bar
A/c motor
Frame
Material suction device
Waste suction device
Inner sheet metal casing
Outer sheet metal casing
TECHNICAL DATA :Inner frame width

=1300 mm

Machine height

= 2100 mm

Machine width

=1464 mm

Machine length

= 1830 mm

Machine weight

=1500 mm

Dia. Of beater roller

= 605 mm

Maximum output

= 850 kg/hr.

Fan speed

=1200 rpm

Beater speed

=780 rpm

Rotation speed limit roll = 1180 rpm


Inlet & outlet pressure difference = 100-320 Pa

Motor speed

= 1450 rpm

Motor rating

= 7.5 kw

Motor frequency

= 50 Hz.

The Grid Bar setting is adjustable & is adjusted acc. to the


requirement of running
Generally it is 2-3 mm.
CALCULATION : - Suppose rotation of beater is x in one
min.& dia. of beater is y Then, how to calculate the no.
of beats/inch.
3.14 *y*no. of beats/inch =x
So, no. of beats/inch =x/3.14*y

MPM-8[MULTI PURUSE MIXER-8]


MANUFACTURER
MODEL
NO. OF MACHINE

TRUTZSCHLER
- MPM-8 (YEAR-2005)

-2

OPERATION PERFORMED
Mixing to different type of cotton,
Stock to material into eight chamber.

Working details : The second concepts are multi mixer MPM-8 , it is available with
eight chambers. The tufts are once again into a m/c by a fan.
The filling procedure & control of the flaps are identical to the
working of multi mixer MPM-8. The difference between the
blending channel underneath the opening rolls, there is no
conveyer belt. The MPM-8 works on the basis of a closed air
circulation, i.e the conveyer air entering the m/c also carries
the material & feeds it into the next m/c .
MACHINE PARTS :This machine is made up of three parts;
1.A storage unit /section ,
Eight chamber
2. An intermediate section ,
Two feed roll , One beater, Sensor
3.A delivery section ,
Air pressure are used for deliver to the material ,conveyer.
TECHNICAL DATA :- Air fan suction pressure =500 Pa

CVT-1( CLEANOMAT)
MANUFACTURER

MODEL

NO. OF MACHINE
OPERATION PERFORMED

TRUTZSHLER

Cleaning of the material,


Removal of dust particals.
MACHINE PARTS : -

CVT-1 (YEAR-2005)
2

Feed lattic
Pressure roller
Feed roller
Roller [with two separating wings , two suction hood & one
carding segment].
Pressure roller.
TECHNICAL DATA: M/c Height

= 1250 mm & M/c width

M/c length

= 2400 mm

= 1800 mm

Connection pressure = 450 Pa [Project planning data]


Feed belt speed

= 0.75-15.17 mtr./min

Inside frame width [IFM] = 1200 & 1800 mm


Roll speed

= 1191-1213 rpm

Beater speed [fine tooth beater] = 900-1300 rpm


Inlet pressure[P1] = 138 Pa & outlet pressure[P2] = 868 Pa
Suction duct pressure = 100-750 Pa
SP-F [FOREIGN FIBRE SEPRATER]
MANUFACTURER

MODEL

TRUTZSCHLER
-

NO. OF MACHINE

SP-F (YEAR-2005)
2

OPERATION PERFORMED
Removal of dust particals,
Removal of dry & colored materials in fibers ,
Removal of all types of contamination like hair,
colored yarn,etc.

MACHINE PARTS : Feed lattic


Pressure roll
Cylinder 1 (with two mote knives, two suction hoods, one
carding segment)
Cylinder 2 (with one mote knives, one suction hood, one
carding segment)
Cylinder 3 (with one mote knives, one suction hood)
TECHNICAL DATA : Maximum detection rate

= 100-5000/hr.

Valve delay angle

= 90-180 degree

Beater speed

= 740 rpm

Detection/hr. per color


Red+

= 5000/hr.

Green+

= 1000/hr.

Blue+

= 5000/hr.

BLOW ROOM F.D.P.


LUWA ROTATARY PRE-FILTER
Dopping waste (maxi flow)
SP-F waste (line-1)
Microdust (CVT-1 line-2)
SP-F waste (line-2)
SP-MF (microdust)

CVT-1 dropping waste (line-1)


CVT-1 dropping waste (line-2)
CVT-1 (microdust)
M/F Microdust
VENTILATOR IN BLOW ROOM SP-MF
MAXI FLOW
MPM-8
CVT-1

ventilator

waste ventilator
-

front ventilator

waste ventilator

SP-F

ventilator

Fire

ventilator

VENTILATOR SPEED =MOTOR RPM* MOTOR PULLY /M/C


PULLY
MACHINE
BDT-019
MPM-8
CVT-1
SP-F
Dust supply pressure

MATERIAL SUPPLY
PRESSURE(Pa)
600-1000
500
500
500
= 50-200 Pa

Dropping waste pressure = 750-1000 Pa


Pipe line used in blow room
Material pipe line (from-to)
BDT-SP-MF
SP-MF MAXI FLOW
MAXI FLOW-MPM8
MPM8-CVT1
CVT1 SP-F
SP-F - CARD

Diameter (mm)
330
300
300
300
300
300

Dropping waste line (fromto)


CVT Pre-filtter
CVT Microdust
SP-F Microdust
SP-MF & LVSB
MAXI FLOW waste pipe
Maxi flow microdust
Fire system

Diameter (mm)
250
300
280
300
150
300
300

CARDING SECTION
M/C SPECIFICATION
MANUFACTURER

MODEL
NO OF MACHINE

TRUTZSCHLER
-

DK800 (YEAR-2006)
9+1[DK780]=10

OBJECTIVES OF CARDING High degree of opening of fibers.


Removal of minute dust particals,

Disentangling of neps,
Fiber blending,
Elimination of impurities,
Elimination of short fibers,
Sliver formation.
Carding is the heart of spinning because above 90%
impurities are removed during carding.
MACHINE PARTS : Feed chute
Feed roller
Feed table
Licker-in
Mote knives
Stationary flats
Cylinder
Flates
Doffer
Grid
Stripper roller
Flat cleaning brush
Top plate
Suction hood
Cross roller
Trumpet
SFL [STATIONARY FLATS LICKER-IN SIDE]

SFD [Stationary flats doffer side ]


MACHINE PARAMETER Feed roller diameter =100 mm
Licker in diameter

= 253 mm

Cylinder diameter

= 1290 mm

Doffer diameter

= 680 mm

Cylinder speed

Doffer speed

= 851-1125 rpm

Flats speed

401-531 rpm

= 80-320 mm/min

No. of flats

= 84

No. of working flats = 30


Feed system

= chute feed

Can diameter

= 40 inch

Can height

= 45 inch

Width of web
Delivery speed

= 830 mm
= 115 m/min

SPECIAL FEATURES OFV DK800 CARD HIGH PERFORMANCE CARD.


AUTO LEVELLER IS USED.
CARD GAUGE SETTING
S.N
O.
1.
2.
3.
4.
5.

SET POINT
Feed plate to feed roll
Feed plate to licker-in
Licker-in to wing
Licker-in to mote knives
Licker-in to cylinder

GAUGE(Th
ou)
4
40
40
40
7,8

6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Cylinder to SFL
Cylinder to back suction
Cylinder to flat
Cylinder to SFD 64 PPSI
Cylinder to front top plate
Cylinder to doffer
Cylinder to front bottom plate
Cylinder to back bottom plate
Doffer to stripper
Stripper roller to cross roller
Cross roller to web plate
Top calendar roll to bottom calendar roll
Cylinder pulley
Licker-in pulley
Flat pulley

18
55
10,8,8,8
12
40
5
14
40
6
6
40
6
210
260
180

CARD SETTING
S.NO.
1
2

WRAPPING
0.160
0.190

FBK PRESSURE(Pa)
400
220

No. of motor in a CARD = SEVEN


TEMP. in carding section is 30.2 degree
Relative humidity (RH%) in carding is 56.9 %

S.N
O.
1.
2.
3.
4.
5.
6.
7.
8.
9.

WRAPPING
0.160
0.160
0.160
0.160
0.160
0.160
0.160
0.190
0.190

PRODUCTION
(KG/HR.)
15
18
20
22
25
30
35
10
15

DELIVERY
SPEED(IN RPM)
67
81
90
99
112
135
137
53
80

10.
11.
12.

0.190
0.190
0.190

20
22
25

107
117
133

TECHNICAL DATA
Cylinder pulley diameter

= 175 mm

Licker-in pulley diameter

= 260 mm

Stripper roller diameter

= 120 mm

Cross roller diameter

= 90 mm

Working width of card

= 1020 mm

Working width of tuft feeder


Machine weight
Machine width

= 920 mm
= 7300 kgs.
= 1994 mm

Machine length

= 5650 mm

Production/SHIFT

= 275.25 kgs/shift

Production/hour

= 34.40 kg/hr.

Height of FBK
Height of machine upto flats

= 2625 mm
= 1900 mm

Width of coiler

= 1940 mm

Draft given by card

= 60-200 Fold

Length of sliver per can

= 8100 mtr.

Wt. of sliver per can

= 25.17 kgs

Hank of sliver

= 0.190 Ne

Linear density of sliver


Fineness

= 3.21 gms/mtr.
= 0.084-0.295 Ne

FBK Pressure

= 0-999 Pa

Floor load

= 8520 N/m2

Operating pressure

= 600-1200 Pa

Flat & licker-in suction pressure = 400 & 700 Pa

CARD CLOTHING DETAILS


Cylinder wire - T20.30.040.0950
Height =2 mm

Angle = 40 *

Thickness = 0.04 mm

No. of teeth = 950/sq. inch

Doffer wire - N.40.30*0.9


Height = 4 mm

Angle = 30*

Thickness = 0.09 mm

No. of teeth = 367/sq. inch

Flat wire - Nova 55


No. of teeth = 150/sq. inch
Licker in

- E.5010-8VG

[ Saw tooth type ]


No. of teeth = 210/sq. inch
SFL Teeth

= 240/sq. inch

SFD Teeth

640/sq. inch

Life expectancy Licker in

= 225 ton

Doffer

= 1500 ton

Flat

= 700 ton

SFL

= 250 ton

SFD

= 450 ton

DRAW FRAME SECTION


BREAKER D/FRAME
MANUFACTURER
MODEL

LAKSHMI RIETER
-

NO. OF MACHINE

LD0/6 (YEAR-2000)

- 2

FEATURES OF LD0/6 Automatic can changing mechanism.


It has 3/3 pressure bar with pneumatic loading .
The sliver delivered from pneumatic loading
calendar roller through coiler into revolving can.
Top stripper to clean top roller.

Bottom stripper with suction hood are used to


clean the bottom roller.

MACHINE PARTS
Creel
Feed roller
Auto leveler
Feed plate
Drafting rollers
Condenser funnel
Coiler trumpet
Pressure arm (Pneumatic)
Two coiler heads

TECHNICAL DATA
Input material

No. of doubling

= up to 8

No. of coiling heads

=2

Total no. of cans

= 12

Roll gauge

card sliver

= 46/50

Creel tension gear wheel = 70,71,72 Teeth


Draft range
Feeding speed
Delivery speed

= 2-12
= up to 42.5 gm/mtr.
= 240-500 m/min.

Draft tension :
Main draft

= 40-80 mm

Break draft

= 36-90 mm

Trumpet size

= 3.5 mm

Production

= 180-360 kgs/hr.

Machine weight

= 2440 kgs

Can size at feed :-

Can diameter = 600 mm


Can Height

= max. 1200 mm

Can size at delivery :Can diameter

350[,400,450,500 ] mm
Can height
Output material

= 914-1200 mm

= draw sliver

DRAFTING : Drafting system

= 3/3

Pressure supply

= Pneumatic [6 bar ]

Load on drafting rollers


On 1st & 2nd top front roller = 3-4 bar
On 3rd top back roller

= 2-3 bar

Pressure on calendar roller

= 0.5-2.5 bar

Can changer

= 4-5 bar

Drafting rollers : Top roller cot size (mm) :- 39*39*39 [ T1, T2, T3 ]
Bottom rollers size (mm) :- 52*28*28 [ B1, B2, B3 ]
Top roller hardness : = 70* SHORE

Top rollers rubber coated,


Bottom roller are of hardness steel fluted rollers
CHANGE POINTS AT D0/6

Draft change gear[DCCP]


Draft range change gear [CP]
Break draft change gear A & B.
Feed change gear
Can change gear E &F .
Delivery change gear, coiler wheel change gear C
& D.
Motor belt pulley.

DRAFT RANGE CHANGE GEAR


DRAFT
3.7-5.1
4.9-7.0
6.3-9.1
8.0-11.0

DCCP GEAR
82 TEETH
63 TEETH
48 TEETH
38 TEETH

MAIN DRAFT

= 4.9

CHANGE PINION

= 92 T

E/F COMBINATION =52-110 T


E/F COMBINATION CHART
COUNT RANGE
20
25-30

E/F COMBINATION GEARS


40/73
50/63

30-40
50-78
70-80
ABOVE 80

38/75
35/78
35/78
27/86

BREAK DRAFT CHANGE GEAR


DRAFT A/B GEAR
61/65
65/61
56/70
70/56

BREAK DRAFT
1.28
1.51
1.71
2.0

DRAFT = FEED WPG. *NO. OF DOUBLING / DEL. WPG


DEL. SPEED = WT. OF SLIVER FEED* DOUBLING /DRAFT

SPECIAL FEATURES OF DO/6 LMW : Mainly use for synthetic & also use to cotton
Use for blending
Double line feeding
Double delivery
Easy to operate
Auto doffing system is used , pneumatic loaded calendar roller
for delivery hence compression takes place , flies on suction fan
hence it is necessary to clean up to 45 min.
Stop motion checking
Creel stop motion
Coiler stop motion
Roll lapping stop motion.
Machine cleaning schedule

PARTS
Roll interchange
Coiler cleaning
Fan waste
Roll washing
Drafting zone
Creel cleaning

SCHEDULE
2hrs
24hrs
30min.
24hrs
2hrs
Every batch

TOOLS
By hand
Water & cloth
By hand
Water & cloth
Cleaning gun
Cloth & Cleaning
gun

LAP FORMER LH-10


MANUFACTURER

MODEL

LAKSHMI
-

NO. OF MACHINE

FEATURES OF LH-10

LH-10 (YEAR-2005)
1

--

Double feeding creel


Two feeding heads
11/11 doubling of draw slivers
Auto doffing system
MACHINE DATA -Drafting system

= 4/4 (with pressure bar)

Total draft

= 1.2 -2.26

Top roller loading

= spring loading system

No. of drafting heads

=2

Doubling

= up to 28 slivers

Del. Speed (max.)


material ]

= 120 m/min [Depending on raw

Can size -- can diameter

=up to 40 inch

Can height
Lap width

= up to 48 inch
= 300 mm

Max. lap diameter

Lap sheet weight

600 mm

= 60-80 gm/mtr.

Lap weight

= 15.40 kgs(with spool)

Break draft

1.042

Draft distance -MAIN DRAFT

BREAK DRAFT

40-60 mm

= 40-60 mm

Compressed air requirement :System pressure

= 7 bar

Operating pressure

= 6 bar

Air consumption pressure

= 3 Nm3/hr

Top rollers buffing :


Hardness

Color

= grey

Quality

= antistatic

Quality code

83*

Lakshmi day 890

Minimum dia.

= 36 mm

Maximum dia.

= 39 mm

Grinding dia. in mm = 0.2 mm


Total draft = Doubling * feed in gm/mtr./del. Lap wt. in gm/ mtr
Ex. T.D. = 26*4.54/80 =1.48
SUCTION POINT IN MACHINE : Spool suction
Main cylinder roller suction suction
Anti lap licking suction
Table calendar roller suction
Drafting roller suction .
CLEANING SCHEDULE OF MACHINE
PARTS
Drafting zone &
stripper
Drum cleaning
stripper
Fan waste
Creel & table
cleaning
Lap forming unit
Head stock inside
the cover
Creel
Ball washing

SCHEDULE
8hrs

TOOLS
Cleaning gun

24hrs

By hand

8hrs
8hrs

By hand
Cloth & cleaning gun

8hrs
24hrs

Bamboo stick
Cleaning gun

After a batch
24hra

Cloth & cleaning gun


By cloth

SLIVER LAP MACHINE


MANUFACTURER

LAKSHMI

MODEL

NO. OF MACHINE

LE2/4a (YEAR-2000)

FEATURES OF SLM
Drafting is pneumatically weighted.
Lap weighted is performed on a patented
automatically system.
Antifriction bearing with continuous lubrication
have been used wherever possible

MACHINE TECHNICAL DATA


SLIVER FED WRAPPING

0.120-0.180

Wt. of sliver fed

= 75-120 gm/mtr

Cleaning efficiency

= 70%

Draft

= 1.5-2.0

Lap weight

= 50-75 gm/mtr

Lap width

= 250mm in case of

feeding to RLM

&

300mm in case of feeding to comber direct


Lap weight

= upto 13 kgs

Working speed

= 65 m/ min

Drafting system

= (pneumatic)4/6

Draft constant

= 1.35

Throttle disc dia.

= 1.8-2.00mm

Doubling

= 21 [11+10]

WEIGHT OF THE MACHINE & ITS COMPONENTS :Auto lap

1440 kg

Drafting system

490 kg

Table

Total m/c weight

240 kg
2170 kg

Compressed air pressure = 6 atu


Del. Speed

= 50-65 m/min

Motor pulley dia.


Total draft

= 140,170,185 mm

= input in gm/mtr /output in gm/mtr

Motor speed

= 1440 rpm

Frequency

= 50 hz

M/c width

= 2260 mm

Can dimensions =>16-40 inch & upto 50 inch


(1250mm) high
Machine cleaning schedule
PARTS
CREEL & TABLE

SCHEDULE
8 HRS.

TOOLS
WATER & CLOTH

CLEANING
BOTTOM PATELI &

8 HRS.

WATER & CLOTH

DISC SIDES
DRAFTING ZONE
TOP ROLL

2 HRS.
24 HRS.

CLEANING GUN
WATER & CLOTH

WASHING
BELOW &

8 HRS.

CLEANING GUN

SURROUNDING
M/C
STOP MOTION CHECKING once in a shift
Creel stop motion
Drafting stop motion
Roll lapping stop motion.

RIBBON LAP MACHINE

MANUFACTURER

MODEL

LAKSHMI
-

NO. OF MACHINE

LE2/4a
1

MACHINE PARTS : Lap feed roller


Drafting system
Feed table
Feed roller calendar roller
Lap roll
Spool supporting plate
Guide roll

Machine technical data : Length of machine

= 5275 mm

Width of machine

= 2907 mm

Machine weight :
Auto lap

1450 kg

Head stock

= 550 kg

Roller & its support = 900 kg


Total m/c weight = 2900 kg
Weight of lap fed = 50-75 gm/mtr
Weight of lap deliver = 50-75 gm/mtr
Working speed

50-65 m/min

Draft

5-8

Max. lap dia.

Lap width

= 300 mm

Drafting system

450 mm

= pneumatic

Compressed air pressure = 6 ate


Quantity required
Motor speed

=1.2 Nm3/hr.
=

960 rpm

The v-pulley are changed on the for changing the


delivery speed
Delivery speed (mtr/min) Motor pulley mean dia.
(mm)
50
140
60
170
65
185
Change wheels & change gears :Change gear position
Chain wheel at calendar roller =24-25 T
Chain wheel at rear lap roller

= 76 T

Chain wheel at front lap roller = 77-78-79 T


Draft change gear (Wn) =53-75 T (4TH roller)
Feed change gear (We) = 60 -64 T
Table draft change gear (Wt) = 79-83 T
Del. Tension change gear(Wa) = 79,80,81 T

Double gear for break draft


Break draft

= 35/40

=1.34,1.02

Chain wheel
For lap roll drive , the following different chain wheels
are sent
Chain wheel at coupling

24/25 T

Chain wheel at lap roller = 77/78/79 T


As per experience , we select the following chain
wheels
For coupling (1) = 25 T
Rear lap roll
Front lap roller

= 76 T
= 78 T

If the machine is operated with light drafting , the


wheels 24 , 76 & 77 are to be used .
Distance between top edge of the saddle top cleaning
device shaft =95T
DRAFTING ARRANGEMENT :These rows of top roller with synthetics covering are
loaded over four rows of bottom fluted rollers. The
nipping distance are adjustable between 3& 55mm in
the break draft zone so that all the fiber length can be
processed & in main zone it is 30 & 54 mm are adjusted
.

FORMULA

Total draft = feed gm/m *doubling/del. gm/m


Draft change gear = total draft / break draft *constant
of main draft
Cleaning schedule of RLM M/c Creel & table
cleaning
Drafting zone
Top & bottom
clearer cloth
Disc sides lap
formation unit
Top roll washing
Below &
surrounding m/c

2 hrs
2 hr
8 hrs

Cloth &cleaning
gun
Cleaning gun
By hand

8 hrs

Cleaning gun

24 hrs
8 hrs

Water & cloth


Cleaning gun

COMBER
Name of

Model

No. of

Manufactur

machine
Comber

machine
E 65
E 66
E 60 H

2
1
3

er
(RIETER)
Year- 2004
Year 2010
Year -1997

OBJECTIVES OF M/C
The main object of comber is to remove short
fibers.
Straightening & parallization on fiber
Upgrade raw material
Yarn evenness
Strength
Cleanliness
Visual appearance
Smoothness
Requires less twist than carded
Removal of neps .
MACHINE PARTS : Lap roller
Feed roller
Nipper
Top comb
Bottom roller

Detaching roller
Web condensing tray
Sliver plate
Delivery roller
Table cylinder
Sliver guide
Trumpet drafting zone
Calender roller
Coiler trumpet

Unilap

TECHNICAL DETAILES OF COMBER E65 RIETER


420V
MXG.

50 HZ

6 BAR

= PIMA 100 %

Sliver hank

= 0.180

Feed system = backward


Roller gauge
Coiler

trumpet

46

= 4.0

Production

= 30 kg/ hr

Delivery speed

= 158 mtr/ min

No. of laps feed per machine


Drafting arrangement

=3/3

= 8

Noil (%)

= 20%

Top comb depth

= + 0.5

Top deteching roller dia. = 23 mm


Circular comb brush dia. 110 mm
Speed of comber

=350 nips/min (250-500nips/min)

Noil Index = 10.5


Feed per nip

= 4.7 mm (4.3-5.9 mm )

Total Draft (GV)


M/c efficiency
Top comb teeth

= 9.12-25.12
= upto 75 %
= 35 teeth/cm.

Sliver wt. at delivery = 3-6 ktex


Noil extraction ( % ) = 8-25 %
Drafting system load per top roll
Break draft ( VV)

650-900 N

= 1.13-2.0

Main draft distance :Setting gauge

= 41-60 mm

Gauge dimensions A= Nipping line distance minus 41


mm.
Break draft gauge dimensions =44-66 mm
Feeding :Lap outside dia.

= 650 mm

Tube/spool outside dia. = 250 mm


Tube length

= 300 mm

Can dimensions :Can table (C) = 25 mm


Can dia.(D)

= 600 mm

Can height (h)

= 1200 mm

Total machine weight

= 4600 kg

Batt tension

60-80 ktex

Floor load

= 10600 N/m2

Force of can spring


Can length
Feed tension

= 855 N
10000 mtr

= 10 %

Top comb density


Piecing index

= 3.5

= +0.3

Drafting trumpet
Table trumpet

= 7.0 mm
=

4.0 mm

Drafting rollers
Top rollers dia. : - T1 =

39 mm

T2 = 39 mm
T3

Bottom rollers dia.

:-

39 mm

B1

= 35 mm ,

B2

= 27 mm , B3

= 27 mm

Break draft change gear


Gear C
59.0
64.9
71.9
78.8
86.9
96
105.7

Break draft
1.13
1.24
1.34
1.50
1.65
1.82
2.0

Main draft change gear Main draft


12.04
12.67
12.84
13.54
14.25
14.59
15.20
15.89
16.55
17.27
17.51
18.30
19.26

Change gear A
38
40
48
45
45
40
48
33
33
33
48
38
40

Change gear B
38
38
45
40
38
33
38
25
24
23
33
25
25

Feed per nip change gear Ratchet Wheel Feed /nip

R.W.

4.3
4.7

22
20

Feed change
gear
62
56

5.2
5.9

18
16

52
45

Change places in comber


All change places in the delivery assemble are really
accessible they are as follows
N COUNT CHANGE
Z - FEED CHANGE
S - RATCHET WHEEL TO FEED ROLLER
V - WEB TRAY DRAFT CHANGE
Prduction of the comber is dependent upon the
following :N- Nips per min
S Feed in mm/ nip
K- Tension draft between lap & feed roller [1.05-1.1 ]
G- lap wt. in gm/ mtr
Stop motions
Lap exhaust stop motion
Opened up detaching roller
Sliver break at coiler
Jam in detaching roller
Sliver break at condensing roller
Sliver break at condensing roller
Cleaning schedule of E 65 RIETER -

Parts
Coiler cleaning
Top comb
Nipper
Detaching roller
area
Roll washing
Wash
duct,front&back
Side cover
Drafting zone

Schedule
24 hrs
4 hrs
24 hrs
8 hrs

Tools
Water & cloth
Top comb brush
Cleaning gun
Cleaning gun

24 hrs
8 hrs

Water & cloth


----------

48 hrs
2 hrs

Vacuum
----------

SPECIAL FEATURES OF E 65 Latest machine


3/3 drafting arrangement
Better reducing the noil %
Easy to operate
Upgraded monitoring display.
COMBING CYCLE IN CASE OF BACKWARD
MOVEMENT
Detaching
Nipper move in backward
Same time feeding
Gripping
Combing

In backward movement or feeding system


the removal of short fiber are higher as compare to
forward feed system .
In comber there are two important index which
give improvement in efficiency of machine
NOIL INDEX This index is used to control %age
of short fiber in material .
PIECING INDEX It is use for maintaining length
of cut lap before detaching roller for over lapping.
PRODUCTION CALCULATION :PRODUCTION =feed/nip
*nip/min*60*8*efficiency*no. of heads*(1-noil
%/100)*(1-bett tension/100)/36*840*2.2*wpg.

DRAW FRAME FINISHER


MANUFACTUER

--

MODEL
D40[YEAR-2006]
NO. OF M/C

RIETER
--

--

RSB-

OBJECT
To reduce weight per unit length of sliver.
To improve the regularity of fibers by drafting
& doubling
To parauelize them to their neighbours

To straightened out the fibers into fibers


exient
To mixing different type of fibers so as to give
a homogeneous blending

TECHINCAL DATA
Drafting system

--

4/3

Doubling

--

10

Efficiency

--

75%

Production

--

30-80kg/h

Front roll dia.

--

38mm

Middle roll dia.

--

30mm

Back roll dia.

--

30mm

m/c height

--

1860-2515mm

Roll gauge

--

46/50

Del. Speed

--

250-1100mtr./min

Feed sliver wt.

--

12-50ktex

Del. sliver wt.

--

1.25-7.00ktex

Draft (v)

--

4.54-11.56

Fibre length

--

max. 80mm

Can dia.

--

210-1000mm

Can height

--

900-1520mm

Scaning roller dia.

--

60mm

Feeding rate

--

300-400mm/min.

Main draft distance (hvd)

--

35.5mm

Break draft distance (vvd) --

36-40mm

Drafting system pressure in newton Back ,middle & del. top roll pressure -440n
Top roll cot dia.

--

36-38mm

Top roll length

--

100-160mm

Grinding disc dia.

--

320-

200-500mm

Grinding disc width --

25-45mm

Circumference speed of grinding disc


1800-2000mtr./min

W1
VZW
W2
VZ

--

Rpm of spindle shaft

--

300-500u/min.

Trumpet size

--

28

Pressure bar setting

-- 6.0

Nw 1 / Nw 2

--

Width of scaning roll

--

98
0.93

99
0.99
52
1.00

100
1.00

39/52
4.0-11.0 mm

101
1.01

51.5
1.01

102
1.02
51
1.02

103
1.03

W8
VA
W4
VV

75.2
0.99
(54.
6)
(1.0
5)

74.4
1.00

(57.
2)
(1.1
0)

W4
VV

59.8 (62.
4)
1.15 (1.2
0)

83.2
1.60

WHERE , VV

73.7
1.01

72.9
1.02

68.0 (67.
6)
1.25 (1.3
0)

88.4
1.70

72.2
1.03
72.8 (78.
0)
1.40 (1.5
0)
93.6
1.80

-- Break draft

V&GV

--

HV

--

Total draft
main draft

SPEED FRAME
MANUFACTURER
MODEL
2005)
NO. OF MACNINE
OBJECT :-

- LAKSHMI
- LF1660(YEAR- 4

The object of the speed frame is to produce out of the


draw sliver to a well prepared roving of required hank
of a well built bobbin for ring spinning frame.
FUNCTION OF SPEED FRAME : DRAWING - To parallise the fibers upto optional
level.
TWISTING To impart necessary strength to
roving .
WINDING- To pul;l the suceesive layer on the
bobbin at a proper rate of speed.
Building To shorted successive layers to make
conical ends on the package of roving.
MACHINE PARTS : CREEL
PATELI CLOTH
CRADLE
TOP & BOTTOM R
TOP & BTTOM APRONS
SPACER
TWIST MASTER
FLYER WITH BOBBIN SUPPORRTING ROLL
SPINDLE
LIFTER RAIL
SLIVER GUIDE

CONDENSOR
TOP ARM/SADDLE
NOSE BAR
TENSIO PULLY
TECHNICAL DATA OF LF1660 :These m/cs are only built with the drive to the right i.e.
the head stock is on the right when looking at the
delivery.
Spindle gauge

= 121.83

No.of spindle

= 120

Bobbin size

= 16*6 inch

Flyer speed mechanically possible = 1400 rpm (max.)


Production

= 50 m/min

[under favourable marginal condition ]


Draft

= 9-24

Count = >
English (Ne)

= 0.5 to 3.0

Metric (Nm)

= 0.85 to 5.0

Drafting arrangement Guide saddle


Drafting arrangement with 3 or 4 rollers,
weighing arm for two spindle ,double aprons , 36,43 &
50 mm cage .
Positively revolving clearer cloth for both top & bottom
rollers

Top apron size

= 37*30 mm

Bottom apron size = 86*30 mm


Total weight of machine

= 12950 kg

Motor speed

= 700-1400 rpm

Flyer speed

= 800 rpm

Supply pressure of drafting system 5-6 kg/cm2

Meaning of lamps when flickering


Green Doffing or trough manual operation
Orange Roving break
White Sliver break
Bottom apron thichness = 0.86 to 1.04 mm
Top apron thichness
Top roll hardness
Roll gauge

= 0.86 to 1.04 mm
= 83* Shore

= 47-55-48

Top roll dia. = 30 mm


Break draft

= 1.05 to 1.10 (for cotton) [& max. 3.0]

Delivery condenser = 7.5 mm (Green)


Wt. of empty bobbin = 200 gm
Length of roving on one bobbin = 2020-5300 mtr
Twist per inch = 1.51
Spacer = 3.5 mm

Bottom roller type = fluted


Bobbin dia.

= 152 mm

Tension draft

= 1.086

Main draft

= 10

Preliminary draft (between 3rd & 4th roll ) = 1.66


Machine length

= 7*1461 mm (96-120 spindle)

Machine width

= 3643 mm

Set tension

= 3.12

Cop content = 1616 gm/spindle


Doff length

= 5200 mtr

No. of layers on bobbin = 118


Lifting wheel = 20 to 42 T
Twist wheel

= 30 to 55T

Twist combination wheel = 65/35 T


BDCP GEAR = 50 to 72 T
Change pinion = 30 to 56T
TPI/TM

= 1.166/1.951

Creel wheel

= 40 to 48 T

Flyer gear belt length = 960 & 840 mm


Pateli cloth length = 815 mm
Main formulae :Creel tension draft = 40.88 *creel wheel

Break draft
T.W.

66.82/BDCP

= 34.552(h/g)/TPI, where (h+g=102)

Main draft = 63.48*(r/l)/C.P.


Where ,r/l = draft combination & r+l =150
Middle draft zone

= 1.087

Total draft = main draft * break draft


L.W. = 12.18 *E/F *B1/root count

STOP MOTION AT SPEED FRAME Sliver break stop motion


Bobbin brust stop motion
Full doff automatic stop motion

CHANGE POINTS Twist change change gear


Lifter change gear
Main draft change gear
Break draft change gear
Creel tension draft change gear

RING FRAME
MANUFACTURER
ELITE COMPECT SET]

- LAKESHMI [SUSSEN

MODEL
2006)
NO. OF MACHINE
MACHINE PARTS: CREEL
HOLDER
HANGER
ROVING GUIDE 3 IN 1
DRAFTING ROLLERS
APRON
CRADLE
SPACER
LAPPET
SPINDLE
TOP ARM/SADDLE
RING
ABC RING
FLY CATCHER
TRAVELLER

LR6/A (YEAR-

17

DOFFING RAIL
SPINDLE TAPE BELT
TIN ROLLER
SUCTION TUBE
ELI TUBE & ELIED APRON
COTS ROLLER
JOCKEY PULLY
NOSE BAR
SPINDLE WHARVE
POSITIVE CLIP RING
RAIL RING
SEPARATER PLATE
SPINDLE BRAKE
M/C TECHNICAL DATA :Bottom roller dia.(In mm) =>
=30

B1=30 , B2 =27 ,B3

Top roller dia. (in mm) => T1 =32 , T2 27 ,T3 =32


Cradle length = 36 mm
Total draft = up to 60
Break draft = 1.07 to 2.24
Spindle gauge = 70 & 75 mm
LOADING TOP ARMS :-

The loading top arm are loaded pneumatically. The


hose pressure can be adjusted with reducing value in
the head stock .
The pressure indicated in table below give a loading of
150-180 N(15-18 kp) per front top roller shaft .
Spacer =

2.5-7.0 mm

Top apron length & width = 37*30 mm


Bottom apron length & width
Spindle pitch
70
75

= 73*30 mm
Pressure
2.1-2.3
2.0-2.2

Twist change gear (A+B) = 165 T


Twist range change gear (C+D) =137 T
Total draft constant = 10.519
Change gear for winding length (E+F) = 113 T
Break draft change gears std. = 32-62 T
Draft change gear (G+H) = 130-175 T
Spindle wharve dia. = 21,19 & 18.5 mm
Twists :TPM (Twist per meter) = 140- 2550
TPI ( Twist per inch) = 3.55-64.77
SPINDLE SPEEDS :Mechanically up to 18000 to 25000 rpm.

Drafting system = 3/3


Spindle taper = 1:40 & 1:64
Spindle tube l;ength = 180 250 mm
Ring dia. Standard (in mm) =>
36,38,40,42 & 45
Ring flange width =>
Flange No. 1 ( b=3.2 mm )
Flange No. 2 ( b =4.0 mm)
Pendulum gauge =>
Long spinning angle = 440 mm
Short spinning angle = 375 mm
Inclination of drafting arrangement = 60* (degree)
Height of separators plate = 233.90 & 185 mm
Material of top roller = synthetic rubber
Material of bottom roller = stainless steel
Surface of top roller = plain
Surface of bottom roller = fluted
Total No. of ring frames = 17
No. of spindle ( in one R/F) = 864
COUNT SPUN = 50, 60, 70, 80, 100, 120 & 140 Ne
Hank of roving fed = 0.8-1.5
Delivery speed = 6-17 m/min

Fly catcher gauge = 1.6 mm


Ring dia. = 38 mm
ABC RING DIA. USED = 36.7 mm
Eli tube length = 180-260 mm
STANDARD SUPPLY ALONG WITH EACH
MACHINE :BREAK DRAFT

BREAK DRAFT CHANGE GEAR


FOR FLUTED ROLLERS
DIA. 27 (B1 )

DIA. 30 (B3)

1.14

59

53

1.24

54

49

CHANGE POINTS AT R/F M/C =>


Twist change geart A/B & twist range change
gear C/D
Change gear E/F for winding length
Ratchet wheel for ring rail drive
Draft chnge gear G & maitin g gear H
CP & BRW for total draft
Changing the spindle twist direction Z or S
SPINDLE RPM.
CALCULATION OF R/F =>

TPI = TM UNDER ROOT COUNT ,where TM = Twist


multiplier
TPM = TPI *39.37
Twist constant = TPI*Twist wheel
F.R. Del. SPEED =SPINDLE SPEED/TPI
PRODUCTION = F.R. DELIVERY
*60*8*EFFICIENCY/36*840*2.2*COUNT (IN
KG/SPINDLE/SHIFT)
BOBBIN CONTENT (GMS) = 3.25*LD square ,
where l =lift in inch ,D= dia.of bobbin in inch
MAIN DRAFT = B/W FRONT ROLLER & BACK
ROOLER
BREAK DRAFT = B/W MIDDLE ROLLER & BACK
ROLLER
TOTAL DRAFT = B/W FRONT ROLLER & BACK
ROLLER
DRAFT CONSTANT = DRAFT*C.P.
change pinoin

where, C.P. =

SPACER:Spacer adjust distance b/w the top & bottom


aprons is adjusted with snap on spacers.
SPACER
2.50
2.75
3.00
3.25
3.50

COLOUR
Brown
Dark Grey
Natural White
Yellow
Black

3.75
4.00
4.50
5.00
5.50
6.00
7.00

Cream
Red
Green
Blue
Grey
Cream
Yellow

APRON DIMENSION TABLE :TOP APRON

BOTTOM APRON

CRADL
E

INSID
E DIA.

THICHNES
S

WIDTH INSID
E DIA.

THICHNES
S

36

39.2

1.05

29.75

80.5

1.05

43

43.3

1.05

29.75

82

1.05

59

53.8

1.05

29.75

89

1.05

Twist
range
change
gear
D & C=
137 T

Twist change gear (B+A= 165T)


B

76

77

78

79

80

89

88

87

86

85

TWIST PER METER (TPM)

102

35

2439

2499

2561

2624

98

39

2103

2155

2262

2262

91

46

1656

1696

1738

1781

82

55

1248

1279

1310

1341

72

85

927

950

973

947

65

72

756

774

793

813

Break draft change gear :BDCP


Br.dra
ft
BDCP
Br.dra
ft

32
2.09

33
2.03

34
1.97

35
1.91

55
1.22

56
1.20

57
1.17

58
1.15

59
1.13

60
1.11

61
1.09

62
1.08

Signal lamps (Tail stock & head stock )=>


RED OFF M/C normal running/mains off
RED ON - Machine fault or machine off
RED Short flash (1sec)- doff
RED LONG flash (2sec) emergency off