AURO SPINNING MILLS

SAI ROAD, BADDI

Distt. - Solan (H.P.)

[A UNIT OF VARDHMAN TEXTILES LIMITED]WINTER TRAINING REPORT

[02 Jan 2011 TO 31 Jan 2011]

SUBMITTED TO:- SUBMITTED BY:-

Mr. ASHWANY SHARMA ABHISHEK CHAUHAN(Manager P & IR) 6TH SEMESTER

TEXTILE TECHNOLOGY

[SPINNING]

(Punjab Institute of Textile Technology, Amritsar, Punjab.)

AURO SPINNING MILLS

SAI ROAD, BADDI

Distt. - Solan (H.P.)

[A UNIT OF VARDHMAN TEXTILES LIMITED]WINTER TRAINING REPORT

[02 Jan 2011 TO 31 Jan 2011]

SUBMITTED TO:- SUBMITTED BY:-

Mr. MAHENDER KANODIA ABHISHEK CHAUHAN( Sr.Manager Production ) 6TH SEMESTER

TEXTILE TECHNOLOGY

[SPINNING]

(Punjab Institute of Textile Technology, Amritsar, Punjab.)

ACKNOWLEDGEMENT I am grateful to the management of Vardhman group for giving me an opportunity to pursue my winter training at their esteemed organization, AURO SPINNING MILLS, at Baddi and to prepare this induction manual for Auro Spinning.

Firstly I thankful to Mr. G.S. BHATTI Sir, principal of my reputed institute & to Mr. NARENDER PAUL Sir (H.O.D. of Spinning Branch). I would also like to thanks to my training officer Ms. JASWINDER ARORA Madam.

I feel hearty thanks to Mr. MAYANK BINDAL (VP of production) & Mr. ASHWANY SHARMA (VP of P & IR).I pay my thanks to Mr. MAHENDER KANODIA (Sr. Manager Production) & Mr. SARVESH KASHYAP (Executive Production), Mr. GAURAV MAHESHWARI (Manager R&D ), Mr. ANUJ AGGARWAL (Executive Maintenance) & Mr. SHIV SHANKER (Astt. Executive) for their guidance & their help.

I also pay my thanks to Ms. POOJA MANDAWAT (S.O.), Mr. KAMESHWAR SINGH (S.O.) & Mr. VISWAJEET (S.O.) for their openly help. I also pay my thanks to Miss GUNJAN, who gave me openly help to pursue my training.

I also pay my thanks to all of those who helped but it is not possible to list all those. ABHISHEK CHAUHAN (Trainee) P.I.T.T. AmritsarVARDHMAN PROFILELate Sh. LALA RATTAN CHAND JI OSWAL, who was the founder of Vardhman was born in 1915 and expired in 1998. After that Sh. S. P. OSWAL, Gold Medalist in M.Com. is the Chairman and MD of Vardhman Group of Industries.

Vardhman have 18 units in different states, they are: - Punjab ----------------- 7 units

Himachal Pradesh --- 9 units

Gujarat ----------------- 1 unit

Madhya Pradesh -----3 units

Tamilnadu ------------- 1 unit

VARDHMAN GROUP TOWARDS PERFECTION IN TEXTILE

This group is major integrated textile producer in India set up in 1962 and achieved Rs. 3186 crore turn over in 2008-09.

BUSSINESS PORTFOLIO: -

YARN: - contributes 48% of total turnover, 8 lacs spindles and largest exporter of yarn from India.

SEWING THREAD: - 11%, SET UP IN 1982 and 2nd largest selling brand in India.

FABRICS: - 22% of total turnover.

ACRYLIC FIBER: - 8%, 1999 and VARLAN is brand name.

STEEL: - 10% of total turnover and set up in 1973.

ASM Profile{Auro Spinning Mills}

ASM is the part of Vardhman spinning and General Mills limited. It is the oldest yarn manufacturing unit at Baddi.

Auro is the first name of Aurovindo Ghosh a renowned fighter n great philosopher.

ASM est. in 1991, oldest unit in Baddi

Running count ------- 7s 200s

Spindle capacity ------- about 80,000

Production -------- abt. 37 tones/day

Product activity (CSY, compact, normal, slub, injecta slub, open end, ply, blend, siro, compact siro)

Major customers (Auro weaving, Ashima, Morarjee, Raymond, Arvind BVM, Sidharth, Berto, EOS)

Departments: -

ASM has various operations within itself. Production house

Maintenance

R&D

Engineering

Planning and Development cell

Commercial related

Industrial research department

Training

Costing

Personal department

Security

Electronic and Data Processing

Material

AccountsFEATURES OF COMPANY

TPM

VTDC, Ludhiana

Anti- Discrimination Policy.

Safety Health and Environment Policy

Quality circle

Culture and System (interaction, communication, helpful and facilities)

Clean and Green Colony

*PASSAGE OF MATERIAL IN SPINNING LINE*SORTING

(MIXING

(BLOWROOM(CARDING(DRAWFRAME BREAKER(COMBING PREPARATORY(COMBING(DRAWFRAME FINISHER(SPEED FRAME(RINGFRAME(WINDING(T.F.O.(PACKING

SORTINGContamination found during sorting:- Coloured paper piece

Polythene pieces

Nylon threads

Hair

Cotton threads

Jute pieces

Paper pieces

Feathers

Metal pieces

Leather pieces

Fabric

Stones

Other Contamination:-

Yellow cotton

Greasy cotton

Solid cotton

Leaf cotton

Types of waste added during Mixing:-

Noil of comber Sliver waste Pneumafil waste Fan wasteBLOW ROOMThe process line in blow room of unit 3 is as follows:-

Line 1 & 2( Line 3 & 4(Bale-Plucker Unifloc ( ( Varioclean Uniclean ( ( Unimix Unimix ( ( E.R.M. Cleaner E.R.M. Cleaner ( Loptex

UNIFLOCManufacturer: - Rieter

Model: - Unifloc A 1/2

WORKING:-

Serves for a dust free opening of bales of cotton.

Working process is controlled by a microcomputer and is fully automatic.

Bales are placed directly on the floor in marked working area.

Machine travels over the bales with the detacher being lowers to the surface of the bales.

The grid glides over the surface of the bales.

The supporting rolls rotates at peripheral speed which is identical to the speed of truck, they prevents the bales from being pushed over the toothed dish rolls on the grids.

The teeth of the toothed disc roll pluck the tufts from the surface of the bales bulging up and flying them into the air stream which removes them by suction.

Due to the depression existing in the suction system, the tufts are sucked by the subsequent fan through the inner suction device.

Automatically determines the length n ht of bale group of a lay down.

MAIN PARTS:-

1. Turret

2. Detacher

3. Chassis

4. Truck

5. Suction station

6. Suction duct system

7. Light barriers

VARIOCLEAN

Manufacturer: - Lakshmi

Model: - LB 9

MAIN PARTS:-

Skeleton

Grids Arrangements

Beater

Hood & Dedusting Arrangement

WCS Arrangement

WORKING OF PARTS:-

1. Skeleton:-

It is the base for the machine. It has the provision for holding the beater, grid arrangements & hood etc.

2. Grids:-

These are located at the bottom of the beater. Totally for positions of grids are available in the machine.

3. Beater:-

It consists of dual beating element which helps in effective opening & cleaning of the material.

4. Hood & Dedusting Arrangement:-

Hood is the main part which helps in opening the tuft. It has baffles inside, designed in such a way that they make the fibres to revolve around the beater for many number of revolutions. The hood also has a false air entry into the air stream of outlet material.

5. WCS Arrangement:-

Varioclean has got a pair of aluminum rollers which are hardened to have a better life. Among the two rollers one is fixed and another is floating to have a better compacting. Gauge between these rollers is 2 mm.

UNICLEANManufacturer: - Rieter

Model: - Uniclean B1

MAIN PARTS:-

Pin roller

Grids

Guide plate

Airlock roller

Conduit

Ventilator

Perforated plated

WORKING:-

1. Air conditions:-

The air i.e. sucked through the ventilator via the perforated plate, thus raw material is largely freed from dust.

Rest of the air is sucked together with material.

2. Cleaning process:-

Material caught by pin roller and opening takes place by the pins on the rotating pin roller

Guide roller carries the material six times over the grids.

The amount of waste can be varied progressively by means of electric cylinder.

3. Waste disposal:-

Waste is removed pneumatically via the airlock roller and conduit.

The airlock roller separates the waste room from the transport air then waste extraction process at the grids not affected.

TECHNICAL DATA:-

Production rate 300-1000kg/h

Pin roller speed 480-800 rpm

Power consumption 3-7 kw

Dia. Of pin roller 750 mm

Dia. Of motor pulley 116 mm

Dia. Of roller pulley 429 mm

Grid setting-1-grid closed AND grid setting-10-grid open

]

UNIMIXManufacturer: - Lakshmi Rieter

Model: - LB 7/4

WORKING:-Trunks are filled with material by an external fan via the connection for material feed. The material is drawn out of the trunks on the feed lattice which transfer the material to the inclined lattice. It consists of a stripper roller & a take off roll which take off the material from the inclined lattice. It deliver this material to delivery rollers which gives feed to the continuous running opening roll, after this the material is sucked through the material suction funnel and is transferred to the subsequent machine.

MAIN PARTS:-

Reserve trunk flap

Reserve trunk

Light barrier

Feed Lattice

Inclined Lattice

Stripper Roll

Take off roll

Delivery rolls

Opening roll

Suction duct

E.R.M. CleanerModel- E.R.M.

Manufacturer- Lakshmi Rieter

WORKING:- It works on the principal of Centrifugal-Forces. When the material revolves around the beater surface, due to centrifugal force , the heavy particle present in the material tend to go outside, while the light particles i.e. fibres tufts remains inside the air currents.

As grids are provided below & lower side of the beater, the heavy particles are separated from the running material.

MAIN PARTS:-

Laminar duct

Cage

Plain drum

Feed rollers

Beater

Grids

TECHNICAL DATA:-

Cage dia 250 mm

Plain Drum dia 250 mm

Beater dia 400 mm

Feed roller large 80 mm

Feed roller small 60 mm

Beater speed 640, 850, 1000 r.p.m.

Grid bars setting 1 to 4 mm {gauge b/w beater & grids}

LOPTEXModel:- OPTOSONIC

Manufacturer: - LOPTEX

WORKING:-

It works on OPTOSONIC principal.

OPTO: - Optical sensor scans the material & find out the coloured fibres or

any other coloured material. In this, light is emitted by emitter

which is received by receiver. It checks out the wavelength of

each particle in the running material. If the range of the

wavelength is out of the given range, then it separates that particle from the running material.

SONIC: - It consists of an Ultrasonic waves emitter which emerges the

ultrasonic waves which when passes through the particle, it

checks out the density of each particle. It consists of a receiver

which receives the Amplitude of the particles. If the range of

the amplitude ranges out of the limit given to machine, then it

separates that particle from the running material.

.

MAIN PARTS:-

Tube Lights

Blow Nozzle

Receivers

Ultrasonic Waves Emitter

CARDModel: - LC-1/3Manufacturer: - Lakshmi Rieter

*HEART OF SPINNING*

PURPOSE OF CARDING:-

Opening to individual fibres.

Elimination of impurities.

Removable of dust.

Disentangling of neps.

Elimination of short fibres.

Fiber blending.

Fiber orientation.

WORKING ZONES:-

1. Tuft feeder (AEROFEED)

2. Feeding zone

3. Licker- in zone (WEBFEED)

4. Carding zone

5. Doffing zone

MAIN PARTS:-

Tuft feeder

Opening roll

Feed roll

Feed plate

Licker- in

Mote knives

Cylinder

Flats

Doffer

Grids

Grooved roll

Take off roll

Crush rollers

Trumpet Calendar rolls

Suction fan

Suction hoods

Carding segments

Coiler calendar rollers

Coiler system

Autoleveller

CHANGE POINTS:-

Flat change gear

Feed roller change gear

Draft change pinion

Calendar roller change pinion

Web take off change gear

Coil changing gear Barrow wheel (Production wheel) TECHNICAL DATA:-

Production Rate 15-55 Kgs/hour

Cylinder dia 1290 mm

Licker in dia 253 mm

Doffer dia 680 mm

Total no. of Flats 110

Working no. of Flats 43

Draft 80-190

Total waste 2-6%

Weight of feed (aero feed) 500-800 g/m

Sliver count range Ktex 7.5 - 3.7

Nm 0.14 0.27

Ne 0.08 0.16

Grains/yard 104 52

SPEEDS OF DIFFERENT PARTS:- MOTOR 50 Hz

1440 rpm 60 Hz

1730 rpm

CYLINDER 250, 360, 450 rpm 280, 360, 450 rpm

Licker in

Pulley 210 mm

Pulley 230 mm 640, 920, 1150 rpm

590, 840, 1050 rpm 720, 920, 1150 rpm

660, 840, 1050 rpm

Doffer 22 100 rpm

SLIVER LAPManufacturer Lakshmi Rieter

Model LE 2/4a

WORKING:-

Sliver lap machine is used for preparing lap for the coming machine. It is called Sliver Lap because slivers delivered by carding machine are fed to this machine & this machine prepare a lap of those slivers.

Draft is also given to slivers for making even lap.

MAIN PARTS:-

Creel Drafting arrangement

Calendar rollers

Shell rollers

Flanges

Spool

TECHNICAL DATA:-

Ends upto 24 Count of sliver fed Ne 0.12 to 0.18 Can dimension 16 to 40 [400 to 1000 mm] Weight of feed 75 120 gm/m Draft 1.5 to 2.0 Lap weight 50 to 75 gm/m Lap width 250 mm in case of feeding Ribbon lap & 300 mm in

case of feeding Comber

directly

Lap weight up to 13 Kg Working speed up to 65 m/min Drafting system pneumatic Drafting arrangement 4/6 Calendar roller loading Notch 1 12 kg/side = 24 kg Notch 2 16 kg/side = 32 kg Notch 3 20 kg/side = 40 kg in gms/mtr RIBBON LAPManufacturer Lakshmi Rieter

Model LE 4/1a

WORKING:-

Ribbon lap machine is used for giving uniformity & evenness to the lap prepared by sliver machine for the comber machine. It is called Ribbon Lap because laps prepared by sliver lap machine are fed to this machine & this machine prepare a lap of those lap by overlapping those laps on each other after drafting.

MAIN PARTS:-

Creel

Drafting arrangement

Calendar rollers

Shell rollers

Flanges

Spool

TECHNICAL DATA:-

Heads 24 Weight of lap feed 50 to 75 gm/m Weight of lap delivered 50 75 gm/m Working speed 50 65 m/min Draft 5 to 8 Lap dia (max.) 450 mm Lap width 300 mm Drafting system pneumatic Drafting arrangement 3/4 Nipping distance In main draft zone 30 to 54 mm In break draft zone 31 to 55 mmV Pulley [Motor Pulley]Delivery Speed in m/min

140 mm 50

170 mm 60

185 mm 65

Constant for main draft:-

When break draft is 1.34 0.0746

When break draft is 1.025 0.0925STOP MOTIONS:-1. FULL LAP MEASUREMENT

When required amount of lap length is wound by the lap roller then the m/c stops automatically.

2. FEED LAP BREAKAGE STOP MOTION

When feed lap sheet breaks then the m/c is stopped. It is done by photo electrically.AUTO LAP DOFFING:-

Six sliver lap is kept in the m/c at a time. There are two pistons, one is horizontal & other is vertical. There is a timer, which measure the pre-setting lap length. When timer gives the signal that full length is measured then a variable speedometer accelerates and the lap breaks. Then horizontal piston released to drop t he full bobbin. Then vertical piston will place an empty bobbin (spool) and the horizontal piston holds it. There is a hammer, which strike the full lap to place it in proper position at time. The hole mechanism is done under electrical monitoring system. COMBERManufacturer: - RieterModel: - E 7/5 A

TASK OF COMBER:-

To improve the quality of raw material.

Yarn evenness

Strength

Cleanliness

Smoothness

Visual appearance

OBJECTIVES:-

Elimination of precisely predetermined quantity of short fibres.

Removal of hooks & neps

Formation of sliver

TECHNOLOGY OF COMBER:-

Main parameters influencing combing process.

Raw material

Material preparation

Factor associated with the machine

Machine setting

Atmospheric condition

MAIN PARTS:-

Nipper

Unicomb

Top comb

Detaching rolls

Drafting system

WORKING OF PARTS: - Nipper: -To nipped the material at the combing action.

Unicomb: - Circular comb have 1/3 part needle on its surface n comb up

the fed lap n remove the short fibres.

Top comb: - This combing plate also takes part in combing action.

Detaching roller: - To detach the material from combing area. Drafting system: - To give proper draft to the sliver n for the sliver

doubling.NIPPING RATE:-

Nipping rate/min corresponds to the no. of revolutions of the unicomb carriers/min.

Higher nipping rate ( Higher production

DETACHING SETTING:-

Distance B/W nippers & nip of detaching roller.

PIECING:-

It is a discontinuous process by which individual packets of fibres are laid on top of one another and therefore the piecing is always visible in place.

The piecing places are not even out until the next passes through the machine on the finisher.

TECHNICAL DATA: - No. of working head 8 Feed system forward n backward feed Layout of detaching roller 2/2 Points density on combs 26-30 needles/cm Feed/nip 4.3/4.7/5.2/5.9mm Speed 300 nips/min. Noil % 8-25 % Drafting range 8-25 Drafting system 3/5CHANGE POINTS: -

Headstock change pulleys for various nips/min. Nipper feed roller ratchet change wheel. Changing the amount of waste extracted by adjusting the detaching distance. Readjusting of circular comb brush. Top comb setting. Change point- table trumpet. Drafting setting.SOME IMPORTANT POINTS: - Leading hook removes by circular comb.

Trailing hook removes by drafting system.

In forward feed, feed length decreases then waste% decreases.

In backward feed, feed length increases then waste% increases.

There is always even number of machines are used after the carding n before the combing to maintain the produced leading hooks same to give better combing action n avoid the neps generation.

DRAWFRAMEManufacturer: - Lakshmi Rieter & Rieter

Model: -DO6 & LRSB 851 & RSB 1OBJECTIVES: -

To contribute towards doubling n draft of the combed material n to change hook disposition.

To straighten the fiber n to make them parallel.

To improve uniformity.

To improve evenness (homogenous sliver structure)

CHANGE POINTS: -

Draft change gears. Draft range change gears. Break draft change gears. Feed change gear. Delivery change gear, coiler wheel change gear. Can change gear. Motor belt pulley.TECHNICAL DATA OF D 06: -

Delivery head 2

Doubling 6

Delivery speed 240, 300, 350, 420,

500m/min

Can dimension 20*42(18kg)

Feed up to 42.5kg

Draft 3.6- 11(5.08)

Drafting system 3/3

Drafting system pneumatic

Can changing automatically

Sliver monitoring at delivery

SPEED FRAME

Manufacturer: - Lakshmi

Model: - LF 1400 & LF 1400 A

Number of simplex: - 12

No. of spindle in a simplex: - 120

Drafting system: - 3/3

PURPOSE: -

To produce a well prepared roving of required hank on a well built bobbin for ring frame from the draw frame sliver.

FUNCTION: - Drafting: - Reduction of the sliver cross section is accomplished by attenuating in

the drafting arrangement of the roving frame.

Twisting: - Give the required twist by the rotating spindle.

Winding: - The twisted roving is wound on to a cylindrical package with conical

ends.

Dust n fly liberated in the drafting arrangement is cleared n collected by the clearer device.

SOME IMPORTANT POINTS: -

The no. of wrapping round the pressure finger affects the winding on tension n thus the hardness of bobbin.

If pkg. soft then the loss in weight n efficiency decreases.

No. of pressure finger wrapping depends on strength of roving.

Excessive tight winding often lead to peeling off, over winding or unrolling of the layer, especially with the hard twisted roving.

Breakage in roving can be caused by the excessive wdg. tension or inadequate roving twist unless the pressure finger is clogged up.OBSERVED DATA:- Drafting arrangement 3/3 Power consumption

Main motor 9.3 kW, 1480 rpm

Fan motor 1.86 kW, 2880 rpm

Building motion motor - 0.09 kW, 1400 rpmInstalled total power 11.25 kW

Front top roller pressure 20-25 Kg Twist per inch of roving 1.36

Twist multiplier 1.15

Delivery speed 15.54m/min

Hank of bobbin 1.4

Spindle speed 832 rpm

No. of spindles 120

Efficiency 88 %

Utilization 95 %

Waste 3.5 %STOP MOTION:-1. Sliver stop motionLight is passed from a source to photocell. A current is flow is sensed by photometer. If any sliver breaks then broken end will disturb the flow of current. Then m/c would stop automatically.

2. Roving stop motion

When a roving is breaks then a suction tube sucks broken end. It is fitted to another side of the m/c. broken end is passed between two photocell and it will disturb the current flow. Then it would stop the m/c automatically.

3. Full bobbin stop motion

Required length on bobbin is wound then m/c stops automatically.

RING FRAMEManufacturer: - Lakshmi Rieter & KTTM

Model: - LR G 5/1 & RXI 240e (KTTM)

Number of Ring Frame: - 41 (24 of G 5/1 & 17 of KTTM)

No. of spindle in Ring Frame: - 1008 (22 R/F) & 864 (19 R/F)Drafting system: - Spring Loaded & PneumaticWORKING:- In a ring frame machine roving is stretched or drafted to produce yarn. After the formation of yarn, it is wound on the bobbin with the help of traveller.

MAIN PARTS:-

Creel

Bobbin holder

Supply package

Roving guide

Drafting zone Lappet hook

ABC ring

Spindle

Traveller

Ring

Traversing rail

Bobbin package

Jockey pulley Spindle tape

Spindle break

Pressure arm Spacer

TECHNICAL DATA:- {KTTM} No. of spindles 864 Spindle gauge 70 mm

Spindle per shaft 8

Max. spindle speed (Mech.) 22000 rpm

Spindle driving system 4 spindle tape drive

Lift 160/170/185 mm

Wharve diameter 20.2/18.5 mm

Spindle speed regulation by inverter

Spindle taper 1:40/1:64

Draft system 3 line, 2 zone double apron

Bottom apron type short bottom apron Yarn count Ne 10 120

Raw material cotton- of all lengths

Man made- staple length 64 mm

T.P.I. 8.1 50.9

Direction of twist z with single jockey pulley

s & z- twin jockey pulley Ring diameter 36,38,40 mm Support gearing at out end for above 528 spindles

Traverse system twin traverse

Pneumafil system twin duct, single nozzle type

Creel six rows with reserve bobbins Roving package size 406 mm 150 mm

Machine control PLC

Operation panel LCD

Weight of gear end 900 Kg Weight of out end 2050 Kg

Weight of middle block 750 Kg

Lifting motion & Through vector drive, Induction snarl elimination motor & gear box

Tube length 180/190/205/210 mm

Roving traverse 2 mm

Apron thickness 1.09 mm

TECHNICAL DATA:- {G 5/1} Raw material cotton of all provenances and

staple lengths, man-made fibres

and blends, staple length up to

80 mm

Drafts total drafts upto 60 Break draft 1.07 to 2.24

Twists 140 to 2550 T.P.M.

3.55 to 64.77 T.P.I.

Spindle speed Mech. upto 18000 rpm(M21Spdl)

Mech. upto 22000 rpm(M19Spdl)

Drafting system pneumatic

Spindle taper 1:64 & 1:40

Tube length 180 mm & 250 mm

Ring Flange no. 1 b = 3.2 mm

Flange no. 2 b = 4.0 mm

Spindle gauge 70 mm & 75 mm

Ring diameter 36 mm

38/40/42/45/48 mm

Roving traverse 6 mm

Spindle wharve dia 19 mm in M 19 spindle

21 mm in M 21 spindle

SPACERCOLOUR

2.5 mmBrown

2.75 mmDark grey

3 mmNatural white

3.25 mmYellow

3.5 mmBlack

3.75 mmCream

4 mmRed

4.5 mmGreen

5 mmBlue

5.5 mmGrey

6 mmCream

7 mmYellow

SIZE OF SPACERS &

THEIR COLOUR

SEGRIGATION

Compact Spinning SystemFrom hand spinning to todays modern spinning technologies enormous human inventive efforts have been spent to develop better twist insertion mechanisms in terms of production speed and yarn quality. A major breakthrough came with the invention of the ring spinning machine more than 160 years ago. The ring spinning machine is still the most widely used spinning machine all over the world at present, and it seems that it will continue to dominate the long and short-staple spinning industries for some time. The popularity of ring spinning comes from its flexibility with respect to type of material and count range, and particularly its optimal yarn structure, which results in outstanding yarn strength. At present ring spun yarn sets the standard against which all other yarn types are judged. Up to a few years ago, ring spun yarns were thought to have reached the ultimate perfection in the art of making yarns from staple fibers. However this changed with the invention of compact spinning. Compact spinning, a new version of the ring spinning process produces substantially better yarn quality and structure.

Principles of Suessens EliTe Spinning SystemThis system consists of an additional drafting zone, which is mounted on a standard 3-roll ring spinning machine (Figure 15). In this drafting zone an airpermeable lattice apron (Figure 16) runs over a suction tube. The suction tube is under negative pressure and there is a slot tilted in the direction of fiber movement for each spinning

position (Figure 17). After the fibers leave the front roller nip line, they are guided by means of the lattice aprons over the openings of the suction slots where they move sideways and are condensed due to suction air flow. The openings of the suction slots are at an incline to the direction of fiber flow. This helps condensing by generating a transverse force on the fiber band during the transport over the slot and causing the fiber band to rotate around its own axis. The lattice apron carries the fibers attached to it up to the delivery nip line. The diameter of delivery (driven) top roller is slightly bigger than the diameter of the front top (driving) roller. This generates a tension in the longitudinal direction during the condensing process. The tension ensures the straightening of curved fibers, and therefore, supports the condensing effect of the negative pressure acting on the fiber band in the slot area of the suction tube.

THE ELITE YARN:The operating method of the SUESSEN EliTe Spinning System is well-known. After the fibres leave the drafting system they

are condensed by an air-permeable lattice apron, which slides over an inclined suction slot. The fibres follow the outer edge of

this suction slot and at the same time they perform a lateral rolling motion.

Above the front bottom roller of the drafting system, the fibre band influenced by high draft is spreading. In the area of the

suction slot, which is covered by the lattice apron, the fibre band is condensed. Commencing from the semi-dotted clamping

line of the EliTe Q Top Roller, twist is being inserted. There is no spinning triangle.

The improvement achieved is shown in Fig .The left side displays the fibre triangle at the exit of a conventional ring frame

drafting system. The twist imparted by the spindle cannot flow up to the clamping line. The outer fibres spread out and are thus

more highly tensioned than those on the inside. The right side of the picture does not show a spinning triangle. The yarn twist

flows right up to the clamping line. The yarn is round and smooth.

Since the spinning triangle is very small, the end breaks will be very less and therefore the fly liberation will also be less.

Condensing of the fibre bundle, which follows the drafting process, can already be seen as a significant development of the ring

spinning technology. Condensed ring yarn is more than a specialty. In view of its manifold advantages.

It is of technological importance that the suction leave l relevant for the condensing operation is exactly the same for all

spinning positions. To fulfill this criteria, individual motors combined with suction units for 6 spinning positions, have been

arranged accordingly. This provides short air-flow distances with identical negative pressures at all spinning points .

During yarn formation all fibres are perfectly condensed and gathered parallel to each other in the compacting zone.

Consequently all fibres are twisted in and contributing to the superior fibre utilization rate compared to conventional ring yarn.

The result is exceptionally low hairiness combined with higher yarn tenacity and elongation. These are the unique

characteristics of these yarns.

ADVANTAGES OF COMPACT YARN:

higher fibre utilization

higher tenacity with same twist factor, or

same tenacity with reduced twist factor for higher production

lowest hairiness (highest reduction in hairs longer than 3 mm)

fewer weak points

better imperfections (IPI) values

higher abrasion resistance

greater brilliance of colour

intensive dye penetration

no singeing before printing

Due to better utilization of fibre substance it is possible to reduce yarn twist of these Yarns, particularly of knitting

yarns, by up to 20%,maintaining the yarn strength of conventional ring yarns. This increases yarn production. The

ends-down rate in spinning these Yarns is reduced by 30 to 60%,which improves machine efficiency.

Applying the same winding speed as with conventional ring yarns, there are less raised points in these Yarns and the

increase in yarn imperfections is reduced because they have a better resistance to shifting. Higher winding speeds

are therefore possible with compact yarns.

In accordance with up to 20%twist reduction in spinning compact yarns, the twisting turns can be reduced for certain

types of yarn. As a result, production of twisting frame is increased and twisting costs are reduced.

Owing to the lower hairiness and higher tenacity of compact Yarns, the ends-down rate in beaming is reduced by up

to 30%.Higher beamer efficiency, higher production and fewer personnel for repair of ends-down in beaming are the

consequence.

Compact Warp yarns help to save up to 50%of sizing agent, while the running behavior of weaving machines is the

same or even better. Cost can be saved in sizing and desizing processes.

Owing to the better work capacity of compact Yarns ,ends down can decreased by up to 50% in the warp and by up

to 30%in the weft. Efficiency is consequently increased by 2 to 3%, production is increased and weaving costs are

reduced. In practice, the average ends-down rate is reduced by 33% per 100,000 weft insertions of compact Yarns on

rapier weaving machines and by 45% on air-jet weaving machines. Instead of a weft insertion of 500 600 m/min with

conventional ring yarn,700-800 m/min is possible with compact Yarns on air-jet weaving machines.

Due to reduced Yarn hairiness, singeing can sometimes be dispensed with, or it can be carried out at a higher cloth

advance speed. As a result, production costs are considerably reduced.

fibres up to 7% can be saved because singing can be avoided

Dyeing and Printing Improved structure of compact Yarns and their reduced twist favors the absorption of colour

pigments and chemical finishing agents. Saving of dyestuff is possible.

Owing to the improved yarn strength, compact Yarns are well suited for non-iron treatment of woven fabrics. In the

course of such treatment, the strength of fabrics made from conventional ring yarns can decrease by up to 25%,with

frequent problems in the manufacture of clothes. compact Yarns make up for this loss in strength.

Knitting :Compact Yarns with their increased yarn strength and reduced formation of fluff permit to achieve higher

machine efficiency and therefore production on knitting machines at a reduced ends-down rate, less interruptions and

less fabric faults. Production costs therefore decrease. The enormously low hairiness of compact Yarns often permits

to dispense with usual waxing. Considerable cost saving is achieved because of this.

In knitting fibre abrasion reduced by 40% due to low hairiness. Fewer defects/ yarn breaks and better quality. Less

contamination on all machines by foreign fibres . Less wear of needles, guide elements and sinkers due to less dust

in the compact Yarn . Low hairiness has positive impact on loop structure . L Low pilling values get more and more

important . In many cases single compact Yarns substitute conventional ply yarns. Waxing can be reduced or

completely dispensed with .

Compact Yarns are much more suitable for warp knitting than conventional ring yarns, because of their higher work

capacity and lower hairiness. They are predestined to bear the high load due to numerous deflecting points with high

friction in the warp knitting machine.

Due to better embedding of fibres (including short ones)in compact Yarn,approx.6%fewer combing noils are possible.

Cheaper carded qualities instead of combed qualities can be spun with the Compact Spinning system.

in many cases single EliTe Yarns can substitute conventional ply yarns

new qualities can be developed, opening up a new creative scope for productsCORE SPUN YARN [CSY]To produce the core spun yarn, in ring frame the roving is passed through the drafting system in usual fashion then the filament of LYCRA or ROICA or is introduced directly through the nip of the front roller so that it is delivered along with the strands of fibers by passing through the further process of twisting.

Produced twisted yarn has the filament as the central core, whereas the drafted fibers form a sheath around the filament, so it is called as core spun yarn. Filament may be of Lycra or Crorae or Roica.

Sheath fiber is cotton fiber.

Modified in properties of resultant yarn n produced yarn will be of better strength.

Sheath fiber gives good moisture absorption, reduced static charge generation n better comfort.

POST SPINNING SECTION

In Post Spinning there are three sections:

1. Winding (Auto Coner Section)

2. Conditioning of Yarn Package

3. Final packaging

AUTOCONER SECTION

FEATURES:-

Manufacturer Schlafhorst / Saurer Type 338 RM No. of machine 10 No. of operating cone 60 Auto doffing arrangement Electrical monitoring system Provided waxing arrangement Electronic Uster Quantum Sensor & Cutter (optical type) Empty bobbin & full cone carried by conveyor belt No. of turns of the drum 3 Objective of winding section:-1. To make large package from small bobbin.

2. To remove the spinning faults of the yarn and to get a suitable package of continuous length.

CONDITIONING SECTION

OBJECTIVES:-

1. The FINAL PACKAGE are regained moisture to increase strength.

2. The weight losses due to the removal of moisture content in the raw material during different spinning process are overcome.

R & D Department

LIST OF TESTING INSTRUMENT IN HALL 3 ( USTER TESTER 3 {UT 3}

USTER CLASSIMAT SYSTEMLIST OF TESTING INSTRUMENT IN HALL 1 ( USTER TENSORAPID 3 {UTR 3}

USTER TESTER 4 {UT 4}

Advanced Fibre Information System {AFIS}

High Volume Instrument {HVI}