Spin Plan of 60S count cotton Yarn 1

Spin plan for a cotton mill (For 60s count):

Number of spindles = 25000

Average count = 60S

Parameter B/R Carding D/R Super lap Combing Simplex Ring

former frame
Hank or count 0.0016 0.16 0.16 0.0098 0.16 3.5 60
(52 grains/yds)
Doubling 8 32
Draft 100 8 1.96 16.32 21.87 17.14
Delivery speed or 12 45 400 90 1500 18000
spindle speed yd/min m/min
Delivery roller dia 9.5 27 inch
inch
TPI 1.87 27
Efficiency % 85 90 85 90 90 85 90
Ideal Time % 12 10 10 7 7 7 5
Waste % 5 5 0.75 2.5 18 0.5 2.5
Delivery per frame or 2 2 8 120 480
Spindles per frame

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 Spin Plan of 60S count cotton Yarn 2

Ring frame:

Total no. of spindles = 25000

Spindle speed = 18000 rpm
Spindle per frame = 480
Yarn count = 60S

TPI = 27
Efficiency = 90%
Waste = 2.5%
Average stoppage = 5%

25000
Required ring frame = = 52.08 ≈ 52 for 24960 spindles.
480

100−5 95
No. of running spindles = 24960 × = 24960 × = 23712
100 100

Production per hour =

𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑 ×60
×𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 × 𝑁𝑜. 𝑜𝑓 𝑟𝑢𝑛𝑛𝑖𝑛𝑔 𝑠𝑝𝑖𝑛𝑑𝑙𝑒𝑠
𝑇𝑃𝐼 ×36 ×840 ×𝐶𝑜𝑢𝑛𝑡

18000 ×60 90
= × × 23712 = 470.48𝑙𝑏𝑠
27 ×36 ×840 ×60 100

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 Spin Plan of 60S count cotton Yarn 3

Simplex section:

Spindle speed = 1500 rpm

Spindle per frame = 120
Roving hank = 3.5
TM = 1

TPI = 1.87
Efficiency = 85%
Waste = 0.5%
Average stoppage = 7%

100+𝑅𝑖𝑛𝑔 𝑤𝑎𝑠𝑡𝑒
Production of simplex = Production of ring frame ×
100

100+2.5
= 470.48 ×
100

= 482.24 lbs
𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑 ×60
Production / hour/ spindle = × 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑇𝑃𝐼 ×36 ×840 ×𝑅𝑜𝑣𝑖𝑛𝑔 ℎ𝑎𝑛𝑘

1500×60 85
= ×
1.87 ×36 ×840 ×3.5 100

= 0.39 lbs
482.24
No. of running spindles = = 1247.65 ≈ 1248
0.39

100+𝑠𝑡𝑜𝑝𝑝𝑎𝑔𝑒 𝑡𝑖𝑚𝑒
No. of established spindles = 1248×
100

100+7
= 1248 ×
100

= 1335.36 ≈ 1335

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 Spin Plan of 60S count cotton Yarn 4

1335
No. of simplex machines = = 11.13 ≈ 11
120

Combing

Feed/Nip = 7 mm
Nips/ min= 250

Feed lap weight = 850 grains/yds

Feed Lap hank = 0.01

Delivery sliver weight =52 grains/yds

Delivery sliver hank = 0.16

Noil = 18%

No. of head/frame = 7
Efficiency = 90%.
Average stoppage time= 7%

100+𝑠𝑖𝑚𝑝𝑙𝑒𝑥 𝑤𝑎𝑠𝑡𝑒
Production of combing = Production of simplex ×
100

100+0.5%
= 482.24×
100

= 484.65 lbs.

Production/hour =

𝑓𝑒𝑒𝑑/ 𝑛𝑖𝑝(𝑚𝑚) 𝑁𝑖𝑝𝑠

× × 60 × 𝑙𝑎𝑝 𝑤𝑡. 𝑖𝑛 𝑔𝑟𝑎𝑖𝑛 × 𝑛𝑜. 𝑜𝑓 ℎ𝑒𝑎𝑑 × 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
1000 𝑚𝑖𝑛

7×250×1.09×60 850 90
= × ×7×
1000 7000 100

=87.55 lbs

484.65
Number of comber = = 5.53
87.55

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 Spin Plan of 60S count cotton Yarn 5

Installed no. of comber = 5.53 × 100+7

100
= 5.91 ≈ 6

Super Lap former:

Delivery speed = 90m/min

Lap hank in grain/yds =850
Lap hank =0.0098
Efficiency =90%
Waste = 2.5%
Stoppage time = 7%

100+𝑤𝑎𝑠𝑡𝑒
Production of lap former = production of comber ×
100

100+18
= 484.65 × = 571.89 lbs
100

𝑔𝑟𝑎𝑖𝑛
𝐷𝑒𝑙𝑖𝑣𝑒𝑟𝑦 𝑠𝑝𝑒𝑒𝑑 ×𝑙𝑎𝑝 ℎ𝑎𝑛𝑘 𝑖𝑛 ×60
𝑦𝑑𝑠
Production per hour = × 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
7000

90 ×1.09×60×850 90
= × = 643.26 lbs
7000 100

571.89
Number of super Lap former = = 0.89
643.26

100+𝑠𝑡𝑜𝑝𝑝𝑎𝑔𝑒 𝑡𝑖𝑚𝑒
Number of Installed super lap former = 0.89 ×
100

100+7
= 0.89× = 0.95 ≈ 1
100

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 Spin Plan of 60S count cotton Yarn 6

Draw frame:

Delivery roller speed = 400 yds/min

Sliver hank = 0.16

Delivery head per frame = 2

Efficiency = 85%
Waste = 0.75%
Stoppage time = 10%

100+𝑆.𝐿.𝐹 𝑤𝑎𝑠𝑡𝑒
Production of draw frame = Super lap former production ×
100

100+2.5
= 571.89 ×
100

= 586.19 lbs
Delivery roller speed × 60
Production /hour/frame = ×𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 × 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑦 ℎ𝑒𝑎𝑑/𝑓𝑟𝑎𝑚𝑒
840 ×𝑆𝑙𝑖𝑣𝑒𝑟 ℎ𝑎𝑛𝑘

400 × 60 85
= × ×2
840 ×0.16 100

= 303.57
586.19
Running Draw frame = = 1.93
303.57

100+𝑠𝑡𝑜𝑝𝑝𝑎𝑔𝑒 𝑡𝑖𝑚𝑒
Install draw frame = 1.93 ×
100

100+10
= 1.93 ×
100

= 2.12 ≈ 2

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 Spin Plan of 60S count cotton Yarn 7

Carding section:

Doffer diameter = 27 inch

Doffer speed = 45 rpm
Sliver hank = 0.16
Efficiency = 90%
Wastage = 5%

Average ideal time = 10%

100+𝐷𝑟𝑎𝑤 𝑓𝑟𝑎𝑚𝑒 𝑤𝑎𝑠𝑡𝑎𝑔𝑒

Carding production = Draw frame production ×
100

100+0.75
= 586.19 ×
100

= 590.59 lbs
𝜋 × 𝐷𝑜𝑓𝑓𝑒𝑟 𝑑𝑖𝑎 ×𝐷𝑜𝑓𝑓𝑒𝑟 𝑠𝑝𝑒𝑒𝑑 ×60
Production/hour/machine = × Efficiency
36 ×840 ×𝑠𝑙𝑖𝑣𝑒𝑟 ℎ𝑎𝑛𝑘

3.14 ×27×45 ×60 90

= ×
36 ×840 ×0.16 100

= 42.58 lbs
𝑇𝑜𝑡𝑎𝑙 Carding production
Running Carding machines =
Production/hour/machine

590.59
= = 13.87
42.58

Installed Carding Machines =

100+𝐴𝑣𝑔.𝑠𝑡𝑜𝑝𝑝𝑎𝑎𝑔𝑒 𝑡𝑖𝑚𝑒
Running Carding machines×
100

100+10
= 11.04 ×
100

= 15.26 ≈ 15

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 Spin Plan of 60S count cotton Yarn 8

Blow Room Section:

Calendar roller Diameter (C.R.D) = 9.5 inch

Calendar roller speed (C.R.S) = 12 rpm
Lap hank = 0.0016
Waste = 5%
Efficiency = 85%

Scutcher / blow room line = 2

Average ideal time = 12%

100+𝐶𝑎𝑟𝑑𝑖𝑛𝑔 𝑤𝑎𝑠𝑡𝑎𝑔𝑒
Blow Room production = Carding production×
100
100+5
= 590.59 ×
100

= 620.12 lbs
𝜋×𝐶.𝑅.𝐷 ×𝐶.𝑅.𝑆 ×60
Pro./hr./Scutcher of Blow room = × 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
36×840×𝐿𝑎𝑝 ℎ𝑎𝑛𝑘

3.14×9.5×12×60 85
= × 𝑙𝑏𝑠
36×840×0.0016 100

= 377.31 lbs
Blow Room production
Running Scutcher =
Pro./hr./Scutcher of Blow room

620.12
=
377.31

= 1.64
100+𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑖𝑑𝑒𝑎𝑙 𝑡𝑖𝑚𝑒
Installed Scutcher = 1.64 ×
100
100+12
= 1.64×
100

= 1.84 ≈ 2
No. of Blow room line = 2/2 = 1

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 Spin Plan of 60S count cotton Yarn 9

Summary:

Number of required machines for 25000 spindles & 60S Count Cotton yarn:

 Blow room line = 1 (2 Scutcher)

 Carding machines = 15

 Draw frame = 02

 Super lap former =01

 Comber = 06

 Simplex = 11

 Ring frame = 52