Summer Internship Report - Vardhman

March 24, 2018 | Author: Ravi Shekhar | Category: Yarn, Spinning (Textiles), Textiles, Spindle (Textiles), Clothing Industry


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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.
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