Internship Report On 18 and 50 Count at TP-1

STUDY OF SPINNING PROCESS OF 18/1 & 50/1 YARN AT
IBRAHIM FIBERS TP-1, FAISALABAD.
Internship Report Submitted by
M Faizan Haider Roll # 16-NTU-0100
University Supervisor : Dr. M Bilal Qadir
Mill Supervisor : Mr. Ahmer Abbas
In partial fulfillment of the requirement for the degree of
Bachelor of Science
In
Textile Engineering
Department of Yarn Manufacturing
Faculty of Engineering & Technology
National Textile University, Faisalabad.

DEDICATION
I dedicate this modest effort to my Parents whose prayers have helped us in deciding the
career of our choice and served as a source of inspiration for me throughout my live and in
helping me decide my career and fulfilling each and every demand unconditionally
throughout my academic career and have also led me to believe in my abilities at hand and
become successful.
I also dedicate this effort to my loving, most caring and helpful General Manager Mr.
Tariq Nazir who treated me as his beloved student and cooperated with me at every
moment of time.
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CERTIFICATE
This Internship report, carried out and written by M Faizan Haider under the direction of
their supervisor DR. Muhammad Bilal Qadir and approved by all the members of Project
Committee of the department, has been presented to and accepted by the Chairman,
Department of Yarn Manufacturing and Dean, Faculty of Engineering & Technology in
fulfillment of the requirement of degree Bachelor of Science in Textile Engineering.
Supervisor Internal Examiner
Chairman DYM Dean FET
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ACKNOWLEDGEMENT
If all of the oceans turn into ink and if all the trees turn into pens even then the praises of
ALLAH SUBHANAHU WA TA`ALA cannot be expressed.
I set my unfeigned and meek thanks before HIM, who created the universe and bestowed
the mankind with the knowledge and wisdom to search for its secrets, favored and
invigorated us with fortitude and capability to aptly complete our search work and
contribute a drop to the existing ocean of scientific knowledge. Trembling lips and wet
eyes praise for the Prophet HAZRAT MUHAMMAD (PBUH) who is forever a torch of
guidance for the entire humanity.
I feel great pleasure in acknowledgment that all credit goes to my loving and sweet parents
for their amicable attitude and love immense orison, mellifluous affection and well-
wishing prayers.
I deem it my utmost pleasure to avail myself this opportunity in recording my deep
feelings of regard and sense of gratitude to my venerated project supervisors Dr.
Muhammad Bilal Qadir National Textile University Faisalabad who in spite of busiest
schedule provided his dexterous guidance and valuable suggestions throughout this work,
even in the midst of his multifarious duties. At time I strayed into the blind alleys and it
was his beacon light that led me out of the lengthening shadows.
I am thankful to Mr. Tariq Nazir (General Manager) , Mr. Rao Naeem (Deputy
Manager) and Mr. Ahmer Abbas (Mechanical Manager) in Ibrahim Fibers limited
Faisalabad, for their help and support that enable me to do work in the Mill comfortably.
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TABLE OF CONTENTS
1 Introduction ................................................................................................................. 11
1.1 History .................................................................................................................. 11
1.2 Organizational Structure ...................................................................................... 11
1.2.1 Textile plants................................................................................................. 11
1.3 Power Generation ................................................................................................. 12
1.4 Polyester Plant ...................................................................................................... 12
1.5 Integrated Manufacturing (CIM). ......................................................................... 12
1.6 Allied Bank .......................................................................................................... 12
1.7 Product Range ...................................................................................................... 12
1.7.1 Textile plant 1 ............................................................................................... 13
1.7.2 Total production: ........................................................................................... 13
1.8 Major Customers .................................................................................................. 13
1.9 Major Suppliers .................................................................................................... 13
1.10 Major Departments And Sections..................................................................... 13
2 Introduction ................................................................................................................. 14
2.1 Properties .............................................................................................................. 14
3 Blow Room ................................................................................................................. 15
3.1 Objectives ............................................................................................................. 15
3.1.1 Opening ......................................................................................................... 15
3.1.2 Cleaning and dust removal............................................................................ 15
3.1.3 Mixing and blending ..................................................................................... 15
3.1.4 Lap forming or even feed of material to the card ......................................... 15
3.1.5 Material issuance and mixing ....................................................................... 15
3.2 Machine Layout And Specifications .................................................................... 16
3.3 Blendomate (BDT-019-011) ................................................................................ 17
3.4 Dosing Opener (FD-S) ......................................................................................... 18
3.5 Tuft Blender (FML) ............................................................................................. 19
3.6 Weighing Scales (PWSE)..................................................................................... 19
3.7 Metal Detector (SP-EM) ...................................................................................... 19
3.8 Multi Mixer MX-U 10.......................................................................................... 20
3.9 Tufto-Mate (To-T1).............................................................................................. 21
3.10 Waste Breaker (Reusable Waste Mixing) ........................................................ 22
3.11 Condenser ......................................................................................................... 22
3.12 Filter room ........................................................................................................ 22
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3.13 Maintenance...................................................................................................... 23
3.14 Manpower ......................................................................................................... 23
4 Card ............................................................................................................................. 24
4.1 Objectives Of Carding .......................................................................................... 24
4.2 Main Actions of Carding Machine ....................................................................... 24
4.3 Functions of The Machine.................................................................................... 24
4.4 Assembly Groups ................................................................................................. 24
4.5 Machine specifications ......................................................................................... 25
4.5.1 Dia. & speeds of different rollers .................................................................. 26
4.5.2 Card Gauges .................................................................................................. 26
4.5.3 Wire specifications........................................................................................ 27
4.6 Filter room ............................................................................................................ 27
4.7 Maintenance ......................................................................................................... 28
4.8 Manpower............................................................................................................. 28
5 Drawing....................................................................................................................... 29
5.1 Actions Involved In Draw Frame ......................................................................... 29
5.2 Tasks of Draw Frame ........................................................................................... 29
5.3 Machine Specifications ........................................................................................ 30
5.4 Process And Quality Parameters Of Product ....................................................... 31
5.5 Maintenance ......................................................................................................... 31
5.5.1 Daily.............................................................................................................. 31
5.5.2 Major parts change schedule ............................................................................. 32
5.6 Manpower............................................................................................................. 32
6 Simplex ....................................................................................................................... 33
6.1 Introduction .......................................................................................................... 33
6.2 Objective Of Roving Frame ................................................................................. 33
6.3 Defects And Its Prevention On Roving Frame..................................................... 34
6.3.1 Roving tension .............................................................................................. 34
6.3.2 Improper handling of material ...................................................................... 34
6.3.3 Improper piecing in roving ........................................................................... 34
6.3.4 Roving breakage ........................................................................................... 34
6.4 Machine Specifications ....................................................................................... 34
6.5 Process and quality parameters of product ........................................................... 36
7 RTS (Roving Transport System) ................................................................................ 37
7.1 RTS Advantages ................................................................................................... 37
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8 Ring Spinning ............................................................................................................. 38
8.1 Objective Of Ring Frame ..................................................................................... 38
8.2 Main Parts Of Ring Frame ................................................................................... 38
8.3 Machine Description ............................................................................................ 39
8.4 Process and quality parameters of product ........................................................... 41
8.5 Maintenance ......................................................................................................... 41
8.6 Manpower............................................................................................................. 41
9 Cone Winding ............................................................................................................. 42
9.1 Objective Of Winding Process ............................................................................. 42
9.2 Importance Of Winding ....................................................................................... 42
9.3 Processed material ................................................................................................ 43
9.4 Elements of process .............................................................................................. 43
9.5 Basic diagram of winding machine. ..................................................................... 43
9.6 Machine Specifications ........................................................................................ 43
9.7 Manpower............................................................................................................. 44
10 Introduction ................................................................................................................. 45
10.1 Objectives ......................................................................................................... 45
10.1.1 Local packing ................................................................................................ 45
10.1.2 Export packing .............................................................................................. 45
10.3.1 Cartons packing .............................................................................................. 45
10.1.3 Pallets packing .............................................................................................. 46
11 CTS (Cone Transport System) .................................................................................... 46
11.1 Process Flow Description ................................................................................. 46
11.2 Automatic sack packing system ....................................................................... 47
11.3 Process flow description: .................................................................................. 47
12 Roller Cover Department ............................................................................................ 49
12.1 Grinding Machine (BERKOL BGSM) ............................................................. 49
12.2 Grinding Machine (BERKOL BG U) ............................................................... 49
12.3 Press (AP H50-H500EV).................................................................................. 50
12.4 Press (PP 125 H100) ......................................................................................... 50
12.5 Top Roller Lubricating ( BOS-01) ................................................................... 50
12.6 Lubriboy ........................................................................................................... 51
12.7 Rubber Cots Uv Treatment ............................................................................... 51
13 Introduction ................................................................................................................. 52
13.1 Objectives ......................................................................................................... 52
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13.2 Testing Equipments .......................................................................................... 52
13.3 Uster Yarn Testers UT4 .................................................................................... 52
13.3.1 Testing methods ............................................................................................ 53
13.4 Mechanical lea strength tester .......................................................................... 54
13.5 Yarn board making machine (For Yarn Appearance) ...................................... 54
13.6 Uster Auto-sorter 3 (For count testing) ............................................................ 55
13.7 Wrapping Reel .................................................................................................. 55
14 Introduction ................................................................................................................. 56
14.1 Objective And Description Of Department ...................................................... 56
14.2 Description Of AC System ............................................................................... 56
14.3 Types Of Air Conditioning Systems ................................................................ 56
14.4 Air Conditioning Process For The Textile Industry ......................................... 56
14.5 Humidification System ..................................................................................... 57
14.6 Components Of Automotive Air Conditioning ................................................ 57
15 Introduction ................................................................................................................. 61
15.1 Objectives ......................................................................................................... 61
15.2 Components Of Compressor ............................................................................ 61
15.3 General Working Of Compressors ................................................................... 61
15.4 Compressed Air In Textile Industry ................................................................. 62
15.5 Use Of Compressed Air In Textile Mills.......................................................... 62
15.5.1 Department wise requirement ......................................................................... 62
15.6 Machine Specifications .......................................................................................... 63
15.5.1 Air intelligence system ................................................................................. 64
15.6 Air Dryers ......................................................................................................... 64
15.7 Maintenance...................................................................................................... 64
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LIST OF FIGURES
Figure 3.1 Blow room line .................................................................................................. 16
Figure 3.2 Blendomate ........................................................................................................ 17
Figure 3.3 Dosing Opener ................................................................................................... 18
Figure 3.4 Tuft blender (FML) ........................................................................................... 19
Figure 3.5 weighing scale (PWSE) ..................................................................................... 19
Figure 3.6 Metal detector (SP-EM) .................................................................................... 20
Figure 3.7 Multi mixer (MX-U).......................................................................................... 20
Figure 3.8 Tufto mate (TO-T1) ........................................................................................... 21
Figure 3.9 Piece Breaker ..................................................................................................... 22
Figure 4.1 Carding machine TC-03 .................................................................................... 25
Figure 5.1 Drawing Department ......................................................................................... 29
Figure 6.1 Roving frame ..................................................................................................... 33
Figure 7.1 RTS parking....................................................................................................... 37
Figure 8.1 Ring machine ..................................................................................................... 38
Figure 9.1 Cone winding machine ...................................................................................... 42
Figure 9.2 Basic Working Diagram of Auto cone Winding machine................................. 43
Figure 11.1 cone transport system ...................................................................................... 46
Figure 11.2 Sack packing machine ..................................................................................... 48
Figure 13.1 Uster Tester 4 .................................................................................................. 52
Figure 13.2 Lea strength tester............................................................................................ 54
Figure 13.3 Yarn board making machine ........................................................................... 54
Figure 13.4 Wrapping wheel............................................................................................... 55
Figure 14.1 Air Washer unit ............................................................................................... 57
Figure 14.2 Water tank ....................................................................................................... 58
Figure 14.3 Dampers ........................................................................................................... 58
Figure 14.4 Rotary Air filter ............................................................................................... 59
Figure 14.5 Water pump ..................................................................................................... 59
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LIST OF TABLES
Table 2.1 Properties of polyester and viscose ..................................................................... 14
Table 3.1. Material Issue ..................................................................................................... 16
Table 3.2 Blendomate specification .................................................................................... 17
Table 3.3 Multi mixer specification .................................................................................... 20
Table 3.4 TO-T1 Specification .......................................................................................... 21
Table 3.5Condenser Specification ...................................................................................... 22
Table 3.6 Filter room specification ..................................................................................... 22
Table 3.7 Manpower in Blow Room Department ............................................................... 23
Table 4.1 Card Specification.............................................................................................. 25
Table 4.2 Dia. & speeds of different rollers........................................................................ 26
Table 4.3 Card Gauges ........................................................................................................ 26
Table 4.4 Card Wire Specification...................................................................................... 27
Table 4.5 Filter room specification ..................................................................................... 27
Table 4.6 Manpower in Card Department .......................................................................... 28
Table 5.1 Breaker and Finisher Specification ..................................................................... 30
Table 5.2 Top Roller Specification of Breaker & finisher.................................................. 31
Table 5.3 Process and quality parameters of product ......................................................... 31
Table 5.4 Man power .......................................................................................................... 32
Table 6.1 Simplex Specification ......................................................................................... 34
Table 6.2 Process and quality parameters of product ......................................................... 36
Table 7.1 RTS Specification ............................................................................................... 37
Table 8.1 Ring Specification............................................................................................... 39
Table 8.2 Process and quality parameters of product ........................................................ 41
Table 8.3 Manpower in Ring Department .......................................................................... 41
Table 9.1 Auto Cone Specification ..................................................................................... 43
Table 9.2 Manpower in Auto Cone Department ................................................................. 44
Table 11.1 CTS Specification ............................................................................................. 46
Table 11.2 Sack packing machine ...................................................................................... 47
Table 12.1 Grinding machine specification ........................................................................ 49
Table 12.2 BERKOL BG U Specification .......................................................................... 49
Table 12.3 press specification ............................................................................................. 50
Table 12.4 PRESS PP 125 H100 specification ................................................................... 50
Table 12.5 Top roller lubricating BOS-01 Specification .................................................... 50
Table 12.6 Lubriboy Specification ..................................................................................... 51
Table 12.7 Rubber cots uv treatment Specification ............................................................ 51
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CHAPTER 1
ORGANIZATION PROFILE
1 Introduction
1.1 History
Late Sheikh M Ibrahim founder of the Ibrahim group settled in Faisalabad. Ibrahim
Fibers Limited (the Company) is incorporated in Pakistan as a public limited company
under the Companies Ordinance, 1984 (the Ordinance) and is listed on Karachi and
Lahore Stock Exchanges in Pakistan. The principal business of the Company is
manufacture and sale of polyester staple fibre and yarn. The registered office of the
Company is located at 1-Ahmed Block, New Garden Town, Lahore. The manufacturing
units are located at Faisalabad- Sheikhpura Road, in the Province of Punjab.
The consortium of Ibrahim Leasing Limited and Ibrahim Group assumed the control of the
Allied bank in August 2004 by injecting Rs 14.2 billion into the capital of Allied bank for
acquiring 325 million additional shares.
Allied Bank Limited was the first bank to be established in Pakistan. Today, with its
existence of over 60 years, the Bank has built itself a foundation with a strong equity,
assets and deposit base. It offers universal banking services, while placing major emphasis
on retail banking. The Bank also has the largest network of over 830 online branches in
Pakistan and offers various technology-based products and services to its diverse clientele.
1.2 Organizational Structure
1.2.1 Textile plants

Spun Yarn Division of Ibrahim Fibres Limited consists of four projects:
1. Textile Plant 1
2. Textile Plant 2
3. Textile Plant 3
4. Textile Plant 4
IFL has a total capacity of 234496 spindles.
Textile plant 1
Constantly upgrading plant and machinery since initial operations in 1980, the
present manufacturing operations of Ibrahim Textile Plant-1 have a total installed capacity
of 54,720 spindles. The project comprises of two units located within the same premises.
Unit I has been upgraded in 2016, consists of 35,280 spindles (21 frames of 1680 spindles
each) from Saurer Zinser Germany with cone-winding of Schlafhorst, Germany.
Unit II consists of 19,440 spindles from Marzoli, Italy with cone winding of Schlafhorst
Germany.
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Textile plant 2
Textile Plant 2 consists of 40,608 spindles and is further divided into two units:
Unit I has a capacity of 19,008 spindles and Unit II compromises of 21,600 spindles.
Textile plant 3
Textile Plant 3 compromises of 39,168 spindles and is further divided into 2 units:
Unit I consists of 19,968 spindles and Unit II consists of 19,200 spindles.
Textile plant 4
Textile plant 4 is under erection . It has a capacity of 1 lac spindles. 25000 spindles
are ready for production with the capacity of 500 bags per day.
1.3 Power Generation

Power Generation Plants of Ibrahim Fibres Limited consist of three production plants;
1. Power Generation Plant-1

Power generation capacity of these plants is 93.3 MW. These Plants are for the sole
objective of catering to the requirements of the company’s industrial operations for
uninterrupted and stable power supply.
1.4 Polyester Plant

Manufacturing operations are staggered in three production lines located within the
same premises, at 38 K.M. Faisalabad - Sheikhupura Road, Faisalabad. It is spread over an
area of more than 100 acres of land with a capacity to produce 390,600 tons per annum of
Polyester Staple Fibre (PSF).
Polyester Plants are based on engineering and technology supplied by Lurgi GMBH
Germany (which is a part of Air Liquide France) who are market leaders in polyester
polymer capacities supplied worldwide representing more than 50% share in the world
market. These plants are equipped with Provox plus Distributed Control System (DCS)
using SRX process controllers providing a foundation for real time, efficient and accurate
control and also monitoring of the process of entire plant through Computer
1.5 Integrated Manufacturing (CIM).

Along with complete technology transfer, the plants have been supplied and
installed as a turnkey project by Lurgi GMBH. The designed capacities of the plants,
consumption of raw materials, utilities and quality of finished products are all guaranteed
by the plant supplier.
1.6 Allied Bank

Ibrahim group is the 51% shareholder of Allied Bank limited.
1.7 Product Range

Ibrahim fibers produces a variety of yarn, it is known by its quality and has set a
benchmark in the textile industry. It produces two types of yarns; polyester viscose blend
12
known commonly as PV in Textile Plant-1 and polyester cotton blend which is famous as
PC in Textile Plant-2 and Textile Plant-3.
1.7.1 Textile plant 1

TP1 produces a variety of PV like 18PV, 20PV, 24PV, 26PV, 30PV, 36PV, 40PV
and also slub yarn. Raw materials used in IFL TP1 are Polyester and Viscose, polyester
(1.2 denier) is used which is manufactured in this organization and viscose (1.40 dtex) is
imported from South Pacific (Indonesia).
1.7.2 Total production:

IFL Textile Plant-1 produces 1000 bags per day (750 bags Unit-I and 250 bags
Unit-II) with a total spindle capacity of 54,720 spindles.
1.8 Major Customers

IFL has an increased number of weaving customers due to its high quality yarn; some
major customers are listed below.
 Sapphire Textiles
 Nishat Textiles
 Al-Karam Textiles
 Arshad Corporation
 Chenab Limited
 Sadaqat Textiles
 Crescent Textiles
 Gull Ahmad Textiles
 Kohinoor Textiles
1.9 Major Suppliers

The raw material used in the manufacturing of yarn is supplied by following suppliers:
 Polyester from IFL polyester plant

 Viscose from Indonesia (South Pacific)
1.10 Major Departments And Sections

Ibrahim fibers have following major departments:
 Human resource & Admin department

 Process department
 Electrical department
 Mechanical department
 Quality Controlled Department
 Excise Department
 Packing Department
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CHAPTER 2
RAW MATERIAL
2 Introduction
Polyester and viscose are used as a raw material in TP-1. The polyester is from
Ibrahim fibers polyester plant while viscose is imported from Indonesia. Polyester is
supplied on daily basis while viscose is stored in ware house. There are 2 warehouse in
TP-1. The yarn is made by blending of polyester and viscose with the ratio of 80 : 20. For
blending these two manmade fibers , we have to check about there properties. The sample
reports are carried and then we decide the mixing plan.
2.1 Properties
There are the following properties of polyester and viscose fibers.
 Length
 Length uniformity
 Strength
 Elongation
 Fineness
 Color
 Moisture
Table 2.1 Properties of polyester and viscose
Property Polyester Viscose

Denier 1.2 D 1.2 D
Tenacity 7.05 g/d 2.59 g/d
T-10 5.59 g/d 1.37 g/d
Elongation 18.20 % 20.7 %
Shrinkage 6.57 % 0.52 %
Elect. Resistance 0.90 Ω x 1011 0.90 Ω x 1011
O.P.U 0.140 0.355
Fibre length 51.13 mm 49 ~ 52 mm
Moisture 0.34 8.17
Color L 94.52 94.74
Color b 1.86 4.80
Crimp No. 12.48 No/inch --
Crimp removal 18.37 % --
Crimp stability 65.58 % --
CV T 9.0 % 5.9 %
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CHAPTER 3
SPINNING PREPARATORY PROCESSES
3 Blow Room
3.1 Objectives
3.1.1 Opening
Opening is the leading operation in the spinning process. It is compulsory in order
to execute all the other processes stages. The aim is always a high amount of openness of
the material with a gentle handling and fiber damage as small as possible. Higher the
degree of opening, higher will be the cleaning. A very high cleaning effect is almost
always purchased at the cost of a high fiber loss. Higher roller speeds give a better
cleaning effect but also more stress on the fibre.
3.1.2 Cleaning and dust removal

Cleaning is necessary to remove the trash, dust, contamination and the entire
foreign particle from the material. A cleaning line only removes the 40-75% of the trash
and dust in the material. The elimination rate depends on the
• Nature of raw material

• The machinery in a job
• Ambient condition
Dust removal is not an easy operation, since the dust particles are completely enclosed
within the flocks and hence are held back during suction (because the surrounding fibers
act as a filter). It is mainly the suction units that remove dust and removal will be more
intensive the smaller the tufts.
3.1.3 Mixing and blending

Mixing and blending is an important preliminary in the production of good quality
yarn. Fiber mixing and blending is done at the different process steps of blow room. A fine
assembled bale layout and synchronized extraction of fibers from all bales is therefore of
vibrant importance. This blending operation must collect the bunch of fibers arriving
sequentially from individual bales and mix them thoroughly.
3.1.4 Lap forming or even feed of material to the card

Finally, the blow room must guarantee that raw material is evenly delivered to the
cards. Formerly, this was carried out by means of accurately weighed laps from the
Sctucher but automatic tuft feeding and chute feeding is used nowadays. At Ibrahim fibers
the chute feed system is used.
3.1.5 Material issuance and mixing

It is the combination of two different raw materials to produce a single product
which is homogeneous in properties and characteristics and which is spin able to produce
a uniform product. The objectives of mixing are to achieve a basic product uniformity
15
which results from the combination of a variety of raw materials. Polyester and Viscose
are manmade fibers. The following parameters vary very much between bales.
• Fiber micronaire
• Fiber length
• Fiber strength
• Fiber color
• Fiber maturity
There are 2 blow room lines in Ibrahim TP-1. Mixing is planned in such a way that all the
bales should be consumed evenly from each lot and there should not be any occurrence of
shade variation in the yarn throughout the year. For mixing we have to see the +b value of
bales.
Table 3.1. Material Issue
Total number of polyester bales 122

Total number of viscose bales 34
Total bales issued per day 155
Average weight of 1 polyester bale 300 kg
When a lot finishes and a new lot is required in mixing, we have to use the very next lot
whose +b value is almost same as that of +b value of previously working lot. This is the
basic principle of mixing.
3.2 Machine Layout And Specifications

Flow chart of bow room Line 1 and Line 2 is shown in Figure 1
Useable Mix Waste Useable Mix Waste
AS-2 AS-1
PWSE-4 PWSE-4
PWSE-3 PWSE-3
PWSE-2 PWSE-2
PWSE-1 PWSE-1
FML-2 FML-1
WASTE ROOM
SPEM-22 SPEM-21
MPM 10/1600 MSL-47 MSL-37 MSL-42 MSL-32 MSL-40 MSL-30 MPM 10/1600
BE 1600 BE 1600 MSL-16 MSL-17 MSL-15 BE 1600 BE 1600
TO-T1-33 TO-T1-35 BDT 019-12 BDT 019-11 TO-T1-34 TO-T1-36

POLYESTER
POLYESTER
VISCOSE
Fourth row cards 3rd row cards 1st row cards 2nd row cards
FOR VISCOSE RAYON
FOR POLYESTER
AIR WITH LINT
Figure 3.1 Blow room line

16
The only difference between these two lines is that in one line only polyester flow and in
seco nd line polyester and viscose both raw materials are flowing, but after passing
through scales(PWSE) both lines have same material.(viscose & polyester).
3.3 Blendomate (BDT-019-011)

This machine opens the bales of synthetic fibers without creating dust. The
working process is controlled by computer. It runs automatically apart from the freeing of
the bales.
Figure 3.2 Blendomate
The bales are plucked off to the height set by the control system, when the bales are being
worked off on the right-hand and left-hand side of the machine; it is possible to switch to
the other working area the pivot drive in the turret then rotates the detacher 180 degree
around the vertical axis. Bale opening continues without the machine corning to a
standstill.
Table 3.2 Blendomate specification
Attribute Specification
Total length 25.5 meter
Working Length 23 meter
Traverse speed 16 rpm/m
Production Up to 1500 kg/hr.
Up and Downward Movement 1800 mm
No. of Beater 2
Beater Speed 1400 rpm
No. of Bales Used 38
Continuous power consumption 4KW
Suction air rate min. 5,500 m3/h
Depending on the travel direction of the machine, the opposed opening rolls are lifted,
thus allowing the teeth to work once in and once opposite the travel direction of the
machine. This results in consistent tuft sizes and uniform production distribution between
the rolls.
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The large working width of the Blendomate of 17,200 mm or 23,000 mm allows lay-down
of up to 150 or 200 and more bales (machine length of 50 m). The Blendomate BO-U can
selectively process bales on one or both sides of the track.
 No. of bales of polyester at BDT-11 = 20

 No. of bales of viscose at BDT-11 = 17
 No. of bales of polyester at BDT-12 = 38
3.4 Dosing Opener (FD-S)

To obtain a more uniform material flow it is practical to use small buffer units in
some cleaning and opening lines for uniform feeding of downstream machines. The first
step in tuft blending is the exact dosing of the blending components. For high production
rates there is a choice between the automatically fed High Performance Weighing Feeder
BL-HW and the manually fed Weigh Pan Bale Opener BO-W.
Figure 3.3 Dosing Opener
The Extra Precision Weighing Feeder BL-EW is used for low blending ratios. For very
small lots or very low production rates, the Component Balance BL-CB is the most
economical solution. It is also suited for pre-blending.
There are following sections:
• Condenser (at top)

• Stock trunk
• Beater (at bottom)
• Width = 1600 mm
• Speed = 550 rpm
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3.5 Tuft Blender (FML)
The tuft size of raw material is reduced in it. One beater is used for the opening purpose.
Speed of beater is about 550 rpm. 7.5 bar pressure is used.
Figure 3.4 Tuft blender (FML)
3.6 Weighing Scales (PWSE)

Scales are used to take the raw material in fixed amount to make the required blend
ratio. The scales open when the required feed weight achieved in it and then it transfers the
material to lattice to move it forward. The lattice stops after 2000mm distance and scales fill
again and this process continue. There are two blow room lines, each line have four scales.
Three have polyester and one viscose to make 80:20 blend ratio of raw material.
Figure 3.5 weighing scale (PWSE)
3.7 Metal Detector (SP-EM)

It detects the presence of any metal particle in the raw material. The portion of raw
material containing metal particle left in the waste trolley and clean it manually. If due to some
reasons the raw material catches fire the showering system is also present to stop fire.
19
Pressure P1= 2.2bar
Pressure P2=3.3 bar
Figure 3.6 Metal detector (SP-EM)
3.8 Multi Mixer MX-U 10

It is used for mixing and opening. There are 10 chambers in the Multi mixer. Each
chamber contains 2 feed rollers and a beater. Motor of speed about 350-650 rpm is driving
the beaters.
Figure 3.7 Multi mixer (MX-U)
Table 3.3 Multi mixer specification
Attributes Specifications
Manufacturer Trutzschler
Total no of machines 2
Model 2004
Production capacity Up to 800 kg/hr.
Machine Width 2.2 m
Machine Length 5.3 m
20
Machine Height 3.7 m
No. of Chambers 10
Compressed Air Consumption 300 pa
Delivery roll/chamber 2
Opening roll/chamber 1
Delivery Roll Speed 672 rpm
Opening Roll Speed 650 rpm
Air Pressure 7 Bar
Trunk Filling Time 3 min
3.9 Tufto-Mate (To-T1)

Two rollers are there to open the raw material into tuft form. One roller having big
teeth (gentle opening) rotating at 680 rpm while second roller has fine teeth and rotating at
655rpm.
Table 3.4 TO-T1 Specification
Attribute Value
Opening Roller Speed 680 rpm
FD-O Roll Speed 655 rpm
Fan Speed 2200 rpm
Dust Cage Speed 141 rpm
Suction Pressure 350 Pa
Gauge feed roller to beater 3.5mm
Figure 3.8 Tufto mate (TO-T1)
21
3.10 Waste Breaker (Reusable Waste Mixing)
Reusable waste is fed in it. It is directly attached with the scale and scale takes the
material from it according to the blending requirement. It has inclined lattice and evener
lattice. The gauge between them is 10mm.
Figure 3.9 Piece Breaker
3.11 Condenser
Table 3.5Condenser Specification
Manufacturer Trutzchler
Maximum Production 1800 kg/hr.
Compressed air requirement 7 bar
Cage dia 490 mm
Fan dia 410 mm
Fan speed 2480 rpm/2930 rpm
Fan motor power 5.5kw/7.5kw
Stripper roller dia 298 mm
Stripper roll speed 438 rpm
No. of fan blades 8
3.12 Filter room

Table 3.6 Filter room specification
Manufacturer LUWA
Type Rotary
Model No IE1
Air volume handled 140000 m3/Hr.
Air change/Hr. 16.0
Motor 45 KW
Rated output of gear motor, 0.75 KW
Pre filter dia 2200 mm
22
Rpm 10-16
Pre filter cloth mesh 80 mesh/inch
3.13 Maintenance
Preventive Maintenance is done in blow room. Blow room machines work 23
hours in a day a 1 hours/day reserved for a daily maintenance.
In daily maintenance
• Cleaning of lenses of the light barrier.

• Eliminate material from the duct.
• Clean the lens of optical sensor.
• Clean soiling from supply chain.
• Check the tension of roller chain.
• Clean fibers from roll drive motor.
• Clean fibers from the toothed disks.
There is also the maintenance of one machine daily except Friday and Sunday. In that
maintenance the greasing of Barings, inspection of gear box, belt tensions are check.
3.14 Manpower
Table 3.7 Manpower in Blow Room Department
Designation Strength
Foreman 1
Head fitter 1
Fitter 1
Assistant fitter 2
Total 5
Manpower production for 1 shift
Supervisor 1
Operator 3
Assistant Supervisor 1
Total 5
23
4 Card
Carding is a mechanical process that breaks up locks and unorganized clumps of
fiber and then aligns the individual fibers so that they are more or less parallel with each
other. Carding is one of the most important operations in the spinning process as it directly
determines the final features of the yarn, above all as far as the content of Neps are
concerned.
Figure 4-1 Card
4.1 Objectives Of Carding

 Opening the tufts into individual fibers;
 Eliminating all the impurities.
 Selecting the fibers on the basis of length, removing the shortest ones;
 Removal of Neps
 Parallelizing and stretching of the fiber.
 Formation of sliver.
4.2 Main Actions of Carding Machine

 Combing action
 Carding action
 Stripping action
 Doffing action
4.3 Functions of The Machine

The card is fed by the integrated tuft feeder. The card splits this feed sliver into
individual fibers and positions them parallel to each other. In the process, any knots
(Neps) and residual soiling is removed. At the outlet from the card, the fiber web is
formed into a sliver which is placed into the cans by a coiler.
4.4 Assembly Groups

The main assembly groups of the card are illustrated in the following schematic
diagram.
1. DIRECT-FEED DFK tuft feeder
2. SENSOFEED+ integral tray
24
3. WEBFEED licker-in unit. 1 or 3 rolls
4. MULTI-WEBCLEAN system with fixed flats
5. Cylinder
6. Revolving flat system
7. MULTI-WEBCLEAN system with fixed flats
8. Doffer section
9. Web doffing section
Figure 4.1 Carding machine TC-03
4.5 Machine specifications
Table 4.1 Card Specification
Manufacturer Trutzschler
Model TC-03
Year 2004
Maximum speed 400 m/min
Maximum production 150 kg/hr.
Total no of cards 36
Waste % 2.2 %
Fly waste 1%
Taker in waste 0.2 %
Efficiency 97 %
Can size 1000mm dia & 1200mm height
Can capacity 10000m
Sliver weight 62 gr/yd. , 65 gr/yd.
Delivery speed 65 m/min , 125 m/min
Production speed 17 kg/hr. , 34 kg/hr.
Installed load Motor 19 KW
No. of motors 16
25
4.5.1 Dia. & speeds of different rollers
Table 4.2 Dia. & speeds of different rollers
Roller name Diameter Speed

Feed roller 4 inch 3 rpm
Taker-in 1 7 inch 609 rpm
Cylinder 50 inch 420 rpm
Doffer 27 inch 27 rpm
Stripping roller 7 inch 156 rpm
Top crush roller 3 inch 333 rpm
Bottom crush roller 3 inch 333 rpm
Calendar roller 3 inch 488 rpm
Coiler calendar roller 3 inch 454 rpm
4.5.2 Card Gauges
Table 4.3 Card Gauges
S. No. Gauge between Gauge

1 Taker-in and mote knife 52 thou
2 Taker-in and under casing Fix
3 1st taker-in to 2nd taker-in 7/1000
4 2nd taker-in to 3rd taker-in 7/1000
5 3rd Taker-in and cylinder 7/1000
6 Cylinder and back bottom plate Top 25/1000
Bottom 40/1000
7 Cylinder and back top plate Top 30/1000
Bottom 22/1000
8 Front 12/1000
Top set and cylinder:
Mid 13/1000
Back 14/1000
9 taker in side 1 mm
Cylinder and Under casing Center 1.5 mm
Doffer side 3.5 mm
10 Cylinder and doffer 7/1000
11 Doffer and stripping roller 7/1000
26
4.5.3 Wire specifications
Table 4.4 Card Wire Specification
Taker in wire
PPSI (Points per square inch) of R1 34
Height 5-6 mm
Angle for R1,R2,R3 20o
Taker in wire life 1200 ton
Cylinder wire
PPSI (Points per square inch) 727
Height 4 - 5.5 mm
Thickness 0.40 mm
Angle 30o
Cylinder wire life 1200 ton
Doffer wire
Height 4 – 5.5 mm
Thickness 0.90 mm
Angle 30o
Doffer wire life 1200 ton
Top set
Total flats 84
Working flats 28
Top set life 600 ton
Stationary flats 26
Stationary flats life 400 ton
4.6 Filter room

Table 4.5 Filter room specification
Manufacturer LUWA
Type Rotary type
Model No 2004
Airflow rate 220000 m3/hr.
Air change/Hr 18.0
Motor 110 KW
Rated output of gear motor, 0.75 KW
Pre filter dia 81 inch
Rpm 10-16 rpm
Pre filter cloth mesh 80 mesh/inch
27
4.7 Maintenance
Preventive Maintenance is done in blow room. Blow room machines work 23
hours in a day a 1 hours/day reserved for a daily maintenance. Cleaning is done daily for
one hour.
There is also the maintenance of one machine daily except Friday. In that maintenance, the
one machine is opened and the wires point, greasing of Barings is checked, belts tensions
are checked.
4.8 Manpower
Table 4.6 Manpower in Card Department
Foreman 1
Assistant foreman 1
Head fitter 1
Fitter 1
Assistant fitter 1
Total 5
Manpower Production for 1 Shift
Supervisor 1
Operator 3
Floor cleaner 0
Total 4
28
5 Drawing
Draw frame is a machine for combining and drawing slivers of a textile. Drawing
is the operation by which slivers are blended, doubled and leveled. In short staple spinning
the term is only applied to the process at a draw frame. In drawing slivers are elongated
when passing through a group of pair rollers, each pair is moving faster than previous one.
Figure 5.1 Drawing Department
5.1 Actions Involved In Draw Frame

• Drafting
It is the process of increasing length per unit weight of sliver. It is mainly due to
the difference in the surface speed of the rollers.
• Doubling
The process of combing two or more carded sliver into a single form is called
doubling. In draw frame m/c generally six slivers are fed to convert into one is known as
doubling of six.
• Drawing
The combine operation of drafting and doubling of slivers is known as drawing.
5.2 Tasks of Draw Frame

• Equalizing or uniforming
One of the main tasks of draw frame is improving evenness over short, medium
and especially long terms. Carded slivers are fed to the draw frame have degree on
unevenness that cannot be tolerated in practice and slivers from the comber contain the
“infamous” piecing. Equalizing is always performed by a first process, namely doubling
and can optionally also be performed by a second process, namely auto leveling. The draft
and the doubling have the same value and lie in the range of 6 to 8.
• Parallelizing
To obtain an optional value for strength in the yarn characteristics, the fibers must
be arranged parallel in the fiber strand. The draw frame has the tasks of creating this
29
parallel arrangement. It fulfills the task by way of the draft, since every drafting step leads
to straightening the fibers.
• Blending
In addition to the equalizing effect, doubling also provides a degree of

compensation of raw material variation by blending. Their results are exploited in
particular way in the production of blended yarns comprising cotton or synthetic blends.
At the draw frame metering of the individual components can be carried out very simply
be selection of the number of slivers entering the machines.
• Dust removal
Dust is steadily becoming a greater problem both in processing and for the
personnel involved. It is therefore important to remove dust to the greatest practical extent
at every possible point within the overall process. Since a large function the smallest
particles adhere relatively strong to the fibers. High performance draw frame is equipped
with appropriate suction removal systems; more than 80% of the incoming dust is
extracted.
5.3 Machine Specifications

Table 5.1 Breaker and Finisher Specification
Machine Breaker Finisher

Manufacturer Trutzschler Trutzschler
Model TD-03 TD-03
Year 2004 2004
Drafting system 4/3 drafting system 4/3 drafting system
Dia. of Rollers Bottom front =35 mm Bottom front = 35 mm
Bottom middle = 30 mm Bottom middle = 30 mm
Bottom back = 30 mm Bottom back = 30 mm
Delivery speed 300-1000 m/min 300-1000 m/min
Delivery single delivery single delivery
Gauge Front to middle = 51 mm Front to middle = 51 mm
Middle to back = 71 mm Middle to back = 71 mm
Top roller pressure Pneumatic pressure Pneumatic pressure
Trumpet size Auto adjustable Auto adjustable
Can capacity 12000 m 6500 m
Draft 4~11 4~11
Bottom roller type Spiral Spiral
Material feed 15~50 Ktex(g/m) 15~50 Ktex(g/m)
Min air pressure 7 Bar 7 Bar
30
Table 5.2 Top Roller Specification of Breaker & finisher
Attributes Breaker Finisher

Bore 23 mm 23 mm
Outer dia 34 mm 34 mm
Length 180 mm 180 mm
Hardness 80 degree shore 80 degree shore
Grinding range 2 mm 2 mm
Washing duration Daily Daily
Grinding duration 02 Month 02 Month
Last grinded dimension when it 32 mm 32 mm

expires
Life 01 year 01 year
5.4 Process And Quality Parameters Of Product

Table 5.3 Process and quality parameters of product
Description Breaker TD03 Finisher TD03

Del. Count 0.139 0.139
Del. Grain/yard 60 60
Doubling 8 8
Draft 8.7 8.0
Del. Speed 400 m/min , 440 m/min 400 m/min , 430 m/min
Production kg/hr 79.6 , 60.2 79.3 , 59.9
Efficiency 78 % , 62 % 78 % , 61 %
No. of units 2,7 2,7
5.5 Maintenance
5.5.1 Daily
• cleaning of drafting gauges of all machines
• cleaning of coiler tube and trumpet
Daily one machine is opened and the overcalling is done. Checking, greasing, and oiling
of all bearings of check jack box, creel, sliver roller bearing cleaning and greasing.
31
5.5.2 Major parts change schedule
The major changing is rubber cots both in breaker and finisher. Changing is done
according to the lab results. Rubber cots are changed after one year.
5.6 Manpower
Table 5.4 Man power
Foreman 1
Assistant Forman 1
Mechanical Supervisor 2
Head fitter 2
Fitter 3
Assistant Fitter 1
Total 10
Production supervisor (3 shifts) 1
Supervisor 1
Operator 4
Bobbin boy 2
Doffer 3
Total 11
32
CHAPTER 04
SPINNING AND PACKAGE WINDING PROCESS
6 Simplex
6.1 Introduction
The draw frame produces a sliver that already exhibits all the characteristics
required for the creation of a yarn, namely an ordered, clean strand of fibers laying parallel
to one another. The roving machine itself is complicated, liable to faults, causes defects,
adds to production costs and delivers a product that is sensitive in both winding and
unwinding.
Figure 6.1 Roving frame
6.2 Objective Of Roving Frame

These are the following task performed on the roving frame.
 Drafting
Drafting is the attenuation of the drawn sliver to produce required amount of

roving by drafting. Thick drawn sliver is converted in to thin roving by drafting system.
 Twisting
Since the resulting fine strand has scarcely any coherence, protective twist must be
inserted in order to hold it together.
 Winding
Winding is the process to wind roving to suitable bobbin for easy efficient
transportation. Build the roving on the bobbin such a form which will facilitate unwinding,
handling and transfer to the next process.
33
6.3 Defects And Its Prevention On Roving Frame
6.3.1 Roving tension

Roving tension is directly related to machine. The roving tension depends upon
delivery rate and the difference between flyer speed and bobbin.
 Prevention:
For preventive action we should keep the delivery length and the speed difference
constant then the tension in this case will be ideal.
6.3.2 Improper handling of material

Roving material is very sensitive regarding to quality point of view. It is necessary
to take care of material. The material should be handled in such a way that fine dust must
not affect the material.
 Prevention:
It must be avoided touching because of its sensitivity. Fresh material should be

used for next process. This material should not be keep for long time. If it will be kept for
long time then it will create variation. C.V% increases if material is not used. Supervisor
must treat its worker in a proper way so that handling of material should be according to
policy of mill.
6.3.3 Improper piecing in roving

This defect occurs due to improper training of worker.
 Prevention:
Supervisor should train his workers in a proper way. If end breakage is disturbed
then its treatment should be proper. If piecing will not be proper then it will affect the next
process.
6.3.4 Roving breakage

This problem is caused due to maintenance problem. Maintenance required
machine stoppage but it is against the production. To enhance the quality of product, the
machine maintenance is the chief requirement.
 Prevention:
For the proper solution of roving breakage, speed of machine, trained operator and
proper management should be must otherwise it create severe problems in ring section.

Table 6.1 Simplex Specification
Manufacturer Zinser
Model 670 RoWeMat
Total frames 9
34
No. of spindle per frame 144
Total lift of machine Mm
Maximum Delivery speed 80 m/min
Maximum Flyer speed 1500 rpm
Maximum bobbin speed 1800 rpm
No. of turns around presser arm 2 turns
Feed of machine 60 gr/yd.
Can size 600 mm x 1200 mm
Type of roller weighing Spring weighing
Spindle gauge 110 mm
Bobbin rail lift 406 mm
Flyer rpm 1100 rpm
Bobbin rpm 1400 rpm
Drafting system
Model SKF PK-1500
Type 3/3 drafting system
Dia. of bottom rollers 30 mm , 25.5 mm , 30 mm
Dia. of top rollers 34 mm
Gauges
Between front and middle roller 30 mm
Between middle and back roller 39 mm
Apron specifications
Top apron 39.8 x 48 x 1.1
Bottom apron 88 x 42 x 1.1
Life 1.5 year
Top Roller Specifications
Dia. with rubber cot 34 mm
Width 40 Mm
Rubber cot dimension 19 x 35 x 40
Hardness 80 degree shore
Grinding range 2 Mm
Polish No
Grinding 3 month
Last grinded dimension when it expires 32 mm
35
Life 3 year
Pressure on top rollers

Front roller 30 Pa
2nd roller 20 Pa
Back roller 25 Pa
Spacer
Color Brown
Size 10 mm
Sliver guide 11 x 3.5 mm
Condenser 8 mm
Front Collector 3 mm
Bobbin specifications
Length 445 mm
Dia 56 mm
Weight 200 g
Roving winding 4000 m , 3100 m
6.5 Process and quality parameters of product
Count 0.95 Ne 1.3 Ne

Grain feed 60 gr/yd. 60 gr/yd.
Draft 6.86 9.51
Spacer Brown Brown
Front roller rpm 455 rpm 396 rpm
Delivery speed 40.73 m/min 35.49 m/min
T.M 0.70 0.69
T.P.I 0.686 0.787
O.P.S 309.10 175.22
Production 157.8 m/min 89.4 m/min
Efficiency 72 % 64 %
No. of unit 1 2
36
7 RTS (Roving Transport System)
The Bobbin transport system provides economic advantage to package handling of
Ring Spinning. It ensures the protection of roving wound around the Bobbin, which is
highly liable to damages during manual transportation. BTS also protects the yarn quality
where the Roving defects are transferred. Bobbin Transport System is certainly the area in
Spinning Mill where the investment in automation is more easily justified due to labour
savings and reduction in yarn faults. Especially in the coarser count spun the labour saving
will be higher.
Figure 7.1 RTS parking
7.1 RTS Advantages

 Can be installed in the existing layout (both Building and Machinery)
 Interface any speed frame and ring frame
 Contact less Bobbin transport
 No Mix-up of yarn counts
 Technology upgradation
 Man power reduction
Table 7.1 RTS Specification
Attribute Specification
Manufacturer Zinser
Transport system Transport of the trolley trains by means of
stationery wheel and disk drives
No. of trolley trains 64
No. of bobbins per trolley train 288
Gauge of trolley train 180 mm
Stripper working rate 2 bobbins/45 second
Exchanger rate 2 bobbins /45 second
Bobbins preparation for one doff 144 bobbins /54 minutes
Speed of train 16 meters per minute
Storage 24 trains
Number of train movements per transport 2.9 trains/hr. one way
direction & 5.8 trains /hr. two way
37
8 Ring Spinning
Ring Spinning is the oldest of the present day spinning processes. Fiber material is
supplied to the ring-spinning machine in the form of roving. The fiber mass of the roving
is reduced by a drafting unit. The twist inserted moves backwards and reaches the fibers
leaving the drafting unit. The fibers lay around one another in concentric helical paths.
The normal forces encountered by the fibers enhance the adhesive forces between the
fibers and prevent fibers from flying or slipping past each other under the tensile strain.
Ring spinning is a comparatively expensive process because of its slower production
speeds and the additional processes (roving and winding) required for producing ring spun
yarns. Ring spun yarns produce high quality and are mainly produced in the medium
range, with a small amount produced in the coarse count range.
Figure 8.1 Ring machine
8.1 Objective Of Ring Frame

 To draft the roving fed to the ring frame to convert roving into very fine strand
called yarn.
 To impart strength to the yarn by inserting the necessary amount of twist.
 To collect twisted strand called yarn onto handy and transportable package by
winding the twisted thread on a cylindrical bobbin or tube.
8.2 Main Parts Of Ring Frame

1. Creel
2. Roving guide
3. Drafting rollers
4. Top rubber cots
5. Top clearer rollers
6. Top apron
7. Bottom apron
8. Pneumaphil Suction Nozzle
9. Yarn guide (Snail Wire)
10. Plastic separator
11. Balloon controlling ring
12. Ring Traveler
13. Traveler clearer
14. Spinning Ring
15. Ring Spindle
38
8.3 Machine Description
Table 8.1 Ring Specification
Manufacturer Saurer Zinser

Model 351
Year 2016
Total frames 21
Spindle / frame 1680
Drafting system 3/3 roller drafting system
Drafting system type PK-2635
Front&back Roller type Spiral
Middle roller type Fluted
No. of motors 30
Spindle Speed Up to 18000 rpm
Traveler specifications
Type C1 LM UDR
Life Different according to count
Ring specifications
Manufacturer BREAKER
Life 5 year
Ring dia 42 mm , 45 mm
Fitting dia 50 mm
Height 9.5 mm
Flange width 3.2 mm
Dia. of different rollers
Front bottom roller 32 mm
Middle bottom roller 30.5 mm
Back bottom roller 32 mm
Front top roller 35 mm
Middle top roller 25 mm
Back top roller 35 mm
Block gauge
Front zone 25.5 mm
Back zone 42.5 mm
Roller Settings
39
Front zone 56.5 Mm
Back zone 73.5 Mm
Bare bobbin dia.
Top 21.22 mm
Bottom 24 mm
Length of bobbin 231 mm
Gauges
Spindle gauge 70 mm
Lappet gauge 20-22 mm
Pressure gauge 3 mm
Traveler clearer gauge 1.5-2.75 mm
Spindle wharve dia. 19 mm
Spindle length 185 mm
Spindle tap thickness 2 mm
Spindle tap width 20 mm
Spindle tap length 138000 mm
Lift of machine 192 mm
Chase length 46 mm , 49 mm
Apron specifications
Top apron 42.1mm x 27.8 mm x 1.0 mm
Bottom apron 79mm x 30 mm x 1.1mm
Life 1.5 year
Top roller specification
Dia. with rubber cot 35 mm
Width 28 mm
Rubber cot dimension 35 x 28 x 19
Hardness 80 degree shore
Grinding range 2 mm
Grinding 3 month
Last grinded dimension 33 Mm

when it expires
Life 4 year
40
8.4 Process and quality parameters of product
Count 18 50
Hanks roving 0.95 1.3
TPI 11.29 20.15
Nominal Draft 22.80 40.65
Break Draft 1.14 1.14
Spindle Speed 12800 rpm 15497 rpm
Delivery speed 29.33 m/min 20.17m/min
T.M 2.66 2.85
O.P.S 14.40 3.87
Production 85.7 kg/hr. 23.0 kg/hr.
Efficiency 90 % 96 %
No. of unit 1 2
8.5 Maintenance
The maintenance of different machine parts depends upon the quality results of the
product.
The hardness of rubber cord increases with the passage of time because of friction. The
grinding of rubber cords is done in the maintenance department workshop. The cleaning of
machine parts is done on daily basis for one hour.
8.6 Manpower
Table 8.3 Manpower in Ring Department
Assistant foreman 2
Head fitter 1
Fitter 2
Assistant fitter 5
Helper 6
Total 16
Manpower Production for 1 Shift
Supervisor 1
Operator 6
Doffer 3
Total 10
41
9 Cone Winding
Winding department comes after the Ring department. Yarn wound on the Ring
bobbins cannot be put to good use in the subsequent process because Ring bobbins are in
the form of small packages.
Figure 9.1 Cone winding machine
9.1 Objective Of Winding Process

 Inspect the yarn.
 Clearing the defects.
 Lubricate the yarn.
 Build a suitable package for subsequent process.
9.2 Importance Of Winding

Unevenness in traditionally spun staple yarns is a natural phenomenon usually
induced by the process of manufacturing. Although with modern process controls and
machines many imperfections in the spun yarns can be controlled, some still remain in the
final yarns. Most common of all imperfections are thin or weak places, thick places, slubs,
neps, and wild fibers, as shown schematically. During the subsequent processes of
winding, warping, and slashing, not all but some of these imperfections create obstacles to
steady and smooth working. Therefore, it is important to classify, quantify, and remove
those imperfections which may cause the interruption of the operation.
This necessitates the preparation of a dense and uniform yarn package of sufficiently large
size which can unwind in the subsequent operations without interruptions. The packages
prepared for warping are normally cross-wound, containing several kilograms of yarns.
This implies that a number of knots or splices are introduced within each final package.
Bear in mind, each knot or splice itself is an artificially introduced imperfection; therefore,
the size of this knot or splice must be precisely controlled to avoid an unacceptable fault in
the final fabric.
42
9.3 Processed material
 Input - Yarn (Spinning bobbins)
 Output - Yarn (large cones, tubes, etc.)
9.4 Elements of process

 Yarn withdrawal
 Yarn tensioner
 Yarn clearing
 Stop motion
 Yarn splicing
 Take up
9.5 Basic diagram of winding machine.
Figure 9.2 Basic Working Diagram of Auto cone Winding machine

Table 9.1 Auto Cone Specification
General
Manufacturer Schlafhorst (AC 6V)
No. of frames 21
Spindles per Frame 60
Doffing and Feeding Automatic
Clearer type Zenit Plus
Cradle type Yoke type
43
Magazine Not available
Suction mouth tip 5 mm
Air consumption for one splice 2.5 Pa
Winding speed 250~2000 m/min
Type of splicer (Air splicer)
Splice length 1.2 inch
Splice strength 92
Pressure on tension disk Electric disc
No. Of Grooves per drum 2.5
Dia of Drum 94 mm
Traverse of Drum 150 mm
Auto doffer per machine 01
Auto doffer speed 42 m/ min
Auto doffer doffing time 7~8 Seconds
Package Diameter 165-300 mm (Maximum)
Count range 15~65 Ne
Staple length range 38~51 mm
Compressed air consumption 450 NL/min
Minimum compressed air Pressure 7 bar
9.7 Manpower
Table 9.2 Manpower in Auto Cone Department
Foreman 1
Supervisor 4
Fitter 4
Assistant fitter 1
Total 10
Head Supervisor (3 Shifts) 1
Total 35
44
CHAPTER 05
YARN PACKING
10 Introduction
The last process in the spinning mill is packing. In this department yarn is packed
in to a suitable form of package so it can be identified, protected, stored or staged before
the shipping to the buyer and so it can be sold out in the market. The beg weight is always
kept 100 lbs. this is the net weight of the yarn excluding beg weight. The weight of other
elements i.e. paper cone, sticker, polyethylene packet, polypropylene bag, cartoon and
strips is considered as the tare weight. Packages are sold on the basis of net weight of
yarn.
10.1 Objectives
 To protect yarn from environment.
 Ease in transport.
 Less yarn damage in storage.
 Different products are identified easily
There are two types of packing in IFL which are

1. Local packing
2. Export packing
10.1.1 Local packing

In local packing poly propylene bags are used for packing which save the packages
from extra moisture. In local packing first of all a worker attaches a sticker to the inner
side of the cone, secondly, a stopper is used on the lower side of the cone which can bear
weight of many pounds and cones can be put over each other in case of export. Stopper
keeps the shape of the cone proper so that in warping unwinding should be smooth. After
that yarn packages are wrapped in poly ethylene bags manually which is called internal
packing. After those processes these cones are packed with the help of poly propylene
bags.
10.1.2 Export packing

Export packing is done with two methods:
1. Cartons
2. Pallets
10.3.1 Cartons packing

In evening wear packing is done in cartons, first of all a worker attaches a sticker
to the inner side of the cone, secondly, a stopper is used on the lower side of the cone
which can bear weight of many pounds and cones can be put over each other in case of
export. Stopper keeps the shape of the cone proper so that in warping unwinding should be
smooth. After that yarn packages are wrapped in poly ethylene bags manually which is
also called internal packing. At the end packages are set in the cartons, and packed.
45
10.1.3 Pallets packing
For pallets packing a machine [SAN-GRato-CMT-Srl] is used for pallet packing.
Its model 2003. In this packing the same process of stickers, stoppers and poly ethylene
bags are used then pallets packing is done. After packing packages are set.
11 CTS (Cone Transport System)
Table 11.1 CTS Specification
Sr No. Attribute Specification

1 No. of Auto winding machines: 21 Schlafhorst AC6 V.
2 Production per day: 36288 Kg
3 Package weight: 1890 Kg
4 Basket size will be suitable for package 130 mm to 240 mm
diameter: (minimum small side to
maximum large side).
5 Maximum performance level 500 cones/hour/line
6 Package type: Conical 5o57” or Cylindrical
7 Number of yarn qualities simultaneously: 10 Maximum
8 Number of hangers will be suitable for Ne 14 to Ne 46
9 Conveyor speed 8~9 m/min
10 Number of loops: 02 as attached layout
11 Compressed air points at off loaders. (Exact location will be
provided by SELLER).
12 Compressed air pressure: 06 bar
13 Volume of air required per minute at off loader: 20 NL/min
14 Installed Power : 30 KW
15 Power consumption approximately: 15~18 KW
11.1 Process Flow Description

Packages will be automatically aligned and unloaded from the winding machines,
by means of package lifters and placed onto an overhead conveyor system. Afterwards the
packages will be transported to the packing area, where they will be unloaded.
Figure 11.1 cone transport system

46
Before unloading the packages will pass a Quality Checking unit, where the tube color and
under UV light material mixture and homogeneity will be checked. Off standard cones
will be unloaded into a gravity chute (10 cones).Packages from the conveyor loops will be
automatically unloaded by means of packages unloaders and moved to the preparation and
centering station. Lifter and unloaders work in synchronization w.r.t. counts, controlled by
software.
Robotic arm picks up cones by multi gripper and build up pallets at designated areas and
also puts separators from their respective separator storage between each layer. Once the
pallet is complete, it will be removed automatically.
Pallets from palletizers will be moved by means of a T-car to a transfer roller conveyor.
The same T-car takes empty pallet bottoms from a dispenser and moves them to the
palletizing places. From transfer roller conveyor pallets move to a turntable. This turntable
will rotate at 90° and pass on the pallet to next T-car via roller conveyor.
The second T-car takes the pallets and moves these pallets to one of the de-palletizing
units and also to the storage area. The de-palletizer picks up 5 packages at the same time
and brings these to the in feed line of the sack packing unit.
The pallet has 240 packages of one quality on the pallet, which means the sack packing
unit can produce 10 bags of one quality. When the pallet is empty, the transfer car takes
out the empty pallet and moves a full pallet into the de-palletizer.
11.2 Automatic sack packing system

Table 11.2 Sack packing machine
Sr No. Attribute Specification

1 Packages per hour / line: 500 pcs.
2 Package diameter: 160 mm ~ 240 mm
3 No. of packages per layer: 12 (horizontally) number will be
always 03.
4 Layers per sack: 1~2.
5 Total packages per sack: Maximum 24 pcs for 1.89kg
(4.17 lbs).
6 Power Consumption approximately 2 x 3 KW.
7 Air Consumption/hour approximately 2x20 m³/ hr.
8 Compressed air pressure: 06 bar
9 Installed Power: 2 x 5 KW
10 Package protection: PE, plastic bag each package
11.3 Process flow description:

Before entering the sack packing unit, the cones will be moved over a weighing
scale and off limit cones will be removed to an attached conveyor (10 cones).
From the weighing scale the cones move forward to the sack packing machine, where
every second one will be turned 180 degree in order to receive a nested packing pattern.
Then the cones move through a unit where each cone will be put into a PE plastic bag.
After bagging, the cones will be put into (double) rows by means of a small pusher and
then by means of a big pusher moved into the sack.
47
Figure 11.2 Sack packing machine
The sack packing unit includes fixation the bag automatically. The filling cycle will repeat
until the sack is full. The full sack then will be moved away from the filling table onto a
conveyor. Here the stitching machine closes the sack and moves them further on the
conveyor.
The sack weight will be checked automatically with the help of integrated weighing scale
and moves them further on the conveyor.
48
12 Roller Cover Department
12.1 Grinding Machine (BERKOL BGSM)

Table 12.1 Grinding machine specification
Year of Manufacturing 2006

Make BERKOL
Model BGSM
Serial Number BGSMB 024/2006
Suitable for Ring & Simplex rubber cots grinding only
Capacity 150 Pairs/Hr.
Grinding stone speed 3000 RPM
Grinding stone dimension 200X200 mm
Circumference speed 30 m / Sec
Minimum cot size required 24 mm
Berkolizing Time 20 Sec ~ 140 Sec
Maximum length of arbor 190 mm
Maximum grinding length 60 mm
Electrical rating 7.5 KW
Operating pressure 6~10 Bar
Maximum air consumption 150 L / Min
UV berkolizer lamp power 1000 W
Dust extraction air rating 20 m3 / min
Berkolizer waste fan 190 m3/ Hour
Space required 3.8X2.2 Meter
Weight 770 Kg
Noise level < 70 dB (A)
12.2 Grinding Machine (BERKOL BG U)

Table 12.2 BERKOL BG U Specification

Make BERKOL
Model BGU
Capacity Manual
Grinding stone speed 2900 rpm
Suitable for Ring, Simplex, drawing, comber, lap
former, Detaching roller grinding
Maximum grinding length 600 mm
Minimum cot size required 25 mm
Maximum cot size required 65 mm
Electrical rating 5 KW / 400 V
Dimension 1320X700X1400 mm
Weight 495 Kg
Dust extraction air rating 10 m3 / min
Spindle speed 150 to 900 rpm
Grinding unit speed 20 to 700 mm / min
Grinding wheel size 225X160X20 mm
Grinding wheel speed 2800 rpm
Noise level < 75 dB (A)
49
12.3 Press (AP H50-H500EV)
Drawing, comber, lap former rubber cot mounting and dismounting machine.
Table 12.3 press specification

Make BERKOL
Connected load 400 V, 50/60 Hz, 0.75 Kw
Weight 88 Kg
Pressing force up to 2900 Kg
Pressing range up to 490 mm
Hydraulic pressure 80 bar
12.4 Press (PP 125 H100)

Ring and simplex rubber cot mounting and dismounting machine.
Table 12.4 PRESS PP 125 H100 specification

Make BERKOL
Weight 40 Kg
Operating pressure 6 to 8 Bar
Force at 6 bar 650 Kg
Force at 8 bar 860 Kg
Noise level 82 dB (A)
Shell dia range 18 to 19 mm
Shell length range 20 to 45 mm
12.5 Top Roller Lubricating ( BOS-01)

Rubber cots lubricating machine.
Table 12.5 Top roller lubricating BOS-01 Specification
Suitable for Ring and simplex rubber cots

Make BERKOL
Dimension 200X250X675 MM
Weight 15.7 Kg
Grease capacity 1 Kg
Maximum grease stroke 0.4 Gram
Maximum shell length 80 mm (Which can be greased)
50
12.6 Lubriboy
Lubrication machine.
Table 12.6 Lubriboy Specification
Suitable for Ring and simplex arbors

Make BERKOL
Weight 72 Kg
Operating pressure 8 to 10 Bar
Pressure tank 40 Liter capacity
Grease gun setting 0.1 to 0.37 cm3
12.7 Rubber Cots Uv Treatment

Table 12.7 Rubber cots uv treatment Specification

Make BERKOL
Suitable for all types of rubber cots (Ring, Simplex,
Comber, lap former)
UV berkolizer lamp power 3000 W
Berkolizing time 10 min to 30 min
Capacity at one time  88 Ring top rollers
 56 Simplex top rollers
 08 Comber top rollers
 08 Lap former rollers
 20 Drawing top rollers
Fitted with exhaust pipe
51
CHAPTER 06
TESTING AND QUALITY CONTROL
13 Introduction
After making yarn it is very necessary to perform certain tests to check whether the
results are up to our expectations are not. In any textile mill the factors which are checked
include yarn strength, elongation, IPI, breaking force and certain other parameters. Several
machines are used for testing and quality purposes.
Ibrahim Fibres TP1 has modern testing laboratory available which is performing its
function efficiently.
13.1 Objectives
 To maintain the quality
 To obtain the optimum level of product
 To control the waste
 To maintain the maximum efficiency
 To maintain the good check and balance system
13.2 Testing Equipments

1. Lea tensile strength tester
2. Uster tester-4
3. Yarn board making M/C (For Yarn Appearance)
4. Wrapping Reel
5. Wrapping Drum
13.3 Uster Yarn Testers UT4

It works on the principle of capacitance. It has two plates used to measure the
thickness of a material passing through .capacitance between the plates is changed when
the thickness of textile material is varied in a given length. This variation is detected by a
sensor attached to it
Figure 13.1 Uster Tester 4

52
A printer is attached to the machine that gives the result on paper and a
spectrogram is also made using it. This printed output contains following parameters;
 U%
 CV% (10m, 3m, lm)
 Relative count %
 Index
13.3.1 Testing methods

Two samples are taken for testing on the machine. These samples are placed in
standard atmospheric conditions. After conditioning in the appropriate environment these
samples are taken to the Uster tester and test is performed. Individual procedure is carried
out for yarn roving and sliver.
For Sliver:
Table 13.1 Testing Parameters for Sliver
Parameters Mean
U% 1.75
CVm 2.20
CVm 1m% 0.52
CVm 3m% 0.34
Rel. Cnt ± % 0.5
After testing the results were displayed on the printed paper attached to the
machine
For Yarn:
For the testing of yarn, below is the information entered in the UT-4.
Table 13.2 Testing Parameters for yarn for wrapping
COUNT U% THIN/KM THICK/KM NEPS/KM HAIRINESS IPI

-50% +50% +200%
18/1 8.85 0 4 17 7.44 21
20/1 8.87 0 4 18 6.09 22
36/1 10.35 2 22 59 4.20 83
46/1 11.49 3 23 87 4.11 113
Ending process is same as for the sliver. Some of the terms indicated in the test are:
 USP (Uster statistics percentile)
It gives the percentage for the mean value of test series performed and their location on the
statistics chart.
 Coefficient of variation (CV)
Variation between tests samples is given by CV .End results is better if CV is small.
 Mean value
53
It‟s the average value of test series performed.
 Confidence range (Q95%)
If the test is performed, several times for the same material than the results would lie
between ranges of acceptable 95% probability. This gives the mean value for which test
results are within the acceptable 95 % probability.
 Max/min value:
It is the highest and lowest sub samples of the test series. It helps to indicate which value
is furthest from the mean value.
13.4 Mechanical lea strength tester

The length of lea tested in this machine is 120 yards. It gives the breaking load for
the yarn in lea form. Combined strength of yarns is tested using this machine. It also
indicates the resistance to loading of yarns in lea form. Below is the image of mechanical
lea strength tester. The machine is shown in Figure.
Figure 13.2 Lea strength tester
13.5 Yarn board making machine (For Yarn Appearance)

This instrument is used for winding yarn evenly on black board for visual
examination and grading the yarn as per ASTM standards for different count ranges. Yarn
board making machine is shown.
Figure 13.3 Yarn board making machine

54
It is available in two types namely
 Motorized Yarn Appearance Board Winder

 Hand Driven Yarn Appearance Board Winder
13.6 Uster Auto-sorter 3 (For count testing)

Determination and analyzing the count of yarn is done by Uster Auto-sorter 3
Uster Auto-sorter 3 is shown in Figure 15
Functions:
Count determination of yarns, roving and slivers and the weight per unit area of
 Textile woven and knitted fabrics

 Easy operation by using pre stored Test Programs
 Customized test programs on parameter and result output
 Plausibility control of the measuring results
13.7 Wrapping Reel

To produce skeins of yarn of a predetermined length and number of turns for count
and/or strength testing rapping reel is used. 1 meter, 36"" or 54"" circumference
collapsible swift (specify). Complete with yarn package stand and pretension device, fitted
with predetermined counter. Warp reel is shown in Figure.
Figure 13.4 Wrapping wheel
55
CHAPTER 7
AIR CONDITIONING SYSTEM
14 Introduction
Air conditioning (often referred to as, AC or A/C) is the process of altering the
properties of air (primarily temperature and humidity) to more favorable conditions,
typically with the aim of distributing the conditioned air to an occupied space to improve
comfort. More generally, air conditioning can refer to any form of technology, heating,
cooling, de-humidification, humidification, cleaning, ventilation, or air movement.
14.1 Objective And Description Of Department

Moisture in atmosphere has a great impact on the physical properties of textile
fibers and yarns. Relative humidity and temperature will decide the amount of moisture in
the atmosphere. High relative humidity in different departments of spinning is not
desirable. It will result in major problems. But on the other hand, a high degree of
moisture improves the physical properties of yarn. Moreover it helps the yarn to attain the
standard moisture regain value of the fiber. Yarns sold with lower moisture content than
the standard value will result in monetary loss. Therefore the aim of air conditioning is to
provide an economical device for supplying the necessary moisture in a short time, in
order to achieve a lasting improvement in quality
14.2 Description Of AC System

It was designed to solve a humidity problem at the Sackett Wilhelms
Lithographing and Publishing Company in Brooklyn, N.Y. Paper stock at the plant would
sometimes absorb moisture from the warm summer air, making it difficult to apply the
layered inking techniques of the time. Carrier treated the air inside the building by blowing
it across chilled pipes. The air cooled as it passed across the cold pipes, and since cool air
can't carry as much moisture as warm air, the process reduced the humidity in the plant
and stabilized the moisture content of the paper. Reducing the humidity also had the side
benefit of lowering the air temperature.
14.3 Types Of Air Conditioning Systems

1) Central air conditioning systems (most common)
2) Evaporative air conditioning systems
3) Auto - miser air conditioning systems
4) Straight humidification system
14.4 Air Conditioning Process For The Textile Industry

Air is drawn in and is passed through the air washer, it gets saturated adiabatically.
Since it is not saturated 100%, the dry bulb temperature of the saturated air will be 1
degree greater than WBT. When this air is admitted into the conditioned space, it gets
heated due to the heat load of the room. During this heating process the air does not lose or
gain any moisture as latent heat load is absent. The air displaces an equal amount of air in
the room which is pushed outside the room.
56
14.5 Humidification System
Humidification system 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 system in the textile industry. The systems
principal components are
 Air moving devices- fans
 Mixing devices for air and washer- i.e. Air washers
 Air moving devices are always broken into two halves,
 Return Air fans and
 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 air fans- supply air to the mill from the plant room.
Air washer is a device for intimately mixing water and air. The intimate contact between
these two elements is best brought about- for this application- by drawing air through a
spray chamber in which atomized water is kept in transit.
14.6 Components Of Automotive Air Conditioning

The following components are a must in a Humidification system
 Return Air and Supply Air fans
 Air washer
 Return Air floor grills
 Return Air trenches
 Exhaust damper
 Fresh air damper
 Supply air ducts and grills
 Face and bypass dampers on the air washer
1. Air washer system
Air washer system has water nozzles supply fans and multistage pump in it which
throws water on the plates of washer system. Therefore water becomes cold and supply
fans take humidified air from there and send it to the whole department.
Figure 14.1 Air Washer unit
57
2. Lovers
Lovers prevent the airborne particles such like leaf, papers, sand etc., to enter into
the unit and block the filters especially in the heavy dust storm.
3. Water tank
Water tank is present to store water which is supplied through nozzels to increase
the humidity of air.
Figure 14.2 Water tank
4. Spray nozzles
Spray nozzles are used to give ideal atomization, ample water volume for efficient
air scrubbing and a stable cone of spray even at high velocity. The high quality of
atomization produces a high surface are of droplets for contact with air which result in
peak humidifying efficiency and also for heat transfer efficiency.
5. Dampers
A damper is a valve or plate that stops or regulates the flow of air inside
a duct, chimney, VAV box, air handler, or other air handling equipment. A damper may be
used to cut off central air conditioning (heating or cooling) to an unused room, or to
regulate it for room-by-room temperature and climate control. Its operation can be manual
or automatic.
Figure 14.3 Dampers
Manual dampers are turned by a handle on the outside of a duct. Automatic dampers are
used to regulate airflow constantly and operated by electric or pneumatic motors,
58
6. Fans
Two types of fans are used in air conditioning system which are:
 Supply fan
 Return fan
Supply fan supplies air from air cooling plant to the whole unit including blow room,
carding, drawing, Drawing/simplex, roving, ring, auto cone and doubling processes. Every
department has its own air conditioning system Supply fan.
Return fan sucks air from inner side of the rotary air filter and it provides required quantity
of air to the air cooling plant and remaining hot air is thrown out.
7. Rotary air filter
This equipment is specially designed for handling high volume of air laden with
fiber and dust returning along with the air from the department/ waste recovery equipment.
Figure 14.4 Rotary Air filter
The fluff, fiber and dust arrested on the filtering media is sucked out by traveling suction
nozzles, moving along the outer surface of the drum and are deposited in collection bags
for easy disposal. The clean air is then either re-circulated or exhausted in to the
atmosphere.
8. Water pump
Water pump is used to fill water tank. When the water in tank becomes muddy or
dirty then it replaced with fresh water for which purpose water pump is installed.
Figure 14.5 Water pump
59
Table 14.1 AC stations data
Sr. No Department AC Station No.

1 Blow Room 1
2 Card 2
3 Drawing & roving 3
4 Ring 4&5
5 Auto winding 6
Table 14.2 AC supply fans data
Department No of Fans Fan Dia. (mm) Motor (KW) Fan RPM

Blow room 1 1600 37 970
Card 4 1100 18.5 1470
Drawing & 4 1100 18.5 1470
roving
Ring 10 1100 18.5 1500
Cone winding 5 1100 18.5 1500
Table 14.3 AC return fans data
Department No of Fans Fan Dia. Motor (kw) Fan rpm

Blow room 1 1100 18.5 1470
Card 1 1100 18.5 1470
Drawing & 2 1600 30 970
simplex
Ring 4 1600 30 1000
Cone winding 2 1400 22 1000
60
Chapter 08
COMPRESSED AIR SUPPLY
15 Introduction
An air compressor is a device that converts power (usually from an electric motor,
a diesel engine or a gasoline engine) into kinetic energy by compressing and pressurizing
air, which, on command, can be released in quick bursts. There are numerous methods of
air compression, divided into either positive-displacement or negative-displacement types.
There are total 5 compressors in Textile Plant-1. Average air consumption for TP-1 is
50,000 c.m/day. Detail of compressors is given below:
BOGE S 220 2003 3

SLF 271 2016 2
15.1 Objectives
There are many uses of compressed air
 Cleaning
 In cards (to press the web sheet)
 Can changing
 Draw frame (drafting system)
 Ring frame (auto doffing)
 Auto cone (cone holding pressure)
 Splicing unit
15.2 Components Of Compressor

Every part of compressor consists of the following major parts:
1. Air filter
2. Intake valve
3. Oil separation tank
4. Cooling agent
5. Compressed air after cooler
6. Pressure switch (for output pressure)
7. Oil filter
8. By pass valve
9. Heat exchanger for oil
15.3 General Working Of Compressors

The air enters the compressor through the intake valve and the small impurities are
filtered by the air filter. The air is compressed up to an optimum level. The oil is use for
two purposes. First it helps in the lubrication and second it removes the heat of
compression from the compressed air. The air then is continuously pumped into the main
storage tank until a specified unload pressure is reached.
61
Oil separation tank separates the oil from air and sends it back to the air end. If the
temperature of oil is increased then it is firstly sent to the cooler and then back to the air
end.
When the specified unload pressure is reached the input air valves are closed by the output
pressure and leave them in IDLE condition for giving some rest to the input valves and
also for allowing the oil to cool down by passing many times through the heat exchanger.
15.4 Compressed Air In Textile Industry

Compressors are the main parts of the compressed air installation of any spinning
unit. Their function is to compress the atmospheric air up to a defined pressure (normally
6 -7.5 bars are required for a spinning unit and compressors work on this much pressure).
Capacity of a compressor can be determined by the amount of air it produces in L/min
15.5 Use Of Compressed Air In Textile Mills

Compressed air is required in spinning, mainly for process control through valves
and cylinders. With the latest machinery and increased automation, use of compressed air
has increased substantially.
In winding machine, compressed air is used for splicing of yarn. Compressed air required
in the mills is at pressures ranging from 4 - 8 kg/cm2. Although, atmospheric air is free, its
compression to the required higher pressure by air compressors is done normally.
15.5.1 Department wise requirement
I. Auto-cone
Winding department is the biggest consumer of the compressed air therefore in most of
the units the maintenance and overseeing of the installation is done by technical staff of
the winding department. The consumption of compressed air is done at following positions
in a winding head:
 Optional pneumatic hairiness reduction devices are the largest consumers of

compressed air because they require a continuous supply of compressed air to
create a hairiness-wrapping vortex.
 Pneumatic or aqua splicer is the second largest consumers of compressed air.
Splicers consume air for untwisting and re-twisting operations of yarn.
 Cleaning jets in 3rd generation winders also use air blasts to remove yarn residuals
from the machines.
 Pneumatic counter-weighting and instant lifting cylinder also consumes
compressed air in lifting the package once each cycle.
 Compressed air is also consumed in operating pneumatics of the machine through
solenoid valves.
II. Ring frame
 Pneumatic roller pressure
 Cleaning the machine part
III. Roving frame
62
IV. Drawing frame
 Auto-leveler
V. Card
 Auto-leveler
VI. Blow-room
 Contamination removal by vision shield or Loptex
 Cleaning the machine
Compressed air used for the above mentioned purpose must fulfill the following
requirements for better results:
 Air should be clean and does not contain any dust or micro particles
 There should be no moisture or oil particles in the air
 The air produced, should have low temperature
 Pressure should be uniform at all times
 There should be as less pressure drops as possible
 The cost of producing air should be kept low as regard economic concerns

Table 15.1 Comparison of Compressors
Sr. NO. Specification BOGE S220 BOGE SLF 271S

1 Compressor drive system Motor With Pulleys & Direct coupled
belts inverter motor
2 Capacity 25.1 m3/min 25.1 m3/min
3 Max. pressure 10 bar 10 bar
4 Rated power of drive motor 200 kW 200 kW
5 Rated capacity of fan Motor 4 kW 7.5 kW
6 No. of Bekomat for moisture 2 2
Drain
7 No of Hyper-Drain for Oil 1 1
drainage
8 Suction temp (min ,max) +5,+450C +5,+450C
9 Residual oil content in 1-3mg/m3 1-3mg/m3
compressed air
10 Sound pressure level 83dB 84dB
11 Width 2265mm 3145mm
12 No of oil separator per 6 8
compressor
13 No. of oil filter per compressor 1 2
14 Depth 1585mm 1910mm
15 Height 2005mm 2145mm
16 Weight 3400kg 4700kg
17 Compression Temp. 1100C 1100C
18 Oil filling quantity 100L 130L
19 Air Telligence System* No Yes
63
15.5.1 Air intelligence system
This is an additional feature is SLF-271, in which the system with the help of a
sensor automatically select the compressor on sharing. In this way all the compressor will
get a chance to be on sharing rather than the conversional system in which the compressor
which is manually select only get chance to be on sharing and compressor operate
continuous.
15.6 Air Dryers

Table 15.2 Air Dryers Specification
Specification D 670 DS 750

Volume flow at 20 1 bar 7 bar
operating pressure 67m³/min 75m³/min
Compressed Air temp. at 55 30
inlet
Permissible Temp. (Min& +2~+50 +5~+50
Max)
Permissible pressure Max. 16 bar 14 bar
Total power consumption 6.3 Kw 5.73Kw
Refrigerant R-134a R-407C
Width 1200mm 1007mm
Depth 1255mm 1810mm
Height 1900 mm 1722 mm
Weight 610 Kg 670Kg
15.7 Maintenance
For proper and trouble-free operation of pneumatic systems provided for the
machines, it is essential to ensure filtration, pressure regulation and lubrication of the
compressed air. Providing filters in the pipeline after the air receiver ensures that filtration.
These can remove dust particles up to 5 micron size. For reducing friction, wear and tear
and preventing corrosion, proper lubrication of compressed air is necessary. This is
achieved by the “oil-fog” airline lubricator.
Table 15.3 parts change schedule
Items Quantity/Each Parts Change Schedule

Schedule
Oil 100 liters 3000 hrs.
Oil Separator 6 3000 hrs.
Fuel Filter 1 3000 hrs.
Air Filter 1 3000 hrs.
V-Belts 6 3000 hrs.
Wearing Part Kit 1 3000 hrs.
Wearing Part Kit(Oil Reg) 1 3000 hrs.
64
CHAPTER 09
CONCLUSIONS
I have conducted internship at IFL TP-1 from 19th August to 18th September. It
was very useful and informative regarding textile spinning process. I learned a lot about
the process flow for yarn manufacturing. Environment and culture of IFL is very
appreciable. Especially the uniform segregation between different departments. In
spinning flow process, best raw material is used. The ring spinning machines are operated
at optimum speed to achieve best quality yarn. State of the art equipment and best
environmental conditions allow to achieve best quality of yarn. Besides this, housekeeping
and healthy working conditions provides a reliable environment for workers and employs
to do their jobs at their best. In short, Ibrahim group of companies is well organized group
and the better platform for learning purpose.
65

Internship Report On 18 and 50 Count at TP-1

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Internship Report On 18 and 50 Count at TP-1

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STUDY OF SPINNING PROCESS OF 18/1 & 50/1 YARN AT

IBRAHIM FIBERS TP-1, FAISALABAD.

Internship Report Submitted by

M Faizan Haider Roll # 16-NTU-0100

University Supervisor : Dr. M Bilal Qadir

Mill Supervisor : Mr. Ahmer Abbas

In partial fulfillment of the requirement for the degree of

Department of Yarn Manufacturing

Faculty of Engineering & Technology

National Textile University, Faisalabad.

Supervisor Internal Examiner

Chairman DYM Dean FET

1.2 Organizational Structure

1.2.1 Textile plants

IFL has a total capacity of 234496 spindles.

1.3 Power Generation

1. Power Generation Plant-1

1.4 Polyester Plant

1.5 Integrated Manufacturing (CIM).

1.6 Allied Bank

1.7 Product Range

1.7.1 Textile plant 1

1.7.2 Total production:

1.8 Major Customers

1.9 Major Suppliers

 Polyester from IFL polyester plant

1.10 Major Departments And Sections

 Human resource & Admin department

Property Polyester Viscose

3.1.2 Cleaning and dust removal

• Nature of raw material

3.1.3 Mixing and blending

3.1.4 Lap forming or even feed of material to the card

3.1.5 Material issuance and mixing

Table 3.1. Material Issue

Total number of polyester bales 122

3.2 Machine Layout And Specifications

BE 1600 BE 1600 MSL-16 MSL-17 MSL-15 BE 1600 BE 1600

TO-T1-33 TO-T1-35 BDT 019-12 BDT 019-11 TO-T1-34 TO-T1-36

FOR VISCOSE RAYON

AIR WITH LINT

Figure 3.1 Blow room line

3.3 Blendomate (BDT-019-011)

Figure 3.2 Blendomate

Table 3.2 Blendomate specification

 No. of bales of polyester at BDT-11 = 20

3.4 Dosing Opener (FD-S)

Figure 3.3 Dosing Opener

There are following sections:

• Condenser (at top)

Figure 3.4 Tuft blender (FML)

3.6 Weighing Scales (PWSE)

Figure 3.5 weighing scale (PWSE)

3.7 Metal Detector (SP-EM)

Figure 3.6 Metal detector (SP-EM)

3.8 Multi Mixer MX-U 10

Figure 3.7 Multi mixer (MX-U)

Table 3.3 Multi mixer specification

3.9 Tufto-Mate (To-T1)

Table 3.4 TO-T1 Specification

Figure 3.8 Tufto mate (TO-T1)

Figure 3.9 Piece Breaker

3.12 Filter room