Cleaner Engineering and Technology 9 (2022) 100536

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Cleaner Engineering and Technology

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A cost-effective approach after implementation of timing belt drive in the

cotton ring-spinning frame
Md Din Islam a, d, Md Nurunnabi b, Fairooz Raisa Mridula b, Rony Mia b, *,
Shah Alimuzzaman Belal c
a
Badsha Textiles Mills Ltd, Dhaka, 1212, Bangladesh
b
Department of Textile Engineering, National Institute of Textile Engineering and Research, University of Dhaka, Dhaka, 1000, Bangladesh
c
Department of Fabric Engineering, Bangladesh University of Textiles, 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon Industrial Area, Dhaka, 1208, Bangladesh
d
Department of Textile Engineering, Mawlana Bhashani Science and Technology University, Santosh, Tangail, 1902, Bangladesh

A R T I C L E I N F O A B S T R A C T

Keywords: The preliminary design of this work aimed at determining whether a flat belt or timing belt drive system was the
Belt drive optimal operating condition for the ring frame machine. The evaluation of production speed, slippage %, and
Inverter cost of the ring frame machine was performed by implementing flat and tooth-bearing timing belt drives. In
Tachometer
addition, the six-month-long survey-based analysis included the variation in production length, doffing weight,
Slippage %
Speed
and production speed of the process. Throughout the study, other parameters that might be affecting the pro­
Production cost duction and the operating system were kept similar. The study found that the timing belt drive system is the
optimal condition improves the production parameters and minimizes the operating cost. Moreover, for the same
service life, on average, around $69.67 more profit can be achieved from the machine equipped with a timing
belt while keeping the slippage % minimum at a value of 0.59%. The timing belt system increased the production
of 1091.797 kg, doffing weight of 912.702 kg, as well as consumption of energy 2952.098 KWH in the study
period of six months. As a result, the implementation of the timing belt drive in the cotton ring-spinning frame
can be a sustainable approach in the textile spinning industry.

1. Introductions mechanical belt drive by using a pulley in “The Dictionary of Local

Plant, animal, or synthetic fibers are drawn out and twisted together
to form yarn in spinning, an ancient textile technique. For thousands of
years, fiber was spun by hand using simple equipment such as the
spindle and distaff (Mia et al., 2021). The spinning wheel did not in­
crease the production of wool until the high middle ages. Individual
spinners and large manufacturing did not exist until the introduction of
the spinning wheel in the 18th century (Wagner-Hasel, 1998). Yarn is
now produced in a variety of ways among which, ring spinning is one of
the most common ones. In spinning, mule was the first process to be
introduced in England in around the 1779 by Samuel Crompton (Hills,
1975). Then came the ring frame invented by an American in 1831 but
could not replace the mule completely (Copeland, 1909). It was after the
civil war, in the beginning of the seventies, ring machine improvements
were implied, by the “Sawyer Rabbeth and some other inventors” con­
tributions (Mass, 1989).
Yang Xiong in 15 BC was the first person to mention about
Expressions” which was used for a quilling machine, winding silk fibers
for weavers’ shuttles (Needham, 1974). Belt drive, a component used
while inventing spinning wheel, was used in both textile technologies
and hydraulic-powered bellows around the 1st century AD (Needham
and Kuhn, 1988). Belts for high precision applications have become
required due to the fast improvement of motor and drive technology, as
well as the usage of timing belts in servo systems. Belt drive systems
offer great speed and acceleration, as well as accurate and repeatable
motion. They also offer excellent performance, extended stroke lengths,
and cheap cost.
In the Ford Motor Company’s factory in 1913, Henry Ford intro­
duced the first conveyor belt-based assembly line (Selezneva, 2007).
Conveyor belts are one of the most cost-effective ways to transport
goods. The product of the belt width, tension difference, and belt ve­
locity determines the power transmitted between the belt and the pulley.
This energy is used for useful work, but some of it is often wasted as
frictional work. Slip between the belt and the pulley is accountable for a

* Corresponding author. Department of Textile Engineering, National Institute of Textile Engineering and Research, University of Dhaka, Dhaka, 1000, Bangladesh.
E-mail addresses: mroni_mia@yahoo.com, mroni_mia@niter.edu.bd (R. Mia).

https://doi.org/10.1016/j.clet.2022.100536
Received 19 April 2022; Received in revised form 5 July 2022; Accepted 13 July 2022
Available online 16 July 2022
2666-7908/© 2022 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).
M.D. Islam et al. Cleaner Engineering and Technology 9 (2022) 100536

portion of the frictional work. This slip also causes rubber wear, Table 1
reducing the belt’s and pulley’s lifetimes (Persson, 2020). The Flat belt Specification of ring frame machine.
transmission system was patented by Kanteru Hasebe, Hiroshi Mat­ Machine for flat belt drive Machine for timing belt drive
suoka, and KyotaroYanagi. The innovation is a flat belt transmission
Machine Name: Ring Frame Machine Name: Ring Frame
system that includes a flat pulley and a flat belt that is reeved around the Brand Name: Shanghai Brand Name: Shanghai
pulley and capable of transmitting a large load (Hasebe et al., 1991). Erfangji Erfangji
Timing belts are used in a variety of power transmission, conveyor, Model: EJM168L Model: EJM168L
control, and multifunctional systems, including power transmission and Origin: China Origin: China
Motor Speed: 1480 rpm Motor Speed: 1480 rpm
conveyor systems, and power transmission and control systems (Nagel, Machine Speed 17500 rpm Machine Speed 17500 rpm
2008). Timing belts come in a range of tooth types and pitches. The drive (Monitor): (Monitor):
belts may be made of thermoplastic or thermosetting polymer (Ahmed Drafting System: Manual Drafting System: Manual
et al., 2021; Chowdhury et al., 2022). The timing belt is constructed of a No. of Spindles: 1152 No. of Spindles: 1152
Doffing Time: 1:50 min Doffing Time: 1:50 min
chemically resistant polymer, while the supporting layer – which covers
Motor pulley Dia 210 Motor pulley Dia 210
the active surface – is constructed of fibers. Timing belts are most (mm) (mm)
frequently utilized in situations involving strong tangent forces and the Motor pulley Teeth N/A Motor pulley Teeth N/A
requirement for initial belt tension (Domek and Kołodziej, 2016). In ring no no
spinning machine, flat belts are used most commonly. How other belt M/c pulley Dia (mm) 191 M/c pulley Dia(mm) 191
M/c pulley Teeth no N/A M/c pulley Teeth no N/A
driving systems affect production and quality is not yet to be discovered. Tin pulley Dia (mm) 250 Tin pulley Dia (mm) 250
Therefore, this work is conducted to find out if other belt drive system Wharve Dia (mm) 18.5 Wharve Dia (mm) 18.5
can be more beneficial. Tape Thickness(mm) 0.6 Tape Thickness(mm) 0.6
The speed of the ring spinning machine is limited. As the spindle Gear Ratio 14.15 Gear Ratio 14.15
speed increases, the strength of the yarn degrades. Yarn breakage rate,
hairiness and strength loss, and fly generation are all issues that arise
when spinning yarns at high spindle speeds. Only at relatively slow Table 2
speeds can suitable yarn be generated. For a given traveler number, Parameters of flat belt and timing belt.
increasing the spindle speed effectively increases the yarn tension. When S/L Flat Belt Timing Belt
traveling at a faster pace, it is advised to use a lighter passenger, and vice No.
versa (Patil et al., 2019). So, the spindle speed is monitored throughout 1 Flat Belt 1260*140*3.50 Timing Belt 1190*514*100
the whole production process. Also, spindle speed, computer estimated dimension dimension
machine speed, tachometer speed and inverter speed is noted to deter­ 2 Flat Belt teeth N/A Timing Belt teeth 85T
mine the slip percentage of the driving system. The machine is calcu­ no no
3 Flat Belt life 18 Timing Belt life 8/16
lated automatically and shown on the screen of the monitor of the
Time(month) Time (L/Ex)
machine. A tachometer is a device that measures the rotational speed of month
spinning objects. A tachometer operates by projecting infrared light onto 4 Flat Belt Price 5000 Timing Belt price 5000/16000
a reflective plane, which then reflects the infrared light detected by a (Tk) (TK)
detector (Tunggal et al., 2020). Basically, a tachometer is a system that
generates a signal proportional to the rotational speed of a joint. Ta­
chometers come in a variety of shapes and sizes, with some measuring Table 3
the frequency or time between pulses produced by the rotating shaft. By Materials specifications.
numerical differencing, any angle-measuring system can be used to S/L Particulars Parameters S/L Particulars Parameters
simulate a tachometer (Lynch et al., 2015). No. No.
One of the primary issues that spinning mills confront is their high 1 Yarn Count 30s/1KH 8 Ring Cop Dia 40
energy consumption and poor output rate. Many approaches are utilized (Ne) (mm)
to boost the rate of production. A fiber arrangement is pulled, twisted, 2 Roving Hank 0.72 9 Spacer color(mm) Liac(2.50)
and coiled on a cop tube in the spinning machine (Shi et al., 2020). The (Ne)
3 Draft 41.72 10 Cot Hardness (b 75◦ –70◦
yarn is prepared for travel once it has been wound. The act of doffing
to fr)
entails removing the yarn coiled cop and installing a fresh one. This 4 TPI 19.79 11 Cot Dia(mm) 28
procedure entails donning the empty cop then donning the wounded cop 5 CSP 2300 12 Cot specification 30*19*28
(Srinivas et al., 2021). The output of the yarn production is mainly de­ 6 Speed(rpm) 17800 13 Top Apron 37*27.8*1
pends on the speed of the spinning machine. On the other hand, the specification
7 Ring 4/0 14 Bottom Apron 84.1*30*1.1
speed of the machine depends on the belt drive system (Goyal and Traveler No. specification
Nayak, 2020). Therefore, the appropriate belt is one of the primary
equipment for increase the production efficiency of spinning machine.
Several researchers have been worked for the increase of production and tooth-bearing timing belt drives, it is evaluated the ring frame
efficiency in the ring spinning by changing different parameters. For machine’s production speed, slippage percentage, and cost. The six-
example, (a) the spinning mills were utilized auto doffing and roving month survey-based research also take into account changes in the
bobbin transport technologies to significantly minimize stopping time process’s manufacturing speed, doffing weight, and duration. Other
and labor (Shi et al., 2020); (b) employing self-lubricating materials, factors that can impact productivity and the operating system are
surface coating, and varnishes for the ring and traveler, to lessen friction maintained constant throughout the trial. The result found that the
between the them and increase productivity (Begum and Helali, 2012); timing belt drive system is best option for increasing production pa­
(c) the ring frame adjustments based on spinning triangles that are rameters and lowering operational costs. Hence, it can be said that the
intended to minimize the hairiness of the staple yarn (Khan et al., 2019). implementation of timing belt drive in the cotton ring-spinning frame
However, till date, no studies have been conducted for increase the will increase the yarn production efficiency.
cost-effective yarn production using timing belt drive system.
Therefore, this studies focused on the cost approaching approach as
well as sustainable yarn production using timing belt drive. By using flat

2
M.D. Islam et al. Cleaner Engineering and Technology 9 (2022) 100536

Fig. 1. (a) Ring spinning frame with timing belt and flat belt drive; (b) Application of flat belt on ring spinning frame; (c) Application of timing belt on ring
spinning frame.

2. Experimental details using two different machines. The two machines using the two different
belts were shown in Fig. 1.
2.1. Materials

The study was conducted in the reputed textile spinning industry
named Badsha Textiles Ltd., Dhaka, Bangladesh. Two machines were
used for the experiment and the parameters were kept same for
obtaining accurate result after implementing flat and timing belt drive.
The specification of the ring frame machine was represented in Table 1.
The two belts were used in this study and their parameters were shown
in Table 2. The materials that were used for the production of yarn using
flat and timing belt drive, that specifications were represented in
Table 3. The speed and slippage percentages were recorded for both belt
2.2. Methods
2.2.1. Calculation of spindle speed
Determination of spindle speed is very important to find out the total
production of a ring spinning frame. For this spindle speed and motor
speed for both actual and calculated were by using tachometer and from
directly inverter. Inverter stores the running speed and timing data
before stoppage the machine and tachometer is a machine that’s
calculate RPM of spindle and motor of a ring spinning frame. Mathe­
matically spindle speeds were calculate by the following equation (1)

Fig. 2. Effect of timing belt and flat belt on (A) Inverter Speed, (B) Calculated Machine Speed and (C) Tachometer Speed.

3
M.D. Islam et al.
Fig. 3. Effect of timing belt and flat belt on (A) Speed Slip % (Inverter-M/C) and (B) Speed Slip % (Inverter- Tachometer).
and (2).
Spindle Speed = Front roller surface speed (Inch/min) × Twist per Inch (TPI)
(1)
Front roller surface speed (Inch/min) = 3.1416 × Front roller diameter × Front
roller rpm (2)
2.2.2. Calculation of belt slippage
Belt slippage is other important parameters to find actual production
of a ring spinning frame. Slip is defined as insufficient frictional grip
between pulley (driver/driven) and belt. Slip is the difference between
the linear velocities of pulley (driver/driven) and belt and it was
calculated using equation (3).
s = s1+s2 (3)
Where, s = Total percentage of slip, s1 = Slip between driver and belt,
and s2 = Slip between belt and follower.
2.2.3. Calculation of production per shift
Production of ring spinning frame per shift was calculated by using
equations (4) and (5):
Spindle ​ Speed × No ​ of ​ Spindle × Effic × 60 × 8
Production per shift =
TPI × Yarn ​ Count × 36 × 840 × 2.2046
in Kg
(4)
And TPI = Tm x √ Count (Ne) (5)
2.2.4. Calculation of energy consumption in ring spinning frame
Two types of energy can be used in a specific spinning mill; electrical
energy and thermal energy. Machines, air conditioning, lamps used for
illumination and compressors consume electrical energy while the
thermal energy is consumed by air conditioning and processes such as
fixation of yarns. Generally ring spinning frame consumes 66.1 KWH
energy per 1000 spindle. To get energy consumption in KWH, just
multiply KW of a motor with machine running time.
KWH counting meter or Digital electricity meter was attached in
machines input terminal of electricity entering point before taking KWH
data from machine. KWH data were calculated as per day consumption
in respect of daily actual production. We were taken KWH data from
Digital Electricity Meter (DEM) and same time. In addition, we were
taken actual amount of production that produced from supplied elec­
tricity. The production was calculated according to formulae and also by
weighted scale. Also costing was determined as per day production and
product value. This trial was carried out round the year and all data
collected and calculation was expressed as per day.
4
Cleaner Engineering and Technology 9 (2022) 100536
3. Results and discussion
3.1. Effect on speed
Fig. 2 shown the effect of timing belt and flat belt on inverter speed,
calculated m/c speed and tachometer speed. It was observed in Fig. 2(A)
that the inverter speed of all the 5 samples were higher when timing belt
was used. Sample group 2 and 5 showed the lowest speed difference
which was 85 rpm, highest speed variation was obtained in group 4
which was 102 rpm and the average speed variation was around 91 rpm.
Similarly, it was observed in Fig. 2(B) and (C) that calculated machine
speed and tachometer speed (actual speed) of all the 5 samples were
higher when timing belt was used. In case of calculated machine speed,
the lowest speed variation was 202 rpm for sample group 5, highest
being as high as 247 rpm for sample group 1 and average speed variation
was 220 rpm. In addition, tachometer speed variation (Fig. 2(C)) was
261, 307 and 285 as lowest, highest and average speed of the sample
groups 2 and 5, respectively. The results suggested that timing belt drive
spindle speed was higher compared to the flat belt drive and the vari­
ation of speed was also notable.
3.2. Effect on slippage %
The results obtained for the Slippage % based on belt drive system of
the ring frame machine, were shown in Fig. 3. The slip % and variation
in slip % for all five sample groups in Fig. 3(A) and (B) were analyzed
considering inverter-machine slip and inverter tachometer slip, respec­
tively. From Fig. 3(A), it was seen that in case of timing belt, average slip
% was 0.13, whereas in flat belt it was 0.86 and average variation be­
tween the two systems were around 0.72%. In case of Fig. 3(B), average
of timing belt slip%, flat belt slip% and variation between the two sys­
tems were around 0.59%, 1.68% and 1.09%. According to the results in
Fig. 3 indicated that when timing belt was used, slippage percent was
always noticeably lower compared to the results obtained when flat belt
was used. Also, the slippage percentage of the timing belt was more
consistent which ultimately lead to the consistency in the timing belt
speed showed in Fig. 2. The comparison of results revealed that
noticeable difference was observed in speed and slippage %, when
timing belt was used instead of flat belt in ring frame machine. The
supremacy of improvement increased by implementing timing belt drive
system, the situations outlined in Figs. 2 and 3 leads up to the assessment
that the use of timing belt was more advantageous. As a result, we
calculated the overall difference of the value of production to see which
one was more economic and advantageous for production.
3.3. Production and cost analysis
The study was conducted for 6 months from January to June in 2021.
During this period, the production in length, doffing weight and pro­
duction speed was tracked for the machine occupied timing belt and the
M.D. Islam et al. Cleaner Engineering and Technology 9 (2022) 100536

Table 4
Effect of timing belt and flat belt on actual production length in avg. kg (for 6 months).
Timing belt Flat belt Timing belt – Flat belt

Month Per. min. Per. Hour Per. Day Per. month. Per. min. Per. Hour Per. Day Per. month. Per. month.

January 0.516 30.965 743.171 23038.296 0.512 30.714 737.14 22851.303 186.99
February 0.516 30.965 743.171 20808.784 0.512 30.714 737.14 20639.887 168.90
March 0.516 30.965 743.171 23038.296 0.512 30.714 737.14 22851.303 186.99
April 0.516 30.965 743.171 22295.125 0.512 30.714 737.14 22114.165 180.96
May 0.516 30.965 743.171 23038.296 0.512 30.714 737.14 22851.303 186.99
June 0.516 30.965 743.171 22295.125 0.512 30.714 737.14 22114.165 180.96
6 Months Total 134513.92 6 Months Total 133422.126 1091.797

Table 5
Effect of timing belt and flat belt on actual doffing weight in kg (for 6 months).
Timing belt Flat belt Timing belt – Flat belt

Month Per. min. Per. Hour Per. Day Per. month. Per. min. Per. Hour Per. Day Per. month. Per. month.

January 0.521 31.264 750.327 23260.123 0.518 31.053 745.28 23103.804 156.32
February 0.521 31.264 750.327 21009.143 0.518 31.053 745.28 20867.952 141.19
March 0.521 31.264 750.327 23260.123 0.518 31.053 745.28 23103.804 156.32
April 0.521 31.264 750.327 22509.796 0.518 31.053 745.28 22358.520 151.28
May 0.521 31.264 750.327 23260.123 0.518 31.053 745.28 23103.804 156.32
June 0.521 31.264 750.327 22509.796 0.518 31.053 745.28 22358.520 151.28
6 Months Total 135809.11 6 Months Total 134896.403 912.702

Table 6
Energy consumption by timing belt and flat belt in KWH (for 6 months).
Timing belt Flat belt Timing belt – Flat belt

Month Per. min. Per. Hour Per. Day KWH/month. Per. min. Per. Hour Per. Day KWH/month. Per. month.

January 0.768 46.086 1106.067 34288.083 0.757 45.407 1089.76 33782.475 505.61
February 0.768 46.086 1106.067 30969.882 0.757 45.407 1089.76 30513.203 456.68
March 0.768 46.086 1106.067 34288.083 0.757 45.407 1089.76 33782.475 505.61
April 0.768 46.086 1106.067 33182.016 0.757 45.407 1089.76 32692.717 489.30
May 0.768 46.086 1106.067 34288.083 0.757 45.407 1089.76 33782.475 505.61
June 0.768 46.086 1106.067 33182.016 0.757 45.407 1089.76 32692.717 489.30
6 Months Total 200198.16 6 Months Total 197246.062 2952.098

belt drive (Table 6). It was worth noting that timing belt consumed more
Table 7
energy than flat belt and which was so negligible and it was consumed
Actual production value for 6 months by timing belt & flat belt and their life
only about $65 extra than flat belt drive. The value of total production
time.
for 6 months were noted in Table 7. For the same service life of the two
Timing belt Flat belt Timing belt – Flat
belts, the timing belt produced $69.67 worth more products for 1 ma­
belt
chine. In addition, the slippage percentage of the ring machine was low
6 Month Total ৳400396.33 ৳394492.123 ৳ 5904.207 for the timing belt drive system.
TK ($4724.49) ($4654.82) ($69.67)
Life Time 9–11 Months 9–11 Months
3.4. Discussion

machine occupied flat belt. Data was recorded in average of per minute,
per hour, per day and per month throughout the 6 months for both
machines. The results in Table 4 shown that the production rate of ring
spinning machine in kg of 6 months for both belt approached. From the
total value, it was observed that a total of 1091.797 kg more production
was achieved by using timing belt over flat belt. As a result, it was
profitable when used timing belt on ring spinning frame and it was $
2948 when yarn price was 2.70 $/kg (100% Card Hosiery 30 Ne) during
six months of production. Doffing weight in kg was also recorded and it
was clearly shown the average doffing weight produced from timing belt
was greater than the machine which occupied flat belt drive (Table 5).
The average gain per 6 month was 912.702 kg for timing belt over flat
belt and it was more profitable than using flat belt. The profit was about
$2465 in the six months production when the yarn price was 2.70$/Kg
(Card Hosiery 30 Ne).
The energy consumption in KWH was recorded for 6 months and it
was clearly seen that average KWH consumed by the machine which
occupied timing belt was greater than the machine which occupied flat
The timing belt drive system was shown more performances than
already used flat belt system. The six months long research shown that
the slipping percentage was reduced to 0.59%, which was the maximum
reduction percentages. It was discovered that employing a timing belt
rather from a flat belt resulted in a total increase in output of 1091.797
kg. As a consequence, it was profitable to employ a timing belt on a ring
spinning frame. The profit was $2948 for the six-month production
period, when the price of yarn was $2.70 per kilogram. Timing belt use
was more lucrative than flat belt use, with an average gain of 912.702 kg
per six months. When the yarn price was $2.70 per kilogram for the six-
month manufacturing period, the profit was around $2465. Therefore,
around $69.67 more profit was achieved using timing belt drive in the
ring-spinning frame machine.
4. Conclusion
This study was conducted for the six months in the industrial scale
and it was concluded that, for a constant amount of time, the machine

5
M.D. Islam et al.
occupied with timing belt had increased production of almost 6.031 kg
per day with better quality over the machine equipped with flat belt
driving system. Compared to the flat belt driving system, the timing belt
system was almost zero slippage percentage with a value of 0.59%. The
variation of cotton ring frame spindle speed was also low in timing belt
system that is why machine running performance was optimum (i.e low
ends breakage%, low vibration etc) which resulted production increased
and also profit increased with a value around $69.67. The tension was
low on timing belt, load on the supporting bearing was also low. As a
result, timing belt drive installation in the cotton ring-spinning frame
can be a more sustainable technique in the textile spinning industry.
Although, timing belt has more production efficiency, it is worth
mentioning that the time belt drive is less available, which makes the
more use of flat belt in the spinning industry. Therefore, how to increase
and implement of the timing belt in the spinning industry with the more
involvement of machineries will be carried out in our future research.
Author statement
We confirm that the manuscript has been read and approved by all
named authors and that there are no other persons who satisfied the
criteria for authorship but are not listed. We further confirm that the
order of authors listed in the manuscript has been approved by all of us.
Declaration of competing interests
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
the work reported in this paper.
Acknowledgement
The authors would like to express thank and gratitude towards
Badsha Textiles Ltd., Dhaka, Bangladesh, for providing machineries and
equipment on time during the research work.
Cleaner Engineering and Technology 9 (2022) 100536
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