2019

AURO SPINNING MILLS

Vardhman

SUMMER TRAINING REPORT

MUDIT BHARGAVA
NITRA TECHNICAL CAMPUS, GZB.
10-Jul-19
 ACKNOWLEDGEMENT

I am very thankful to Mr. Shekhar Chand Sharma

(VP), Mr.Mohan Jangra(Head HR) for giving me
opportunity for the summer training at Vardhman
Spinning Mills Baddi(H.P.)
I also thankful to Firstly Our Mentor Mr.
Sarvesh Kashyap(Sr. Manager), Our Guider Mr.
Abhishek Chauhan (G.S.O) & Helping Hands
Mr.Tirath Singh ( Manager, Maintenance), Mr.
Sagar kanzarkar Sir ( Executive,R & D), Mr.Rahul
Dayal ( Executive ,Maintaince)
I would like to thanks Mr. Atul Dhiman(HR)& Neha
Sharma for making me introduce to every person
related to my internship and giving attention to my
every problems and solving those positively every
time.
At Last I am thankful to Hall No-05 Shift officers
(Mr. Abhishek Yadav, Mr. Rohit Sharma , Mr.
Bidhayak Modak & Mr.Amir Ahamad ), staff , All
Foreman & Fitter of maintenance deptt. for giving
the better guidelines and co-ordination.
Firstly I thankful to Mr. Bhaskar Gupta , director of
my reputed institute, Mr. Neeraj Aggarwal
(H.O.D. TEXTILE TECHNOLOGY). & Mr. Vijay
Shankar Kohiwal TPO of Our College for giving
me support.
I am thankful to ASM family for their
appreciable co-ordination.
I wish them Best of luck & success in future
endeavors.

MUDIT BHARGAVA

(SUMMER TRAINEE)

NITRA TECHNICAL CAPMUS,

GHAZIABAD.
 VARDHMAN PROFILE

Late Sh. LALA RATTAN CHAND JI OSWAL, who was the

founder of Vardhman was born in 1915 and expired in
1998. After that Sh. S.P. OSWAL, Gold Medalist in
M.Com is the Chairman and MD of Vardhman Group of
Industries.
Vardhman have 18 units in different states, they are: -

 Punjab ----------------- 7 units

 Himachal Pradesh --- 9 units
 Gujarat ----------------- 1 unit
 Madhya Pradesh -----3 units
 Tamil Nadu ------------- 1 unit

“VARDHMAN GROUP TOWARDS PERFECTION IN

TEXTILE”

This group is major integrated textile producer in India

set up in 1962 and achieved Rs. 3186 crore turn over in
2008-09.
 BUSSINESS PORTFOLIO: -
YARN: - contributes 48% of total turnover, 8 lacs
spindles and largest exporter of yarn from India.
SEWING THREAD: - 11%, SET UP IN 1982 and 2nd largest
selling brand in India.
FABRICS: - 22% of total turnover.
ACRYLIC FIBER: - 8%, 1999 and VARLAN is brand name.
STEEL: - 10% of total turnover and set up in 1973.
 ASM PROFILE
{Auro Spinning Mills}

ASM is the part of Vardhman spinning and General Mills limited. It is

the oldest yarn manufacturing unit at Baddi.

 Auro is the first name of Aurovindo Ghosh a renowned fighter

n great philosopher.
 ASM est. in 1991, oldest unit in Baddi
 Running count ------- 7’s – 200’s
 Spindle capacity ------- about 80,000
 Production -------- abt. 37 tones/day
 Product activity (CSY, compact, normal, slub, injecta slub, open
end, ply, blend, siro, compact siro)
 Major customers (Auro weaving, Ashima, Morarjee, Raymond,
Arvind BVM, Sidharth, Berto, EOS)
 Departments: -

ASM has various operations within itself.

 Production house
 Maintenance
 R&D
 Engineering
 Planning and Development cell
 Commercial related
 Industrial research department
 Training
 Costing
 Personal department
 Security
 Electronic and Data Processing
 Material
 Accounts
PASSAGE OF MATERIAL IN SPINNING LINE

SORTING

MIXING

BLOWROOM

CARDING

DRAWFRAME BREAKER

COMBING PREPARATORY

COMBING

DRAWFRAME FINISHER

SPEED FRAME

 RINGFRAME

WINDING

CONDITIONING

PACKING
 PRODUCTION HOUSE
ASM has Six production units where different production process is being carried out. At ASM
the following process for the production of yarn is being followed viz.

MIXING DEPARTMENT
Raw material received in bales is opened up manually and workers take out
foreign matters. Raw material of different qualities is mixed to give an even
effect to the yarn. Then workers in which it is kept for 24 hours to enable it to
acquire department conditions as regards to humidity and temperature place this
sorted material in bins.

BLOW ROOM
Raw material passes though a number of openings and cleaning machines, which
give through opening, and extracts out material impurities from the raw material. The material
automatically goes into carding through chute feed system.

CARDING REQURIMENT
The material received though chute feed system is further opened up into
individual fibers and cleared. The ultimate product of these machines is called sliver, which is
a long strand of opened and cleaned fiber. The strand of fiber is collected into containers called
cans.

COMBING DEPARTMENT
Combing process is done only for superior quality of yarn. In combing
process short fibers are extracted out and the fibers having desired lengths are
allowed to go in the combed slivers. This is transferred Draw Frame Department

DRAWFRAME DEPARTMENT
The objectives of DrawFrame are to parallellise and eliminate long and short
variation within the body of carding sliver. The card cans are brought full of carding
sliver and 16 cans are fed behind each draw frame at one time and the process is
repeated as to give further parallelization effect and for the elimination of variation.

SPEED FRAME

Draw Frame sliver though very well cleaned is quite thick; to produce yarn from such sliver it
needs further thinning on subsequent machines called Speed Frames. Draw Frames Cans full
of sliver are brought behind the speed frame manually and they are drafted as stated above
into thick strands of fibers called Roving. The Roving is warped around, the bobbins, total
contents being about 1.25 Kg.

RING FRAME
The roving bobbins of the speed frame are bought to and crewed on
Ring Frame. These machines convert the Roving into yarn. These machines further
attenuate and draft the Roving to the desired thickness of yarn, which is the wound
on bobbins.

WINDING DEPARTMENT
Here yarn is wounded again on cones, total weight is approx. 2 kg of yarn. This is
done on winding machines. The cones are then send to packing department where bags of 50 kg are
made to be sent to the market.

MAINTEINANCE DEPARTMENT

The main objective of maintenance department is to eliminate the breakdown’s, maximum

utilization of machines operating time, incorporation of new technologies and engineering
development in the basic design of the machines, augmentation of machines capabilities and
optimum expenditures on maintenance function and activities. This aspect of maintenance
function helps in reducing or completely prevents maintenance efforts during lifetime of the
equipment.

There is a review committee comprising of Spinning superintendent, maintenance in-charge

and his assistants. This committee holds its meeting on 10 th of every month and reviews the
maintenance performance in the following areas: -

 Analysis of breakdowns.
 Ratio of downtimes too available operating time.
 Ratio of other maintenance holds ups to available operating time.
 Review of maintenance costs.
 Review of major replacement.
 Review of maintenance function and performance.
 Review of training program.
 Review of work done by the maintenance personnel.
 ENGINEERING DEPARTMENT

The objective of the engineering department is to provide uninterrupted good quality

power supply, oil and water free compressed air, healthy and well-maintained humidified air
to the production plant thereby adding value in producing good quality yarn. It also helps in
catering to the needs of colony residents, club and administration by maintaining safe
electricity and water distribution, sewage treatment plants etc.

The engineering department has two source of power supply. It purchases power from
HPSE Board (Himachal Pradesh State Electricity Board) at 266 kV and it also generates power
with in the premise of ASM at 6.6 KV.

RESEARCH AND DEVELOPMENT

Research and development deals with testing of yarn, various process

developments, maintaining quality policy, handling customer complaints etc. It helps in
acquiring new technologies, which helps the production department to perform in a much
better way so as to minimize the various technical faults.

INDUSTRIAL RELATION DEPARTMENT

The procedure underlines the system and methods relation to the functional
responsibilities of Industrial Relations department, i.e. man power planning, recruitment, time
office functioning, training and development, grievance handling, welfare and colony
administration etc. The system has been designed to provide better services to the human
resource and helping them achieving the quality standards as required under ISO 9002.

TRAINING DEPARTMENT

Training and development has been regarded as an important tool for the improvement of
skills level, work habits, development of positive attitude of the worker and upgrading the
system. Training and development servers as an important means for preparing workers for
modified performance standards, improvement of quality of product and reducing
absenteeism, accidents and material wastage.
 COSTING AND MIS

Costing and MIS is important as it acts like a planning department, where all the budgeting
exercise is conducted. This helps in having a proper-laid plan for future. Budgets are prepared
on annual and monthly basis. Then every month end, the performance is reviewed unit wise
by preparing certain MIS reports. These are then put forward in front of top management and
then the targets are set for future, keeping in the earlier performance.

It also includes product costing and standard costing which deals with deciding the
prices of the yarn to be quoted in the market according to the prevailing market conditions.
The marketing department forecasts the quantity of yarn which they can sell and the
production department reports the amount of yarn which the unit can produce. The costing
department then makes the annual and monthly budgets. The budget includes the following
factors:

 Labour wages
 Raw material
 Packing material
 Electricity
 Transport (raw material and dispatch)
 Maintenance cost incurred during production run.

MATERIALS DEPARTMENT

The main function of the material department is to procure all the materials except raw
material like packing material, electrical material, machines spares parts, oil & lubricants, fuel
and building material, furniture and fixtures and administration equipment. It helps in providing
the various request made by all the departments in an effective and efficient way so that there
is no wastage of time.

ACCOUNTS DEPARTMENT

Accounts department is mainly responsible for generation of all kinds of financial reports and
book keeping. The main activity for which the accounts are responsible are book-keeping,
payments (payment to suppliers, salaries to employees etc.), compliance with law i.e. income
tax, sales tax etc., insurance function etc.
 SECURITY
It deals with providing security for the company’s property, company’s information and
personnel security. As and when a person enters the premises of VSM he has to report to the
security cell, to define the purpose of visit and then he is guided to the right person at the first
go. Security also performs the following functions:-

 Fire safety
 Transportation
 Housekeeping
 Horticulture
 Postal services
 Maintenance of Club
 Keeping pace with government and outside persons.


TPM Policy of Vardhman Group

1. What is TPM

o TPM aims to create a corporate system that maximizes the efficiency of

the production system (overall efficiency improvement)
o TPM creates system for preventing the occurrence of all losses on the
front line and is focused on the end product. This includes system for
realizing “zero accidents, zero defect and zero failure” in the entire life
cycle of the production system.
o TPM is applied in all sectors including the production, development and
administration departments.
o TPM is based on the participation of all members, ranging from the top
managements to the front line employees
o TPM achieves the zero losses through overlapping small group activities.

2. TPM Mission

o To maximize overall equipment effectiveness and improve flexibility

through achievement of total reliability of the plant and machines and
development of human resources by ushering a cultural change by
involving all personal work in the company.
o Maximize overall effectiveness and reliability of the plant and
machinery by aiming at “zero breakdowns, zero defects, zero losses
and zero accidents through nurturing team work and continuous
development of all employees, following JIPM road map for
implementation of Total Productive Maintenance (TPM) in the
company.
3. TPM 5’s

1st S: Sorting
To get rid of unwanted Items.
2nd S: Set locations and limits
To locate a specific place for specific items of a specific quantity where
needed
3rd S: Shine and sweep
To use cleaning to identify abnormalities and areas of improvement.
4th S: Standardize
To consolidate the first 3S by establishing standard procedures.
5th S: Sustain
To sustain improvements and make further improvement by
encouraging effective use of the Plan, Do, Act and Check.

HUMIDIFICATION PLANT

The basic objective of an H-plant in a textile mill is to condition the air so that
the fibers can be processed easily by supplying the conditioned air to
department. The hot air laden with dust and fly from the department is carried
out by underground suction ducts through exhaust fans. The fibers are sucked
on the surface of the cylinder covered with a special type of blanket and finally
the fibers are removed by stripping.
In winter season the air is reintroduced in the department for maintaining the
required temp. The fresh air is sucked form the outer through the supply fans
to cool down the department. Sometimes the water droplets are mixed with
the supply air for maintaining the humidity between 55-60%. Bigger droplets
are taken out by the eliminator plate before sending humid air to department.
 RANGE OF HUMIDITY

SL. DEPARTMENT STANDARD RH % TEMPERATURE ACTUAL RH%

NO.
*C %

1 MIXING 55-70 33 56.5

2 BLOWROOM 55-70 33 56.5

3 CARDING 55-60 34 55.9

4 DRAW FRAME 50-60 34 55.9

5 SIMPLEX 50-60 35 55.5

6 RING SPINNING 55-60 35 53

7 CONE WINDING 55-65 36 57.2

 Make and model of available machines in various

Section
Sr.No. Section Machine name No. of m/c Make Model
1. SORTING 1. MBO 1 Lakshmi LLB3/6

2.Bale press 02 MAK ….

2. BLOWROOM 1 .Blendomat 01 Trûtzschler BDT-019
2.SP-MF 01 Trûtzschler ED-50
3.MAXI-FLOW 01 Trûtzschler MFC
4.LVSA 03 Trûtzschler LVSA-375
5. MPM 02 Trûmac MPM 8
6. Magic Eye 02 Jossi
7. CVT-01 01 Trûtzschler CVT1-1200

8.CVT-03 01 Trûmac CVT3 -1600

9.Dustex 1 Trûtzschler DX
3. CARDING Card 10 Trûtzschler Dk800
01 Trûtzschler TC 10
4. PRE-COMBER D/F Breaker D/F 02 Lakshmi LD2

5. COMBING Unilap 01 Rieter LH10

PREPARATION
6. COMBING Sliver Lapper 01 Lakshmi LE2/4A
PREPARATION

7. COMBING Ribbon Lapper 01 Lakshmi LE4/1A

PREPARATION

8. COMBING Comber 06 Rieter E65

9. DRAWING Finisher D/F 01 Rieter RSB-D 40
02 Rieter RSB-D40c
10. ROVING Speed frame 04 Lakshmi LFS 1660
11. RING FRAME Ring frame 16 Lakshmi LR6/A
02 Lakshmi LR6/S
12. WINDING Lincconer 05 Schlafharst sauser Autoconer X5
Group
13. CONDITIONING 1 Xorella …..
 SORTING
Contamination found during sorting:-
 Colored paper piece
 Polythene pieces
 Nylon threads
 Hair
 Cotton threads
 Jute pieces
 Paper pieces
 Feathers
 Metal pieces
 Leather pieces
 Fabric
 Stones
 Rubber
 Tobacco Packets

Other Contamination:-
 Yellow cotton
 Greasy cotton
 Solid cotton
 Leaf cotton

Types of waste added during Mixing:-

 Noil Waste of comber
 Sliver waste
 Pneumafil waste
 Fan waste
 RAW MATERIAL INFORMATION

S.No. Name of cotton & fiber Bale (Avg. weight Price/kg

(Rs./Kg)
1 Viscose (Co 230 kg 160-170
2 Acrylic 300 kg 110-140
3 Lydocell 300-310 kg 240-346
4 Bamboo 295 kg 169-210
5 Play 265-295 kg 105-200
6 Jute 265-295 kg 105-200
7 Polyester 295 kg 105-140
8 Silk As per need 1700-1400
9 Indian DCH-32 Conventional cotton 165 kg 154.73
10 Indian DCH-32own lining cotton 165 kg 156.70
11 Indian DCH-32 Organic cotton 165 kg 165 kg
12 Indian J 34 RCT Conventional cotton 165 kg 121.55
13 Indian J-34 Conventional cotton 165 kg 119.01
14. Indian HCO -5 Conventional cotton 165 kg 123.43
15 Indian HCU-5 fair trade organic cotton 165 kg 132.78
16 Indian HCU-5 Conventional cotton 165 kg 121.72
17 Indian MEH-1 Conventional cotton
18. Post-Consumer Recycled Cotton – Bleach 165 kg 66.46
19 Post-Consumer Recycled Cotton – CREAN 165 kg 65.00
20. Recycled Cotton 165 kg 96.90
21. Indian Slikon-6 BCI Cotton 165 kg 130.22
22 Indian Slikon-6 own lining cotton 165 kg 121.20
23 Indian Slikon-6 Organic Cotton 165 kg 174.49
24. Imported Pair trade Organic West African cotton 165 kg 229.85
25. Y-1 Conventional Cotton 165 kg 91.67
26 Imported Acala Cotton 165 kg 150.52
27. Imported Australian Cotton long staple 165 kg 147.5 kg
28. Imported Giza-86 Cotton 165 kg 211.32
29 Imported Giza-88 Cotton 165 kg 1456.70
30 Imported Cotton Hot (fabric max) 165 kg 211.32
31. Imported Cotton Hot (fabric max) 165 kg 128.22
32. Imported Pima Cotton 225 kg 277.25
33. Imported Ultima Cotton 165 kg 160.30
34 Viscose Imported (Australian) 330 kg 160.40
 PRODUCT DESCRIPTION
Indian DCH-32 Conventional cotton 154.73
Indian DCH-32 Own ginning cotton 156.70
Indian DCH-32 Organic cotton 150.05
Indian J-34 BCI cotton 121.55
Indian J-34 Conventional cotton 119.01
Indian Mcu-5 Conventional cotton 123.43
Indian Mcu-5 Fair trade Organic 132.78
cotton
Indian Mcu-5 Organic cotton 121.72
Indian Mech-1 Conventional cotton 117.67
POST CONSUMER RECYCLED 66.46
COTTON – BLEACH
POST CONSUMER RECYCLED 65.00
COTTON – CREAM
RECYCLED COTTON 96.90
Indian Shankar-6 BCI cotton 130.22
Indian Shankar-6 Conventional 121.20
cotton
Indian Shankar-6 Own ginning BCI 124.49
cotton
Indian Shankar-6 Organic Cotton 125.85
Imported Fair trade Organic West 229.67
African Cotton
Y-1 Conventional Cotton 91.52
123.54
Imported Acala Cotton 150.26
Imported Australian cotton Long 147.59
Staple
Imported Giza-86 Cotton 211.32
Imported Giza-88 Cotton 156.70
Imported Cotton MOT (Fiber max) 133.21
Imported Cotton MOT (Fiber max) 128.22
Imported Pima Cotton 217.25
Imported Ultima Cotton 166.30
 Waste Recovery Plant
Flow chart of waste Recovery Plant-:

Mixing Bale Opener

Ulticleaner

Intensive Cleaner

Tetra 1&2

SP-F

BALE PRESSER
 BLOW ROOM

BLENDOMAT -BDT

SP-MF

MAXI FLOW

MPM-8 MPM-8

CVT-1 CVT-3

MAGIC EYE MAGIC EYE

DUSTEX DUSTEX

CARDING
 BLENDOMAT – BDT

OBJECTIVES-:
 Gentle uniform opening.
 Picking material from Bales.
 Production rate up to 1500 Kg / Hr.
 Easy operation.
 Up to 3 bale groups at the same time.
 Up to 180 bales in one lay down and uninterrupted
production up to 2 days.
 Feeding in up to 3 lines.
 Processing by lot or continuous bale supply.

TECHNICAL DETAILS -:

Suction Rail.
Suction Duct.
Beater.
Grid Bar.
Supporting Roll.

MACHINE VIEW-:

MANUFACTURING DETAILS-:

 Manufacturer- Trutzschler
 Year- 2005
 Model – BO-A 2300
 SP-MF

OBJECTIVE-:
 Initial dust removal; protects downstream machinery.
 Prepared for installation of individual fire protection
devices (spark detectors).
 Material separation: actively and reliably protects cleaners
and cards from metal particles.
 Cleaning line is protected even at high production
rates (of over 2000 kg/h).
 Multi function heavy part separator that works reliably
even at high production rates (of over 2000 kg/h).
 Integrated micro-computer system offers precise
control of suction, heavy part separation, metal
separation, dust removal / air separation, waste
feeding.

TECHNICAL DETAILS:-

ROTARY SPEED(front roller 50

delivery)(mpm)

VOLUMETRIC FLOW (m 3 /h) 5000

METAL DETECTOR:
Material contains certain metallic pieces even after sorting cotton. If these
pieces allow going through the B/R machines then they may lead to damage
various parts of machines like they may leads to damage the clothing of beaters.
So these should be removed before passing the material to the next machine.
 PRINCIPAL OF METAL DETECTOR:
Metal detector works on the principle of variation in mass.

As material is transported by the air through the ducts so on the mass of cotton
transported should be uniform. It contains the plated of capacitor
through which cotton is transported. As any metal particle comes in duct and it
passes through the plates of capacitor refractive index between the plates of
capacitor varies. It gives the signal to block the line which passes the material to
other machine and it also gives the signal to open the duct of EMA. So the cotton
having metal particle is ejected to EMA where these are collected in EMA trolley.

WORKING PRINCIPLE

From Blendomat the material is transported to Multi function

separator; there the material is passed through under-casings ,then
to the metal detector and fire detector. Finally taken by means of air
to the next machine .The metals are collected by means of gravity in
the trolley.

Material is transported from the BDT is by the air suction. It contains

some heavy particles. Material is passed through the pipe of semi-
circular path. When material transported by the air is passed through
this trap. Heavy particles get trapped due to inertia the heavy
particles could not change their direction in circular tube so they fall
down in the waste trolley while cotton being lighter able to change
its direction in the pipe trap. So the cotton gets separated from the
heavy trash particle.
 LINE DIAGRAM OF SP-MF-:

Machine specification:-

 Manufacturer -: Trutzschler
 Type no. -: 145496
 Designation -: SP-MF
 Year -: 2005
 MAXIFLOW
Maxi flow contains two cylinder having needles with very low point density each
cylinder having its own set of grid bars under it and both are moving in opposite
direction. When material is passed through these cylinders spikes of the
cylinders do the beating action on the material. It throws the material over the
grid bars having its particular settings according to trash present in the material.
Heavy trash particles are removed through the spacing

between grid bars. In the mean time material flows from bottom to the top and
goes to the exhaust pipe.

OBJECTIVES:
 To separate air from material
 To remove trash and dust particles

MACHINE COMPONENTS:
 Pinned beaters
 Grid bars

WORKING PRINCIPLE:
 The material input vertically and freely in the machine through
the feed duct.
 There are two roller beaters with rod type spikes inside the
chamber.
 Input material is opened and cleaned by the material.
 The dust particles, seed coats and other foreign materials are
separated from the tufts by beating action
 Separated trashes are deposited in trash-chamber via grid-bars.
 Beaters rotate in same direction and transport the material
towards the output duct.
 IMPORTANT SETTINGS:
 Grid bar settings-:
 Increase in grid bar settings will increase the amount of waste
percentage removal.
 Pin roller speed-:
 As the pin roller speed increases the intensity of fiber opening
increases.

MACHINE SPECIFICATION:-
 Sr. No.:- 80
 Designation :- MFC
 Type no.:- 053.2501
 Year of manufacture :- 2005

LINE DIAGRAM OF MACHINE:-

 Technical Data/Features:-
 Inner Frame width : 1300mm
 Machine Height : 1655mm
 Machine Width : 1545mm
 Machine Length : 1370mm
 Max. Continuous Power Input : 0.7kW
 Connected Load(50 Hz) : 2.2kW
 Beater Roll Speed : 420rpm
 Weight : 1500 kg
 MULTI MIXER
Multi mixer also known as MPM is the machine used for thorough mixing of
cotton. It also acts as reserve tank to supply cotton to further machine while BDT
providing the supply of other mixing of cotton to other blowroom line.

Working principle:
 Tufts feed through the chute via air-pressure of fan in feed tube.
 By the variation of air pressure in chambers of MPM, the
material feed accordingly. From the feed side to delivery side.
 When one chamber is getting full, the material flows to the next
chamber for filling that. This process continues from feed side
to delivery side.
 After feeling one chamber, the material starts to move to the
conveyer chain, which is in the bottom of chambers, by the feed
roll couple.
 In between the flow from chamber to conveyer belt the opening
of tuft, also get done by a set of opening roller.
 According to this process, blending is being done on the basis of
Blending Delay Time

TECHNICAL DATA:
 SPECIFICATIONS VALUES
 Machine Name MPM-8
 Manufacturer Trutzschler
 Manufacturing Year 2005
 Number of Chamber 8
 Capacity of Machines 500 Kg
 Change over pressure 50-900 Pa
 Production 550 Kg/hr

OPERATING PRESSURE:
 Min 100Pa
 Max 500Pa

FILLING QUANTITY PER TANK (30 kg/m3):

 Min: 41.4kgs
 Max: 77.4kgs
 Condenser
As BDT transports the material with blowing of air which is mixed with
material. It is necessary to remove this air before feeding this material to
further B/R machine because every machine works with its own pressure rage
so if pressure exceeds or lag that pressure range then it leads to abnormal
output supply of machine. Also the material contains dust and seed particles.
Condenser removes these particles and the machine known as LVSA.

OBJECTIVES:
 To separate air from material
 To remove trash and dust particles

MACHINE DIMENSIONS:
 Machine height: 1000mm
 Machine width: 1464mm
 Machine depth: 1100mm

TECHNICAL DATA:
 Manufacturer: Trûtzschler
 Model: LVSA 375
 Year: 1997
 Fan speed: 2170-2910rpm
 Dust cage speed: 108/129rpm
 Finned stripper roll speed: 357/428rpm
 Inlet pipe dia: 250-350mm
 Exhaust dia: 250-350mm
 Inlet pressure: 125-200Pa

INSTALLED POWER:
 Fan drive: 7.5kW
 Dust cage and finned stripper drive: 0.75kW
 Machine weight: 580kg
 CVT-1 (CLEANOMAT)

OBJECTIVE:
 Fine opening and Cleaning of fibers

PRINCIPLE OF WORKING:
The machine consists of one beater that beats and opens the
fiber tufts. This machine is the final machine in the blow room
line that opens the fiber. After this machine, the fibers opens
up very well.

IMPORTANT SETTINGS
 FEED ROLL
 WING

FEED ROLL
 Feed roller speed must be set based on the type of fiber.
 Huge increase in feed roll speed may affect the fiber length.

WING
Wing setting has a great influence on the waste percentage. The
increase in wing setting increases the waste percentage removal.

NUMBER OF BEATING POINTS = 1

TECHNICAL DATA:
 Make :- Trutzschler
 Sr. No. : - 59
 Designation :- CVT-1
 Type no. :- 0970705
 Year of Manufacturer :- 1998

COMPONENTS SETTING-:
 Feed Roll 20%
 Wing 35%
 Cylinder 1000 rpm
 Suction Duct Minimum 100 Pa
 Suction Duct Maximum 350-1250 Pa

LINE DIAGRAM OF MACHINE:

 CVT-3

CVT-3 also known as Cleanomat. The main purpose of CVT3 is to open the
material thoroughly and to remove trash if any form cotton.

LINE DIAGRAM OF CVT-3 IS SHOWN IN THE FIGURE-:

WORKING PRINCIPLE:
 Feed material is feeded through the feed trunk and press roller
from the MPM.
 Feed material get transferred to the beater by the feed lattice.
 Before the action of beater, the material pressurized towards
the beater by the pressure roller.
 After press roll, a feed roll arrangement feeds the material to
the beater.
 Mote knives arrangements are responsible for removal of
foreign particles from tufts.
  Once the waste and dust separated cannot drift anymore
throughout the waste chamber and immediately carried off via
the suction hoods.
 A deflector blade is situated before the second mote knife and
be sleeplessly adjusted during production.
 In this way, the quantity and composition of the waste could be
done.

TECHNICAL DATA:
 Manufacturer: Trûtzschler
 Model
 Year: 1997
 Inner machine width: 1200mm
 M/c height: 1250mm
 M/c width: 1800mm
 M/c length: 2455mm

MATERIAL SUCTION:
 Air intake rate: 3000+10% m3/h
 Connection pressure: -390Pa
 Max. Continuous production: 450Kg/h

Feed belt speed: 0.757-15.15 m/min.

 Magic Eye
Cotton contains many coloured impurities in it these may be coloured plastic,
coloured yarn, hair etc. so if they processed in cotton as it is then it may cause
problem in spinning and also cause the colour variation in the fabric. So to
remove them Magic Eye is employed.

OBJECTIVE OF MAGIC EYE:

 To remove the colored impurities from the cotton.
 Special feature to eject white polypropylene.

LINE DIAGRAM OF MAGIC EYE-:

 WORKING PRINCIPLE:
 Magic eye installed after the Cleanomat.
 The Cameras and pressure nozzles attached inside the magic
eye in the area through which material is entering into it.
 These cameras are used to detect any type of contamination in
the cotton flowing.
 When any type of contamination come it get detected by the
cameras and then pressure nozzle attack on it and throws it in
the bag attached to it.
 There are three parts inside the magic eye. These three parts
plays the following role-:

MACHINES SPECIFICATIONS:

TECHNICAL DATA:
 Machine Name Magic Eye
 Manufacturer USTER JOSSI
 Manufacturing Year 2005
 Model UJME-1200

IMPURITIES REMOVED IN MAGIC EYE:-

1. Jute Sutli 5. Hair
2. Plastic dori 6. Colored Threads
3. White PP 7. Cloth
4. Paper 8. Feather
 DUSTEX

Cotton delivered by the CVT 1 is open enough to feed this into the card. But
this opened cotton contains some dust particles which create problem to the
Labour working in spinning mill and also deteriorate the quality of product
produced. So dust should be removed from the cotton before feeding the cotton
to card.

Dustex commonly known as DX is used to separate dust from the cotton.

OBJECTIVE:
 To remove micro dust & air from cotton.
 To condense the coming cotton.
 Transfer the raw material further to carding section.

Diagram showing various parts of machine is given bellow-:

 WORKING PRINCIPLE:
 The fed material is transported through the caged duct.
 The micro dust out from the chamber through perforation of
cage in duct, and the cotton goes away.
 By varying the pressure in various place, the material is being
condensed

MAINTENANCE schedule:

Full Maintenance and cleaning: 3 months

TECHNICAL DATA:
 Manufacturer: Trûtzschler
 Model: DX3
 Year: 1997
 Nos. of machines: 2
 Frame width (LGW): 1600mm
 M/c height 2650mm
 M/c width: 1864mm
 M/c depth: 2150mm
 Weight: 1800kg

DUCTS:
 Yellow: waste suction
 Green: material supply.
 Blue: suction pipe
 Red: fire extinguisher
 CARDING

Carding is carried out by passing entangled fibers between closely spaced surfaces of
cylinder and flats covered with sharp metal teeth .The surfaces are moved relative to
each other as a result of which fibers get disentangled.

INTRODUCTION:
 In carding, the opening of cotton is done to the fibre-
level.
 In carding operation, the absolute cleaning and opening
of fibre done. Theoretically, 70% of cleaning done in
carding.
 Here neps removal of fiber done.
 The ultimate quality of yarn is based on the carding
operation mostly.
 Carding deals with the fibre arrangements in yarn. Better
the carding action, tends to better quality of yarn.
 This is why, carding is called “The heart of spinning”.
OBJECTIVE:
 Individualisation of fibres.
 Opening of cotton at fiber level.
 Removal of dust and impurities at extreme level.
 Elimination of neps.
 Formation of Sliver
 MATERIAL FLOW:

FEED TRUNK DFK FEED ROLLER OPENING ROLLER

CYLINDER LICKER IN INTERGRATED FEED

TRAY

DOFFER SQUEEZING ROLLER TRUMPET

MATERIAL OUT CALENDAR ROLLER

MACHINE DIAGRAM:
 DK 800 TC –10

WORKING PRINCIPLE:

Sr. MACHINE PARTS DESCRIPTIONS WORKING/OPERATION

No.
1. Chute feed It is the Chute system connected
from Blowroom Line to the Card
Line. This whole system is made of Feed of material from Blowroom line
steel. Air fan is attached to this to carding machine.
system to vary the
Pressure
2.
Webfeed DFK It is a system with feed roller First the material is accumulated,
arrangements, installedjustbefore and then the web of cotton is
the licker in. feededthroughtheroller to the
operation zone of
Machine.
3.
SENSOFEED It is a feed roller with deflacting multi- Theplatemakestheweb ofmaterial
plate arrangements appropriateI volume, and the roller
feeds the web to licker-
in.
4.
Licker-in It is a saw tooth clothed roller with Lickesthewebfromthe feed.
256 mm diameter
5.
Main Cylinder It is a small saw tooth Clothed roller Forms the area for
with 129 mm Diameter. It is the carding action. Opens the fibre for
main zone of carding main cylinder carding
produces the land/area for carding
action
6.
Flats Toothed Movable For Carding action action. Individuals each
84 Strips of Flats is Being and every fibre. Removes the Neps.
accumulated for carding action of
fibre ,from which 30 flats strips are
 working. This is the main parts for
carding
7.
SFL Same profile of wire strip having a opens the fibre. Prepare
twin top arrangements for the fibre for carding.
preiopening of fibre. It situated
before the flats I the licker-in side.
Hence it is called the Stationary Flat
Licker-in. it is 3 in number in one
carding machine.
8.
SFD Same stationary flats situated in Further carding for better quality
Doffer side Hence its called
Stationary Flat Doffer. It is 2 in
numbers
9.
DOFFER Doffer is a saw toothed roller having
diameter of680 mm, and situated
after the cylinder to collect the Stripes the material from cylinder.
carded material from the cylinder
zone.
10.
REDIRECTING The toothed roller having diameter Directs the material as per
of 120 appropriate direction of flow
ROLLER mm. it is situated after the doffer. towardsthe output.

11.
CROSS It is a smmoth roller having spiral air Passes the air current. Help the fibre
channel on it. It is situated after web for sliver formation.
ROLLER Redirecting roller. The diameter of
cross roller
is 80 mm.
12.
COILER It is the fluted small twin roller coils the sliver
arangements
ROLLER situted in coiler zone
13.
CANS This is the collecting pot for sliver Collects the sliver
having diameter of 24" and
length of 40"
14.
MOTES KNIVES Metallic knives for cleaning te fibre, Removes the seed, dust from fibre
which situted in between feed- by penetrating into the webs
roll and licker-in
15.
SUCTION This is the duct for suction of Sucks the impurities from the licker-
impurities by air pressure from every in zone, Flats zone, cylinder zone
SYSTEM Zones of the machine. and doffer zone.
16.
STRIP ROLLER It is the roller having brush spirally
attached with it. Two types of brush
line, i.e. metallic brush and nylon
brush, spirally attached with it. It is Cleans every strips of flats after
situated in the top of the flats for every carding action.
flat
Cleaning
17.
CAN It is arrangements having hand and
roller attached with it for can change
CHANGER operation. It is situated in can Automatically change the can after
changer filling.
Part.
18.
DUST Vaccum chamber for collecting the Collects the heavy dust
dust removed from fibre. It is particles(heavy dust, seed, leaf etc).
CHAMBER situated under the
 BREAKER DRAW FRAME

Although the fibres are separated up to individual state but they are in random
disorganized manner in the card sliver. Draw frame straightens and aligns the
fibre along the axis of the sliver in order to have strong and even spinning.

OBJECTIVE-:

 To straighten the fibres & to make them parallel

 To improve uniformity
 To improve evenness (homogeneous sliver structure)
and blending is also achieved

MACHINE DIAGRAM:
 WORKING PRINCIPLE:
 Six or Eight numbers of Carded Sliver are fed to the Breaker
Draw Frame from Carded Sliver can.
 The carded sliver can are arranged in such a way that further
mixing of carded sliver is being done in Breaker Draw Frame.
 The feed roller pair is located above each can to enable the
feeding step to be performed in a controlled manner without
false drafts.
 The feed roller pairs are mounted in a creel frame or table and
each is positively driven.
 After feeding of sliver, the slivers doubled by a compression
plate before drafting roller.
 After doubling, the slivers are drafted by drafting rollers and
cots.
 In Breaker Draw Frame, the drafting arrangement is of 4- over-
3 types.
 The front top roller is forward advanced for better control to
fibre, and better uniformity.
 In order to avoid disintegration of the web, which would
otherwise be unavoidable at the high operating speeds

 currently in use, it is condensed into a sliver immediately after

the drafting arrangement.
 After making the sliver, the sliver is coiled into the empty D/F
can, which have size of 24” x 48”.And the can is stored for used
in Lap-former.
 MACHINE DETAILS:

MODEL LD-2
MANUFACTURER LAKSHMI
YEAR 2000
NO. OF HEADS 2
DOUBLING 6
DELIVERY DOUBLE DELIVERY
MATERIAL PROCESSED COTTON

CREEL DETAILS:

CREEL SYSTEM POSITIVE DRIVEN ROLLERS

CREEL TYPE DOUBLE COLUMN

DRAFTING DETAILS:

DRAFTING 4 OVER 3
ARRANGEMENT
DRAFTING SYSTEM SPRING
TOTAL DRAFT 6.2 4.104
BREAK DRAFT 1.28 119.71
CREEL DRAFT MIN-1.00 0.00694
MAX – 1.04
FEED DRAFT 0.95 0.0119
WEB TENSION DRAFT 1.01 0.0175
 ROLLER DETAILS:

Front bottom roll 40 mm

Back and middle bottom roller 30 mm
Roll Gauge
Min – 36,40
Max – 60,88
Front roller advancement
Belt leg 9355mm

PRODUCTION DETAILS:

Delivery speed 410 m/min

Efficiency 67%
Count of sliver 0.135
Doff length 6000 m
Production 72 Kg/hr

CHANGE POINTS:
o Feed change gear
o Draft constant change gear
o Draft change pinion
o Web tension change gear
o Coiler change gear
o Can change gear
 LABOUR EMPLOYED:
o Operator: 1
o Reliever: 1(common for preparatory)
o Sweeper: 1(common for preparatory)
 LAP WINDERS

INTRODUCTION:
o The sheet of fibre is called lap. In lap-winder machine, the sheet
or lap is wound on a spool.
o By doubling and appropriate drafting of a high numbers of sliver,
the lap is formed.
o The lap is the feed material of comber.

OBJECTIVES:
o To make even feed for comber.
o Removing the trailing hooks.
o Parallelisation of fibre
o To give high level of attenuation.

 TYPES OF LAP-WINDER:
There are three types of lap winder machine. These are:
1. Lap former (LH-10).
2. Sliver Lap (LE-2)
3. Ribbon Lap (LE-4)
 SLIVER LAP MACHINE

OBJECTIVE-:
 Doubling and drafting the sliver
 Lap formation

WORKING PRINCIPLE-:
The card slivers are taken to the sliver lap machine where the
number of slivers is combined to form a lap. Here 24 slivers are laid
parallel to each other and they are drafted to form a sliver.

STOP MOTIONS:-
 SLIVER BREAK STOP MOTION
 ELECTRIC STOP MOTION
 WHEN JAM IS ON FEED ROLLER

DRAFTING SYSTEM:-
4/6 DRAFTING SYSTEM IS USED

EFFICIENCY OF M/C:- 60-70%

 LINE DIAGRAM OF SLIVER LAPPER

MAIN COMPONENTS
Creel
Drafting arrangement
Calendar rollers
Shell rollers
Flanges
Spool

DRAFTING ARRANGEMENT:
 The machine is fitted with DK-2 drafting system. This comprises of
two double nip assemblies consisting of two bottom
rollers each topped by a rubber roller, with succeeding
simple nip assembly each comprising of fluted bottom
rolls and a top roller. Each double nip assembly is
Followed by a drafting field and preceded by a draftless zone.
 The delivery rate of the fluted rollers is as much as 20% higher
than that calculated on the basis of roller diameter and this factor
must be taken into consideration while calculating draft.
 TECHNICAL DATA:

Machine details:

Model Le2/4A
Manufacturer L.M.W
No. of machine 1
Doubling 24
Magazine Capacity 8 to 9
Creel Capacity 24 Slivers
Can diameter 24 inches
Can Height 48 inches
Spool diameter 145 mm
Spool Height 250 mm
No. of ends 24 Ends Possible
Count of sliver feed 0.12 to 0.81
Weight of feed 50 to 120 gm/m
Lap weight delivered 50 to 75gm/m
Lap width 250 mm
Draft 1.5 to 2.0
Working speed 65m/min
Drafting system Pneumatic
Power of the motor 4 HP
Motor speed 1440 rpm
 CLEANING SCHEDULE:

Table 2 hrs
Creel and creel table After every batch
General cleaning 8 hrs
Floor cleaning 2 hrs
Above and below calendar roll After 2 batches
Behind sliver lap After every batch
Top roll 24 hrs
Drafting zone 2 hrs
Machine 4 hrs
Disc slide 8 hrs
Charge cleaning At the end of the shift
 RIBBON LAP
OBJECTIVE

 Doubling and drafting

 To increase the lap evenness

WORKING PRINCIPLE

Here 8 sliver laps are combined together then doubled and drafted.
These slivers are overlapped with each other and then drafted.

LINE DIAGRAM OF RIBBON LAPPER-:

 MAIN PARTS

Creel
Drafting arrangement
Calendar rollers
Shell rollers
Flanges
Spool

STOP MOTIONS:-
1. FULL LAP MEASUREMENT-:
When required amount of lap length is wound by the lap roller
then the m/c stops automatically.
2. FEED LAP BREAKAGE STOP MOTION-:
When feed lap sheet breaks then the m/c is stopped. It is done
by photo – electrically.

AUTOMATIC DOFFING OF LAP-:

Six sliver laps is kept in the m/c at a time. There are two pistons, one is
horizontal & other is vertical. There is a timer, which measure the pre-
setting lap length. When timer gives the signal that full length is measured
then a variable speedometer accelerates and the lap breaks. Then
horizontal piston released to drop the full bobbin. Then vertical piston will
place an empty bobbin (spool) and the horizontal piston holds it. There is
a hammer, which strike the full lap to place it in proper position at time.
The hole mechanism is done under electrical monitoring system.
 MACHINE SPECIFICATIONS:

Model LE4/A
Manufacturer L.M.W
No. of machine 1
Doubling 6
Magazine Capacity 8 to 9
Spool diameter 14 mm
Spool Height 302 mm
No. of Spool 6 Spool
Weight of feed 68 to 80 gm/m
Lap weight delivered 68 to 80gm/m
Lap width 300 mm
Draft 5 to 8
Working speed 50-60m/min
Drafting system Pneumatic
Power of the motor 4 hp
Motor speed 1440 rpm
Compressed air Pressure 6 atm
Compressed Air Required 1.2 Nm3/hr
Length of Machine 5275 mm
Width of Machine With Rack 2907 mm
 Lap Former

Sliver from card which is passed through the breaker drawframe is not suitable
to feed in the comber because the feed material or the comber is lap sheet so
preparation process known as lap preparation is done and machine used for
the preparation is known as lap winding machine.

OBJECTIVES OF LAP PREPARATION:

 To make even feed for comber
 To present sliver hooks as leading hooks to the comber
 To make the fibres more parallel

LINE DIAGRAM OF LAP FORMER:

A. drafting zone 1
B. drafting zone 2
 MACHINE DATA:

Model LH-10
Manufacturer LMW
No. of machine 1
Doubling 28
Spool diameter 20cm
Spool Height 30cm
No. of Drafting Heads 2
Creel type Double column
Creel system Positive driven with photo sensors
Delivery speed 84m/min
Draft 1.20-2.26
Can diameter 24”
Drafting system 4/4 with pressure bar
Length of Sheet 260m
Lap formation time 3 min.
Lap sheet weight 68 g/m
Length of sheets in one lap 260m
 COMBER

Combing is the process which is used to upgrade the raw material. It influences the
following yarn quality

 yarn evenness
 strength
 cleanness
 smoothness
 visual appearance

In addition to the above, combed cotton needs less twist than a carded yarn

INTRODUCTION:
Combing is the most important process for producing the
quality-yarn. In Comber, the removal of short fibre is being
done. So, to produce the yarn quality better to best, the
comber is the most important process

OBJECTIVE:
 Elimination of a precisely predetermined quantity of
short fibers.
 Elimination of the remaining impurities.
 Elimination of neps in the fiber material.
 Formation of sliver having maximum possible fibre
parallization
.
 TASK OF THE COMBER
WORKING PRINCIPLE:

Feed Feed rollers move, lap sheet forward bya small amount
(4.3 - 6.7 mm), while nippers are kept open.
Nipping Upper nipper plate is lowered onto cushion plate, so
that the fibers are clamped between them.
Rotary combing Combing segment, mounted on rotating cylinder, sweeps
saw-teeth through fiber fringe and carries away
anything not held by the nippers.
Nippers forward The nippers open again and move toward detaching
rollers.
Web Return Meanwhile detaching rollers have returned part of the
previously drawn-off stock by means of a reverse rotation, so
that the web protrudes from the back of the detaching device.
Piecing In the course of the forward movement of the nippers, the
projecting fiber fringe is placed on the returned web.
Detaching The detaching rollers begin to rotate in the forward direction
again and draw the clamped fibers out of web held fast by
feed rollers (inside the nippers).
Combing Cycle Contrary to the movements of the other parts, the combing
cylinder rotates continuously. During this rotation and at a
certain instant the combing segment is brought into the
vicinity of a rapidly revolving brush mounted below the
combing cylinder. During this process, this the brush
removes the imperfections, dust etc., from the combing
segment, and ejects them into an
extractor that carries the noil away to a collecting filter
system.
 LINE DIAGRAM OF COMBER:

SEQUENCE OF OPERATIONS IN A COMBER:

 Lap from Unilap M/c is fed by feed roller
 fed lap is gripped by the nippers
 gripped lap is combed by circular comb
 detaching roller grips the combed lap and moves forward
 while the detaching roller delivers the material, top comb comes into action to
further clean the lap
 While going back, nippers open and receive a new bit of lap.

TYPES OF FEEDS:
 Forward feed (concurrent feed):Feed of the sheet into the nippers occurs
while the nippers move towards the detaching roller
 Backward feed (counter-feed): Feed of the sheet occurs during return of the
nippers.
 PRODUCTION CALCULATIONS
Production of the comber is dependent upon the following

 Let we assume that

 N- Nips per min

 S- feed in mm/nip
 G- lap weight in g/m
 K- Noil percentage
 A- tension draft between lap and feed roller(from 1.05 to 1.1)
 E- efficiency Then

Production = N*S*G*(100-K%)*E*60*8 / 1000*1000*100*A

MACHINE DETAILS:

MANUFACTURER MODEL RIETER

YEAR 2005
NO. OF MACHINES 6
NO. OF HEADS 8
U% VALUE 3.5
CV % VALUE 2.2
NIP/CYCLE 375 U/MIN
FEED/NIP 4.7 MM
DRAFTING ARRANGEMENT 3 OVER 3
MAIN DRAFT MAX
MIN
BREAK DRAFT MAX
MIN
TOP COMB DENSITY 35
 Half lap toNipper 0.25-0.35mm
Top comb -1 to +1
Top comb to detaching roll 0.3 – 7.2mm
Nipper Gauge (for 7 index) 7.1( +1)mm
Brush 12 mm
Control disk -2 to +2
Suction 12,14,16,18 mm gap between duct
and plate
Unicomb 36 index
Noil index 8- 12.5
In hall-5 Max used –12
Top comp depth -1 to +1

CHANGE POINTS:

Trumpet web plate CHANGED ACCORDING TO SLIVER

THICKNESS
Trumpet coiler CHANGED ACCORDING TO WRAPPING
Feed change gear TO CHANGE THE FEED/NIP
Top comb depth TO CHANGE THE DEPTH OF ACTION
Top comb density TO CHANGE THE NUMBER OF PASSAGE
OF FIBRE
Gears A,B,C,D CHANGED ACCORDING TO CHANGING
OF DRAFT
Noil index TO CHANGE THE NOIL %
Piecing index TO CHANGE OVERLAPPING OF WEB
 CLEAN DETAILS:

Top Comb 4 hrs

Behind cover 24 hrs
All rollers 24 hrs
Coiler 24 hrs
General cleaning 8 hrs
Nippers of 3 machine at a time 24 hrs

PRODUCTION DETAILS:

NIP/CYCLE 375
FEED/NIP 4.7 MM
FEED BATT TENSION 10%
BATT WEIGHT 50 TO 72 GM/M
NUMBER OF HEADS 8
NOIL% 20% (APPROX.)
EFFICIENCY 86%
PRODUCED SLIVER COUNT 0.140 NE
PRODUCTION 32 KG/HR

DRAFTING DETAILS:
 Drafting system: 3/3
 Doubling: 8 fold
 Sliver weight: 3-6 kTex
 Break draft: 1.14-1.5
 Total draft: 9.0-23.1
 PRESSURE:
 Loading: pneumatic
 Top detaching roller: 3-4bar
 Drafting system front roll: 2.5-3bar
 Drafting system 2nd and 3rd rolls: 3.5-4.5bar

MAINTENANCE SCHEDULE:
Full cleaning and maintenance: 1 month

Cot size:

 Detaching rolls (mm): 5.92x24.5x345

 Drafting rolls (mm): 29.9x45x200
 Delivery top roll (mm): 29.9x45x300

Hardness of rolls:

 Detaching rolls: 65o

 Drafting top rolls: 63o (F), 70o (M), 85o (B)
 Delivery top rolls: 83o

BUFFING SCHEDULE:
 Detaching roller: no
 Drafting top rolls: 1month
 Delivery top rolls: no

TEMPERATURE AND HUMIDITY:

 Temperature: 32-35 oC
 Humidity: 52-55% R
 Finisher draw frame

Sliver from comber before feeding to speed frame is passed through

finisher drawframe to get maximum possible evenness which result
in the even roving at roving frame.

INTRODUCTION:
 Finisher Draw Frame is the final zone for quality control
of product.
 Here the doubling and drafting of combed liver is being
done.
 The purpose of Finisher Draw Frame is to maintain the
final uniformity the product as well as the yarn.
 Finisher Draw Frame is functioned with the operations
of Autoleveller.

OBJECTIVES:
 To maintain the uniformity of Combed sliver.
 Levelling the unevenness by the control of Autoleveller.
 Final attenuation of fibres.
 Final parallelisation of fibres
 To make sliver with maximum possible evenness.
 To make required hank for input in speed frame.
 MATERIAL FLOW DIAGRAM IS GIVEN BELOW:

10

AUTOLEVELLING:
RSB-40, RSB-40-C both are autoleveller. Here when sliver is passed through the
scanning rollers then it measures the thickness of material. Scanning rollers are
connected to the signal generator which converts thickness variation in the
electronic signals. These signals are compared by standard value by the electronic
memory and then it gives the signal to the servo drive to maintain the proper draft
with particular thickness.

WORKING PRINCIPLE-:
 The combed sliver is being fed to the Finisher D/F.
 Doubling of 6 sliver is done
 The Autoleveller sensing system senses the unevenness of
sliver in feed side.
 The signal is send to the correction zone.
 According to the signal, the power of middle and back roller is
controlled.
 According to the variations of power, the speed of middle and
back roller is being adjusted.
 So, the break draft and main draft is being adjusted with the
autoleveller signal.
 The irregularity of sliver is adjusted with the changing of draft.
 Thus, the sliver irregularity is being checked.

MACHINE DETAILS:

MODEL RSB D-40, RSB D-40C

MANUFACTURER RIETER
NO. OF MACHINES 2,1
DOUBLING 6
DELIVERY SINGLE DELIVERY
DRAFTING ARRANGEMENT 4 OVER 3
DRAFT LOADING SPRING OR PNEUMATIC
TOTAL DRAFT 5.9 TO 6.2
BLACK COT SHORE 73 degree
FRONT ROLL GUAGE 35-80
BACK ROLL GAUGE 35-100
SCANNING ROLL DIAMETER 3.9,4.2
U% 2-2.2
CV% 0.6
 CHANGE POINTS:

 Change points of RSB Purpose for changing

 Roll guage change according to

the types of cotton to be processed.
 Gear W4 for changing break draft
 Gear Nw1 & Nw2 for changing total draft

 Trumpet size for changing the degree of

condensation

Hardness of top rollers:

 Draft range: 5.5-11.5

 Sliver hank delivered: 0.12-0.19

Top roller cot size:

 Top rolls(mm): 26x38x160

 Hardness of top rolls: 78o
 Sliver cans in creeling zone: 8 8
 No. of coiling head: 1 1
 Delivery speed: 250m/min 400m/min (max)
 MAINTENANCE SCHEDULE:
 Maintenance and full cleaning : I month
 Buffing frequency of top rolls: 15 days.

CALCULATIONS:
Production of finisher draw

= delivery speed x 1.093 x 8 x 60 x efficiency

840 x 2.2 x sliver hank

 SIMPLEX (ROVING) FRAME

Simplex is the intermediate machine between draw frame and the ring frame. The
purpose of the roving frame is to produce out of the draw frame sliver a well prepared
roving of required hank as well as to prepare bobbin suitable for use in the ring frame
.

OBJECTIVES OF SPEED FRAME:

 To draft the material to the required hank.

 To insert minimum required level of false twist.
 To produce a suitable package for the next process.
 To reduce the thickness of the sliver.

DIAGRAM OF SPEED FRAME:

 WORKING PRINCIPLE:
 The sliver from RSB is fed to the Roving Frame.
 The slivers are input to the drafting zone through creel.
 The creel is positively driven with the movement of sliver to
avoid the insertion of false draft
 The sliver is drafted in range of 8.9 to 19.3 to make the
attenuation of fibre better, and for high level of parallelisation
of fibre.
 The highly drafted sliver is fed to the flyer groove through the
false twisting nozzle. False twisting nozzle provides the
protective twist to the drafted sliver inside the groove of flyer.
 In every rotation of flyer, one twist is imparted to the drafted
sliver. After twisting, the roving is winded on roving bobbin
with the help of pressure arm.
 The roving bobbing building mechanism is regulated by
1. Servo Motor for reducing the speed with increase of diameter
of roving
2. Pressure switch for changing the upward and downward
direction of movement of roving rail.
3. Ratchet wheel and dead weight for adjusting the lift of roving
bobbin.
4. Thus a package of 1800 gm of roving is formed for further
processing in Ring Frame.

MACHINE DETAILS:

 Subject Data
 Manufacturer LMW
 Model LFS1660
 No. of machines 4
 No. of spindles/machine 120
 TECHNICAL DETAILS:
 No of Spindles 120
 Lift 15.7 inch
 Twist per inch (TPI) 1.45
 Roll Guage 47/55/52
 Saddle Guage 56/53/52
 U% 3.5
 CV% 2.2
 Turns on pressure Arm 2.5
 No. of grooves in twist master 12

 Flyer speed 1130 rpm

 Leading types Bobbin leading

PACKAGE DETAIL:
 Weight of one package 1800 gm
 Numbers of layer in one full package 142
 length of roving in one full package 3930 m
 TPI 1.45
 Count of material 1.30 Ne
 Taper angle 27 degree
 DRAFTING DETAIL:
SUBJECT DATA
Type of drafting system 4 over 4
Loading on drafting system Spring loading
Spacer White – 3.4 mm
Black – 4.4 mm
Break Draft 1.114
Main Draft 8.421
Tension draft 1.038
Middle zone draft 1.087
1st Roll offsetsetting Forward offset- 6mm
3rd Roll offsetsetting Backward offset- 2mm

PRODUCTION DETAIL:

 Delivery speed 19.7 m/min

 Machine efficiency 90% (average)
 TPI 1.45
 Production 75 gm/spindle/shift
 CHANGE POINTS:

Change Points Purpose for change

 Change Pinion (C.P) For changing the main draft
 Twist Wheel (T.W) For changing the T.P.I value
 Break Draft Change Pinion (B.D.C.P) For changing the break
draft
 Creel Wheel To change the creel tension draft
 Lifting Wheel To change the lift
 Draft Combination wheel (r & l)
 Twist Combination wheel (h & g)

BUFFING SCHEDULE:
 Front cot: 2months
 Zinser: 2months
 Middle cot: 9months

GREASING SCHEDULE:
 Front cot: 36months
 Zinser: 36months
 Middle cot: 36months

Recommended buffing cycle: 3months

MAINTENANCE PARAMETERS
 Full cleaning: 1month
 Top and bottom path: 15 days
 Bottom roller gauge change: 1 year
 Top apron change: 2 years
 Creel cover opening: 3 months
IMPORTANT POINTS

 Twist is inserted with the help of the flyer depend upon the count of yarn to be
prepare.
 Flyer rpm and delivery speed depend upon the count of roving to be prepared.
 In bobbin leading bobbin speed is more than that of the flyer speed.
 RING FRAME
Ring spinning is the last state of conversion of fibre to yarn completely. Ring frame
is the last machine in the spinning section.

OBJECTIVES OF RING FRAME:

It performs mainly two operations:

 To convert roving into yarn of required count.

 To wind yarn on the cop.
 To insert required amount of twist in the yarn.

LINE DIAGRAM OF RING FRAME:

 MACHINE DIAGRAM-:

MACHINE SPECIFICATION:
Manufacturer: SEIGER
Model: LR9
Year: 1997
Total no. of machines: 17
No of spindles per machine: 864
Creel type: six row standard creel
Bobbin holder weight: 40g

DRAFTING SYSTEM:
 Drafting arrangement: 3/3 double apron.
 Load on top arm: spring load.

BOTTOM ROLLS DIAMETERS:

 Front roll: 27
 Middle: 27
 Back: 27
 TOP ROLLS:

 Front: 29
 Middle: 25
 Back: 29
 Spacer used: 2.2, 3.2, 3.8, 2.5, 2.8
 Bottom apron type: long apron with spring loaded tensioner.
 Weighting arm: SKF PK225/PK235
 Load on each top roller: 14kgs
 Total length of drafting zone: 145mm

COP DIMENSIONS:

 Bobbin bottom dia: 27mm

 Bobbin top dia: 21mm
 Average bobbin dia: 24mm
 Cop dia: 35mm
 Chase: 44mm
 Lappet hook dia: 3mm

 Cop weight: 50-54gm

 Spindle speed: 20000 rpm (max)
 Spindle driving system: four spindle tape drive with single jockey pulley
 Lift: 185mm/205mm
 Wharve dia: 20.2mm/18.5mm
 Spindle speed regulation by Servomotor
 Spindle taper: 1:64
 YARN COUNT: 50-200Ne
 Twist per inch: 8.1-50.1

 Direction of twist: ‘Z’ Twist standard

 ‘S’ and ‘Z’ twin jockey pulley
 (optional)
 Ring dia: 38mm single flange.
 Lifting motion: During normal running: by heart cam
During under winding: motor drive
Restart after doffing: motor drive
 Spindle tape type: endless

 Tape length: 2430mm

 Spindle tape width: 11mm
 Creel six row with reserve bobbins

HARDNESS:
 Front cot: 68o
 Back cot: 83o

RING FRAME PARTS REPLACEMENT:

Sr. No. Part name Life Size

(mm)

1 Ring 5years 38

2 Front cots 1.5 month 19x29x28.5

3 Back cots 4.5 months 19x29x28.5

4 Top apron 24 months 37x27.8x1.0

5 Bottom apron 24-26 months 73x30x1.05

6 Spindle tape 12-18 months 2441x11

 MAINTENANCE SCHEDULE:
 Full cleaning and maintenance: 1 month.
Greasing schedule:

 Front cot: 4.5months

 Back cot: 12 months
 Middle cot : 12months
Buffing Frequency:

 Front cot: 1.5month

 Back cot: 4.5months
 Middle cot: no buffing required
 Winding section

The package obtained from ring spinning contains a vry less amount of yarn making it difficult to be
used in the processes of weaving Knitting etc. Thus the smaller ring frame bobbins are required to
be converted into the larger packages.

Also the yarn obtained from ringframe contains many faults such as thick and thin places, slubs ad
neps. Thus to come out of these problems winding machine is employed.

OBJECTIVES OF WINDING
 To convert the small packages into bigger packages
 To remove the faults (thick and thin places).
 To form a package of suitable shape and density which is easy to store and manage.

Machines used for the process of winding are known as winding machines.

Autoconer is the winding machine used at ASM for the winding purpose.

AUTOCONER

Autoconer is a M/c for automatic winding of cross wound packages. The autoconer
represents an autonomous, compact winding machine with integrated drive, with a splicer on each
winding unit, and with a corresponding sub pressure supply. Plug type connections are provided for
electricity and compressed air supply.

Autoconer is conceived as a single unit machine in one sided length

construction as RH or as LH machine. There are 6 machine sections, each having 10 winding heads.
The winding unit gauge is 320mm from one unit to next one. Each winding unit is self sufficient,
composed of an upper part containing the assemblies required for winding, and a lower part for
transport and creeling of supply packages.
 SUMMER TRAINING REPORT

WORKING:
As shown in the diagram bobbin is held on bobbin holder.

Now the yarn from bobbin is passed through loop gate and then from unwinding accelerator
which controls the ballooning of yarn. After this the yarn is passed

through lower yarn sensor and then from tensioning assembly which provides the proper
tension for yarn to form a compact package.

Now the next assembly is the splicer which along with the cooperation of
suction arm and griper arm accomplishes the splicing of yarn whenever yarn breakage takes
place. Here the suction arm provides the upper end of yarn and griper arm provides the lower
end of yarn for splicer. Next to the splicer there is an electronic yarn clearer which senses the
unevenness in the yarn and cuts the faults. Next is the yarn tension sensing device which
senses the yarn tension and sends the signal to pre- tensioner whenever tension changes.
After this there is a waxing assembly which rotates continuously to apply the wax uniformly.
Just after the waxing assembly there is a yarn trap which traps the extra or broken yarn. Now
the last is the winding assembly which is having a grooved drum and cradles. Cradles hold
the cone and drum provides the traversing motion to the yarn.

MACHINE DESCRIPTION:
Machine Manufacturer Model Type No. of M/c No Number
machines

Machine 1-4 Muratec Process Coner II Q PRO 4

Machine 5 Muratec Process Coner II 21 F 1

YARN CLEARING SYSTEM:

It is a yarn clearing system for winding machines. It interprets and displays
the yarn characterstics within minutes and processes a starting point for
clearing limits with a cut forecast by pressing a single button.

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MEASURING PRINCIPLE:
 Capacitive measuring principle – C sensor
 Optical measuring principle – O sensor

MACHINE DETAILS:

Machine Name Quantum 3

Manufacturer Uster

BOBBIN FAULT (ALARM):

 B0 Supply Error
 B1 Bobbin supply error
 B3 Start-up cut alarm
 B5 Count alarm
 B6 IPM alarm
 B7 Moire alarm
 B8 CV alarm
 B9 Coloured fibre alarm
 A1 Quick breakage in new package
 A2 Quick breakage in new package
 A3 Empty cone
 A4 New package does not start after complitation of old package
 BA Hairiness alarm
 BB IPI alarm
 BD YF alarm
 BG PP alarm
 P1 Upper yarn end find error
 P2 Upper double yarn alarm

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 P4 Package break error
 P5 PJC alarm (upper limit)
 P6 PJC alarm (lower limit)

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CONDITIONING AND PACKING
After the winding zone cones are send to the condition room where the conditioning of yarn is done.

INTRODUCTION:
 After preparation of cone, the conditioning is of package is very much
important.
 To maintain the quality of package and for appropriate weight of package,
conditioning is being done.

OBJECTIVE:
 To maintain the appropriate weight of package.
 To increase the strength of package.
 To increase the luster of package.
 To increase the serviceability.

UV Room:
Before passing the material to conditioning room material is checked in UV room for checking
whether whole of the yarn is of same material.

Preconditioning room:
After passing the yarn through UV room yarn is kept in the precondition room for 2 hours where
yarn gets moisture of 7-8%. Not all the material is passed through the preconditioning room, it
depends upon the requirement of customer.

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WORKING PRINCIPLE-

Input of package in

of weight of 500 Kg. minutes.

for 20 minutes

Xorella wettingen:

In this machine the material is kept under the specified conditions of temperature and
vaccum.Material is conditioned in two cycles. The schedule and parameters for conditioning is as :

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Sr. Yarn Cycle no. 1 Cycle no. 2
no. type
temp time vacuum Temp. Time vacuum

1 Hosiery 52oC 5 min 143 58oC 30 min 151

2 Gunze 70oC 51 min 180 80oC 25 min 220

MACHINE DETAIL:

Manufacturer: Contexxor Compact Xorella Model AG

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PACKING

After the process of conditioning, the material goes for packing

There are two type of packing.
 Carton Packing
 Pallet packing

PARTICULARS WRITTEN ON CARTON:

 Description:
 Count
 EXC./CTN. No
 Gross weight
 Net weight
 Lot no.
 Made in India

Various sizes:

Dimensions capacity weight cone weight

655x460x506x 18 cones 47.7kg 2.65 kg

580x400x350 12cones 22.86kg 1.89 kg

580x400x506 18 cones 34.02kg 1.89 kg

Pallet size:
Domestic:

Dimensions capacity weight cone weight 900x900x120

252 cones 476.28 kg 1.89 kg

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Export:

Dimensions capacity weight cone weight

1145x1145 360

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RESEARCH AND DEVELOPMENT

INTRODUCTION
Research and development department deals with the testing of the raw material, final product and the various
intermediate products so that we get a quality final product. Apart from this it also includes various efforts done to
further improve the quality of the product.

The testing laboratory includes following testing equipments.

1. USTER HIGH VOLUME INSTRUMENT 900

2. USTER ADVANCED FIBER INFORMAION SYSTEM PRO
3. USTER TESTER 5
4. USTER TESTER 6
5. USTER CLASSIMAT SYSTEM

USTER HVI 900:

This instrument is used to determine following parameters:

 Fiber length
 Fiber strength
 Length uniformity
 Elongation
 Micronaire
 Color
 Trash

USTER AFIS PRO:

This instrument is used to determine following parameters:

 Nep content
 Nep classification
 Length of the fiber
 Maturity of the fiber
 Fineness of the fiber
 Trash

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USTER TENSOJET:

This instrument is used to determine following parameters:

 Elongation
 RKM
 Work of rupture
 B-force

USTER TESTER 5:
This instrument is used to determine following parameters:

 Evenness
 Imperfections of the yarn
 Hairiness of the yarn
 Count
 Diameter
 Structure
 Density
 Shape
 Trash
 Dust

STATISTICAL QUALITY CONTROL

This department performs the testing of the cotton fibres of various varieties the company uses. When the
bales arrive, a certain % of bales are used for checking the parameters. It is important as it aids in deciding
which quality of bales to use in a certain order of yarn. After testing the parameters, the mixing ratio is decided
according to the requirements of the end product. The cotton from bales undergoes testing in 3 kinds of
machine. They are:

 HVI 900
 AFIS PRO
 MDTA

STORE DEPARTMENT

To store the raw material, work in process and final product, there are total 13 godowns at ASM,
Baddi for raw material. Out of godowns 12 are used for bales storage one for waste bale. there

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capacity is to store 4000 to 4100 bales and there are godown -6. which is having slightly large
capacity? They have a storage capacity of 4200 to 6000 bales and there mainly yarn is stored.

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