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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

Ring frame (Required Input)

= 1320 kg / 10 machines Actual production

= (

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:

Speed frame production / spindle /8 hours

=

7.2

×

Spindle speed (rpm)

× Machine efficiency (%)

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

No. of Speed frame required

Total speed frame production

= Ring frame input required

Speed frame production

= 1347 / 490.8

= 2.74 ∞ 3 machines

= 490.8 × no. of machines

= 490.8 × 3

= 1472.4 kg / 3 machines

© 2016 by Woodhead Publishing India Pvt. Ltd.

Speed frame (Required Input)

Annexure: Basic conversion charts

Actual production

= (

)

100 – std waste% /100

1472.4

= (

)

100 – 1 /100

= 1487.27 kg

Finisher draw frame

Draw frame production /delivery/8 hrs

397

 

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

= 610.6 × no. of machines

= 610.6 × 3

= 1831.8 kgs / 3 machines Actual production

Total speed frame 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

 

© 2016 by Woodhead Publishing India Pvt. Ltd.

398 Process control and yarn quality in spinning

Breaker Draw frame Actual Production = 1744.6 kg / machine

No. of Breaker Draw frame required

= Finisher Draw frame Input 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

No. of card required

Total card production

= Breaker Draw frame Input required

Card production

= 1850.15 / 255

= 7.25 ∞ 7 machines (2 machine cushioning = 9 machines)

= 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

= 1730 kg / scutchers

No. of scutchers required

×

100

=

Card required input

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

Number of cotton bales required (170 kg each)

= 5880.27 kg

= 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.