Industrial Attachment of Zubair spinning mill
Introducing & Overview the Report
Textile spinning and weaving is one of the oldest reflections of human ingenuity and cotton yarn is the great significance for the textile industry. With progress of civilization, the demand of cotton yarn, not only increased in terms of quantity also flourished in many splendor varieties. In recent yarn years fabrics exports based on cotton yarn have earn the most foreign currency for the nation. The government of most yarn producing countries as well as Bangladesh also heavily involved in yarn production marketing and formulate a textile policy with a view to attain eventual self-sufficiency in textile and clothing, because socio economic and strategic importance. Textile Engineering is a vast practical oriented subject and as its engineering; some sort of engineering must be pushed here. Actually the textile engineers, unless get any chance for the thrive of engineering, will just go fade. So practical implication is very essential for any textile person, engineer or student. It is beyond saying that textile industry is the heart of Bangladesh economy and industries are run by successful, skilled engineers. They are again the heart of any textile company. To gather this skill, practical involvement is very urgent, even from the student life.
Textile technology education is based on industrial back ground. Theoretical background is not so important. By industrial training we can achieve vast knowledge about practical knowledge. So industrial training is a very essential part of our study to make us technically strength.
Daffodil International University is serving the nation with her education, building successful engineers. At the same time, arranging an industrial attachment for each batch to different industries, this Varsity is contributing to increase the know-how of the students.
Industrial training as offered by the University is very useful which gives the directions and ideas about the production, manufacturing, capacity, power etc. of a certain mill and with these ideas getting adopted, a student can flourish his debut in the engineering field.
Zubair spinning mills ltd is on the thirst strategic business units of the company. Zubair spinning with its 72576 spindles is one of the modern spinning mills of the country. It equipped with the most modern machines and equipments, this unit is creating to export oriented Spinning factories of the country.
A rational behind the existing structure & future expansion of the textile division is to capture value added at each stage of textile manufacturing process. Inspire Bangladesh’s lack of producing of Export Quality Yarn Zubair spinning mills Ltd tries to produces export Quality of yarn. Zubair Spinning Mills Ltd keeps Export competitiveness to maximum level.
Site plan
The factory plant of Zubair Spinning Mills Ltd was setup to Gilarchala, Masterbari, Sreepur at Gazipur, near about Maona and beside the link road which connected with the Dhaka-Mymensing high way on about 64 bigha of land. It has covered the floor space of total about 3, 50,000SFT (Factory, Raw Cotton & Finished Godown).The Factory is the one storied building. Factory is a biggest project of Noman group. Zubair Spinning Mills Ltd is the new bright baby of the textile sector of Bangladesh. The project went into commercial operation from 15th July 2008. All plant is acquitted with modern machineries these are imported from Japan, Germany, china and Switzerland.
Background of Noman Group
Noman group is a family business which was established in the year of 1986 by Md. Nurul Islam. The business initially stated as Garments Manufacturing Unit on its own premises which is also currently the corporate office. The vision of the management gradually turned into a reality with the formation of the member units marketing a growth pattern of the group.
1. Company of Noman Group
2. Zubair Spinning Mills Ltd
3. Sufia Cotton Mills Ltd
4. Talha Spinning Mills Ltd
5. Yasmin Spinning Mills Ltd
6. Zaber Spinning Mills Ltd
7. Noman Spinning Mills Ltd
8. Ismail Rotor Spinning Mills Ltd
9. Yasmin Textiles Mills Ltd
10. Nice Denim Mills Ltd
11. Ismail Textile Mills Ltd
12. Zaber Textile Mills Ltd
13. Noman Textile Mills Ltd
14. Noman Home Textile Mills Ltd
15. Noman Weaving Mills Ltd
16. Noman Terry Towel Mills Ltd
17. SaadSaan Textile Mills Ltd
18. Talha Fabrics Ltd
19. Zarba Textile Mills Ltd
20. ZaberZubair Fabric
To uphold social commitment at highest level and for achieving expected Quality production of exported garments, the board of Director has decided to establish a 100% export oriented cotton spinning mills to turn the group as composite knit project in true sense.
Keeping the above in view this good management has started Zubair Spinning Mills Limited with 72576 spindles to get 25000kgs production per day. The total investment is about USD 24 Million. The produced yarn will be consumed by sister concern.
Company Profile
Name of the Company : Zubair spinning mills Ltd (ZuSML)
Chairman : Md. Nurul Islam
General Manager : Engr.AbdusSamad
Type: Spinning mill
Head Office:
Adamjee Court (4th Floor)
115-120 Motijheel C/A
Dhaka-1000.
Factory:
Gillarchala,
Sreepur, Gazipur.
Sponsor:
Noman Group.
Mill at a glance
Commercial production: 15th July 2008
Business line : Manufacturing and Marketing of Cotton Yarn
Nature of the Company: Private Limited Company.
Number of spindles installed (Ring Section):
1008*72 = 72576 [Here 72 Ring Frame machine and each machine with 1008 spindles]
Number of Spindle installed (Rotor section):
130*6= 1560 [Here 6 Ring Frame machine and each machine with 130 spindles]
Product Mix: Ring Yarn:
Carded Yarn
Combed Yarn: Rotor/OE yarn
Majority wastage (short fiber) and cotton fiber.
Count Range: Ring Yarn
40 – 100 Ne: Rotor/OE yarn
07s~30s OE
Production Capacity: 30 ton/day
Production capacity Achievement: 85%
Different Department:
1. Production Department.
2. Quality Control and Assurance Department.
3. Maintenance Department.
4. Utility Department
5. Store Department
6. Power Generation Department
7. Workshop Department
8. Administration Department
9. Medical Department
10. Security Department
Raw Cotton use in Zubair Spinning Mills
CIS (Uzbekistan, Tazakistan)
Memphis (USA)
Shankar (India)
Upland
MCU-5
Pakistani (Pakistan)
Cameron
Product customer
Jaber&Jubair Fabrics Limited
Nice denim Ltd.
Fariha Knit Tex Ltd.
Yasmin textile Mills Ltd
Noman Home Textile Mills Ltd.
Noman Weaving Mills Ltd.
Epyllion Knitex Ltd.
SaadSaan Textile Mills Ltd
Talha Fabrics Ltd.
Noman Terry Towel Mills Limited.
Physical Infrastructure:
Zubair Spinning Mills Ltd is organized into three major parts-Factory, Sales & Production Department, and Finance & Accounts Department of which the factory consists of five departments namely Production, Maintenance, Quality Control & Assurance, Administration and Information Technology.
Company mission
Each of Zubair Spinning Mills Ltd activities must benefit and add value to the common wealth to our society. They firmly believe that, in the final; analysis they are accountable to each of the constituents with who are interacting; namely; their employees, their customers, their follow citizens and their client. Zubair Spinning Mills is a profitable project of Noman Group of Industry. Noman Group earns a lot of foreign currency and contributes the economy of our country.
MANPOWER MANAGEMENT
Organization structure & Man power
Manpower Administration
Zubair Spinning Mill is a well Organized Company. Its management system and manpower management is completely different from other local company.
Production Department:
| Serial No. | Designation | Number of Post |
| 1 | AGM Production | 1 |
| 2 | A.P.M Production | 1 |
| 3 | Sr. Production Officer | 5 |
| 4 | Production Officer | 4 |
| 5 | Ass. Production Officer | 14 |
| 6 | Worker | 2200 |
| Total | 2228 |
Quality Control Department:
| Serial No. | Designation | Number of Post |
| 1 | Manager | 1 |
| 2 | Sr.Quality Control Officer | 1 |
| 3 | Quality Control Officer | 2 |
| 4 | Ass. Quality Control Officer | 4 |
| 5 | Lab Asstt. | 12 |
| 6 | Lab Boy | 8 |
| Total | 28 |
Maintenance Department:
| Serial No. | Designation | Number of Post |
| 1 | Manager | 1 |
| 2 | ENGINEER | 2 |
| 3 | FITER | 4 |
| 4 | HELPER | 48 |
| Total | 55 |
Administration:
| Serial No. | Designation | Number of Post |
| 1 | D.G.M (Admin) | 1 |
| 2 | Sr.Admin Officer | 1 |
| 3 | Admin Officer | 4 |
| 4 | Accounts Officer | 2 |
| 5 | Time Keeper | 5 |
| 6 | Exec. Security | 1 |
| 7 | Secu.Inspector | 4 |
| 8 | Secu.Guard | 30 |
| 9 | PC Operator | 1 |
| 10 | Admin.Asst | 1 |
| 11 | Driver | 5 |
| 12 | Forklift Operator | 3 |
| 13 | Peon | 5 |
| 14 | Swep/Gardenar | 6 |
| Total | 69 |
Medical Department:
| Serial No. | Designation | Number of Post |
| 1 | Medical Officer | 1 |
| 2 | Medical Asst. | 2 |
| 3 | Nurse | 2 |
| Total | 5 |
MIS Department:
| Serial No. | Designation | Number of Post |
| 1 | MIS Officer | 1 |
| 2 | Jr.MIS Officer | 2 |
| Total | 3 |
Utility Department:
| Designation | Number of Post | |
| Manager | 1 | |
| Generator & Maintenance | Engineer | 1 |
| Asst. engineer | 1 | |
| Sub-Asst. Engineer | 7 | |
| Electrical | Engineer | 1 |
| Sub-Asst. Engineer | 5 | |
| Electrician | 4 | |
| Work Shop | Head Fitter | 1 |
| helper | 6 | |
| AC/Chil/Boi/EGB | Engineer | 1 |
| Fitter | 6 | |
| helper | 10 | |
| Total | 44 |
Store Department:
| Serial No. | Designation | Number of Post |
| 1 | Manager | 1 |
| 2 | Asst. Manager | 1 |
| 3 | Store Keeper | 5 |
| Total | 07 |
Responsibilities of a Production Officer:
· To collect necessary information and instruction from the previous shift officer.
· To run his shift smoothly and accurately.
· To make decisions how to operate whole production process.
· To supervise junior officer and worker.
· To check the worker setting for the process.
· To control the production process and quality parameters.
Ensure target production of each m/c with appropriate quality.
In case of m/c breakdown he has to start it as early as possible.
· To control the workers so that they can operate the m/c as per instruction.
· To ensure target production of each m/c.
· To check the rules and regulation inside the factory.
· To arrange necessary punishment for the worker if they violate discipline.
Ensure cleanliness of all m/c and floor.
· To train up the learners.
· To Checking of m/c setting, drafting zone cleaning.
· To check the proper use of waste sliver and “pneumafil” in the Blow room.
· To minimize m/c down time.
· To take necessary steps to reduce wastage.
· To check the production report.
· Checking of sticker, defective cone and package weight in finishing avoiding mixing.
· To hand over the shift with all information to the coming shift officer.
Shift Change:
· A-Shift : 6 am to 2 pm
· B-Shift : 2 pm to 10 pm
· C-Shift : 10 pm to 6 am
· General Shift : 8 am to 5 pm
Job Description of Sr. Production Officer & Production Officer:
Production monitoring of Blow room to finishing achieving target production.
· To cheek count wise and lot wise process parameter from Blow room to finishing.
· To take the charge from the outgoing shift and hand over the charge to the incoming shift.
· To control unusable wastage in every stage from Blow room to Finishing.
· To allow leave of workers & subordinate supervising staffs in systematic way.
· To supervise performance evaluation.
· To cheek attendance.
· To check Humidity of the different section.
· To control count mixing, lot mixing of sliver, roving yarn and mixing / Bale management of raw cotton.
· To charge Ring traveler as per schedule.
· To cheek count wise and lot wise process parameter from Blow room to finishing against standard value.
· To attend duties self and subordinate supervising staff and workers by minimum 15 minutes earlier.
· To charge Ring traveler as per schedule.
· To maintain doff ticket and control of doffing time in ring section.
Management philosophy
Problem solving procedure
A co-ordination meeting is held regularly with all departmental heads and floor officers are participated in this meeting. Various problems are discussed in this meeting and solutions also find out from the meeting. On the other hand internal notes are given to the departmental heads from floor officers in case of any kind of problem.
Appraisal System
In our mill we have maintained a decent appraisal system where following criteria are included:
· Leave (by record)
· Absenteeism (By record)
· Performance (by record)
· Position knowledge (by interview)
· Wastage Grade (by record)
· Work ability (by record)
Compliance
· Worker facilities
· In ZuSML mill following facilities are given to the workers.
· Annual Increment
· Annual Games and sports
· Merit scholarship for poor students
· Financial help from benevolent fund.
· Maternity leave
· Pure drinking water system
· Medical facilities
· Gratuity
· Festival Bonus and festival leave.
· Proper sanitation
· Productivity decreases for different types of problem at ZuSML
· Personal affairs/ Family affairs
Most of our workers are female and they are muscularly dominating by their husbands. Poverty is the main problem to lead their life through a superb way. They are bound to perform their household works and factory works simultaneously. So, excessive leave is required to beat their personal problems.
Habitual absent, especially at night shift
Some workers are habitually insincere to act in accordance with the service rules. At times, they remain absent from their duties without informing their section in charge. Besides, they can’t show any reasonable causes to support their non-attendance. During night shift this type of tendency increases.
Sickness
Generally, a worker takes his/her leave due to sickness. Some workers are not conscious to inform their section in charge about their sickness in due time. That’s why section officers are unable to favor them with required leave through the systematical (Official) way. Moreover, at times, section officer faces difficulties to run his section smoothly because of worker shortage.
Managerial problem
A supervisor should have the competence to inspire his subordinates and must have to be familiar with his subordinates. Otherwise, he will not be able to organize their activities. He should have the ability to provide solution at what time a worker is in distress. It is a matter of regret that some officers are incapable of scheming excessive leave and absenteeism of worker.
Faulty settings as well as gauging
A faulty setting of gear or any other parts of any machine increase the depreciation of the respective machine and deteriorates quality of the product.
Recommendation
· People should be treating fairly.
· Employee needs should be satisfied.
· Work related goal should be setting.
· Reward should be given on job performance basis.
· Increase the wages of direct worker after analysis the work-study is needed for actual working load and idle worker should be removed so that we can increase the wages.
· Motivation is needed and performance related pay is required to given. For this reason, performance should be measured accurately & carefully.
· Adequate medical facilities both doctor & medicine is required for treatment which is the part of motivation.
· Management training is required for the supervising officers.
· Ethical development is needed though proper training.
· Job design is needed for some officers & workers.
· Chain of command should be maintained. We can apply scientific management approach
PROCESS FLOWCHART AND MACHINE DESCRIPTION
Process flow Chart of Ring Spinning:
Combed yarn is more precise than card yarn. Here is the process flowchart of Combed Yarn and carded yarn. To produce Carded Yarn needs fewer steps to follow to make a yarn than the Combed yarn. The main purpose of Combed yarn manufacturing is to create a yarn which is highly finer and highly qualified and combed yarn is most precious, finer and thinner than the carded yarn.
Carding:
“Card is the heart of spinning mills” and “well carded is half spun” are two proverbs of experts. Carding maybe defined as the reduction of an entangled mass of fibers to a filmy web working between two closely spaced, relatively moving surface clothed with sharp wire points. The carding is the heart of spinning and well card is half of spun demonstrate the immense significance of carding for the final result of the spinning operation. The importance of carding is still greater where new spinning systems are concerned.
The Objective of Carding:
· The fiber to fiber separation.
· To effect a through mixing of fibers.
· Removed of trash in the lap or opened cotton in blow room process.
· Conversion of lap or opened cotton in the blow room process into sliver from suitable for further processing
Flow chart of card yarn:
Combing:
For high quality yarn, an extra process is introduced called combing. Combed sliver has a “silkier” appearance than card sliver because of the enhanced fiber alignment.
The objective of combing machine:
Combing is the process which is used to upgrade the raw material. It influences the yarn quality like yarn evenness, strength, cleanness, smoothness, visual appearance Remove short fiber.
In addition to the above, combed cotton needs less twist than a card yarn and Improve fiber orientation
Flow chart of Combed yarn:
Machine Description:
Contents:
· Brand name.
· Manufacturer.
· Number of machine.
· List of machines.
· Remarks.
Blow room: Flow Chart of Blow Room
Layout of Blow Room
Blow room
Building Space (m2) : 1020
No. of Line / Passage: Two (2)
Machine Description for Blow Room:
BLENDOMAT:
No. of machine: One
Manufacturer : GARMANY
Brand name : TRUTZSCHLER
Model No. : BOA-2300
Function : To plucking raw material and forward to next.
PRE OPENER:
No. of machine: One
Manufacturer : GARMANY
Brand name : TRUTZSCHLER
Model No. : BO-COI
Function : To remove the dust and trash particle.
SP-EM:
No. of machine: Two
Manufacturer : GARMANY
Brand name : TRUTZSCHLER
Model No. : SP-EM
Function : To mix the fiber and store.
PER-CLEANER:
No. of machine: TWO
Manufacturer : GARMANY
Brand name : TRUTZSCHLER
Model No. : CL-P
Function : It works as super cleaner.
MULTIMIXER:
No. of machine: TWO
Brand name : TRUTZCHLER
Manufacturer : GARMANY
Function : To detect fire
CLEANOMAT CLEANER:
No. of machine: TWO
Brand name : TRUTZCHLER
Manufacturer : GARMANY
Function : To detect heavy Mattel.
LOPTEX:
No. of machine: Two
Brand Name: Trutzchler
Manufacturer: Germany
Function: It sorts out the colored contamination by optical means and also detects the colorless (e.g. Poly propylene) contamination by ultrasonic means.
OPTOSONIC SORTER:
No. of machine: TWO
Manufacturer : ITALY
FOREIGN FIBER AND PP DETECTOR:
No. of machine: TWO
Manufacturer : GARMANY
Delivery System: Chute Feed System Equipment.
Accessories:
| Item Name | Qty. |
| Bale Trolley | 06 |
| Wastage Carrier Trolley | 04 |
| Bale Cutter | 05 |
| Helmet | 04 |
| Bale Cleaner | 06 |
| Spud | 04 |
Layout Plan of Back Process
| Carding m/c=24 |
| Breaker D/F=8 |
| Finisher D/F=8 |
| Lap Former=4 |
| Simplex=24 |
| Comber=17 |
Carding:
Carding machine is called The Heart of Spinning. Because the Quality of yarn fully depends on the performance of carding. It mainly removes Neps, Short fiber and also impurities. The short fiber is removed by the action of flat and Cylinder. The most important part of carding is various setting points for better performance. The small tuft turns sliver by the help of carding machine.
Area:
Carding (m2): 996 [For 24 carding machine]
Preparation (m2): 996 [For 24 carding machine]
Information:
No. of machine: 24
Model: TC-06
Manufacturer: TRUTZSCLER (GERMANY)
Manufacturing year: 2008
Efficiency: 95%
Delivery speed: 62kg/hr
Feed roller diameter: 172 mm
Feed roller speed: 17-30 rpm
Opening roller diameter: 292 mm Chute Feed System
Opening roller speed: 850 rpm
Delivery roller diameter: 156 mm
Delivery roller speed: 17-30 rpm
Feed roller diameter: 100 mm
Feed roller speed: 17-30 rpm
Licker in diameter: 253 mm
Licker in speed: 1300-1700 rpm
Cylinder diameter: 814 mm
Cylinder diameter speed: 500-900 rpm
Doffer diameter: 680 mm
Doffer speed: Depends on delivery
Stripping roller diameter: 118 mm
Stripping roller speed: Depends on delivery
Squeezing roller diameter: 80 mm
Squeezing roller speed: Depends on delivery
Cleaning roller diameter: 100 mm
Cleaning roller speed: Depends on delivery
Disc roller diameter: 72 mm
Disc roller speed: Depends on delivery
Flat speed: Depends on cylinder
No of flat: 84
Pre carding segment in licker in.
Cleaning efficiency depends on Suction hood & Knife
Gauge Setting: Feed plate to feed weight: 0.15 mm
: Feed roller to Licker in : 0.80 mm
: Licker in to Cylinder : 0.20 mm
: Cylinder to Flat : 0.225 mm
: 0.20 mm
: 0.150 mm
: Doffer to Cylinder : 0.175
: Doffer to Stripping roller : 0.15 mm
: Stripping to Squeezing : 0.175 mm
Breaker Draw Frame:
The carded sliver is feed in Breaker Draw Frame. In ZuSML 8 (eight) card sliver cans are feed in each Breaker Draw frame. The more no of doubling give more remove of irregularity. If doubling is more than draft should also more. But more draft leads more unevenness in the drawn sliver. So optimum doubling should be maintained.
Name of m/c: Breaker draw frame
Company name TOYOTA
Country of origin: JAPAN
Model no. DX-8
Manufacturing Year: 2008
No of m/c: 08
Drafting system: 4 over 3
| Top | mm |
| Front | 38 |
| Second | 38 |
| Third | 42 |
| Back | 38 |
Roller Dia:
| Bottom | mm |
| Front | 40 |
| Middle | 35 |
| Back | 35 |
Roller gauge:
Front to middle: 40 mm
Middle to back: 38 mm
Cot roller hardness: 70 Shore (comb), 80(card)
Creel roller dia: 70 mm
Quartz length: 157 mm
No of doubling: 6-8
Maximum speed: 700 m/min.
Pneumatic pressure: 140 bar (card), 120 bar (comb)
Size of Condenser: 4.6 mm (inside dia)
Type of roller: Black (comb), Gray (card)
No of sensor: Delivery sensor, can change sensor
Present of autoleveller: No
Sliver wt: 69.4 gr/yd
Power consumption: 5.65 kW
Features:
Auto doffing
Auto stop motion
Problem indicating lamp signals
More uniform sliver by doubling and drawing
Making more parallel fiber.
Finisher Draw Frame:
This machine is use both card and comb yarn. The card and comb sliver both are fed to the Finisher draw Frame. If any fault is occurred in this process it cannot be removing in further process. The main deference of finisher draw frame is auto leveler. If sliver mass variation is occurred then it tries to remove it. The auto leveler can remove only ±25% variation. The scanning roller consistently scans any unevenness in sliver and send signal to the servo motor. The result is excellent short, medium, and long term evenness.
Name of m/c: Finisher draw frame
Company name: TOYOTA
Country of origin: JAPAN
Model no. DX-8 LT
Manufacturing Year: 2008
No of m/c: 08
Drafting system: 4 over 3
Roller Dia:
| Top | Mm |
| Front | 38 |
| Second | 38 |
| Third | 42 |
| Back | 38 |
Roller gauge:
| Bottom | mm |
| Front | 40 |
| Middle | 35 |
| Back | 35 |
Front to middle: 40 mm
Middle to back: 38 mm
Cot roller hardness: 70 Shore (comb), 80 (card)
Creel roller dia: 70 mm
Quartz length: 157 mm
No of doubling: 6-8
Maximum speed: 500 m/min.
Pneumatic pressure: 140 bar (card), 120 bar (comb)
Size of Reducer: 3.5 mm (Comb), 4.2mm (Card)
Type of roller: Black (comb), Gray (card)
No. of sensor: Delivery sensor, can change sensor
Present of autoleveller: Yes
Sliver wt: 69.4 gr/yd
Power consumption: 5.78 kW
Lap former is used to produces combed yarn. In ZuSML lap former is used. Good lap are the important for satisfactory combing. In lap former slivers produces faultless lap sheet by distributing the fiber evenly the whole lap width.
No. of m/c: 04
Company: Rieter
Manufacturing Year: 2005
Country of origin: Switzerland
Model no.E-32
No. of doubling: 26 (maxm -28)
Delivery speed: 110 m/min
Drafting system: 3 over 3
Front roller dia: 39 mm
Back roller dia: 32 mm
Lap dia: 650 mm (maxm)
Delivery length: 200 mm
Lap weight: 17 kg
Lap width: 300 mm
Spool dia-200 mm
Top roller hardness: 83 shore
Power consumption: 11 kW
Comber:
Combing is process for better quality of combed yarn. To upgrading the quality of combed yarn combing process must be done. It influence the quality by-
· Extraction of short fiber in order to improve the staple diagram.
· Remove the excessive Neps which cannot remove from carding.
· More parallelization of fiber.
· Finally formation of combed sliver with necessary cohesive force.
Manufacturer: RIETER
Country of origin: Switzerland
Model: E-66
No of m/c: 17
No of head: 01
Delivery speed: 425-460 nips/min
M/C efficiency: 80-90%
Drafting system: 3 over 3
Can size 🙁 25 mm*600 mm*1200 mm)
Feed/nip: 4.7 mm
Noil: 16-17.5%
Auto stop motion: Yes
Auto doffing: Yes
Lap dia-550 mm
Lap length-230 mm
Lap weight: 79.5 gm/m
Spool dia: 200 mm
Problem indicating lamp system: Yes
Roller dia:
| Top | Front detaching R/r dia | 24.5 mm |
| Top | Back detaching R/r dia | 24.5 mm |
| Bottom | Front detaching R/r dia | 25 mm |
| Bottom | Back detaching R/r dia | 25 mm |
Draw box roller dia:
Front-35 mm
Middle-27 mm
Back-27 mm
Total draft: 9.12-25.12
Signal system: Yellow (Can change)
Roller hardness: Front-76, middle-80, back-80 (shore)
Roller gauge:
Front to middle: 41 mm
Middle to back: 44mm
Power consumption for comber: 3.79 kW
Simplex:
The finisher draw frames slivers are fed to the simplex. The sliver is extent and small amount of twist is inserted. This twist only helps to hold the fiber during winding and unwinding of roving.
Name of m/c: Simplex
Company: TAIHANG
Model no.FA-425A
Manufacturing Year: 2008
No of m/c: 24
No of creel: 4
Total creel capacity: 120
Drafting system: 4 over 4
Spindle gauge: 133 mm
Staff length: 520 mm
Auto stop motion: Yes
Problem indicating lamp system: Yes
Roller dia:
| Roller | Bottom(mm) | Top(mm) |
| Front | 28.5 | 28 |
| Second | 28.5 | 28 |
| Third | 28.5 | 25 |
| Back | 28.5 | 28 |
Roller setting:
Front to second: 37.5 mm
Second to third: 48.5 mm
Third to back: 49.5 mm
Bobbin dimension
Bobbin length-445mm
Lift length-385 mm
Shoulder angle-35
Avoiding area-100 mm
Winding margin-35 mm
Cradle type: OH 514
Apron manufacturer: Hokushin.
Spacer dimension:
| Color | Size(mm) |
| Black | 4.5 |
| White | 5.0 |
| Red | 4.5 |
Sensor used in Simplex:
Cover open sensor
Roving breakage sensor
Roving breakage in bobbin sensor
Sliver breakage sensor
Maximum rpm in ZSML: 1000
Advantages of modern Simplex:
More speed
High efficiency
Automatic tension controller
Auto Greasing System After 70 hours for 6 min
Bobbin information:
Wt.237.337 gm
Length: 44.5 cm
Outer upper dia: 4.5 cm
Outer lower dia; 6 cm
Bobbin color: Blue, orange black, white, red, brown, yellow.
Power consumption of simplex: 10.64 kW
ROVING BOBBIN DIMENSION:
| Bobbin length=44mm |
| Winding margin=35mm |
| Avoiding area=100mm |
| Lift length=385mm |
| 45° |
Layout Plan of Ring to Finishing
| Packing Area |
| Sticker zone |
Identification:
| Ring Frame=72 |
| Winding m/c=21 |
| Re Winding=01 |
Ring Frame
The roving is fed Ring Frame to produce yarn. The necessary amount of draft is also need. The twist is inserted to improve the strength. But excessive twist decreases the strength. The traveler is mainly inserted the twist. The Ring bobbins are doffed automatically.
Manufacturer: JINGWEI (Suessen, EliTErCompactset)
Country of origin: CHINA
Model no: F1520
Manufacturing Year: 2008
No of m/c: 72
No. of Spindle/machine: 1008
Spindle speed: Up to 18000 rpm
Spindle gauge: 75 mm
Lift: 7 inch
Ring cup dia: 40 mm
Spindle type: Eye type
Drafting system: 3 over 3(SKF-PK2025)
Roller dia:
| ROLLER | TOP | BOTTOM |
| Front | 28.5 mm | 27 mm |
| Middle | 28.5 mm | 27 mm |
| Back | 28.5 mm | 27 mm |
Roller gauge:
Back to middle: 51mm
Middle to front: 44mm
Apron specification:
Top-37 mm*27.8 mm*1 mm
Bottom-73 mm*30 mm*1.1 mm
Spacer color: YELLOW, RED, VIOLET
Cradle type: OH 2024
Cradle size: 36 mm
Specification of bobbin cops:
Total lift length-180 mm
Ring bobbin dia-Top-21 mm, Bottom-27 mm
Ring bore dia (38, 40) mm
Bobbin length-210 mm
Traveller specification:
Flange width-3.2 mm
Raw material-Stainless steel
Traveller clearer gauge-(2.2-2.5 mm)
Lappet specification: Bore dia: 2.5 mm
Spindle driving system: 4 types
Roller pressure:
| color | Front | Middle | Back |
| Green | 14 kg | 10 kg | 12 kg |
| Red | 18 kg | 14 kg | 16 kg |
| Black | 10 kg | 10 kg | 10 kg |
Arbar dia: 19 mm
Wharves dia-18.5 mm
Flange shape: Regular
Building system: Cop building
Creel of bobbin: Umbrella type
Bobbin colour: yellow, red, blue, green, white, ash
Weighting system: pendulum
Angle of drafting zone: 45
Count range: 24- 60 Ne
Doffing: Manual
Traveller manufacturer: KANAI (JAPAN), BRACKER (GERMANY)
Traveller no.
| Yarn count | Tr. No. | M/c speed |
| 40/1 CW | 6/0 | 18000 |
| 40/1 CW(Compact) | 7/0 | 18500 |
| 32/1 KW | 3/0 | 16500 |
| 30/1 KW | 3/0 | 15500 |
| 26/1 KW | 2/0 | 15000 |
| 50/1 CW | 7/0 | 20000 |
| 24/1 KH | 1/0 | 14500 |
Power consumption of ring section: 33 kW
Winding Section:
The autoconer machine is used to build the large package. The faulty part of yarn is cut during winding. It cuts the faulty parts of yarn and then join is done by the help of air. USTER analyzer is works here.
Name of machine: Process coner
Brand name: Muratec
Country of origin: Japan
Model no: 21C (Magazine type)
No of m/c: 21
Power consumption: 13 kW
Main Parts:
· Drum
· Pilot motor
· Suction mouth
· Retie pipe
· Cutter
· Balcon
· Cradle
· Tensor box
· Loepfy (electronic yarn clearer )
Important Parameter:
| PARAMETERS | VALUES |
| Winding Position | 60 |
| Drum Dia | 100 mm |
| Tensioning Device | Tensor box |
| Yarn Speed | 1200 ~1550m/min |
| Splicing System | Auto |
| Finished Package Wt. | 2083 gm |
| Yarn Length | Depend on count |
| Electronic Clearer | Loepfy |