Annexure: Basic conversion charts

395

Production program ring spinning

Assuming that the installed capacity of the spinning mill is 12,000 spindles
comprising of 10 Ring Spinning Frames (1200 spindles/machine), the daily
production will depend upon the production program.

Process parameters for production balancing

S. No. Department Process Parameters

1 Ring Frame Count – 40s

Spindle speed – 18,00 rpm
Machine Efficiency – 93.5%
TM – 4.35
TPI – 27.51
Waste – 2%

2 Speed Frame Hank – 1.2

Spindle speed – 1100 rpm
Machine Efficiency – 85%
TM – 1.25
TPI – 1.37
Waste – 1%

3 Finisher Draw frame Hank – 0.13

Delivery speed – 350 mpm
Machine efficiency – 80%
Waste % – 0.5%

4 Breaker Draw frame Hank – 0.13

Delivery speed – 500 mpm
Machine efficiency – 80%
Waste % – 0.5%

5 Carding Hank – 0.13

Delivery speed – 130 mpm
Machine efficiency – 90%
Waste % – 7%

6 Blow room Diameter of Lap Roller – 9”

Speed of Lap Roller – 15 rpm
Linear density of Lap – 400 g/m,
Lap length – 40 m
Efficiency – 85 %
Hank of Lap – 0.0015

© 2016 by Woodhead Publishing India Pvt. Ltd.

 396 Process control and yarn quality in spinning

Ring frame
Ring frame production / spindle/8 hrs
7.2 × Spindle speed ( rpm ) × Machine efficiency ( % )
=
Count × TPI × 100
7.2 × 18000 × 93.5
=
40 × 27.51 × 100
= 110 g / spindle / 8 h × No. of spindles
= 110 × 12000
Ring frame Actual Production = 1320 kg / 10 machines
Actual production
Ring frame (Required Input) =
(100 – std waste% ) /100
1320
=
(100 – 2 ) /100
= 1347 kgs

Simplex frames
On the basis of the foregoing assumptions, the number of Simplex frames
required to supply roving to be ring shed are calculated as follows:
7.2 × Spindle speed ( rpm ) × Machine efficiency ( % )
Speed frame production / spindle / 8 hours =
Count × TPI × 100000

7.2 × 1100 × 85
=
1.2 × 1.37 × 100
= 4.09 kg / spindle / 8 hours × No. of spindles
= 4.09 × 120
Speed frame Actual Production = 490.8 kgs/machine
Ring frame input required
No. of Speed frame required =
Speed frame production

= 1347 / 490.8
= 2.74 ∞ 3 machines
Total speed frame production = 490.8 × no. of machines
= 490.8 × 3
= 1472.4 kg / 3 machines

© 2016 by Woodhead Publishing India Pvt. Ltd.

 Annexure: Basic conversion charts 397

Actual production
Speed frame (Required Input) =
(100 – std waste% ) /100
1472.4
=
(100 – 1) /100
= 1487.27 kg

Finisher draw frame

Draw frame production /delivery/8 hrs
0.2835 × delivery speed ( mpm ) × m / c efficiency ( % )
=
Sliver hank × 100
0.2835 × 350 × 80
=
0.13 × 100
= 610.6 kg / delivery / 8 hrs
Draw frame Actual Production = 610.6 kgs / machine
Speed frame input required
No. of Speed frame required =
Draw frame production
= 1487.27 / 610.6
= 2.43 ∞ 3 machines
Total speed frame production = 610.6 × no. of machines
= 610.6 × 3
= 1831.8 kgs / 3 machines
Actual production
Finisher draw frame (Required Input) =
(100 – std waste% ) /100
1831.8
=
(100 – 0.5) /100
= 1840.95 kg

Breaker draw frame

Draw frame production /delivery/8 hrs
0.2835 × delivery speed ( mpm ) × m / c efficiency ( % )
=
Sliver hank × 100
0.2835 × 500 × 80
=
0.13 × 100
= 872.3 kg / delivery/8 hours × no. of deliveries
= 872.3 × 2

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 398 Process control and yarn quality in spinning

Breaker Draw frame Actual Production = 1744.6 kg / machine

Finisher Draw frame Input required
No. of Breaker Draw frame required =
Breaker Draw frame production
= 1840.95 / 1744.6
= 1.05 ∞ 1 machines
Total Breaker Draw frame production = 1840.95 kg / machine
Actual production
Breaker draw frame (Required Input) =
(100 – std waste% ) /100
1840.95
=
(100 – 0.5)/100
= 1850.15 kgs

Cards
Card production / spindle/8 hrs
0.2835 × delivery speed ( mpm ) × m / c efficiency ( % )
=
Sliver hank × 100
0.2835 × 130 × 90
=
0.13 × 100
= 255 kg / card / 8 hours
Breaker Draw frame Input required
No. of card required =
Card production
= 1850.15 / 255
= 7.25 ∞ 7 machines (2 machine cushioning = 9
machines)
Total card production = 255 × no. of machines
= 255 × 7
= 1785 kg / 7 machines
Actual production
Card (Required Input) =
(100 – std waste% ) /100
1785
=
(100 – 7 ) /100
= 1919.3 kg

© 2016 by Woodhead Publishing India Pvt. Ltd.

 Annexure: Basic conversion charts 399

Usually 2 extra cards will be installed to add flexibility to the carding

process and take care of stoppage of any card for replacement of old wire.

Blowroom
Daily production required from Blow Room Line @ 7 % waste at the carding
stage is 1919.3 kg Production required per hour = 240 kg/h
If Chute Feed System is not provided, number of scutchers required is
calculated as follows:
Production/scutchers/8 hrs (kg)
0.2835 × delivery speed ( mpm ) × m / c efficiency ( % )
=
Lap hank × 100
0.2835 × ( 3.14 × 9” × 0.0254 × 15 ) × 85
=
0.0015 × 100
= 1730 kg / scutchers
Card required input
No. of scutchers required =
Blow room production
= 1919.3 / 1730
= 1.1 ∞ 1 scutcher
Total blow room production/day = 1730 × no. of scutchers × no. of shifts
= 1730 × 1.1 × 3
= 5709 kg / day

Cotton required
The quantity of cotton required per day can be calculated is shown:
Cotton required per day @ 3 % waste in Blow Room = 5709 × 1.03
= 5880.27 kg
Number of cotton bales required (170 kg each) = 5880.27 / 170
= 35 bales / day

Summary
Process wise number of machines calculated above for achieving production
balance is summarized below:

© 2016 by Woodhead Publishing India Pvt. Ltd.

 400 Process control and yarn quality in spinning

1. Ring Spinning Economic Unit = 12,000 spindles, 10 Ring Spinning

Frames, 1200 spindles each
2. Simplex Frames = 3 Roving Frames, 120 spindles each
3. Finisher Drawing Frames = 3machines (single delivery)
4. Breaker Draw frame = 2 (twin delivery)
5. Carding Machines = 9 machines
6. Blow Room = 2 scutcher line

© 2016 by Woodhead Publishing India Pvt. Ltd.