SPINNING DEPARTMENT

Interloop Limited has two spinning units situated in Faisalabad. These units are
equipped with the competent machines in all of their departments. In the spinning
units the fiber is converted into yarn, and as this the quality of yarn is very important
in the textile sector so spinning units have a lot of importance.

Generally the spinning mills mechanism is very similar. It starts from the mixing
department where the bales of cotton are mixed and at that section the most visible
impurities are taken out. This mixed cotton is then taken to the blow room by a
machine. After going through a process it is taken to the card room for the next
process.

After the card room the route is taken by keeping in view that whether carded yarn is
the end product or the combed yarn. The combed yarn is of better quality and its
process is a bit bigger than the other one.

For the carded portion the drawing breakers & drawing finishers are used to prepare
the fiber to a certain level so that the process on the simplex machine can be carried
out. On the other hand, in the combed portion, after the drawing breaker the cotton
goes through the lab former, & after that it goes through the combing machine,
where the comer noil and comber sliver are separated.

The comber sliver, after passing through the PC drawing & Drawing finisher goes to
the simplex machine. The product that comes from the simplex machine is then
taken to the Ring section where the yarn is to be made. Finally after passing through
the auto cone the yarn comes in the packing department. In Interloop the process of
Ultra Violet Checking is also practiced to ensure the quality of the yarn.

SPIN PLAN

Spin planning is the job to control production and quality of end product i.e. yarns at
various stages of spinning process.

Factors on which “SPIN PLAN” will depend

1. Type of raw material.

2. Production capacity of mills.

3. Capacity of each machine.

4. Counts to be spun and their quantities.

5. Number of machines available.

6. Number of qualified personals.

MIXING

Number of bales used daily = 280 bales

Method of mixing = Mechanical

BLOW ROOM

Number of lines = 2 lines of reiter and 1 of laskhmi

Blow room efficiency = 98%

Waste % = 3.5% - 4.5%

Cleaning efficiency = 40%

CARDING

Total no. Of cards = 19

Card (cotton) = 17

Grains/yd = 120

Mechanical draft = 98.317

Actual draft = 105.60

Cleaning efficiency = 50-55 %

Production efficiency = 85 %

Production = 420 - 450 lbs / hr / card

Waste % = 7.50 %

Fly waste = 7.5%

Licker in waste = 3.5%

DRAW FRAME BREAKER

Total number of frames = 5

Grains / yd = 88

Draft = 8.03

No. of Doubling = 5
No of delivery heads = 2

Delivery rate = 350 m / min

Efficiency = 75 %

Production = 322 lbs / hr / frame

DRAW FRAME FINISHER

Total number of frames = 10

Grains / yd = 75

Draft = 7.04

Doubling = 6

No. of delivery heads = 2

Delivery rate = 700 m / min

Production efficiency = 85 %

Production = 336.6 lbs / hr / frame

SIMPLEX

Total number of frames = 11

No. of spindle per frame = 144

For carded quality = 4

Motor speed = 1090 rpm

Flyer speed = 1250 rpm

Total draft = 7.2

Delivery rate = 23.64 m/min

Twist per inch = 1.12

Production rate = 322 lbs / hr / frame

Efficiency = 82%
RING FRAME

Count = 20/1, 30/1

Total no. Of frames = 20

Spindle per frame = 1296

Draft = 25.09

T.P.I = 17.4

Delivery rate = 21.52 m / min

Spindle speed = 14750.8 rpm

O.P.S. calculated = 10.765

Production efficiency = 95 %

WINDING

Total no. Of machines = 11

Winding rate = 1100 m / min

Cone weight = 1883 g

Tolerance limit = + 20 gm

Efficiency = 87.1 %

Production = 181.38 lbs / hr / frame

PACKING

No. Of cones / bag = 24

Net weight of one cone = 4.17 lbs

Net weight of bag = 100 lbs

 STUDY OF THE RAW MATERIALS
Cotton
Cotton belongs to a hibiscus and okra family,
produces a natural vegetable fiber that are used in
manufacturing of fabrics. Cotton produces sweet
nectar that attracts a variety of destructive insect
pests, including the boll weevil, bollworm, armyworm
and the red spider. In addition to insect pests, there is
also a very destructive fungus, called the wilt,
which attacks the root system of the cotton
plant.The quality of the yarn entirely depends upon the
raw material ( ginned cotton/fiber) used to make it.

Properties
Cotton, as a natural cellulose fiber, has a lot of characteristics, such as:
• Comfortable Soft hand
• Good absorbency (Avg 7-9% moisture)
• Color retention
• Prints well
• Machine-wash able
• Good strength
Cotton grows into balls and flowers and later converts to cotton lint and make yarn.
Ginning factories are involved in removing bornula and seeds from cotton lint thereby
compressing them and pack them in the form of bales.These bales are brought to
spinning mill factories through trolleys. At one time about 200 bales are transported
in trolleys. These are equivalent to 2 lots and 1 lot equals to 200 bales. The cotton
quality measures are checked at each level from inspection of raw materials till the
end product (yarn).
 1 bale : 155-157kg (avg)

Inspection Criteria:
 At first moisture meter is used to check the moisture level in 20 of the total
cotton bales from trolley.
 Second HVi (high Volume instrument) testing is done of 10 bales from
trolley.
  Thirdly Trash testing is done of 2 bales out of 200 bales in a trolley, taking
100 grams of a sample.

Quality Specs of Yarn:

HVi testing machine provides accurate quality parameters of raw cotton. It provides
reliable information about the physical characteristics of cotton fibers that are
measured at the same time. It measures the cotton quality in terms of:
 Fiber length and uniformity:
The HVI system gives an indication of the fibre length distribution in the bale by use
of a length uniformity index. Fiber length is one of the most important
characteristics of cotton. It defines the spinability of the fiber. A reading of
80% is considered average length uniformity. Higher numbers mean better length
uniformity and lower numbers poor length uniformity.
Staple length (inch) Points Grade
1.05 ~ 1.07 10 C
1.08 ~ 1.10 12 B
1.11 ~ 1.13 15 B+
1.14 ~ 1.17 18 A
More than 1.17 20 A+

Uniformity Points Grade

Less than 77 3 C
77 ~ 80 5 B
81~ 84 7 B+
85 ~ 87 8 A
87.1 and High 10 A+

 Micronaire ( a measure of fineness)

Fibre fineness is normally expressed as a micronaire value (microgram per inch). It
is measured by relating airflow resistance to the specific surface of fibres and gives
iinformation whether cotton fiber is very fine, fine, medium , coarse or very coarse.
 Micronaire Points Grade
Less than 3.0 5 C
3.0 ~ 3.6 7 B
3.7 ~ 4.7 10 A
4.8 ~ 5.4 7 B
5.5 ~ Hig 5 C

 Strength and Elongation:

Strength is measured physically by clamping a fibre bundle between 2 pairs of
clamps at known distance. The second pair of clamps pulls away from the first
pair at a constant speed until the fibre bundle breaks. The distance it travels,
extending the fibre bundle before breakage, is reported as elongation and the
force used to break the fibers tells the strength. Fiber strength is measured in
grams per tex (g/t).
Strength (Gram/Tex) Points Grade
Less than 22 4 C
22 ~ 24 7 B
25 ~ 27 12 B+
28 ~ 30 17 A
31 and High 20 A+

Elongation Points Grade

Less than 5 4 C
5.0 ~ 5.8 7 B
5.9 ~ 6.7 8 B+
6.8 ~ 7.6 9 A
7.7 and High 10 A+

 Maturity:
The maturity of cotton is defined in terms of the development of the cell wall,
whether it is fully developed, half developed or immature fiber. A fully developed
fiber ensures good length and strength of fibers.
Maturity Ratio Points Grade
Less than 0.75 1 C
0.76 ~ 0.80 4 B
0.81 ~ 0.85 6 B+
0.86 ~ 0.90 8 A
0.91 and High 10 A+

 Color grade:
It measures the Rd (Whiteness), +b (Yellowness), Colour Grade. It is measured
optically by using different colour filters and converted to regional customized
colour chart. Natural colour of cotton highly influences the chemical
processing and dyability of the finished product.
Rd Points Grade
More than 81.5 5 A+
78.25 ~ 81.5 4 A
76.0 ~ 78.24 3 B+
73.50 ~ 75.99 2 B
Less than 73.5 1 C

+b Points Grade
Less than 7.6 5 A+
7.6 ~ 8.5 4 A
8.6 ~ 9.3 3 B+
9.4 ~ 10.0 2 B
10.1 and High 1 C

 Short fiber content:

The measure of short-fibre content (SFC) in HVI systems is based on the fibre
length distribution throughout the test specimen. It is not the staple length that is
so important but the short fibre content which is important. The lesser the short
fibers are, better the quality of cotton yarn.
SFI Points Grade
Les than 81.5 10 A+
6~9 9 A
10 ~ 13 7 B+
14 ~ 17 5 B
18 and High 3 C

 SCI:
SCI(SpinningConsistencyIndex)tells if the cotton fibers can or cannot be spun pro
perly or in easy words to check the spinability of fibers.
SCI Points Grade
More than 130 10 A+
121 ~ 130 9 A
111 ~ 120 7 B+
101 ~ 110 5 B
Less than 101 2 C

 Moisture:
It shows the amount of water in the cotton sample at the time of testing. High
moisture content means cotton is damp and low trash amount will be dropped in
blow room. Hence approximately 7-8% moisture content is best.
Moisture% Points Grade
Less than 4.5 10 A+
4.5 ~ 6.5 8 A
6.6 ~ 8.0 6 B+
8.1 ~ 10.0 3 B
10.1 and High 1 C

 Trash count:
This includes the trash count, % surface Area Covered by Trash, Trash grade. It
is measured optically by utilizing a digital camera, and converted into customized
regional trash standards. The values of trash content should be between the
range 0-1.6%.

Trash count Points Grade

Less than 7 5 A+
8 ~ 14 4 A
15 ~ 24 3 B+
25 ~ 39 2 B
More than 39 1 C

Trash Area% Points Grade

Less than 0.08 10 A+
0.9 ~ 0.12 9 A
0.13 ~ 0.18 7 B+
0.19 ~ 0.34 4 B
0.35 ~ and High 2 C

Waste calculations in Raw material:

Waste = lint + Trash

Trash = Foreign matter only

Waste % = (input-output) x 100

Input
TECHNOLOGY USAGE:
The Plant & Machinery required for the Spinning Mill process for manufacturing
yarn of different counts are auto pluckers, blow room machinery, metal detection
system, carding machines, card accessories, draw frame (Finisher &Breaker),
speed frame, combers, ring frame, electrical infrastructure, yarn testing
instruments, waste collection system and automatic cone winding machines, etc.
METHOD OF MIXING IN INTERLOOP SPINNING MILLS UNIT NO. 2
No. of bales blended daily = 250-300 bales
No. of lots present = 70 lots
No. of bales taken / lot = 200 bales / lot
Net weight of bale = 155-157 kg
In Interloop Spinning Mills Unit No. 2 the mixing is done mechanically by means
of 6 Auto Pluckers, 25 bales are placed in each Plucker. 150 bales are fed in all
Auto Pluckers and time taken to open and mix all the bales is 8 hours. Condenser
takes the material from Auto Plucker. Six condensers are used for Auto Plucker.
From condenser material is passed to feed lattice of Bale opener. The entire
condensers are fitted with the yellow color pipes that are used to carry waste to
the filter bags.
AUTO PLUCKER

The function of the auto plucker machine is to pluck the cotton, medium length
fibers and synthetic fibers.
TECHNICAL DATA:
Name = Jinsheng Saurer

M/C model = AQ45B

No. of Machines = 6

Out put = 1743.75 kg/hr

 Beater rpm = 600-750

MIXING
Mixing is done to thoroughly mix the fibers with each other as they have
different physical parameters. The natural fibers always differ from each other
in the following properties i.e. length, maturity, strength cleanliness, moisture
etc.
 Uniform mixing is very essential to achieve uniform yarn results
 Higher production rate can be achieved.
Sometimes different varieties of cotton are mixed for two purposes.
 To achieve the required results of yarn
 To minimize the cost

AIR CONDENSER
The condenser is one of the most important machine in blow room line.
Function of the condenser is to convey the opened fibre material and is used
for transporting the fibers from one machine to the next. Mixing is done for
whole day in general shift and then machines are cleaned. Any major
maintenance is done when required.

BLOW ROOM

This is the section where the compressed cotton is opened, cleaned, blended
and mixed to transform it into uniform lap of a specific length. The blow room’s
cleaning efficiency is between 4 to 5 percent. It the first part of spinning the cotton
yarn.
Operations in the Blow room
1. Opening
Here the tuft size is reduced to as small as possible.
2. Cleaning
Here the physical impurities are removed from the tufts. These may include
metals, leafs, stones, fibers, broken seeds and plastic contaminations.
3. Dust Removal
Dust particles removal is difficult because they are enclosed within the fibers
of cotton. Hence high speed air suction is done to remove them. This process
continues at all the stages of spinning to completely eliminate them.
4. Mixing and Homogenous blending
It involves simultaneous extraction and thorough mixing of cotton fibers taken
from different classes and grades of cotton.
5. Even supply of material to the carding machine
The blow room ensures that all the cotton fibers are evenly distributed to the
carding machine.
Blow room installation consists of a sequence of different machines to carry out
the above said operations. In addition, as cotton's tufts are becoming smaller and
smaller, different machine configurations are necessary for the appropriate
processing intensities. Almost all the machines associated with blow room work
with air currents hence this unit of machines is called Blow Room.
PRINCIPLE OF WORKING
Following are the principles on which different machines of blow room work.
 Opposing spikes action
 Actions of air currents
 Action of beaters
 Regulating action
 Action of gravitational forces and centrifugal forces.
The whole machine is subject to suction and the dust is collected in special filters;
the material, on the other hand, undergoing simultaneously, the rotary action of
the cylinder and suction along the operating width and later on transferring
uniformly to carded machines.
BLOW ROOM LINE
Sequence of machines with make and model:
 Line no 1 Line no 2 Line no 5
(Lakshmi)
B 12 B 12 DDS
B 76 B 76 Vario Clean
B 79 B 79 Unimix
Jossi Vision Shield Jossi Vision Shield Flexiclean
Loptex
Line no 3 Line no 4
B 12 B 12
B 76 B 76
B 79 B 79
SP-FPO SP-FPO

METAL DETECTOR:
Metal Detector detects any metal part in blow room line. There are two metal
detector in two blow room lines of unit #2.

Waste calculations in Blow room:

Waste = lint + Trash

Trash = Foreign matter only

Waste % = (input-output) x 100

Input

CLEANING EFFICIENCY:

Cleaning efficiency of the machine is the ratio of the trash removed by the machine
to that of total trash fed to the machine, expressed as percentage.

Cleaning efficiency % = Trash%in mixing-Trash % in lap х100

Trash % in mixing

CARDING:
Carding is a mechanical process that breaks up locks and unorganized clumps of
fiber and then aligns the individual fibers so that they are more or less parallel with
each other. Carding can also be used to create blends of different fibers or different
colors. Carding plays a crucial role in all spinning cycles particularly in the woolen
spinning cycle, in which it incorporates different functions, all essential in order to
obtain the level of quality required for the product.
"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.

Card Machine DK 903

Make Trutzschler
Model DK 903
No. of card 19
Temp. 34 oC
RH% 51 %

OBJECTIVES OF CARDING
In short the objects of carding are:
 To open the lap into individual fibres
 Elimination of impurities that were not removed in the previous cleaning areas
 Fiber blending
 Reduction of neps
 Elimination of dust
 Elimination of short fibres
 Fiber orientation ( parralising and stretching of the fiber)
 Transforming the lap into uniform Sliver formation

PRINCIPLES OF CARDING
Point to point ( Opening and transferring the material to liker in )
The point of wire end of one surface faces the point of wire end of other surface.
These results in opening of fibers into single fiber state which causes cleaning of
material.
Point to back ( Doffing )
The point of wire point of one surface faces the back of wire point of other surface.
This results in transfer of material from latter to the former surface.
Carding is thus the process of arranging the fiber in parallel fusion. This is necessary
for all staple fiber. Otherwise it would be impossible to produce fine yarn. Before the
raw stock can be made into yarn, the remaining impurities must be removed. The
fiber must be in different angle & they must be straight turned. The card is the hard
of the spinning mill & well carded is half spun.
DIFFERENT ACTION IN CARDING

1. Carding action:
When two close surfaces (flats and cylinder) have opposite wire direction and their
speed direction or relative motion is also opposite. Then the action between two
surfaces is called carding action.
Function:
 Maximum individualization of fibers is achieved in this region.
 Neps, short fibers, dirt and dust are removed by this action.
2. Stripping action:
When two close surfaces (licker in and cylinder) have same wire direction and their
speed direction or relative motion is opposite then the action between two surfaces is
called stripping action.
Function:
 Individualization of fiber is by this action.

3. Doffing action:
When two close surfaces (cylinder and doffer) have opposite wire direction and their
speed direction or relative motion is also opposite then the action between two is
called doffing action
Function:
 Web formation is accrued by this action.
What we get after doffing is a thin web of cleaned, less neps and short fiber in a
uniform web cotton fiber that is condensed (converged to single strand) that we
name as sliver.

Card Production calculations:

1 lb = 7000 Grains
1 kg = 2.2046 lbs
1 gram = 15.432 grains
Grains/yard: 75- 120
Speed = meter/ min
Pak cotton: 172m/min – 235m/min
Production on card ( Kg/hr) =

POINTS IN CARD OF WASTE EXTRACTION

There are waste collection points where waste is separated from fibers on the card.
A suction system collects all the falling waste at one end of card. From there they are
conveyed to the filter room, in which fibers are separated from dust and other
material on a special machine called fiber separator.
The card fly waste is also sucked by vacuum pipes and carried to filter room by a
separate duct.

DRAW FRAME
Drawing is an operation by
which slivers are blended,
doubled or leveled and by
drafting reduced to proper sized
sliver suitable of being fed to the
simplex. Draw frame contributes
less than 5% to the production
cost of yam; however its
influence on quality of yam is
significant.
Draw frame process
considerably influences the final
product, as draw is last point of
compensation for the elimination
of errors produced by subsequent m/c. the inadequacies in the sliver leaving the
draw frame pass in to the yarn and are reinforced by the drafting after the draw
frame that is why yam can never be better in evenness than the sliver.
NEED OF DRAW FRAME
From a purely commercial viewpoint the draw frame is of little significance. It usually
contributes less than 5% to production costs of the yarn. However, its influence on
quality, especially evenness, is advantage of this. Further if the draw frame is not
perfectly adjusted there will also be effects on yarn strength and elongation.
There are two main reasons for the considerable influence of the draw frame on
evenness. First, within the sequence of machines in the cotton-spinning mill, the
draw frame is definite compensation point for eliminating errors. The yarn can never
be of good quality without draw frame passage.
TASK OF DRAW FRAME
 Through doubling the slivers are made even
 Doubling results in homogenization (blending)
 Through draft fibers get parallelized
 Through the suction, intensive dust removal is achieved
 Auto leveler maintains absolute sliver fineness
 Blending

TECHNICAL POINTS:
 Quality of the draw frame sliver determines the yarn quality.
 Drawing is the final process of quality improvement in the spinning mill.
 Drafting is the process of elongating a strand of fibers, with the intention of
orienting the fibers in the direction of the strand and reducing its linear
density.
 Drawing apart of the fibers is affected by fibers being carried along with the
roller surfaces. For this to occur, the fibers must move with the peripheral
speed of the rollers. This transfer of the roller speed to the fibers represents
one of the problems of drafting operation.
 Roller drafting adds irregularities in the strand.
 Drafting also actually reduced the strand irregularities by breaking down the
fiber groups. Drafting is accompanied by doubling on the draw
frame, this off sets the added irregularity.
 In spinning mill unit 2, there are total ten drawing frames. Five drawing frames
are used as breaker, five as finisher.
 CAN CHANGE MOTION
 Photo-cells are mounted at the machine which senses the absence of any
sliver. When one can is filled, it is replaced by empty can and machine starts
automatically.
 ATMOSPHERIC CONDITIONS
 Temperature = 96oF
 Relative humidity = 58%

Drawing Calculations:
Card production: 120 g/yard × 5 cans
 = 600 g/yard
Draft production: Grains feed
Grains Delivered

= 600 = 6.82
88
UNI LAP FORMER:
In this machine a single lap is formed as a resultant product after giving the number
of slivers as its input. so as to make the fibers parallel and are fed to a similar
machine to get a better parallelization which goes to the next department.

Objectives of unilap former machine:

 To reduce fiber damage

 To reduce the wastage chance of good fibers
 To reduce short fibers
 To reduce thick and thin places in the sliver
 Efficiency %= 74%
 Grains per yard=1100 to1150

COMBING:
The process of straightening and parallelizing of fibers and the removal of short
fibers and impurities by using a comb on combs assisted by brushes and rollers is
called combing. The combing process is carriedout in order to improve the quality of
the sliver coming out of the card.The process eliminates short fibers, it achieves
better parallelization of fibers, it straightens curls, and it removes neps and residue
impurities.

OBJECTIVES
 To remove neps in the carded sliver.
 To make the fiber more parallel and straighter.
 To produce a uniform sliver of required per unit length.
 To remove the fiber shorter than a predetermined length.
 To remove remaining impurities in the comber lap.

Comber Noil
The wastage which is removed from the comber m/c during processing is known as
comber’s noil. It is expressed as percentage. It is mainly of short fibers and neps.
Noil is used for lower count as raw material.
SIMPLEX
Objective of roving frame
 To attenuate of the draw frame sliver.
 To inset the twist.
 To wind the roving on bobbin.
Drafting
Drafting is basically to reduce mass per unit length. For this purpose two type
of drafting system often used. 4 over 4 and 3 over 3 drafting system.

Twisting
It is necessary to produce twist in the roving to impart strength. Twist level is
very low for roving. It is depending upon the flyer speed and front roller
delivery.
Winding
Reduce the reversal point of the bobbin rail to reduce the length of the roving
layer on the bobbin to build a tapered flanged package. Reverse the direction
of movement of bobbin rail at the upper and lower end.

RING FRAME
After the roving frame yarn-manufacturing process is started. The
process is accomplished by using ring frame which performs following functions.
FUNCTIONS OF RING FRAME
 To draft the roving until the required fineness is achieved.
 To impart strength to the fiber, by inserting twist.
 To wind up the twisted strand (yarn) in a form suitable for storage,
transportation and further processing.

ADVANTAGES OF RING FRAME

 It is universally applicable, i.e. any material can be spun to any required
count.
 It is simple and easy to master.
 The know-how is well established and accessible for everyone.
WINDING
Introduction

“Winding is the process which result in producing a good package of long length and
fault free yarn.” Most of the spinning mills use automatic winding machines. Quality
of yarn and package and winding machine production are improving day by day. The
requirement of yarn from the ring department comes in the small packages (Ring
Bobbins). This yarn is full of defect i.e., thick and thin places etc. these defects are
removed on the winding machines. The objects of winding are:

 To prepare a bigger package having sufficient length of yarn on it.

 To remove spinning faults i.e. thick and thin places.
 To improve the quality of the yarn
AUTO CONER

It is the final stage of spinning. After manufacturing of yarn, it is ready to make a

shape into final cone form so that it can be shipped to customer for use. The
development of automatic winding has reduced the labour requirement of winding
and along with the development of electronic yarn clearer has been a major factor
leading to the most universal adoption of single yarn winding and cleaning.

QUANTUM 3

It is an optical sensor and also check the yarn by capacitive action. It monitors the
regularity of the yarn (neps, thick & thin places, colored cotton). If improper yarn then
it cuts the yarn.

Objectives of auto cone:

➢ Winding

➢ Inspect the yarn

➢ Clearing the defects.

➢ Build a suitable package for subsequent process

➢ Lubricate the yarn.

Elements of process
  Yarn withdrawal
 Yarn tensioner
 Yarn clearing
 Stop motion
 Yarn splicing

INFORMATION ABOUT DEPARTMENT

No. of machines 6

Make MURATA

Model Mach coner 7-11

Mfg. Year (4) 1984, (1) 1986, (1) 1992

No. of spindle per machine 84

Cradle Cantilever type

Winding speed 1000 m/min

Winding range 800 - 1200 m/min

Winding angle 50- 57˝

PRODUCTION

Delivery speed of winding drum = 1000 m/min

Efficiency = 86 %
No. of spindles for 20 CD/M = 84

Production = 1000 × 1.0936 × 60 × 1 × 86

Total production of 20CD
840×20 100
= 3.359 lbs/hr/drum
= 3.359 × 84
= 282.149 lbs/shift
= 2257.19 lbs/day
No. Of bags/day = 67.716 bags

Packing

Packing is the last stage in the yarn manufacturing process. Packing in charge under
the super vision of GM mills is held responsible for all the issues relating to the
packing of the yarn. There are two types of packing

Export Packing

“Cartons are used in the export packing”

Local Packing

“Poly propylene bags are used for local packing”

Each bag weight is 100 lbs or 45.36 kgs(excluding tare) In packing department
following kinds of cones are packed:

FIBER TESTING LABORATORY

Quality lab has following instrument for testing quality parameters of cotton fibre,
yarn and fabric. Polyester fibres are also tested here.

MOISTURE METER
This moisture meter is used for measuring
moisture content of cotton. Samples from
lot are tested by this meter and reading of
moisture content is noted from three
different places and then takes its
average for accurate reading of moisture
content.
TRASH ANALYZER
It is also called Shirley analyzer. It is used to
determine amount of trash in raw cotton.
Sample of cotton is weighted before and
after trash drop out and so amount of trash is
calculated by difference of weight.

UV METER:
It is also called as ultra violet meter. It is used for testing color fastness of polyester.
A sample is tested from four sides by UV meter and then average of four readings is
calculated for accurate results. As reading is high polyester is of good quality and
vice versa.

HVI SPECTRUM
HVI Spectrum is used to determined
micronaire value, maturity, length,
uniformity, amount of fibres, short fibre
index, strength, elongation, moisture,
Rd value, +b value, color grade, trash
count, trash area and trash grade.
Moisture and maturity are two additional properties of HVI spectrum.

Uster AFIS-PRO 2

AFIS (Advanced Fiber Information System) is used for testing different parameters of
cotton and sliver. This instrument is used for nep testing, length and maturity testing
and trash classification testing.

Necessary Parameters

 A sliver of weight 0.4-0.6gm with length 30 cm is used for accurate

determination of neps, trash and fibre count.
 USTER AFIS PRO measures 3000 individual fibers to give a report.

Test Modules:
  NC( Nep classification) Module
 L & M( Length and Maturity) Module
 T (Trash) Module

Measuring content:

1. NC (Nep classification) Module:

 Nep count per gram

 Nep size (micron)
 Seed coat nep count per gram
 Seed coat nep size (micron)
 Mean length

2. L & M (Length and Maturity) Module:

 Mean length by weight

 Length variation by weight
 Upper quartile length by weight
 Short fiber content by weight
 Mean length by Number
 Short fiber content by number
 Fineness(militex)
 Maturity ratio
 Immature fiber content

3. T (Trash) module:

 Dust count per gram

 Dust size (micron)
 Trash size (micron)
 Visible foreign matter (%)

SLIVER TO YARN TESTING

1) Wrapping drum
Wrapping drum is used to test the count of sliver and roving at different stages so
that the fineness of yarn can be maintained.
Testing procedure
 Sample size = 4 sample from 1 machine
 1 Sample length of = 6 yards (sliver)
 1 Sample length of = 6 yards (roving)
 1 revolution = 1 yard
 Weight of sample is measured
 Then the count is measured through the formula
Formula:
 Count = weight/length
Standard weights
▪ For card sliver ⇒ 120 ± 2 grains/yard
▪ For breaker sliver ⇒ 88 ± 2 grains/yard
▪ For finisher sliver ⇒ 75 ± 0.3 grains/yard
▪ For simplex roving ⇒ 0.7 ± 0.1 grains/yard
2)Wrap reel:
This machine is used to make yarn lea to test the count of yarn.
Necessary Parameters
 8 sample from 1 ring machine = 120 yard / sample
 4 cones from 1 machine (2 samples from 1 cone) = 120 yard /sample
 Reel circumference = 1.5 yards
 Revolution for making 120 yards yarn lea = 80
Testing procedure:
 120 yards sample is made by wrap reel
 Weight of sample is measured in gram/meter
 Then by using formula count is determined
Formula:
 Count (Ne) = 68.4/ Lea weight in grams
3)Uster auto sorter:
 120 yards sample is made by wrap reel
 Weight of sample is measured
 Then the count is measured through the formula
Formula
Count = no. of hanks/lbs
4) Strength tester (Auto DYN)
It is used to determine the strength of yarn lea.
Necessary Parameters
 Sample type= Yarn Lea
 Sample length = 120 yard
 Clamp to clamp distance = 0.75 yards
 Strength unit = CLSP
Testing procedure
 120 yards sample is taken by wrap reel
 Count is determined
 Then sample is set in machine
 Machine is run
 After the sample being broken the reading (breaking tension in lb) is taken
 Then by adopting formula CLSP is calculated
Formula:
CLSP = count (Ne) ｘ breaking tension (lb)
5) Automatic Twist Tester
It is used for checking TPI (twist per inch) in yarn.
Testing Procedure:
 20 inch sample is set in the machine
 Respective weight is added according to yarn
 Machine is run
 After the yarn completely being untwisted the machine is automatically
stopped gives the reading in the display that indicates TPI
6) Attrifil Friction Tester
▪ Only for hosiery yarn
▪ Sample = 1 cone from 1 bag
▪ Wax sensor
For Hosiery Yarn:
 Standard ⇒ COF (𝜇) = 0.15
 Acceptable ⇒ COF (𝜇) ≤ 0.18
 Rejected ⇒ COF (𝜇) > 0.20

7) Uster Eveness Tester UT-5 USTER®TESTER

The instrument is used to check unevenness (U%) , co-efficient of variation of mass
(CVm%), yarn hairiness, imperfection index (IPI) and thick, thin place, neps etc per
unit length of  yarn, roving sliver. The capacitive measuring system permits fast and
reproducible measurements. Based on spectrograms and diagrams, it is easy to
eliminate the sources of defects.

Fig. 6
Mass variations /
Coefficient of variation CV

s
Definition: CV =
x
x
X
x
s = standard deviation
x = mean value
L = test length

Formula
 IPI = thin + thick + Neps
 IPI= -50%+(+50%) +(+200%)

Characteristics Unit Description

Um [%] Mean linear irregularity (now obsolete, CVm is
more common today, Fig. 5)
CVm [%] Coefficient of variation of the yarn mass (Fig. 6)

CVm (L) [%] Coefficient of variation of the yarn mass at cut

lengths of 1, 3, 10, 50, 100 m and in the Inert and
Half Inert modes
Mass deviation m(max)= maximum mass m(min)=
minimum mass
cut lengths for the calculation are 1, 3, 10 m or Half
Inert
 Imperfections Number of thin places, thick places and neps at
selected sensitivity settings (staple fiber yarns only)
thin places: -30% , -40% , -50% , -60% thick
places: +35% , +50% , +70%, +100% neps:
+140% , +200% , +280%, +400%

Rel. count [%] Count deviation relating to the length of yarn

tested, the mean corresponds to 100%
Abs. count [e.g. tex, Linear density of the yarn unit length (yarn count)
Ne]

Testing Speed: Testing Time:

m
For Sliver ⇒ 25 ⁄min For
For Sliver ⇒ 5 min

m For Roving ⇒ 2.5 min

Roving ⇒ 50 ⁄min

m
For Yarn ⇒ 1 min
For Yarn ⇒ 400 ⁄min

8) Conventional strength and elongation (USTER®TENSORAPID)

This machine is used to test the strength and extension of single yarn.
 Testing speed = 5000 mm/ min
 Sample size
 1 machine = 5 cones
 1 cone = 10 meters
 Total tests = 20
 1 test = 0.5 meter
 ↑ RKM ↑ strength

Characteristics Unit Description

 Pretension Force applied to the yarn at the beginning of the
strength test to guarantee reproducible initial
conditions. Standard pretension is 0.5 cN/tex.
Time to Br. [sec] Time elapsed between the start of the
measurement and the breakage of the specimen.
(Fig. 8)
B-Force [cN] Breaking force = maximum tensile force measured
(Fig. 8)
Elongation [%] Breaking elongation = elongation at maximum
force. (Fig. 8)
Tenacity [cN/tex] Breaking force divided by the linear density of the
specimen

B-Work [cNcm] Work to break= work at maximum force (area

below the force/elongation curve drawn to the
point of maximum force. (Fig. 8)
Work [cNm] Partial work (area below/elongation curve drawn
between two specified elongation values)

Ref. val. Reference values (maximum of 8 values)

F …% [cN] Force at a specified elongation

E …N [%] Elongation at a specified force

E (F-) [%] Elongation at a specified force drop

F (1.br.) [cN] Breaking force of the first filament at a defined

force drop

M1 …% [N/tex] Modulus (maximum of 8 values), either secant

M2 …% [N/tex] Modulus or Young’s modulus = slope of the

force/elongation curve measured at a specified
elongation

YARN CONDITIONING AND PACKING

Finally, cones are sent to packing section where these cones are thoroughly
examined under "ultraviolet lights". Contamination is checked after that cones are
kept in the controlled temperature of packing hall for 24 hours for conditioning. Then
these cones are packed in cartoons, after wrapping in polythene bags. One bag
contains 24 cones and has a net weight of 100 lbs. 4.17 lb is weight of one cone in
the bag.
 Grams/meter of sliver fed to the draw frame
 Fiber length
 Fiber fineness
  Delivery speed
 Type of drafting

Important Parameters of Yarn:

 Yarn count

 Strength LCSP

 U percentage

 Thin Places

 Thick Places

 Neps

 IPI (Imperfection)

Yarn Elongation (Flexibility)

 Single Yarn Strength

 TPI

 Twist Multiplier

Automation and Electronics role in Yarn spinning

In most of the areas of the world cotton spinning is automatic which was a fully
manual operation in earlier times. To a great degree, ginning is also automated.This
process was accomplished through continuous innovation and modified plant
automation. A cotton fiber test that used to take hours to perform 20 years ago can
now be done in a matter of seconds using the HVI system. This process has been
achieved through constant innovation and updated automation in the plant
capacities. They are pointed out below:

1. Yarn forming process has seen advancements and automation by introduction of

newer methods of spinning apart from ring spinning like open-end spinning, airjet
spinning.

2. Cotton mixing in blow room has been automated so that cotton from several
bales can be drawn and mixed together, forming a more homogeneous mixing of
cotton, thus reducing batch to batch variation in cotton spun yarn lots.
3. Carding machines using feed systems, auto levelers for improvement in quality
or productivity and reduced handling have helped in increasing evenness in the yarn.

4. The ring spindle speeds have gone upto 20,000 and high-speed rotors upto
1,00,000 rpm are available. Today, spinning machines can produce yarns upto 20
times faster than what they used to produce 20years ago.  

5. Autoconers with splicing and yarn fault detection have been devised to obtain
yarns with lower unevenness and better quality.

Advantages of Automation in Ring Spinning:

 A complete reduction of manual bobbin handling, which results in a

substantive direct improvement of product quality.
 A secure and efficient material/product flow through the compact system
configuration.
 A big reduction of labour costs which results into quick return of investment
( less than 3 years payback time ).

 A clean, proper and efficient production environment.

 Very reliable system.

 No special skill needed for setting

 This system is still little expensive to implement

 Setting done at the press of a button.

 No special skill needed for setting

 All rollers driven by individual motors, controlled by individual drives.

 Possible to alter draft and twist from the key pad. Fine tuning of twist & draft
adjustments possible.

 Possible to manufacture fashion yarn like multi twist , multi count , slubyarn.

 Reduced manpower requirement.

 Increase machine productivity.

 Reduce need for supervision.

 Increase life of components and accessories like spindle & bobbins. 

 Very safe and reliable system.