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vardhaman report

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internship report
153
OBJECTIVE OF INTERNSHIP To understand the concept of spun yarn production, dyeing, printing and finishing of yarns, testing and their quality aspects both technical as well as for commercial purpose. The machinery features, machine and material process parameters have been described in detail in the areas as mentioned below: Assignment – 1: Observations to be made and information to be documented on the Yarn manufacturing and winding section: A. Raw material storage and inspection section. B. Blow room section. C. Carding section. D. Drawing section. E. Combing section. F. Roving section. G. Spinning section. Assignment – 2: Observations to be made and information to be documented on the Dyeing section Assignment – 3: 1
Transcript
Page 1: vardhaman report

OBJECTIVE OF INTERNSHIP

To understand the concept of spun yarn production, dyeing, printing and finishing of

yarns, testing and their quality aspects both technical as well as for commercial

purpose.

The machinery features, machine and material process parameters have been

described in detail in the areas as mentioned below:

Assignment – 1:

Observations to be made and information to be documented on the Yarn

manufacturing

and winding section:

A. Raw material storage and inspection section.

B. Blow room section.

C. Carding section.

D. Drawing section.

E. Combing section.

F. Roving section.

G. Spinning section.

Assignment – 2:

Observations to be made and information to be documented on the Dyeing section

Assignment – 3:

Observations to be made and information to be documented on the Testing and

Quality control sections

1

Page 2: vardhaman report

GROUP PROFILE

Vardhman Group is a leading textile conglomerate in India having a turnover of

$700 mn. Spanning over 24 manufacturing facilities in five states across India, the

Group business portfolio includes Yarn, Greige and Processed Fabric, Sewing

Thread, Acrylic Fibre and Alloy Steel.

Vardhman Group manufacturing facilities include over 8,00,000 spindles, 65 tons per

day yarn and fibre dyeing, 900 shuttleless looms, 90 mn meters per annum

processed fabric, 33 tons per day sewing thread, 18000 metric tons per annum

acrylic fibre and 100,000 tons per annum special and alloy steel.

Vardhman has evolved through history from a small beginning in 1965 into a modern

textile major under the dynamic leadership of its chairman, S.P.Oswal. His vision and

insight has given Vardhman an enviable position in the textile industry. Under his

leadership, Vardhman is efficiently using resources to innovate, diversify, integrate

and build its diverse operations into a dynamic modern enterprise.

An Insight into the Vardhman Logo:

The “Flame” signifies the growth of each and every individual

associated with it whether he or she is a worker, an employee,

share holder or a customer.

The “Stick” symbolises cotton, which is basic raw material of the core product

of Vardhman Group.

The “V” stands for Vardhman Group.

2

Page 3: vardhaman report

MISSION:

Vardhman aims to be world class textile organization producing diverse

range of products for the global textile market.Vardhman seeks to achieve

customer delight through excellence in manufacturing and customer service

based on creative combination of state-of-the-art technology and human

resources. Vardhman is committed to be responsible corporate citizen.

PHILOSOPHY:

Faith in bright future of Indian textiles and hence continued expansion in

areas “which we know best”.

Total customer focus in all operational areas.

Product to be of best available quality for premium market segments through

TQM and Zero Defect Implementation in all functional areas.

Global orientation targeting atleast 20% production for exports.

Integrated diversification/product range expansion.

World-class manufacturing facilities with most modern R&D and process

technology.

Faith in individual potential and respect for human values.

Encouraging innovation for constant improvements to achieve excellence in

all functional areas.

Accepting change as a way of life.

Appreciating our role as a responsible corporate citizen.

3

Page 4: vardhaman report

HISTORY

The industrial city of Ludhiana, located in the fertile Malwa region of Central Punjab

is otherwise known as the "Manchester of India". Within the precincts of this city is

located the Corporate headquarters of the Vardhman Group, a household name in

Northern India. The Vardhman Group, born in 1965, under the entrepreneurship of

Late Lala Rattan Chand Oswal has today blossomed into one of the largest Textile

Business houses in India.

At its inception, Vardhman had an installed capacity of 14,000 spindles, today; its

capacity has increased multifold to over 8 lacs spindles. In 1982 the Group entered

the sewing thread market in the country which was a forward integration of the

business. Today Vardhman Threads is the second largest producer of sewing thread

in India. In 1990, it undertook yet another diversification - this time into the weaving

business. The grey fabric weaving unit at Baddi (HP), commissioned in 1990 with a

capacity of 20,000 meters per day, has already made its mark as a quality producer

of Grey poplin, sheeting, shirting in the domestic as well as foreign market. This was

followed by entry into fabric processing by setting up Auro Textiles at Baddi and

Vardhman Fabric at Budhni, Madhya Pradesh. Today the group has 900 shuttleless

looms and has processing capacity of 90mn meters fabrics/annum.

In the year 1999 the Group has added yet another feather to its cap with the setting

up of Vardhman Acrylics Ltd., Bharuch (Gujarat) which is a joint venture in Acrylic

Fibre production undertaken with Marubeni and Exlan of Japan. The company also

has a strong presence in the markets of Japan, Hong Kong, Korea, UK and EU in

addition to the domestic market. Adherence to systems and a true dedication to

quality has resulted in obtaining the coveted ISO 9002/ ISO 14002 quality award

which is the first in Textile industry in India and yet another laurel to its credit.

4

Page 5: vardhaman report

PORTFOLIO:

The group portfolio includes Yarn, Fabrics, Sewing Thread, Fibre and Alloy Steel.

Business Wise Turnover for the financial Year

2010-11

Actual 2010-11Group Total

(Rs crore)USD Million

Yarn 2280 500

Fabric 1093 240

Sewing Thread 440 97

Steel 435 95

Power plant 9 2

Fibre 235 52

Total 4492 986

5

Page 6: vardhaman report

Yarns

Yarn Manufacturing is the major activity of the group accounting for 51 percent of the

group turnover. Vardhman is virtually a supermarket of yarns, producing the widest

range of cotton, synthetics and blended, Grey and Dyed yarns and Hand Knitting

Yarns, in which Vardhman is the market leader in India. The group has twenty one

production plants with a total capacity of over 8.8 lacs spindles, spread all over the

country. In many of the yarn market segments, Vardhman holds the largest market

share. Vardhman is also the largest exporters of yarn from India, exporting yarns

worth more than USD 282 million.

PERFORMANCE:

During the last 16 years, Vardhman Group has recorded 13 percent top line growth

rate, which is higher than the industry average growth rate. The Group turnover has

grown from Rs 723 crores in 1995 to Rs 4492 crores (about USD 986 million) in

2010-11. The exports has grown from negligible level in early nineties to Rs 1287

crores (USD 282 million) in 2010-11.

Financial Indicators Of Vardhman Group (Rs. In Crores)

Particulars Group Group Group Group Group

2010-11 2009-10 2008-09 2007-08 2006-07

Gross Sales 4492.16 3391.39 3186.32 2692.93 2454.00

Fob Value Of Exports 1286.79 751.89 688.67 495.73 482.93

Profit Before Tax 755.36 411.32 137.41 204.8 264.73

Cash Accrual (PBT + Dep.) 1020.03 667.96 380.79 376.74 398.32

Gross Block 4415.57 4176.40 3935.47 3460.86 2467.71

Net Block 2690.45 2598.58 2571.33 2219.22 1386.84

Capital Employed 5753.88 4747.86 4555.61 3917.86 3181.18

6

Page 7: vardhaman report

Gross

Sales

Fob Valu

e of E

xports

Profit B

efore

Tax

Cash Accr

ual (PBT +

Dep)

Gross

Block

Net Block

Capita

l Employe

d0

1000

2000

3000

4000

5000

6000

7000

2006-072007-082008-092009-102010-11

PRODUCTS:

Cotton Yarn

Organic Cotton Yarn

Organic Fair Trade Cotton Yarn

Ellitwist Yarn

Vortex Yarn

Slub Yarn

Acrylic Yarn

Synthetic blends

Synthetic Cotton blends

Special Blended Yarn

Core Spun Yarn

Melanges

Gassed Mercerised Yarn

Modal Yarn

Tencel Yarn

Hand Knitting Yarn

Speciality Yarn

CUSTOMER FOCUS:

7

Page 8: vardhaman report

At Vardhman, each customer is special and a constant source of inspiration.

Therefore, the Group has leveraged technology to develop a highly sensitive

response system for addressing customer needs. A high-tech in-house

sampling unit and a design studio enable Vardhman to provide customers with the

most innovative products. Vardhman has also implemented Enterprise Resource

Planning (ERP) System to provide facilities like online tracking of orders.

HUMAN RESOURCES:

The human resource development at Vardhman is aimed at enabling people

discover their true potential. The company endeavours to provide opportunities to

experiment with a strong culture built around talent, team work, competitive spirit,

continuous learning, trust and transparency. The well-designed system of

knowledge dissemination across various levels ensures access to intellectual

capital. The knowledge bank facilitates individual growth and excellence. Vardhman

believes that winning leaders are teachers and winning organisations always

encourage and reward teaching. The business processes, organisational structure

and day to day operating mechanism promote teaching for developing a stream of

young leaders.

The calibre and professionalism of its people has helped Vardhman achieve and

maintain its leadership in the competitive environment of today. The Group has

initiated a number of human resource development processes to facilitate

consistent improvement in performance, productivity and effectiveness.

Vardhman believes in continuous learning and adapting to change as a way of life.

Preparing for transformation, the Group has designed elaborate training and

development programmes that encompass the technical, managerial, behavioural

and spiritual growth of its employees. Vardhman Training and Development

Centre at Ludhiana, caters to the distinct needs of its employees, where training

programmes are conducted throughout the year by in-house and external faculty.

Manav Vikas Kendras and Quality Circles are also similar initiatives where trained

faculty impart regular training, especially to workmen. Apart from this, managers

participate in training at some of the best institutes like the Harvard Business

8

Page 9: vardhaman report

School (USA), Institute of Management Development (Switzerland), ISB and IIMs in

India. Vardhman sincerely believes that when technology converges, people will

make all the difference.

THE SOCIAL DIMENSION:

As a commitment to the society and the workforce, Vardhman has provided

schools for the children, functional residential complexes for employees and

working women hostels for single women workers. Numerous recreational activities,

sports programmes and cultural events during festivities are regularly organised.

Besides these, the Company runs medical camps to meet the health requirements of

the people.

Sri Aurobindo College of Commerce and Management in Ludhiana and the

Aurobindo Public School at Baddi (Himachal Pradesh) are stellar examples of how

Vardhman is involved in providing specialised education and improving

competence levels in the society at large. Responding to the call for inclusive

growth, Vardhman Group has started a Capability Enhancement Training

Programme for socially under-privileged students on regular basis. The training

aims at enhancing the employability of under-privileged students belonging to

scheduled castes, scheduled tribes and other backward classes.

The Vardhman Group made earnest efforts to increase the income of cotton

growing farmers by imparting training to them on various aspects of cotton

cultivation through “Village Adoption Programme”. As a result of these efforts, the

cotton productivity of the adopted villages increased manifold and has crossed the

national cotton productivity average.

9

Page 10: vardhaman report

ENVIRONMENTAL CONSCIOUSNESS:

Decreasing green belts and ever increasing pollution has become the bane of

modernization. Vardhman has always made a conscious effort not only to preserve

the environment around us but also to contribute its mite towards building a better

world. A corollary of this consciousness is visible in the best pollution control

devices and practices. Vardhman has also increased green cover across all

manufacturing units. Going further, Vardhman group actively pioneered the setting -

up of Nimbua Greenfield Punjab Limited, a company dedicated to solid waste

treatment, storage and disposal in the State of Punjab, India.

10

Page 11: vardhaman report

VARDHMAN SPINNING & GENERAL MILLS

LTD. (LUDHIANA) – VSGML

This unit was installed in august 1965 with 12000 spindles and as on date the

number of spindles has increased to 59728 indulged in the manufacturing processes

like spinning, worst & knitting yarn. Here acrylic woolen, dyed yarn and worsted yarn

is manufactured. The yarn of this unit is widely accepted in the market and is

exported to various countries in the world.

Manufacturing activityCotton Spinning, Worsted

Spinning, Dyeing

Production activity 24,496 spindles

Major customers

Domestic: Orient Crafts Ltd.,

Gurgaon; Soma Textiles;

Raymonds; Arvind; V and S;

Matrix; Richa Global Ltd. etc.

Export: Hansole, Korea; Ecolex,

Bangladesh; Chauri, Japan etc.

Yarn Count Spun 20s, 28s, 30s, 34s, 37s

Quantity of Cotton Consumed/day 20 tonnes

Quantity of Manmade Fibres

Consumed/day7 tonnes

Average Ring Frame Utilisation/Day 97.10%

Address

Vardhman Spinning and General

Mills Ltd.,Chandigarh Road,Near

Samrala Chowk,

Ludhiana – 141010, Punjab.

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Page 12: vardhaman report

VSGML AS A TEAM:

VSGML has various operations with in itself. Following are the departments, which

helps in achieving the set objectives of VSGML:

1) Production

2) Engineering

3) Maintenance

4) Research & Development

5) Training

6) Costing & MIS

7) Materials & Stores

8) Industrial Relations

9) Personnel & Administration

12

Page 13: vardhaman report

QUALITY MANAGEMENT TECHNIQUES

At Vardhaman Spinning and General Mills, Ludhiana, quality management

techniques are given a lot of credit and are followed religiously. One of the major

quality management techniques followed by them is Total Productive Maintenance

(TPM).

Total Productive Maintenance is a maintenance program which involves maintaining

plants and equipment. The goal of the TPM program is to markedly increase

production while, at the same time, increasing employee morale and job satisfaction.

TPM brings maintenance into focus as a necessary and vitally important part of the

business. Down time for maintenance is scheduled as a part of the manufacturing

day and, in some cases, as an integral part of the manufacturing process. The goal

is to hold emergency and unscheduled maintenance to a minimum.

TPM starts with 5S. Problems cannot be clearly seen when the work place is

unorganized. Cleaning and organizing the workplace helps the team to uncover

problems. Making problems visible is the first step of improvement.

Japanese TermEnglish Translation

Equivalent 'S' term

Seiri Organisation Sort

Seiton Tidiness Systematise

Seiso Cleaning Sweep

Seiketsu Standardisation Standardise

Shitsuke Discipline Self - Discipline

13

Page 14: vardhaman report

KAIZEN

"Kai" means change, and "Zen" means good ( for the better ). Basically kaizen is for

small improvements, but carried out on a continual basis and involve all people in the

organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no

or little investment. By using a detailed and thorough procedure we eliminate losses

in a systematic method using various Kaizen tools. These activities are not limited to

production areas and can be implemented in administrative areas as well.

In the organization, workers are encouraged to come up with new techniques or

solutions for problems or methods which have a better efficiency to eliminate losses.

The method along with the result and the name of the employee who has suggested

the change are put up next to the machine or department where it is to be

implemented. This motivates the employees to use the various Kaizen tools more.

14

Total Productive Maintenance instructions and methods have been put up in the factory to increase awareness

Page 15: vardhaman report

ORGANIZATIONAL STRUCTURE

15

Chief Managing Director

MR. S.P. OSWAL

Executive DirectorMR. SACHIT JAIN

Vice-President (Commercial & Administration)

Chief Manager

Executive, Officers &

Staff

Managers (Accounts/HR/Costi

ng/Commercial)

Executive, Officers &

Staff

Vice President (Production)

MR.VINEET PANDEY

Asst. Vice President

(Engineering)MR. DHEERAJ

MEHTA

Chief Manager (Worsted)MR. J.S. REKHI

Executive, Officers & Staff

Production Supervisors

Workmen

Senior Manager (Spinning 1 & Spinning 2)

MR. VASANT BISEN

Executive, Officers & Staff

Production Supervisors

Workmen

Manager (Dye House)

MR. ATUL VERMA

Executive, Officers &

Staff

Production Supervisors

Workmen

Page 16: vardhaman report

ASSIGNMENT- 1

16

Page 17: vardhaman report

PROCESS FLOW OF COTTON SPINNING

17

Opening & Sorting

Mixing

Blowroom

Carding

Pre-Combing

Combing

Draw Frame

Speed Frame

Ring Frame

Winding

Conditioning

Packing

Page 18: vardhaman report

BLOWROOM

OPENING, SORTING AND MIXING

This process involves opening of fibre bales and opening tufts of cotton into smaller

tufts and removal of foreign materials. Mixing and sorting is done to:

Reduce the cost of raw materials

Have a uniform distribution of different types of cotton

Moisturise the cotton and allow them to open up

While mixing, it should be considered that fibres should have identical properties like

length, strength etc. Price, colour and grade of cotton should be of approximately

same quality. Optimum amount of different varieties should be mixed to keep the

quality up to the mark. Soft waste should be added as per requirement.

Mixing: The material from the compressed bales are torn into small flocks manually

and stored into the mixing room for 12 hours. Meanwhile, the fibres absorb the

moisture from the air and get conditioned. Oil and water are sometimes used in the

mixing room and they are sprayed on the mixed lot. The mixture helps to moisturise

the material and reduce the fly and fluff in the mixing room.

Sorting: It is the procedure in which the compressed bales are broken into small

tufts which is done manually. Contaminations are sorted out in this process.

18

Page 19: vardhaman report

Technical Specifications for Cotton

Cotton Varieties Usedi. J-34 (70%)

ii. S-6 (30%)

Bale Size 25” x 17” x 49”

Bale Weight 165-170kg

Cotton Varieties Parameters

Parameters J-34 S-6

Staple Length (mm) 28-29 29-30

Strength (gm/tex) 30-31 30-31

Elongation (%) 5.1-5.2 5.2-5.3

Micronnaire 4.8-5.0 3.8-4.2

Reflection Degree (Rd) 72-76 76-80

Brightness (B) 8-9 8-9

Technical Specifications for Polyester

Bale Size 39” x 25” x 49”

Bale Weight 400 kg

Length of Fibre 44mm

Count of Fibre 1.2 Dtex

Lustre Bright

Technical Specifications for Acrylic

Bale Size 40” x 24” x 46”

Bale Weight 300-350 kg

Length of Fibre 40mm

Count of Fibre 1.3 Dtex

Lustre Bright

19

Page 20: vardhaman report

Godowns Within The Mills:

SR.

NO.

GODOWN

NO.

LENGTH

(in ft)

WIDTH

(in ft.)

AREA

(in sq.

Ft.)

MATERIAL STORAGE

1 114 160 85 13600 Acrylic Fiber, Nylon Fiber,

Polyester Fiber

2 67A 100 60 6000 Acrylic Tow

3 105 100 60 6000 Acrylic Tow & Fiber

4 55 75.2 60 4512 All Types of Filament Yarns

5 33 80 90 7200 Raw Cotton

6 35 75 80 6000 Raw Cotton

7 105A 100 60 6000 Grey Yarn

8 66 60 42 2520 Grey Yarn

9 66A 43 50 2150 Grey Yarn

10 37 66 44 2904 Grey Yarn

11 63 66 47 3102 Grey Yarn

12 64 66 47 3102 Grey Yarn

13 36 152 45 6840 All types of waste

SR.

NO.

GODOWN NO. LENGTH

(in ft.)

WIDTH

(in ft.)

AREA (in

sq. Ft.)

MATERIAL STORED

1 S.T.-II Godowns

(A)

95 92 8740 Raw Cotton

2 S.T.-II Godowns

(B)

95 92 8740 Raw Cotton

3 S.T.-II Godowns

(C)

95 92 8740 Raw Cotton

4 S.T.-II Godowns

(D)

59 47.5 2805 Raw Cotton

20

Page 21: vardhaman report

In the blowroom, input is being fed in the form of cotton bales and the output appears

in the form of flocks. The main function of blow room is the opening, cleaning and

mixing of bale.

The main identifiable impurities are being removed by the machines at the farming

stage, the process is called ginning. Ginning process removes the main impurities

like seed coats, hair, stones, plastic, jute, cords etc. After ginning cotton bales are

formed in the compressed form. Each bale weighs approx 170 kg. Sometimes,

imported bales weigh even up to 300 kg.

The blow room of UNIT-I consists of 2 lines: Line-I and Line-II. Each line is formed by

the laydown of bales in the form of stack one over another, approximately 50 in

number.

Mixing can also be done at this stage by creating a laydown which consists of two or

more varieties, in the approximate ratios, according to the end-product requirement.

21

Blowroom: Laydown of cotton bales before mixing and sorting

Page 22: vardhaman report

Machines used:

22

UNIFLOCK

CONDENSER

MAXI FLOW

HEAVY PARTICLE

SEPARATER- ASTA

MPM

CVT-3

SECUROMATC-4 CARDDK CARD

Page 23: vardhaman report

Unifloc A-10

Manufacturer: RIETER

This machine is used pluck the flocks out of the laid down bales, basically with the

help of suction. It consists of a take-up unit which is connected by vacuum. It has 2

types of rollers: 1 beater roller and 2 stripper roller.

The 2 stripper rollers consist of metallic blades on its surface, which penetrate inside

the bales for better grip on both the sides.

In between are the main rollers i.e. the beater rollers, which again have got spikes on

its surface. Its main function is to open the compressed bales and pluck out the

fibers, so that they can be sucked by the pneumatic action.

Traversal speed of take - up unit = 10.5m/min

Capacity of the machine = 1000kg/hr

In addition, the workers also pick the noticeable trash by hand like: hair, jute, plastic,

paper, stones etc. they also open the bunch of fibres manually.

23Sorting and Mixing done by the Unifloc Machine.

Page 24: vardhaman report

TRANSPORTATION PIPES:

The flocks plucked in Uniflock through chute-feed system,(the pipes utilize

pneumatic action to pass on the plucked fibres) get more opened, while travelling

through the duct. In between there is also a metal detector which detects the

presence of any metal pieces inside the flocks and the damper diverts it into the

waste bag.

The ducts/pipes have been given colour coding:

Sr.

NoColour Code Function of Pipeline

Diameter

of Pipes

(mm)

Location

1 Green Material

Transportation

300 In all machines (Blowroom and

Card)

2 Blue Waste Transportation 220,300,55

0

MFC, CVT-3, Comber

3 Yellow Microdust

Transportation

300 LVSA, CVT-3, SP-F, Card

4 Red Fire Diversion 300 MFC, MPM,SP-F, Card

In case of spark inside the FBK pipes due to friction/metal particles, the entire

material inside the ducts is diverted outside the unit for preventing the fibre from

spreading.

CONDENSER:

Manufacturer : Trutzschler

Once the material has been passed through the metal detector, it goes to the

Condenser where the heavy particles are sucked and they fall down. Thus, in this

way the material is further cleaned.

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Page 25: vardhaman report

MAXI FLOW:

Manufacturer : Trutzschler

The material is dropped in the machine by gravity through the Condenser and

advances with the beater action. The dust and contamination is separated and falls

down. The material is removed from the maxi flow with the help of suction from the

maxi machines.

SEPARATOR:

Manufacturer : Trutzschler

Heavy Particle Separator is a simple equipment working on aero-dynamics principle.

The machine removes contaminations in the mixing such as metal parts and other

heavy impurities which may otherwise cause damage to expensive blow room and

carding machinery.

25

Asta: Heavy particles are separated in this machine before they go to MPM-4 and MPM-6.

Page 26: vardhaman report

MPM:

Manufacturer : Trutzschler

The multi-mixer ensures a good blending at the beginning of the spinning process

which is essential for a uniform distribution and representation of all fibre

components into the yarn cross-section. This needs to be achieved during the

spinning processes as it cannot be achieved by the later processes alone. Proper

blending avoids variation in running conditions, yarn strength, uniformity and dye

take-up. The multi-mixer is usually available in 4, 6 or 8 chambers. In Vardhaman,

there were two lines one containing the 6 chamber MPM and the other containing an

8 chamber MPM.

CVT-3

Manufacturer: Trutzschler

This is another machine which is used for cleaning of the material. First of all, the

feed roller feeds the material inside the machine. Then it passes through three

spikes beater of increasing spike intensity, which carries out the opening. It has a

color contamination sorter (CCS).

Width of the machine :1600mm

Capacity: 600- 800 kg/hr

26

Page 27: vardhaman report

SECUROMAT:

Manufacturer : Trutzschler

Foreign fibre detection takes place at the end of the blowroom line and directly

before the cards, where the opening degree of the fibres has reached a maximum

value, the foreign parts, however, are still existing in a coherent form. 

The separation of the foreign parts is effected by means of 32 compressed air

nozzles (10) distributed over the total working width of 1600 mm, which can be

individually controlled by pneumatic valves, in fact exactly at the point where a

foreign part is located on the surface of the needle roll.

27

Page 28: vardhaman report

CARDING

Manufacturer: Lakshmi Rieter

No. Machines: 10

Manufacturer: Trutzschler

The carding process essentially involves the opening of fibre aggregates by working

between two closely spaced surfaces covered with inclined wires. The main objects

of carding are:

To carry further process of fibres opening to a state of fibre individualization

To remove neps, tiny lumps of fibres

To deliver a continuous sliver for further processes.

To remove impurities from the material by individual fibre separation.

To enable parallelization of fibres.

The carding machine is supplied with cotton flocks through FBK ducts continuously.

The cotton then traverses through the rollers. The material is fed inside with the help

of feed roller which is located above the feed plate. The feed roller is followed by the

licker-in cylinder.

There is a licker-in undercasing and back plate below and in front of the rollers

respectively. Undercasing is a perforated plate which is responsible for collection of

the waste removal from the card. Back plate is positioned between the licker-in and

cylinder. Front plate is positioned between cylinder and the doffer. Both have spikes

and perform the same function as that of the set of cylinder and flats.

Flats are clothing on the rollers which is in the form of spiked belt. There are 102

flats of which about 42 are in working position at time of contact with cylinder.

Cylinder moves very fast as compared to the flats. Due to this movement, the best

fibres are straightened, made parallel and opening and cleaning is performed.

The back plate and front plate reduces the loading on the cylinder. The voids

between the cylinder, licker-in and cylinder, doffer are thus covered by front and

back plates.28

Page 29: vardhaman report

The cylinder is having the main function of opening and cleaning the fibres.

The main function of the doffer is to collect the fibres from the cylinder and deliver

them in the form of a web. The function of the licker-in is breaking and opening of the

tufts of cotton and pass them onto the cylinder without retaining any of them.

To get optimum performance from the various elements of a card, it is essential to

use the right type and right combination of wire clothing. The metallic wire particulars

which could influence the carding process are: wire width, wire point density, tooth

angle, shape and height.

Carding performance can be improved by increasing the number of teeth cross wise

along the width of the card. This has led to the development of finer rib wires. The

doffer is clothed with a wire which has a higher trapping and holding power than the

cylinder wire. Thus it has a greater point density than cylinder wire.

29

Carding Machine

Page 30: vardhaman report

Machine Specifications

Cylinder Speed 450-500 rpm

Licker-in Speed 1100-1200 rpm

Doffer Speed 25-30 rpm

Flat Speed 22-25 cm/min

Cylinder Diameter 1290 mm

Licker-in Diameter 250 mm

Doffer Diameter 500 mm

Can Diameter 24”

Can Height 42”

Technical Specifications

Linear Density of Lap Fed 400 gm/m

Rate of Feed 500 gm/min

Length of Sliver/Can 5500 m

Weight of Sliver/Can 26 kg

Linear Density of Sliver 4.8 gm/m

Production/min 85 m/min

Production/hour 5100 m/hr

Production (kg/hr) 25 kg/hr

30

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CARDING EFFICIENCY AND BREAKAGE MONITORING

DK 780 Card Efficiency

Date Shift (%)

Morning Evening Night

7/12/11 72 85 97

8/12/11 99 96 96

9/12/11 98 97 94

10/12/11 86 98 96

11/12/11 82 96 99

12/12/11 88 97 97

13/12/11 76 97 83

14/12/11 80 62 94

15/12/11 46 95 98

C- 4 Card Efficiency

Date Shift (%)

Morning Evening Night

7/12/11 56 96 95

8/12/11 98 96 85

9/12/11 93 95 95

10/12/11 66 93 89

11/12/11 92 93 90

12/12/11 89 70 95

13/12/11 74 94 93

14/12/11 76 90 98

15/12/11 37 88 98

As observed in the above tables, the maximum efficiency is in the night shifts.

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PRE-COMBING

Within the overall spinning process, the combing operation serves to improve the

raw material. Its use in the production of medium, medium fine and fine yarns

enables a positive effect to be exerted primarily on the following yarn characteristics:

Yarn evenness

Yarn strength

Cleanliness

Smoothness

Visual appearance

Elimination of short fibres produces an improvement mainly in the staple length of

the fibre, but it also affects the fineness of the raw material. Since noil is on average

finer than the original raw material, the micronnaire value of the combed sliver is

slightly higher than that of the feed stock. The various machines used are:

Sliver Lap Machine

Manufacturer: Lakshmi

It is the preparatory process for combing. The basic purpose of this machine is to

mix different card can slivers, for homogeneous mixing to ensure uniformity among

the fibers. It is used to convert the leading hooks into trailing hooks. It also eliminates

wastes. Drafting arrangement – 4/6

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Page 33: vardhaman report

Machine specifications:

Linear Density of Sliver Fed 4.8 gm/m

Rate of Feed 75-120 gm/min

Weight of Lap Delivered 10.45 kg

Weight of Bobbin 1.25 kg

Net Weight of Material 9.2 kg

Length of Lap 150 m

Linear Density of the Lap 61.33 gm/m

Time taken for one Lap 150 seconds

Delivery Speed 60 m/min

Delivery in gm/min 3679.8 gm/min

Production in kg/hr 220.74g/hr

Ribbon Lap Machine

Manufacturer : Laxmi

It the second step in the pre-combing process. In this machine the fibers are evened

out.

Unilap machine

This machine performs the combined function of sliver lap and ribbon lap. It’s major

advantage is that it takes less time than the two machines combined.

33

Production of ribbon laps

Page 34: vardhaman report

COMBING

Manufacturer: Lakshmi Rieter

Model: E7/4

Number of Machines: 9

The main objectives are:

Elimination of short fibres

Elimination of remaining impurities

Elimination of large proportion of neps

Straight and parallelization of fibres

The input of this machine is 8 laps. The waste of coming is termed as “noil “.

The lap is passed through a top comb which has got 26 needles or pins per cm. The

function of this top comb is to catch the short fibres out of the lap. It is followed by

another brush roller which consists of plastic bristles on its surface to catch the fibres

flying around. After the combing action, the laps pass through three sets of rollers, of

which top ones are covered with rubber and bottom ones are made of steel. The

material then passes through a condenser acting as a guide and calendar roller to

form a sliver. Top clearer is present in the machine to take care of the fly being

generated.

Machine Specifications:

Number of Heads 8

Length of Machine 5.169 m

Width of Machine 1.318 m

Loading of Rollers Pneumatically

Can Diameter 18”

Can Height 40”

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Page 35: vardhaman report

Technical Specifications:

Noil Percentage 8-25%

Feed Lap Weight 62.5 gm/m

Feed Lap Width 300 mm

Feed Lap Diameter (max) 450 mm

Delivery Speed 32 m/min

Length of Sliver in One Can 4000 m

Time Taken for One Can 125 minutes

Output/Machine 16-40kg/hr

Nips/min 300

35

Combing Machine

Page 36: vardhaman report

COMBER PRODUCTION MONITORING

Year Average Production (kgs)

2006-07 7925

2007-08 7304

2008-09 7205

2009-10 7130

April 2010

May 2010

June 2010

July 2010

August

2010

Septem

ber 2010

October

2010

November

2010

December

2010

January

2011

Febru

ary 2011

March 2011

5500

6000

6500

7000

7500

8000

COMBER PRODUCTION MONITORING

Average Production

Average production for the year 2010-11 is 6947kgs. It is observed that the

production per year has been decreasing every year.

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DRAW FRAME

Manufacturer: Lakshmi

Manufacturer: RIETER

The main objectives are;

Parallelization and equalization of fibres.

Doubling

Blending

Removal of hooks

Reducing the co – efficient of variation among the fibres

There are two types of drawframes:

Single head: in which one can is formed from doubling of 6 slivers.

Double head: in which two cans are formed. Each can is from doubling of six slivers.

Main features of RSB drawframe are:

It is equipped with automatic can changer system.

It features an autoleveller. A particular fineness value for the sliver is being set in

the machine. Variation of ±

(1-5) % from the reference value, for a set time, say 3 sec, is sensed by the

displacement sensor. The sensor converts this variation into the pulse form at sends

the signal to control the feed accordingly. If the thickness is increased, feed is

reduced and vice-versa

It is equipped with top and bottom stripper for cleaning top and bottom roller.

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Machine Specifications:

LDO/6

Number of Deliveries 2

Can Changing System Automatic

Roller Weighing Pneumatic

Calendar Rollers Weighing Pneumatic

Can Diameter 18”

Can Height 40”

Top Roller Diameter 38.2 mm

Calendar Roller Diameter 62 mm

RSB 851

Delivery Speed 250-750 m/min

Rate of Feed 20-50 gm/min

Top Roller Diameter 39.2 mm

Can Changing System Automatic

Delivered Sliver Weight 4.8-4.92 gm/m

Comparison between RSB 851 and LDO/6

S.

No.parameter RSB 851 LDO/6

1. Number of Deliveries Single Double

2. Can Changer Automatic Automatic

3. Creel Driving negative Positive

4. Delivery Speed (max) 800 m/min 500 m/min

5. Creel Capacity 8 16

6. Number of Doublings 8 8

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SPEED FRAME (Simplex)

Model no. – LF-1400 A

Manufacturer – Lakshmi (LMW)

The speed frame performs three major functions:

Drafting: it is the process where the sliver is attenuated by means of exerting

a pull on it with sets of rollers. This process ensures that the sliver increases

in length and the mass per unit length is decreased.

Twisting: it is the process where the attenuated sliver is given rotational

twists by means of the rotatory movement of the spindle

Roving: it is the output of the speed frame. It takes a highly reduced

thickness (mass per unit length) in comparison of the sliver. The roving is

stored on bobbins and these forms the feed package for the ring frame.

The existence of the speed frame is justified by the fact that the sliver cannot be fed

directly to the ring frame, firstly due to the very high draft requirement at ring frame

and secondly, due to the very large space requirement in ring frame section.

Therefore, the need for the speed frame is to impart draft to the sliver to prepare it

for the ring frame and twist to provide strength to roving.

Main parts of speed frame:

Creel – Here, the cams carrying the D.F. sliver are being placed. The function

of creel is to let the sliver reach the drafting zone, without any obstruction the

drafting zone, without any obstruction. The drafting zone, without any

obstruction, the main parts of creel are as follows:

Creel rollers: it consists of sliver guides, which rotate with the help of creel

roller.

Sliver guide: sliver guide shouldn’t be worn out so that the sliver doesn’t get

abraised due to friction.

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Drafting zone – this is the main portion of the machine, where the thick sliver

is converted into thinner one by applying appropriate draft. Its main parts are

as follows:

Sliver guide: the sliver from the creel reaches first to the sliver guide of the

drafting zone. This guide is located on a traverse plate. Its size and color

varies acc. To the sliver hank. The guide shouldn’t be worn out and no cotton

fibres should be trapped in between.

Bottom drafting rollers: there are three rollers made of steel arranged at

equal distances according to the length of the machine:

1. front bottom roller

2. middle bottom roller

3. back bottom roller

All the other parts of the machine which are required to provide draft to the

sliver, rotate with the help of these rollers.

Nosebar plate and spacer – In between the front and middle bottom roller,

lies a plate which is called nosebar plate. On this plate lies a square shaped

piece made of Al, which is called spacer. The size of the spacer varies

according to the roving hank. Its size – no.(in mm) is mentioned over its

surface itself. This spacer decided the gap between the 2 aprons. In a

machine, all the spaces should be of equal size and any roving should not be

made without spaces, as it would affect the quantity of the roving

Bottom and top apron – Bottom apron runs between bottom roller, nosebar

plate and tension pulley. The tension pulley provides proper tension to the

apron. In between these two aprons, the sliver, after drafting, forms the roving.

That is why, it is very important that the aprons should not be worm out or

loose. They should be cleared up, time – to time. So that they could run

without any obstruction, otherwise the no. of breakages can increase and the

quality can deteriorate.

Top arm – The arm placed over the bottom rollers is called top arm, which

consists of 3 rollers: front pair, back pair and cradle rollers. The top arm

presses the top rollers over the bottom ones, then pneumatic pressure 40

Page 41: vardhaman report

because of which the slivers, after passing through the drafting zone, take the

form of roving. The top arm should be cleaned regularly for good quantity.

Spindle parts –

Spindle: spindles are positioned in front of the top arm on a rail. Spindles are

run through gear mechanism. Bobbin and flyer are placed on the spindle. To

rotate the bobbin separately, the bobbin rail also consists of gears. The

bobbin rail move up and down through ‘building motion’ because of which the

roving gets wound over the bobbin.

Flyer: the part which helps to wind the roving over the bobbin is call flyer. A

‘twist master’ is placed over it, which helps in imparting twist to the roving,

which comes from the drafting zone. There is a finger on one side of the flyer

which keeps the roving under pressure while it is being wound over the

bobbin.

Separator: the steel plate lying between drafting zone and flyer is termed as

separator, which prevents the mingling of broken roving with the ones,

nearby. Machine shouldn’t be run when separator is down position.

Gearing parts: gears are placed on the right side of the machine, which are

responsible for providing necessary motion to the different necessary motion

to the different parts of the machine.

Fan: it is placed on the left side of the machine. There is a separate motor for

running the fan. Below each delivery lies a suction pipe, whose other end

goes to the suction duct. Inside the duct, there are 2 photocells. Because of

the fan, suction is generated in the whole duct. Because of which broken

roving gets sucked inside. The moment, this roving passes in between the 2

photocells, the machine stops automatically. The waste of the fan must be

cleaned time to time.

41

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FAULTS OCURRING IN SPEED FRAME

The main faults that occurs in the output of speed frame are as follows

A. Double roving: when, one roving breaks and clings to the surrounding roving,

while the machine is in running position.

Reasons:

Less amount of pressure in the suction tube.

The suction tube gets clogged because of cotton fluff

Separator is not positioned correctly

42

Simplex Machine

Page 43: vardhaman report

B. Cuts in the roving:

Reasons:

Cuts in the sliver during drawframe only

Incorrect – pressure of the top arm.

Rubber of top roller is having cuts or worn out

Worn out apron

Worn out twist master and flyer finger.

C. Undrafted roving:

Reasons:

Less pressure from top arm

Incorrect setting of temperature and humidity

Incorrect setting of break draft, gauge, spacer etc. according to the

required count.

Hard bobbin:

Reasons:

Less pressure on back rollers therefore thick roving

high tension on the roving

more twist in the roving than the required amount

D. Soft bobbin:

Reasons:

less tension in the roving

less twist in the roving than the required amount

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E. Flied and fluffed bobbin;

Reasons:

in calculation of fly and fluff from the surroundings into the roving

uncovered draw frame cans

not cleaning the racks and trolleys where bobbin are to be placed

F. Stained bobbin:

Reasons:

not cleaning the grease or oil on the machine during maintenance cleaning

uncleaned hands of the workers

dropping the bobbins on the floor

Machine Specifications:

Number of Spindles 120

Bobbin Length 32 cm

Bobbin Diameter 4.8 cm

Flyer Speed (max.) 1400 rpm

Delivery Speed (max.) 30 m/min

Full Bobbin Weight (max.) 3 kg

Drafting System 3/3

Technical Specifications:

Linear Density of Sliver Fed 4.8 gm/m

Delivery Speed 18 m/min

Length of Roving on one Bobbin 2000 m

Production/hour/spindle 1080 m/hr

Production in kg/hour/spindle 0.772 kg

Waste Percentage 1%

TPI 0.96

RING FRAME

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Manufacturer: Lakshmi Reiter

Model: DJ/5

Number of Machines: 24

In the Ring Frame department, yarns of required count are made from the bobbins.

Here, draft is being provided with the help of rollers and then twist is being imparted

with the help of spindle wound, side by side. So, the yarns made by this method are

wound on the ring bobbin.

Parts of a Ring Frame Machine are as follows:

Creel – this is the top most part of the machine where the speed frame bobbin

is mounted. The various parts of the creel are :

Bobbin holder: on the bobbin holder, the simple bobbin holder, the simple

bobbin is mounted. It is denoted that the bobbin is mounted properly and the

holder is not clogged. If it is so, the roving will not be fed properly and there

might be some tension which can cause breakage and neps formation.

Creel rod: it is present between the drafting and the bobbin holder. It acts as

a guide for carrying the roving. Roving should always come from above the

guide rod.

Drafting Zone – This is the most important Zone of the machine. Here the

roving is stretched to from the yarn. Its various parts are :

Roving guide: it is used to guide the roving to the centre of the roving might

move outside the roller surfaces and generate waste. It is mounted near the

back roller.

Bottom rolls: the machine has three bottom rolls. On top of the set of bottom

rolls, there is the top arm. The top arm also has 3 rollers and a cradle. The

cradle has spacers.

Bottom apron & Top apron: bottom apron is mounted on the middle roller

and cradle of the bottom roller set. Top apron is mounted on the middle roller

and cradle of the top arm. On these aprons, the roving thread opens up to

take the form of final yarn.45

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Spindle Zone –

Spindle: This is an important part of the machine which rotates with the help

of the spindle tape. This always rotates in the centre of the ring and the

bobbin is lifted on it. If the spindle tape is not tightly, attached the spindle may

stop.

Ring and Ring Traveller: it is a metallic ring on which the traveller holds the

yarn and moves along the periphery. The spindle moves up and down and

hence the bobbin gets filled.

Laput hook and laput rail: before the thread gets wound on the bobbin it

passes through the laput hook. It should have a proper gauge.

Gearing Zone – this has all the gears and wheels which need to be oiled and

maintained. This area should always be kept covered to prevent the entry of

fluff.

Fan Zone – this zone consists of the main motor and the fan. Because of the

rotation of the fan at a high speed, suction is generated and waste is sucked,

which gets collected in the waste box. When this box gets filled completely, all

the waste should be taken out from the box and it should be cleaned so as to

avoid any chance of jamming in the fan and parts malfunctioning.

Jockey Pulley and Drum Pulley Zone – the setting of the jockey pulley

should be correct, otherwise the tape bar would become out of track. It should

not get jammed, so it is cleaned from time to time.

Overhead Blower Zone – the pressure with which the blower throws the air

should not be blocked with fluff and they should be properly set, otherwise it

would affect the quality.

46

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Different Colour Bobbins and Their Importance:

In ring frame, bobbins of different colors are used like: red, yellow, blue, white

etc. the color of bobbin varies according to the count of yarn. While the

production with bobbins of one color is going on, the bobbins of other colors

should be used, otherwise the mixing of various varieties will occur and quality

will get deteriorated. The weight of speed frame bobbin varies from 1- 1.5 kg,

while that of ring frame varies from 60 – 65 gm.

47

Ring Frame

Page 48: vardhaman report

Main Faults That Occur In Ring Frame:

A. BOBBIN FAULTS :

(i) Ring cut and black bobbin: Sometimes, the thread gets cut by the ring and

sometimes it gets cut by the ring and sometimes it gets blackened because of

the ring. The main reasons of its occurrence are:

Improper setting of bobbin over the spindle because of the

accumulation of hard waste over the spindle

Occurrence of double roving in the speed frame bobbin

Slight displacement of ring of ring rail.

(ii) Bottom spoiled bobbin: if the yarn in the bobbin comes out from the bobbin

and gets entangled then it is called bottom spoiled bobbin. Its main reasons

are as follows.

Improper setting of spindle

Improper setting of bobbin on spindle due to carelessness

Improper setting of bobbin on spindle due to tight bottom portion of the

bobbin

Improper setting of the reel rail

(iii) Over filled bobbins: if the yarn from the upper position of the bobbin gets

entangled, then it is called over filled bobbins. Reasons:

Using small bobbin than the required size.

The machine still keeps on running even when doff has been achieved.

(iv) Soft bobbin:

less twist in the yarn because of rotation of lower speed due to any

reason.

Less tension of traveler acc. to the count.

(v) stained bobbin : reason :

not wiping off the oil & grease.

Uncleaned hands of the worker.

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B. YARN FAULTS:

(i) Double roving:

Mingling of broken roving with the neighbouring rovings of the creel.

Malfunctioning of suction tube because of blockage due fluff.

(ii) Weak yarn:

Occurrence of single roving in the speed frame bobbin.

Loose tape

Cut tape

(iii) Yarn with fluff:

Inculcation of fluff from the environment into the yarn.

Improper cleaning of the drafting zone & other parts.

Dirty speed frame can/drum.

Uncovered drums/cans.

Malfunctioning of overhead blowers.

(iv)Yarn slub: yarn should be uniform in diameter. But at some places, the yarn

become fuller, where twist becomes less and the strength of the yarn reduces;

which is called slub.

Improper pressure from the top arm.

Apron which is being cut.

Improper setting of the spacer.

(v) Neppy yarn: In the blow room, due to the formation of bunches of fibres

which occur on the surface, this defect arises. To regulate this, care is taken

at blowroom, carding and combing department.

(vi)Yarn with thick and thin places: the yarn thickness should be uniform

everywhere, but when thick & thin places arise in the yarn, with the length

varying from 8-10 mm, then such a yarn is called defected. These defects are

measured by uster machine per Km. eg. + 50% thick place means that the

thickness of the fault is 50% more than the actual thickness. Similarly, -50%

thin places imply that the fault is 50 % less than the actual thickness of the

yarn. The yarn with the thin place has comparatively lesser strength.

49

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(vii) So, it can break and create more waste and effect the production &

quality adversely. Its main reasons are as follows :

Improper pressure of the top rollers.

Apron being cut or dented.

Improper setting of the top arm.

Incompatible size of spaces in relation to the count.

Draft applied is not in accordance with the count.

The yarn realisation of the cotton fibres comes approximately 87 kg for carded yarns

and approximately 70 kg for combed yarns. This is so as the combing process

removes the short fibres. The noil % (waste removal %) for the combing process is

around 17%.

The bobbins from the ring frame m/c are collected in containers after their doffing

point has reached. In each container, a doff slip is put. This slip is important as it

contains the following details:

Spindle no.

Machine no.

Count

Time

Date

Name

This is important as the person loading the bobbins for identifiable faults. Also they

are important for count identification. After this, the trolleys are sent to the Autoconer

Machines. This has the function of forming bigger packages in the form of cones

which can be used for doubling and then twisting on the T.F.O.

50

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Machine Specifications:

Spindle Height 240 mm

Spindle Diameter at Top 11 mm

Spindle Diameter at Bottom 15 mm

Distance Between Two Spindles 70 mm

Length of Separators 140 mm

Number of Spindles Per Ring Frame 448

Spindle Speed (max.) 18000 rpm

Delivery Speed 18 m/min

TPI 21.06/19.58

Production till 11/12/11 for the year 2011

(Tonnes)Manpower/Shift

Ring Frame Production 11.56 84.01

Ring Frame Utilization(%)

93.42 84.01

51

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January February April May June July August0

2

4

6

8

10

12

14

16

11.711.9

12.6 13.4 13.9 14.2

Ring Frame Production/Month(Tonnes)2011-12

Ring Frame Production

52

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WINDING SECTION

Yarn produced in the ring frame in the form of bobbins is taken into the winding

section for the formation of large package which is easily transported and various

faults are removed during the winding operation such as thick places, thin places

and neps.

After winding, the package should not contain the faults. The strength, elongation at

break point and appearance should not be altered and the quality of splicing should

be good. The weight of the cone produced is 2.05 – 2.45 kg and 1.25 kg as per

demand.

Manufacturer: Schalfhorst

Model: 338

Number of Machines: 4

53Autoconer: For bigger yarn packages

Page 54: vardhaman report

The bobbins are attached on the spools and when the bobbins get exhausted, new

bobbin is attached manually after every bobbin change, splicing is done by the

machine for the identification of the counts of yarns. The machine follows the

following detection mechanism:

Electronic sensors which detect the yarn breakage and stop the machine.

This is done through capacitors.

Machine Specifications:

Number of Drums on the Machine 60

Number of Bobbins on the Creel 5

Distance Between Two Spindles 13”

Drum Speed 1300-1600 m/min

Splicing Pneumatic

Magazine Capacity 6

54

Inspection of cone in the Autoconer

Page 55: vardhaman report

January February April May June July August86.4

86.6

86.8

87

87.2

87.4

87.6

87.8

88

88.2

87.0587.07

87.93

88.188

87.74

Yarn Realization: Carded (%)2011-12

Yarn Realization

January February April May June July August70.4

70.5

70.6

70.7

70.8

70.9

71

71.1

70.6670.68

70.89

70.8

71

70.67

Yarn Realization: Combed (%)2011-12

Yarn Realization

55

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January February April May June July August26.5

27

27.5

28

28.5

29

29.5

30

28.2

29.68

28.87

27.7

29.3

28.92

Average Yarn Count2011-12

Yarn Count

In this section the cones are kept under UV Light for inspection. This is one of the steps in detecting any yarn faults and difference in colour of the grey yarn.

56

Inspection of cones under UV light

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CONDITIONING

In VSGML, conditioning of the cones is done manually, i.e., room conditioning. The

moisture percent in the cotton yarns comes out to be 7.4%. The material after

conditioning remains for 15-20 minutes outside the conditioning room and final

packaging is done in cartons or pallets according to the requirement.

To avoid the loss of moisture from the cones, two humidifiers are provided in the

packing room. Because of these humidifiers, there is an additional gain of moisture

in the yarns on the cones. Increase in the moisture content of the yarn increases the

yarn realization; therefore, the conditioning of the yarns is necessary.

Following are the main objectives of conditioning:

Imparting strength to the yarn

Imparting uniformity to the yarn

Imparting evenness to the yarn

Increasing the moisture content in the yarn

Increasing the yarn realization

57

Conditioning room for yarn where sprinklers impart moisture before the cones undergo conditioning in the Xorella Machine.

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58

Xorella Machine: A set of cones are put in the machine for moisture regaining

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PACKING SECTION

According to the requirement of the buyer, the yarn package is made as cone or

cheese form. Further the yarn packages are packed in the following ways:

Palette Packing:

This is done on reusable palettes which are wooden stands on which the

cones are kept in layers. After each layer of cones a cardboard is placed on

which further cones is placed. The total weight of the palette is approximately

750 kg. This palette packing is more cost effective as the cost incurred is only

of the cardboard sheets and plastic sheets. The following description is

mentioned on each palette.

Count

Lot no.

Net weight

Gross Weight

Excise no.

Date

59Palette Packing

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Carton Packing:

The cones can be packed in cartons. The following description is mentioned

on each carton.

Description

Count Ne

Excise no.

Carton no.

Gross weight

Net weight

Lot no.

60

The carton packing is less cost effective as the cartons are not reusable

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PROCESS FLOW OF WORSTED SPINNING

61

Mixing

(Laydown)

A variety of fibers, depending upon the output, are mixed so as to make them uniform.Sandwich laydown takes place wherein a 60:40 ratio of regular and high bulk fiber is laid.

Willowing

Input: Small bale tuft, Output: Open fiber tuft

Carding

Separation of each and every fiberSliver preparationInput: Open sliver tuft, Output: Card Sliver

Levellin

g (Gill Box)

Increasing uniformity of fibersParallelising the fibers

Simplex Machine

Input: Uniform Sliver, Output: Roving

Ring Frame

The draft is made according to the count of rovingYarn is made out of roving.

Autoconer

Removal of unwanted deformities of yarn and converting the ring frame yarn into a bigger package

Cheese Winding

For plied yarns

TFOTwo For One twister where plied yarns are twisted in order to achieve the output.

Reeling

Either the yarn is packed after this or it is sent to the dyeing house in the form of hanks.

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WILLOWING

Number of machines: 1

Manmade fibres do not require any cleaning so they are directly made into cards

from their fibre tufts. The primary purpose of the willowing machine is to open up the

fibre tufts into smaller tufts and to mix up various kinds of fibres.

This opening is accomplished by passing the material between two beaters. After

this, material is transported to the cards through a network of pipes.

Unlike the cotton spinning process, in the worsted process (where we to have to

process only synthetic fibres), there is no need of cleaning the fibres as they are

manmade.

62

Synthetic fiber is fed in the Willow Machine for opening and mixing

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CARDING

Manufacturer: Thibeau, Tatham and Hergeth

Model Number: CA-6

Number of machines: 5

The carding process aims at forming a sliver. The fibres are individualised by means

of an extensive arrangement of numerous cylinders. These are arranged so as to

open up the fibres to the optimum and ultimately to separate each single fibre.

The carding machines used are “Thibeau” (manufacturer) aerofeed cards. These

cards are fed by means of pipes, which are connected, to the willow machine.

Inside these machines, exists a complex arrangement of cylinders of various sizes

and this arrangement is designed to optimally open the fibres. The output of these

machines is a sliver, i.e., a loose rope of totally individualised fibres. This sliver is

stored in cans for transportation to the gill boxes.

Weight of Card Sliver 30-35 kg

Fibres Used 100% Acrylic, Nylon, Polyester and Blends

Capacity of the Machine 65-75 kg/hr

63

Slivers of synthetic fiber coming out of the Carding Machine

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LEVELLING (GILL BOX)

Manufacturer: Schlumberger

Number of Machines: 13

The gill box is the equivalent of the draw frame used in the cotton spinning process.

Here the gill box is used to form tops or balls, which form the feed package for the

next stage. The gill box also combs the fibres to achieve the maximum parallelisation

of fibres. In addition, the gill box compresses a few card slivers into one sliver so it is

used for blending different kinds of material into one sliver.

In the gill box, the combing is done at the “faller” arrangement and the delivery rolls

do the calendaring. Thus the sliver produced is a blend of many slivers, i.e., is a

blend of different types of materials. According to the properties of the material it

may be given more than one passage through the machine. The sliver produced can

be stored in cans or be made into tops as per the requirement of the next process.

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Parallelization of fibers in the Gill box

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No.of Faller 2 x 72

Delivery Cans 1, 2 or 4

Can Specification 800 x 1100 mm

Diameter of Top Roll 80 mm

Bottom Delivery Roll Diameter 60 mm

Drafting Range 4.1- 11.9

Number of Cards fed to the machine 8

Capacity GN type: 800-1000kg/shift

GC type: 2000-3000 kg/shift

65

Drafting inside the Gill box: The sliver becomes thinner and finer

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SIMPLEX

Manufacturer: NSC

Number of Machines: 3

Model Numbers: FMV-32 (2 numbers), FM-7 (1 number)

The speed frame performs three major functions:

Drafting: it is the process where the sliver is attenuated by means of exerting

a pull on it with sets of rollers. This process ensures that the sliver increases

in length and the mass per unit length is decreased.

Twisting: it is the process where the attenuated sliver is given rotational twists

by means of the rotary movement of the spindle

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Simplex Machine

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Roving: it is the output of the speed frame. It takes a highly reduced thickness

(mass per unit length) in comparison of the sliver. The roving is stored on

bobbins and these forms the feed package for the ring frame.

The existence of the speed frame is justified by the fact that the sliver cannot be fed

directly to the ring frame, firstly due to the very high draft requirement at ring frame

and secondly, due to the very large space requirement in ring frame section.

Therefore, the speed frame imparts draft to the sliver to prepare it for the ring frame

and twist to provide strength to roving.

Machine Specifications:

Number of Drafting Elements 12

Drafting Range 9-26

Maximum Delivery Speed 200 m/min

Number of Cans Fed 24

Feed Roll Diameter 40 mm

Delivery Roll Diameter 25 & 50 mm

Capacity 100-200 kg/spindle/hr

Maximum Rubbing 1100 cycles/min

Bobbin Length 240 mm

Tension range between feed roll and

draft apron

0.3% to 7.8%

Tension range between rubbing apron

and winding roller

0% to -11%

Tension range between draft roller and

rubbing apron

0% to 6%

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RING FRAME

Manufacturer: Ishikawa

Number of Machines: 26

This is the stage where the yarn is finally formed. The ring frame gives the final draft

and the twist to the roving received from the speed frame.

The mechanism used consists of three sets of rollers for drafting and spindles for

providing twist to the yarn.

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Ring Frame

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The process is carried out with the help of rollers and the roving is drafted to a

requisite mass per unit length. It also imparts the required twist to the yarn through

the rotation of the spindle. The spindles have a very high rate of revolutions per

minute. This and some other criteria are adjusted so as to acquire a definite level of

TPI, i.e., twist per inch length of yarn.

The input in the ring frame is the roving received from the speed frame. This roving

is ultimately converted to “yarn”.

Machine Specifications:

Number of Spindles 400

Drafting System 3

Bobbin Length 220 mm

Spindle Length 240 mm

Capacity 12-15 metric ton/day

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AUTOCONER

Manufacturer: Jehlafhorjt and Murata

Number of Machines: 6

The bobbins from the ring frame m/c are collected in containers after their doffing

point has reached. In each container, a doff slip is put. This slip is important as it

contains the following details:

Spindle no.

Machine no.

Count

Time

Date

Name

This is important as the person is loading the bobbins for identifiable faults. Also they

are important for count identification. Each order has a specific colour bobbin allotted

to its lot. After this, the trolleys are sent to the Autoconer Machines. This has the

function of forming bigger packages in the form of cones which can be used for

doubling and then twisting on the T.F.O.

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Machine Specifications:

Manufacturer Jehlafhorjt

Number of Machines 5

Number of Heads in one Machine 60

Diameter of Yarn Guide Drum 95 mm

Width of Splicing Chamber 3.5 mm

Package Diameter (maximum) 326 mm

Capacity 8-20 kg/spindle/shift

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Splicing is done side by side as the bigger packages are formed in the Autoconer

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TFO

Manufacturer: Veejay Lakshmi

Model Number: VJ 160 HS

Number of Machines: 43

This machine is used for doubling of yarn. The single yarn in the cone form is

converted into cheese. Two, three or four cones can be used to double the yarn

without applying any twist. This doubled yarn is wound on cheese.

This machine operates on the two for one principle of applying twist. The yarn is

gripped at two points during twisting before being wound on the cones.

The yarn packages in the form of cheese are kept in the containers of the TFO

twister. The yarn is threaded and is gripped at one point below the spindle and at the

other point , which continuously rotates and inserts twist. The twisted yarn is wound

on the cones. The twist is varied by changing the speed of rotating spindle in the

container which grips the yarn. After the cones are removed from the TFO, the

following data is mentioned.

TPI

Cone Weight

Customer

Count

M/C Number

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Machine Specifications:

Number of Spindles 168

Number of Spindles/Section 6

Spindle Gauge 254

Pot Diameter 168 mm

Twist Range 2.5-4.3 TPI

Package Type Cheese

Maximum Length of Package (mm) 170

Spindle Speed 12000 rpm

Stop Motion Mechanical

Machine Width 1.1 m

Machine Length 23.3 m

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Two For One Twister

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CHEESE WINDING

Manufacturer: Saurer Allma

Number of Machines: 4

This step is carried out in order to increase the twist of the yarn. The cheeses

produced in the autoconer are wound onto bobbins using this machine. A total of 116

bobbins are produced at one go.

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Cheese Winding Machine

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REELING

This is the process which is carried out in order to convert bobbins to hanks

depending upon the customer’s request. Each machine has 44 heads for preparing

44 hanks. Weight of the hank also depends upon the customer’s specifications.

Number of Machines: 18

Time taken for winding 44 hanks: 10 minutes for hanks of 150 gm each

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Reeling is taking place in the Hank to Cone section

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PACKING

For worsted spun yarns, packing is done in three ways:

Hank Packing (Automatic packer)

Cone packing (Palette)

Carton Packing

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Autopacker

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FANCY YARNS

Fancy yarns or novelty yarns are typically made of two or more strands which are

produced to provide decorative surface effects. Based on the purpose of yarn, each

strand is referred to as the base yarn, the effect yarn or the binder yarn.

The base yarn provides the structure and strength, the effect yarn creates a

decorative detail like loops and knots and the binder yarn is used to tie the effect

yarn and the base yarn if binding is necessary.

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L-R: Flurry Yarn, Boucle Yarn, Loop Yarn

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Fancy yarns in VSGML are produced by four machines:

NEEDLE SPINDLE MACHINE

The effect yarn is cut by a blade so as to produce the flurry effect after which it is

twisted with the base yarn.

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The triangular blade in the Needle Spindle Machine is used to produce the Flurry effect

Production of Flurry Yarn

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CROCHET MACHINE

This is a knitting machine which works on the principle of warp and weft yarn. The

yarn is firstly knit and then it is cut by the blade in order to create effects like feather

and knop. It is also used to make laces.

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Crochet Machine

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HOLLOW SPINDLE FANCY TWISTER - EHP MACHINE

EHP machine is a multi-purpose machine which is capable of producing most of

the effects. Loop, caterpillar, boucle, slub and knop are some of them. These

effects are created by setting the speed of the drafts according to the effect

required. For example, for a loop effect, the speed of the draft for base yarn

would be lesser in comparison to the speed of the draft of the effect yarn. This

way more yarn is wound around the base yarn in a shorter period of time creating

loops.

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Hollow Spindle Fancy Twister

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ESP MACHINE

In this machine, one yarn comes straight passing through the hollow spindle,

which is known as the base yarn, while the other yarn which is the effect yarn is

wrapped around the base yarn by a twister which moves around the base yarn.

SEQUIN MACHINE

In this machine, sequins are added to the base yarn one by yarn or at regular

intervals that are set depending on the requirement. Garlands of sequins are

loaded on the machine while the base yarn is fed from one side. Once the

sequins have been attached to the effect yarn it is twisted along with the base

yarn and finally wound on a cone.

81

Sequins are kept on the top inside a very long inverted tube from where the sequins are fed into the yarn periodically

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ASSIGNMENT- 2

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DYEING

At VSGML, yarn dyeing is carried out. Mostly hank dyeing is done.

BULKING:

Bulking is mainly done to give relaxation to the yarn, which can otherwise create

problem of shrinkage in home laundering.

To attain shrinkage at yarn stage.

To get even and better quality yarns.

To improve running characteristics of material.

Bulking can be done by two methods

Water bulking

Steam bulking

Water Bulking: water bulking is done in a hank machine. The

temperature in the machine is maintained at 80°C. It takes about 10

minutes for bulking of yarns.

Steam Bulking: steam bulking uses autoclave for the bulking process. This process

involves homogenous moistening of materials which reduce electrostatic charge

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which otherwise, influence evenness of yarn. This is done to get even and better

quality yarn. Also, to improve running characteristics of material. Efficient steaming

enables to achieve homogenous moistening important for proper dye ability.

Manufacturer: STAFFI – R.B. Electronics

Machine Specifications:

Capacity 180 kg

Number of Trolleys in Machine 5

Quantity Load per Stick 2.25 to 3 kg

Limit of Vacuum Pressure 0.5 kg/cm²

Limit of Steam Pressure Not more than 0.8 kg

Limit of Temperature 98°C

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Bulking of Reels inside the Autoclave

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HANK DYEING MACHINE- CABINET DYEING:

Number of Machines: 32 (3 are sample machines)

Manufacturers: Tung-Shing, Lorris Bellini, Tekst

It is suitable of processing natural fibers, synthetic and blends at temperature lower

than 100°C. Scouring, bleaching, dyeing and washing are processes done at boil, by

loading once. There is belt driven speed system to suit different kinds of yarn. The

industry has machines of 3 different manufacturers. They differ in their dyeing

capacity, water capacity, water consumption/lot, power consumption/lot, steam

consumption/lot, compressed air consumption/lot and number of sticks.

Machine Specifications:

Number of Carriers/Machine 2

Operating Steam Pressure 5 kg/cm²

Limit of Temperature 102°C

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Dyed Reels in the Cabinet Dyeing Machine

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Main parts of machine

a) Kier

b) Sampling devices

c) Loader

d) Additional tank

e) Cooling water outlet

f) Steam trap

g) Additional tank drain

h) Feed pump

i) Additional flow control

j) Impeller

k) Water drain

l) Pulley

m) Water supply

n) Cooling water inlet direct heating

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HYDRO EXTRACTOR:

Manufacturer: Minnetti Italia (Officine)

Number of Machines: 6

It is used to remove excess water from hank after dyeing. It works on the principle of

centrifugal force. The time required to hydrate the cotton material is more than the

acrylic as cotton has more moisture regain than acrylic. If cotton is not properly dried

then it may create problems during cone winding.

Machine Specifications:

Capacity 5 machines have 30 kg capacity and 1

machine has 45 kg capacity

RPM of Motor 1450

Cage Drum 690-700 rpm

Quantity Loaded per Batch 30 kg for Acrylic

Cycle Time of One Batch 8 minutes for Acrylic

Standard Productivity 1350 kg/hand

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Hydro Extractor

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DRYER:

Manufacturer: Minnetti Italia (Officine)

Number of Machines: 2 (1 old and 1 new)

Hank dryer is used to completely dry the hanks of yarns after dyeing and

hydroextraction.

Machine Specifications:

Features Old Dryer New Dryer

Number of Hangers 180 210

Temperature 95-105˚C 95-105˚C

Capacity 1 kg 2.75 g

PRINTING MACHINE:

Manufacturer: 5WA (Italy)

Number of Machines: 1

Number of Colour Tanks: 4

This is a new addition to the VSGML dye house for creating yarns with multiple

colours. In this printing machine, roller printing machine is used to carry out localized

dyeing, for giving fancy effect.

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In this machine, 48 cones are printed at a time. There are mainly 3 rollers:

Furnishing Roller: always remains dipped in colour and transfers colour to the

other roller.

Engraved Roller: Transfers colour to the yarn band and doctor blade here,

removes extra colour.

Pressure Roller: provides pressure to the yarn band. Yarns are dried and

hanks are formed.

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Printing Machine; Output of one of the Rollers which is then forwarded for heat setting of colour

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DRESSING:

Dressing is the main part in the yarn hank processing because in bulking, dyeing,

dyeing etc. the yarns in the hanks are entangled and they create problems during

hank to cone winding. Thus, it is very necessary to dress the hanks after drying as it

makes hank to cone winding operation easier.

90

Dressing is done by one of the workers in Hank to Cone section

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DYEING PROCEDURES

There were various dyeing processes going on during our internship period which we

covered. They are explained below:

Process of 100% Acrylic Violet Shade

91

Take 85˚C warm water & water bulking for 10 minutes

Overflow it at 50˚C

Add I.G. Surf, Acetic Acid, Retarder, Softener

Run it for 20 minutes

Add half colour and dozing it for 10 minutes

Run it for 10 minutes

Raise the temperature at 60˚C at 1˚C/minute

add the other half colour and dozing it for 10 minutes

Run it for 10 minutes

Raise the temperature at 80˚C at 1WC/minute

Run it for 10 minutes

Raise the temperature at 90˚C at 0.5˚C/minute

Run it for 10 minutes

Raise the temperature at 99˚C at 0.3˚C/minute

Run it for 10 minutes

Hold the material and overflow it

Drain the material

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Process of Acrylic/Nylon Violet Shades

92

Take 45˚C warm water for the material

Add IG Surf, Acetic Acid and run for 10 minutes

Add half colour and dozing it for 10 minutes

Run it for 10 minutes

Then add next half colour and dozing it for 10 minutes

Run it for 10 minutes

Raise the temperature at 99˚C at 1˚C/minute

Hold the material as required

Overflow at 40˚C

Then add 1% wacker finish & 0.5% Formic Acid

Run it for 10 minutes

Raise the temperature at 90˚C at 0.5˚C/minute

Run it for 10 minutes

Drain the material

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Process of 100% Polyester Dyeing

93

Take 45˚C warm water for the material

Add IG Surf, Acetic Acid and run for 10 minutes

Add half colour and dozing it for 10 minutes

Run it for 10 minutes

Then add next half colour and dozing it for 10 minutes

Run it for 10 minutes

Raise the temperature at 99˚C at 1˚C/minute

Hold the material as required

Overflow at 40˚C

Then add 1% wacker finish & 0.5% Formic Acid

Run it for 10 minutes

Raise the temperature at 90˚C at 0.5˚C/minute

Run it for 10 minutes

Drain the material

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PROCESS FLOW OF HANK TO CONE WINDING

94

Entry of Dyed Material in Hank to Cone Section

Dressing

Loaded on Winding Machines

Hank to Cone Winding

Cones are placed in a trolley

Checking of Cones

Packing

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Different types of machine knitting, hand knitting and specialized yarns are

processed on hank to cone winding machines for further processing or to be

delivered to the market. The machines used are:

PS Mettler

Number of Machines: 9

In this machine, paper cone is attached to the adaptor, one side of which is

attached to the spring to hold cone. It is then brought in contact with the revolving

drum.

Machine Specifications:95

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Number of Drums on Each Machine 36 (7 machines), 40 (2 machines)

Drum rpm 300

Weight of Cone 1 kg

SSM

Number of Machines: 3

Number of Drums in Each Machine 24

Drum rpm 400

Weight of Cone 2kg

FADIS

Number of Machines: 10

Number of Drums in Each Machine 35

Drum rpm 350

Weight of Cone 2.25 g

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REELING:

This process leads to the formation of lea (lachhi) from cone and then sent for

packing in lea form.

Name: METRO – Automatic Reeling Machine & Hydraulic Bundle Press

Number of leas formed in each cycle: 44

Weight of each lea: 150 gm

Time Taken for 44 leas: 10 minutes

RAISING:

Raising is a process of lifting a layer of fibres from the surface of the fabric so as

to form a hairy surface on pile. The process imparts a warm and soft handle. It is

the process of raising the fibres from the surface of the yarn according to

customer’s demand. It gives finishing to the yarn that results in:

Bulkiness

Increase in luster

Improved quality

Attractive look

Soft handle

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PACKING:

Packing in VSGML is done in four forms depending upon the customer’s demand:

Ball

Lea

Bundle

Cone

Ball: yarn balls are either packed with weight 25 gm or 50 gm. Packing can be in jar

or box. Each jar/box may contain 4, 6 or 10 balls

Lea: each lea weighs 50 gm and given a tag. 2 leas of 100 gm are packed in a small

packet. 20 such small packets make one big packet. 0ne carton contains 16 big

packets.

Bundle: this packing has leas of 200 gm and given a tag. 3 kg of such leas make

one bundle. 5 bundles are packed in one packet.

Cone packing: Cones free from faults are with polythene sheets. 2 layers of cones

are packed containing 9 cones in each layer. Bag is stitched and carton of 40 kg is

prepared.

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Balls are being made in the Automatic Ball Machine ;Lea Packing

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Manual Ball making and packing

Bundle Packing

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EFFLUENT TREATMENT PLANT (ETP)

ParametersResult treated

EffluentOnline Monitoring

on ETP

PPCB Prescribed Limits for Sewerage

pH 8.09 7.59 5.5-9.0Total Suspended

Solids(TSS)[mg/L]

15 - 100

Total Dissolved Solids(TDS)

[mg/L]1240 - 2100

Dissolved Oxygen (DO)

[mg/L]- 3.59 -

Chemical Oxygen Demand(COD)

[mg/L]36 - 250

Biochemical Oxygen Demand

[mg/L]7 - 30

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MATERIAL DEPARTMENT

The main function of the material department is to procure the raw material in the

form of bales for the spinning process, packing material, electrical material, electrical

material, machine spare parts, oil and lubricants, fuel and building material,

furniture and fixtures and administration equipments. It helps in providing the various

request made by all the departments in an effective and efficient way so that there is

no wastage of time.

This department ensures that the unit never falls short of raw material wherever

required. The process flow is as follows:

The corporate office at Ludhiana receives orders from various buyers for yarn

of specific count and yarn

The office then allots the units with the function of production needed to be

carried out e.g. if the buyers demand acrylic yarn, the office will provide unit1 with

the amount of yarn count to be produced.

The units then submit their yearly requirement of cotton or other raw material.

Their estimate of requirement is calculated with the ERP system. The ERP system is

fed with all the details like: production per shift and material requirement according to

the count demanded.

The office then deals with cotton sourcing stations i.e. various states in India

and procures cotton from there.

This detail is intimated to the material department at the spinning unit. The

detail includes the number of trucks/ total quantity (in terms of net weight) to be

coming to supply the materials.

Once the details are received, the material department looks after the

receiving, checking, paying for and storing of the bales.

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WHILE RECEIVING THE MATERIAL:

The following things are needed to be checked while receiving the materials from

trucks.

Whether the material is designated to be supplied to the particular company

or not because here are two spinning companies of the same Vardhman group,

requiring raw material cotton.

Net weight of the bales is cross checked with that mentioned on the slip

carried by the invoice given to the driver. The weight is calculated by weighing the

truck at the time it comes (with the material) and after unloading the trucks.

Quality of the bales – if the bales are darkened in color and dirty, the defect is

brought into notice of the corporate office. Since the material is insured, the office

itself decides to pay the charges before or after claiming the insurance.

Various places from which bales are procured:

Punjab

Gujarat

Madhya Pradesh

Rajasthan

Karnataka

Andhra Pradesh

Various qualities of cotton procured are:

Indian cotton : Shankar 6, J-34

Varieties Cost (Rs. / kg)

Shankar 6 52-54

J-34 46

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The procurement is done once or twice in a year. But can also be done whenever

required. The season begins from October/November and ends in February/march.

After checking all the above mentioned details, the material is sent to be

stored in the godown.

In the godown, the bales are stored in form of stacks.

Stickers are put on the bales which are used to identify the number of bales

stored.

Bales face is always kept on the outer side for identifying the stickers.

The no. of the bales stored into the stack and the information is entered into

the ERP system.

The details which are fed are the quality of the bales i.e. the variety, number

of bales of each kind station from which they are received.

The bales are pressed bales which have no chance of getting fire.

It is always taken care of that the godowns never fall short of material stored.

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DISPATCH

The production department submits the requirement of the raw material to the

material department. The variety of cotton and the number of bales is specified.

The godown then issues the cotton bales to the production unit and the

corresponding issue slip is filled.

On an average the production unit requires 300 bales/day.

The issue system is FIFO (first in first out) i.e. the bales which are arriving first

are issued first. The pressed bales can be kept in the godown for long time also as

they are not affected by fire or water.

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MAINTENANCE DEPARTMENT

The main objective of maintenance department is to eliminate the breakdowns,

maximum utilization of machines operating time, incorporations of new technologies

and engineering development in the basic design of the machines, augmentation of

machine capabilities and optimum expenditures on maintenance function and

activities. This aspect of maintenance function helps in reducing or completely

prevents maintenance efforts during lifetime of the equipment.

It involves various maintenance activity that are to be recorded a year head which

helps in planning of manpower, material and service which are required for the

period. This system helps in analysis of maintenance work measurement, machine

replacement, nature of breakdown and downtimes etc.

There is a review committee comprising of spinning superintendent, maintenance in

charge and his assistants. This committee holds its meeting regularly and reviews

the maintenance performance in the following areas :-

Analysis of breakdowns.

Ratio of downtimes too available operating time.

Ratio of other maintenance hold ups to available operating tome.

Review of maintenance costs.

Review of major replacement.

Review of maintenance function and performance.

Review of training program.

Review of work done by the maintenance personnel.

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ENGINEERING DEPARTMENTThe objective of the engineering department is to provide uninterrupted good quality

power supply, oil and water free compressed air, healthy and well-maintained

humidified air to the production plant thereby adding value in producing good quality

yarn. It also helps in catering to the needs of colony residents, club and

administration by maintaining safe electricity and water distribution, sewage

treatment plants etc.

INDUSTRIAL RELATIONS DEPARTMENTThe procedure underlines the system and methods relation to the functional

responsibilities of industrial relations department, i.e. manpower planning,

recruitment, time office function, training and development, grievance handling,

welfare and colony administration etc. The system has been designed to provide

better services to the human resource and helping them achieving the quality

standards as required under ISO 9002.

The endeavor of IR department is to promote harmony and industrial pace, fair shop

floor practices and promote good relations with local external agencies.

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TRAINING DEPARTMENT

Training and development has been regarded as an important tool for the

improvement of skills level, work habits, development of positive attitude of the

worker and upgrading the system. Training and development serves as an important

means for preparing workers for modified performance standards, improvement of

quality of product and reducing absenteeism, accidents and material wastage.

Since training is a continuous and time consuming process and entails much

expenditure thus while designing and implementing training program, due

consideration is given to the organization and workers needs. The activities relating

to workers training are organized in workers training and development center i.e.

Manav Vikas Kendra (MVK), which is within the premises of Vardhman Spinning and

General Mills Ltd. To achieve these objectives more emphasis and importance has

been given to impart a systematic attitudinal and function training to the workers.

Once a positive work culture and attitude is developed the workers shall they be

interested in improving their skills and knowledge. The main focus is on workers

learning and not on teaching them.

January February March April May June July235

240

245

250

255

253255 254

238239

236

Manpower/Day(2011-12)

Average Operators

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COSTING DEPARTMENT

The marketing department forecasts the quantity of yarn which they can sell and the

production department reports the amount of yarn which the unit can produce. The

costing department then makes the annual and monthly budgets. The budget

includes the following factors:

Labour wages

Raw material

Packing material

Electricity

Transport (raw material and dispatch)

Maintenance cost incurred during production run.

The budget and the production plan are installed in the ERP system which is

transparent. The users can see the activity schedule of the production planning

through various codes specified. The ERP system is also fed by the daily production

details of the units.

The costing department checks the production details through the ERP system

production delays can cause high costs to the company.

The department is given the inputs regarding the count of the yarn to be made, the

total amount of time of dispatch. The department ensures that no ring frame remains

idle or in non working condition during any of the shifts.

The department checks the report for any kind of detensions (detension report) or

stoppages during production. By checking the detension reports the department

comes to know the reason and timing of the machine stoppage. The machine

stoppage has direct effect on the production of the unit. Some serious causes

requiring maintenance department look after are brought into notice and checked.

For any production order running the following is the estimated cost break up in the

percentage.

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RAW MATERIAL 50 – 55 %

POWER COST 12 – 15 %

These two factors account for the major cost incurred. The department also looks

into the profitability factor. After receiving the order, allotted by the corporate office,

the department decides the time required for the completion. This time is calculated,

as specified earlier, through the machine productivity data available in the ERP

system. The daily production details are checked and thus the order is kept under

track.

It is also to note that the cost of storing the finished good i.e. yarn is incurred. Thus

the dispatch is done within a time of 10-12 days otherwise the working capital gets

blocked.

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LEARNING OUTCOME

The learning at Vardhaman Spinning and General Mills was indeed a unique one

with a lot to understand and take with us. The major learning outcomes at VSGM

were based on the following points:

Understanding of the different departments working at the factory

Necessary processes to be carried out before final delivery

Inevitable constraints for any process

Understanding of spinning, problems and their solutions

Understanding the importance of workforce and results of absenteeism on

production

Understanding the machine effectiveness and addressing their maintenance

issues

The process flow of Production Department and the steps involved

The above areas of understanding made us more aware of the spinning

operations, weaving operations and finishing operations.

The learning experience was also a helping tool in making us aware of our role

as garment and textile experts

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