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Basic idea about spinning mill visit.
Mill visit to Panna Textile Ltd.
City University 1/24/2011
Umera Islam Lecturer of B.S.T.E. City University
Shahriar Al-Sehab Faysal Islam Mohammad Sajib Aminul Islam Mehedi Arif Sheikh Shezan Alam Sumon Miah Ahsan Habib ID 09322131 09322015 09322073 09322031 09322108 09322064 09322120 09322173
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Name of section
Preface Blow Room Carding Drawing Roving Ring frame Last word
01 02-05 05-08 08-11 11-14 14-17 17
In our daily life, we use cars, bases, micros and many other things as transport but without the tyre of the transports why they are for. Similarly without 1. Yarn Manufacturing 2. Fabric Manufacturing 3. Wet Manufacturing 4. Garments Manufacturing We can’t think about textile. As student of textile we have to gather knowledge about those four more and more. We are thankful to our course instructor Umera Islam. She gives us change to acquire knowledge, practical knowledge (which is very much important for any engineering). She takes us to Panna textile mills, to show us how fiber turns to yarn. We get a change to compare between there & practical knowledge. Here we are trying to describe that…...........
Spinning is the process by which fibers turn to yarn but it is not a single step process. For these we have to go through by
Process Flow Chart of Carded Yarn Manufacturing:
Input Material ———Processing Machines ——–Output Materials Raw Cotton >>>>>> Blow Room>>>>>>>>>>>Lap Lap>>>>>>>>>>>Carding>>>>>>>>>>>>>>Carded Sliver Carded Sliver>>>>>Drawing 1>>>>>>>>>>>>Drawn Sliver
Breaker Sliver>>>>>Drawing 2>>>>>>>>>>>>Finisher Drawn Sliver Finisher Drawn Sliver>>Simplex/ Speed Frame>>>Roving Roving>>>>>>>>>Ring Frame>>>>>>>>>>>>Yarn Yarn>>>>>>>>>>Winding>>>>>>>>>>>>>>Yarn In Large Package.
To make easy our discussion we are describing the process of carded yarn & the information we get from Panna Textile Mill.
Blow rooms theory
Blow room installations consist of a sequence of different machines to carry out the operations described below. Moreover Since the tuft size of cotton becomes smaller and smaller here.
Opening cleaning mixing or blending micro dust removal uniform feed to the carding machine Recycling the waste.
There is some action which is carried out on blow room section of textile spinning manufacturing section.
1. Action of opposite strike: The actions of opposite spike opened the cotton fiber. By this action the large pieces of cotton have been reduced in size.
2. Action of air current: During processing, the movement of cotton from machine to machine is done by air current. It also helps the separation of lint and trash.
3. Action of beater: Beaters are responsible for removing almost all of the impurities extracted in the blow room. Beaters also helps opening and cleaning.
4. Actions of regulating motion: The action of regulating motion gives the uniform output by the help of sewing door, swing paddle.
Blow room of Panna textile
In Panna Textile, there is no digital system for opening, cleaning, mixing and blending, all those process done manually in Panna textile. After this, the hand mixed cotton feed to Hopper bale breaker. The process and the every step from this to lap formation is given below.
Hopper bale breaker
Lap is output of this process. To flow cotton from one step to another adjusting fans & feeding fans are used.
Photo gallery of blow room of Panna Textile
The pictures are about
1. Cotton bale 2. Opening and mixing 3. Feeding in hopper feeder 4. Lap, as output from Scutcher
5. Collecting impurities 6. Observation of wastage
Theory of Carding
In yarn production, a process of separating individual fibers, causing many of them to lie parallel and removing most of the remaining impurities. Cotton, wool, waste silk, and man-made staple are subjected to carding. Carding produces a thin sheet of uniform thickness that is then condensed to form a thick, continuous, untwisted strand called sliver. When very fine yarns are desired, carding is followed by combing, a process that removes short fibers, leaving a sliver composed entirely of long fibers, all laid parallel and smoother and more lustrous than uncombed types. Carded and combed sliver is then spun. "Card is the heart of the spinning mill" And "Well carded is half spun” are two proverbs of the experts. These proverbs inform the immense significance of carding in the spinning process. High production in carding to economies the process leads to reduction in yarn quality. Higher the production, the more sensitive becomes the carding operation and the greater danger of a negative influence on quality. The technological change that has taken place in the process of carding is remarkable.
TECHNOLOGICAL POINTS IN CARDING. There are two types of feeding to the cards 1. Feeding material in the form of Scutcher lap 2. Flock feed system (flocks are transported pneumatically)
Carding process in Panna Textile
In Panna textile feeding to the cards Scutcher is used. This is done by carding machine of trutzschler. Carding process of Panna Textile is given bellow as flowchart.
Input of lap (in the form of Scutcher lap)
Carded sliver as output
Carded sliver collected in cans.
Photo gallery of carding of Panna Textile
The pictures are about
1. Carding machine 2. Carding machine 3. Better & spikes of carding machine 4. Carded lap as output 5. Carded lap as output 6. Collection of carded lap to cane.
Theory of drawing
A process in short, staple spinning in which the slivers are blended, doubled leveled & drafted by each pair moving faster than the previous one.
Draw frame is a very critical machine in the spinning process. Its influence on quality, especially on evenness is very big. If draw frame is not set properly, it will also result in drop in yarn strength and yarn elongation at break. The faults in the sliver that come out of draw frame cannot be corrected. It will pass into the yarn.
The factors that affect the yarn quality are
The total draft no of draw frame passages Break draft No of doublings Feeding amount of draw frame Fiber length Fiber fineness Delivery speed Type of drafting, etc.
Drawing process of Panna Textiles
In Panna textile feeding to the cards Scutcher is used. This is done by drawing machine of trutzschler. Drawing process of Panna Textile is given bellow as flowchart……………
Carded sliver as input
Drawn sliver as out put
From here drawn sliver are taken to simplex machine for forming roving.
Photo gallery of drawing of Panna textile
The pictures are about 1. 2. 3. 4. Carded slivers are in cane. Carded slivers are going for drawing. Inputting in drawing machine Roving.
Theory of Roving Frame
Roving: A loose assemblage of fibers drawn or rubbed into a single strand, with very little twist. In the modern cotton spinning system, it is an intermediate state between sliver & yarn. Roving frame: A machine used in yarn manufacture to reduce the size of sliver to roving, insert a slight amount of twist, & wind it on a package.
Roving machine is complicated, liable to faults, causes defects, adds to production costs and delivers a product that is sensitive in both winding and unwinding. The following parameters are very important in roving frame. They are…….. Feed hank Delivery hank Roving tension break draft Drafting system Bottom roller setting Top roller setting condensers and spacers Twist in the roving Bobbin content flyer speed Creel and creel draft Draw frame sliver and can Bobbin height Breakage rate
Roving process in Panna Textile
Simplex machine are used for roving & for roving Panna Textile use “Lakshmi LF-1400-A” simplex machine.
Rubbed in a single strand
Very little twist
Wind on a package
From here drawn sliver are taken to Roving frame machine for forming roving.
Photo gallery of roving frame of Panna textile
The pictures are about 1. 2. 3. 4. 5. 6. Drawn sliver as input A small part of simplex machine Rubber pad observation Drafting of roving Output from simplex m/c Untwisted rope (roving)
Theory of Ring frame
The ring frame machine was invented in the year 1828 by the American Thorp.
Twist is inserted into a yarn after it emerges from the front drafting rolls by passing it through a yarn guide, to a traveler, and to a rapidly rotating robbing simultaneously and continuously. Ring spinning produces stronger yarn than open end spinning and is economical of finer counts.
A machine for spinning cotton, worsted, woolen, flax, spun silk and manufactured fiber yarn. The machine delivers sliver or roving to a drafting system. The yarn strand that emerges from the front drafting rolls from a balloon between a yarn guide and a traveler that circles a bobbin. The yarn winds onto the spinning bobbing at a rate determined by the delivered speed of the drafting system; all addition rotation o f the bobbin inserts twist into the yarn.
Ring frame Technology is a simple and old technology, but the production and quality requirements at the present scenario puts in a lot of pressure on the Technologist to select the optimum process parameters and machine parameters, so that a good quality yarn can be produced at a lower manufacturing cost.
Following are the points to b e considered in a ring frame Drafting and setting Ring and travelers Spindle speed
Twist Lift of the machine Creel type Feed material Length of the machine Type of drive , above all
Simplex in Panna textile
Ring frame machine are used for twisting or completing the process of yarn manufacturing and “MARZOLI” spinning solution used in Panna textile…………. Roving as input
Twisted yarn in creel form
From here the reels are taken away to auto cone for cone winding after cone winding the cone are ready for sell but before this a little finishing process take place. To make stable the twist the cone are go through into a finishing process, for this 500 cone are gathered in one boiler. For these 500 cone 3 kg water are heated to 90 C & spread for 40 - 50 minutes. After this wet of every cone increased 2 pound.
Photo gallery of Ring frame Auto cone & finishing boiler
Creation of something is not as easy as use it. The engineers are creator. By their creativity & knowledge they create, but the creation is not only for them they do so for mankind. Nothing can do without any pathfinder. Engineers are not out of this. When they are becoming ready they also need pathfinder. Here the teachers contributes as pathfinder. Without them (teachers) a student can’t prepare for the very important responsibility of creation. And of-course we are the student of textile engineering, for this the responsibility (mentioned above) becomes our responsibility too, our teachers are not lacking behind too. So, if we can’t do our part, what will be our excuse to our next generation? Not to face this situation, the mill visit to Panna Textile is a very small effort we did & we will be.