Yarn formation I – Tutorials

Q1—Calculate the production of scutcher if the lap wt. is 400 g/m, and the dia and speed of
shell roller are 11 rpm and 240 mm respectively. provide the production in kg/hr, kg/shift and
bags/day when the efficiency of the m/c is 75%, assume a shift of 8hrs/day and 1 bag weighing
100 kg.:
Solution:

Lap wt/l = 400g/m

Shell roller speed, N = 11 rpm
Shell roller dia., D = 240 mm = 0.24 m
Efficiency, η = 75% = 75/100 = 0.75
P [kg/hr] , P [kg/shift] & P[bag/day] = ?

P[g/ hr ] = πDN × 60 × lap ct (gm- 1 ) × η

= π × 0.24 × 11 × 60 × 400 × 0.75
= 149288.483 g/ hr
P[g/ hr ]
P[kg/ hr ] = = 149.288 kg/ hr
1000
P[kg/shift] = P[kg/ hr ] × 8hr = 1194.308 kg/shift
24
P[bag/day] = P[kg/ hr ] × = 35.829 ≈ 36 bags / day
100

Q2—The fluted lap roller of a scutcher of 9” dia. makes 10 revolutions per minute. If the lap
count is 434.0476 g/m, calculate the production of scutcher in one shift at 80% efficiency.
provide the production in kg/hr, kg/shift and bags/day , assume a shift of 8hrs/day and 1 bag
weighing 100 kg.:

Solution:
roller dia, D = 9 x 0.0254 = 0.2286m
roller speed, N = 10rpm
efficiency, η = 80% = 80/100 = 0.80
Lap count = 434.0476 g/m

P[g/ hr ] = πDN × 60 × lap ct (gm-2) × η

= π × 0.2 286 × 1 0 × 60 × 434.0476 × 0. 8
= 149625.183 g/ hr
P[g/ hr ]
P[kg/ hr ] = = 149.6251833 kg/ hr
1000
P[kg/shift] = P[kg/ hr ] × 8hr = 1197.001466 kg/shift

24
P[bag/day] = P[kg/ hr ] × = 35.91004398 ≈ 3 6 bags/day
100

Q3—What will be the production of a carding engine in 8 hours at 84% efficiency, if the speed
of 2” coiler calendar rollers is 125 rpm with the carded sliver weighing 2000 g/m? provide the
production in kg/hr, kg/shift and bags/day, assume a shift of 8hrs/day and 1 bag weighing 100
kg.:

Solution:
roller dia, D = 2 x 0.0254 = 0.0508m
roller speed, N = 125rpm
efficiency, η = 84% = 84/100 = 0.84
Lap count = 2000 g/m

P[g/ hr ] = πDN × 60 × sliver ct (gm- 1 ) × η

= π × 0. 0508 × 1 25 × 60 × 2000 × 0. 8 4
= 2010870.626 g/ hr
P[g/ hr ]
P[kg/ hr ] = = 2010.870626 kg/ hr
1000
P[kg/shift] = P[kg/ hr ] × 8hr = 16086.96501 kg/shift
 24
P[bag/day] = P[kg/ hr ] × = 482.6089502 ≈ 48 3 bags/day
100

Q4—The 3” diameter calendar rollers of a 6 delivery drawing frame revolves 125 rpm. Calculate
the production, if the drawn sliver is 2034gm-1 and the machine works for 8 hrs at 70%
efficiency: provide the production in kg/hr, kg/shift and bags/day , assume a shift of 8hrs/day
and 1 bag weighing 100 kg.:

Solution:
roller dia, D = 3 x 0.0254 = 0.0762 m
roller speed, N = 125rpm
efficiency, η = 70% = 70/100 = 0.70
Lap count = 2034 g/m
no. of machines = 1
no. of machine heads = 6

P[g/ hr ] = πDN × 60 × sliver ct (gm- 1 ) × η × no. of m/c heads × no. of m/c

= π × 0.0762 × 1 25 × 60 × 20 34 × 0.70 × 6 × 1

= 1533791.570 g/ hr
P[g/ hr ]
P[kg/ hr ] = = 1533.79157 kg/ hr
1000
P[kg/shift] = P[kg/ hr ] × 8hr = 12270.33256 kg/shift
24
P[bag/day] = P[kg/ hr ] × = 368.1099767 ≈ 368 bags/day
100

Q5—The speed and diameter of the fluted lap drum of a sliver lap machine are 30 rpm and 16”
respectively. If 24 card cans having 3.937 g/m sliver are fed to the machine, what will be the
production in one shift at 70% efficiency?
Solution
Lap roller speed, N = 30 rpm
Lap roller dia., D = 16” = 16 x 0.0254 = 0.4064
Efficiency, η = 70% = 0.7
Feeding sliver count = 3.937 g/m

Length (m) of each sliver delivered in 1 shift at 70% efficiency

P[g/ hr ] = πDN × 60 × 8 × η
= π × 0.4064 × 30 × 60 × 8 × 0.70
= 12869.572 m / s h ift

Weight (g) of each sliver delivered in 1 shift at 70% efficiency

P [m / shift ] 12869.572
P[g/shift] = = = 3268.927908 g/ shift
sliver ct . 3.937

count (g/m) of each sliver delivered

P[ g / shift ] 3268.927908
P[g/ m ] = = = 0.2540044 g/ m
P[m / shift ] 12869.572
count (g/m) of 24 slivers delivered
P[g/m] = 24 x 6.096105588 g/m

∴ total production;
P[g/ hr ] = πDN × 60 × sliver ct (gm- 1 ) × η × no. of m/c

= π × 0.4064 × 30 × 60 × 6.096105588 × 0. 70 × 1

= 9806.784 g/ hr
P[g/ hr ]
P[kg/ hr ] = = 9.806783727 kg/ hr
1000
P[kg/shift] = P[kg/ hr ] × 8hr = 78.45426981 kg/shift
Q6—The cylinder of a 6 head comber is running at a speed of 100 revolutions per minute and
each roller feeds 0.25” lap. The lap count is 35.575 g/m. calculate the production of comber in 8
hours at 70% efficiency and 12% waste:
Solution
Comber speed = 100rpm
Feeding rate = 0.25”/min = 0.25 x 0.0254 = 0.00635 m/min
Count of lap = 35.575 g/m
No. of heads = 6
No. of m/c = 1
Efficiency = 70% = 0.7
%Waste, w = 12%

∴ total production;
P[g/ hr ] = πDN × 60 × sliver ct (gm- 1 ) × η × no. of m/c heads × no. of m/c × ( 1−%w )

= π × 0.00635 × 100 × 60 × 35.575 × 0.70 × 6 × 1 × 1− ( 12

100 )
= π × 0.00635 × 100 × 60 × 35.575 × 0. 70 × 6 × 1 × ( 1−0.12 )
= π × 0.00635 × 100 × 60 × 35.575 × 0. 70 × 6 × 1 × 0.88
= 15738.079 g/ hr
P[g/ hr ]
P[kg/ hr ] = = 15.73807895 kg/ hr
1000
P[kg/shift] = P[kg/ hr ] × 8hr = 125.9046316 kg/shift