0

A SUMMER INTERNSHIP PROJECT

REPORT

ALOK INDUSTRY LIMITED SPINNING DIVISION SURVEY NO

412/ 1-2 RAKHOLI SAYLI ROAD SILVASSA 396230(D&N.H)

UNDER THE GUIDANCE OF

Mr.S.T.JHADHAV (DEPUTY GENERAL MANAGER.

Mr. RADHEYSHYAM NAYAK (CHIEF MANAGER H.R.)
Mr. B.L.GAUTAM (TRAINING EXECUTIVE)

SUBMITTED BY

KAUSHAL KISHOR
B.TECH
TEXTILE TECHNOLOGY

UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE,

KANPUR(U.P.)
1

ACKNOWLEDGEMENT
We would like to express our gratitude towards Mr.S.Bannerjee for
allowing us for summer training in Alok Industry. We pay our thanks
to Mr. S.T.Jadhav(Deputy General Manager),Mr. Mandar
Kulkarni(Deputy Production Manager),Mr. Ranjith
Surendran(Deputy Maintenance Manager ),Mr. Rajnikanth
Tripathi(Quality Assurance Department), who gave their valuable
time & attention on us during training. Their instructions are very
beneficial for getting the practical knowledge.
The services of all the employees, especially the technical staffs are
hereby acknowledged with thanks.
We are really very thankful to our institute (U.P.T.T.I.) for providing
us the opportunity of getting the practical knowledge,under the
direction of our most respected
Director DR.MUKESH KUMAR SINGH
,DR.J.P.SINGH(Training&Placement Coordinator)
We have got full support & instructions from Mr B.L
Gautam(training executive) for the preparation of the project during
training. We have also got full support from our teachers of our
institute.
We are also very thankful to whole Alok Industry for providing us the
best facility & good environment during the training period. We
express our gratitude to each & every employee of Alok Group for
their co-operation & valuable time.

SUBMITTED BY :-

Kaushal kishor
2

COMPANY PROFILE

Bench marking standard speed, innovation in technology and quality,

consistency and punctuality, Alok offers world class integrated textile
solutions.
Keeping itself abreast with the international trends in fabrics fashion
and technology Alok possesses vertically integrated, state of the art
production facilities for home textile, woven and knitted apparel
fabrics, garment and polyester yarns.
Today, Alok has emerged as one of the India’s leading textile
group.

ORIGIN AND GROWTH:-

 Incorporated in state of Maharashtra as a private limited company on

12 march 1986 in the name of
“Alok Textile Private Limited”.
 Alok began with the texturising of yarn and steadily expanded to
weaving, knitting, processing, home textiles and readymade garments.
 Its first share cost was 10 rupees per unit and total share released by
company was 20 lakhs 50 thousands.
 Name of company was changed to “Alok Textiles Industries Private
Limited” on 17 November 1992 and then converted into public limited
company on 11 February 1993.
 Subsequently on 8 November 2000 name of company was changed to
“Alok Industries limited”.
3

Alok’s Vision
To be the world’s best integrated textile enterprise, driven by research
& innovation, with a leadership position across & stakeholder
expectations.

Alok’s Mission
We will:

 Be a knowledge leader & an innovative in our business

 Maximize people: development initiatives
 Optimize use of all resources
 Become a process driven organisation
 Exceed complains and global quality standards
 Actively explore potential marker and products
 Offer innovative customised and value added service to customer
 Be an ethical, transparent and responsible global organisation.

ALOK INDUSTRIES LIMITED

FEATURES
 Integrated textile solution
 Economies of scale
 State of the art machineries with latest technology
 Wide range of products
 System and product certification.
 Design archive & product development.
 Alok and organic footprints.
 Sustainable growth.
4

Alok’s Values
 Customer satisfaction

We will be attuned to market needs, wherever possible, we will

anticipate market needs, we will respond quickly to the changes in
the customer requirements, we will completely focused on quality, we
will keep delivery commitment on time and every time.

 Passionate about excellence

 Excellence is non negotiable in every aspect of our business
process superior quality of performance is critical to our business
growth and success. We will constantly strive to exceed expectations:
be it internal or external.

 Develop Human Capital

We will empower, energize and inspire our people to perform

beyond the best; we will create empowered teams that take informed
decision; we will recognise and leverage skills and strength of various
teams; we will enable sharing of knowledge; we will create an
adequate ‘bench strength’ that will take care of changes in business
scenarios.

 Fair to all

All our actions will be determined by fairness; we shall be fair to our

customers, vendors, shareholders, all our business partners and society
at large. Fairness is not just sticking to the letter of the law or the
contract but appreciating its spirit and basing all our actions on being
fair to the spirit of that understanding.

 Concern for the environment and the community

We will take the utmost care of our environment and the the
communities in which we operate; we shall nurture our environment
5

and its natural resources and shall ensure that none of our actions
deplete or pollute them;
Safety and health

We will provide a safe workplace. We will promote the health and well-
being of our people and their families. Wewill encourage healthy work
habits and a work-life balance. We believe that working safely and
protecting the health of our people is working smart and creates
greater and more sustainable wealth.

 Responsible Corporate Citizen

We recognise that we have our responsibilities towards the society in

which we operate. We commit ourselves to be a responsible corporate
citizen; our activities should not only create share holder wealth, but
also community wealth

Alok’s Awards
2012

 Turnover crosses Rs. 8900 crores, exports reach Rs. 3030

crores.
 Completion of expansion of polyester production from 900
tones/day to 1400 tones/day
 Gold trophy for global export of bleached/dyed/yarn
dyed/printed fabrics in fabric category
 Gold trophy for exports of bed linen/bed sheets/quilts in
made-ups category
 Silver trophy for second best export performance for the year
2010-2011 in the category yarn.
2011

 Turnover crosses Rs. 6300 crores, export reach to Rs. 2200

crores.
6

 Awarded the IMC-Ramakrishna Bajaj National Quality

(RBNQ) performance excellence trophy in the manufacturing
category.
 Awarded status of ‘Recognised Trading House’
2010
Turnover crosses Rs. 4300 crores, export reach to Rs. 1500
crores.
 Qualified institutional placement of equity shares of Rs. 425
crores.
 Added Terry towel to its product range.
2009

 Rights issue of equity shares of Rs. 450 crores. Completed

integration of polyester by commissioningcontinuous polymerisation
capacity of 600 tones per/day

2008

 Turnover crosses Rs. 2000 crores, export reach to Rs. 1000

crores.
 Awards from TEXPROCIL for 2007-2008.
 Gold trophy for global export of bleached/dyed/yarn
dyed/printed fabrics.
 Silver trophy for highest exports made-ups.
 Bronze trophy for highest global export performance for the
year 2010-2011 in the category yarn.

SPINNING DIVISION

 Number of units : 9
 Spindle capacity : 411840
 O/E Rotor : 5680
 TFO Drum : 12120
 Type of yarn produced: Compact yarn, Lycra yarn, Carded yarn,
Slub yarn, Open end yarn, Double yarn, Double Gassed yarn, 3 ply
yarn, 4 ply yarn.
7

PROCESSES INVOLVE IN SPINNING

 BLOW ROOM
 CARDING
 DRAWING
 LAP FORMER
 COMBER
 LRSB(DRAWING)
 SPEED FRAME
 RING FRAME
 WINDING
 CONDITIONING
 PACKING AND DISPATCHING

MILL Building (roof plan)

 ASBESTOS SHEET
 GLASSWOOL
 FALSE CEILING

POWER CONSUMPTION PER DAY IN UNIT 3

SECTION POWER USED(UNIT)
BLOWROOM&CARD 5800
PREPRATORY 5000
RINGFRAME&LINKCONER 45000
LIGHT 2000
LUWA WASTE CLEANING 20000
COMPRESSOR 12000
TOTAL 89800
8

NO OF SPINDLES COUNT WISE

COUNT NO OF NO OF TOTAL
MACHINES SPINDLES/MACHIN SPINDLES
E
30 6 1200 7200
41 13 1200 15600
60 23 1200 27600
60 9 900 8208

TOTAL NO OF SPINDLES =7200+15600+27600+8208=58608

YARN COUNT SPUN

30’ 40’&60’ NE COUNT YARN ARE SPUN PRESENTLY IN UNIT 3
AVERAGE COUNT OF OF THE SPINNING DEPARTMENT:- 42.26

SHIFT WISE NO OF WORKERS

DEPARTMENT NAME NO OF WORKERS

PRODUCTION 73
MAINTENANCE 18
ENGG DEPARTMENT 6
NON M/C 18
TOTAL NO OF WOKERS 115
9

BLOWROOM

OBJECTS:-

1. OPENING
The raw material enters spinning mill in the highly compressed form to
enable optimum transport and storage condition in blow room. The
bigger tufts of fibres are made into smaller tufts with minimum
damage to the fibres.

2. CLEANING
To remove foreign seed particles leave from fibres. During opening and
cleaning there is always loss of good fibres. So the blow room line is
selected such that the optimum opening and cleaning is obtained with
minimum loss of good fibres. The cleaning efficiency of cotton in blow
room section is approximately 75 – 80%.

3. DUST REMOVAL
To remove finer impurities like dust particles and very short fibres by
suction units e.g. cages. As the opening of the material increases the
dust removal capacity also increases.

4. MIXING
To mix the different varieties of cotton bales thoroughly. This will give
a homogeneous distribution of fibre in the yarn cross section.
10

BALE MANAGEMENT

In a particular lot

 Micronaire range of the cotton bales used should be same for all
the mixings of a lot
 Micronaire average of the cotton bales used should be same for all
the mixings of a lot
 Range of colour of cotton bales used should be same for all the
mixings of a lot
 Average of colour of cotton bales used should be same for all the
mixings of a lot
 Range of maturity coefficient of cotton bales used should be same
for all mixings of a lot
 Average of maturity coefficient of cotton bales used should be
same for all mixings of a lot

CHARACTERISTICS OF COTTON USED

MECH
STATION SELU
GINNER NAME KBR COMMODITIES
FQI 178.5
SCI 97
MIC 4.34
MAT .89
LEN 28.38
AMT 521
UNF 83.3
SFI 6
STR 33.3
ELG 5.7
11

SHANKAR 6
STATION VIJAYPADI
GINNER NAME KEDIA EXPORTS
INDUSTRIES
FQI 157.2
SCI 83
MIC 4.1
MAT .87
LEN 29.23
AMT 468
UNF 82.3
SFI 6.3
STR 30.8
ELG 5.8

MCU-5

STATION SELU
GINNER NAME KBR COMMODITIES
FQI 178.5
SCI 97
MIC 4.34
MAT .89
LEN 28.38
AMT 521
UNF 83.3
SFI 6
STR 33.3
ELG 5.7
12

MIXING
OBJECTS:-

 To reduce the cost of raw material used.

 To have a uniform distribution of the different types of cotton.
 In order to have the best results, following points should be
considered:
 Fibres must have same origin.
 Price, colour and grade of cotton is also kept in mind while
mixing.
 Quality of mixing to be laid.
 Soft wastes to be added as per requirement.

-MACHINES INVOLVED IN BLOW ROOM PROCESS-

SERIAL MACHINE MODEL NAME PHASE PHASE
NO. NAME A B
1 BALE PLUCKER LA23 1 1
2 HEAVY 1 1
PARTICLE
SEPERATOR
3 METAL 1 1
DETECTOR
4 SDDU 1 1
5 VARIOCLEAN LB9/2 1 1
6 UNIMIX LB7/4R 2 2
7 THE VISION JOSSI 2 2
SHIELD(mpix)
8 FLEXICLEAN LB5/6 2 2
9 THE VISION 1 1
SHIELD(Inspect4
)
10 SP-FPU TRUTZSCHLER 1 1
13

TEMPERATURE AND HUMIDITY

35°C 55%

MECH MIXING
331 332 339 331 332 339 330 332 331 330 339 331L 332L
L L L L L L L L L L L
332 339l PN 330 PN 331 SLV 339 PN 331 PN 332 330
l F L F L L F L F L L
330 PN PN SLV 339 PN 332 PN 339 PN 332 SLV 339
L F F L F L F L F L L
339 331 332 339 331 332 339 331 332 339 331 330 331
L L L L L L L L L L L L L

339 331 332 339 331 332 339 331 332 339 331 330 331
L L L L L L L L L L L L L
330 PN PN SL 339 PN 332 PN 339 PN 332 SL 339
L F F V L F L F L F L V L
332 339 PN 330 PN 331 SL 339 PN 331 PN 332 330
l l F L F L V L F L F L L
331 332 339 331 332 339 330 332 331 330 339 331 332
L L L L L L L L L L L L L
COTTON DETAILS MECH :-100%
LOT NO 330L 331L 332L 339L TOTAL
NO OF BALES
6 11 11 12 40

WASTE PERCENTAGE WEIGHT

SLIVER 1 63.19
PNEUMAFIL 2 126.38
REO 0.5 31.60
TOTAL NO OF BALES:- 40
TOTAL WEIGHT:- 6319.02Kg
14

Flowchart of blowroom line

Bale plucker
Heavy particle separator
Metal detector
Metal separater
Fire detector
Fire separator
SDDU
Varioclean

Fire detector Fire detector

Fire divertor Fire divertor
Unimix -1 Unimix-2
Tvs -1 TVS-1
Hena tex Hena tex
Flexiclean Flexiclean
Tvs -2 SP-FPU
Condenser Condenser
Fire detector Fire detector
Fire divertor Fire divertor
Card chute(1-7) Card chute(8-14)
15

BALE PLUCKING MACHINE

SYSTEMS:-
 Track
 Suction canal
o Cover belt
 Ground plate
 Tower
 Plucking head
 Machine panel
 Operating panel
 Lifting sling
 Suction hood
 Main bale block
 Reserve bale block
16

GENERAL INFORMATION OF MACHINE &ITS FUNCTIONS:-

The laxmi autometic bale plucking machine is high degree spinning machine.
It can be used for all types of cotton & man made fibres upto astaple length of
60 mm

PROCEES PARAMETER SETTING:-

Traverse speed 12
Depth(mm) 2
Plucking roller speed(rpm) 16000
Working width 2300
Plucking roller diameter 288mm
Contact roller diameter 125mm
No.of teethon plucking 300
Roller
17

POWER &SPEED IN DETAIL:-

MOTOR POWER SPEED REARKS
Trolley motor 0.55kw*2 23 Geared motor
Lifting motor 1.5kw 8.5 Geared motor
Plucking roller 4kw*2 1420
Motor
Contact roller 0.55 kw 24 Geared motor
motor

Turning motor 0.2kw 17 Geared motor

Belt motor 0.5kw 21 Geared motor
Motor
Controls 12.4kw

VARIO CLEANER

The vario cleaner (LB9/2) machine from laxmi is a high

Efficiency opening &cleaning machine is capable of processing
of all kind of cotton &man made fibre upto staple length of 60mm

POWER DETAILS
Motor drive 9.3kw
Wcs drive 0.37kw
Feed ventilator 4kw
Positive suction 3kw
Controls 0.5kw
Total 17.17kw
18
19

MAIN COMPONENT DETAIL:-

Working width 1600mm
Working depth 1200mm
Beater diameter 800mm
Beater length 1580mm
Wcs roller diameter 156mm
Wcs roller length 913mm

PROCESS PARAMETERS
Particulars Parameters
Opening roller speed(rpm) 550
Grid bar setting(index) 3/4/4/4
20

UNIMIX

Machine working width is 1600mm. It has larger buffer volume

With production upto 800kg/hr per opening & cleaning.it have intensive three
point blending all types of cottons &man made fibre and their blends
21

 Storage location
 Conveyer belt
 Top exhaust air exit
 Delivery section
 Stripper roller
 Bypass roller
 Opening &cleaning
22

PROCESS PARAMETERS:-
Particulars Parameters
Beater speed(rpm) By-pass
Lattice speed(mpm) 45
Conveyer speed(mpm) 0.4
Feed roll(mpm) By-pass
Beater to traverse bar setting(mm) 3
Beater to feed roller setting(mm) 3
Beater to grid bar setting(mm) 4
Lattice to evener roller(mm) 15
Lattice to take-off roller(mm) 3
Between feed roller setting(mm) 1
Waste plate setting(mm) 2/1/1/1/1

FLEXICLEAN

Production upto 600Kg/hr infinitely variable production achieved by invertor

drive
Controlled fibre feed for optimum opening and mass clean efficiency
Fine opening achieved by sawtooth or needle beater
Efficient micro dust removal arrangement
Controlled waste removal through adjustable grid bar
23
24
25

Parts:

1. Feed head with fan

2. Material supply
3. Exhaust air chamber
4. Delivery of material
5. Laminae chute
6. Plain drum
7. Dust cage
8. Feed roller
9. Opening roller
10. Suction dust
11. Waste chamber
12. Drive motor
13. Knife gold
14. Waste removal pipe

PROCESS PARAMETERS:-
Particulars Parameters
Beater speed (rpm) 400
Feed roll speed(mpm) 8.5
Beater to traverse bar setting(mm) 1.5
Beater to feed roller setting(mm) 1.5
Beater to grid bar setting(mm) 3
Between fees roller setting(mm) 1
Waste plate setting(mm) 2/1/1/1/1

MAINTENANCE PROGRAM:-
General cleaning/greasing 7 days
Gear box oil change 6 months
Beater wire change 3 years
26

PRODUCTION OF BLOWROOM:-

Production of 1 card = 28.07Kg/hr

Waste removed by card = 8.72%
Feed to card = 28.07(1+8.72/100)
= 30.495Kg/hr
Feed to 14 cards = 30.495*14
1 blowroom line
Production = 426.93Kg/hr

FIRE PROTECTION SYSTEM:-

 Water type (gas cartridge, capacity of 50l, capacity of Co2 gas

cartridge 250gm)
 Carbon dioxide (4.5Kg capacity)
 Fire detector & fire separator in the blowroom line present after
metal separator, before unimix, after condensor

CONTAMINATION DETECTION SYSTEM:-

This system is used for detecting and removing the contamination from
the material. The machine used for this purpose are as follows:-
1) Vision shield :- mpix&inspect4
2) SP-PFU
27

VISION SHIELD(MPIX&INSPECT4)

Inspect4 can detect polypropylene too while mpix can not otherwise both
are same

FUNCTIONS:-
 Detection and removal of foreign matter from cotton stream
 Colour detection
 VTECT for optically brightened contamination
 Polypropylene and other plastic detection with ‘scattering effect’
 It has 4 flourescent lamps /2 background stripes
28

SP-FPU

 24 zones individual measurement over the entire channel width

 6 bar pressure recommended
 Evacuation bag for waste collection
29

This is high tech machine featuring sophisticated sensors and

computational algorithms provides an increased detection efficiency of
foreign in cotton materials. It incudes the detection of transparent
material such as polypropylene contaminants
The three detection modules in SP-FPU are as follows
 Birefringence(PP module)
 Fluorescence(UV module)
 Spectral absorption at visible light wavelength(colour module)
The inspection area consist of glass duct segement and an illumination
unit which accommodates a fluorescent tube& a polarisation glass
duct, three ultraviolet (UV) fluorescent tubes are utilised to illuminate
the fibre flow. The tufts are monitored by 3-CCD colour line scan
camera with a second polarization filter attached to it, first inspection
area identifies any contaminants. The second inspection area identifies
any contaminants that deviates from cotton tufts in term of colour &
brightness

NO OF BEATING POINTS

Flexiclean 1
Varioclean 0.5
Total 1.5

BLENDER
Unimix is the only mixer used in UNIT 3
QUALITY CONTROL PROGRAM

Cotton moisture regain 6.5% (max)

30

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

OBJECTS:-

 Individualisation of fibre between flat &cylinder

 Elimination of dust &impurities
 Disentanglement of neps
 Improvement of fibre orientation (parallelisation)
 Formation of sliver

Model used in unit -3 :- LC-300AV3

31

POWER INPUT&CONNECTED LOADS

Motor Power(kw) Motor speed

Main motor 5.5 1440
Doffer motor 1.8 1440
Fan motor 3.7 2880
Feed motor 0.75 920
Brush motor 0.25 2780
Philipson brush 0.12 1380
motor
Delievery motor 0.55 1380
Control circuit 0.65
Total power 13.320

MAIN COMPONENT DIAMETER

Cylinder over clothing 1290mm
Licker in over clothing 253mm
Doffer over clothing 680mm

NO.OF FLATS:-
Total 94
In working condition 33

COMPREESED AIR SUPPLY

System pressure 6 bar (87psi) minimum
Operating pressure 4-5 bar (58-72)psi
Air consumption 0.71 n-m³/hr
With waste removal 1.31 n-m³/hr
Connecting pipe diameter 12mm
32

Fan diameter - 490mm Air exhaust rate -1.11m³/sec

Temp-33°c Can size :-40”*48”
Humidity -52%

HANDELING OF MATERIAL-
As chute feed from b/r through fine feed

MAINTENANCE SCHEDULE
Activity Frequency
General cleaning 7 days
Full setting 1 month
Coiler service 12 month
Coiler gear box oil change 6 month
Feed roller gear box oil 6 month
Change
CARDING SETTING
Zone Position Thio(1/1000”)
Feed roller to feed 4
plate
Feed Feed plate to licker 30
in
Feed roller to licker 40
in
Segment to licker in 20
Grid to licker in 22
Licker –in tocylinder 8
Licker-in Flat(2 flat) to 44
cylinder( bottom)
control flat(channel)
Pre-carding Middle mot knife to 8
cylinder
Flat gauge mm 12,12,10,10,10
Carding Front top plate plate 30
to cylinder
33

Gap b/w mot knife to 160

front top plate
Post carding segment Mot knife to cylinder 10
Redirecting roller to 5
doffer
Doffing Sweep roller to 10
redirecting roller
Crush roller(top) 4
roller to redirecting
roller
NEP STUDY
Card no. Nep in chute Nep in sliver Efficiency
Card 1 329 92 72.04%
Card2 329 69 79.03%
Card3 329 115 65.05%
Card4 329 100 69.60%
Card5 329 80 75.68%

AUTOLEVELLER
The autoleveller arrangement consist of five sensors to maintain the
uniform sliver thickness .five linear proximity sensor are used in order
to measure to feed thickness the avg value of feed thickness is sensed by
the the programmable logic controllers.plc which varies the feed motor
sped in order to maintain constant feed wt. A linear proximity is sensor
is fitted on to delievery roller arrangement to measure the sliver
thickness.the output of this sensor is connected to plc compared this
value with slection nominal value &correct the deviation again by
varying the feed motor speed on whole the feed motor speed depends on
feed thickness &delievery thickness
QUALITY CONTROL PROGAMME
Sliver hank Standard hank+/0.005
Nep removal efficiency Min 50%
34

PRE COMB DRAWFRAME(LDO/6)

FUNCTION:-

The high performance drawframe LDO/6 has two deliveries and may be
occupied with or without coil changers for cans of 350 to500 mm dia
*1200mmheight
The universally applicable pressure bar drafting system with pneumatic
loading allows delivery speed upto 500mpm. Both waste and fibre upto
75mm long can be handled. The sliver are feed in over the feed table
with automatic stop motion for sliver breaks. Feed can upto 600*200mm
may be presented. The sliver is delivered through pneumatically loaded
calender roller through the coiler wheel into revolving can. The filling
wt may be increased by addition translator motion of cans.

OBJECTS:-
 To straighten the crimped, curled and hooked fibres.
 To make the fibre parallel to their neighbours.
 To improve uniformiy of fibres by drafting and doubling.
 To reduce weight per unit length of sliver.
 To remove dust from slivers.
 To blend raw material of same hank perfectl
35

PROCESS PARAMETERS
Particulars Parameters

Sliver hank 0.130

Delivery speed 430
No. Of doubling 6
Draft 4.95
Draft wheel & DCW 82/63
Break draft 1.71
Break draft wheel(A/B) 65/61
Roller gauge(mm) 42/44

PRODUCTION CALCULATION

Production(kg/Hr)
= delivery speed(mpm)*.59056*60/(0.13*1000)
= 430*59056*60/(0,13 *1000)
= 117.20Kg/hr

QUALITY CONTROL PROGRAMME

Sliver hank Stnd hnk +/- 0.005
36

LAP FORMER

FUNCTIONS:-

 Delivery speed up to 120 mts/min

 Batt weight up to 80 gms/mt
 Pro-In control for lap build-up
 4/4 spring loaded drafting system
 Integral top roller release
 Variable top roller loading
 Modular construction
 Complete belt drive
 Auto spool changer
 Positively driven creel
 Lap transport through lap trolley.
37

PROCESS PARAMETER
Lap wt gm/m 70
Speed m/min 78
No of end up 20
Roller gauge(mm) 42/44/46
Total draft 1.286
Main draft 1.20
Main draft wheel g/h 35/42
Brek draft 1.042
Break draft pulley 35.5

PRODUCTION ( kg/hr)

=Delievery speed (mpm)*lap wt(g/m)*60/1000

=70*78*60/1000
=327.6 kg/hr

MAINTENANCE SCHEDULE

General cleaning 15 days

Cots buffing 3 month

QUALITY CONTROL PROGAMME

Unilap Lap wt gm/m Standard gm/m+ /2.0

38

COMBER

OBJECTIVES
 To remove the predetermined short fibers from the stock.
 To remove foreign matter & neps which are present in the
material.
 To improve orientation & parallelization of the fibers.
 To straighten the leading hook formation.
MATERIAL HANDELING
8 laps feeded from lap former manually
TEMP. =38°c
HUMIDITY =55%
PRODUCTION
=60*feed/nip*nip/min*lap wt.*doubling*(1-noil/100)
=60*4.7*350*70*8*(1-18/100)/1000
=45.32 kg/hr
39

COMBER SETTING
Sliver hank 0.12
Feed /nip-mm 4.7
Feed change gear 56
Ratchet wheel 20
Type of feed Forward
Top comb peneteration-mm +1
Nips/min 350

FINISHER DRAWFRAME

The drawframe LRSB 851 is one delivery drawframe with leveling

system. This model is equipped with leveling system. The model is
equipped with 3 over 3 draft system with pressure bar as well as with
cleaning & suction system
40

OBJECTIVES:

1) Drafting or attenuation i.e reducing the weight per unit length.

2) Parallelisation of fibres.
3) Equalization of fibres.
4) Removal of dust

AUTO LEVELLER:-
In the m/c. the feed sliver is sensed at sensing rollers in creel zone
& at tongue & groove in the zone before drafting system. Here the
variation is sensed at the tongue & groove & indication is given to
drafting system. The servo motor varies the speed at back & then servo
motor varies the speed of back & middle roller & sliver evenness is
controlled.
41

PROCESS PARAMETER

Sliver hank .120

Delievery roller 350
Roller gauge mm 41/45
Scanning roller 7.9/8.2
Web guide roller 8
Insert 8
Trumpet mm 3.8
No of doubling 5.8
Draw of roll mm 7.71
Draft wheel nw1/nw2 46/59
Brerak draft 1.28
42

Break draft wheel 38.3

Web tension draft 1.02
Creel tension draft 1.03
Scanning roller load 140 kg

MAINTENANCE SCHEDULE
General cleaning 16 days
Gear box oil change 6 month
Coiler servicing 1 year
Creel servicing 6 months
Cots buffing 30 days

QUALITY CONTROL PROGRAMME\

Sliver hank Standard hank +/- 0.0015
A5 +/-0.50%

SPEEDFRAME
43

FUNCTIONS
 Basic function of roving frame is attenuation or drafting so that
mass per unit length of sliver may be reduced down to extent which is
suitable to fed to ringframe. The range of draft at roving frame is 5 to
20
 After deafting the fibre strand of fobtrs has very little coherence and
become unsuitable for further attenuation at the ring frame. Amount of
twisgt given at roving frame is low and ranges from .7 to 2 TPI
 The drafted & twisted roving has to properly wound on package
called as bobbin. This is done by winding operation roving frame. The
winding mechanism is complex process which not only winds the roving
on bobbin but also maintain proper building of package

PROCESS PARAMETERS
PARTICULARS PARAMETERS
Count 40/1 CHX
roving hank 1.00
spindle speed 950RPM
number
t.m/t.p.i. 1.40/1.40
spacer mm 6.5(GREEN)
roller setting- 47-56/53-54
bottom/top
draft number 8.33
bd number 1.15
creel tension 1.027
condenser GREEN(15*3)
feed/middle GREEN(11)
delivery/floating GREEN(11)
condenser
false twister-no. of 10G
grooves/dia
44

MATERIAL HANDLING :-
Cans from LRSB are placed manually to their respective position in
speedframe

TEMPERATURE :
- 36°C

HUMIDITY :-
50.2%

TOTAL NO OF SPINDLES
= 120(spindles)*16(machines)=1920spindles
PRODUCTION
Delivery speed = 16m/mm
Count = 1Ne
No of spindles = 120
Production/hr/machine=( delivery speed*.5905*no of spindles)/
(count*1000)
=16*.5905*120/(1*1000)
=68.025kg/Hr
Roving bobbin size = 45mm*425mm
Can size = 20mm*42mm

QUALITY CONTROL PROGRAMME

Roving hank Standard hank +/- 2.5%
Roving stretch <1.0%
45

MAINTENANCE PROGRAM
General cleaning 16 days
Gear box oil change 2 months
Creel greasing 2 months
Cots buffing 3 months
Bottom roller gauge &load 6 months
checking
Grease change-flyer grear box 3 months
Headstock gear working 6 months
Bottom apron change 18 months
Bottom apron washing 6 months
Top apron change 24 months
Top apron washing 6 months
Creel servicing 12 months
Fakse twister change 3years
Clearer cloth replacement 5years
Bobbin tough level checking 1year
Bobbin roller eccentricity 1year

RINGFRAME(LR6/AXL)
 46

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

OBJECTS:
Drafting - To reduce the weight per unit length of material i.e. to bring
the material to required count.
Twisting - To give necessary strength to yarn according to its
application.
Winding – To form a cop shaped bobbin. And the bobbin so formed
should be uniform and required for unwind to form bigger package.

PROCESS PARAMETER

Particulars Parameter 1 Parameter 2 Paramete3 Paramete 4

Count 40Ne 41 Ne 60 Ne 30Ne
Roving hank 1 Ne 1 Ne 1.48 Ne 1 Ne
Mixing MECH MECH MECH S -6
Average spindle 19300 17000 19200 17200
speed
TPI/TPM 26.62/4.21 27.66/4.32 33.95/4.38 20.55/3.75
Spacer(mm) 3.25 3.00 2.75 3.25
Ring traveller 7/0 EL HRW 7/0 EL HRW 15/0 4/0hrw
C/D 65/72 72/65 65/72 82/55
 47

A/B 89/76 79/86 79/86 79/86

Winding length 40/73 40/73 40/73 50/63
change Gear
Break draft 1.14 1.17 1.17 1.14
G/H 26/109 27/108 26/108 35/107
Break draft wheel 59 57 57 59
r.w. index 30/2pin 34/2pin 24/2pin 36/2pin
Draft 44.09 42.67 43.67 32.15

MAINTENANCE SCHEDULE
General cleaning & greasing 34days
1st bottom roller greasing 1months
2nd &3rd bottom roller greasing 2 months
Top roller buffing 68days
ROCOS roller buffing N.A
Delay draft checking 3 months
Auto doffer setting 2 months
Main shaft bearing greasing 6 months
Gear box oil change 6 months
Bottom roller& top roller gauge 6 months
Ring/ABC/lappet centering 9 months
Spindle oiling 9 months
Jockey pulling greasing 9 months
Top apron washing 6 months
Bottom apron change 15 months
Top apron change 21 months
Bottom apron change/ROCOS N.A
Top apron change/ROCOS N.A
Spindle tape change 24 months
Bottom roller 24 months
eccentricitychecking
48

QUALITY CONTROL PROGRAMME

YARN TPI Standard TPI +/- 2.50%

RINGFRAME PRODUCTION CALCULATION

Gms/spindle/hr = delivery speed*(.5905/count)*60*efficiency(100%)

Gms/spindle/shift = gms/spindle/hr*8
Kg/shift = gms/spindle/shift*no of spindles/1000

Production 30Ne KW 40Ne CW 41 Ne CW 60Ne CW

according to count
Delivery 18.26m/min 18.32m/min 17.69m/min 14.36m/min
Gms/spindle/hr 21.056 16.22 15.28 8.47
Gms/spindle/shift 172 129.81 122.29 67.83
Kg/shift 207.024 155.778 146.758 81.403
49

LINKCONER

Winding is a very important part in spinning and it is responsible for

the formation of final package which is required for knitting and
weaving process so it is important to form a stable and uniform
package.

OBJECTIVES:
1. Removing objectionable faults
2. Winding of continuous long length
3. Formation of bigger package
50

SPECIFICATIONS:-
Average production/shift/head 13kg
Package wt range 1900gram
Speed of machine 1450m/min
Bobbin yarn wt 42g
Bobbin length 200mm
Yarn strength 360Cn
Average package length 96528
51

YARN CONDITIONING(XORELLA)
Moisture in atmosphere has a great impact on the physical properties of
textile fibres and yarns. Relative humidity and temperature will decide
the amount of moisture in the atmosphere. High relative humidity in
different departments of spinning is not desirable. It will result in
major problems. But on the other hand, a high degree of moisture
improves the physical properties of yarn. Moreover it helps the yarn to
attain the standard moisture regain value of the fibre. Yarns sold with
lower moisture content than the standard value will result in monetary
loss. Therefore the aim of CONDITIONING is to provide an
economical device for supplying the necessary moisture in a short
time, in order to achieve a lasting improvement in quality.

In these days there is a dramatic change in the production level of

weaving and knitting machines, because of the
sophisticated manufacturing techniques. Yarn quality required to run
on these machines is extremely high. In order to satisfy these demands
without altering the raw material, it was decided to make use of the
physical properties inherent in the cotton fibres. Cotton fibre is
hygroscopic material and has the ability to absorb water in the form of
steam. It is quite evident that the hygroscopic property of cotton fibres
depends on the relative humidity. The higher the humidity, more the
moisture absorption. The increase in the relative atmospheric humidity
causes a rise in the moisture content of the cotton fibre, following an
S-shaped curve.

The relative humidity in turn affects the properties of the yarn via the
moisture content of the cotton fibre. The fibre strength and elasticity
increase proportionately with the increase in humidity. If the water
content of the cotton fibre is increased the fibre is able to swell,
resulting in increased fibre to fibre friction in the twisted yarn
structure. This positive alteration in the properties of the fibre will
again have a positive effect on the strength and elasticity of the yarn.
52

ADVANTAGES OF CONDITIONING:-
 Twist setting in the yarn so that snarling of yarn is not there.
 Strength of the yarn increased.
 Moisture content is increased.
 Due to conditioning smoother working of yarn will be possible in
further processes.

PRINCIPLE OF WORKING
 Thermal conditioning uses low-temperature saturated steam in
vacuum. With the vacuum principle and indirect steam, the yarn is
treated very gently in an absolutely saturated steam atmosphere. The
vacuum first removes the air pockets from the yarn package to ensure
accelerated steam penetration and also removes the atmospheric
oxygen in order to prevent oxidation. The conditioning process makes
use of the physical properties of saturated steam or wet steam (100%
moisture in gas-state). The gas uniformly moistens the yarn. The great
advantage of this process is that the moisture in the form of gas is very
finely distributed throughout the yarn package and does not cling to
the yarn in the form of drops. This is achieved in any cross-wound
bobbins, whether the yarn packages are packed on open pallets or in
cardboard boxes
53

PACKAGING
Cones obtained from the conditioning are sent to the packaging
Section.
There are two types of packaging-
1. Neutral packaging: LOGO is not there on the cartoon.
2. Regular packaging: LOGO is there on the cartoon.
# Cardboard used for making cartoons is of 5 ply or 7 ply.
Dimensions of cartoon=765*380*510 mm
Proper care is taken for packing the material export purpose.
The packed material obtained is kept in the go down and transport to its
destination afterwards.

Following particulars are put on the packing cartoon-

 100% combed cotton yarn on cones

 Count
 Excise number
 Lot number
 Cartoon number
 Gross weight
 Net weight
 Cartoon size
 In one cartoon box=24 cones
30KW
GROSS WT 48.260Kg
TARE WT 2.900Kg
NET WT 45.360Kg
SIZE OF BOX 765*380*510
24(8*3) ARE PRESENT IN BOX

In ballet either 160 or 192 cones are packed together in set of 24*8 and
20*8 respectively
54

QUALITY ASSURANCE DEPARTMENT

INTRODUCTION:

QAD 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 include various efforts done to further
improve the quality of the product. The testing laboratory included
following testing equipments:
 USTER AFIS
 HVI TESTER
 USTER TESTER 4
 YARN STRENGTH TESTER
 LEA STRENGTH TESTER
 WRAP REEL
USTER AFIS( ADVANCED FIBRE INFORMATION
SYSTEM)

This instrument is used to determine the following parameters.

● Neps
● short fibre content(SFC)
● Maturity
● Efficiency
Stepwise testing of sliver from blow room.
Sample wt. – 0.50 g
SFC less than – 12.7mm
55

HVI-TESTER (High Volume Instrument)

In HVI raw material is tested ( cotton ). The USTER HVI 900 measure
the seven physical characteristics :

 Fibre length
 Fibre strength
 Length uniformity
 Elongation
 Micronaire
 Color – Rd, +b
 Trash
 SFI (short fibre index
USTER TESTER 4

 Uster %
 Thick= -50%
 Thin= +50%
 Neps= +200
 Hairiness
 IPI - -50% +50% +200%
This is used for sliver (CARD) , roving, yarn.

WRAP REEL:

To check simplex , LRSB, card hank and yarn count.

 Yarn length- 120 yard

 Carding – 15 yard or 30 yard
 Comber – 6yard