Gohar textile mills

(pvt.) LTD

MUHAMMAD
MUNEEB SAJID

[INTERNSHIP REPORT]
SUBMITTED TO: M. IQBAL IRSHAD
 Author

MUHAMMAD MUNEEB SAJID

A report submitted in partial fulfillment of the requirements for the

Internship.

Spinning Unit
Gohar Textile Mills (Pvt.) Ltd.
Faisalabad.
August 2018
 Abstract

Gohar Textile Mills (Pvt.) Ltd

Gohar Textile the state of the art equipment from Europe converts the 50 tons of

cotton per day through the various stages of manufacture and into the array of

products we export worldwide annually. Industry have 6 factories and 3000 staff

members spread across 120 acres of land in Faisalabad, Pakistan combined with a

manufacturing facility in Manchester, UK to ensure consistent output and the

quality Gohar Textile is synonymous with. Industry teams of over 50 international

designers based in Faisalabad and Manchester consistently monitor trends,

techniques and finishes to offer the best designs. At Gohar Textile innovation is

key and with 40 years of experience in the industry stay at the forefront of cutting

edge technology and combined with our strict quality, technical and social

compliance policies we ensure customers’ requirements are met.

 ACKNOWLEDGEMENTS

We have worked hard to find the accurate data about Gohar textile mills (pvt) ltd and

technical working description about the machines being used over there. We have studied

different number of machines regarding Gohar textile mills spinning unit to increase our

knowledge so that we may get able to write a comprehensive report about Gohar textile

mills. We give special thanks to our instructor of Mechanical Department who gave us

enough knowledge to study any working of machines and to write report on it. They told

us all the parameters that have to be considered to analyze any machine.

 TABLE OF CONTENTS

Abstract..............................................................................................................

Acknowledgement..............................................................................................

Chapter I: Introduction........................................................................................

1.1 Company introduction.............................................................................

1.2 Mission Statement...................................................................................

1.3 Product Line...........................................................................................

1.4 R & D Dept. …………………………………………………………..

1.5 Shipment Efficiency………………………………………………………

1.6 Major Customer ………………………………………………………

………………………………………………………………………

Spinning Unit ………………………………...……………………………...

Electrical Store…………………………………………………………

Power House ………………………………...……………………………...

 Chapter I

Introduction
1.1 Introduction:

Gohar Textile Mills was incorporated in 1993 in the most renowned textile
city of Pakistani . e . F a i s a l a b a d . E v e r s i n c e i t s f or m a t i o n i t i s
e x p o r t i n g i t s t o t a l p r o d u c t i o n t o t h e International Markets. Gohar
Textile Mills (Pvt) Ltd is a group that is expanding from a modest base on a
very consistent & practically enviable growth rate. We are a supply partner
for businesses who value the quality and like to enjoy it on a consistent
basis.

1.2 Mission Statement:

G o h a r a i m s t o b e a w or l d c l a s s t e x t i l e o rg a n i z a t i o n
p r o d u c i n g d i v er s e r a n g e o f products for the global textile market.
Gohar seeks to achieve customer delight through excellence
in manufacturing & customer service based on creative
combination of state o f t h e
art technology & human resources. Gohar
i s c o m m i t t e d t o b e r e s p o n s i b l e corporate citizen.

1.3 Product Line:

G o h a r Te x t i l e M i l l s p r o d u c e d d i ff e r e n t h i g h q u a l i t y
e x p o r t or i e n t e d pr o d u c t s t o t h e international market. These are as
under:-

 Quilts(Comforters)
 Bed linen
 Kitchen linen
 Processed fabrics

1.4 R & D Department:

In order to achieve and maintain market leadership, we have

invested significantly in extensive research and development facilities to
stay abreast of latest trends in print and
fabric confection we get consultation from Europe
an
d e s i g n e r s a n d e v e n o u r representatives visit various top of
the line stores in foreign markets regularly. That
market data is then converted into our own registered
d e s i g n s t h r o u g h o u r R & D department and is offered to
our customers.

1.4.1 Quality Policy:

To develop and maintain a consistent quality standard for our customers

through reducing the tolerances to the minimums that are practically
possible. We fight and win the quality war and not the price war.

1.4.2 Quality Assurance/Lab:

The equipments are calibrated after a specific time period to maintain the
stringent testing conditions. Periodic maintenance of individual
machines is defined and is carried out accordingly on time and are
monitored through the ISO systemization. Produced article with the
machinist and the machine numbers is another feature to have the
quality assured. Customer standards and procedures are carefully
documented and administered through the merchandizing team. We have
been approved over the years in quality audits by our customers
like IKEA, M&S and others.

1.5 Shipment Efficiency:

Critical paths are made and monitored by the PPC department to ensure
timely handlings of the orders. Critical paths of each order / Job are
prepared and are sent to customer so that both the sides abide by these
to achieve timely shipments.

1.5.1 Sales Figure

Gohar Textile Mills last year’s annual turnover was US $ 24

Million. This has seen a consistent double figure growth in the last three
years respectively.

1.5.2 Strength

•No outside financing so we can under take big orders for longer periods
without having to think about any financial constraints.
•High Cumulative Customer retention rate since the start of operations
•Sustained growth rate of annual sales turnover.
•Consistent Quality ; Timely shipments

1.6 Major Customer:

The industry leaders who are our top four volume customers are,
•
IKEA Europe.
•
Metro Group Europe.
•
Marimac Canada.
•
PID Designs Canada
 Spinning Unit
Blow Room:

 Automatic Bale openers\Pluckers:

1. Moving bale type

The first generation bale opening machines were mostly stationary. Only the bales were
moved either backward or forward or in a circle. The examples of these types of
machines are Trutzschler multi-bale plucker, karousel-beater type opener by Rieter, etc.

2. Moving beater type

The second generation machines are of the travelling type i.e. they move past the bales of
the layout and extract material from top to bottom. Travelling machines have
the advantages that more bales can be processed as an overall unit, and thus better long-
term blend is achieved. It should be noted however that these machines extract material
only in batches, i.e. they can process only one, two or maximum three bales
simultaneously.
If long term blend is needed to be achieved, then mixing machines must be included
downstream from the bale opener. These machines are completely electrically controlled
and extract material evenly from all bales evenly, independently of varying bale density.

 Multi function separator:

It is necessary to combine cleaners in a line of a blow room for cleaning of Pakistani

cottons, known for their high trash content and contaminations. In almost all cleaning
machines the cotton under the grip of the feed roller is fed forward. The revolving beater
opens up the tufts by dragging cotton against the grid bars. The separated trash falls
through the grid bars while cotton is carried forward to the next machine. Thus, similar
type of treatment is repeated and the beater acts practically on the same side of the cotton
stock. The separation of trash is incomplete.

The chances of recombination of a part of the separate trash during subsequent transport
from one machine to the other cannot be ruled out. Likewise, there is a possibility of
damage to the cotton fibres during dragging action of the beater against the grid bars.

 Uniclean B11:

Uniclean B11 machine is used as a first stage cleaning point in the blow room. The
working principles of this machine, as follow

· Mechanical transport of the material after pneumatic delivery to the machine for
reducing loss of spinnable fibre.

Material is fed into the machine without clamping which minimises fibre damage and nep
formation.

UNI-Clean B11 is a popular machine in the rotor spinning sector because of its high dust
removal efficiency.

 Multi Mixer (JWF 1024):

In multi mixer there are three cleaning rolls are used. The density of clothing i.e. points
per sq. inch increases gradually from the first to the third roll. Thus, opening and cleaning
of cotton is based on the principle of stepwise cleaning. The cleaning rolls clean the
material on both sides as it passes over the carding segments, openings and mote knives.
The mote knives are equipped with direct suction units which collect the released dirt.
Like the clothing wire density the rotational speed also increases from the first to the
third roll which results in proportional increase of the peripheral speed and the centrifugal
forces acting on the material.

Also the conventional blow-room set up does not include any device for the separation of
foreign fibres. However, Metal Part Separator is invariably included. Unfortunately,
Pakistani cottons are not only known for their abnormally high trash content but also for
the presence of foreign contaminants such as pieces of broken combs, hairs, hairpins and
wool fibres from the sweaters of female cotton pickers, jute fibres and small pieces of
polypropylene.

Vision shield is available which contains camera which is also used to remove
contaminations.

Carding Machine

The carding machine is located in the spinning process between the blow room and the
drawing frame. It cleans and parallelizes the fibers. The resulting card web is then formed
into a tape and placed into a can. The working elements are taker-in, main cylinder, card
top and doffing cylinder.
The working elements are equipped with saw-tooth wires. In addition to the general
advantages our solutions for carding machines help you optimize your production results
through:

High availability through teleservice

Reduced spare parts and service costs through consistent range of drives.

JWF 1206 and TC15 are machines in card department.

 Objects of Carding Machine

 Opening to individual fibers.

 Elimination of impurities.

 Elimination of dust.

 Disentangling of naps.

 Elimination of short fibers.

 Fiber blending.

 Fiber orientation.

 Sliver formation.

Machine Parts of Carding Machine :

 Ducting pipe.

 Chute feed.

 Feed roller.

 Transport roller.

 Brush roller.

 Flat.

 Fixed carding bars.

 Taker in.

 Grid bar.

 Suction duct.

 Main cylinder.

 Doffer.

 Stripping device.
  Calendaring roller

 Coiler.

 Can.

Action in Carding Machine :

The following actions take place in a carding machine.

 Combing action.

 Carding action.

 Stripping action.

 Doffing action.

i. Combing action :

Combing action takes place feed roller & taken in. Here the pin directions of two surfaces
are the same. Combing is the straightening & paralleling of fibers & the removal of short
fibers & impurities by using a comb or combs which is assisted by roller & brushed.

ii. Carding action :

Carding action takes place between flat & cylinder.

In carding action,

Directions of wire in two surfaces are opposite.

The moving directions of roller are also opposite.

One roller is slower & other is faster.

So carding action is known as “Point against point” action.

iii. Stripping action :

Stripping action takes place between,

a) Taker in and Cylinder &

b) Doffer and stripper.

In stripping action,

Wire direction will be the same.

Roller moving direction will be the same.

One roller will be faster than another.

So stripping action is known as “Point back point” action.

iv. Doffing action :

This action takes place between cylinder & doffer. In this place fiber is transferred from
cylinder to differ. Low speed doffer is called fiber form of high speed cylinder & makes a
condensed web for formation of sliver.

 Working principle of Carding Machine :

Supplying raw material by ducting pipe .

Chute feed evenly compress a bat of 500-900 kfex.

Transport roller forwards the material to feed plate.

Feed arrangement consists of feed roller & feed plate.

Taker in opens the material to small flocks . When the material passes to main cylinder,
mote knives, grid bars & carding segments eliminate a great part of impurities.

Grid equipment.

Suction dust to carry away the waste.

Main cylinder & fixed carding segments designed to assist the carding operation.

The main carding operation occurs between flats & cylinder. Flats compromise 80 to 116
individual carding bars combined into a band moving on an endless path. 30 to 46 flats
are always in action.
Cleaning unit cleans stripes fiber, naps & foreign matters from flats.

Grid or cover plate.

The doffer combines the fiber into a web. Because of it’s substantially lower speed
relative to the cylinder.

Stripping device & doffing master draw the web from the doffers.

Calendar roller calendars the cotton & moves that toward.

At last by can & coiler the fabric is produced.

Draw Frame :

Drawing is the operation by which slivers are blended, doubled and leveled. In short
staple spinning the term is only applied to the process at a draw frame. In drawing
slivers are elongated when passing through a group of pair rollers, each pair is
moving faster than previous one.

This permits combing, drawing and elongating of several slivers to make them strong
and uniform. In most modern worsted drawing sets there are 3 passages of pin
drafting and roving process. The drawing process consists of three steps to complete
with the help of machine for each step.

1. Breaker drawing
2. Inter machine.

3. Finisher machine.

These three machines are used to mix the cotton and polyster with the stronge
grip.

D24 and FA-306 are machines in drawing department.

 Objects of drawing

 To straighten the crimped, curled and hooked fibers.

 To make the fiber parallel to their neighbors.

 To improve uniformity of fibers by drafting and doubling.

 To reduce weight per length unit of sliver.

 To remove dust from slivers.

 To blend raw material of same hank perfectly.

 Importance or Necessity of draw frame in yarn production

o To parallelization of fiber and blending the carded sliver, draw frame is

needed.

o In carded sliver, fibers are present in hook form i.e. trailing hooks and
leading hooks. To parallel these hooks raw frame is used.

o Majority of the fiber hooks in a carded sliver are trailing hooks while
leading hooks are comparatively less.

o Trailing hooks are also known as major hooks, while leading hooks are
known as minor hooks.

 What should do for better performance of draw frame:

o Always keep a watch on humidity and temperature as it affects the

working.

o Keep a watch on stop motions and ensure that no singles or doubles are
 fed to drafting. Ensure machine stopping before a broken sliver entering
drafting zone.

o Verify the trumpets size as per the hank, and ensure in good condition.

o Keep a watch on the surface of the top rollers and pressure on top rollers.

Simplex Machine(JWF 1435) for Spinning Process

Simplex Machine for spinning process is an industrial machinery used for

spinning process of Textile technology to transform the drawn sliver into
roving. The main function of simplex machine is the attenuation of drawn
sliver and insert small amount of twist to give required strength of roving

. Finally, the twisted roving is wound on to bobbin. Simplex machine is

used to the carded and combed yarn process but for the rotor spinning
system this process can be eliminated.

 Functions of this Spinning Machines

 Drafting:

The main task of the spinning machines to attenuation of the sliver to

required count of the roving.
 Twisting:

To hold it together, small amount of twist is inserted. The numbers of twist

is very low.

 Winding:

To easily transport the twisted roving, it winds onto the bobbin developed
by textile machine manufacturers

 Recent Developments of Simplex Machine

 Higher flyer speed: maximum 2000rpm. 1000~1500rpm is commonly

used.

 Improved drafting system: for example, SKF PK1500 and SKF

PK1600. Apron drafting, better control of fibre and draft range 4-20 .

 Improved flyer design

 Higher flyer speed: up to 1500 rpm

 Plastic flyer: Light in weight, enables higher flyer speed and less
power consumption.

 Top mounted flyer

 No spindle is used; flyer gets drives from the top.

 Suction unit in the drafting zone.

 Data collection system.

 Automatic Tension Control device(ATC)

 Improved building mechanism

 Higher content of roving

 Sliver stop motion

 Roving stop motion

 Separate flyer and bobbin drive

 Over Headed Traveling cleaner(OHTC) is used

 Speed profile

 Desired doff length can be achieved

 False twister

 Equal angle of roving

 Computerized monitor

 Inching motion

 Gearing in the oil bath for smooth running of the machine and high
production.

Ring(F1520) process:

The long central section of the machine, on which production is actually

carried out, consists primarily of longitudinal members in the form of
spindle rails and drafting rollers extending over the complete machine
length.

These longitudinal members are secured to intermediate sections arranged

at short intervals along the machine length. The sections also serve as
supports for the creel .

The ring spinning machine has been the most widely used form of
spinning and it will continue for some more time, because it has unique
advantage over new spinning technologies:

 It is universally applicable, most of the textile fibres can be spun to

required fineness.

 The yarn spun from this machine demonstrate excellent quality

features like uniform structure and good strength.

 It is easy to operate as compared to other spinning machines.

 The “know-how” for operation of the machine is well established.

 It is flexible as regard to quantities in terms of blend and lot sizes.

 For these reasons, new spinning processes (with the exception of rotor
 spinning) have difficulty in gaining wide spread acceptance.

 Operation of the Ring frame

 Task of the ring spinning

 Attenuate the roving until the required fineness is achieved

 To impart strength to fiber strand by twisting it

 To wind up the resulting yarn in a form suitable for storage,

transportation and further processing

 Principles of operation.

Main part of this machine is Yarn guider.

Main Faults in Ring:

Breakage of Yarn guider

Timing Belts

Ring main motor:

  It is two speed(slow-high) motor.It can rotate on two speeds and
two different rpm’s.

 If it runs slow then it will be 18.5KW motor which will consume

36.5 Amp current and will run at 970 rpm.

 If runs fast then it will be 30KW motor which will consume 55.8
Amp current and will run at 1470 rpm.

 It has 3 phase connections.

Other motors of Ring:

1. Compact fan motor is 5.5KW and consumes 4.5Amp current.

2. Suction fan motor is 2.2KW and consumes 4.4Amp current.

3. Blor motor which is 2.0KW and consumes 2.8Amp current.

Main breaker of Ring machine is of 25Amp.

Auto-Cone(Savio Polar) :

Auto cone is a modern yarn winding machine. It is use to prepare bigger

package from ring bobbin. It is just not only has a winding machine, there also
some extra specification of this machine.
  Features of auto cone winding:
• Auto splice without knot.

• Automatically remove yarn fault.

• Make bigger package

• Pneumatic disc type tensioner

• Electronic yarn clearer

• Reserve ring bobbin

 Parts of AUTOCONE Machine:

• Bobbin Magazine

• Chute guide
• Bobbin peg

• yarn feeler

• Pre clearer

• Re-tie arm

• Yarn tensioner

• Suction arm/mouth

• Splicer

• Electronic yarn clearer

• Drum

• Package cradle

• Unit start & stop switch

• Unit indicator

• Cone conveyor

• Over head cleaner

• Machine ON switch

• Machine OFF switch

• Blower ON switch

• Blower OFF switch

 Working principle / Function of auto cone machine

• Making Cone package from cops.

• Remove yarn fault (Thick & thin place, naps, foreign materials etc)

• Remove knot of yarn by auto splicing.

 • To wax the materials

• Minimize yarn imperfections

• To wax yarn

• Improve yarn quality

• Give suitable shape of cone package

• Make uniform yarn

• Achieve higher production and less power consumption

Main Faults in Auto-cone:

Bearing

Winding of Thread on Cone

Electrical Store:

 Normally open and normally close:

When a momentary switch is not actuated, it's in a “normal” state. Depending on how
the button is constructed, its normal state can be either an open circuit or a short circuit.
When a button is open until actuated, it's said to be normally open (abbreviated NO) and
if it is close until actuated, it’s said to be normally close (abbreviated NC).
  Simple Megnetic Starter:
A magnetic starter is an electromagnetically operated switch which provides a safe
method for starting an electric motor with a large load. Magnetic starters also provide
under-voltage and overload protection and an automatic cutoff in the event of a power
failure.

 Operation:
 Typically starters are operated by two push buttons, a "start" switch which
is normally-open (i.e. push-to-close) and a "stop" switch which is
normally-close (i.e. push-to-open).
 When the motor is not running, although line voltage is available, no
current is drawn by the starter or motor.
 When the "start" button is pressed, the motor is not powered directly,
rather the electromagnet in the contactor is energized. The magnetic
switch in the contactor then engages, simultaneously switching current to
the motor and providing self-sustaining current to maintain its own state.
Thus when the start button is released, the magnetic switch remains
engaged and the motor remains running.
 Pressing the "stop" button breaks the circuit to the contactor which
consequently de-energizes its electromagnet thus cutting current to the
motor.
 Connections:
Connections of a simple magnetic starter are shown in the figure where L1 is the main
phase supply which is connected to normally close(OFF) switch and then to normally
open switch(ON).13 and 14 are the normally close points of magnetic starter which are
used in this circuit to hold the starter.A1 and A2 are the points of the coil of magnetic
starter.At A1 is connected with phase and A2 is connected with neutral.

 Star-Delta Magnetic Starter:

In a (squirrel) cage induction motor, the starter is used only to decrease the input voltage
to the motor so as to decrease the starting current. It is T.P.D.T switch used to first start
the motor with the winding connected in star and then switch for delta connection in
running position

Working Principle: This is the reduced voltage starting method. ... During starting
the motor windings are connected in star configuration and this reduces the voltage
across each winding 3. This also reduces the torque by a factor of three.
 Operation:
 Starting in star, the main contactor connects the mains to winding endings U1, V1,
W1.The star contactor shorts winding endings U2, V2, W2.

 After successful run-up, the star contactor switches itself off and the delta
contactor connects terminals U1/V2, V1/W2,W1/U2.

 When changing from star to delta, we should pay attention to ensure it running in
the correct phase sequence.Incorrect phase sequence can lead to very high current
peaks during the cold switch-over pause, due to the easy torque reduction
following re-start.

 Connections:
In the above circuit diagram all the connections for a three phase star-delta starter are
shown.R is the red wire in three phase supply,Y is yellow and B is blue wire.

 Control Panels in GTM:

A control panel is a flat, often vertical, area where control or monitoring instruments are
displayed or it is an enclosed unit that is the part of a system that users can access, such
as the control panel of a security system (also called control unit).

Almost all the control panels in Gohar Textiles are of this type i.e almost in all control
panels there is:

 Main circuit breaker

 Star-Delta starter

 Timers
  Relay

 Fuses

 Push buttons

 Other small circuit breakers

 Timer:
A time switch (also called a timer switch, or simply timer) is a timer that operates
an electric switch controlled by the timing mechanism. The switch may be connected to
an electric circuit operating from mains power, including via a relay or contactor; or low
voltage, including battery-operated equipment in vehicles.

 Relay:
A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, but other operating principles are also used, such as solid-
state relays. Relays are used where it is necessary to control a circuit by a separate low-
power signal, or where several circuits must be controlled by one signal. The first relays
were used in long distance telegraph circuits as amplifiers: they repeated the signal
coming in from one circuit and re-transmitted it on another circuit.
  Fuse:
In electrical engineering, a fuse is an electrical safety device that operates to
provide overcurrent protection of an electrical circuit. Its essential component is a metal
wire or strip that melts when too much current flows through it, thereby interrupting the
current. It is a sacrificial device; once a fuse has operated it is an open circuit, and it must
be replaced or rewired, depending on type. The voltage rating of the fuse must be equal to
or, greater than, what would become the open-circuit voltage.

 Push Buttons:
Push buttons are generally of two types i.e Normally open and Normally close.when a
momentary switch is not actuated, it's in a “normal” state. Depending on how the button
is constructed, its normal state can be either an open circuit or a short circuit. When a
button is open until actuated, it's said to be normally open (abbreviated NO) and if it is
close until actuated, it’s said to be normally close (abbreviated NC).

Power House:
 Two main supply

 HFO and LFO

 HFO means Heavy fuel oil(furnace oil) and LFO means low fuel oil(Diesel)

 HFO and LFO injected through pipes at unloading area.

 Two pumps are available for HFO of different capacity and one pump is available for
LFO

 Different color pipes show main stream of HFO and LFO.

 First fuel is stored into storage tank with viscosity and tempreture of HFO and LFO.
Tempreture and Viscosity factor are maintained for both HFO and LFO. Steam is passed
through HFO pipe lines and storage tank.
 After storage tank fuel is move to buffer tank pump system is available to pump the fuel
supply.

 To start the engine all conditions must be true as shown on panel. Fuel supply first
entered in compressor the move to seperator where different particles are to be filtered its
pressure can be increased more.

 Fuel is then moved to booster and then move into different chamber where combustion
process is takes place and total power is generated which is 3.2 MW.

 Different control panel shown in Panel room from which power was going to
spinning,waving,hostel and other departments in GTM.