blowroom carding Draw frame

Speed frame Draw frame Combing

Yarn
Ring frame Winding
conditioning
 Blowroom: Functions
 Opening
 Mixing
 Cleaning
 Recycling
 Opening

Opening Mixing

Cleaning

To carding
 Opening is the
first operation it
means, tearing
apart the
compressed and
matted cotton
until it is very
much loosened
and separated
into small tufts
with a gentle
treatment, and a
fiber loss as small
as possible.
The plucker carriage, supported by a rotating tower,
internally contains two plucker cylinders covered
with spikes made from a special tungsten-carbide
alloy, capable of extracting raw cotton from the
bales being processed. The high number of blades
with spikes are located on both of the two plucker
cylinders - allow the tufts to be opened to a certain
degree when the bale is plucked, making the
successive repeated untangling easier.
 The bales being opened are placed lengthwise or
crosswise on both sides of the bale opener, and
the take-off unit can process up to four different
assortments
 Reduction of the raw material into micro-tufts is
assured by the patented double teeth on the
take-off roller and the grid with closely set
clamping rails.
 The patented take-off roller and the grid design
with small gaps between the clamping rails
enables small fibre tufts ( micro tufts ) to be
extracted.
Bale Profiling:
• The height
profile of the bale
lay-down is
precisely detected
by light barriers
and memorized.
• In the process the system automatically
compensates for differences in height in the bale
profile. Labour-intensive manual levelling is
eliminated. After the required height range, take-
off depth and speed of travel have been entered for
each group of bales, take-off proceeds fully
automatically.
 Blending of fiber material is an essential
preliminary in the production of a yarn.
 A well-assembled bale layout and even (and
as far as possible, simultaneous) extraction of
fibers from all bales is of paramount
importance.
Objectives of mixing or blending
 Economy
 Processing performance
 Functional properties
 The machine consists of several (from six to
eight) chute chambers into which the material
is blown from above.
 The chutes are filled successively, and the
material is removed from all chutes
simultaneously.
 Ejection of flocks onto a collecting conveyor
is done by take-off and beating rollers under
the chutes.
 The machine is made up of three parts: a
storage section, an intermediate chamber,
and a delivery section.
 Flocks are fed pneumatically and
simultaneously into six J-shaped chutes (2),
arranged one behind the other in the storage
section.
 A conveyor belt (3) leads the stock through
the intermediate chamber to the take-off
unit. The material columns are thus diverted
out of the vertical into the horizontal.
 The cleaning efficiency has to be optimised
and not maximized.
 To extract the impurities like broken seeds,
husks, leaves, sand, stone & iron particles,
short fibres, immature fibres, dust, dirt and
other foreign materials from the cotton
 Cotton contains up to 18% trash; in most
cases, this figure lies between 1 % and 7%.
 To clean the material adequately, it is
unavoidable to remove at least as much fiber
as waste.
 The degree of cleaning cannot be better than
the degree of opening. Dirt can be removed
practically only from surfaces.
 New surfaces must therefore be created
continuously.
 Cleaning Efficiency = (Extracted trash/Trash
Content in Material) * 100
 In Uniclean, Cleaning is performed without
nipping and is therefore very gentle to the fibers
and at the same time efficient.
 The uniclean removes loose trash particles, fibre
fragments and dust. It is designed for intensive
cleaning.
 The raw material is beaten above the grid bars
several times in order to remove the impurities.
 Simultaneously material passes from dust
extraction chamber, which results in high
dedusting.
• A suction fan in the feeding duct
helps to get the raw material with
specially designed flip-flop feeding
device.
• Forms a homogeneous length and
width, lap type feeding and the air is
extracted from this lamina chute.
This chute first filled according to
required production.
• Two drums above the beater and
at the end of chute extract the
material one of them is perforated
which is for extra dedusting.
• The feeding roll and the
servomotor control the adjustable
feeding plate to pass the fibers on
to the unit.
• The cylinders guide the fibres over
grid bars and adjustable mote
knives seperating rest of the trash
intensively.
 The waste from all the subsequent processes
like carding, combing and drawframe is
returned to the blowroom where a specific
machine is kept just for the purpose of
opening and mixing the waste.
The objective of carding is:
 To open the flocks into individual fibers
 Cleaning or elimination of impurities
 Elimination of dust
 Elimination of short fibers
 Fiber blending
 Fiber orientation or alignment
 Sliver formation
 There are two types of feeding to the cards,
lap feed system, in which the fibers are
formed into a lap or a compact sheet, and
chute feed system, in which flocks are
transported pneumatically.
Advantages Disadvantages

High performance in carding due Linear density of the web fed to

to high degree of openness of the card is not as good as lap.
feed web.

Labor requirement is less due to The installation is not flexible.

no lap transportation and lap
change in cards.

For high production cards, only Auto-leveler is a must for

chute feeding system is suitable. controlling weight per unit
length, hence investment cost
and maintenance cost is more.
Advantages Disadvantages

The linear density of the lap Transportation of lap needs

is very good and uniformity is more manual efforts
easier to maintain.

The whole installation is very Lap run out is an additional

flexible source of fault, as it should
be replaced by a new lap

Deviations in card output will Fiber loss can take place

be nil, as laps can be rejected during lap change

Auto-levelers are not More load on the taker-in, as

required, hence investment laps are heavily compressed
cost and maintenance cost is
less
 Sliver coming out of the carding
machine

Chute feed feeding the machine

with cotton
• Equalizing
• Parallelizing
• Blending
• Dust removal
4 to 8 card or drawframe slivers are fed to the drafting arrangement
(3).
A feed roller pair (2) is located above each can (1) to enable the
feed step to be performed in a controlled manner without false
drafts.
The feed roller pairs are carried in table and each is positively
driven.
The slivers runs into the drafting arrangement, subjected to a draft
of 4 to 8 and leave it as a web lacking significant cohesion.
In order to avoid disintegration of the web, which would other wise
be unavoidable at the high operating speeds currently in use, it is
condensed into a sliver immediately after the drafting arrangement.
The factors that affect the yarn quality are
 the total draft
 no of drawframe passages
 break draft
 no of doublings
 grams/meter of sliver fed to the drawframe
 fibre length
 fibre fineness
 delivery speed
 type of drafting
 type of autoleveller
 autoleveller settings
 The total draft depends upon
◦ material processed
◦ short fibre content
◦ fibre length
 Drafting: It is the process of increasing length
per unit weight of sliver. It is mainly due to
peripheral speed of the rollers.
 Doubling: The process of combing two or more
carded sliver into a single form is called
doubling. In draw frame m/c generally six slivers
are fed to convert into one i.e. six doubling.
 Drawing: In the cotton industry the term is
applied exclusively to processing on the draw
frame, where the operation is one of doubling
and drafting. Drawing= Drafting + Doubling
 Drafting is the process of elongating a strand
of fibres, with the intention of orienting the
fibres in the direction of the strand and
reducing its linear density. In a roller drafting
system, the strand is passed through a series
of sets of rollers, each successive set rotating
at a surface velocity greater than that of the
previous set.
 During drafting, the fibres must be moved
relative to each other as uniformly as possible
by overcoming the cohesive friction. Different
cans from different carding machines are
used for doubling so as to maintain
homogeneity. 28 cans are used in a single
drawframe. Each drawframe has three pairs of
rollers that adjust speed for providing
uniform sliver of fibre. The first roller is the
slowest in speed, and the delivery roller is the
fastest.
Need For Lap Formation: The raw material
delivered by the carding machine cannot be fed
directly to the comber. Lap preparation is
a must. A good lap fed to the comber should
have
1. highest degree of evenness so that lap is gripped
uniformly by the nipper
2. a good parallel disposition of fibres so that long
fibres will not be lost
 Sliver Lap: In sliver lap carded slivers are
converted into sliver lap

 Ribbon Lap Here lap uniformity is improved

by doubling. It uses sliver lap utilising several
sliver laps to make one ribbon lap.
Sliver Lap Formation Ribbon Lap Formation
This is the third kind of lap where 12-24
drafted slivers are made into one super lap

 Objective
 Drafting, doubling, parallelisation

 It utilises a Sliver Doubling machine

Combing is the process which is used to upgrade the raw
material. It influences the following yarn properties:
1. yarn evenness
2. strength
3. cleanness
4. smoothness
5. visual appearance
In addition to the above, combed cotton needs less twist
than a carded yarn because the short fibres are
removed.
In order to produce an improvement in yarn quality, the
comber must perform the following operations:
1. elimination of short fibres
2. elimination of remaining impurities
3. elimination of neps

The basic operation of the comber is to improve the mean

length or staple length by removing the short
fibres. Since fineness of short fibres (noil) is low, the overall
micronaire of the sliver after combing is high.
Because of combing, fibre parallelization increases.
In order to produce an improvement in yarn quality, the
comber must perform the following operations:
1. elimination of short fibres
2. elimination of remaining impurities
3. elimination of neps

The basic operation of the comber is to improve the mean

length or staple length by removing the short
fibres. Since fineness of short fibres (noil) is low, the overall
micronaire of the sliver after combing is high.
Because of combing, fibre parallelization increases.
 It is clear from these functions that the combing process is
essentially aimed at obtaining excellent quality yarns and to
fulfill this objective raw materials with above average physical
and mechanical features must be used from the very
beginning of the spinning process.
Necessity of Combing The following quality of fibers can only
be obtained by combing
 Absence of nap

 More parallel arrangement of fibers

 Straight fibers

 Clean finer fiber

 Uniformity in length of fiber

 Input
Ribbon Lap or Super Lap

Output
Combed sliver
Lakshmi LK 54 Comber

The sequence of operation in a comber is as follows:

1. Feeding of the lap by feed roller
2. The fed lap is gripped by the nipper
3. The gripped lap is combed by circular comb
4. The detaching roller grips the combed lap and moves forward
5. While the detaching roller delivers the material, top comb
comes into action to further clean the lap.The short fibres are
removed.
6. While going back, nipper opens and receives a new bit of lap.
Objective

1.Through doubling, the slivers are made even

2.Doubling results in homogenization (blending)
3.Through draft, fibres get parallelized
4.Hooks created in the card are straightened
5.Through the suction, intensive dust removal is achieved
6.Autoleveller maintains absolute sliver fineness
 Through doubling the slivers are made even

 doubling results in homogenization(blending)

 through draft fibres get parallelised

 autoleveller maintains absolute sliver fineness

 Quality of the drawframe sliver determines the yarn quality.

 Input
Combed or carded sliver

Output
Drafted sliver
Lakshmi LRSB 851 Drawframe

 It uses rollers, which can be changed to vary count

 Autoleveller is an additional device which is meant for
correcting the linear density variations in the delivered
sliver
Lakshmi Metal Works Draw Frame
 Speed Frame is the process in
spinning which involves the
preparation of the package for the
next step which is the Ring Frame.
 The Input for this process is
Combed Sliver which then exits in
the form of Roving.
 It is present in the carded ring
spinning cycle and in the combed
ring spinning cycle, in the first
case it is found following the
post-carding drawframe ,while in
the second case after the post-
combing drawframe
Roving Frame is responsible for the following –

 Drafting the sliver into Roving

 Twisting the drafted strand
 Winding the twisted roving on a Bobbin.
 This machine is forced to be used by the spinner
for the following reasons –
 Sliver is thick, untwisted strand that tends to be
hairy and to create fly. So draft is needed to
reduce the linear density of sliver.
 Drafting arrangements of ringframes are not
capable of processing this strand in a single
drafting operation to create a yarn that meets all
the normal demands on such yarns.
 Plus the drawframes cans represent the worst
conceivable mode of transport & presentation of
feed material to the Ring Spinning Frame.
Drafting
In roving frame two drafting
frame are commonly used.
 4 over 4 drafting system – is
used in case of higher draft
applications.
 3 over 3 drafting system -
is better in when there is
good fiber length.
Twisting
 A very important factor which
produces strength in the
roving and twist is inserted
with the help of flyer. When
flyer rotates, the twist is
produce in the sliver. Twist
level depends upon flyer
speed and delivery speed.
 The twist is given by the
rotation of the flyer located
on the spindles, in fact the
exit roving coming from the
draft cylinders enters in the
higher hole of the flyer,
passing through the hollow
arm and then winding on the
bobbin.
Flyer & Bobbin
Winding
 Winding of roving is based on the
principle that "there should be
difference in speeds of flyer and
bobbin“. This is done so as to
accommodate for the layers that
are formed over time on the
bobbin, which leads to increase
in the bobbin diameter.
 During winding the flyer speed is
kept constant simultaneously
keeping the difference in speeds
of flyer & bobbin constant.
 But as the bobbin diameter
continuously increases, the
bobbin rotation rate is reduced to
maintain the required difference
in speed.
 • To prepare the sliver as its next medium of
transport.
Drafting • Sliver isn’t suitable as it as for Ring Frame

• To impart twist to the Roving so as to

strengthen it.
Twisting

• To wind the Roving on to the bobbin.

• The bobbin is what is used as input in the next
Winding process.
 Ring Frame gives the final output for spinning process
which is the yarn.
 Objective
 To reduce the thickness of the roving to the desired yarn count by means
of drafting rollers.
 To impart twist into the yarn to strengthen it and prevent the short fibers
from protruding.
• Flow of material
 Roving bobbins are mounted on the
stand and the end is drawn through the
machine.
 Roving is made to pass through
guides to drafting rollers to reduce the
thickness to required yarn
count.
 Yarn is passed through balloon
control rings and end breakage
sensors (working on optical principle)
 It is passed through a small metal

traveler moving on the ring rail and

winding the yarn around the spindle.
 Mechanism
 Traveller:
Traveller imparts twist to the yarn.
Traveller and spindle together help
to wind the yarn on the bobbin.
One revolution of traveler
gives one twist to the yarn.
The shape formation of the cop
takes place with the help of cam
that lifts the ring rail through
shafts.
The cam pushes the shaft down
and the ring rail lifts up. There is
a tape that controls the continuous
up and down movement. The shape
of the cam defines the shape of
the cone.
 Spinning Triangle:
 Twist in a yarn is generated at the traveller .
 Twist must run back as close as possible to the nip of the rollers, but it
never penetrates completely to the nip
 There is always a triangular bundle of fibres without twist at the exit of
the rollers; this is called as spinning triangle.
 Most of the end breaks originate at this point.
 Machinery Used
 1. RXI 240 Kirloskar Tyoda Textile Machinery
 2. Lakshmi LR 6/S
 No. of spindles – 1200/ frame
WINDING Transferring Of Yarn from Bobbin into
suitable package.
Warp  Cone, Cheese, Flanged Bobbin
Weft Pirn

OBJECTIVE Transfer yarn from one package to another

suitable packages this can be Conveniently
used for weaving purposes.
Clean Yarn & Remove yarn faults like
hairiness neps, slubs, of foreign matters.
Get suitable package to transfer and store
yarn

CHECKLIST Min Fault, No Yarn Damage, Easy Winding,

Suitable Size n Shape of Package

TYPES 1. Parallel wound package warp yarn

or weavers yarn
2. Near parallel wound package pirn,
Flanged bobbin.
3. Cross wound package cone,
cheese, spool
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Friday, 17 September 2021
CROSS WOUND PACKAGE: Yarn is Laid on the
package at an appreciable helix angle so that the
layers cross one another to Give stability. Package
is stable w/o Flanged. Transverse Mechanism Rqd.

PRECISION WINDING : Parallel – Low Stable – Hard

– Compact – Dense – Slow Unwinding - maybe
Flanged – High Yarn Tension.
NON-PRECISION WINDING: Helix – High Stable –
Soft – Less Compact – Min Yarn Stored – High
Unwinding – Less Yarn Tension.

WINDING EFFICIENCY % :
(Actual Prod. / calculated Prod. ) X 100
EFFICIENCY LOSS % :
(calculated Prod. - Actual Prod. / calculated Prod. )
X 100

EFFICIENCY FACTORS :
Spindle/Drum Speed , Yarn Count , Yarn Quality,
Worker Efficiency, Humidity, Workload per worker, 75
Maintenance, Power Failure, Creeling Time,
Doffing Time, Piecing, Capacity Utilization
Friday, 17 September 2021
Parameter in Winding:
1. Slub Catcher Setting {D=1/(28 X Nˆ[1/2] ) }
2. Yarn Tension Level
3. Winding Speed
YARN TENTIONING DEVICE: Checks Damaging of Yarn / Unstable Packaging

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CONDITIONING

85

Friday, 17 September 2021

PACKAGING PACKAGING

PALLET PACKING BOX PACKING

Friday, 17 September 2021

PACKAGING PROCESS FLOW
Waiting for pkg. Cone check & put h.m.bags Ctn marking

Ctn tapeing top side Cones filling in ctn Ctn tapeing bottom

Nylon striping in ctn Pack ctn on pallet Ctn pallet Trans.w/h

Thank you