Innovation and technological advancement in
Spinning Subject – Fabric Knowledge for Merchandiser
Faculty – Ms. Bhavana Rawat
Submitted by:
Ashish Singh M/FMS/08/08 Kanika Srivastava M/FMS/08/13
Bhavik Gandhi M/FMS/08/10 Ridhima Ranga M/FMS/08/14
Gaurang Gupta M/FMS/08/11 Vijesh Kumar Baraskar M/FMS/08/34
Kanika Jain M/FMS/08/12 Watan Gupta M/FMS/08/35
INTRODUCTION
The Indian textile industry plays
a significant role in the
country’s economy for its
contribution to the Gross
Domestic Product (GDP),
employment generation and
earning foreign exchange. The
textile industry contributes
significantly to the world textile
production capacity and supply
of fibers. The Indian Spinning
machinery manufacturers have
created a milestone in the year
2007-08 with supply of over 3.5
million spindles in the industry.
Constituents of Yarn Spinning
Manufacturing Cost
The raw material accounts for
55 – 60% of the total yarn
manufacturing cost followed by
power cost, labor cost and
interest & other cost. Non-
availability and increased cost
are the major reasons for the raw
material to constitute the larger
share in the yarn manufacturing
cost. The paucity and
intermittent distribution of
power is another major
challenge facing the industry.
Interest & Other 10-15%
Labour 8-12%
Power 12–15%
Raw Material 55-60%
Hence it is crucial to handle the
above factors to achieve profits
in this competitive scenario.
Interest & other
Labour
Power
Raw material
The Indian textile industry
is large and diverse,
unique for its coverage of
the entire gamut of
activities ranging from
production of raw material
to providing the
consumers, high value
added products, such as
fabrics and garments.
Challenges Faced by the
Spinning Sector
The challenges of the
Spinning Industry which
would impede the Growth
and development of the
Industry are:
Raw material
availability
Human resource
Power cost &
availability
Investment &
Interest cost, etc.
Raw Material
Global and Indian Cotton
Scenario
Raw Material
RAW MATERIAL
Global and Indian Cotton Scenario
06/07 07/08 08/09 06/07 07/08 08/09
Million Tons Million Tons
Production 26.65 26.28 24.9 122.4 120.7 114
Consumption 26.66 26.67 26.4 122.5 122.5 121
Exports 8.13 8.19 8.8 37.3 37.6 40
Ending Stocks 12.41 12.10 10.7 20.7 57.0 49
Cotlook A index 59.15 73 83 59.15 73 83
Source - ICAC
The world 2008/09 projections indicate lower beginning stocks,
production, consumptions, and ending stocks. World production will
reduce by 1.5 million bales of 480 lbs. due to mainly reduced
production.
The world 2008/09
The world 2008/09
projections indicate lower
beginning stocks, production,
consumptions, and ending
stocks. World production will
reduce by 1.5 million bales of
480 lbs. due to mainly
reduced production.
Cotton Balance Sheet (October – September)
(in lakh bales of 170 kg )
06/07 07/08(E)
Supply
Opening Stock 52.00 47.50
Crop 280 315
Imports 5.53 6.5
Total Supply 337.53 369.00
Demand
Mill Consumption 194.89 203
Small Scale Unit Consumption 21.26 23
Non-Mill Consumption 15.88 15
Exports 58 85
Total Off-take 290.03 326
Carry-over stock 47.5 43
Source – Cotton advisory board E=estimated
The cotton scenario in the country also presents a difficult picture with
decrease in carry forward stock for the upcoming year and decrease in
acreage allotted for cotton production. This would lead to increase in
price of raw material which would subsequently lead to its increase in
yarn manufacturing cost.
Raw Material vs.
Yarn Quality
Modern developments
in Spinning Machinery
are mainly focused on
the key properties of a
fiber. Synthetics do not
pose challenge as the
fibers could be
controlled to a great
extent. However, the
following are the key
properties of cotton
fibers which determine
yarn quality.
Micronaire and
C.V.% of
Micronaire
Fiber Neps
Contamination
Short fiber
content
Micronaire and Neps
contribute a major
percentage in the yarn
quality determining
factors.
Yarn Realization
In the production economics of a
spinning mill, yarn realization
plays a important role. The
machines in every sub system of
the Spinning system are
configured by attaching
importance to raw material
characteristics and yarn
realization.
Human Resource
The Indian textile industry is
facing challenges on the
following in the human resource
front:
Non availability of labor
Skilled manpower
To address the above issues to
an extent, automation in the
machines are designed with state
of the art technologies.
Power
The energy efficiency and
power utilization for machinery
has become the need of the hour
to address the power availability
issues. The machines in the
entire spinning system are
designed with less energy
consumption parts.
Short Staple Spinning System
The short staple spinning system
comprises of the following
system:
Cost silver system- blow room
and cards
Combing system- non
autoleveller draw frame, lap
former, comber, autoleveller
draw frame
Ring spinning system- speed
frames, ring frame, and compact
spinning.
Card Sliver System
Blow Room with Bale
plucker Line
Production upto 1500
kg/hr
Bale plucker with
autoscanning increases
machine utility and
efficiency and
elimination of skilled
man power
Chute feed systems to
cards
Automatic Can Changers
at card
Delivery in sizes upto
40” to 48”
Maintenance free digital
drives
Blow room and card
together form the package in
catering to the deficiencies
of the raw cotton due to
continuous down grading of
the fibre properties, stress is
put more on blow room
machine and cards.
Blow Room
The fibers are subjected to
gentle and soft treatment to
avoid NEP generations /
increase in short fibre content.
The nature of
contamination/impurity such as
seed coat fragments, husk, leaf
bits, etc. are difficult to extract.
Due this blow room had to be
readopted with machines
capable of intensifying the
cleaning significantly.
This has resulted in a pre-
cleaning with free movement of
fibers by air handling and fine
cleaning with different beaters
depending on the fibre nature.
The beater in the blow room are
also designed to suit both cotton
and synthetic handling.
The concept of modern blow
room development is based on
the following:
OPTIMAL OPENING
OPTIMAL CLEANING
OPTIMAL DEDUSTING
OPTIMAL BLENDING
But above all, by treating the
fibres softly and gently and
saving the raw material through
less fiber loss. Blow room is
configured with high production
machines thereby decreasing
number of ventilators.
Cards
Basic principles of carding
remains unaltered even though
there are other technological
development. The production
rates are determined by raw
material properties. The
emphasis is on devices which
could control the deterioration
of fiber and maintain optimum
production. The neps are
disentangled and reaches the
minimum level at carding stage.
The wire points in the carding
machines are configured to suit
all types of cotton varieties and
synthetics.
Combing System
Non auto levelor draw
frame.
High delivery speed upto
1000 mpm.
Feed and delivery can
with 40” X 48”
Lap former and Comber
Automatic lap
transportation system
Automatic / Semi
automatic batt piecing.
\
In the production
economics of
spinning mill, yarn
realization plays a
significant role. The
machine in every
sub system of the
Spinning system are
configured by
attaching
importance to
material
characteristics and
yarn realization.
Draw frame
Automatic draft control
Auto Can Changers with
magazines
Maintenance free digitals
drive
Combing developments are
being carried under the
following criteria :
Saving the noils
Higher productivity
Cost effectiveness
The percentage of noil
extraction depends on the raw
material selection and intended
use of the end product. Combers
are designed for noils savings
with optimum parameters.
Comber
High precision combing
dynamics and processes
Synchronized and
optimal movement of
parts
Reduced moving parts
All machine are equipped with
energy efficient drives.
Automatic waste collection in
blow room cards and combers
removes wastes from these
machine either continuously or
intermittently. This system helps
to control incident of fly and
fluff generation and reduces
manpower require to collect and
transfer waste.
Ring Spinning System
Speed Frame
Suspended flyer
Bobbin package size –
16” Height X 6”
Diameter
Servo bobbin build
Ring frame
Spindle speed upto
25000 rpm
Servo drive system for
ring rail
Auto doffing for speed
frame and ring frame
Link coner attachment
Automatic bobbin
transportation system
Maintenance free digital
drive
Energy saving is achieved with
the following machine
configuration:
Energy efficient, high
performance, noise less
high speed spindles
New light weight
spindles (lesser DUI)
4 spindle tape drive
Lower diameter ring
Lower lift
Improved suction tubes
High efficiency motors
for the same load draw
By technological
advancements and
increase in production
the investments cost
in spinning mill has
drastically reduced.
less input power than
an ordinary motor and
a considerable
percentage of energy
is saved. The high
efficiency is achieved
by reducing electrical
and mechanical losses
in the motor.
Compact Spinning is value
addition in ring spinning. The
principle of compacting or
considering during the
spinning process minimizes
the width and height of the
spinning triangle. The fibre
are aligned in the yarn with
uniform twist.
Compact spinning system
ensures appreciable reduction
in hairiness and significant
increase in yarn strength with
enhanced yarn appearance.
Investment Analysis
By technological
advancements and increase in
production the investment
cost in spinning mill has
drastically reduced. The chart
A depicts clearly the
reduction in machine required
for the same spindlege
capacity.
Past and present – Machinery requirements
For a mill producing Ne 30s C, with production 13.7 Tons/day
Old line: 28,244 Spdls. & New line: 25,200 Spdls.
1995 2008
No. of Machines
Human resource requirements
The following illustration highlights the savings in:
Manpower
Space
Recurring cost by way of automation
The savings in manpower is an automated plant is around 40%.
Card Sliver system 29 15
Combing system 37 20
38 Ring Spinning Sys 29
Spindleage Non Automatic
plant
Automatic
Plant
30000 320 180
50000 500 300
To summarize, the above technological advancements and automation are the key factor in assisting the
capital intensive spinning industry.
Optimal realization of raw material
Reduce manpower dependency and
Lower energy consumption
Spinning machinery produced in india can meet the requirement of the spinning industry with cost
effective solutions.
HISTORICAL DEVELOPMENT OF YARN MANUFACTURING
Hand Spinning
Earlier staple fibers were twisted together by hand to form yarn.
Rolling the fiber between the hand and the leg is another primitive method to produce yarn.
In both the above method excellent yarn is produced by experienced and skilled person.
Carding process was done to the fiber in which fibers were straightened before Hand Spinning process.
Fibers could be made completely parallel by a further step called Combing, this process also include the removal of very short fibers.
Hand spinning with Spindle & Distaff. The woman holds the distaff under her left arm, draws fibers from the bundle tied to the distaff, and spins fibers into yarn by lowering the spindle with a spinning motion. Spun yarn is wrapped around the spindle as it is formed.
A major improvement in the spinning of yarn originated in India in the form of Charka or Spinning Wheel. It seems to have been invented sometime between A.D. 500 and A.D. 1000.
In the 16th century Flyer and detachable bobbin were invented which allowed the simultaneous and winding of yarn into bobbin.
MECHANIZED SPINNING
In 1741 John Wyatt and Lewis Paul built the first series of spinning machines for spinning cotton yarns. They used a Roller-Drafting principle which helped in producing strand of fibers called Roving. This roving was stretched to Bobbin-and-Flyer twisting mechanism.
Arkwright used this same principle in 1769 when he constructed a spinning machine called the Water Frame which was given this name because it was operated by water power.
James Hargreaves in 1760’s invented Spinning Jenny which made eight yarns at the same time. The yarns made by Hargreaves and Arkwright machine were not as strong as hand spun yarn.
Samuel Crompton combined water frame and spinning jenny into one basic machine known as Spinning Mule, which was basic machine for producing cotton yarn in England until well into 20th century.
John Thorpe invented Automatic Spinning Mule in 1830 which is also called Ring Spinning Machine and used even today.
Open End Spinning in which air suction takes the fibers through tube in which twist is imparted to fiber was invented for staple fiber.
