Spinning With Technical Acess
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The document discusses the spinning process in textile engineering, detailing the conversion of fibers into yarn through various machine stages including blowroom, carding, and ring spinning. It provides a comprehensive list of machines and their functionalities, specifications, and technical data for ensuring efficient production and fiber processing. Key steps include blending, cleaning, and carding to achieve high-quality yarn while maintaining operational efficiency.
Spinning With Technical Acess
- 1. SPINNING WITH TECHNICALACESS BY ESHAN BANSAL DEPARTMENT OF TEXTILE ENGINEERING GZS PTU CAMPUS BATHINDA
- 2. SPINNING Spinning is a process of conversion of fibers (raw material) which possess certain characteristics into yarn of desirable characteristics through various stages involving preparatory stages and ring spinning stage.
- 4. RAW MATERIAL SPECIFICATIONS Sr. No. PARAMETER J-34 (100%) 1. Length 29.4mm 2. Micronaire 4.2 3. Strength 30 g/tex 4. Trash 4.8% 5. Maturity Ratio 0.92
- 5. LIST OF MACHINES Sr. No. MACHINE NAME MACHINE MANUFACTURER MODEL NO OF M/C B/R LINE-1&2 1 BLENDOMAT TRUETZSCHLER BDT-019 1 2 CONDENSOR TRUETZSCHLER LVSA-375 3 SECUROMAT TRUETZSCHLER SC-154 1 4 UNICLEAN RIETER B-11 1 5 MULTIMIXER TRUETZSCHLER MCM-6 2 6 CLEANOMAT TRUETZSCHLER CVT-3 2 7 CCS-BASIC SIEGER 2 8 DUSTEX TRUETZSCHLER DX385 2 CARD 1 CARD TRUETZSCHLER DK-803 17 2 CARD TRUETZSCHLER TC-03 1 BREAKER D/F 1 DRAW FRAME RIETER SB-2 2 2 DRAW FRAME LAKSHMI LD0/6 1 UNILAP 1 UNILAP RIETER E-30 2 2 UNILAP LAKSHMI LH-10 1 COMBER 1 COMBER RIETER E-62 8 2 COMBER RIETER E-60H 3 3 COMBER LAKSHMI LK-64 3 FINISHER D/F 1 DRAWFRAME RIETER RSB-D851 5 2 DRAWFRAME RIETER RSB-D30 3 SPEED FRAME 1 SPEED FRAME LAKSHMI LF-1400 7 2 SPEED FRAME LAKSHMI LF-1400A 4 RING FRAME 1 RING FRAME RIETER G 5/1 20 2 RING FRAME LAKSHMI LR 6/S 9 AUTOCONER 1 AUTOCONER SCHLAFHROST 338 5 2 AUTOCONER SCHLAFHROST 5 3 T.F.O 1 T.F.O VEEJAY LAKSHMI VJ-150-HS 4 2 T.F.O VEEJAY LAKSHMI VJ-190 2
- 6. BLOWROOM The basic purpose of Blow room is to supply • small fibre tufts • clean fibre tufts • homogeneously blended tufts if more than one variety of fibre is used to carding machine without increasing fibre rupture, fibre neps, broken seed particles and without removing more good fibres. The above is achieved by the following processes in the blow room • Pre-opening • Pre-cleaning • Mixing or blending • Fine opening • Dedusting
- 7. BLENDOMAT BDT O19 • It can be freely programmed to allocate up to 3 bale groups, to feed up to 3 blow room lines. • Bales of varying heights can also be easily processed. • It is very sturdy and robust machine capable of producing production up to 1200 kgs/hr. • The penetration control mechanism avoids reversal of rotation direction of the opening roll and avoids the wear intensive braking and acceleration after each passage of bales.
- 8. UNIQUE INVERSION MECHANISM • The blendomat is equipped with two opening rolls rotating in opposite direction. • Depending on the direction of travel one roll is always working against the travel and one with the travel. • The one which is operating in opposite direction to the travel, is raised by up to 10 mm by means of a motor. • The roll which operates in the same direction as the travel penetrates more deeply into the bale. • The result is the even distribution of production from both rolls and equal tuft sizes from both rolls. • TECHNICAL DATA Production- 900 – 1000 kg/hr Efficiency- 88.6% Traverse drive speed- 11.6 m/min Rpm of take-off roller- 1500 – 1800 r.p.m Nominal take off depth- 2.5- 3 mm Beating Points – 0.5
- 9. LVSA 375 The purpose of the condenser is twofold: • To transport cotton and synthetic fibers pneumatically in the form of tufts • To de-dust these tufts at the same time. The fan (7) produces the air current required to transport the material. The stock is separated from the transporting air by the perforated drum (3) and removed from the drum (3) by the take-off roller (9). The exhaust air (5) is deflected to the filter unit. • TECHNICAL DATA Diameter perforated drum- 480 mm Diameter take-off roller- 300 mm Diameter fan wheel 50 Hz- 528 mm Speed perforated drum- 80/min Speed take-off roller- 410/min Speed fan wheel 50 Hz- 1410/min Production- up to 1200kg/hr
- 10. SECUROMAT SC154 Its objectives are: • To separate the metal particles especially iron particles from the raw material. • To feed the material to the next machine for further processing. Basically, electronically controlled metal separation is carried out from the raw material so as to protect the cleaners and cards from metal parts. It requires no exhaust air and filter capacity.
- 11. UNICLEAN B11 • It is used for cleaning and extracting dust from cotton of any origin and blends of cotton/man- made fibers very gently and effectively. • The raw material is fed without nipping. • The guide plates (14) carry the tufts in a spiral manner over the grid (11) seven times. • The combination of cleaning intensity and waste rate ensures efficient cleaning with few good fibers in the waste and no crushed waste particles. • Waste is removed periodically via the air lock roller (9) and the conduit (2). • TECHNICAL DATA Diameter of pin roller 750 mm Diameter of lock roller 350 mm Speed of pin roller 480 – 960 rpm Speed of lock roller 16 – 19.2 rpm Electric cylinders per m/c 2 Shearing force 2000 N Lift 100 mm Lifting speed 5.6 mm/s Beating Point 1.0 Grid angle 4.40
- 12. MULTIMIXER MCM6 • To blend different varieties of cotton in order to achieve maximum homogeneity of the mix. • It acts as a storage unit to feed raw material to the card uniformly in case of any malfunction in the pre-process. • There are six reserve trunks which comprises of reserve trunk flap (3), perforated partition wall and light barrier for minimum filling level monitoring. • Each trunk is filled until the set pressure is reached. • When the pressure is reached, the controller identifies the trunk as full and the next trunk is filled. • The trunk is ready to receive the material again only when the calculated filling level has fallen to 75% • If all the trunks are ready to receive material, the system switches to next trunk after a maximum of one min even if the changeover pressure is not reached. • TECHNICAL DATA Storage volume per trunk 1.38 – 2.58 m3 Reserve capacity per trunk 41.4 – 77.4 kg Opening roll speed 1000 rpm Delivery roll speed 0.05-0.83 rpm Tray suction fan speed 2860 rpm Conveyor belt speed 1.8-35.5 rpm
- 13. CLEANOMAT CVT3 • It is a combination of one spiked roll and two saw-tooth rolls which ensures high degree of opening and cleaning especially of medium grade cottons. • These rollers work in combination with mote knives and suction hood to remove fine trash impurities in all types of cotton very effectively. • Roll 1 has two separating wings. A carding segment is installed after the first wing. Waste is extracted directly from the separating wings, via suction hood i.e. a continuous suction flow removes all contamination produced by separation. • Before the second separating wing, a guide wing is situated which can be steplessly adjusted during production. In this way, the quantity and composition of the waste can be regulated. • Roll 2 (6) runs faster than roll 1 and receives the material. Roll 2 is equipped with a guide wing, a carding segment, a separating wing and a connected suction hood (7). • Roll 3 (8), which in turn runs faster than roll 2, is also equipped with a guide wing, a separating wing and a connected suction hood (9). From here the material is extracted to the next machine.
- 14. TECHNICAL DATA Figure: Roll 1 Figure: Roll 2 Figure: Roll 3 Speed of feed belt- 0.757 -15.15 m/min Speed of roll 1- 1244rpm Speed of roll 2- 1864rpm Speed of roll 3- 2968rpm Beating point- 1.0
- 15. DUSTEX DX385 • It ensures effective dedusting which results in thoroughly dedusted slivers which ensure optimized running behaviour during yarn formation. ADVANTAGES • Higher efficiency rates • Longer lives of clothing and spinning components • Better running behaviour of the spinning machines • Clean ambient air
- 16. CARDING DK803 • The function of the carding machine is to open the tuft web coming from the tuft feeder into a fiber web, to card (parallelize) the fibers, to extract the waste particles (dust, trash, etc.), to form the carded web into the sliver and to feed this to the coiler for being deposited in a can. The main components of the card DK 803 serving for this function are: • Tuft feeder DIRECTFEED DFK • Feed roll • SENSOFEED • Deflector blades, mote knives with suction hoods and carding segments • WEBFEED • Precarding segments and suction hoods with mote knife- WEBCLEAN- • Flats cleaning device • Cylinder covering segments with suction hoods and mote knives • Revolving flats • Cylinder • Suction hoods with mote knives and post carding segments- WEBCLEAN- • Doffer • Cleaning roll • Stripping roll • Squeezing rolls • Calendar rolls with can changer
- 17. OPERATING ZONES • The feed roll seizes the web, condenses it and forwards it to the L-in. • The feeding system (SENSOFEED) enables the web being clamped and measured section by section. • The function of the WEBFEED is to open the web supplied from the feed roll, to clean and feed it to the cylinder. • The main cleaning is performed on the first roll (1). Fine trash particles and dust are extracted on the second and third roll. • The extraction quantity is determined by a corresponding setting of the deflector blades (7). • Carding-parallelization-cleaning and opening into individual fibers takes place between the clothing of the cylinder and the revolving flats. • The clothing of the revolving flats are designed to pick up short fibers and impurities in the form of strips. • The clothed doffer carries the fiber web over the web guiding section to the stripping roll (1). • The WEBSPEED brings the web together. • In the web trumpet the card sliver is formed from the web, and the sliver is drawn off by the calendar rolls and orderly deposition of the sliver into the can takes place. Fig: Tuft feed direct feed DFK Fig: Feed Zone Fig: WEBFEED Fig: Web doffing unit, WEBSPEED calendar unit
- 18. AUTOLEVELLERS IN CARD 1. CORRECTACARD (CCD) • This serves for a long term levelling and monitoring of the sliver count. 2. CORRECTAFEED (ICFD) • This serves for levelling of the sliver count (CV- value). The levelling system works already from a sliver length of 1 m.
- 19. TECHNICAL DATA Feed roller-L-in- 35 thou L-in-L-in- 7 thou L-in-cylinder- 8 thou Cylinder-flat- 8 thou Cylinder-doffer- 5 thou Knife-cylinder- 21.6 thou 1st Knife-doffer- 11.8 thou 2nd knife-doffer- 9.8 thou L-in 2- Graf: K 50 20 X16 VG TCC: T 50 20 160 0164 35/V L-in 3- Graf: N 50 20 B16 VG TCC: T 50 20 160 210 35/VB Cylinder- Graf: R 20 30 X0.5 TCC: T 17 30 050 0860 05/X1 Doffer- Graf: N 40 30 X0.85 TCC: T 40 30 090 0367 31/BRZ Flat tops- Graf: Spacetop 55 TCC: Novotop 55 Fineness- 0.125 Ne Draft- 104 Target pressure DFK- 300 Pa Diameter of L-in 1- 172.5 mm Diameter of L-in 2- 172.5 mm Diameter of L-in 3- 172.5 mm Diameter of cylinder- 1287 mm Diameter of doffer- 700 mm Speed of cylinder roll- 560 rpm Speed of L-in 1- 1152 rpm Speed of L-in 2- 1788 rpm Speed of L-in 3- 2343 rpm Speed of feed roll- 10.9 rpm Speed of flats- 400 mm/min Speed of DFK beater roll- 830 rpm Web thickness- 1.03 mm Balancing value CCD- 5.70 mm Total no of flats- 84 No. of flats in working position- 30 Delivery speed- 184 m/min Production- 52.1 kg/hr Efficiency- 96.3% SETTINGS WIRE SPECIFICATIONS
- 20. BREAKER DRAWFRAME SB-2 Its objectives are: • Equalizing i.e. through doubling the sliver are made even. • Parallelizing i.e. through drafting the fibers get parallelized. • Hooks created in the carding machine are straightened. • Dust removal. Doublings – 7 Drafting arrangement – 3/3 Type of weighing – Spring loaded Type of coiling – Over coiling No. of deliveries – 2 Diameter – Top (mm) Bottom(mm) Front 26 40 Middle 29 30 Back 38 30 Hardness of top roll – 830 shore Roller gauge – 40/42 Break draft – 1.4 Main draft – 3.78 Total draft – 5.3 Hank fed – 0.125 Hank delivered – 0.094 Delivery speed – 750 m/min Efficiency – 85% Auto can changer – Yes Auto leveller – No Sliver monitor – No TECHNICAL DATA
- 21. UNILAP E30 Its objective is: To form a lap of desired fineness, weight, length and fiber orientation to be fed to the comber for effective combing operation. Doubling – 22 Drafting system – 3/3 Type of loading – Pneumatic Lap length – 230m Lap wt. – 80 g/m Hank fed – 0.094 Hank delivered – 0.007 Efficiency – 82.2% Total draft – 1.64 TECHNICAL DATA
- 22. COMBER E62 Its objectives are: • Elimination of a precisely pre-determined quantity of short fibers. • Elimination of remaining impurities. • Elimination of a large proportion (not all) of the neps in the fiber material. • Formation of a sliver having maximum possible evenness.
- 23. SEQUENCE OF OPERATIONS • Feed rollers (S) move lap sheet (W) forward by a small amount ,while nippers (Zo/Zu) are held open (feed). • Upper nipper plate Zo is lowered onto cushion plate (Zu) so that the fibers are clamped between them (nipping). • Combing segment (K), mounted on rotating cylinder (Z), sweeps saw-teeth through fiber fringe (B) and carries away anything not held by the nippers (rotary combing). • The nippers open again and move toward detaching rollers (A) (nippers forward). • Meanwhile detaching rollers (A) have returned part of the previously drawn-off stock (web V) by means of a (partial) reverse rotation, so that the web protrudes from the back of the detaching device (web return). • In the course of the forward movement of the nippers the projecting fiber fringe (B) is placed on the returned web (V) (piecing). • The detaching rollers begin to rotate in the forward direction again and draw the clamped fibers out of web (W) held fast by feed rollers (S) (inside the nippers) (detaching). • Before the start of the detaching operation, top comb (F) has thrust its single row of teeth into the fiber fringe, (passive combing by the top comb). • As the nipper assembly is retracted, the nippers open for the next feeding step. The top comb is withdrawn. A new combing cycle begins.
- 24. SETTINGS TECHNICAL DATA Feed/nip 5.2 mm (S= 18) Nips/min 400 Lap wt. 80 g/m Dia of full lap 550m Noil % 18.60 Batt tension 9% Type of feed Concurrent feed Point density of top comb 32 needles/cm Drafting arrangement 3/5 Type of weighing Pneumatic Break draft 1.36 Main draft 10.22 Total draft 13.9 Hank fed 0.007 Hank delivered 0.115 Doublings 8 No. of deliveries 1 Delivery speed 167.1 m/min Efficiency 90.8% Can filling 6000m Noil index- 24-40 Nipper-cylinder comb- 0.3 mm Nipper-bottom detaching roller- 8 mm Cylinder- brush- 18 mm
- 25. FINISHER DRAWFRAME RSB851 Its objectives are: • To control the count variation within the sliver by using auto levellers. • To make the required hank of sliver for feed to the speed frame.
- 26. AUTOLEVELLER TECHNICAL DATA Doublings – 6 Drafting arrangement – 3/3 Type of weighing – Spring loaded Type of coiling – Over coiling No. of deliveries – 1 Diameter – Top (mm) Bottom(mm) Front 38 40 Middle 38 30 Back 38 30 Hardness of top roll – 830 shore Roller gauge – 39/41 Break draft – 1.28 Main draft – 4.61 Total draft – 5.9 Hank fed – 0.115 Hank delivered – 0.120 Delivery speed – 400 m/min Efficiency – 82% Auto can changer – Yes Auto leveller – Yes Sliver monitor – Yes
- 27. SPEEDFRAME LF1400 Its objective are: • Attenuation of the draw frame sliver. • Insertion of protective twist. • Winding of the roving into a package which can be transported, stored and donned on the ring spinning frame. The building motion performs three essential functions during the winding operation: a. Shifting of the cone belt corresponding to increase in the bobbin diameter. b. Reverse the direction of the bobbin rail at the upper and lower ends of the lift stroke. c. Shorten the lift after each layer to form tapered ends on the bobbins. (a) (b) (c)
- 28. TECHNICAL DATA Drafting arrangement- 3/3 Type of drafting system- Pneumatic Apron size- Bottom apron Top apron 76*65*1.02 42*38*1.02 Diameter- Top (mm) Bottom (mm) Front 19 27 Middle 29 27 Back 38 27 Roller gauge- 45/50 Saddle gauge- 52/48 Break draft- 1.01 Main draft- 7.75 Total draft- 7.83 Hank fed- 0.120 Hank delivered- 0.90 Flyer speed- 980 rpm Delivery speed- 450m/min
- 29. RING FRAME G 5/1 Its objectives are: • Attenuate the roving until the required fineness is achieved. • To impart strength to the fiber strand by twisting it. • To wind up the resulting yarn in a form suitable for storage, transportation, and further processing. WINDING MECHANISM This has to perform two movements: a. Continuous rising and lowering in order to apply alternate main and cross windings (layering traverse) and b. A continuous ascent in very small amounts after each layering traverse in order to fill the cop (switching traverse). (a) (b)
- 30. TECHNICAL DATA Drafting arrangement- 3/3 double apron Type of drafting arrangement- Pneumatic Diameter- Top (mm) Bottom (mm) Front 19 27 Middle 30 25 Back 28.5 27 Roller gauge- 42.5/60 Saddle gauge- 50.5/62 Ring dia- 42mm Total draft- 26.67 Hank fed- 0.90 Hank delivered- 24s COM No of spindles- 864 Spindle speed- 14600 Traveler speed- 32 m/sec Tpi- 17.34 Production- 252.60 g/shift/spindle
- 31. AUTOCONER SCHLAFORST 338 TYPE RM Its objectives are: • To make a bigger package which has much higher content of yarn than bobbin. • To remove the faults that are generated in spinning i.e., thin, thick and weak places No. of machine sections- 6 No. of winding drums per section- 10 Total no. of winding drums on machine- 60 Creeling- Manual into circular magazines (6 pockets) Winding speeds- 1650 m/min Diameter of drum- 95 mm TECHNICAL DATA
- 32. CONDITIONING AND PACKING Fig: Contexxor conditioning process by xorella Its objectives are: • To improve the physical properties of yarn like strength, elasticity etc. • To minimize monetary loss by selling yarns with standard moisture content. After this, the cones are brought in the packing department where they are weighed, the cartons are marked accordingly to yarn counts and then the cones are packed in cartons to export. Temperature 550 C, 650 C (depending on the type of yarn being processed) Pressure 130, 140 mBar TECHNICAL DATA