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PTJ February 2010 47
Entrepreneurs must fulfill many important requirements in
order to set up viable yarn manufacturing plants. Some of these
requirements are selection of most suitable site and machinery
combination, economic size of the unit and operational flexibility.
However, once the plant has been installed and commissioned,
spinning managers endeavour to achieve the required product
quality at standard output rate. Therefore, it is necessary to main-
tain production balance between preparatory, spinning and wind-
ing stages and ensure the following parameters:
No section of any winding machine should be out of produc-
tion due to shortage of yarn supply from the ring spinning
shed.
Similarly, the ring spinning frame or any back process
machine should not be idle due to shortage of feed material.
There should not be an excessive stock of yarn, roving, sliver
and blowroom laps, as accumulation of material at any pro-
cessing stage may lead to temporary stoppage of the back
process machine.
Machines should not be operated at maximum speed in order
to consume the accumulated stock of back process materials.
1. Economic size of the spinning unit
The installed capacity of spindles for an economic size unit has
progressively increased in Pakistan. During the eighties a spinning
mill with an installed capacity of about 14000/15000 spindles
was considered to be an economic unit. However with the com-
mencement of World Free Trade Regime (W.T.O) the textile
industry of Pakistan is facing multiple challenges. The textile and
clothing products can find access in the international export
market only on the basis of the required quality and competitive
price. With an escalation in the prices of all inputs, currently, a
spinning unit with an installed capacity of about 20160 spindles is
considered to be an economic unit. This would require installation
of 40 Ring Spinning Frames with 504 spindles each.
2. Production program ring spinning
Assuming that the installed capacity of the spinning mill is
20,160 spindles comprising of 40 Ring Spinning Frames, the daily
production will depend upon the production program. A typical
production program for ring spinning machines is tabulated
below.
2.1. Simplex frames
For the supply of roving to the ring shed operating in accor-
dance with the above production program two types of roving
hanks have been selected. Roving hank of 0.80 for yarn counts
of 10.20 Ne and 16.20 Ne. and roving hank of 1.0 for yarn
counts of 20.20 Ne and 30.20 Ne. The number of hanks of roving
is generally kept as small as possible. The objectives are to facili-
tate balancing of production, implementation of colour scheme
and elimination of mixed yarn production. On the basis of the
foregoing assumptions, the number of Simplex frames required to
supply roving to be ring shed are calculated as follows:
2.2 Drawing frames ( 2 Passage)
Assuming waste of 0.50 % at the roving stage, production
required from the Drawing Frames works out as:
11471.93+26895.61) 1.005 = 38367.541.005 = 38559.38 LBS
Linear Density of finished sliver = 70 grains per yard = 0.119
Delivery speed of Drawing Frames = 400 MPM.
Production of one set of Drawing Frame (double delivery) per
day at 85 % efficiency equals to:
Assuming linear density of sliver at Breaker Drawing Frame is
equal to 70 grains per yard, delivery speed equal to 400 MPM
and waste at the Finisher Drawing Frames at 0.25 %, production
required from Breaker Drawing Frames works out at
38559.381.0025 = 38655.78 LBS.
Production of one Drawing Frame (Breaker) = 10712.82 LBS.
Production balance in spinning mills
Dr. [Link], professor, Emeritus, Textile Institute of Pakistan.
Nominal yarn count
Particulars 10 16 20 30
Actual count (Ne) 10.20 16.20 20.20 30.20
Spindle speed (RPM) 11,000 16,000 16,800 17,500
Twist factor 4.2 4.2 4.2 4.25
Turns per inch 13.41 16.91 18.88 23.36
OPS 100% (ozs per spindle shift) 20.43 14.84 11.19 6.3
Efficiency % 88 92 92 93
Actual OPS 17.98 13.65 10.30 5.86
Production per Ring Frame per
day (504 Spindles ) in Lbs.
1699.11 1289.93 973.35 553.77
Allocation of ring frame 2 6 20 12
Daily production
count-wise (in Lbs.)
3398.22 7739.58 19467 6645.24
Total Daily Production = 37250.04 Lbs.
Average Yarn Count = 10.23398.22+16.27739.58+20.219467+30.26645.24
37250.04
753962.67
37250.04
= = 20.24 Ne
Actual yarn count
Particulars 10.2 & 16.2 20.2 & 30.2 Remarks
Daily yarn
production (LBS)
11, 137.80 26,112.24
Production required from
simplex frames with 3%
waste in ring spinning.
11,471.93 26,895.61
Hank of roving 0.8 1.0
Twist factor and
turns per inch
0.85/0.76 1.0/1.0
Flyer speed (RPM) 1,100 1,100
Delivery in inches per
minute
1,447,37 1,100
100% production per
spindle per day (LBS)
86,15 52.38
Actual production
/spindle/day
73.23 44.52
Efficiency =
85%
No. of simplex frames
spindles required
156.66 604.12
No. of simplex
frames required
1.31 5.03
Simplex frame
with 120
spindles each.
Total number of Simplex frames = 6.34 or 7.0
4001.093660240.852
0.119840
=10712.82 LBS.
Number of Drawing Frames (Finisher) required
38559.38
10712.82
= 3.6 say 4 sets.
Number of Drawing Frames (Breaker required) =
38655.78
10712.82
= 3.61 say 4 sets.
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48 PTJ February 2010
2.3. Cards
Assuming waste at the Breaker Drawing Frames at 0.25 %,
production required from the cards works out at =
38655.781.0025 = 38752.419 LBS.
Linear density of card sliver = 70 grains per yard = 0.119.
Delivery speed = 145 MPM. Efficiency of card = 86 %.
Usually 2 extra cards will be installed to add flexibility to the
carding process and take care of stoppage of any card for replace-
ment of old wire.
2.4. Blowroom
Daily production required from Blow Room Line @ 7 % waste
at the carding stage 38752.419 1.07 = 41465.09 LBS.
Production required per hour = 1727.71 LBS = 783.68 KG.
If Chute Feed System is not provided, number of scutchers
required is calculated as follows:
Diameter of Lap Roller = 9 inch.
Speed of Lap Roller = 15 RPM.
Linear density of Lap = I LB/yard, Efficiency = 85 %
Hank of Lap = 0.00119
2.5 Cotton Required.
The quantity of cotton required per day can be calculated is
shown in the next column:
2.6. Auto cone winding machines
The ring cops produced on the Ring Spinning Frames are not
marketable. In order to produce cones which are marketable,
winding of ring cops is carried out on Auto-Cone Winding
Machines.
The number of winding machines required is calculated as follows:
Total number of drums required = 21.75+74.94+224.33+104.95
= 425.97
Summary
Process wise number of machines calculated above for
achieving production balance are summarized below:
a. Ring Spinning Economic Unit = 20,160 spindles, 40 Ring
Spinning Frames, 504 spindles each.
b. Simplex Frames, 7 Roving Frames, 120 spindles each.
c. Drawing Frames, (2 Passage), 4 Double Delivery Drawing
Frames.
d. Carding Machines, 22 cards.
e. Blow Room, cleaning Line of machines with Chute Feed
System or 3 Single Process Scutchers.
It may also be pointed out that leading textile machinery
manufacturers are marketing modern state of the art machines
with operating speeds higher than those used in the foregoing
calculations. Many entrepreneurs would like to install these
machines at their Spinning Mills, and above mentioned machin-
ery combinations are determined by the financial resources and
the investment capabilities of the respective entrepreneurs as well
as presently installed spinning mills in Pakistan.
Acknowledgement
Assistance received from Tanzeel Minhaj, Bilal Ahmed,
Muhammad Adnan and Danyal Siddiqui (Final year students of
T.I.P.) is gratefully acknowledged.
Production of card per day =
1451.093660240.86
0.119840
= 1964.54 LBS
Number of cards required =
38752.419
1964.54
= 19.73 or say 20 cards
Production per scutcher per day=
TT 91560240.85
= 14431.68 LBS
360.00119840
Number of scutchers required =
41465.09
= 2.87 or say 3 scutchers.
14431.68
Cotton required per day @ 7 % waste in Blow Room = 41465.09
1.07 = 44367.65 LBS.
Number of cotton bales required (375 LBS each) is equal to:
375
44367.65
= 118.3 or say 119 bales.
Nominal/Actual Yarn Count
Particulars 10/10.2 16/16.2 20/20.2 30/30.2
Daily production (LBS) 3398.22 7739.58 19467 6645.24
Winding speed (MPM) 1000 1050 1100 1200
Operating efficiency 85% 85% 85% 85%
Production per
drum per day (LBS)
156.23 103.28 86.78 63.32
No. of drums required 21.75 74.94 224.33 104.95
Number of winding machines required (60 drums each) is equal to:
425.97
60
= 7.0995 or say 7 machines.
Iran has been one of the most promi-
nent markets for Italys textile machinery
manufacturers. The sales of Italian textile
machinery to Iran during the first 9
months of 2009 (most updated figures)
amounted to 16 million Euros, ranking Iran
fifth overall among Asian markets for
Italys textile machinery industry.
The type of machinery requested has
changed partially, with a growing interest
for finishing machinery. During the period
from January to September 2009, sales of
Italian machinery to Iran were distributed
as follows: finishing machinery 46% of
total, other machinery 16%, weaving
machines 13%, spinning machines 11%,
accessories 11%, knitting machines 3%.
The mounting share of finishing machines
highlights a continuing surge in qualitative
levels for Iranian textile production, which
has been increasingly offering products
with greater added value.
The ever-growing interest on the part
of Iranian companies for Italian finishing
machinery has prompted ACIMIT
(Association of Italian Textile Machinery
Manufacturers) and ICE (Italian Trade
Commission), in partnership with the
Iranian Textile Association, to promote a
technology check-up for Italian textile
companies operating in the finishing
sector. To this end, during the second half
of 2009, an Italian expert in the sector vis-
ited 10 local textile manufacturers to pin-
point any technology gaps, simultaneously
identifying possible solutions by Italian
textile machinery manufacturers. The data
collected was gathered in brief information
files and distributed to each Iranian com-
pany visited. The files portray an overview
of the existing situation, indicating possi-
ble technology solutions.
This technology check-up represents
yet another moment of synergy between
Italys textile machinery manufacturers and
Irans textile and garments industry, and is
an integral part of an intense promotional
campaign being promoted by ACIMIT and
the ICE in the Iranian market over many
years now. The technology check-up thus
served as a natural follow-up to the tech-
nology symposiums which took place in
February 2009 in Teheran and Isfahan.
Italian technology serving Iranian textile producers: A winning alliance