Sei sulla pagina 1di 9

YARN REALIZATION & CONTROL OF WASTE IN SPINNING

Mr. Akash S. Bansode


bansodeaknasa@gmail.com
D.K.T.E. Societys Textile and Engineering Institute, Ichalkaranji - 416115.
ABSTRACT:
A 1% reduction in yarn realization has almost the same economic impact
on the mills profit as an increase on 1% in the mixing cost. This is because the
resale value of wastes is much less than the price of the cotton or the yarn. The
control of yarn realization is thus as important to a mill as the control of cotton and
mixing cost. And yet in most mills, the approach to the control of yarn realization is
half-hearted, and depends on records of dubious accuracy.
In this paper, we will first consider the quantities for which records have
to be maintained for estimating waste losses and yarn realization, and then give
specific recommendations on how to collect data, and use them for computing
accurately the mixing wise yarn realization. A simple but effective method of
crosschecking the accuracy of the entire recording system will also be outlined.
Norms for waste losses and yarn realization will be given mixing wise, and an
appropriate procedure will be suggested for utilizing the norms for evaluating the
performance of a mill.
Key Words:
Yarn Realization, Process Waste, Product Waste, Invisible Loss, Assessment of Yarn
Realization, Doff Weight method, Hank Meter Reading.
INTRODUCTION:
Yarn Realization denotes the percentage of yarn produced from a
given weight of bale material. The rest is the waste which has much less worth
compared to fresh fibers or yarn. In the last decade or so, the Indian mills have
become acutely aware of this aspect and have introduced effective control and
monitoring mechanism. The wastes are distinctly of two types:
(a) The Process waste taken out in the blow room, cards and combers which accounts
for nearly 80% of the total wastes losses in cotton spinning and 50% in manmade
and blends spinning. The process waste is decided by arriving at optimum levels
required to achieve the desired yarn quality.
(b) The product wastes which are incurred at each stage of processing, the control over
product wastes has to be exercised through effective floor supervision.
The levels should also be guided by the standards arrived at by the research
associations. A 1% reduction in yarn realization has almost same economic impact
on mills profit as increase of 1%. The records required to be maintained for waste
losses and yarn realization are outlined here. Norms for waste losses and yarn
realization are also given.
To have a good control on the process wastes it is important to assess the
wastes in blow room, carding, comber and ring frame at regular intervals. It should

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 (%)

for carded yarn


for combed yarn

Yarn Realization is affect by following cotton characteristics:


Trash % in cotton purchased:
Higher the trash% content in bale, higher will be need remove waste in Blow
Room & lower is the Yarn Realization. Material handling storing of material in ginning
process is more responsible for trash% in cotton.
Moisture content in cotton:
As amount of moisture in cotton goes up, the yarn realization goes down.
Short Fiber content in material:
Higher the short fiber content, higher is the removing efficiency of short fiber
at comber stage because of that yarn realization become lower.
Departments for Yarn Realization:
For Carded Yarn: Blow Room, Carding & Ring Frame
For Combed Yarn: Blow Room, Carding, Comber & Ring Frame
The control over the Yarn Realization can be done by Owner of Organization,
Manager of Organization, H. O. D. of each department, Supervisors, Workers these
peoples.
How Yarn Realization will improve?
Yarn Realization associated mainly with Cotton Feed, Yarn Produce &
Waste generation. To improve yarn realization % we have to concentrate on
reduction in waste generation. Better way to control over the yarn realization by
means of better practical way to control over the waste generation.

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:

A. Blow Room Lap= 100/ (100-B. R. Waste %)


B. Card sliver/Drawing sliver/ Roving= 100/ {100-(B. R. waste%+ Card Waste %)}
C. Combed Yarn= 100/ {100-(B. R. waste%+ Card Waste %+comber Waste %)}

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.

Problems associated with Assessments of Exact amount of Fiber Feed:


Weight of bale is high so that to weigh the bale more number of laboures are
required
The quantity of Fiber feed to process is very high its more than 10.000 kg/ day
High capacity & sensitive weight balance is required to weigh the bale of high weight
which is not easily available in mill.
TOTAL WEIGHT of BALE = Net Weight of fiber + Weight of Packing Material.

Problems associated with Assessments of Exact amount of Waste:


Some amount of Fiber goes in atmosphere in the form of FLUFF.
Moisture affects on waste amount.

Problems associated with Assessments of Determination of exact Yarn


Formed:
Limitations of Doff weight Method.
Lot of Labour required.
Transportation required.
Handling of Material.
Exact weight of Yarn produce.
Limitations of Hank Meter Method.
Accuracy of Hank Meter.
Twist Contraction.
Idle Spindle percentage.
Bonda Waste
Norms for Wastes &Yarn Realization:
The values of all wastes are expressed as % of cotton consumed
Content

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

Standards for Yarn Realization

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 %

Control on waste in spinning:


To have a good control on the process waste it is important to assess the
waste in Blow Room, Carding, Comber & Ring Frame at regular intervals. It should
be noted here that the control on waste has to be concomitant with achieving the
desired
level
of
cleaning.

4.

Blow Rom Waste:


The cleaning at Blow Room should always be considered alongwith the following
things:The cleaning efficiency of blow room machines for, seed coats is much less than for
leafy matter & sand dust taken together.
The cleaning efficiency & waste increases as trash content increases.
No aspect of yarn quality other than neps & foreign matter is influenced by the quality
of blow room processing.
An optimum level of opening is essential for cleaning of cotton.

1.
2.
3.
4.

Improving Cleaning Efficiency & Reducing waste at Blow room:


To improve cleaning efficiency of beater, first examine the mechanical
condition of machine, spikes on Krischner beater, blades and fingers on bladed and
Porcupine openers & repair or replace as required. The inter grid bars space should
be check for any chock up. The waste is affected by changes such as
Distance between the grid bars and the angle of inclination of bars.
Speed of Beater.
Fan speed in relation to the beater speed.
Setting between feed rollers & Beaters.

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

Cleaning coefficients for


Seeds & Seed
Leafy matter
coats
& sand dust
0.42
0.72
0.50
0.80
0.56
0.84
0.60
0.87
0.64
0.89
0.66
0.90

Norms for Collected Waste & Cleaning efficiency of Card


Cleaning
Efficiency%

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

Norms for Comber Waste

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

Ring Frame Waste:


At many stages of spinning process waste is removed to clear the
cotton or to separate the short fibers but at the stage of Ring spinning there is no
need to remove waste. This step is exclusively for drafting twisting and packing the
yarn in the shape of bobbin. Whatsoever material is wasted here is because of our
inability to control the machine, process or processing condition. Thus control the
waste we have to control all factors.
At the ring frame stage a scope for saving 1.5 to 2 % on these wastes. Waste
at ring frame means wastage of raw material & wastage of conversion cost upto yarn
stage. If a mill spinning 20 count, having 25000 spindles and production 205
grams/spindle at 96% spindle utilization saves 1% waste in ring frame it can save
about Rs. 12 lacs per year.
Factors Responsible for waste generates in Ring Frame
Yarn Breakage rate.
Time taken in attending to the yarn breakage.
Working practice & culture.
Housekeeping & material handling.
Mechanical breakdown & failures.
Methods of attending to the break downs.

1.
2.
3.
4.

Waste Control in Ring frame


This is done in the following steps:Analysis and segregation of the waste of different types
Weigh that waste and recording that section wise, person wise, shift wise.
Comparison with the standards.
Feed backs and action to improve waste generation.
For check & control all types waste
The following questions are helps to check and control all types of wastes:
Q. Whether a scheduled maintenance program is followed effectively?
Q. Is there cleaning of the floor can do properly?
Q. Is the material handling minimum & adequate?
Q. Whether the stocking place for cotton & yarn is good & sufficient?
Q. Is the average yarn content per bobbin optimum?
Q. Is the proper humidity & temperature being maintained in departments?
If the above questions are put, the solution are worked out effectively
implemented with the basic principles of collection of data, analysis and feed backs
are followed consistently, not only that waste would be controlled also The
productivity, working environment and culture all would simultaneously improve and I
feel that if firmly determined every one of us is capable of controlling it.
Conclusion:

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

Potrebbero piacerti anche