Material handling lecture note
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This document provides an overview of yarn production processes and material handling. It discusses the key raw materials used, including various natural and synthetic fibers. The major steps of yarn production covered are blowroom operations, carding, drawing, roving and ring spinning. Material handling equipment used at each stage is described and illustrated, such as trolleys, conveyors and chutes. Health and safety precautions for material handling and operating machinery are also outlined. The goal is to understand raw material preparation and the production of yarn through various processes.
Material handling lecture note
- 1. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. YABA COLLEGE OF TECHNOLOGY DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY TET II3: YARN PRODUCTION 1 COURSE OUTLINE 1.0 Understand the handling of raw materials in a typical textile industry. 2.0 Understand the principles of fibre mixing, opening, cleaning and blending processes. 3.0 Understand the functions and operations of the Revolving flat card and the high production card. 4.0 Understand lap preparation by both traditional and modern methods. 5.0 Understand the principles and operations of rectilinear comber.
- 2. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. A REFERENCES 1. R. Senthil Kumar., Process Management in Spinning, CRC Press, Boca Raton, USA, 2015. 2. Uttam, D., Material handling in textile industries. International Journal of Advanced Research in Engineering and Applied Science, June 2013. 3. http://www.bdtextileinfo.blogspot.com.-Assessed on 25.05.16 12:10pm 4. Nkeonye, P.N., Introductory textiles, ABU Press, Zaria, Nigeria, 2003. 5. What is a textile? A flexible material constructed from a network of natural or artificial fibres. TEXTILE RAW MATERIAL Raw materials are unique substance in any production oriented textile industry. They play a vital role in continuous production and for high quality fabric. Textile raw materials are selected as per the manufacturing policy of the company i.e. whether a composite mill or only a spinning, weaving or dyeing/finishing. Types of Textile Raw Material; they include the following: 1. Fibre 2. Fabric 3. Dyestuff 4. Chemical and Auxiliaries FIBRE: A fibre has been defined according to ASTM as ‘a unit of matter characterized by flexibility, fineness and a high ratio of length to thickness’.
- 3. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. Name & Source: Cotton, Silk, Jute, Wool, Polyester, Nylon, Spandex, Flax, Acrylic, Aramid, Polyethylene, etc. FABRIC: Fabric is a planar textile structure formed by interlacing yarns, fibres or filaments. It may be woven, knitted or nonwoven. Name & Source: 100% cotton fabric, 65% cotton/35% polyester fabric, etc. DYES: A dye is a coloured substance that has an affinity for the substrate (e.g. fibre, yarn, fabric, paper, etc.), on which it is applied. Dyes are generally applied in an aqueous solution and require a mordant to improve the fastness of dyes on substrate. The following dyes are used; Reactive, Disperse, Acid, Basic, Direct, Sulphur, Azoic, Vat, etc. CHEMCALS & AUXILIARIES: Dyeing auxiliaries are chemicals or formulated chemical product which enables processing operation in preparation, dyeing, printing or finishing to be carried out more effectively or which is essential if a given effect is to be obtained. Examples are; sequestering agent, lubricants, desizing agent, mercerizing agent, etc. MATERIAL HANDLING Material handling can be defined as an “art and science of conveying, elevating, positioning, transporting, packaging and storing of materials.” Starting from the time, the raw materials (such as fibres for spinning unit or yarns for weaving/knitting unit and fabrics for wet processing or garmenting units) enters the mill and goes out of the mill in the form of finished products; it is handled at all stages within mill boundaries such as within and between raw materials stores, various section of production department, machine to machine and finished product stores. Material handling involves the movement of materials, manually or mechanically in batches or one item at a time within the plant. The movement may be horizontal, vertical or both. Material movements add to the cost but not to the product value. The ideal manufacturing plant will have an absolute minimum material handling and more use of mechanical material handling equipment. Some benefits associated with effective material handling in textile/manufacturing industry are listed below; Improving productivity Increasing the speed of material movement
- 4. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. Reducing man-power Reducing materials wastage and minimizing production cost Promoting easier and cleaner handling Eliminating idle time of machines, equipment and workers Reducing fatigue incurred by the workers Locate and stock materials better and in less space Increasing safety and minimizing, etc. FUNCTIONS OF MATERIAL HANDLING SECTION There are basically two functions of material handling section: 1. To select production machinery and assist in plant layout so as to eliminate as far as possible the need of material handling. For examples: in a spinning mills chute feed cards, open end spinning machine, auto-doffing ring frames and autoconer etc. reduce the material handling activities hence material handling cost. 2. To choose most appropriate material handling equipment which is safe and can fulfill material handling requirements at the minimum possible overall cost. For example: Air conveyor pipes within the blow room and between blow room and cards, big size plastic container trolley for handling ring frame bobbins, cones and fabrics in a textile mill. MATERIAL HANDLING EQUIPMENTS Wide ranges of material handling equipment’s are available in the market; which are suitable to the most of the industrial requirements. Material handling equipment’s are classed as: 1. Industrial trucks: manual and powered 2. Cranes: overhead bridge crane, jib crane and gantry crane 3. Conveyors: belt conveyors, roller conveyor, chain or cable conveyor, etc. 4. Monorail 5. Lift 6. Slides & chutes 7. Hoists: chain type manual, electrical & pneumatic. 8. Tractors & trailers etc. MATERIAL HANDLING IN SPINNING UNITS
- 5. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. The figures below are some of the material handling equipment’s commonly used in textile mills. I. FROM TRUCK TO MILL STORES Figure 1: 2-wheeled industrial truck/trolley Figure 2: 4-wheeled industrial truck/trolley Figure 3: Forklifts Figure 4: Platformtruck Typesof material handlingequipment’susedinthe spinningmillsare shownin Table 1 below S.No Process Material Material handlingEquipment 1. From suppliertomill Cotton/Polyesterinbale form Truck or train or ship 2. From truck to store Bale of raw material Manual 2,3 or 4 wheeledtruck 3. Raw material store tomixing section Bale Manual 2,3 or 4 wheeledtruck 4. Mixingto blowroomline Loose cotton Special designedtrolleysor lattice or suction 5. Blow room tocard Laps or loose cotton SpeciallydesignedtrolleyorAir pipe conveyorandchute 6. Cardingto draw frame Slivercans Manual trolleyorcans fitted castro wheels 7. Draw Frames to SpeedFrame Slivercans Manual trolleyorcans fitted
- 6. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. castro wheels 8. Speedframe toringframe Rovingbobbins Manual trolley/Tapaorspecial designedtrolley 9. Ringframe doffing Ringbobbins Doffingtrolleys 10. Ringframe to winding Ringbobbins Speciallydesignedplastictrolley 11. Windingtopacking Cones Big size plastictrolleyorspecial designedtrolley Table 1: Material handlinginspinningunits ii.FROMMIXING TO BLOW ROOM Figure 5: Iron trolley Figure 6: Mixingtrolley III.WITHIN BLOW ROOMLINE Figure 7: Belt Conveyor
- 7. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. Figure 8: Air Pipe Conveyor iv.FROMBLOW ROOMTO CARDINGDEPARTMENTS Figure 9: Trolleyfor blowroom laps Figure 10: Chute FeedingSystem V.FROM CARDINGMACHINETO DRAWFRAME & DRAW FRAME TO SPEED FRAME
- 8. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. Figure 11: Slivercans Figure 12: Cans carrying trolley vi.SLIVER LAP/RIBBON LAP MACHINE TO COMBER Figure 13: Sliver/ribbonlaps carrying trolley
- 9. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. Vii.FROMSPEEDFRAME TO RING FRAME Figure 14: Big size trolleyfor speedframe Figure 15: Porcupine type trolleyfor speedframe viii.TROLLEY FORSPEED FRAME FLYERS Figure 16: Trolley for speedframe flyers Ix.FROMRING FRAME DOFF TROLLEY
- 10. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. Figure 17: Ring frame doffingtrolley Figure 18: Ring frame doffingtrolley X.POST SPINNING Figure 19: Trolley fittedwithcone holderpegs MATERIAL HANDLING & SAFETY A. The Blow room 1. Cotton grownand harvestedbythe farmerwasuntil 1987 soldto marketing boardfor onwardsales to the textile mills.However,withthe abolitionof the marketingboard,the textile millsorabody representingthembuydirectlyfromthe cottonfarmers.
- 11. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. 2. The cottonarrivesinthe factorypremisesinthe formof a highlycompressedmasscalled BALESone of whichweighsbetween200-300kg. 3. Balesto be usedare movedfromthe warehouse tothe blow room,where theywill be openedand allowedtoremainforat least24 hoursinorder forthe fibresto/mightabsorbmoisture before beingput ontothe machines. 4. During processinginthe blow room,the cottonisopened,cleaned,mixedandblended.Heavyand lightparticlessuchasstones,sandsticksand cottonseedreminants,leavesandotherimpuritiesare removed,andcleancotton formedeitherintoamat-like sheetcalledaLAP, or feddirectlybychutesto the carding machine. Material HandlingPrecautions: 1. During balescarriage fromthe warehouse tothe blow sroom, care shouldbe takento avoidaccidents causedby a careless liftingof baleswhichweighbetween200 and 300kg 2. Blowingroomstandardhumidityhastobe maintainedat55-65%. Thisis forbetterprocessingof raw materialsaswell asconvenienceof the workers. 3. Workers inthe blowroomare warnedto alwayswear theirnose/mouthmasksfortheirsafety.Hand glovesmaybe wornwhennecessary. 4. To avoiddamage tothe openersandblowingmachinebeaters,feedersare instructedtopickany piece foundinthe rawcotton whenfeedingisinprogress. NB: Bar magnetsare fixedonsome machine passagestoattractmetal piece foundinthe raw cotton whenfeedingisinprogress.Barmagnetsare fixedonsome machine passagestoattractmetal pieces duringprocessing. B. Carding Section 1. Laps producedinthe blowroomare laidonthe lap standbehindthe cardingmachine.Theyare loweredandfedtothe taker-injustbefore the previouslapunwindscompletely,forcontinuity. 2. Laps fedto the carding machine are opened,andshortfibres,sticks,leaves,sandandsmall dust particlesare removed.The fibresare formedinto WEBandthe webcondensedbycalenderrollersto formsliverwhichiscoiledintoa CAN. 3. Humidityincardingsectionisbetween50-55% and temperature ismaintainedat30-350 c. Material HandlingPrecautions: 1. Cardingmachine operativesandmaintenance workersare instructedtouse mouth/nose masksfor healthreasons.
- 12. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. 2. Cardingengineshave heavyandfastmovingpartse.g.cylinderandtaker-in.Workersare toavoid bodilycontactwiththese partswheninoperation. 3. A machine due formaintenance shouldhave asignplacedonitto warn everyone nottostart it.The powersupplytosuch a machine mustbe disconnected,andif possible, mustnotbe restore withoutthe knowledge of the maintenance staff. 4. Cardingoperativesandmaintenance workers are advisedtobe careful whencleaningmachinewith sticks,brushesandmetal hooks.Whenthese are takenintothe machine duringoperation,theywill damage the cylinder,dofferandflatteeth. C. Drawing Section Here,card sliversare passesthroughtwosetsof drawingmachines.These makesindividualfibreswithin the sliverbetterorientedandparallelized. The purpose of draftingfor lightandheavysliversthroughthe same passage intoone sliver istoeven out the differencesinthemandproduce amore regularsliver. The sliverisfinallycoiledintoacan similartothe cards. Material HandlingPrecautions: The drawingmachine isthe safestto operate inthe spinningdepartment.Onlysignsare placedonitfor notificationduringmaintenance. D. Roving Section 1. Draw framessliversare arrangedbehindthe rovingframe anddrawnthroughpairsof draftingrollers to formroving.A rovingisthe drawnsliverfurtherreducedtoa smallersize withjustalittle twist insertedandwoundontoa package knownas BOBBIN. 2. During operation,breakagesmayoccuralongsliverlengths,the operativesshouldnotallow piecing up to exceed1½ inches,andonlyverylittle twistapplied. 3. Rovingpiecingshouldbe carriedoutonlybyexperiencedoperativesandmustbe done soas to avoid frequentmachine stoppage. Material HandlingPrecautions: 1. The sliversandroving’sinthissectionshouldbe carefullyhandledtoavoiddamage. 2. Operativesandmaintenance menshouldnotwearlongrobes.Thiscaneasilygetcaughtby flyersand seriousaccidentmayoccur.
- 13. , LECTURE NOTE PREPAREDBY MUHAMMED RAJI.A. DEPARTMENT OF POLYMER & TEXTILE TECHNOLOGY YABA COLLEGE OF TECHNOLOGY, LAGOS NIGERIA. 3. The humidityappliedhere isaboutthe same asthat inthe carding and drawingsections. E. RingSpinningSection 1. Rovingbroughtfrom the speedframesare arrangedontop of the ringframesand fedtothe drafting rollers.Here,the rovingisreducedinsize,twistedintoyarnandwoundontoa BOBBIN. 2. Windingof the yarn onto a BOBBIN is done withthe aidof travellers. 3. During operation,doffingissocontrolledthatmachinesare stoppedfordoffingalternatelyandonly one machine isstoppedata time fordoffing.Whilethe remainingonesare inoperation. 4. Humidityinthissectioniscontrolledsothatrollerlappingshall notoccur.Standardhumidityinthis sectionisabout50%. Material Handling Precautions: 1. Operatorsare to be careful inthe use of hookswhenremovingrollerlapping,because itcould damage rollersandrubberaprons. 2. Bobbinsandtravellersdroppedonthe spinningfloorsshouldbe pickedimmediately.Bobbinscan cause accidents and travellersdroppedwill be wasted. 3. Maintenance workersshouldplace warningsignsonthe machine whenworkingonitsothat other workerscouldkeepoff.Rollersandgearscan easilycause injuries..