REPORT ON MILL VISIT

Course code: Tex-202

Course title: Yarn Manufacturing
Technology-I
Submitted Date: th
6 August, 2008.

Submitted by:

NAME ID
MIR IFTE KHAIRUL HAIDER 06313208
MUHAMMAD RIYAZ-UL-ISALM 06313241
KHANDAKER RAJESH SOBHAN 06313239
IBRAHIM KHALIL 06313180
MD. CHAND MIAH 06111003

Submitted To:
MD. ROKONUZZAMAN,
LECTURER OF BSTE,
CITY UNIVERSITY.
Mill visit report:
In 3rd July, our university had arranged a mill visit in panna
spinning mill for TEX-202, Yarn Manufacturing Technology-I. According to
visit this textile mill, we gathered knowledge of yarn, which are given below.

Flow chart of carded in manufacturing

Bale management

Bale Blow room Lap

Lap Carding Sliver

Sliver Barker draw frame Sliver

Sliver Finisher draw frame Sliver

Sliver Roving frame/Simplex Roving

Roving Ring frame yarn

Yarn Auto cone/finishing yarn package/cone

Yarn Heat setting heat setting yarn

Heat sated yarn Packing Finished bag

Bale management:
Testing, sorting and mixing bales according to the properties of
fibre for producing specific good quality of yarn at minimum cost is called
Bale management.

Object of Bale management:

1. An evening out of the quality characteristics of a yarn.
2. A means of avoiding quality jumps.
3. A possibility of reducing costs as a result of an improved
knowledge of the fibre characteristics.

Specification of a cotton bale:

1. Origin: CIS( UZ bekistan) raw cotton
2. Crop year: 2008-2009
3. Bale weight: 215-220 kgs(approximately).
4. Staple length: 1⅛ inches
5. Micronaire: 4.0 – 4.8
6. Strength : 24-29 gram/tex
7. Grade: SMW( Strict middling white)
8. Price: 65.5 usc/lb

# After collecting cotton bales, the cotton bales are opened for mixing by
manually or automatically.
Mixing:
When different grade same yarn are mixed together is called
mixing. As for example, 50% of 1⅛ inches staple length + 50% of 1⅝
inches staple length.
Blending:
When different types of fibre are mixed together is called mixing.
As for example, 65% polyester + 35% cotton.
Types of mixing
1. Weight mixing
2. Volume mixing
3. Hand stack mixing
4. Bin mixing
5. Mixing by hopper
6. Lap mixing
7. Card mixing
8. Sliver mixing
9. Automatic mixing
Types of blending
1. Hand stack blending
2. Bin blending
3. Lap blending or blow room blending
4. Card blending
5. Draw frame blending

Objects of mixing and blending:

1. To achieve uniform quality.
2. To improve performance.
3. To reduce and control of production cost.
4. To met the function and user requirements.
5. It influences to increase aesthetic properties i.e. appearance, color, luster etc.
6. It influences to increase physical properties i.e. tensile strength, abrasion
resistance, stetch etc.
Blow room:
Blow room consists of a number of machines used in succession to open
and clean the cotton fiber to the required degree. 40to70% trashes are removed in
this action.

Pics: Blow room line machine

Blow room section:

A section in which the supplied compressed bales are opened, cleaned and
blending or mixing to form uniforms lap of specific length is called Blow room section.
The cleaning efficiency of blow room is 60 to 65%. This is the first section of the
spinning line.
After collecting cotton bales, the cotton bales are opened for mixing by manually or
automatically. Then the opened and mixing fiber is feeded into feed lattice and then it is
passed big pipe line into machine by air current for opening and cleaning which is carried
out by different kinds of beater and grid bar.
 Operation involved in Blow room line:
1. Opening
2. Cleaning
3. Mixing and blending
4. Lap forming
5. Dust removal

Opening:
1. To open the compressed bales of fibre.
2. To make the cotton tuft a small size as for as possible

Cleaning:
To remove the dirt, dust, broken seeds, broken leaf, and stack and foreign
materials from the fibers.

Blending and mixing:

To make good value of yarn and to decrease the production cost by mixing
different grade of fibers.

Lap forming:
1. To transfer the opened and cleaned fibers into a sheet form of definite
width and uniform unit length is called lap.
2. To roll the lap of predetermined length in a cylindrical shape around a
lap pin.
3. To transfer the lap from the lap pin to a rod to suitable handle and feed
it to subsequence processing carding m/c.
Dust removal:
To remove dust which is completely enclosed in the flocks and are held
back during suction.

Specification of B/R lap:

1. Lap hank : 0.0014
2. Lap Length : 60-80 yds
3. Total weight : 20-32 kgs
4. Lap weight/yd : 12-14 oz/yd
5. Lap width : 40 inches
Types of m/c comprising blow room line installation:
1. Opening m/c
a. Conventional bale opener
b.Scubert and Salzer blending grab
c. Hergeth Hollings worth bale opener
d. Modern m/c used for export
e. Trutzschler automatic bale opener
f. The unifloc of Rieter
Features of Trutzschler automatic bale opener :

Country : Germany

Company : trutzschler

Fully automated

Universal application

Production up to 2,000 kgs/h

Simple operation

Minimum maintenance
Trutzschler blow room line for coarse & fine grade cotton:
Fine line: ( Modern blow room Coarse line: (Lap feed,
line) Conventional)

BDT GBR

SPMF AFC

CLP MXU

MXU RN Beater

CLC3 RSK Beater

SPF Scutcher

Chute feed

Features of the unifloc of Rieter:

Country : Germany

Company : trutzschler

This is also the most widely used type of machine today.

The Rieter unifloc enables processing up to 70 bales

Production up to 750 kgs/hr
Machine sequence in Rieter Blow room line:

Unifloc (A11) (BDT)

Uniclean (B11) (CLP)

Unimix (B70) (MXU)

Uniflex (B60) (CLC3)

Chute

Cleaning machine:
Modern machine,
 Step cleaner
 Dual roller cleaner
 Monocylinder cleaner
 The RN cleaner for Trutzschler
 ER cleaner for Reiter

Scutcher machine:
Scutcher machine is the last m/c of the blow room line. It is used to form
lap.
Object of Scutcher machine.
1. To produce a uniform lap.
2. To open the cotton fiber further to the smallest tuft size.
3. To extract the remaining trash in the cotton as for as possible.
 CARDING
Carding is the process in which sliver is formed from lap by carding m/c. Carding
may be defined as the reduction of an entangled mass of fibers to a filmy web working two
closely spaced, relatively moving surface clothed with sharp wire points. The carding is the
heart of the spinning mill.

Picture of Carding machine

Object of carding:
1. Opening to individual fibres:
The blow room only opens the raw material to flocks where as
the card opens it to the stage of individual fibres.
2. Elimination of impurities and dust:
Elimination of foreign matter occurs mainly licker-in or taker-
in region. The card also removes a large proportion of micro-particles.
3. Elimination of short fibres:
Short fibres can only be eliminated if they are pressed into the
wire points.
4. Disentangling of neps:
The card reduces the number of neps from the Blow room.
Actually neps are not eliminated at the card, intact they are mostly opened out.
5. Fibre blending:
Intimate fibre with fiber mixing is achieved in carding.
6. Fibre orientation:
The card is often attributed effect of parallelizing.
7. Sliver formation:
Sliver is formed in carding as an intermediate product.
Generally, the card sliver hank lies between 4 ktex to 5.5 kilotex. From the above
discussion, it is cleared that carding is called the “Heart of spinning”.
Different action in carding:
1. Carding action:
When two close surfaces 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:
 it is occurred between flats and cylinder.
 Maximum individualization of fibers is achieved in this region.
 Naps short fibers dirt and dust are removed by this action.
 There always should be point against point action.

2. Stripping action:
When two close surfaces have same wire direction and their speed direction or
relative motion is opposite then the action between two surfaces is called stripping action.

Object:
 It is occurred between licker in and cylinder.
 There are should be point against back action.
 Individualization of fibre is also by this action.

3. Doffing action:
When two close surfaces have opposite wire direction and their speed direction
or relative mot6ion is also opposite then the action between two is called doffing action

Object:
 It is occurred between cylinder and doffer.
 Web formation is accrued by this action.
 There always should be point against point action.
 Draw Frame
Drawing:
Drawing is a process of yarn manufacturing in which the sliver is
elongated when passing through pairs of rollers, each pair faster than the previous
one.

Picture of Draw frame machine

Objects of drawing:
 To straighten the fibers in the slivers.
 To make them lie is a parallel to their neighbors and to the
sliver axis.
 To improve the uniformity and evenness of the slivers.
 To reduce weight per unit length of sliver.
 To remove dust from sliver
 To make perfect blending of the sliver.
 To reduce irregulations of fiber by doubling and drafting.

Necessity of draw frame:

To parallisation of fiber and blending carded-carded sliver. In carded sliver, fiber
present in hook form i.e. trailing hooks and leading hooks.

Tasks of draw frame:

Equalizing

Parallelizing

Blending

Dust removal

Actions involved in draw frame:

1. Drafting:
The process of attenuating or increasing length per unit weight of sliver.
It is mainly due to peripheral speed the rollers.
 2. Doubling:
The process of combing two or more carded sliver into a single form is
called doubling. In generally six slivers are fed and converted into one i.e. six
doubling.
3. Drawing:
In the cotton industry, the term is applied exclusively to processing on
the draw frame, where he operational is one of doubling and drafting.

Drawing = Drafting + Doubling

Draw frame is carried out by two processes. One is called breaker draw frame and another
is finisher draw frame. In breaker draw frame, 8 or 6 doubling is done. In finisher draw
frame finer sliver is produced.

.THE END.