ORavi Shekhar SEM-V, NIFT DELHI Auro Spinning Mills – Hall 5 TABLE OF CONTENTS ACKNOWLEDGEMENT 1 VARDHMAN GROUP 2 INTROUCTION 2.1 MANUFACTURING 2.2 PORTFOLIO 2.3 ADMINISTRATION 2.4 QUALITY POLOCY 2.5 PHILOSOPHY 2.6 AURO SPINNING MILLS 3 PRODUCTION DETAILS 3.1 AURO LAYOUT 3.2 RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3 PROCESS FLOW 3.4 BLOWROOM 3.5 CARDING 3.6 DRAWING 3.7 LAP FORMER 3.8 COMBING 3.9 FINISHER DRAW FRAME 3.10 DRAW FRAME 3.11 SPEED FRAME 3.12 RING FRAME 3.13 WINDING 3.14 PACKING 3.15 SPIN CALCULATION & PLANNING PRODUCTION 4 GOAL OF THE PROJECT 4.1 THE PROPOSAL 4.2 AN INTRODUCTION TO NEW SYSTEM 4.3 ASSESMENT OF CURRENT SYSTEM 4.4 SILENT FEATURES OF NEW SYSTEM 4.5 TECHNICAL REQUIREMENT FOR NEW SYSTEM 4.6 DEVELOPERS REQUIREMENT 4.7 DATA FLOW DIAGRAM 4.8 UNIT CONVERSION AND SPIN CALCULATION 4.9 MAINTENANCE : UPDATION & SUPPORT 4.10 SNAP SHOTS 4.11 BIBLIOGRAPHY 5 2 3-6 3 3 5 5 6 6 7-27 7-8 9 10 11 12-15 16-17 18 19 20-21 22 23 24 25 26 27 28-46 28 29 30 31 33 34 35 36 37 44 45 47 1 I am very thankful to the whole Vardhman Group for providing me the best possible facilities and good environment during the period of my internship. Senthil Venkat for the full support and step-‐by-‐step assistance. I would also like to express my gratitude towards my mentor Ms Parul (HRD) and Project Guide Mr. Suruchi Mittal. Mr Devendra Vasist(R&D) and Un-‐doubly Mr Ravi Ranjan (TPM) for his all source of inspiration all along. guidance and providing useful data. Mr.. Sunil Mishra and Mr Harpeet Rana (Shift Officer.. Punit Singhal (R&D) for giving me chance to work on such a nice project. namely Mr Ravindra Yadav (R&D). All Thanks to my institute NIFT. Instructions of each person I meet in Auro were very beneficial for the successful completion of my project report. co-‐ operation. 2 .ACKNOWLEDGEMENT | This Internship Proved to bridge the gap between the theoretical and Practical Aspects of textile Field. It was a great pleasure to be part of Vardhman Group. Vipin Sachan. I am also greatly thankful to my subject faculty Dr. Noopur Anand and Ms. I pay my special thanks to all the other HODs also for their valuable time. New Delhi for providing me the opportunity for getting the practical knowledge at such an eminent company. Unit 5) who gave his valuable time and attention during my training and completion of project report. I acknowledge deep gratitude towards each and every employee of the Auro Spinning Mills. I am also Thankful to my Internship Mentors Dr. I pay my thanks to Mr. Baddi for providing me with their valuable time. weaving and finishing.000 spindles which is largest any single group has in India. 3 .Spin Weave Process VARDHMAN GROUP 2|TWO Vardhman is a leading conglomerate with interests in textiles and steel having a turnover of Rs. Today 5. which remains the largest industry in our country. Besides it has weaving capacity of 264 looms and fabric finishing capacity of 95.000 tons per annum special and alloy steel Vardhman started its operation in 1965 from Ludhiana with a modest capacity of 14000 spindles. 00. In addition it has mercerizing and dyeing of yarn and fiber and an acrylic production unit at Gujarat. The Vardhman group comprises six companies and twenty production units located in Punjab. By and large it has a strong focus on textiles. A growth rate of almost 15% per year in turn over the last five years has been reflected in the financial results of the group.2|TWO Vardhman group consists of integrated facilities of spinning.000 meter per day. 00.2100 crores. • Over 8. MANUFACTURING 2.000 spindles • 65 tons per day yarn and fiber dyeing • 900 shuttle-‐less looms • 90 million meters per annum processed fabric • 33 tons per day sewing thread • 18000 metric tons per annum acrylic fiber • 100. Himachal Pradesh and Madhya Pradesh. H.M. H.P.G.U. Sewing Threads Unit 2 Ludhiana. H. • Vardhman Spinning and General Mills Ltd. • Mahavir Spinning Mills Ltd.P.M.S. • V.O. H.P. • Auro Weaving Mills Baddi. By and large it has a strong focus on textiles. 4 .G.P. Baddi. Hoshiarpur • Arihant Spinning Mills Malarkotla • Anant Spinning Mills • Vardhman Special Steel Lidhiana. Baddi. H.S. Gujrat • Vardhman Threads Ltd. Unit 2 Ludhiana • V.L. Unit 3 Ludhiana • Mahavir Spinning Mills Ltd.T.S. which remains the largest industry in our country. Punjab • V. Ludhiana • Auro Spinning Mills Baddi. Punjab • Arist spinning Mills Baddi. • Auro Textiles Baddi.MANUFACTURING UNITS 2.G. H. H.2|TWO Vardhman group consists of integrated facilities of spinning. • V. Baddi.P. • Auro Dyeing Baddi. weaving and finishing.U. • Vardhman Acrylic Ltd. • Vardhman Ploytex ltd.M. Ltd. Punjab • M. Spinning Co. H.P.M. Bhatinda.P.M.P. Baddi. Punjab • Anshupati Textiles Ludhiana. Bharuch. 100% E.P.O. H.S. • Vardhman Spinning and General Mills Ltd. • Arist Spinning Mills 100% E. • Vardhman Polytex ltd.2. fabrics.000 spindles and 264 looms producing yarns and fabrics. Vardhman Group has administrative and marketing branches all over India and in more than 20 countries for its various businesses. a gold medalist in M.3|TWO Actual 2008-09 Group Total USD Million ( crores) 329 150 73 71 47% 22% 11% 10% % Share Business Wise TurnOver for Financial Year 2008-2009 Yarn 47% Yarn Fabric Sewing Thread 1513 689 337 327 Fabric 22% ST 11% Steel 10% Fiber 8% Steel Power plant 66 14 2% Power Plant 2% Steel Yarn Fibre 254 55 8% Fiber ST PowerPlant Fabric Total 3186 693 100% ADMINISTRATTION 2. cotton yarns.PORTFOLIO 2. hand knitting yarns.Com. It came into being in 1995. Shree S.P. acrylic yarns etc.4|TWO Corporate office located in Chandigarh road in Ludhiana adjacent to Vardhman Spinning and General Mills Ltd.00. heads the group who is the chairman and managing director of all group companies. 5 . with a capacity of over 5. The group is well diversified in making sewing threads. Oswal.(Ludhiana). access to state of the art technology.5|TWO Quality should be built into company’s products to not only meet customer requirements continuously but also exceed them. Cost reduction. Improved productivity. 2. The quality policy shall be integrated with the company’s main objectives: 1. PHILOSOPHY 2. 6. To remain market leader in the quality.6|TWO 6 . Increase market share with focus on niche segments. 4. The management shall be committed to provide capital and human resources to achieve the above objectives. R&D process development and adoption of innovative manufacturing and marketing strategies. Reduction in percentage of seconds. The company shall achieve this through an interface with the market place. 5. 3. The quality policy shall be implemented through a network of systems and procedures understood and followed throughout the company. A companywide quality culture shall be created through training and motivation of people at all levels of organization.QUALITY POLICY 2. 1|THREE Manufacturing Activity Greige Cotton ( both cared & combed) and core spun with lycra.1.1. a weaving subsidiary of Vardhman Spinning and General Mills Limited.2|THREE Manufacturing Activity Sliver preparatory and sample line Unit Capacity Product Range • • 1382 spindles Production of sliver per day: 9.1|THREE Production Halls Production Units 5 UNIT 1 (HALL1) 3. has now emerged as one of the premium companies in India. compact. compact+lycra. Unit Capacity Product Range • • 24. slub+lycra. slub.AURO SPINNING MILLS (77904 SPINDLES) Auro Spinning Mills Baddi (Himachal Pradesh) 3|THREE 77904 Auro weaving mills. Blends 7 .000 kg 10s-60s UNIT 2 (HALL 2) 3.000 kg Lycra. PRODUCTION DETAILS 3.422 spindles Production of yarn per day: 16. 1. fancy yarns UNIT 4 (HALL 4) 3.end yarn Unit Capacity Product Range • • 6s-20s 1248 rotors Production of yarn per day: 12.UNIT 3 (HALL 3) 3. slub.1.5|THREE Manufacturing Activity Unit Capacity Product Range Compact ( Elite) spun yarn 14256 spindles Production of yarn per day: 4000 kg 40s-200s 8 .3|THREE Manufacturing Activity Unit Capacity Product Range Cotton and lycra (bulk orders) 38592 spindles Lycra.1.4|THREE Manufacturing Activity Open.000 kg UNIT 5 (HALL 5) 3. 2|THREE 9 .AURO LAYOUT 3. RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3.3|THREE • • HVI: High Volume Instrument AFIS: Advance Fiber Information System 10 .3.2|THREE • • • • • • • • • Origin: Thickness or Fineness (micronaire) Bale weight: 165 or 220 kgs (approximately). Staple length: 30-‐35mm Degree of Reflection (RD): 60-‐80Degrees Strength : 24-‐29 gram/tex Moisture regain Evenness Maturity MACHINE USED FOR TESTING OF FIBER 3.3|THREE BALE SPECIFICATION 3.3.1|THREE • • • • • • Fiber Net Weight Origin/Supplier Length Width Staple length BALE INSERTION PARAMETER 3. PROCESS FLOW 3.4|THREE Godown Mixing (MBO) Sorting (Manualy) Carding Blow Room Bale Formation Pre-Combing Combing Drawing (F D/F) Winding Ring Frame Speed Frame Conditioning Packing Dispatch 11 . 3. Vardhman Textiles uses Trutzschler Blendomat BDT (019) as the preopening machine. thus creating a large surface area for easy and efficient removal of trash particles by the fine openers.BLOW ROOM 3.3.3|THREE The basic purpose of Blow-‐room is to supply • small fiber tufts • clean fiber tufts • Homogeneously blended tufts if more than one variety of fiber is used. fiber neps.3. 12 . without increasing the fiber rupture. and broken seed particles and without removing more good fibers.1|THREE Blow-‐room consists of a number of machines used in succession to open and clean the cotton fiber.4|THREE Effective preopening results in smaller tuft sizes. PRE-‐OPENING 3. About 40% -‐ 70% trash is removed in blow-‐room section.5|THREE INTRODUCTION 3.3. PROCESS FLOW IN BLOWROOM 3.2|THREE • pre opening with Blendomat BDT • metal or fire detection by SPMF • pre cleaning by Maxi-‐flow • mixing or blending by MPM • fine opening by CVT PROCESS PARAMETER IN BLOWROOM 3. then four mixings can be done METEL / FIRE DETECTION 3. 13 .3.PRE-‐OPENING FEATURES 3.7|THREE Vardhman Textiles uses Trutzschler Maxi flow for this work.5|THREE • It helps maintaining the homogeneity of the long term blending • cotton is opened gently without recycling as it is done in manual bale openers • the tuft size can be as small as 50 to 100 grams without rupturing the fibers • the opening roller speed is around 1500 to 1800 rpm. Vardhman Textiles uses Trutzschler SPMF for this process.3. Cotton fiber also may generate sparks due to friction while passing through connecting ducts. • the depth of penetration of the opening should be as minimum as possible for better quality • If the production per feeding machine is less than 150 kg. Thus it needs to be blown out.6|THREE Cotton fiber may catch some metal components while its fiber extraction process which needs to be removed before it goes into any further processing. This is done just after the blendomat takes up the fiber from the manually opened bales. PRECLEANING AND BEATING 3.3. 14 .8|THREE • The fiber treatment in this machine is very gentle because the fibers are not gripped by the feed roller during beating. fineness.VARIOUS MACHINE PARAMETERS 3. a high degree of fibre preservation and minimum nep generation • in general the beater speed is around 750 and minimum 50 pascal suction pressure to be maintained in the suction chamber MIXING OR BLENDING 3.3.3. and are reproducible. then it is called mixing. when different fibers of same or different grades are kept together. higher the nep generaion and higher the fiber rupture • the optimum cleaning means maximum cleaning performance. higher the good fiber loss. minimum loss of good fibers. whereas. Fiber tufts treated by the pin beater when it is carried by air medium • • • all heavy trash particles fall down before it is broken cleaning efficiency of this machine is very high in the blow room line Mostly all heavy seeds( full seeds) fall in this machine without any problem • around 50 pascal suction pressure should be maintained in the waste chamber for better cleaning efficiency • beater speed. grid bar setting and gap between grid bars will affect the cleaning efficiency • higher the cleaning efficiency. air velocity through the machine. Physical properties (fibre length. then it is called blending. strength) of the resultant blend can be predicted.9|THREE If different grade of same fibers are kept together. color. To reduce and control the production cost. Trash particles released due to centrifugal forces are separated at the mote knives and continuously taken away by the suction.MIXING OR BLENDING: OBJECTIVES 3.e. The cleaning points in CVT1 consist of opening roller. To enhance aesthetic properties i. mote knives and suction hood. appearance.3. lusters etc.10|THREE Vardhman employs Trutzschler CVT1. To enhance physical properties i.3. To meet the functional and user requirements. abrasion resistance. To improve performance.e. 15 . FINE CLEANING 3.10|THREE • • • • • • To achieve uniform quality. This gives better cleaning. deflector blades. Vardhman Textiles uses Trutzschler MPM machine for uniform mixing and blending of fibers. tensile strength. stretch etc. 6. Latest machines achieve the production rate of 60 -‐ 200 kgs / hr. High production in carding to economize the process leads to reduction in yarn quality. MACHINES AVAILABLE 3. of Machines: 10 Delivery Speed: 76 mt/min 16 . which used to be 5 -‐ 10 kgs / hr.1|THREE Carding process is considered as heart of spinning. Any defects occurring in this process continue throughout the remaining process of spinning resulting in defective yarn. up to 1970.6.6|THREE INTRODUCTION 3. In this process the cotton fibres pass through in between two sets of wire points moving in opposite direction resulting in the parallelization of fibers.2|THREE Machine: Trutzschler DK-‐800 No.CARDING 3. 3|THREE • cleaning or elimination of impurities • to open the flocks into individual fibers • reduction of neps • elimination of dust • elimination of short fibers • fiber blending • fiber orientation or alignment • sliver formation TYPES OF FEEDING 3.PURPOSE OF CARDING 3.5|THREE • high performance in carding due to high degree of openness of feed web • labor requirement is less due to no lap transportation and lap change in cards • flock feeding is the only solution for high production cards • linear density of the web fed to the card is not as good as lap • installation is not flexible • auto leveler is a must. hence investment cost and maintenance cost is more 17 .6.6.4|THREE • Feeding material in the form of scutcher lap • Flock feed system (flocks are transported pneumatically) PROPERTIES OF FLOCK FEEDING (TRUTZSCHLER USES) 3.6. 18 .7. Sliver Compression: Sliver compression before coiling increases can content 3. It means 6 slivers are taken together to form one sliver which is the input for the formation of laps.2|THREE Machine: Lakshmi Reiter No.3|THREE • To straighten the fibers and make them parallel • To improve uniformity • To improve evenness PROCESS PARAMETER 3.7.7. The process is called as Doubling One for Six (DO/6).4|THREE 1.7.1|THREE The sliver from the carding section is combined together to form one dense sliver. Flexibility: The pneumatically loaded 3-‐cylinder pressure bar drafting arrangement makes the processing of noils as well as fibres of a staple length upto 75 mm possible Controlled positive sliver feed table for can size of 600 x 1100 mm (24''x42'') 2.7|THREE INTRODUCTION 3. MACHINES AVAILABLE 3. Automatic can change: Increases the efficiency of the machine 4.DRAWING 3. Cleanliness: Dust extraction improves working condition Doubling 6 for 1. of Machines: 2 Drafting arrangement: 3 over 3 Type of weighing: Pnuematic Loaded High delivery speed: upto 500 mts/min Production: upto 360 kg MAIN OBJECTIVES 3. 8. of Machines: 2 Delivery speed: up to 120 mts/min Batt weight: up to 80 gms/mt Time to complete one lap: 2. MACHINES AVAILABLE 3.1|THREE Lap former machines form the lap from the sliver of desired fineness and weight.5 min 19 .8|THREE INTRODUCTION 3.LAP FORMER 3. When tube is full it is automatically changed for an empty one. The D/F slivers are drafted and wound into a lap. This is then wound onto a tube by the lap rolls and lap roller flanges. 8-‐12 slivers are fed into drafting arrangement from both sides and these are drafted in drafting system to produce fleeces.2|THREE Machine: Lakshmi UNIlap (LH-‐10 & LE4/1a) No.8. These are then drawn into the lap head by the calendar rolls which compresses its strongly to form a lap sheet (batt). 9.COMBING 3.3|THREE No.9.9. It is optional as per the end-‐use of the yarn.1|THREE Combing is the operation in which the short fibers in the cotton are removed so that the final yarn appearance and strength of the yarn is improved.93 Comber LK-‐54 8 1 3 over 5 Pneumatic 250 to 300 N 540 mm ( 500-‐650 mm) 0.16 Ne 250 mpm 689. MACHINES AVAILABLE 3.9|THREE INTRODUCTION 3.2|THREE Machine: -‐ Lakshmi REITER E-‐65 and LK 54 Number of machines: -‐ 6 Capacity: -‐ 3000-‐5000mtr MACHINES SPECIFICATION 3. of Deliveries Drafting arrangement Weighing arrangement Lap Diameter Hank Delivered Delivery speed Production (in kg) ( per shift per machine) Comber E-‐65 8 1 3 over 3 Pneumatic 250 to 300 N 550 mm (500-‐650 mm) 0. of heads No.9 20 .16 Ne 300 mpm 965. PROCESS & OBJECTIVES 3.4|THREE Combing is a process which is meant for upgrading the cotton raw material so that the following yarn properties will improve compared to the normal carded yarn. • Tenacity • gms/tex • Trash in the yarn • Lustre • Visual appearance Slivers from carding section can go either directly to Finisher Drawing through Breaker Drawing or through Uni Lap/Comber to Finisher Drawing.9. 21 . 10. Used for weight control to form products of fine quality. To contribute towards doubling and draft of the combed material and to change hooks disposition.10|THREE INTRODUCTION 3. 2.15 kg/hr 800 m3 per hr 450 Pa 1.2|THREE Machine: Trutzschler D-‐40 & TD-‐03 No. of machines: 3 MACHINES SPECIFICATION 3.10. To straighten the fibres and to make them parallel. 22 .10.1|THREE MACHINES AVAILABLE 3. 3. To improve uniformity and eveness(homogenous sliver structure).4|THREE Upto 8 ply 4 over 3 ( with adjustable pressure bar) Pneumatic loaded Combed 300-‐1000 mt/min Yes Yes Max 0.3|THREE Doubling Drafting arrangement Type of weighing Material Delivery speed Auto can changer Auto-‐leveller Waste quantity Suction air rate Operation pressure PROCESS & OBJECTIVES 3. 4.FINISHER DRAW FRAME 3.10. to draft the draw-‐frame sliver to make roving 2. of machines: 4 machines Delivery rate: up to 50 m/min MACHINES SPECIFICATION 3.SPEED FRAME 3. of spindles: 120 spindles No.1 1.11.11.38 85% 2.3|THREE Count: 0.2|THREE Machine: Lakshmi LFS 1660 Simplex No. to wind the roving on the bobbin for ring frame machine 23 .13 J34/ S6 4 over 4 Pneumatic 8.21 tpi ( running) Production Rate: 21.75 PROCESS & OBJECTIVES 3.31 1. to impart necessary twist to the roving 3.1|THREE MACHINES AVAILABLE 3.3 mt/min ( roving) Machine Efficiency: 75.11.4|THREE 1.11.1% Drafting Array Type of weighing Total Draft Hank Fedytg6 Efficiency Production ( in kg) per shift per spindle) Ultima/ MCU5 4 over 4 Pneumatic 10.8 85% 2.7 Ne ( running) Twist per Inch: 1.11|THREE INTRODUCTION 3. 07 z 590.8 40.22 1.12. To form a suitable package of required dimension for subsequent processing.04 Delivery Rate (spindle speed/Tpi) 326. MACHINES AVAILABLE 3.RING FRAME 3.89 z Elitwist 3 over4 Spring 18362 rpm 21000rpm 33. 3.2|THREE Machine: LR6 R/frs with ELITE Attachments No. 24 . These machines convert the roving into yarn. Speed Tpi (nominal) ELITE Compact 3 over 4 Spring 16300 rpm 17500 rom 13. which is then wound on bobbins. To insert the required twist to provide sufficient strength.12. 2.12|THREE INTRODUCTION 3.82 PROCESS & OBJECTIVES 3.3|THREE Drafting arrangement Type of weighing Spindle speed Max.4|THREE 1.12. of Machine: 16 ring frame MACHINES SPECIFICATION 3.11.38 68.1|THREE The roving bobbins of the speed frame are brought to and crewed on ring frame.60 Hank Fed Production (in gm ) ( per shift per spindle) 1. These machines further attenuate and draft the roving to the desired thickness of yarn. To attenuate the roving to get the desired fineness. of Machines : 5 PROCESS & OBJECTIVES 3.5 gm/cc Pneumatic 80-‐85% 60s 1. Pkg.13|THREE MACHINES AVAILABLE 3. of Drums Pkg.1|THREE Machine: Autoconer-‐ 338 with Uster Quantum clearer 2 No.3|THREE Material Package Wt. MACHINES SPECIFICATION 3. To clear excessively weak spots in the yarn by tensioning 4. High degree of tension is not given as it can lead to loss of elongation of yarn. Density Splicing Splice strength 58s 2.13.5 gm/cc Pneumatic 80-‐85% 70-‐75% 80s 1 kg 135000 m 1000 mpm 9 60 0.WINDING 3.13.13.2|THREE 1.89 kg 195200 m 1200 mpm 14 60 0.5 gm/cc Pneumatic 80-‐85% 70-‐75% Actual Production 70-‐75% 25 . To form a suitable bigger package with continuous length 2.01 kg 195200 m 1200 mpm 14 60 0. To clear objectionable faults 3. Length Speed Tension (cN) No. To let the material reach required moisture regains value so that the company does not suffer commercial losses.CONDITIONING 3.2|THREE Machine: CONTEXX or Xorella AG Heating medium: Saturated steam Power Consumption: 150kW Working pressure: -‐1 to 3 bar Starting temperature: 400 C Maximum conditioning time: 12 hrs.14.14|THREE OBJECTIVES 3. Efficiency: 70-‐75% Hoseiry Time 5 min 25 min Warp 5 min 10 min Perforated Cheese Improved Elongation 5 min 10 min Temp. 55 C 60 C 760 C 800 C 760 C 800 C 0 0 Pressure 88% 88% 80% 80% 80% 80% Improved Strength 26 . MACHINES SPECIFICATION 3. 2.14. Twist setting of the final yarn.1|THREE 1. Maha-‐Bali Lot • • • Pallet Packing 1. Maha-‐Bali Lot • • • Dimension: 1150 mm x 1150 mm For 2.5 kg cones: 25 layers x 13 cones For 1. the material is packed according to the customer’s demand. Carton packing 2.15|THREE TYPES 3. Normal Size • Dimension: 640 mmx 480 mmx 350 mm Capacity: 24 cones Headed to Japan Dimension: 1150 mm x 790 mm For 1. Pallet packing SIZE 3.15.89 kg cones: 24 layers x 13 cones • 2.PACKING 3.89 kg cones: 36 layer x 13 cones 27 . Normal Size • Dimension: 655 mm x 460 mm x 515 mm Capacity: 18 cones Headed to other countries • • 2.2|THREE Carton Packing 1.1|THREE After conditioning.15. There are two ways of packing: 1.