Govt.

College of Technology
SWAT
Project Training Report
KAWSAR Engineering(PVT) LTD,
B-Tech (Electrical)
Supervisory Training Program
Session 2013-2017
Affiliated With

University of Engineering and Technology,

Peshawar.
Submitted by:
IJAZ UL HAQ
B-Tech Electrical
4th year
Roll no- 1312
Training duration: 6 months
 PREFACE

This report has been created keeping in view the academic

needs and learning capabilities of the students of Electrical
engineering. . It is even to regulate every field of life and
every field of engineering is incomplete without studying
it. This thesis explains the in depth detail of my research
and internship training, during at KAWSAR Engineering
(PVT) LTD Peshawar . The fields of study covers during
this training are Operational Maintenance,Protection and
Instrumentation (relays and protection system).
 CONTENTS

SERIAL NO. TOPIC PAGE NO.

1. Introduction 3
2. Rehman cotton mill classification
3. Introduction of rehman cotton parts
4. To be continued
Introduction
.3

INTRODUCTION
In 1950s late Khan Abdul Rahman Khan established a spinning
unit at Takht-I-Bhai (Mardan). The name of this unit was Yousaf Zai
industry. Late Khan had no experience to run a textile mill, so as a
result it became bankrupt. In late sixties this sick unit was
purchased by one of the well-known industrialist of North West
Frontier Province late. Lt. Gen (Retd) Habibullah Khan Khattak.
Later on the name of this mill was changed and it has been known
as Rahman Cotton Mills. From 1973 to 1975 this unit was run by a
team of experts from Faisalabad. Later on some of the members of
this team resigned. In result mills profitability tend to decrease year
by year.

In 1984, the Executive Director Technical Muhammad Ismail Khurram

recalled the same team. A hardworking manager named Alam Din Niazi
supervised the technical team. When this manager took the charge the
condition of the mill was very poor but with passage of time it improved the
production as well as quality of the yarn with the hard working of the team.
Upto 1990 the company had the old machinery of 1960 model but later on this
machinery was changed with the new machinery of China, France and Italy.
Now most of the machinery is new and as a result of this change there is an
increase in the production as well as quality. Now this unit is producing
supper fine count of yarn. The technical staff has been working since 1984.

ORGANIZATIONAL CHART

Rahman Cotton Mills Limited

Takht- Bhai (Mardan)
Organizational chart
Chairman

Chief executive

Executive director
(tech) Chief financial officer
 Finance department
Production department Admin department

THE PRODUCTION PROCESS:

During this process fiber is converted into yarn, it may be natural fibers such
as cotton or man made fibers such as polyester. Importance of spinning in the
make up of the finished garment cannot be elaborated enough due to the fact
that all the later stages of value addition i.e. weaving, processing and stitching
are dependent upon the outcome of the entire value chain till the substandard
stitched garments

Following steps are taken while converting fiber into yarn.

BLOW ROOM OPERATIONS:

In the first step of spinning, cotton is converted into laps. Cotton

bales are opened up and fed in to flakers, which open up the cotton
fiber through tearing action. From here it is sent to blow room,
different lots of opened up cotton are mixes to achieve
homogeneity and then passes through different stages of blow
room and thrashing to remove trash and open it up further (usually,
eight stages are used), if required, blending of fibers is also carried
out in the blow room. In the end we get straightened layers of
cotton wrapped in the form of rolls called laps. In chute feed system
laps formation is eliminated and clean and bended cotton fibers
passes directly to the carding machine by pneumatic controls.

CARDING:

The laps from blow room are fed in to the carding machines to get uniform
slivers, which are in the form of loss continuous stands of cotton staple.
Another purpose of carding is to further clean the impurities that are left
during the blow room operations. Some short fibers and any other foreign
matters are also removed in the process. The slivers are kept in especially
made lightweight drums. Slivers from carding section can go either to finisher
drawing through breakers drawing or through uni-lap / comber to finisher
drawing.
 DRAWING:

Purpose of drawing is to straight the fibers and removes any curls.

This take place by passing the livers through different sets of rollers
that are revolving at different speeds. The speed of the rollers
increase as the sliver moves from one stage to the next. The
progressive attenuation reduces the size and weight of single
slivers. The final sliver has been fed. The final sliver that comes out
of drawing is of the same weight and size as the number of slivers,
which are fed, compensating for the attenuation of the individual
slivers. In the drawing section, it is first passed through breaker
drawing process to mix sliver from different laps, again to achieve
homogeneity. The same process is repeated at the finisher drawing
stage.

COMBING:

Combing is a process that is usually required for production of high

value added yarns. This process serves three important purposes.

Firstly, it separates the short fibers from the long fibers;

Secondly, it straightens the fibers, and

Thirdly, it removes any foreign matters and neps. (NEP is a small

knot of entangled fibers which in case of cotton usually comprises
of dead or immature cotton hairs) the resulting product is a smooth
more uniform and stronger yarn. For combing sliver from the
carding, it is passed through pre-comber drawing and then through

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 Internship Report on Rahman Cotton Mills Limited

the uni-lap to get smaller lap of cotton. These laps are then fed to
combers to get sliver, which has 14 % to 18 % of shorter staples
removed from it.

ROVING:

Slivers from the drawing stage are passed to the roving frame. The
purpose is to further reduce the size of the sliver and to impart a
little twist to enable it to withstand the tension in the ring spinning
frame. The product from this operation is also called roving and is
spun around big sized bobbins.

RING SPINNING:

Ring spinning is the stage from which yarn is obtained in its proper
count and twist. Four actions take place in this stage.

First is roving delivery.

Second is drafting that is the process in which the liner density of

the roving is decreased by controlling the surface speed of the input
and output machine components.

Thirdly, twist insertion in to yarn and final action is winding. All

these operations take place continuously in a relative order.
Product of ring spinning is the yarn of given; twist type (S or Z) draft
and (TPI) twist per inch.

CONE WINDING:

Yarn from ring frames is the input for cone winding machine. Here
yarn is wound on cones, which is the final product to be sold in the

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 Internship Report on Rahman Cotton Mills Limited

market. If 2-Ply yarn is a needed cone from this section are taken to
double winding machine with twist two single yarn standards to give
2- Ply yarn on cones.

CONDITIONING:

Before packing in polyethylene bags, conditioning is done by

storing the cones in a controlled moisture environment for 24 hours.

This allows the yarn to absorb moisture to a certain level that is

necessary for keeping its strength.

Production staff is totally concerned with the quantity of the yarn.

Maintenance staff is responsible for repair and maintenance of the
machinery;

The most important staff of production department is quality staff.

They are only responsible for the best quality of the yarn.

The production department is further divided in to two departments:

Production

Technical

PACKING:

After the cones are made, then they are transferred to the last
department called "PACKING".

In this department first of all, all of the cones of the different counts
are segregated on the basis of their different colors. Then cones
are weighted and then they are transferred for packing. Then the

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Internship Report on Rahman Cotton Mills Limited
 cones are packed into plastic bags or into the polythene bags. More labor is
required and work there as compare to any step of the packing.

In the next step these packed cones are placed into big corrugated boxes or simply called
carton boxes. Then they again packed into another big "polypro line" bags. These are the
big hard plastic bags like we have seen in market where flour is packed in those bags. This
step-by-step packing, weighting and care are made in order to ensure the safety of the yarn
and the protection of the yarn, from the weather, transportation, and from other conditions
which harm the quality of the yarn.

CHAPTER

Power house of rehmano cotton mill

Generators
Total generators are 6

1 model 3515A
Mninimum rating 1750kv

Maximum rating 2500kv

Frequency 50hz

Speed 1500rpm

Voltage 220 to 13800

 2. Model3516c

Minium rating 1650ekw

Maximum rating 2500ekw

Frequeny 60hz

Voltage 220 t0 13800

Speed 1800 rpm

All generator used gas as fuel

 Transformers
Two transformers of 2500 kva

2500 kv transformer