SPINNING WITH TECHNICAL ACESS

BY ESHAN BANSAL

DEPARTMENT OF TEXTILE ENGINEERING

GZS PTU CAMPUS

BATHINDA

SPINNING

Spinning is a process of conversion of fibers (raw material) which possess certain characteristics into yarn of desirable characteristics through various stages involving preparatory stages and ring spinning stage.

STAPLE FIBER PROCESSINGBLOWROOM

CARD

PRECOMBED DRAWFRAME

UNILAP

COMBER

FINISHER DRAWFRAME

SPEEDFRAME

RINGFRAME

AUTOCONER

PACKING

RAW MATERIAL SPECIFICATIONS

Sr. No. PARAMETER J-34 (100%)

1. Length 29.4mm

2. Micronaire 4.2

3. Strength 30 g/tex

4. Trash 4.8%

5. Maturity Ratio 0.92

LIST OF MACHINESSr. No. MACHINE NAME MACHINE

MANUFACTURER

MODEL NO OF M/C

B/R LINE-1&2

1 BLENDOMAT TRUETZSCHLER BDT-019 1

2 CONDENSOR TRUETZSCHLER LVSA-375  

3 SECUROMAT TRUETZSCHLER SC-154 1

4 UNICLEAN RIETER B-11 1

5 MULTIMIXER TRUETZSCHLER MCM-6 2

6 CLEANOMAT TRUETZSCHLER CVT-3 2

7 CCS-BASIC SIEGER   2

8 DUSTEX TRUETZSCHLER DX385 2

CARD

1 CARD TRUETZSCHLER DK-803 17

2 CARD TRUETZSCHLER TC-03 1

BREAKER D/F

1 DRAW FRAME RIETER SB-2 2

2 DRAW FRAME LAKSHMI LD0/6 1

UNILAP

1 UNILAP RIETER E-30 2

2 UNILAP LAKSHMI LH-10 1

COMBER

1 COMBER RIETER E-62 8

2 COMBER RIETER E-60H 3

3 COMBER LAKSHMI LK-64 3

FINISHER D/F

1 DRAWFRAME RIETER RSB-D851 5

2 DRAWFRAME RIETER RSB-D30 3

SPEED FRAME

1 SPEED FRAME LAKSHMI LF-1400 7

2 SPEED FRAME LAKSHMI LF-1400A 4

RING FRAME

1 RING FRAME RIETER G 5/1 20

2 RING FRAME LAKSHMI LR 6/S 9

AUTOCONER

1 AUTOCONER SCHLAFHROST 338 5

2

AUTOCONER

SCHLAFHROST 5 3

T.F.O

1 T.F.O VEEJAY LAKSHMI VJ-150-HS 4

2 T.F.O VEEJAY LAKSHMI VJ-190 2

BLOWROOMThe basic purpose of Blow room is to supply • small fibre tufts• clean fibre tufts• homogeneously blended tufts if more than one variety of fibre is used

to carding machine without increasing fibre rupture, fibre neps, broken seed particles and without removing more good fibres.

 

The above is achieved by the following processes in the blow room• Pre-opening• Pre-cleaning• Mixing or blending• Fine opening• Dedusting

BLENDOMAT BDT O19• It can be freely programmed

to allocate up to 3 bale groups, to feed up to 3 blow room lines.

• Bales of varying heights can also be easily processed.

• It is very sturdy and robust machine capable of producing production up to 1200 kgs/hr.

• The penetration control mechanism avoids reversal of rotation direction of the opening roll and avoids the wear intensive braking and acceleration after each passage of bales.

UNIQUE INVERSION MECHANISM• The blendomat is equipped with two

opening rolls rotating in opposite direction.

• Depending on the direction of travel one roll is always working against the travel and one with the travel.

• The one which is operating in opposite direction to the travel, is raised by up to 10 mm by means of a motor.

• The roll which operates in the same direction as the travel penetrates more deeply into the bale.

• The result is the even distribution of production from both rolls and equal tuft sizes from both rolls.

• TECHNICAL DATA

Production- 900 – 1000 kg/hrEfficiency- 88.6%Traverse drive speed- 11.6 m/minRpm of take-off roller- 1500 – 1800 r.p.mNominal take off depth- 2.5- 3 mmBeating Points – 0.5

LVSA 375The purpose of the condenser is twofold:• To transport cotton and synthetic

fibers pneumatically in the form of tufts

• To de-dust these tufts at the same time.

The fan (7) produces the air current required to transport the material. The stock is separated from the transporting air by the perforated drum (3) and removed from the drum (3) by the take-off roller (9). The exhaust air (5) is deflected to the filter unit.• TECHNICAL DATA

Diameter perforated drum- 480 mmDiameter take-off roller- 300 mmDiameter fan wheel 50 Hz- 528 mmSpeed perforated drum- 80/min Speed take-off roller- 410/minSpeed fan wheel 50 Hz- 1410/minProduction- up to 1200kg/hr

SECUROMAT SC154Its objectives are:• To separate the metal

particles especially iron particles from the raw material.

• To feed the material to the next machine for further processing.

Basically, electronically controlled metal separation is carried out from the raw material so as to protect the cleaners and cards from metal parts. It requires no exhaust air and filter capacity.

UNICLEAN B11• It is used for cleaning and extracting dust from

cotton of any origin and blends of cotton/man-made fibers very gently and effectively.

• The raw material is fed without nipping.• The guide plates (14) carry the tufts in a spiral

manner over the grid (11) seven times.• The combination of cleaning intensity and waste

rate ensures efficient cleaning with few good fibers in the waste and no crushed waste particles.

• Waste is removed periodically via the air lock roller (9) and the conduit (2).

• TECHNICAL DATA

Diameter of pin roller 750 mmDiameter of lock roller 350 mmSpeed of pin roller 480 – 960 rpmSpeed of lock roller 16 – 19.2 rpmElectric cylinders per m/c 2Shearing force 2000 NLift 100 mmLifting speed 5.6 mm/sBeating Point 1.0Grid angle 4.40

MULTIMIXER MCM6• To blend different varieties of cotton in

order to achieve maximum homogeneity of the mix.

• It acts as a storage unit to feed raw material to the card uniformly in case of any malfunction in the pre-process.

• There are six reserve trunks which comprises of reserve trunk flap (3), perforated partition wall and light barrier for minimum filling level monitoring.

• Each trunk is filled until the set pressure is reached.

• When the pressure is reached, the controller identifies the trunk as full and the next trunk is filled.

• The trunk is ready to receive the material again only when the calculated filling level has fallen to 75%

• If all the trunks are ready to receive material, the system switches to next trunk after a maximum of one min even if the changeover pressure is not reached.

• TECHNICAL DATA

Storage volume per trunk 1.38 – 2.58 m3

Reserve capacity per trunk 41.4 – 77.4 kgOpening roll speed 1000 rpmDelivery roll speed 0.05-0.83 rpmTray suction fan speed 2860 rpmConveyor belt speed 1.8-35.5 rpm

CLEANOMAT CVT3• It is a combination of one spiked roll and two

saw-tooth rolls which ensures high degree of opening and cleaning especially of medium grade cottons.

• These rollers work in combination with mote knives and suction hood to remove fine trash impurities in all types of cotton very effectively.

• Roll 1 has two separating wings. A carding segment is installed after the first wing. Waste is extracted directly from the separating wings, via suction hood i.e. a continuous suction flow removes all contamination produced by separation.

• Before the second separating wing, a guide wing is situated which can be steplessly adjusted during production. In this way, the quantity and composition of the waste can be regulated.

• Roll 2 (6) runs faster than roll 1 and receives the material. Roll 2 is equipped with a guide wing, a carding segment, a separating wing and a connected suction hood (7).

• Roll 3 (8), which in turn runs faster than roll 2, is also equipped with a guide wing, a separating wing and a connected suction hood (9). From here the material is extracted to the next machine.

TECHNICAL DATA

Figure: Roll 1

Figure: Roll 2

Figure: Roll 3

Speed of feed belt- 0.757 -15.15 m/min

Speed of roll 1- 1244rpm

Speed of roll 2- 1864rpm

Speed of roll 3- 2968rpm

Beating point- 1.0

DUSTEX DX385• It ensures effective

dedusting which results in thoroughly dedusted slivers which ensure optimized running behaviour during yarn formation.

ADVANTAGES• Higher efficiency rates• Longer lives of clothing

and spinning components

• Better running behaviour of the spinning machines

• Clean ambient air

CARDING DK803• The function of the carding machine is to open

the tuft web coming from the tuft feeder into a fiber web, to card (parallelize) the fibers, to extract the waste particles (dust, trash, etc.), to form the carded web into the sliver and to feed this to the coiler for being deposited in a can.

The main components of the card DK 803 serving for this function are:• Tuft feeder DIRECTFEED DFK• Feed roll• SENSOFEED• Deflector blades, mote knives with suction

hoods and carding segments• WEBFEED• Precarding segments and suction hoods with

mote knife- WEBCLEAN-• Flats cleaning device• Cylinder covering segments with suction

hoods and mote knives• Revolving flats• Cylinder• Suction hoods with mote knives and post

carding segments- WEBCLEAN-• Doffer• Cleaning roll• Stripping roll• Squeezing rolls• Calendar rolls with can changer

OPERATING ZONES• The feed roll seizes the web, condenses it

and forwards it to the L-in.• The feeding system (SENSOFEED) enables

the web being clamped and measured section by section.

• The function of the WEBFEED is to open the web supplied from the feed roll, to clean and feed it to the cylinder.

• The main cleaning is performed on the first roll (1). Fine trash particles and dust are extracted on the second and third roll.

• The extraction quantity is determined by a corresponding setting of the deflector blades (7).

• Carding-parallelization-cleaning and opening into individual fibers takes place between the clothing of the cylinder and the revolving flats.

• The clothing of the revolving flats are designed to pick up short fibers and impurities in the form of strips.

• The clothed doffer carries the fiber web over the web guiding section to the stripping roll (1).

• The WEBSPEED brings the web together.• In the web trumpet the card sliver is formed

from the web, and the sliver is drawn off by the calendar rolls and orderly deposition of the sliver into the can takes place.

Fig: Tuft feed direct feed DFK

Fig: Feed Zone

Fig: WEBFEED

Fig: Web doffing unit, WEBSPEED calendar unit

AUTOLEVELLERS IN CARD1. CORRECTACARD

(CCD)• This serves for a long term

levelling and monitoring of the sliver count.

2. CORRECTAFEED (ICFD)

• This serves for levelling of the sliver count (CV-value). The levelling system works already from a sliver length of 1 m.

TECHNICAL DATA

Feed roller-L-in- 35 thouL-in-L-in- 7 thouL-in-cylinder- 8 thouCylinder-flat- 8 thouCylinder-doffer- 5 thouKnife-cylinder- 21.6 thou1st Knife-doffer- 11.8 thou2nd knife-doffer- 9.8 thou

L-in 2- Graf: K 50 20 X16 VG TCC: T 50 20 160 0164 35/VL-in 3- Graf: N 50 20 B16 VG TCC: T 50 20 160 210 35/VBCylinder- Graf: R 20 30 X0.5 TCC: T 17 30 050 0860 05/X1Doffer- Graf: N 40 30 X0.85 TCC: T 40 30 090 0367 31/BRZFlat tops- Graf: Spacetop 55 TCC: Novotop 55

Fineness- 0.125 NeDraft- 104Target pressure DFK- 300 PaDiameter of L-in 1- 172.5 mmDiameter of L-in 2- 172.5 mmDiameter of L-in 3- 172.5 mmDiameter of cylinder- 1287 mmDiameter of doffer- 700 mmSpeed of cylinder roll- 560 rpmSpeed of L-in 1- 1152 rpmSpeed of L-in 2- 1788 rpmSpeed of L-in 3- 2343 rpmSpeed of feed roll- 10.9 rpmSpeed of flats- 400 mm/minSpeed of DFK beater roll- 830 rpmWeb thickness- 1.03 mmBalancing value CCD- 5.70 mmTotal no of flats- 84No. of flats in working position- 30Delivery speed- 184 m/minProduction- 52.1 kg/hrEfficiency- 96.3%

SETTINGS

WIRE SPECIFICATIONS

BREAKER DRAWFRAME SB-2

Its objectives are:• Equalizing i.e. through doubling the sliver are made even.• Parallelizing i.e. through drafting the fibers get parallelized.• Hooks created in the carding machine are straightened.• Dust removal.

Doublings – 7

Drafting arrangement – 3/3

Type of weighing – Spring loaded

Type of coiling – Over coiling

No. of deliveries – 2

Diameter – Top (mm) Bottom(mm)

Front 26 40

Middle 29 30

Back 38 30

Hardness of top roll – 830 shore

Roller gauge – 40/42

Break draft – 1.4

Main draft – 3.78

Total draft – 5.3

Hank fed – 0.125

Hank delivered – 0.094

Delivery speed – 750 m/min

Efficiency – 85%

Auto can changer – Yes

Auto leveller – No

Sliver monitor – No

TECHNICAL DATA

UNILAP E30

Its objective is:

To form a lap of desired fineness, weight, length and fiber orientation to be fed to the comber for effective combing operation.

Doubling – 22

Drafting system – 3/3

Type of loading – Pneumatic

Lap length – 230m

Lap wt. – 80 g/m

Hank fed – 0.094

Hank delivered – 0.007

Efficiency – 82.2%

Total draft – 1.64

TECHNICAL DATA

COMBER E62

Its objectives are:• Elimination of a precisely pre-determined quantity of short fibers.• Elimination of remaining impurities.• Elimination of a large proportion (not all) of the neps in the fiber material.• Formation of a sliver having maximum possible evenness.

SEQUENCE OF OPERATIONS• Feed rollers (S) move lap sheet (W) forward by a

small amount ,while nippers (Zo/Zu) are held open (feed).

• Upper nipper plate Zo is lowered onto cushion plate (Zu) so that the fibers are clamped between them (nipping).

• Combing segment (K), mounted on rotating cylinder (Z), sweeps saw-teeth through fiber fringe (B) and carries away anything not held by the nippers (rotary combing).

• The nippers open again and move toward detaching rollers (A) (nippers forward).

• Meanwhile detaching rollers (A) have returned part of the previously drawn-off stock (web V) by means of a (partial) reverse rotation, so that the web protrudes from the back of the detaching device (web return).

• In the course of the forward movement of the nippers the projecting fiber fringe (B) is placed on the returned web (V) (piecing).

• The detaching rollers begin to rotate in the forward direction again and draw the clamped fibers out of web (W) held fast by feed rollers (S) (inside the nippers) (detaching).

• Before the start of the detaching operation, top comb (F) has thrust its single row of teeth into the fiber fringe, (passive combing by the top comb).

• As the nipper assembly is retracted, the nippers open for the next feeding step. The top comb is withdrawn. A new combing cycle begins.

SETTINGS

TECHNICAL DATA

Feed/nip 5.2 mm (S= 18)Nips/min 400Lap wt. 80 g/mDia of full lap 550mNoil % 18.60Batt tension 9%Type of feed Concurrent feedPoint density of top comb 32 needles/cmDrafting arrangement 3/5Type of weighing PneumaticBreak draft 1.36Main draft 10.22Total draft 13.9Hank fed 0.007Hank delivered 0.115Doublings 8No. of deliveries 1Delivery speed 167.1 m/minEfficiency 90.8%Can filling 6000m

Noil index- 24-40

Nipper-cylinder comb- 0.3 mm

Nipper-bottom detaching roller- 8 mm

Cylinder- brush- 18 mm

FINISHER DRAWFRAME RSB851

Its objectives are:• To control the count variation within the sliver by using auto

levellers.• To make the required hank of sliver for feed to the speed

frame.

AUTOLEVELLER TECHNICAL DATA

Doublings – 6Drafting arrangement – 3/3Type of weighing – Spring loadedType of coiling – Over coilingNo. of deliveries – 1Diameter – Top (mm) Bottom(mm)Front 38 40Middle 38 30Back 38 30Hardness of top roll – 830 shoreRoller gauge – 39/41Break draft – 1.28Main draft – 4.61Total draft – 5.9Hank fed – 0.115Hank delivered – 0.120Delivery speed – 400 m/minEfficiency – 82%Auto can changer – YesAuto leveller – YesSliver monitor – Yes

SPEEDFRAME LF1400

Its objective are:• Attenuation of the draw frame

sliver.• Insertion of protective twist.• Winding of the roving into a

package which can be transported, stored and donned on the ring spinning frame.

The building motion performs three essential functions during the winding operation:

a. Shifting of the cone belt corresponding to increase in the bobbin diameter.

b. Reverse the direction of the bobbin rail at the upper and lower ends of the lift stroke.

c. Shorten the lift after each layer to form tapered ends on the bobbins.

(a)

(b)

(c)

TECHNICAL DATADrafting arrangement- 3/3

Type of drafting system- Pneumatic

Apron size- Bottom apron Top apron

76*65*1.02 42*38*1.02

Diameter- Top (mm) Bottom (mm)

Front 19 27

Middle 29 27

Back 38 27

Roller gauge- 45/50

Saddle gauge- 52/48

Break draft- 1.01

Main draft- 7.75

Total draft- 7.83

Hank fed- 0.120

Hank delivered- 0.90

Flyer speed- 980 rpm

Delivery speed- 450m/min

RING FRAME G 5/1Its objectives are:• Attenuate the roving until the

required fineness is achieved.• To impart strength to the fiber

strand by twisting it.• To wind up the resulting yarn in a

form suitable for storage, transportation, and further processing.

WINDING MECHANISM

This has to perform two movements:

a. Continuous rising and lowering in order to apply alternate main and cross windings (layering traverse) and

b. A continuous ascent in very small amounts after each layering traverse in order to fill the cop (switching traverse).

(a)

(b)

TECHNICAL DATADrafting arrangement- 3/3 double apron

Type of drafting arrangement- Pneumatic

Diameter- Top (mm) Bottom (mm)

Front 19 27

Middle 30 25

Back 28.5 27

Roller gauge- 42.5/60

Saddle gauge- 50.5/62

Ring dia- 42mm

Total draft- 26.67

Hank fed- 0.90

Hank delivered- 24s COM

No of spindles- 864

Spindle speed- 14600

Traveler speed- 32 m/sec

Tpi- 17.34

Production- 252.60 g/shift/spindle

AUTOCONER SCHLAFORST 338 TYPE RM

Its objectives are:• To make a bigger package which has much higher content of

yarn than bobbin.• To remove the faults that are generated in spinning i.e., thin,

thick and weak places

No. of machine sections- 6

No. of winding drums per section- 10

Total no. of winding drums on machine- 60

Creeling- Manual into circular magazines (6 pockets)Winding speeds- 1650 m/min

Diameter of drum- 95 mm

TECHNICAL DATA

CONDITIONING AND PACKING

Fig: Contexxor conditioning process by xorellaIts objectives are:• To improve the physical properties of yarn like strength, elasticity etc.• To minimize monetary loss by selling yarns with standard moisture content.

After this, the cones are brought in the packing department where they are weighed, the cartons are marked accordingly to yarn counts and then the cones are packed in cartons to export.

Temperature 550 C, 650 C (depending on the type of yarn being processed)

Pressure 130, 140 mBar

TECHNICAL DATA