YARN MANUFACTURING PROCESS

M.B.O
SORTING
BALE PRESSING M/C
BLOW ROOM
CARDING
BREAKER D/FRAME

SLIVER LAP M/C

LAP FORMER

RIBBON LAP M/C

COMBER
FINISHER D/FRAME
SPEED FRAME
RING FRAME
WINDING M/C
CONDITIONING
PACKING

KINDS OF COTTON USED :-

 INDIAN COTTON
IMPORTED COTTON
INDIAN COTTON TYPE
S-6

100%

S-6

ONGIN

S-6

ORGANIC

J-34

100%

DCH32

100%

DCH32

ONGIN

DCH32

ORGANIC

MCU-5

FAIR TRADE

MCU-5

100%

MCU-5

ORGANIC

IMPORTED COTTON
GIZA-86

EGYPT

GIZA-88

EGYPT

AKDLA

AUSTERLION

ULTIMA

U.S.A

PIMA

U.S.A

SICALA

DISCRIPTION OF M.B.O. :MANUFACTURE

LAKSHMI

MODEL

LB3/4 (YEAR 1997)

NO. OF M/C

OBJECT OF M/C : To make homogeneous mixture of different types of fibers.

Opening & cleaning of the material.
Mixing & blending of the fibers.

Removal of dust as a percentage of dust content of the fibers.

M/C PARTS: Feed lattice with conveyer belt,

Bottom feed lattice with conveyer belt,
Inclined lattice,
Stripper roller,
Evener roller,

Feed roller,

Saw tooth beater.

SORTING
OBJECT :To remove the contamination like hair, colour yarn, jute plastic,
polythin, sutli,etc.
PROCEDURE OF SORTING :FOR COTTON SORTING {PROCESS} 1.To hold the cotton in one hand & open the cotton slightly by other hand.

2. Then, to separated the contamination like hair, pouch, sutli, white plasti ,etc
in different places.
3. Kept the contamination in different places.
4. And after this procedure count to the register.
This process is done by manually.
No. of worker or sorter required for process= 30-40.

PROCESS SEQUENCE BALE (TO BE SORTED)--M.B.O. (MIXING BALE OPENER)-FIRST SORTING SECOND SORTING -TUFT IS FED TO BALE PRESS M/C
Sorting load acc. to mixing of cotton fibersMIXING
LOAD

A
90

B
60

C
45

D
35

E
30

NOTE:- Sorting load in kg/shift/ sorter.

CALCULATION:- If we have 32 sorter in a shift & work load is 90kgs , then how
to calculate the no. of bale.
No. of sorter = 32
Work load = 90kgs/sorter
Wt. of one bale = 170kgs
So, No. of sorter = no. of bale *wt. of one bale /work load
No. of bale = 32*90/170
=17 (approx.)

COTAMINATION SORTOUT IN 45KGS.

VARITY
J-34
S-6
S-6 OG
DCH32
MCU-5
MCU-5 SUPER
DCH32

TOTAL
123
149
105
255
461
234
178

STANDARD
131
169
114
271
495
252
189

EFFICINCY(%)
94
94
93
94
93
93
94

CONTAMINATION STANDARD IN KGS.

VARITY
J-34
S-6
S-6 OG
DCH32
MCU-5
MCU-5 SUPER
DCH32

TOTAL
113
135
101
237
405
208
154

STANDARD
131
169
114
271
495
252
189

BLOW ROOM DEPTT.

OBJECT :-

EFFICINCY(%)
86
85
89
87
82
83
81

 Opening of the raw material.

Cleaning of the raw material.
Mixing of the raw material.
To achieve the uniform yarn quality.
To avoid lot to lot variation.
Removal of magnetic material.
MATERIAL PROCESS FLOW IN BLOW ROOM M/CsBLENDOMAT (BDT)
SP-MF
MAXI FLOW
MPM8

MPM-8

CVT-1

CVT-1

SP-F

SP-F

The Factors which influence the opening and cleaning efficiency Position of m/c in blowroom sequence.
Penetration of opening spikes.
Angle of grid bars.
Speed of opening rollers.
Area of the grid surface.
Pre-opening of material.
Thickness of feed web.

TYPES OF PIPE USED IN B/R LINE Fire pipes

Material transfer pipes
Micodust pipes
Dropping waste pipes
& some ventilators

NO. OF WORKER IN blowroom = 3

Collection of waste from blow room =6%
Hygrometer type sensor is used in blowroom for atmospheric
conditions.
Relative Humidity (RH%)= 63*F
Temp. in blowroom

= 29*c

DESCRIPTION OF EACH M/C IN BLOW ROOM LINE

BDT(BLENDOMAT)
Manufacture

- TRUTZSCHLER

Model

- BO-A-2300(YEAR-2005)

No of m/c

- 1

Operation Performed Bale opening

Blending
Transfer of material to next m/c
Machine Parts :
Suction duct system
Truck
Suction duct for system covering
Tarret
Light burries station
Operators console
Detacher
Working area safeguard system or safety system for working area

TECHNICAL DATA :
M/C HEIGHT =2.90 mtr
M/C WIDTH = 5.16 mtr
Working height =1.70 mtr
Working length =5.81-45.41 mtr
Working width =1.60-2.20 mtr
Working speed =5-15 m/min.

Lifting speed

= 0.85-7.0 m/min.

Speed of toothed disc roll =1.5 rev./min.

Speed of supporting roll =12-36rev./min.
Suction duct unit has length = 2475 mm.
Air fan suction pressure =600-1050 Pa
No of sensor in m/c = 6
Wt. of machine = 2700kgs
Production of m/c =1000 kgs /hr.

The setting of BDT depending upon two factors :

Overall production of the unit,
Length of belt.

Suction duct
Truck :- It give way or it is help in moving to the machine from left to
right & right to left on laydown in straight manner.
Suction duct covering consist
Cover belt
Wind up device
Cover belt : one end is fitted at suction station & other end is on
winding roller.
Wind up device it is fitted on the truck.
Turret :- In inner suction system ,transformation of tufts from detacher
to inner suction system.

Pressure =0.6 kpa

Two guide rollers,
Two disc tooth rollers,
Two grid bar used below disc tooth rollers.

SP-MF (MULTI FUNCTION SEPRATOR)

MANUFATURER

TRUSTZSCHLER

MODEL

SP-MF(YEAR-2005)

NO. OF MACHINE

OPERATION PERFORMED : The pneumatic transport of open tuft material through pipe lines.
The intensive extraction of dust from draw in tuft material.
The separation of heavy material or particals from suction air stream.
Separation of metal particals.
MACHINE PARTS : Frame
Sheet metal cover
Doors
Fan (BR-FD 500)Drive
Metal detector
Sensor
Fire sensor/ detector
CO 2 Extinguish system

 Dust cage & finned stripper roller drive

Exhaust
TECHNICAL DATA :Inner frame width = 1000 mm
Machine width

= 1464 mm

Machine length

= 1100mm

Fan speed

= 1360-2960 rpm

Weight of machine = 580 kgs.

MAXI FLOW PRE-CLEANER

MANUFACTURER

TRUTZSCHLER

MODEL

- 0532501 (YEAR-2005)

NO. OF MACHINE

OPERATION PERFORMED
Removal of microdust particals.
Heavy impurities.
Removal of trash from fibers like seed, chaff(leaf ,stalk),dirt &dust,etc.
Removal of dropping waste.
MACHINE PARTS : Two beater (pin type) with drive
Grid bar
A/c motor
Frame
Material suction device

 Waste suction device

Inner sheet metal casing
Outer sheet metal casing
TECHNICAL DATA :Inner frame width

=1300 mm

Machine height

= 2100 mm

Machine width

=1464 mm

Machine length

= 1830 mm

Machine weight

=1500 mm

Dia. Of beater roller = 605 mm

Maximum output

= 850 kg/hr.

Fan speed

=1200 rpm

Beater speed

=780 rpm

Rotation speed limit roll = 1180 rpm

Inlet & outlet pressure difference = 100-320 Pa
Motor speed

= 1450 rpm

Motor rating

= 7.5 kw

Motor frequency

= 50 Hz.

The Grid Bar setting is adjustable & is adjusted acc. to the requirement of
running
Generally it is 2-3 mm.
CALCULATION : - Suppose rotation of beater is x in one min.& dia. of beater is
y Then, how to calculate the no. of beats/inch.
3.14 *y*no. of beats/inch =x

So, no. of beats/inch =x/3.14*y

MPM-8[MULTI PURUSE MIXER-8]

MANUFACTURER

- TRUTZSCHLER

MODEL

- MPM-8 (YEAR-2005)

NO. OF MACHINE

-2

OPERATION PERFORMED
Mixing to different type of cotton,
Stock to material into eight chamber.
Working details : The second concepts are multi mixer MPM-8 , it is available with eight
chambers. The tufts are once again into a m/c by a fan. The filling procedure &
control of the flaps are identical to the working of multi mixer MPM-8. The
difference between the blending channel underneath the opening rolls, there
is no conveyer belt. The MPM-8 works on the basis of a closed air circulation,
i.e the conveyer air entering the m/c also carries the material & feeds it into
the next m/c .
MACHINE PARTS :This machine is made up of three parts;

1.A storage unit /section ,

Eight chamber
2. An intermediate section ,
Two feed roll , One beater, Sensor
3.A delivery section ,
Air pressure are used for deliver to the material ,conveyer.
TECHNICAL DATA :- Air fan suction pressure =500 Pa

CVT-1( CLEANOMAT)
MANUFACTURER

TRUTZSHLER

MODEL

CVT-1 (YEAR-2005)

NO. OF MACHINE

OPERATION PERFORMED Cleaning of the material,

Removal of dust particals.
MACHINE PARTS : Feed lattic
Pressure roller
Feed roller
Roller [with two separating wings , two suction hood & one carding
segment].
Pressure roller.
TECHNICAL DATA: M/c Height

= 1250 mm & M/c width

= 1800 mm

M/c length

= 2400 mm

Connection pressure = 450 Pa [Project planning data]

Feed belt speed

= 0.75-15.17 mtr./min

Inside frame width [IFM] = 1200 & 1800 mm

Roll speed

= 1191-1213 rpm

Beater speed [fine tooth beater] = 900-1300 rpm

Inlet pressure[P1] = 138 Pa & outlet pressure[P2] = 868 Pa
Suction duct pressure = 100-750 Pa
SP-F [FOREIGN FIBRE SEPRATER]
MANUFACTURER

TRUTZSCHLER

MODEL

SP-F (YEAR-2005)

NO. OF MACHINE

OPERATION PERFORMED
Removal of dust particals,
Removal of dry & colored materials in fibers ,
Removal of all types of contamination like hair, colored yarn,etc.
MACHINE PARTS : Feed lattic
Pressure roll
Cylinder 1 (with two mote knives, two suction hoods, one carding
segment)
Cylinder 2 (with one mote knives, one suction hood, one carding
segment)
Cylinder 3 (with one mote knives, one suction hood)

TECHNICAL DATA : Maximum detection rate = 100-5000/hr.

Valve delay angle

= 90-180 degree

Beater speed

= 740 rpm

Detection/hr. per color

Red+

= 5000/hr.

Green+ = 1000/hr.
Blue+

= 5000/hr.

BLOW ROOM F.D.P.

LUWA ROTATARY PRE-FILTER

Dopping waste (maxi flow)

SP-F waste (line-1)
Microdust (CVT-1 line-2)
SP-F waste (line-2)
SP-MF (microdust)
CVT-1 dropping waste (line-1)
CVT-1 dropping waste (line-2)
CVT-1 (microdust)
M/F Microdust
VENTILATOR IN BLOW ROOM SP-MF

ventilator

MAXI FLOW

waste ventilator

MPM-8

front ventilator

CVT-1

waste ventilator

SP-F

ventilator

Fire

ventilator

VENTILATOR SPEED =MOTOR RPM* MOTOR PULLY /M/C PULLY

MACHINE
BDT-019
MPM-8
CVT-1
SP-F
Dust supply pressure = 50-200 Pa

MATERIAL SUPPLY PRESSURE(Pa)

600-1000
500
500
500

Dropping waste pressure = 750-1000 Pa

Pipe line used in blow room
Material pipe line (from-to)
BDT-SP-MF
SP-MF MAXI FLOW
MAXI FLOW-MPM8
MPM8-CVT1
CVT1 SP-F
SP-F - CARD

Diameter (mm)
330
300
300
300
300
300

Dropping waste line (from-to)

CVT Pre-filtter
CVT Microdust
SP-F Microdust
SP-MF & LVSB
MAXI FLOW waste pipe
Maxi flow microdust
Fire system

Diameter (mm)
250
300
280
300
150
300
300

CARDING SECTION
M/C SPECIFICATION
MANUFACTURER

TRUTZSCHLER

MODEL

DK800 (YEAR-2006)

NO OF MACHINE

9+1[DK780]=10

OBJECTIVES OF CARDING High degree of opening of fibers.

Removal of minute dust particals,
Disentangling of neps,
Fiber blending,
Elimination of impurities,
Elimination of short fibers,
Sliver formation.

Carding is the heart of spinning because above 90% impurities are

removed during carding.
MACHINE PARTS : Feed chute
Feed roller
Feed table
Licker-in
Mote knives
Stationary flats
Cylinder
Flates
Doffer
Grid
Stripper roller
Flat cleaning brush
Top plate
Suction hood
Cross roller
Trumpet
SFL [STATIONARY FLATS LICKER-IN SIDE]
SFD [Stationary flats doffer side ]
MACHINE PARAMETER Feed roller diameter =100 mm
Licker in diameter

= 253 mm

Cylinder diameter

= 1290 mm

Doffer diameter

= 680 mm

Cylinder speed

= 401-531 rpm

Doffer speed

= 851-1125 rpm

Flats speed

= 80-320 mm/min

No. of flats

= 84

No. of working flats = 30

Feed system

= chute feed

Can diameter

= 40 inch

Can height

= 45 inch

Width of web

= 830 mm

Delivery speed

= 115 m/min

SPECIAL FEATURES OFV DK800 CARD HIGH PERFORMANCE CARD.

AUTO LEVELLER IS USED.
CARD GAUGE SETTING
S.NO. SET POINT

GAUGE(Thou)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

4
40
40
40
7,8
18
55
10,8,8,8
12
40

Feed plate to feed roll

Feed plate to licker-in
Licker-in to wing
Licker-in to mote knives
Licker-in to cylinder
Cylinder to SFL
Cylinder to back suction
Cylinder to flat
Cylinder to SFD 64 PPSI
Cylinder to front top plate

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Cylinder to doffer
Cylinder to front bottom plate
Cylinder to back bottom plate
Doffer to stripper
Stripper roller to cross roller
Cross roller to web plate
Top calendar roll to bottom calendar roll
Cylinder pulley
Licker-in pulley
Flat pulley

5
14
40
6
6
40
6
210
260
180

CARD SETTING
S.NO.
1
2

WRAPPING
0.160
0.190

FBK PRESSURE(Pa)
400
220

No. of motor in a CARD = SEVEN

TEMP. in carding section is 30.2 degree
Relative humidity (RH%) in carding is 56.9 %

S.NO. WRAPPING
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

0.160
0.160
0.160
0.160
0.160
0.160
0.160
0.190
0.190
0.190
0.190
0.190

PRODUCTION
(KG/HR.)
15
18
20
22
25
30
35
10
15
20
22
25

DELIVERY SPEED(IN
RPM)
67
81
90
99
112
135
137
53
80
107
117
133

TECHNICAL DATA
Cylinder pulley diameter

= 175 mm

Licker-in pulley diameter

= 260 mm

Stripper roller diameter

= 120 mm

Cross roller diameter

= 90 mm

Working width of card

= 1020 mm

Working width of tuft feeder

= 920 mm

Machine weight

= 7300 kgs.

Machine width

= 1994 mm

Machine length

= 5650 mm

Production/SHIFT

= 275.25 kgs/shift

Production/hour

= 34.40 kg/hr.

Height of FBK

= 2625 mm

Height of machine upto flats

= 1900 mm

Width of coiler

= 1940 mm

Draft given by card

= 60-200 Fold

Length of sliver per can

= 8100 mtr.

Wt. of sliver per can

= 25.17 kgs

Hank of sliver

= 0.190 Ne

Linear density of sliver

= 3.21 gms/mtr.

Fineness

= 0.084-0.295 Ne

FBK Pressure

= 0-999 Pa

Floor load

= 8520 N/m2

Operating pressure

= 600-1200 Pa

Flat & licker-in suction pressure = 400 & 700 Pa

CARD CLOTHING DETAILS

Cylinder wire - T20.30.040.0950
Height =2 mm

Angle = 40 *

Thickness = 0.04 mm

No. of teeth = 950/sq. inch

Doffer wire - N.40.30*0.9

Height = 4 mm

Angle = 30*

Thickness = 0.09 mm

No. of teeth = 367/sq. inch

Flat wire - Nova 55

No. of teeth = 150/sq. inch
Licker in - E.5010-8VG
[ Saw tooth type ]
No. of teeth = 210/sq. inch
SFL Teeth

= 240/sq. inch

SFD Teeth

= 640/sq. inch

Life expectancy Licker in

= 225 ton

Doffer

= 1500 ton

 Flat

= 700 ton

SFL

= 250 ton

SFD

= 450 ton

DRAW FRAME SECTION

BREAKER D/FRAME
MANUFACTURER

- LAKSHMI RIETER

MODEL

- LD0/6 (YEAR-2000)

NO. OF MACHINE

- 2

FEATURES OF LD0/6 Automatic can changing mechanism.

It has 3/3 pressure bar with pneumatic loading .
The sliver delivered from pneumatic loading calendar roller
through coiler into revolving can.

 Top stripper to clean top roller.

Bottom stripper with suction hood are used to clean the

bottom roller.

MACHINE PARTS
Creel
Feed roller
Auto leveler
Feed plate
Drafting rollers
Condenser funnel
Coiler trumpet
Pressure arm (Pneumatic)
Two coiler heads

TECHNICAL DATA
Input material

card sliver

No. of doubling

= up to 8

No. of coiling heads

=2

Total no. of cans

= 12

Roll gauge

= 46/50

Creel tension gear wheel = 70,71,72 Teeth

Draft range

= 2-12

Feeding speed

= up to 42.5 gm/mtr.

Delivery speed

= 240-500 m/min.

Draft tension :
Main draft

= 40-80 mm

Break draft

= 36-90 mm

Trumpet size

= 3.5 mm

Production

= 180-360 kgs/hr.

Machine weight

= 2440 kgs

Can size at feed :-

Can diameter = 600 mm

Can Height

= max. 1200 mm

Can size at delivery :Can diameter = 350[,400,450,500 ] mm

Can height
Output material

= 914-1200 mm

= draw sliver

DRAFTING : Drafting system

= 3/3

Pressure supply

= Pneumatic [6 bar ]

Load on drafting rollers

On 1st & 2nd top front roller = 3-4 bar
On 3rd top back roller

= 2-3 bar

Pressure on calendar roller = 0.5-2.5 bar

Can changer
Drafting rollers : -

= 4-5 bar

Top roller cot size (mm) :- 39*39*39 [ T1, T2, T3 ]

Bottom rollers size (mm) :- 52*28*28 [ B1, B2, B3 ]
Top roller hardness : = 70* SHORE
Top rollers rubber coated,
Bottom roller are of hardness steel fluted rollers
CHANGE POINTS AT D0/6 Draft change gear[DCCP]
Draft range change gear [CP]
Break draft change gear A & B.
Feed change gear
Can change gear E &F .
Delivery change gear, coiler wheel change gear C & D.
Motor belt pulley.

DRAFT RANGE CHANGE GEAR

DRAFT
3.7-5.1
4.9-7.0
6.3-9.1
8.0-11.0
MAIN DRAFT

DCCP GEAR
82 TEETH
63 TEETH
48 TEETH
38 TEETH
= 4.9

CHANGE PINION = 92 T

E/F COMBINATION =52-110 T

E/F COMBINATION CHART
COUNT RANGE
20
25-30
30-40
50-78
70-80
ABOVE 80

E/F COMBINATION GEARS

40/73
50/63
38/75
35/78
35/78
27/86

BREAK DRAFT CHANGE GEAR

DRAFT A/B GEAR
61/65
65/61
56/70
70/56

BREAK DRAFT
1.28
1.51
1.71
2.0

DRAFT = FEED WPG. *NO. OF DOUBLING / DEL. WPG

DEL. SPEED = WT. OF SLIVER FEED* DOUBLING /DRAFT

SPECIAL FEATURES OF DO/6 LMW : Mainly use for synthetic & also use to cotton
Use for blending
Double line feeding
Double delivery
Easy to operate
Auto doffing system is used , pneumatic loaded calendar roller for delivery
hence compression takes place , flies on suction fan hence it is necessary to
clean up to 45 min.

Stop motion checking

Creel stop motion
Coiler stop motion
Roll lapping stop motion.
Machine cleaning schedule
PARTS
Roll interchange
Coiler cleaning
Fan waste
Roll washing
Drafting zone
Creel cleaning

SCHEDULE
2hrs
24hrs
30min.
24hrs
2hrs
Every batch

LAP FORMER LH-10

MANUFACTURER

- LAKSHMI

MODEL

- LH-10 (YEAR-2005)

NO. OF MACHINE

FEATURES OF LH-10

--

Double feeding creel

Two feeding heads
11/11 doubling of draw slivers

TOOLS
By hand
Water & cloth
By hand
Water & cloth
Cleaning gun
Cloth & Cleaning gun

 Auto doffing system

MACHINE DATA -Drafting system

= 4/4 (with pressure bar)

Total draft

= 1.2 -2.26

Top roller loading

= spring loading system

No. of drafting heads = 2

Doubling

= up to 28 slivers

Del. Speed (max.)

= 120 m/min [Depending on raw material ]

Can size -- can diameter

Can height

=up to 40 inch
= up to 48 inch

Lap width

= 300 mm

Max. lap diameter

= 600 mm

Lap sheet weight

= 60-80 gm/mtr.

Lap weight

= 15.40 kgs(with spool)

Break draft

1.042

Draft distance -MAIN DRAFT

= 40-60 mm

BREAK DRAFT

= 40-60 mm

Compressed air requirement :System pressure

= 7 bar

Operating pressure = 6 bar

Air consumption pressure = 3 Nm3/hr
Top rollers buffing :

Hardness

= 83*

Color

= grey

Quality

= antistatic

Quality code = Lakshmi day 890

Minimum dia.

= 36 mm

Maximum dia.

= 39 mm

Grinding dia. in mm = 0.2 mm

Total draft = Doubling * feed in gm/mtr./del. Lap wt. in gm/ mtr
Ex. T.D. = 26*4.54/80 =1.48
SUCTION POINT IN MACHINE : Spool suction
Main cylinder roller suction suction
Anti lap licking suction
Table calendar roller suction
Drafting roller suction .
CLEANING SCHEDULE OF MACHINE
PARTS
Drafting zone & stripper
Drum cleaning stripper
Fan waste
Creel & table cleaning
Lap forming unit
Head stock inside the
cover
Creel
Ball washing

SCHEDULE
8hrs
24hrs
8hrs
8hrs
8hrs
24hrs

TOOLS
Cleaning gun
By hand
By hand
Cloth & cleaning gun
Bamboo stick
Cleaning gun

After a batch
24hra

Cloth & cleaning gun

By cloth

SLIVER LAP MACHINE

MANUFACTURER

- LAKSHMI

MODEL

NO. OF MACHINE

LE2/4a (YEAR-2000)
1

FEATURES OF SLM
Drafting is pneumatically weighted.
Lap weighted is performed on a patented automatically
system.
Antifriction bearing with continuous lubrication have been
used wherever possible

MACHINE TECHNICAL DATA

SLIVER FED WRAPPING

= 0.120-0.180

Wt. of sliver fed

= 75-120 gm/mtr

Cleaning efficiency

= 70%

Draft

= 1.5-2.0

Lap weight

= 50-75 gm/mtr

Lap width

= 250mm in case of feeding to RLM

&

300mm in case of feeding to comber

direct
Lap weight

= upto 13 kgs

Working speed

= 65 m/ min

Drafting system

= (pneumatic)4/6

Draft constant

= 1.35

Throttle disc dia.

= 1.8-2.00mm

Doubling

= 21 [11+10]

WEIGHT OF THE MACHINE & ITS COMPONENTS :Auto lap

1440 kg

Drafting system

490 kg

Table

240 kg

Total m/c weight

2170 kg

Compressed air pressure = 6 atu

Del. Speed

= 50-65 m/min

Motor pulley dia.

= 140,170,185 mm

Total draft

= input in gm/mtr /output in gm/mtr

Motor speed

= 1440 rpm

Frequency

= 50 hz

M/c width

= 2260 mm

Can dimensions =>16-40 inch & upto 50 inch (1250mm) high

Machine cleaning schedule
PARTS

SCHEDULE

TOOLS

CREEL & TABLE

8 HRS.

WATER & CLOTH

8 HRS.

WATER & CLOTH

DRAFTING ZONE

2 HRS.

CLEANING GUN

TOP ROLL WASHING

24 HRS.

WATER & CLOTH

BELOW &

8 HRS.

CLEANING GUN

CLEANING
BOTTOM PATELI &
DISC SIDES

SURROUNDING M/C

STOP MOTION CHECKING once in a shift

Creel stop motion
Drafting stop motion
Roll lapping stop motion.

RIBBON LAP MACHINE

MANUFACTURER

- LAKSHMI

MODEL

- LE2/4a

NO. OF MACHINE

- 1

MACHINE PARTS : Lap feed roller

Drafting system
Feed table
Feed roller calendar roller
Lap roll
Spool supporting plate
Guide roll

Machine technical data : Length of machine

= 5275 mm

Width of machine

= 2907 mm

Machine weight :

Auto lap

1450 kg

Head stock = 550 kg

Roller & its support = 900 kg
Total m/c weight = 2900 kg
Weight of lap fed = 50-75 gm/mtr
Weight of lap deliver = 50-75 gm/mtr
Working speed
Draft

50-65 m/min

= 5-8

Max. lap dia. = 450 mm

Lap width

= 300 mm

Drafting system

= pneumatic

Compressed air pressure = 6 ate

Quantity required
Motor speed

=1.2 Nm3/hr.
=

960 rpm

The v-pulley are changed on the for changing the delivery speed
Delivery speed (mtr/min)
50
60
65

Motor pulley mean dia. (mm)

140
170
185

Change wheels & change gears :Change gear position

Chain wheel at calendar roller =24-25 T

Chain wheel at rear lap roller

= 76 T

Chain wheel at front lap roller = 77-78-79 T

Draft change gear (Wn) =53-75 T (4TH roller)
Feed change gear (We) = 60 -64 T
Table draft change gear (Wt) = 79-83 T
Del. Tension change gear(Wa) = 79,80,81 T
Double gear for break draft

= 35/40

Break draft =1.34,1.02

Chain wheel
For lap roll drive , the following different chain wheels are sent
Chain wheel at coupling

= 24/25 T

Chain wheel at lap roller = 77/78/79 T

As per experience , we select the following chain wheels
For coupling (1) = 25 T
Rear lap roll

= 76 T

Front lap roller

= 78 T

If the machine is operated with light drafting , the wheels 24 , 76 &

77 are to be used .
Distance between top edge of the saddle top cleaning device shaft
=95T
DRAFTING ARRANGEMENT :-

These rows of top roller with synthetics covering are loaded over
four rows of bottom fluted rollers. The nipping distance are
adjustable between 3& 55mm in the break draft zone so that all the
fiber length can be processed & in main zone it is 30 & 54 mm are
adjusted .

FORMULA
Total draft = feed gm/m *doubling/del. gm/m
Draft change gear = total draft / break draft *constant of main draft
Cleaning schedule of RLM M/c Creel & table cleaning
Drafting zone
Top & bottom clearer
cloth
Disc sides lap
formation unit
Top roll washing
Below & surrounding
m/c

2 hrs
2 hr
8 hrs

Cloth &cleaning gun

Cleaning gun
By hand

8 hrs

Cleaning gun

24 hrs
8 hrs

Water & cloth

Cleaning gun

COMBER
Name of
machine
Comber

Model
E 65
E 66
E 60 H

No. of machine Manufacturer

(RIETER)
2
Year- 2004
1
Year 2010
3
Year -1997

OBJECTIVES OF M/C
The main object of comber is to remove short fibers.
Straightening & parallization on fiber
Upgrade raw material
Yarn evenness
Strength
Cleanliness
Visual appearance
Smoothness
Requires less twist than carded
Removal of neps .
MACHINE PARTS : Lap roller

 Feed roller
Nipper
Top comb
Bottom roller
Detaching roller
Web condensing tray
Sliver plate
Delivery roller
Table cylinder
Sliver guide
Trumpet drafting zone
Calender roller
Coiler trumpet

Unilap

TECHNICAL DETAILES OF COMBER E65 RIETER

420V 50 HZ
MXG.

6 BAR

= PIMA 100 %

Sliver hank

= 0.180

Feed system = backward

Roller gauge

= 46

Coiler trumpet

= 4.0

Production

= 30 kg/ hr

Delivery speed

= 158 mtr/ min

No. of laps feed per machine

= 8

Drafting arrangement =3/3

Noil (%)

= 20%

Top comb depth

= + 0.5

Top deteching roller dia. = 23 mm

Circular comb brush dia. 110 mm
Speed of comber

=350 nips/min (250-500nips/min)

Noil Index = 10.5

Feed per nip

= 4.7 mm (4.3-5.9 mm )

Total Draft (GV) = 9.12-25.12

M/c efficiency
Top comb teeth

= upto 75 %
= 35 teeth/cm.

Sliver wt. at delivery = 3-6 ktex

Noil extraction ( % ) = 8-25 %
Drafting system load per top roll
Break draft ( VV) = 1.13-2.0

Main draft distance :-

= 650-900 N

Setting gauge

= 41-60 mm

Gauge dimensions A= Nipping line distance minus 41 mm.

Break draft gauge dimensions =44-66 mm
Feeding :Lap outside dia.

= 650 mm

Tube/spool outside dia. = 250 mm

Tube length

= 300 mm

Can dimensions :Can table (C) = 25 mm

Can dia.(D) = 600 mm
Can height (h) = 1200 mm
Total machine weight = 4600 kg
Batt tension

60-80 ktex

Floor load

= 10600 N/m2

Force of can spring

Can length
Feed tension

10000 mtr
= 10 %

Top comb density

Piecing index

= 3.5

= +0.3

Drafting trumpet
Table trumpet

= 855 N

= 7.0 mm
= 4.0 mm

Drafting rollers
Top rollers dia. : - T1 = 39 mm
T2 = 39 mm
T3 = 39 mm

Bottom rollers dia.

B1 = 35 mm ,

:B2

= 27 mm , B3

= 27 mm

Break draft change gear

Gear C
59.0
64.9
71.9
78.8
86.9
96
105.7

Break draft
1.13
1.24
1.34
1.50
1.65
1.82
2.0

Main draft change gear Main draft

12.04
12.67
12.84
13.54
14.25
14.59
15.20
15.89
16.55

Change gear A
38
40
48
45
45
40
48
33
33

Change gear B
38
38
45
40
38
33
38
25
24

17.27
17.51
18.30
19.26

33
48
38
40

23
33
25
25

Feed per nip change gear Ratchet Wheel Feed /nip

4.3
4.7
5.2
5.9

R.W.
22
20
18
16

Feed change gear

62
56
52
45

Change places in comber

All change places in the delivery assemble are really accessible they
are as follows
N COUNT CHANGE
Z - FEED CHANGE
S - RATCHET WHEEL TO FEED ROLLER
V - WEB TRAY DRAFT CHANGE
Prduction of the comber is dependent upon the following :N- Nips per min
S Feed in mm/ nip
K- Tension draft between lap & feed roller [1.05-1.1 ]
G- lap wt. in gm/ mtr
Stop motions

 Lap exhaust stop motion

Opened up detaching roller
Sliver break at coiler
Jam in detaching roller
Sliver break at condensing roller
Sliver break at condensing roller
Cleaning schedule of E 65 RIETER Parts
Coiler cleaning
Top comb
Nipper
Detaching roller area
Roll washing
Wash
duct,front&back
Side cover
Drafting zone

Schedule
24 hrs
4 hrs
24 hrs
8 hrs
24 hrs
8 hrs

Tools
Water & cloth
Top comb brush
Cleaning gun
Cleaning gun
Water & cloth
----------

48 hrs
2 hrs

Vacuum
----------

SPECIAL FEATURES OF E 65 Latest machine

3/3 drafting arrangement
Better reducing the noil %
Easy to operate
Upgraded monitoring display.
COMBING CYCLE IN CASE OF BACKWARD MOVEMENT

 Detaching
Nipper move in backward
Same time feeding
Gripping
Combing
In backward movement or feeding system the removal of
short fiber are higher as compare to forward feed system .
In comber there are two important index which give improvement
in efficiency of machine
NOIL INDEX This index is used to control %age of short fiber
in material .
PIECING INDEX It is use for maintaining length of cut lap
before detaching roller for over lapping.
PRODUCTION CALCULATION :PRODUCTION =feed/nip *nip/min*60*8*efficiency*no. of
heads*(1-noil%/100)*(1-bett tension/100)/36*840*2.2*wpg.

DRAW FRAME FINISHER

MANUFACTUER

--

MODEL

--

NO. OF M/C

--

RIETER
RSB-D40[YEAR-2006]
3

OBJECT
To reduce weight per unit length of sliver.

 To improve the regularity of fibers by drafting & doubling

To parauelize them to their neighbours
To straightened out the fibers into fibers exient
To mixing different type of fibers so as to give a
homogeneous blending

TECHINCAL DATA
Drafting system

--

4/3

Doubling

--

10

Efficiency

--

75%

Production

--

30-80kg/h

Front roll dia.

--

38mm

Middle roll dia.

--

30mm

Back roll dia.

--

30mm

m/c height

--

1860-2515mm

Roll gauge

--

46/50

Del. Speed

--

250-1100mtr./min

Feed sliver wt.

--

12-50ktex

Del. sliver wt.

--

1.25-7.00ktex

Draft (v)

--

4.54-11.56

Fibre length

--

max. 80mm

Can dia.

--

210-1000mm

 Can height

--

900-1520mm

Scaning roller dia.

--

60mm

Feeding rate

--

300-400mm/min.

Main draft distance (hvd) -- 35.5mm

Break draft distance (vvd) --

36-40mm

Drafting system pressure in newton Back ,middle & del. top roll pressure -- 320-440n
Top roll cot dia.

--

36-38mm

Top roll length

--

100-160mm

Grinding disc dia.

--

200-500mm

Grinding disc width -- 25-45mm

Circumference speed of grinding disc
2000mtr./min
Rpm of spindle shaft

--

300-500u/min.

Trumpet size

--

28

Pressure bar setting

W1
VZW

--

39/52

Width of scaning roll

--

4.0-11.0 mm

99
0.99

1800-

-- 6.0

Nw 1 / Nw 2

98
0.93

--

100
1.00

101
1.01

102
1.02

103
1.03

W2
VZ

52
1.00

W8
VA

75.2
0.99

W4
VV

51.5
1.01
74.4
1.00

(54.6) (57.2) 59.8

(1.05) (1.10) 1.15

W4
VV

83.2
1.60

WHERE , VV

73.7
1.01
(62.4) 68.0
(1.20) 1.25

51
1.02
72.9
1.02

(67.6) 72.8
(1.30) 1.40

88.4
1.70

-- Break draft

V&GV

-- Total draft

HV

-- main draft

SPEED FRAME
MANUFACTURER

- LAKSHMI

MODEL

- LF1660(YEAR-2005)

NO. OF MACNINE

- 4

OBJECT :-

72.2
1.03

93.6
1.80

(78.0)
(1.50)

The object of the speed frame is to produce out of the draw sliver to
a well prepared roving of required hank of a well built bobbin for ring
spinning frame.
FUNCTION OF SPEED FRAME : DRAWING - To parallise the fibers upto optional level.
TWISTING To impart necessary strength to roving .
WINDING- To pul;l the suceesive layer on the bobbin at a
proper rate of speed.
Building To shorted successive layers to make conical ends on
the package of roving.
MACHINE PARTS : CREEL
PATELI CLOTH
CRADLE
TOP & BOTTOM R
TOP & BTTOM APRONS
SPACER
TWIST MASTER
FLYER WITH BOBBIN SUPPORRTING ROLL
SPINDLE
LIFTER RAIL
SLIVER GUIDE
CONDENSOR

 TOP ARM/SADDLE
NOSE BAR
TENSIO PULLY
TECHNICAL DATA OF LF1660 :These m/cs are only built with the drive to the right i.e. the head
stock is on the right when looking at the delivery.
Spindle gauge

= 121.83

No.of spindle

= 120

Bobbin size

= 16*6 inch

Flyer speed mechanically possible = 1400 rpm (max.)

Production

= 50 m/min

[under favourable marginal condition ]

Draft

= 9-24

Count = >
English (Ne)

= 0.5 to 3.0

Metric (Nm)

= 0.85 to 5.0

Drafting arrangement Guide saddle

Drafting arrangement with 3 or 4 rollers, weighing arm for
two spindle ,double aprons , 36,43 & 50 mm cage .
Positively revolving clearer cloth for both top & bottom rollers
Top apron size

= 37*30 mm

Bottom apron size = 86*30 mm

Total weight of machine = 12950 kg

Motor speed = 700-1400 rpm
Flyer speed

= 800 rpm

Supply pressure of drafting system 5-6 kg/cm2

Meaning of lamps when flickering

Green Doffing or trough manual operation
Orange Roving break
White Sliver break
Bottom apron thichness = 0.86 to 1.04 mm
Top apron thichness
Top roll hardness
Roll gauge

= 0.86 to 1.04 mm
= 83* Shore

= 47-55-48

Top roll dia. = 30 mm

Break draft = 1.05 to 1.10 (for cotton) [& max. 3.0]
Delivery condenser = 7.5 mm (Green)
Wt. of empty bobbin = 200 gm
Length of roving on one bobbin = 2020-5300 mtr
Twist per inch = 1.51
Spacer = 3.5 mm
Bottom roller type = fluted

Bobbin dia.

= 152 mm

Tension draft

= 1.086

Main draft

= 10

Preliminary draft (between 3rd & 4th roll ) = 1.66

Machine length = 7*1461 mm (96-120 spindle)
Machine width

= 3643 mm

Set tension = 3.12

Cop content = 1616 gm/spindle
Doff length = 5200 mtr
No. of layers on bobbin = 118
Lifting wheel = 20 to 42 T
Twist wheel = 30 to 55T
Twist combination wheel = 65/35 T
BDCP GEAR = 50 to 72 T
Change pinion = 30 to 56T
TPI/TM = 1.166/1.951
Creel wheel = 40 to 48 T
Flyer gear belt length = 960 & 840 mm
Pateli cloth length = 815 mm
Main formulae :Creel tension draft = 40.88 *creel wheel

Break draft = 66.82/BDCP

T.W. = 34.552(h/g)/TPI, where (h+g=102)
Main draft = 63.48*(r/l)/C.P.
Where ,r/l = draft combination & r+l =150
Middle draft zone = 1.087
Total draft = main draft * break draft
L.W. = 12.18 *E/F *B1/root count

STOP MOTION AT SPEED FRAME Sliver break stop motion

Bobbin brust stop motion
Full doff automatic stop motion

CHANGE POINTS Twist change change gear

Lifter change gear
Main draft change gear
Break draft change gear
Creel tension draft change gear

RING FRAME
MANUFACTURER
SET]

- LAKESHMI [SUSSEN ELITE COMPECT

MODEL

- LR6/A (YEAR-2006)

NO. OF MACHINE

- 17

MACHINE PARTS: CREEL

HOLDER
HANGER
ROVING GUIDE 3 IN 1
DRAFTING ROLLERS
APRON
CRADLE
SPACER
LAPPET
SPINDLE
TOP ARM/SADDLE
RING
ABC RING
FLY CATCHER

 TRAVELLER
DOFFING RAIL
SPINDLE TAPE BELT
TIN ROLLER
SUCTION TUBE
ELI TUBE & ELIED APRON
COTS ROLLER
JOCKEY PULLY
NOSE BAR
SPINDLE WHARVE
POSITIVE CLIP RING
RAIL RING
SEPARATER PLATE
SPINDLE BRAKE
M/C TECHNICAL DATA :Bottom roller dia.(In mm) => B1=30 , B2 =27 ,B3 =30
Top roller dia. (in mm) => T1 =32 , T2 27 ,T3 =32
Cradle length = 36 mm
Total draft = up to 60
Break draft = 1.07 to 2.24
Spindle gauge = 70 & 75 mm

LOADING TOP ARMS :The loading top arm are loaded pneumatically. The hose pressure
can be adjusted with reducing value in the head stock .
The pressure indicated in table below give a loading of 150-180 N(1518 kp) per front top roller shaft .
Spacer = 2.5-7.0 mm
Top apron length & width = 37*30 mm
Bottom apron length & width

= 73*30 mm

Spindle pitch
70
75

Pressure
2.1-2.3
2.0-2.2

Twist change gear (A+B) = 165 T

Twist range change gear (C+D) =137 T
Total draft constant = 10.519
Change gear for winding length (E+F) = 113 T
Break draft change gears std. = 32-62 T
Draft change gear (G+H) = 130-175 T
Spindle wharve dia. = 21,19 & 18.5 mm
Twists :TPM (Twist per meter) = 140- 2550
TPI ( Twist per inch) = 3.55-64.77
SPINDLE SPEEDS :-

Mechanically up to 18000 to 25000 rpm.

Drafting system = 3/3
Spindle taper = 1:40 & 1:64
Spindle tube l;ength = 180 250 mm
Ring dia. Standard (in mm) =>
36,38,40,42 & 45
Ring flange width =>
Flange No. 1 ( b=3.2 mm )
Flange No. 2 ( b =4.0 mm)
Pendulum gauge =>
Long spinning angle = 440 mm
Short spinning angle = 375 mm
Inclination of drafting arrangement = 60* (degree)
Height of separators plate = 233.90 & 185 mm
Material of top roller = synthetic rubber
Material of bottom roller = stainless steel
Surface of top roller = plain
Surface of bottom roller = fluted
Total No. of ring frames = 17
No. of spindle ( in one R/F) = 864
COUNT SPUN = 50, 60, 70, 80, 100, 120 & 140 Ne

Hank of roving fed = 0.8-1.5

Delivery speed = 6-17 m/min
Fly catcher gauge = 1.6 mm
Ring dia. = 38 mm
ABC RING DIA. USED = 36.7 mm
Eli tube length = 180-260 mm
STANDARD SUPPLY ALONG WITH EACH MACHINE :-

BREAK DRAFT

BREAK DRAFT CHANGE GEAR FOR

FLUTED ROLLERS
DIA. 27 (B1 )

DIA. 30 (B3)

1.14

59

53

1.24

54

49

CHANGE POINTS AT R/F M/C =>

Twist change geart A/B & twist range change gear C/D
Change gear E/F for winding length
Ratchet wheel for ring rail drive
Draft chnge gear G & maitin g gear H
CP & BRW for total draft
Changing the spindle twist direction Z or S
SPINDLE RPM.
CALCULATION OF R/F =>

TPI = TM UNDER ROOT COUNT ,where TM = Twist multiplier

TPM = TPI *39.37
Twist constant = TPI*Twist wheel
F.R. Del. SPEED =SPINDLE SPEED/TPI
PRODUCTION = F.R. DELIVERY
*60*8*EFFICIENCY/36*840*2.2*COUNT (IN KG/SPINDLE/SHIFT)
BOBBIN CONTENT (GMS) = 3.25*LD square , where l =lift in inch ,D=
dia.of bobbin in inch
MAIN DRAFT = B/W FRONT ROLLER & BACK ROOLER
BREAK DRAFT = B/W MIDDLE ROLLER & BACK ROLLER
TOTAL DRAFT = B/W FRONT ROLLER & BACK ROLLER
DRAFT CONSTANT = DRAFT*C.P. where, C.P. = change pinoin
SPACER:Spacer adjust distance b/w the top & bottom aprons is adjusted
with snap on spacers.
SPACER
2.50
2.75
3.00
3.25
3.50
3.75
4.00
4.50
5.00
5.50
6.00

COLOUR
Brown
Dark Grey
Natural White
Yellow
Black
Cream
Red
Green
Blue
Grey
Cream

7.00

Yellow

APRON DIMENSION TABLE :TOP APRON

BOTTOM APRON

CRADL
E

INSID THICHNES
E DIA. S

WIDT
H

INSID THICHNES
E DIA. S

WIDT
H

36

39.2

1.05

29.75

80.5

1.05

30

43

43.3

1.05

29.75

82

1.05

30

59

53.8

1.05

29.75

89

1.05

30

Twist
range
change
gear

Twist change gear (B+A= 165T)

B

76

77

78

79

80

D & C= 137 A
T

89

88

87

86

85

TWIST PER METER (TPM)

102

35

2439

2499

2561

2624

2688

98

39

2103

2155

2262

2262

2318

91

46

1656

1696

1738

1781

1825

82

55

1248

1279

1310

1341

1375

72

85

927

950

973

947

1022

65

72

756

774

793

813

800

Break draft change gear :BDCP

Br.draft
BDCP
Br.draft

32
2.09
57
1.17

33
2.03
58
1.15

34
1.97
59
1.13

35
1.91
60
1.11

Signal lamps (Tail stock & head stock )=>

RED OFF M/C normal running/mains off
RED ON - Machine fault or machine off
RED Short flash (1sec)- doff
RED LONG flash (2sec) emergency off

55
1.22
61
1.09

56
1.20
62
1.08