SPINNING:

It is a part of textile manufacturing process. It is basically a process of drawing out yarns,

inserting the twist and winding into bobbins. In this the fibres are passed through different
processes.

Blowroom

Carding

Breaker draw frame

Uni-lap

Comber

Finisher

Speed frame

Ring frame

Auto coner

Packing
Main godown:

It is used for storage of raw materials. It can consist upto 2 lakh bales. 1 cotton bale is is of
165 kg. In this room sorting is done. Bales are kept one above the other. Different type of
cotton used in the industry are:

100% organic cotton- 80 count

100% MCU5 cotton- 55 count
100% Giza cotton- 80 count
65% MCU5 and 35% DCH cotton- 80 count

1. Blowroom:
This is used for opening and cleaning of bales. Bale plucker machine is used for
opening. Blowroom consist of 4 machines. The process flow of blow room is :

Uniflock

Uniclean

Unimix

Uniflex

Uniflock machine-this is used to take up the material from the bale cotton
Uniclean machine- this is used for opening and cleaning of cotton
Unimix machine- this consist of 4 compartments which are used for mixing of
all the materials
Uniflex machine- this is used for fine cleaning of cotton.

BALE PLUCKER: Opening of bale

This machine opens the bale and feeds it into another machine.Speed: 20mtrs/min. Length:
50Mtrs.

SP-FPU: Contamination Sorter.It is a motor-cell based machine with a camera fitted inside it.
Any contamination particles if present are detected by the camera are ejected.

Normal (Foreign Particles)- 192 ejections/hr

Normal (Plastic)- 189 ejections/hr

Red pipes-if there is fire in one machine then the supply stops and the cotton which caught
fire is removed through the red pipe into the quenching tank. Then after water is sprinkled
into the tank to stop fire.

2. Carding: Carding is one of the most important operations in the spinning process as it
directly determines the final features of the yarn, above all as far as the content of neps
and husks are concerned.
There are many objectives of the carding process and these can be summarized as:
Opening the tufts into individual Fibres.
Eliminating all the impurities contained in the Fibre that were not eliminated in the
previous cleaning operations.
Selecting the Fibres on the basis of length, removing the shortest ones.
Removal of neps. Parallelizing and stretching of the Fibre.
Transformation of the lap into a sliver, therefore into a regular mass of untwisted
Fibre.
CARDING: 53 Machines
Fibre Selection and cleaning.
Speed: 300 mtrs/min

3. Draw Frame: This is the machine on which drafting & doubling are carried out.
Carded sliver is that they are not even (uniform) enough to produce to good quality
yarns. Therefore, usually all the carded slivers are subjected to Doubling & Drafting
on a machine called Draw Frame.
Doubling is the practice of feeding two or more strands to produce one Strand. To
attenuate fiber laps to slivers, Drafting is carried out.
Different methods are used to draft sliver or yarn. One method is called Roller
Drafting. During drafting the number of fibers in the cross section of the sliver or lap
is reduce.
It is occurred between flats and cylinder. Maximum individualization of fibers is
achieved in this region. Naps short fibers dirt and dust are removed by this action.
There always should be point against point action.
Carding Action-It is occurred between licker in and cylinder. There are should be
point against back action. Individualization of Fibre is also by this action.

Task of draw frame:

Equalizing
Parallelizing
Blending

BREAKER DRAW FRAME: 9 Machines

 It reduces thickness.
Helps in parallelization
Speed: 800mpm.

4. Combing:
Combing is a process which is introduced into the spinning of finer and high quality
yarns from cotton. The carded materials (sliver) contain certain amount of short fibres,
neps, fine kitty and leaf particles. Short fibres are a hindrance to spinning of finer counts
where the number of fibre in the cross section of the yarn is less. The short fibres cause
thick and uneven places in the yarn length and the yarn looks hairy. Apart from this, very
short fibres do not contribute anything to yarn strength. Short fibres below a certain pre-
determined length can be easily separated out by using comber.

Objects of Comber:
To remove the short fibres below a pre-selected length so that the spinner enable to
produce finer or better quality of yarn that cannot be possible in carding state.
Elimination of remaining impurities.
Elimination of large proportion (not all) of the neps in the fibre.
Formation of sliver having maximum possible evenness.
To straighten the fibres.

Basic working of a Comber or Combing sequence :

Lap feeding by feed roller

Lap nipping by the nipper
Combing by the cylinder
Nipper opening and forwarding
Detaching roller backward movement
Piecing
Combing by the top comb
Detaching roller forward movement
Starting a new cycle
Cleaning of cylinder comb

There are 28 Comber Machines in the industry. It removes short fibres. It also decides how
much % of short fibre is to be removed. Speed of machine 500npm (n-neps). Efficiency is
92.06%.

5. Speed Frame

The product delivered by roving machines is called Roving. Roving is a Fibre strand of
lesser count than that of a sliver. It is also has a small twist to keep Fibres together. It is
wound on to a package which is suitable for feeding spinning machines.
 Objectives of speed frame:

Attenuation of draw sliver to a suitable size for spinning.

To insert a small amount of twist to strengthen the roving.
To wind the twisted strand roving into a bobbin.

Operation involved in speed frame:

Drafting: To reduce the weight /unit length of sliver to make it suitable for ring
spinning system.
Twisting: To insert small amount of twist to give required strength of roving.
Winding: To wind the twisted roving on to bobbin

FINISHER DRAW FRAME:

Evenness and parallelization.

Cans vary according to machines.

SPEED FRAME,ROVING FRAME,SIMPLEX:

Sliver Roving FrameBobbin

Reduces Thickness.

Standard:1.8 hank.

No. Of spindles:192

Speed:1300 rpm

Bobbins are wound on spindles, thread is wound on the bobbin with the help of flyer.

Speed Frame- Autodoffing

Ring Frame

The ring spinning machine was first invented in 1828 by the American Thorp. In 1830,
another American scientist, Jenk, contributed the traveler rotating on the ring. There have
been many development has done in ring spinning machine for the last years but the basic
concept remained unchanged.

Functions of ring frame:

Draft the roving until the required fineness is achieved

 Twist the drafted strand to form yarn of required count and strength
Winding the twisted yarn on to the bobbin for suitable storage, transportation and
further processing.

Operations involved in ring frame:

Creeling
Drafting
Twisting
Winding
Building
Doffing

Advantage of Ring Spinning System:

Any type of material (Fibre) can be spun

Wide range of count can be processed
It delivers a yarn with optimum characteristics.
Idealized twisting system
It is uncomplicated and easy to operate
Higher yarn strength can be achieved
Disadvantages of Ring Spinning System:
Low production
Machine generates more heat

Limitations:

In ring spinning machine twisting and winding are done simultaneously. Thats why the
power consumption is higher.

RING FRAME:

Capacity-1632 spindles/ring frames

Machines-104

Speed-18000rpm

Total- 1,69,728

1 spool 40 gm

Autoconer

The main drawbacks of manual winding are labor intensive, less productive and less
effective. In order to overcome the limitations , the autoconer winding machine has been
introduced four decades ago , now the fifth generation machine is also been launched .The
improvements in autoconer machine has been a continues process . In autoconer machine, the
speed is 1300 metre per minute. The EYC used, will clear the faults to the maximum possible
extend. Usually 50 to 60 breaks per lakh metre faults are cleared .The joining of the ends is
made by a unique process known as splicing ,were the ends are opened, mingled and
retwisted by which the appearance will be uniform and knot is eliminated here. The labor
requirement is very much reduced and the splicing is carried out by the machine itself. The
autoconer machines are now been widely used to overcome the labor shortage, improve
machine productivity and the quality of yarn dispatched for sales.

LINK CONER/ AUTO CONER X5:

Company: Saurer schlafhorst

M/c-Xchange

BobbinBobbin holderYarn Bind

Speed-18000rpm

Machines-104

ConeLifterFiller

The cone automatically travels and gets feeded

NeunhauserLifter

INTERMEDIATORY STORAGE:

Bobbins are stored from roving frame and ring frame.

Where demand arises they are transported there to meet the demand. If in this process bobbin
gets dirty then it is cleaned using a machine with vacuum cleaner.

AUTO-PACKING AREA:

It is fully computerised with very less or no manpower.

Loaded yarn comes in through overhead conveyor and are unloaded by unloader after
unloading of every 6 cones on the slider,transport car comes and picks the cones due to
suction and places them on pallets.

1 palletseiser

10 pallets can be stacked one above the other.

Conditions: Moisture is to be added.

According to yarn count bar code is attached.

Yarn Production: 25 tonnes/day