YARN MANUFACTURING PROCESS
M.B.O
SORTING
BALE PRESSING M/C
BLOW ROOM
CARDING
BREAKER D/FRAME
SLIVER LAP M/C
LAP FORMER
RIBBON LAP M/C
COMBER
FINISHER D/FRAME
SPEED FRAME
RING FRAME
WINDING M/C
CONDITIONING
PACKING
KINDS OF COTTON USED :-
INDIAN COTTON
IMPORTED COTTON
INDIAN COTTON TYPE
S-6
100%
S-6
ONGIN
S-6
ORGANIC
J-34
100%
DCH32
100%
DCH32
ONGIN
DCH32
ORGANIC
MCU-5
FAIR TRADE
MCU-5
100%
MCU-5
ORGANIC
IMPORTED COTTON
GIZA-86
EGYPT
GIZA-88
EGYPT
AKDLA
AUSTERLION
ULTIMA
U.S.A
PIMA
U.S.A
SICALA
DISCRIPTION OF M.B.O. :MANUFACTURE
LAKSHMI
MODEL
LB3/4 (YEAR 1997)
NO. OF M/C
OBJECT OF M/C : To make homogeneous mixture of different types of fibers.
Opening & cleaning of the material.
Mixing & blending of the fibers.
Removal of dust as a percentage of dust content of the fibers.
M/C PARTS: Feed lattice with conveyer belt,
Bottom feed lattice with conveyer belt,
Inclined lattice,
Stripper roller,
Evener roller,
Feed roller,
Saw tooth beater.
SORTING
OBJECT :To remove the contamination like hair, colour yarn, jute plastic,
polythin, sutli,etc.
PROCEDURE OF SORTING :FOR COTTON SORTING {PROCESS} 1.To hold the cotton in one hand & open the cotton slightly by other hand.
2. Then, to separated the contamination like hair, pouch, sutli, white plasti ,etc
in different places.
3. Kept the contamination in different places.
4. And after this procedure count to the register.
This process is done by manually.
No. of worker or sorter required for process= 30-40.
PROCESS SEQUENCE BALE (TO BE SORTED)--M.B.O. (MIXING BALE OPENER)-FIRST SORTING SECOND SORTING -TUFT IS FED TO BALE PRESS M/C
Sorting load acc. to mixing of cotton fibersMIXING
LOAD
A
90
B
60
C
45
D
35
E
30
NOTE:- Sorting load in kg/shift/ sorter.
CALCULATION:- If we have 32 sorter in a shift & work load is 90kgs , then how
to calculate the no. of bale.
No. of sorter = 32
Work load = 90kgs/sorter
Wt. of one bale = 170kgs
So, No. of sorter = no. of bale *wt. of one bale /work load
No. of bale = 32*90/170
=17 (approx.)
COTAMINATION SORTOUT IN 45KGS.
VARITY
J-34
S-6
S-6 OG
DCH32
MCU-5
MCU-5 SUPER
DCH32
TOTAL
123
149
105
255
461
234
178
STANDARD
131
169
114
271
495
252
189
EFFICINCY(%)
94
94
93
94
93
93
94
CONTAMINATION STANDARD IN KGS.
VARITY
J-34
S-6
S-6 OG
DCH32
MCU-5
MCU-5 SUPER
DCH32
TOTAL
113
135
101
237
405
208
154
STANDARD
131
169
114
271
495
252
189
BLOW ROOM DEPTT.
OBJECT :-
EFFICINCY(%)
86
85
89
87
82
83
81
Opening of the raw material.
Cleaning of the raw material.
Mixing of the raw material.
To achieve the uniform yarn quality.
To avoid lot to lot variation.
Removal of magnetic material.
MATERIAL PROCESS FLOW IN BLOW ROOM M/CsBLENDOMAT (BDT)
SP-MF
MAXI FLOW
MPM8
MPM-8
CVT-1
CVT-1
SP-F
SP-F
The Factors which influence the opening and cleaning efficiency Position of m/c in blowroom sequence.
Penetration of opening spikes.
Angle of grid bars.
Speed of opening rollers.
Area of the grid surface.
Pre-opening of material.
Thickness of feed web.
TYPES OF PIPE USED IN B/R LINE Fire pipes
Material transfer pipes
Micodust pipes
Dropping waste pipes
& some ventilators
NO. OF WORKER IN blowroom = 3
Collection of waste from blow room =6%
Hygrometer type sensor is used in blowroom for atmospheric
conditions.
Relative Humidity (RH%)= 63*F
Temp. in blowroom
= 29*c
DESCRIPTION OF EACH M/C IN BLOW ROOM LINE
BDT(BLENDOMAT)
Manufacture
- TRUTZSCHLER
Model
- BO-A-2300(YEAR-2005)
No of m/c
- 1
Operation Performed Bale opening
Blending
Transfer of material to next m/c
Machine Parts :
Suction duct system
Truck
Suction duct for system covering
Tarret
Light burries station
Operators console
Detacher
Working area safeguard system or safety system for working area
TECHNICAL DATA :
M/C HEIGHT =2.90 mtr
M/C WIDTH = 5.16 mtr
Working height =1.70 mtr
Working length =5.81-45.41 mtr
Working width =1.60-2.20 mtr
Working speed =5-15 m/min.
Lifting speed
= 0.85-7.0 m/min.
Speed of toothed disc roll =1.5 rev./min.
Speed of supporting roll =12-36rev./min.
Suction duct unit has length = 2475 mm.
Air fan suction pressure =600-1050 Pa
No of sensor in m/c = 6
Wt. of machine = 2700kgs
Production of m/c =1000 kgs /hr.
The setting of BDT depending upon two factors :
Overall production of the unit,
Length of belt.
Suction duct
Truck :- It give way or it is help in moving to the machine from left to
right & right to left on laydown in straight manner.
Suction duct covering consist
Cover belt
Wind up device
Cover belt : one end is fitted at suction station & other end is on
winding roller.
Wind up device it is fitted on the truck.
Turret :- In inner suction system ,transformation of tufts from detacher
to inner suction system.
Pressure =0.6 kpa
Two guide rollers,
Two disc tooth rollers,
Two grid bar used below disc tooth rollers.
SP-MF (MULTI FUNCTION SEPRATOR)
MANUFATURER
TRUSTZSCHLER
MODEL
SP-MF(YEAR-2005)
NO. OF MACHINE
OPERATION PERFORMED : The pneumatic transport of open tuft material through pipe lines.
The intensive extraction of dust from draw in tuft material.
The separation of heavy material or particals from suction air stream.
Separation of metal particals.
MACHINE PARTS : Frame
Sheet metal cover
Doors
Fan (BR-FD 500)Drive
Metal detector
Sensor
Fire sensor/ detector
CO 2 Extinguish system
Dust cage & finned stripper roller drive
Exhaust
TECHNICAL DATA :Inner frame width = 1000 mm
Machine width
= 1464 mm
Machine length
= 1100mm
Fan speed
= 1360-2960 rpm
Weight of machine = 580 kgs.
MAXI FLOW PRE-CLEANER
MANUFACTURER
TRUTZSCHLER
MODEL
- 0532501 (YEAR-2005)
NO. OF MACHINE
OPERATION PERFORMED
Removal of microdust particals.
Heavy impurities.
Removal of trash from fibers like seed, chaff(leaf ,stalk),dirt &dust,etc.
Removal of dropping waste.
MACHINE PARTS : Two beater (pin type) with drive
Grid bar
A/c motor
Frame
Material suction device
Waste suction device
Inner sheet metal casing
Outer sheet metal casing
TECHNICAL DATA :Inner frame width
=1300 mm
Machine height
= 2100 mm
Machine width
=1464 mm
Machine length
= 1830 mm
Machine weight
=1500 mm
Dia. Of beater roller = 605 mm
Maximum output
= 850 kg/hr.
Fan speed
=1200 rpm
Beater speed
=780 rpm
Rotation speed limit roll = 1180 rpm
Inlet & outlet pressure difference = 100-320 Pa
Motor speed
= 1450 rpm
Motor rating
= 7.5 kw
Motor frequency
= 50 Hz.
The Grid Bar setting is adjustable & is adjusted acc. to the requirement of
running
Generally it is 2-3 mm.
CALCULATION : - Suppose rotation of beater is x in one min.& dia. of beater is
y Then, how to calculate the no. of beats/inch.
3.14 *y*no. of beats/inch =x
So, no. of beats/inch =x/3.14*y
MPM-8[MULTI PURUSE MIXER-8]
MANUFACTURER
- TRUTZSCHLER
MODEL
- MPM-8 (YEAR-2005)
NO. OF MACHINE
-2
OPERATION PERFORMED
Mixing to different type of cotton,
Stock to material into eight chamber.
Working details : The second concepts are multi mixer MPM-8 , it is available with eight
chambers. The tufts are once again into a m/c by a fan. The filling procedure &
control of the flaps are identical to the working of multi mixer MPM-8. The
difference between the blending channel underneath the opening rolls, there
is no conveyer belt. The MPM-8 works on the basis of a closed air circulation,
i.e the conveyer air entering the m/c also carries the material & feeds it into
the next m/c .
MACHINE PARTS :This machine is made up of three parts;
1.A storage unit /section ,
Eight chamber
2. An intermediate section ,
Two feed roll , One beater, Sensor
3.A delivery section ,
Air pressure are used for deliver to the material ,conveyer.
TECHNICAL DATA :- Air fan suction pressure =500 Pa
CVT-1( CLEANOMAT)
MANUFACTURER
TRUTZSHLER
MODEL
CVT-1 (YEAR-2005)
NO. OF MACHINE
OPERATION PERFORMED Cleaning of the material,
Removal of dust particals.
MACHINE PARTS : Feed lattic
Pressure roller
Feed roller
Roller [with two separating wings , two suction hood & one carding
segment].
Pressure roller.
TECHNICAL DATA: M/c Height
= 1250 mm & M/c width
= 1800 mm
M/c length
= 2400 mm
Connection pressure = 450 Pa [Project planning data]
Feed belt speed
= 0.75-15.17 mtr./min
Inside frame width [IFM] = 1200 & 1800 mm
Roll speed
= 1191-1213 rpm
Beater speed [fine tooth beater] = 900-1300 rpm
Inlet pressure[P1] = 138 Pa & outlet pressure[P2] = 868 Pa
Suction duct pressure = 100-750 Pa
SP-F [FOREIGN FIBRE SEPRATER]
MANUFACTURER
TRUTZSCHLER
MODEL
SP-F (YEAR-2005)
NO. OF MACHINE
OPERATION PERFORMED
Removal of dust particals,
Removal of dry & colored materials in fibers ,
Removal of all types of contamination like hair, colored yarn,etc.
MACHINE PARTS : Feed lattic
Pressure roll
Cylinder 1 (with two mote knives, two suction hoods, one carding
segment)
Cylinder 2 (with one mote knives, one suction hood, one carding
segment)
Cylinder 3 (with one mote knives, one suction hood)
TECHNICAL DATA : Maximum detection rate = 100-5000/hr.
Valve delay angle
= 90-180 degree
Beater speed
= 740 rpm
Detection/hr. per color
Red+
= 5000/hr.
Green+ = 1000/hr.
Blue+
= 5000/hr.
BLOW ROOM F.D.P.
LUWA ROTATARY PRE-FILTER
Dopping waste (maxi flow)
SP-F waste (line-1)
Microdust (CVT-1 line-2)
SP-F waste (line-2)
SP-MF (microdust)
CVT-1 dropping waste (line-1)
CVT-1 dropping waste (line-2)
CVT-1 (microdust)
M/F Microdust
VENTILATOR IN BLOW ROOM SP-MF
ventilator
MAXI FLOW
waste ventilator
MPM-8
front ventilator
CVT-1
waste ventilator
SP-F
ventilator
Fire
ventilator
VENTILATOR SPEED =MOTOR RPM* MOTOR PULLY /M/C PULLY
MACHINE
BDT-019
MPM-8
CVT-1
SP-F
Dust supply pressure = 50-200 Pa
MATERIAL SUPPLY PRESSURE(Pa)
600-1000
500
500
500
Dropping waste pressure = 750-1000 Pa
Pipe line used in blow room
Material pipe line (from-to)
BDT-SP-MF
SP-MF MAXI FLOW
MAXI FLOW-MPM8
MPM8-CVT1
CVT1 SP-F
SP-F - CARD
Diameter (mm)
330
300
300
300
300
300
Dropping waste line (from-to)
CVT Pre-filtter
CVT Microdust
SP-F Microdust
SP-MF & LVSB
MAXI FLOW waste pipe
Maxi flow microdust
Fire system
Diameter (mm)
250
300
280
300
150
300
300
CARDING SECTION
M/C SPECIFICATION
MANUFACTURER
TRUTZSCHLER
MODEL
DK800 (YEAR-2006)
NO OF MACHINE
9+1[DK780]=10
OBJECTIVES OF CARDING High degree of opening of fibers.
Removal of minute dust particals,
Disentangling of neps,
Fiber blending,
Elimination of impurities,
Elimination of short fibers,
Sliver formation.
Carding is the heart of spinning because above 90% impurities are
removed during carding.
MACHINE PARTS : Feed chute
Feed roller
Feed table
Licker-in
Mote knives
Stationary flats
Cylinder
Flates
Doffer
Grid
Stripper roller
Flat cleaning brush
Top plate
Suction hood
Cross roller
Trumpet
SFL [STATIONARY FLATS LICKER-IN SIDE]
SFD [Stationary flats doffer side ]
MACHINE PARAMETER Feed roller diameter =100 mm
Licker in diameter
= 253 mm
Cylinder diameter
= 1290 mm
Doffer diameter
= 680 mm
Cylinder speed
= 401-531 rpm
Doffer speed
= 851-1125 rpm
Flats speed
= 80-320 mm/min
No. of flats
= 84
No. of working flats = 30
Feed system
= chute feed
Can diameter
= 40 inch
Can height
= 45 inch
Width of web
= 830 mm
Delivery speed
= 115 m/min
SPECIAL FEATURES OFV DK800 CARD HIGH PERFORMANCE CARD.
AUTO LEVELLER IS USED.
CARD GAUGE SETTING
S.NO. SET POINT
GAUGE(Thou)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
4
40
40
40
7,8
18
55
10,8,8,8
12
40
Feed plate to feed roll
Feed plate to licker-in
Licker-in to wing
Licker-in to mote knives
Licker-in to cylinder
Cylinder to SFL
Cylinder to back suction
Cylinder to flat
Cylinder to SFD 64 PPSI
Cylinder to front top plate
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Cylinder to doffer
Cylinder to front bottom plate
Cylinder to back bottom plate
Doffer to stripper
Stripper roller to cross roller
Cross roller to web plate
Top calendar roll to bottom calendar roll
Cylinder pulley
Licker-in pulley
Flat pulley
5
14
40
6
6
40
6
210
260
180
CARD SETTING
S.NO.
1
2
WRAPPING
0.160
0.190
FBK PRESSURE(Pa)
400
220
No. of motor in a CARD = SEVEN
TEMP. in carding section is 30.2 degree
Relative humidity (RH%) in carding is 56.9 %
S.NO. WRAPPING
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
0.160
0.160
0.160
0.160
0.160
0.160
0.160
0.190
0.190
0.190
0.190
0.190
PRODUCTION
(KG/HR.)
15
18
20
22
25
30
35
10
15
20
22
25
DELIVERY SPEED(IN
RPM)
67
81
90
99
112
135
137
53
80
107
117
133
TECHNICAL DATA
Cylinder pulley diameter
= 175 mm
Licker-in pulley diameter
= 260 mm
Stripper roller diameter
= 120 mm
Cross roller diameter
= 90 mm
Working width of card
= 1020 mm
Working width of tuft feeder
= 920 mm
Machine weight
= 7300 kgs.
Machine width
= 1994 mm
Machine length
= 5650 mm
Production/SHIFT
= 275.25 kgs/shift
Production/hour
= 34.40 kg/hr.
Height of FBK
= 2625 mm
Height of machine upto flats
= 1900 mm
Width of coiler
= 1940 mm
Draft given by card
= 60-200 Fold
Length of sliver per can
= 8100 mtr.
Wt. of sliver per can
= 25.17 kgs
Hank of sliver
= 0.190 Ne
Linear density of sliver
= 3.21 gms/mtr.
Fineness
= 0.084-0.295 Ne
FBK Pressure
= 0-999 Pa
Floor load
= 8520 N/m2
Operating pressure
= 600-1200 Pa
Flat & licker-in suction pressure = 400 & 700 Pa
CARD CLOTHING DETAILS
Cylinder wire - T20.30.040.0950
Height =2 mm
Angle = 40 *
Thickness = 0.04 mm
No. of teeth = 950/sq. inch
Doffer wire - N.40.30*0.9
Height = 4 mm
Angle = 30*
Thickness = 0.09 mm
No. of teeth = 367/sq. inch
Flat wire - Nova 55
No. of teeth = 150/sq. inch
Licker in - E.5010-8VG
[ Saw tooth type ]
No. of teeth = 210/sq. inch
SFL Teeth
= 240/sq. inch
SFD Teeth
= 640/sq. inch
Life expectancy Licker in
= 225 ton
Doffer
= 1500 ton
Flat
= 700 ton
SFL
= 250 ton
SFD
= 450 ton
DRAW FRAME SECTION
BREAKER D/FRAME
MANUFACTURER
- LAKSHMI RIETER
MODEL
- LD0/6 (YEAR-2000)
NO. OF MACHINE
- 2
FEATURES OF LD0/6 Automatic can changing mechanism.
It has 3/3 pressure bar with pneumatic loading .
The sliver delivered from pneumatic loading calendar roller
through coiler into revolving can.
Top stripper to clean top roller.
Bottom stripper with suction hood are used to clean the
bottom roller.
MACHINE PARTS
Creel
Feed roller
Auto leveler
Feed plate
Drafting rollers
Condenser funnel
Coiler trumpet
Pressure arm (Pneumatic)
Two coiler heads
TECHNICAL DATA
Input material
card sliver
No. of doubling
= up to 8
No. of coiling heads
=2
Total no. of cans
= 12
Roll gauge
= 46/50
Creel tension gear wheel = 70,71,72 Teeth
Draft range
= 2-12
Feeding speed
= up to 42.5 gm/mtr.
Delivery speed
= 240-500 m/min.
Draft tension :
Main draft
= 40-80 mm
Break draft
= 36-90 mm
Trumpet size
= 3.5 mm
Production
= 180-360 kgs/hr.
Machine weight
= 2440 kgs
Can size at feed :-
Can diameter = 600 mm
Can Height
= max. 1200 mm
Can size at delivery :Can diameter = 350[,400,450,500 ] mm
Can height
Output material
= 914-1200 mm
= draw sliver
DRAFTING : Drafting system
= 3/3
Pressure supply
= Pneumatic [6 bar ]
Load on drafting rollers
On 1st & 2nd top front roller = 3-4 bar
On 3rd top back roller
= 2-3 bar
Pressure on calendar roller = 0.5-2.5 bar
Can changer
Drafting rollers : -
= 4-5 bar
Top roller cot size (mm) :- 39*39*39 [ T1, T2, T3 ]
Bottom rollers size (mm) :- 52*28*28 [ B1, B2, B3 ]
Top roller hardness : = 70* SHORE
Top rollers rubber coated,
Bottom roller are of hardness steel fluted rollers
CHANGE POINTS AT D0/6 Draft change gear[DCCP]
Draft range change gear [CP]
Break draft change gear A & B.
Feed change gear
Can change gear E &F .
Delivery change gear, coiler wheel change gear C & D.
Motor belt pulley.
DRAFT RANGE CHANGE GEAR
DRAFT
3.7-5.1
4.9-7.0
6.3-9.1
8.0-11.0
MAIN DRAFT
DCCP GEAR
82 TEETH
63 TEETH
48 TEETH
38 TEETH
= 4.9
CHANGE PINION = 92 T
E/F COMBINATION =52-110 T
E/F COMBINATION CHART
COUNT RANGE
20
25-30
30-40
50-78
70-80
ABOVE 80
E/F COMBINATION GEARS
40/73
50/63
38/75
35/78
35/78
27/86
BREAK DRAFT CHANGE GEAR
DRAFT A/B GEAR
61/65
65/61
56/70
70/56
BREAK DRAFT
1.28
1.51
1.71
2.0
DRAFT = FEED WPG. *NO. OF DOUBLING / DEL. WPG
DEL. SPEED = WT. OF SLIVER FEED* DOUBLING /DRAFT
SPECIAL FEATURES OF DO/6 LMW : Mainly use for synthetic & also use to cotton
Use for blending
Double line feeding
Double delivery
Easy to operate
Auto doffing system is used , pneumatic loaded calendar roller for delivery
hence compression takes place , flies on suction fan hence it is necessary to
clean up to 45 min.
Stop motion checking
Creel stop motion
Coiler stop motion
Roll lapping stop motion.
Machine cleaning schedule
PARTS
Roll interchange
Coiler cleaning
Fan waste
Roll washing
Drafting zone
Creel cleaning
SCHEDULE
2hrs
24hrs
30min.
24hrs
2hrs
Every batch
LAP FORMER LH-10
MANUFACTURER
- LAKSHMI
MODEL
- LH-10 (YEAR-2005)
NO. OF MACHINE
FEATURES OF LH-10
--
Double feeding creel
Two feeding heads
11/11 doubling of draw slivers
TOOLS
By hand
Water & cloth
By hand
Water & cloth
Cleaning gun
Cloth & Cleaning gun
Auto doffing system
MACHINE DATA -Drafting system
= 4/4 (with pressure bar)
Total draft
= 1.2 -2.26
Top roller loading
= spring loading system
No. of drafting heads = 2
Doubling
= up to 28 slivers
Del. Speed (max.)
= 120 m/min [Depending on raw material ]
Can size -- can diameter
Can height
=up to 40 inch
= up to 48 inch
Lap width
= 300 mm
Max. lap diameter
= 600 mm
Lap sheet weight
= 60-80 gm/mtr.
Lap weight
= 15.40 kgs(with spool)
Break draft
1.042
Draft distance -MAIN DRAFT
= 40-60 mm
BREAK DRAFT
= 40-60 mm
Compressed air requirement :System pressure
= 7 bar
Operating pressure = 6 bar
Air consumption pressure = 3 Nm3/hr
Top rollers buffing :
Hardness
= 83*
Color
= grey
Quality
= antistatic
Quality code = Lakshmi day 890
Minimum dia.
= 36 mm
Maximum dia.
= 39 mm
Grinding dia. in mm = 0.2 mm
Total draft = Doubling * feed in gm/mtr./del. Lap wt. in gm/ mtr
Ex. T.D. = 26*4.54/80 =1.48
SUCTION POINT IN MACHINE : Spool suction
Main cylinder roller suction suction
Anti lap licking suction
Table calendar roller suction
Drafting roller suction .
CLEANING SCHEDULE OF MACHINE
PARTS
Drafting zone & stripper
Drum cleaning stripper
Fan waste
Creel & table cleaning
Lap forming unit
Head stock inside the
cover
Creel
Ball washing
SCHEDULE
8hrs
24hrs
8hrs
8hrs
8hrs
24hrs
TOOLS
Cleaning gun
By hand
By hand
Cloth & cleaning gun
Bamboo stick
Cleaning gun
After a batch
24hra
Cloth & cleaning gun
By cloth
SLIVER LAP MACHINE
MANUFACTURER
- LAKSHMI
MODEL
NO. OF MACHINE
LE2/4a (YEAR-2000)
1
FEATURES OF SLM
Drafting is pneumatically weighted.
Lap weighted is performed on a patented automatically
system.
Antifriction bearing with continuous lubrication have been
used wherever possible
MACHINE TECHNICAL DATA
SLIVER FED WRAPPING
= 0.120-0.180
Wt. of sliver fed
= 75-120 gm/mtr
Cleaning efficiency
= 70%
Draft
= 1.5-2.0
Lap weight
= 50-75 gm/mtr
Lap width
= 250mm in case of feeding to RLM
&
300mm in case of feeding to comber
direct
Lap weight
= upto 13 kgs
Working speed
= 65 m/ min
Drafting system
= (pneumatic)4/6
Draft constant
= 1.35
Throttle disc dia.
= 1.8-2.00mm
Doubling
= 21 [11+10]
WEIGHT OF THE MACHINE & ITS COMPONENTS :Auto lap
1440 kg
Drafting system
490 kg
Table
240 kg
Total m/c weight
2170 kg
Compressed air pressure = 6 atu
Del. Speed
= 50-65 m/min
Motor pulley dia.
= 140,170,185 mm
Total draft
= input in gm/mtr /output in gm/mtr
Motor speed
= 1440 rpm
Frequency
= 50 hz
M/c width
= 2260 mm
Can dimensions =>16-40 inch & upto 50 inch (1250mm) high
Machine cleaning schedule
PARTS
SCHEDULE
TOOLS
CREEL & TABLE
8 HRS.
WATER & CLOTH
8 HRS.
WATER & CLOTH
DRAFTING ZONE
2 HRS.
CLEANING GUN
TOP ROLL WASHING
24 HRS.
WATER & CLOTH
BELOW &
8 HRS.
CLEANING GUN
CLEANING
BOTTOM PATELI &
DISC SIDES
SURROUNDING M/C
STOP MOTION CHECKING once in a shift
Creel stop motion
Drafting stop motion
Roll lapping stop motion.
RIBBON LAP MACHINE
MANUFACTURER
- LAKSHMI
MODEL
- LE2/4a
NO. OF MACHINE
- 1
MACHINE PARTS : Lap feed roller
Drafting system
Feed table
Feed roller calendar roller
Lap roll
Spool supporting plate
Guide roll
Machine technical data : Length of machine
= 5275 mm
Width of machine
= 2907 mm
Machine weight :
Auto lap
1450 kg
Head stock = 550 kg
Roller & its support = 900 kg
Total m/c weight = 2900 kg
Weight of lap fed = 50-75 gm/mtr
Weight of lap deliver = 50-75 gm/mtr
Working speed
Draft
50-65 m/min
= 5-8
Max. lap dia. = 450 mm
Lap width
= 300 mm
Drafting system
= pneumatic
Compressed air pressure = 6 ate
Quantity required
Motor speed
=1.2 Nm3/hr.
=
960 rpm
The v-pulley are changed on the for changing the delivery speed
Delivery speed (mtr/min)
50
60
65
Motor pulley mean dia. (mm)
140
170
185
Change wheels & change gears :Change gear position
Chain wheel at calendar roller =24-25 T
Chain wheel at rear lap roller
= 76 T
Chain wheel at front lap roller = 77-78-79 T
Draft change gear (Wn) =53-75 T (4TH roller)
Feed change gear (We) = 60 -64 T
Table draft change gear (Wt) = 79-83 T
Del. Tension change gear(Wa) = 79,80,81 T
Double gear for break draft
= 35/40
Break draft =1.34,1.02
Chain wheel
For lap roll drive , the following different chain wheels are sent
Chain wheel at coupling
= 24/25 T
Chain wheel at lap roller = 77/78/79 T
As per experience , we select the following chain wheels
For coupling (1) = 25 T
Rear lap roll
= 76 T
Front lap roller
= 78 T
If the machine is operated with light drafting , the wheels 24 , 76 &
77 are to be used .
Distance between top edge of the saddle top cleaning device shaft
=95T
DRAFTING ARRANGEMENT :-
These rows of top roller with synthetics covering are loaded over
four rows of bottom fluted rollers. The nipping distance are
adjustable between 3& 55mm in the break draft zone so that all the
fiber length can be processed & in main zone it is 30 & 54 mm are
adjusted .
FORMULA
Total draft = feed gm/m *doubling/del. gm/m
Draft change gear = total draft / break draft *constant of main draft
Cleaning schedule of RLM M/c Creel & table cleaning
Drafting zone
Top & bottom clearer
cloth
Disc sides lap
formation unit
Top roll washing
Below & surrounding
m/c
2 hrs
2 hr
8 hrs
Cloth &cleaning gun
Cleaning gun
By hand
8 hrs
Cleaning gun
24 hrs
8 hrs
Water & cloth
Cleaning gun
COMBER
Name of
machine
Comber
Model
E 65
E 66
E 60 H
No. of machine Manufacturer
(RIETER)
2
Year- 2004
1
Year 2010
3
Year -1997
OBJECTIVES OF M/C
The main object of comber is to remove short fibers.
Straightening & parallization on fiber
Upgrade raw material
Yarn evenness
Strength
Cleanliness
Visual appearance
Smoothness
Requires less twist than carded
Removal of neps .
MACHINE PARTS : Lap roller
Feed roller
Nipper
Top comb
Bottom roller
Detaching roller
Web condensing tray
Sliver plate
Delivery roller
Table cylinder
Sliver guide
Trumpet drafting zone
Calender roller
Coiler trumpet
Unilap
TECHNICAL DETAILES OF COMBER E65 RIETER
420V 50 HZ
MXG.
6 BAR
= PIMA 100 %
Sliver hank
= 0.180
Feed system = backward
Roller gauge
= 46
Coiler trumpet
= 4.0
Production
= 30 kg/ hr
Delivery speed
= 158 mtr/ min
No. of laps feed per machine
= 8
Drafting arrangement =3/3
Noil (%)
= 20%
Top comb depth
= + 0.5
Top deteching roller dia. = 23 mm
Circular comb brush dia. 110 mm
Speed of comber
=350 nips/min (250-500nips/min)
Noil Index = 10.5
Feed per nip
= 4.7 mm (4.3-5.9 mm )
Total Draft (GV) = 9.12-25.12
M/c efficiency
Top comb teeth
= upto 75 %
= 35 teeth/cm.
Sliver wt. at delivery = 3-6 ktex
Noil extraction ( % ) = 8-25 %
Drafting system load per top roll
Break draft ( VV) = 1.13-2.0
Main draft distance :-
= 650-900 N
Setting gauge
= 41-60 mm
Gauge dimensions A= Nipping line distance minus 41 mm.
Break draft gauge dimensions =44-66 mm
Feeding :Lap outside dia.
= 650 mm
Tube/spool outside dia. = 250 mm
Tube length
= 300 mm
Can dimensions :Can table (C) = 25 mm
Can dia.(D) = 600 mm
Can height (h) = 1200 mm
Total machine weight = 4600 kg
Batt tension
60-80 ktex
Floor load
= 10600 N/m2
Force of can spring
Can length
Feed tension
10000 mtr
= 10 %
Top comb density
Piecing index
= 3.5
= +0.3
Drafting trumpet
Table trumpet
= 855 N
= 7.0 mm
= 4.0 mm
Drafting rollers
Top rollers dia. : - T1 = 39 mm
T2 = 39 mm
T3 = 39 mm
Bottom rollers dia.
B1 = 35 mm ,
:B2
= 27 mm , B3
= 27 mm
Break draft change gear
Gear C
59.0
64.9
71.9
78.8
86.9
96
105.7
Break draft
1.13
1.24
1.34
1.50
1.65
1.82
2.0
Main draft change gear Main draft
12.04
12.67
12.84
13.54
14.25
14.59
15.20
15.89
16.55
Change gear A
38
40
48
45
45
40
48
33
33
Change gear B
38
38
45
40
38
33
38
25
24
17.27
17.51
18.30
19.26
33
48
38
40
23
33
25
25
Feed per nip change gear Ratchet Wheel Feed /nip
4.3
4.7
5.2
5.9
R.W.
22
20
18
16
Feed change gear
62
56
52
45
Change places in comber
All change places in the delivery assemble are really accessible they
are as follows
N COUNT CHANGE
Z - FEED CHANGE
S - RATCHET WHEEL TO FEED ROLLER
V - WEB TRAY DRAFT CHANGE
Prduction of the comber is dependent upon the following :N- Nips per min
S Feed in mm/ nip
K- Tension draft between lap & feed roller [1.05-1.1 ]
G- lap wt. in gm/ mtr
Stop motions
Lap exhaust stop motion
Opened up detaching roller
Sliver break at coiler
Jam in detaching roller
Sliver break at condensing roller
Sliver break at condensing roller
Cleaning schedule of E 65 RIETER Parts
Coiler cleaning
Top comb
Nipper
Detaching roller area
Roll washing
Wash
duct,front&back
Side cover
Drafting zone
Schedule
24 hrs
4 hrs
24 hrs
8 hrs
24 hrs
8 hrs
Tools
Water & cloth
Top comb brush
Cleaning gun
Cleaning gun
Water & cloth
----------
48 hrs
2 hrs
Vacuum
----------
SPECIAL FEATURES OF E 65 Latest machine
3/3 drafting arrangement
Better reducing the noil %
Easy to operate
Upgraded monitoring display.
COMBING CYCLE IN CASE OF BACKWARD MOVEMENT
Detaching
Nipper move in backward
Same time feeding
Gripping
Combing
In backward movement or feeding system the removal of
short fiber are higher as compare to forward feed system .
In comber there are two important index which give improvement
in efficiency of machine
NOIL INDEX This index is used to control %age of short fiber
in material .
PIECING INDEX It is use for maintaining length of cut lap
before detaching roller for over lapping.
PRODUCTION CALCULATION :PRODUCTION =feed/nip *nip/min*60*8*efficiency*no. of
heads*(1-noil%/100)*(1-bett tension/100)/36*840*2.2*wpg.
DRAW FRAME FINISHER
MANUFACTUER
--
MODEL
--
NO. OF M/C
--
RIETER
RSB-D40[YEAR-2006]
3
OBJECT
To reduce weight per unit length of sliver.
To improve the regularity of fibers by drafting & doubling
To parauelize them to their neighbours
To straightened out the fibers into fibers exient
To mixing different type of fibers so as to give a
homogeneous blending
TECHINCAL DATA
Drafting system
--
4/3
Doubling
--
10
Efficiency
--
75%
Production
--
30-80kg/h
Front roll dia.
--
38mm
Middle roll dia.
--
30mm
Back roll dia.
--
30mm
m/c height
--
1860-2515mm
Roll gauge
--
46/50
Del. Speed
--
250-1100mtr./min
Feed sliver wt.
--
12-50ktex
Del. sliver wt.
--
1.25-7.00ktex
Draft (v)
--
4.54-11.56
Fibre length
--
max. 80mm
Can dia.
--
210-1000mm
Can height
--
900-1520mm
Scaning roller dia.
--
60mm
Feeding rate
--
300-400mm/min.
Main draft distance (hvd) -- 35.5mm
Break draft distance (vvd) --
36-40mm
Drafting system pressure in newton Back ,middle & del. top roll pressure -- 320-440n
Top roll cot dia.
--
36-38mm
Top roll length
--
100-160mm
Grinding disc dia.
--
200-500mm
Grinding disc width -- 25-45mm
Circumference speed of grinding disc
2000mtr./min
Rpm of spindle shaft
--
300-500u/min.
Trumpet size
--
28
Pressure bar setting
W1
VZW
--
39/52
Width of scaning roll
--
4.0-11.0 mm
99
0.99
1800-
-- 6.0
Nw 1 / Nw 2
98
0.93
--
100
1.00
101
1.01
102
1.02
103
1.03
W2
VZ
52
1.00
W8
VA
75.2
0.99
W4
VV
51.5
1.01
74.4
1.00
(54.6) (57.2) 59.8
(1.05) (1.10) 1.15
W4
VV
83.2
1.60
WHERE , VV
73.7
1.01
(62.4) 68.0
(1.20) 1.25
51
1.02
72.9
1.02
(67.6) 72.8
(1.30) 1.40
88.4
1.70
-- Break draft
V&GV
-- Total draft
HV
-- main draft
SPEED FRAME
MANUFACTURER
- LAKSHMI
MODEL
- LF1660(YEAR-2005)
NO. OF MACNINE
- 4
OBJECT :-
72.2
1.03
93.6
1.80
(78.0)
(1.50)
The object of the speed frame is to produce out of the draw sliver to
a well prepared roving of required hank of a well built bobbin for ring
spinning frame.
FUNCTION OF SPEED FRAME : DRAWING - To parallise the fibers upto optional level.
TWISTING To impart necessary strength to roving .
WINDING- To pul;l the suceesive layer on the bobbin at a
proper rate of speed.
Building To shorted successive layers to make conical ends on
the package of roving.
MACHINE PARTS : CREEL
PATELI CLOTH
CRADLE
TOP & BOTTOM R
TOP & BTTOM APRONS
SPACER
TWIST MASTER
FLYER WITH BOBBIN SUPPORRTING ROLL
SPINDLE
LIFTER RAIL
SLIVER GUIDE
CONDENSOR
TOP ARM/SADDLE
NOSE BAR
TENSIO PULLY
TECHNICAL DATA OF LF1660 :These m/cs are only built with the drive to the right i.e. the head
stock is on the right when looking at the delivery.
Spindle gauge
= 121.83
No.of spindle
= 120
Bobbin size
= 16*6 inch
Flyer speed mechanically possible = 1400 rpm (max.)
Production
= 50 m/min
[under favourable marginal condition ]
Draft
= 9-24
Count = >
English (Ne)
= 0.5 to 3.0
Metric (Nm)
= 0.85 to 5.0
Drafting arrangement Guide saddle
Drafting arrangement with 3 or 4 rollers, weighing arm for
two spindle ,double aprons , 36,43 & 50 mm cage .
Positively revolving clearer cloth for both top & bottom rollers
Top apron size
= 37*30 mm
Bottom apron size = 86*30 mm
Total weight of machine = 12950 kg
Motor speed = 700-1400 rpm
Flyer speed
= 800 rpm
Supply pressure of drafting system 5-6 kg/cm2
Meaning of lamps when flickering
Green Doffing or trough manual operation
Orange Roving break
White Sliver break
Bottom apron thichness = 0.86 to 1.04 mm
Top apron thichness
Top roll hardness
Roll gauge
= 0.86 to 1.04 mm
= 83* Shore
= 47-55-48
Top roll dia. = 30 mm
Break draft = 1.05 to 1.10 (for cotton) [& max. 3.0]
Delivery condenser = 7.5 mm (Green)
Wt. of empty bobbin = 200 gm
Length of roving on one bobbin = 2020-5300 mtr
Twist per inch = 1.51
Spacer = 3.5 mm
Bottom roller type = fluted
Bobbin dia.
= 152 mm
Tension draft
= 1.086
Main draft
= 10
Preliminary draft (between 3rd & 4th roll ) = 1.66
Machine length = 7*1461 mm (96-120 spindle)
Machine width
= 3643 mm
Set tension = 3.12
Cop content = 1616 gm/spindle
Doff length = 5200 mtr
No. of layers on bobbin = 118
Lifting wheel = 20 to 42 T
Twist wheel = 30 to 55T
Twist combination wheel = 65/35 T
BDCP GEAR = 50 to 72 T
Change pinion = 30 to 56T
TPI/TM = 1.166/1.951
Creel wheel = 40 to 48 T
Flyer gear belt length = 960 & 840 mm
Pateli cloth length = 815 mm
Main formulae :Creel tension draft = 40.88 *creel wheel
Break draft = 66.82/BDCP
T.W. = 34.552(h/g)/TPI, where (h+g=102)
Main draft = 63.48*(r/l)/C.P.
Where ,r/l = draft combination & r+l =150
Middle draft zone = 1.087
Total draft = main draft * break draft
L.W. = 12.18 *E/F *B1/root count
STOP MOTION AT SPEED FRAME Sliver break stop motion
Bobbin brust stop motion
Full doff automatic stop motion
CHANGE POINTS Twist change change gear
Lifter change gear
Main draft change gear
Break draft change gear
Creel tension draft change gear
RING FRAME
MANUFACTURER
SET]
- LAKESHMI [SUSSEN ELITE COMPECT
MODEL
- LR6/A (YEAR-2006)
NO. OF MACHINE
- 17
MACHINE PARTS: CREEL
HOLDER
HANGER
ROVING GUIDE 3 IN 1
DRAFTING ROLLERS
APRON
CRADLE
SPACER
LAPPET
SPINDLE
TOP ARM/SADDLE
RING
ABC RING
FLY CATCHER
TRAVELLER
DOFFING RAIL
SPINDLE TAPE BELT
TIN ROLLER
SUCTION TUBE
ELI TUBE & ELIED APRON
COTS ROLLER
JOCKEY PULLY
NOSE BAR
SPINDLE WHARVE
POSITIVE CLIP RING
RAIL RING
SEPARATER PLATE
SPINDLE BRAKE
M/C TECHNICAL DATA :Bottom roller dia.(In mm) => B1=30 , B2 =27 ,B3 =30
Top roller dia. (in mm) => T1 =32 , T2 27 ,T3 =32
Cradle length = 36 mm
Total draft = up to 60
Break draft = 1.07 to 2.24
Spindle gauge = 70 & 75 mm
LOADING TOP ARMS :The loading top arm are loaded pneumatically. The hose pressure
can be adjusted with reducing value in the head stock .
The pressure indicated in table below give a loading of 150-180 N(1518 kp) per front top roller shaft .
Spacer = 2.5-7.0 mm
Top apron length & width = 37*30 mm
Bottom apron length & width
= 73*30 mm
Spindle pitch
70
75
Pressure
2.1-2.3
2.0-2.2
Twist change gear (A+B) = 165 T
Twist range change gear (C+D) =137 T
Total draft constant = 10.519
Change gear for winding length (E+F) = 113 T
Break draft change gears std. = 32-62 T
Draft change gear (G+H) = 130-175 T
Spindle wharve dia. = 21,19 & 18.5 mm
Twists :TPM (Twist per meter) = 140- 2550
TPI ( Twist per inch) = 3.55-64.77
SPINDLE SPEEDS :-
Mechanically up to 18000 to 25000 rpm.
Drafting system = 3/3
Spindle taper = 1:40 & 1:64
Spindle tube l;ength = 180 250 mm
Ring dia. Standard (in mm) =>
36,38,40,42 & 45
Ring flange width =>
Flange No. 1 ( b=3.2 mm )
Flange No. 2 ( b =4.0 mm)
Pendulum gauge =>
Long spinning angle = 440 mm
Short spinning angle = 375 mm
Inclination of drafting arrangement = 60* (degree)
Height of separators plate = 233.90 & 185 mm
Material of top roller = synthetic rubber
Material of bottom roller = stainless steel
Surface of top roller = plain
Surface of bottom roller = fluted
Total No. of ring frames = 17
No. of spindle ( in one R/F) = 864
COUNT SPUN = 50, 60, 70, 80, 100, 120 & 140 Ne
Hank of roving fed = 0.8-1.5
Delivery speed = 6-17 m/min
Fly catcher gauge = 1.6 mm
Ring dia. = 38 mm
ABC RING DIA. USED = 36.7 mm
Eli tube length = 180-260 mm
STANDARD SUPPLY ALONG WITH EACH MACHINE :-
BREAK DRAFT
BREAK DRAFT CHANGE GEAR FOR
FLUTED ROLLERS
DIA. 27 (B1 )
DIA. 30 (B3)
1.14
59
53
1.24
54
49
CHANGE POINTS AT R/F M/C =>
Twist change geart A/B & twist range change gear C/D
Change gear E/F for winding length
Ratchet wheel for ring rail drive
Draft chnge gear G & maitin g gear H
CP & BRW for total draft
Changing the spindle twist direction Z or S
SPINDLE RPM.
CALCULATION OF R/F =>
TPI = TM UNDER ROOT COUNT ,where TM = Twist multiplier
TPM = TPI *39.37
Twist constant = TPI*Twist wheel
F.R. Del. SPEED =SPINDLE SPEED/TPI
PRODUCTION = F.R. DELIVERY
*60*8*EFFICIENCY/36*840*2.2*COUNT (IN KG/SPINDLE/SHIFT)
BOBBIN CONTENT (GMS) = 3.25*LD square , where l =lift in inch ,D=
dia.of bobbin in inch
MAIN DRAFT = B/W FRONT ROLLER & BACK ROOLER
BREAK DRAFT = B/W MIDDLE ROLLER & BACK ROLLER
TOTAL DRAFT = B/W FRONT ROLLER & BACK ROLLER
DRAFT CONSTANT = DRAFT*C.P. where, C.P. = change pinoin
SPACER:Spacer adjust distance b/w the top & bottom aprons is adjusted
with snap on spacers.
SPACER
2.50
2.75
3.00
3.25
3.50
3.75
4.00
4.50
5.00
5.50
6.00
COLOUR
Brown
Dark Grey
Natural White
Yellow
Black
Cream
Red
Green
Blue
Grey
Cream
7.00
Yellow
APRON DIMENSION TABLE :TOP APRON
BOTTOM APRON
CRADL
E
INSID THICHNES
E DIA. S
WIDT
H
INSID THICHNES
E DIA. S
WIDT
H
36
39.2
1.05
29.75
80.5
1.05
30
43
43.3
1.05
29.75
82
1.05
30
59
53.8
1.05
29.75
89
1.05
30
Twist
range
change
gear
Twist change gear (B+A= 165T)
B
76
77
78
79
80
D & C= 137 A
T
89
88
87
86
85
TWIST PER METER (TPM)
102
35
2439
2499
2561
2624
2688
98
39
2103
2155
2262
2262
2318
91
46
1656
1696
1738
1781
1825
82
55
1248
1279
1310
1341
1375
72
85
927
950
973
947
1022
65
72
756
774
793
813
800
Break draft change gear :BDCP
Br.draft
BDCP
Br.draft
32
2.09
57
1.17
33
2.03
58
1.15
34
1.97
59
1.13
35
1.91
60
1.11
Signal lamps (Tail stock & head stock )=>
RED OFF M/C normal running/mains off
RED ON - Machine fault or machine off
RED Short flash (1sec)- doff
RED LONG flash (2sec) emergency off
55
1.22
61
1.09
56
1.20
62
1.08
