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be noted here that the control on wastes has to be concomitant with achieving the
desired level of cleaning.
YARN REALIZATION:
Establishment of norms for wastes is a pre-requisite for a successful waste
control in a mill. Yarn realization (YR) is largely governed by the level of trash in
cotton, expected yarn quality and type of machinery. Yarn Realization is governs to
improve Yarn Quality, Productivity & waste reduction in process.From the SITRA
paper publication achievable yarn realization can be obtained using the following
formulae:
A. For mills reusing the entire usable wastes in the same mixing
YR (%) = 97.5 t Wk Wh
for carded yarn
YR (%) = (100 t Wk) {1-(Wc/100)} Wh 2.5
for combed yarn
B. For mills not reusing the usable wastes in the same mixing
YR (%) = 97.5 t Wk Wh Wu
YR (%) = (100 t Wk) {1-(Wc/100)} Wh Wu 2.5
Where,
t = trash in mixing (%)
Wk = card waste (%)
Wc = comber noil (%)
Wh = yarn waste (%)
Wu = usable waste (%)
The percentage yarn realization depends primarily on process waste taken out at
blow room, card & comber. Waste taken out in bow room depends on trash content
of the mixing. The waste in Cards depends on type of card& also to some extent, on
trash in lap. The waste in comber, depends on nature if fiber length distribution in
feed
Record to Account for Yarn Realization
Cotton Consumed:
Cotton issued: - In Bale form of 160 to 165 kg.
Stock in process: - Stock in process at various stages has to be adjusted as the
weight in kg. should be multiplied by a factor:
Waste Generate:
The Process Waste taken out in Blow room, Cards & Combers which account for
nearly 80% of total waste losses in cotton spinning & 50% manmade & blend
spinning.
The Product wastes which are required a specified treatment at each stage of
processing.
The Invisible loss is not directly measured. The invisible loss refers to loss caused
by evaporation of moisture content in cotton, dust in atmosphere, fluff. The amount of
soft waste generated in order of 6% for medium & fine count and 8-12% for coarse
count.
Yarn Produce:
The amount of Yarn Produce is measured by two methods as
1. Doff Weight Method: In this method the amount of yarn produce is measure by
governs the weight of Empty bobbin, weight of tray & weight of full doff.
2. Hank meter Reading: In this method the yarn produced is measured on length
basis as the hank meter is attach with front roller on ring frame.
Assessment of Yarn Realization:
The exact assessment of Yarn Realization is not possible. Because problems
associated with Assessments of:A. Exact amount of Fiber Feed.
B. Determination of exact Yarn Formed.
C. Exact amount of Waste.
Carded
Combed
MMF
Count
4-9
10-13
14-25
26-34
28-34
35-44
45-70
71-99
Trash%
11
10
B.R. Dropping
12
11
7.7
5.4
5.4
4.4
3.2
2.2
0.1
Card waste
4.2
4.2
4.4
4.5
4.5
4.3
4.3
6.4
0.1
Comber Waste
10.9
12
13
Sweeping
1.8
1.6
1.4
1.4
1.2
0.5
Clearer waste
0.6
0.5
0.4
0.4
0.4
0.3
0.2
0.1
0.1
Hard waste
0.6
0.5
0.3
0.3
0.3
0.3
0.3
0.3
0.4
Invisible loss
1.8
1.7
1.6
1.5
1.5
1.3
1.3
1.3
0.3
Y. R %
78.1
79.7
83.6
86.5
77.5
77.4
77.9
77.9
97.6
Category
B. R.
Waste
Card
waste
Comber
Waste
Ring
Frame
Yarn
Realization
Carded Cotton
Count
56%
56%
3%
85 88 %
35%
Combed
Cotton Count
56%
56%
3%
70 75 %
Manmade
Fibers
1%
1%
2%
95 97 %
4.
1.
2.
3.
4.
1.
2.
3.
5. Setting
between
Beater
&
Grid
bars.
Carding waste:
The behavior of waste & cleaning at cards depends on the following considerations:
1. The total collected waste at card does not show any close relationship with the trash
in the lap feed to the card.
2. The cleaning efficiency achieve in mills is about 80% for most mixing. However, for
fine and superfine mixing for which very high flat speed and low production rates are
employed, a cleaning efficiency of 85% or more is achieved. The overall effect is that
the lint loss in card waste will increases with decreasing trash content in lap.
3. There is a tendency for the card to compensate for any lack of cleaning in blow room.
The overall cleaning efficiency achieve in the blow room & the card taken together
remains
within
a
narrow
range
of
93-95%.
Controlling the waste at Card:
The following facts should be kept in mind while controlling the waste & cleaning at
cards:
1. Use of only one mote knife, placed slightly below the normal position of the top mote
knife has been observed to give less waste and better cleaning in cotton mixing.
2. Higher licker-in speed or greater wire point density on licker-in gives higher cleaning
efficiency accompanied by some increase in the lint lost under the licker-in.
3. Use of perforated undercasing helps in reducing waste.
4. With other speeds and setting held constant, the flat strip waste varies almost
proportionately with the flat speed.
5. Wider front plate and back plate setting increase flat strip waste.
6. For controlling cleaning of the card, almost the only place is the licker-in region.
7. Card is excellent cleaning machine for seed coats especially the cylinder-flat region
which removes 80% of the seed coats. A higher flat alongwith higher cylinder speed
can be use for better removal of seed coats and also reducing neps, thick places and
Classimat A & B faults. The seed coat content of 0.1% in the card sliver can be
considered as satisfactory.
8. The tandem card gives 5-7% higher cleaning efficiency and better removal of seed
coats.
Comber waste:
One of the main functions of combing is to remove short fibers through
taking out a certain amount of comber waste. The waste thus removed also contains
a large number of neps and foreign matter. Obviously, combing is not required for
manmade fibers as they are free from short fibers and foreign matter. A higher % of
comber waste need not always means that better removal of short fibers and neps,
and therefore may not always be advantageous either for yarn quality or
performance beyond a certain level.
Technological Consideration:
For an effective removal of short fibers, retention of long fibers and
removal of neps the following considerations are of up-most importance:
1. The card trailing hooks are longer and more numerous than the leading hooks. They
are removed when fed as leading hooks by keeping an even number of reversals
between the cards and the comber.
2. The waste at comber can be reduced by increasing pre-comber draft without
affecting the resultant yarn quality. However, a high comber draft also result in
extremely low inter fiber cohesion causing excessive lap linking, frequent sliver
breaks at comber, draw frame and the can feed inter creel. Therefore, a pre-comber
draft of 30-40 for counts upto 40 is adequate. Pre-comber draft of above 20 is
suitable only for very long staple cottons.
3. The proper place for controlling neps is carding and no combing. It is often more
economical to run cards a somewhat low production rate than to take out extra
comber waste.
The waste at comber needs to check and controlling due to the following reasons:
1. More waste than the nominal means financial loss.
2. Less waste than the nominal could lead to unacceptable yarn quality and
performance.
3. Comber waste variation could contribute to lea count variation.
Norms
for
cleaning
coefficients
in
Blow
Room
Number
of
Machines
3
4
5
6
7
8
Category of waste
Licker-in
Others
Total
2.9
1.6
0.5
4.5
Mixing
Trash in
lap %
Type of
card
Flat Strips
Superfine &
Fine
Less than
2
SHP
Medium &
Coarse
2.0 to 2.5
HP
1.9
1.6
0.5
4.0
SHP
2.0
2.0
0.8
4.8
HP
1.5
2.0
0.8
4.3
83
1.5-2.5
1.5-2.0
0.5-1.0
4-6
85-90
Range
Warp Count
Group
28-34
Level of
Comber Waste
%
7-9
88
35-44
46-60
11-13
12-14
61-90
13-15
91-120
14-16
1.
2.
3.
4.
In many mills, there is good scope for improving yarn realization and reducing
wastes. Because in the spinning mill waste are generates in more amount & it can
controllable & reducible at some extent. Improvement in yarn realization results in
Rs. 3 to 10 lakhs savings per year.
The following 6 steps would be helpful to improve yarn realization:Step 1: Calculate actual yarn realization and different categories of wastes
Step 2: Using the formulae given in this presentation, estimate the expected yarn
realization for the existing working conditions.
Step 3: Compare the actual yarn realization with the expected value and actual
wastes with norms.
Step 4: Analyse the causes for deviation and initiate corrective action.
Step 5: Create awareness among the workers and technical staff about the
importance of waste control.
Step 6: Good supervision and proper maintenance of machinery would help to
reduce the waste.
References:
Process Control in Spinning by Gadre & Subhramanyam: ATIRA publication, page
No.(45 to 107).
Process Control in Spinning by Rattnam, page No. (11 to 30)
Paper published by D.Shanmuganandam (Assistant Director) SITRA.
Waste
Control
at
Ring
Frame
by
S.
K.
Srivastav:
NITRA
publication,
page No. (1.1 to 1.9)
Waste Investigation & Control for a Spinning Mill article in The Indian Textile Journal,
September 1984 ,published by, Mr. A. R. Nityanand page no.(79 to 86)
A study on carding waste collection system in mill article in The Indian Textile
Journal, April 2012,published by, M Muthuvelan, H Balasubramanian and A
Sivaramakrishnan
www.fibre2fashion.com
www.sitra.org.in