Innovation and technological advancement in

Spinning
Subject – Fabric Knowledge for Merchandiser

Faculty – Ms. Bhavana Rawat

Submitted by:

Ashish Singh M/FMS/08/08 Kanika Srivastava M/FMS/08/13

Bhavik Gandhi M/FMS/08/10 Ridhima Ranga M/FMS/08/14

Gaurang Gupta M/FMS/08/11 Vijesh Kumar Baraskar M/FMS/08/34

Kanika Jain M/FMS/08/12 Watan Gupta M/FMS/08/35

INTRODUCTION

The Indian textile industry plays

a significant role in the The Indian textile industry
country’s economy for its Interest is large and diverse,
contribution to the Gross & other
unique for its coverage of
Domestic Product (GDP), Labour
employment generation and
the entire gamut of
earning foreign exchange. The Power activities ranging from
textile industry contributes production of raw material
Raw
significantly to the world textile to providing the
material
production capacity and supply consumers, high value
of fibers. The Indian Spinning
added products, such as
machinery manufacturers have Interest & Other 10-15%
created a milestone in the year
fabrics and garments.
2007-08 with supply of over 3.5 Labour 8-12%
Challenges Faced by the
million spindles in the industry.
Power 12–15% Spinning Sector
Constituents of Yarn Spinning
Raw Material 55-60% The challenges of the
Manufacturing Cost
Hence it is crucial to handle the Spinning Industry which
The raw material accounts for
above factors to achieve profits would impede the Growth
55 – 60% of the total yarn
manufacturing cost followed by
in this competitive scenario. and development of the
power cost, labor cost and Industry are:
interest & other cost. Non-
availability and increased cost
 Raw material
are the major reasons for the raw availability
material to constitute the larger  Human resource
share in the yarn manufacturing  Power cost &
cost. The paucity and
availability
intermittent distribution of
power is another major  Investment &
challenge facing the industry. Interest cost, etc.
Raw Material Global and Indian Cotton Scenario

06/07 07/08 08/09 06/07 07/08 08/09

Raw Material vs. Million Tons Million Tons
Yarn Quality Production 26.65 26.28 24.9 122.4 120.7 114
Consumption 26.66 26.67 26.4 122.5 122.5 121
Modern developments Exports 8.13 8.19 8.8 37.3 37.6 40
in Spinning Machinery Ending Stocks 12.41 12.10 10.7 20.7 57.0 49
are mainly
Global focused
and Indian on
Cotton Cotlook A index 59.15 73 83 59.15 73 83
the key properties of a
Scenario Source - ICAC
fiber. Synthetics do not
Raw Material The world 2008/09 projections indicate lower beginning stocks,
pose challenge as the production, consumptions, and ending stocks. World production will
RAW
fibersMATERIAL
could be reduce by 1.5 million bales of 480 lbs. due to mainly reduced
controlled to a great production.
extent. However, the
following are the key
Cotton Balance Sheet (October – September)
properties of cotton
fibers which determine (in lakh bales of 170 kg )
yarn quality. 06/07 07/08(E)
Supply
 The
Micronaire and
world 2008/09 Opening Stock 52.00 47.50
C.V.% of Crop 280 315
Micronaire Imports 5.53 6.5
 Fiber Neps Total Supply 337.53 369.00

The  Contamination
Demand
world 2008/09 Mill Consumption 194.89 203

projections indicate fiber
Short lower Small Scale Unit Consumption 21.26 23
beginningcontent
stocks, production, Non-Mill Consumption 15.88 15
consumptions, and ending Exports 58 85
Micronaire
stocks. and Neps
World production will Total Off-take 290.03 326
contribute
reduce a major
by 1.5 million bales of Carry-over stock 47.5 43
480 lbs. duein the
percentage to mainly
yarn Source – Cotton advisory board E=estimated
reduced
quality production.
determining
The cotton scenario in the country also presents a difficult picture with
factors. decrease in carry forward stock for the upcoming year and decrease in
acreage allotted for cotton production. This would lead to increase in
price of raw material which would subsequently lead to its increase in
yarn manufacturing cost.
Yarn Realization to address the power availability machine utility and
issues. The machines in the efficiency and
In the production economics of a entire spinning system are elimination of skilled
spinning mill, yarn realization designed with less energy man power
plays a important role. The consumption parts.  Chute feed systems to
machines in every sub system of
cards
the Spinning system are Short Staple Spinning System
 Automatic Can Changers
configured by attaching
The short staple spinning system at card
importance to raw material
comprises of the following  Delivery in sizes upto
characteristics and yarn
system: 40” to 48”
realization.
 Maintenance free digital
Cost silver system- blow room drives
Human Resource
and cards
The Indian textile industry is Blow room and card
facing challenges on the Combing system- non together form the package in
following in the human resource autoleveller draw frame, lap catering to the deficiencies
front: former, comber, autoleveller of the raw cotton due to
draw frame continuous down grading of
 Non availability of labor the fibre properties, stress is
Ring spinning system- speed
 Skilled manpower put more on blow room
frames, ring frame, and compact
spinning. machine and cards.
To address the above issues to
an extent, automation in the
Card Sliver System
machines are designed with state
of the art technologies.  Blow Room with Bale
plucker Line
Power
 Production upto 1500
The energy efficiency and kg/hr
power utilization for machinery  Bale plucker with
has become the need of the hour autoscanning increases
Blow Room Cards
In the production
The fibers are subjected to Basic principles of carding economics of
gentle and soft treatment to remains unaltered even though
spinning mill, yarn
avoid NEP generations / there are other technological
increase in short fibre content. development. The production realization plays a
The nature of rates are determined by raw significant role. The
contamination/impurity such as material properties. The
machine in every
seed coat fragments, husk, leaf emphasis is on devices which
bits, etc. are difficult to extract. could control the deterioration sub system of the
Due this blow room had to be of fiber and maintain optimum Spinning system are
readopted with machines production. The neps are
configured by
capable of intensifying the disentangled and reaches the
cleaning significantly. minimum level at carding stage. attaching
The wire points in the carding importance to
This has resulted in a pre- machines are configured to suit
cleaning with free movement of material
all types of cotton varieties and
fibers by air handling and fine synthetics. characteristics and
cleaning with different beaters
yarn realization.
depending on the fibre nature. Combing System
The beater in the blow room are
also designed to suit both cotton  Non auto levelor draw
and synthetic handling. frame.
 High delivery speed upto
The concept of modern blow 1000 mpm.
room development is based on  Feed and delivery can
the following: with 40” X 48”
OPTIMAL OPENING Lap former and Comber
OPTIMAL CLEANING  Automatic lap
transportation system
OPTIMAL DEDUSTING
 Automatic / Semi
OPTIMAL BLENDING automatic batt piecing.

But above all, by treating the

fibres softly and gently and
saving the raw material through
less fiber loss. Blow room is
configured with high production \
machines thereby decreasing
number of ventilators.
 Draw frame manpower require to collect and
transfer waste.
 Automatic draft control
 Auto Can Changers with Ring Spinning System
magazines
Speed Frame
 Maintenance free digitals
drive  Suspended flyer
 Bobbin package size –
Combing developments are
16” Height X 6”
By technological being carried under the
Diameter
following criteria :
advancements and  Servo bobbin build
increase in production  Saving the noils
Ring frame
 Higher productivity
the investments cost
 Cost effectiveness  Spindle speed upto
in spinning mill has 25000 rpm
The percentage of noil
drastically reduced.  Servo drive system for
extraction depends on the raw
ring rail
material selection and intended
use of the end product. Combers  Auto doffing for speed
are designed for noils savings frame and ring frame
with optimum parameters.  Link coner attachment
 Automatic bobbin
Comber transportation system
 Maintenance free digital
 High precision combing
drive
dynamics and processes
 Synchronized and Energy saving is achieved with
optimal movement of the following machine
parts configuration:
 Reduced moving parts
 Energy efficient, high
All machine are equipped with performance, noise less
energy efficient drives. high speed spindles
 New light weight
Automatic waste collection in
spindles (lesser DUI)
blow room cards and combers
 4 spindle tape drive
removes wastes from these
 Lower diameter ring
machine either continuously or
intermittently. This system helps  Lower lift
to control incident of fly and  Improved suction tubes
fluff generation and reduces  High efficiency motors
for the same load draw
  less input power than Past and present – Machinery requirements
an ordinary motor and
For a mill producing Ne 30s C, with production 13.7 Tons/day
a considerable
percentage of energy Old line: 28,244 Spdls. & New line: 25,200 Spdls.
is saved. The high
efficiency is achieved 1995 2008
by reducing electrical
No. of Machines
and mechanical losses
in the motor.
29 15
Card Sliver system
Compact Spinning is value
addition in ring spinning. The 37 20
Combing system
principle of compacting or
considering during the
Ring Spinning Sys 38 29
spinning process minimizes
the width and height of the
spinning triangle. The fibre
are aligned in the yarn with Human resource requirements
uniform twist. The following illustration highlights the savings in:
Compact spinning system  Manpower
ensures appreciable reduction  Space
in hairiness and significant
 Recurring cost by way of automation
increase in yarn strength with
enhanced yarn appearance. Spindleage Non Automatic Automatic
plant Plant
Investment Analysis

By technological 30000 320 180

advancements and increase in
production the investment 500 300
50000
cost in spinning mill has
drastically reduced. The chart
A depicts clearly the The savings in manpower is an automated plant is around 40%.
reduction in machine required
for the same spindlege
capacity.
To summarize, the above technological advancements and automation are the key factor in assisting the
capital intensive spinning industry.

 Optimal realization of raw material

 Reduce manpower dependency and
 Lower energy consumption

Spinning machinery produced in india can meet the requirement of the spinning industry with cost
effective solutions.

HISTORICAL DEVELOPMENT OF YARN MANUFACTURING

Hand Spinning

 Earlier staple fibers were twisted together by hand to form yarn.

 Rolling the fiber between the hand and the leg is another primitive method to produce yarn.
 In both the above method excellent yarn is produced by experienced and skilled person.
 Carding process was done to the fiber in which fibers were straightened before Hand Spinning
process.
 Fibers could be made completely parallel by a further step called Combing, this process also
include the removal of very short fibers.
 Hand spinning with Spindle & Distaff. The woman holds the distaff under her left arm, draws
fibers from the bundle tied to the distaff, and spins fibers into yarn by lowering the spindle with a
spinning motion. Spun yarn is wrapped around the spindle as it is formed.
 A major improvement in the spinning of yarn originated in India in the form of Charka or Spinning
Wheel. It seems to have been invented sometime between A.D. 500 and A.D. 1000.
 In the 16th century Flyer and detachable bobbin were invented which allowed the simultaneous
and winding of yarn into bobbin.

MECHANIZED SPINNING

 In 1741 John Wyatt and Lewis Paul built the first series of spinning machines for spinning cotton
yarns. They used a Roller-Drafting principle which helped in producing strand of fibers called
Roving. This roving was stretched to Bobbin-and-Flyer twisting mechanism.
 Arkwright used this same principle in 1769 when he constructed a spinning machine called the
Water Frame which was given this name because it was operated by water power.
 James Hargreaves in 1760’s invented Spinning Jenny which made eight yarns at the same time.
The yarns made by Hargreaves and Arkwright machine were not as strong as hand spun yarn.
 Samuel Crompton combined water frame and spinning jenny into one basic machine known as
Spinning Mule, which was basic machine for producing cotton yarn in England until well into 20th
century.
 John Thorpe invented Automatic Spinning Mule in 1830 which is also called Ring Spinning
Machine and used even today.
 Open End Spinning in which air suction takes the fibers through tube in which twist is imparted to
fiber was invented for staple fiber.