Beruflich Dokumente
Kultur Dokumente
Bachelor of Science
In
Textile Engineering
2
CERTIFICATE
This Internship report, carried out and written by M Faizan Haider under the direction of
their supervisor DR. Muhammad Bilal Qadir and approved by all the members of Project
Committee of the department, has been presented to and accepted by the Chairman,
Department of Yarn Manufacturing and Dean, Faculty of Engineering & Technology in
fulfillment of the requirement of degree Bachelor of Science in Textile Engineering.
3
ACKNOWLEDGEMENT
If all of the oceans turn into ink and if all the trees turn into pens even then the praises of
ALLAH SUBHANAHU WA TA`ALA cannot be expressed.
I set my unfeigned and meek thanks before HIM, who created the universe and bestowed
the mankind with the knowledge and wisdom to search for its secrets, favored and
invigorated us with fortitude and capability to aptly complete our search work and
contribute a drop to the existing ocean of scientific knowledge. Trembling lips and wet
eyes praise for the Prophet HAZRAT MUHAMMAD (PBUH) who is forever a torch of
guidance for the entire humanity.
I feel great pleasure in acknowledgment that all credit goes to my loving and sweet parents
for their amicable attitude and love immense orison, mellifluous affection and well-
wishing prayers.
I deem it my utmost pleasure to avail myself this opportunity in recording my deep
feelings of regard and sense of gratitude to my venerated project supervisors Dr.
Muhammad Bilal Qadir National Textile University Faisalabad who in spite of busiest
schedule provided his dexterous guidance and valuable suggestions throughout this work,
even in the midst of his multifarious duties. At time I strayed into the blind alleys and it
was his beacon light that led me out of the lengthening shadows.
I am thankful to Mr. Tariq Nazir (General Manager) , Mr. Rao Naeem (Deputy
Manager) and Mr. Ahmer Abbas (Mechanical Manager) in Ibrahim Fibers limited
Faisalabad, for their help and support that enable me to do work in the Mill comfortably.
4
TABLE OF CONTENTS
1 Introduction ................................................................................................................. 11
1.1 History .................................................................................................................. 11
1.2 Organizational Structure ...................................................................................... 11
1.2.1 Textile plants................................................................................................. 11
1.3 Power Generation ................................................................................................. 12
1.4 Polyester Plant ...................................................................................................... 12
1.5 Integrated Manufacturing (CIM). ......................................................................... 12
1.6 Allied Bank .......................................................................................................... 12
1.7 Product Range ...................................................................................................... 12
1.7.1 Textile plant 1 ............................................................................................... 13
1.7.2 Total production: ........................................................................................... 13
1.8 Major Customers .................................................................................................. 13
1.9 Major Suppliers .................................................................................................... 13
1.10 Major Departments And Sections..................................................................... 13
2 Introduction ................................................................................................................. 14
2.1 Properties .............................................................................................................. 14
3 Blow Room ................................................................................................................. 15
3.1 Objectives ............................................................................................................. 15
3.1.1 Opening ......................................................................................................... 15
3.1.2 Cleaning and dust removal............................................................................ 15
3.1.3 Mixing and blending ..................................................................................... 15
3.1.4 Lap forming or even feed of material to the card ......................................... 15
3.1.5 Material issuance and mixing ....................................................................... 15
3.2 Machine Layout And Specifications .................................................................... 16
3.3 Blendomate (BDT-019-011) ................................................................................ 17
3.4 Dosing Opener (FD-S) ......................................................................................... 18
3.5 Tuft Blender (FML) ............................................................................................. 19
3.6 Weighing Scales (PWSE)..................................................................................... 19
3.7 Metal Detector (SP-EM) ...................................................................................... 19
3.8 Multi Mixer MX-U 10.......................................................................................... 20
3.9 Tufto-Mate (To-T1).............................................................................................. 21
3.10 Waste Breaker (Reusable Waste Mixing) ........................................................ 22
3.11 Condenser ......................................................................................................... 22
3.12 Filter room ........................................................................................................ 22
5
3.13 Maintenance...................................................................................................... 23
3.14 Manpower ......................................................................................................... 23
4 Card ............................................................................................................................. 24
4.1 Objectives Of Carding .......................................................................................... 24
4.2 Main Actions of Carding Machine ....................................................................... 24
4.3 Functions of The Machine.................................................................................... 24
4.4 Assembly Groups ................................................................................................. 24
4.5 Machine specifications ......................................................................................... 25
4.5.1 Dia. & speeds of different rollers .................................................................. 26
4.5.2 Card Gauges .................................................................................................. 26
4.5.3 Wire specifications........................................................................................ 27
4.6 Filter room ............................................................................................................ 27
4.7 Maintenance ......................................................................................................... 28
4.8 Manpower............................................................................................................. 28
5 Drawing....................................................................................................................... 29
5.1 Actions Involved In Draw Frame ......................................................................... 29
5.2 Tasks of Draw Frame ........................................................................................... 29
5.3 Machine Specifications ........................................................................................ 30
5.4 Process And Quality Parameters Of Product ....................................................... 31
5.5 Maintenance ......................................................................................................... 31
5.5.1 Daily.............................................................................................................. 31
5.5.2 Major parts change schedule ............................................................................. 32
5.6 Manpower............................................................................................................. 32
6 Simplex ....................................................................................................................... 33
6.1 Introduction .......................................................................................................... 33
6.2 Objective Of Roving Frame ................................................................................. 33
6.3 Defects And Its Prevention On Roving Frame..................................................... 34
6.3.1 Roving tension .............................................................................................. 34
6.3.2 Improper handling of material ...................................................................... 34
6.3.3 Improper piecing in roving ........................................................................... 34
6.3.4 Roving breakage ........................................................................................... 34
6.4 Machine Specifications ....................................................................................... 34
6.5 Process and quality parameters of product ........................................................... 36
7 RTS (Roving Transport System) ................................................................................ 37
7.1 RTS Advantages ................................................................................................... 37
6
8 Ring Spinning ............................................................................................................. 38
8.1 Objective Of Ring Frame ..................................................................................... 38
8.2 Main Parts Of Ring Frame ................................................................................... 38
8.3 Machine Description ............................................................................................ 39
8.4 Process and quality parameters of product ........................................................... 41
8.5 Maintenance ......................................................................................................... 41
8.6 Manpower............................................................................................................. 41
9 Cone Winding ............................................................................................................. 42
9.1 Objective Of Winding Process ............................................................................. 42
9.2 Importance Of Winding ....................................................................................... 42
9.3 Processed material ................................................................................................ 43
9.4 Elements of process .............................................................................................. 43
9.5 Basic diagram of winding machine. ..................................................................... 43
9.6 Machine Specifications ........................................................................................ 43
9.7 Manpower............................................................................................................. 44
10 Introduction ................................................................................................................. 45
10.1 Objectives ......................................................................................................... 45
10.1.1 Local packing ................................................................................................ 45
10.1.2 Export packing .............................................................................................. 45
10.3.1 Cartons packing .............................................................................................. 45
10.1.3 Pallets packing .............................................................................................. 46
11 CTS (Cone Transport System) .................................................................................... 46
11.1 Process Flow Description ................................................................................. 46
11.2 Automatic sack packing system ....................................................................... 47
11.3 Process flow description: .................................................................................. 47
12 Roller Cover Department ............................................................................................ 49
12.1 Grinding Machine (BERKOL BGSM) ............................................................. 49
12.2 Grinding Machine (BERKOL BG U) ............................................................... 49
12.3 Press (AP H50-H500EV).................................................................................. 50
12.4 Press (PP 125 H100) ......................................................................................... 50
12.5 Top Roller Lubricating ( BOS-01) ................................................................... 50
12.6 Lubriboy ........................................................................................................... 51
12.7 Rubber Cots Uv Treatment ............................................................................... 51
13 Introduction ................................................................................................................. 52
13.1 Objectives ......................................................................................................... 52
7
13.2 Testing Equipments .......................................................................................... 52
13.3 Uster Yarn Testers UT4 .................................................................................... 52
13.3.1 Testing methods ............................................................................................ 53
13.4 Mechanical lea strength tester .......................................................................... 54
13.5 Yarn board making machine (For Yarn Appearance) ...................................... 54
13.6 Uster Auto-sorter 3 (For count testing) ............................................................ 55
13.7 Wrapping Reel .................................................................................................. 55
14 Introduction ................................................................................................................. 56
14.1 Objective And Description Of Department ...................................................... 56
14.2 Description Of AC System ............................................................................... 56
14.3 Types Of Air Conditioning Systems ................................................................ 56
14.4 Air Conditioning Process For The Textile Industry ......................................... 56
14.5 Humidification System ..................................................................................... 57
14.6 Components Of Automotive Air Conditioning ................................................ 57
15 Introduction ................................................................................................................. 61
15.1 Objectives ......................................................................................................... 61
15.2 Components Of Compressor ............................................................................ 61
15.3 General Working Of Compressors ................................................................... 61
15.4 Compressed Air In Textile Industry ................................................................. 62
15.5 Use Of Compressed Air In Textile Mills.......................................................... 62
15.5.1 Department wise requirement ......................................................................... 62
15.6 Machine Specifications .......................................................................................... 63
15.5.1 Air intelligence system ................................................................................. 64
15.6 Air Dryers ......................................................................................................... 64
15.7 Maintenance...................................................................................................... 64
8
LIST OF FIGURES
Figure 3.1 Blow room line .................................................................................................. 16
Figure 3.2 Blendomate ........................................................................................................ 17
Figure 3.3 Dosing Opener ................................................................................................... 18
Figure 3.4 Tuft blender (FML) ........................................................................................... 19
Figure 3.5 weighing scale (PWSE) ..................................................................................... 19
Figure 3.6 Metal detector (SP-EM) .................................................................................... 20
Figure 3.7 Multi mixer (MX-U).......................................................................................... 20
Figure 3.8 Tufto mate (TO-T1) ........................................................................................... 21
Figure 3.9 Piece Breaker ..................................................................................................... 22
Figure 4.1 Carding machine TC-03 .................................................................................... 25
Figure 5.1 Drawing Department ......................................................................................... 29
Figure 6.1 Roving frame ..................................................................................................... 33
Figure 7.1 RTS parking....................................................................................................... 37
Figure 8.1 Ring machine ..................................................................................................... 38
Figure 9.1 Cone winding machine ...................................................................................... 42
Figure 9.2 Basic Working Diagram of Auto cone Winding machine................................. 43
Figure 11.1 cone transport system ...................................................................................... 46
Figure 11.2 Sack packing machine ..................................................................................... 48
Figure 13.1 Uster Tester 4 .................................................................................................. 52
Figure 13.2 Lea strength tester............................................................................................ 54
Figure 13.3 Yarn board making machine ........................................................................... 54
Figure 13.4 Wrapping wheel............................................................................................... 55
Figure 14.1 Air Washer unit ............................................................................................... 57
Figure 14.2 Water tank ....................................................................................................... 58
Figure 14.3 Dampers ........................................................................................................... 58
Figure 14.4 Rotary Air filter ............................................................................................... 59
Figure 14.5 Water pump ..................................................................................................... 59
9
LIST OF TABLES
Table 2.1 Properties of polyester and viscose ..................................................................... 14
Table 3.1. Material Issue ..................................................................................................... 16
Table 3.2 Blendomate specification .................................................................................... 17
Table 3.3 Multi mixer specification .................................................................................... 20
Table 3.4 TO-T1 Specification .......................................................................................... 21
Table 3.5Condenser Specification ...................................................................................... 22
Table 3.6 Filter room specification ..................................................................................... 22
Table 3.7 Manpower in Blow Room Department ............................................................... 23
Table 4.1 Card Specification.............................................................................................. 25
Table 4.2 Dia. & speeds of different rollers........................................................................ 26
Table 4.3 Card Gauges ........................................................................................................ 26
Table 4.4 Card Wire Specification...................................................................................... 27
Table 4.5 Filter room specification ..................................................................................... 27
Table 4.6 Manpower in Card Department .......................................................................... 28
Table 5.1 Breaker and Finisher Specification ..................................................................... 30
Table 5.2 Top Roller Specification of Breaker & finisher.................................................. 31
Table 5.3 Process and quality parameters of product ......................................................... 31
Table 5.4 Man power .......................................................................................................... 32
Table 6.1 Simplex Specification ......................................................................................... 34
Table 6.2 Process and quality parameters of product ......................................................... 36
Table 7.1 RTS Specification ............................................................................................... 37
Table 8.1 Ring Specification............................................................................................... 39
Table 8.2 Process and quality parameters of product ........................................................ 41
Table 8.3 Manpower in Ring Department .......................................................................... 41
Table 9.1 Auto Cone Specification ..................................................................................... 43
Table 9.2 Manpower in Auto Cone Department ................................................................. 44
Table 11.1 CTS Specification ............................................................................................. 46
Table 11.2 Sack packing machine ...................................................................................... 47
Table 12.1 Grinding machine specification ........................................................................ 49
Table 12.2 BERKOL BG U Specification .......................................................................... 49
Table 12.3 press specification ............................................................................................. 50
Table 12.4 PRESS PP 125 H100 specification ................................................................... 50
Table 12.5 Top roller lubricating BOS-01 Specification .................................................... 50
Table 12.6 Lubriboy Specification ..................................................................................... 51
Table 12.7 Rubber cots uv treatment Specification ............................................................ 51
10
CHAPTER 1
ORGANIZATION PROFILE
1 Introduction
1.1 History
Late Sheikh M Ibrahim founder of the Ibrahim group settled in Faisalabad. Ibrahim
Fibers Limited (the Company) is incorporated in Pakistan as a public limited company
under the Companies Ordinance, 1984 (the Ordinance) and is listed on Karachi and
Lahore Stock Exchanges in Pakistan. The principal business of the Company is
manufacture and sale of polyester staple fibre and yarn. The registered office of the
Company is located at 1-Ahmed Block, New Garden Town, Lahore. The manufacturing
units are located at Faisalabad- Sheikhpura Road, in the Province of Punjab.
The consortium of Ibrahim Leasing Limited and Ibrahim Group assumed the control of the
Allied bank in August 2004 by injecting Rs 14.2 billion into the capital of Allied bank for
acquiring 325 million additional shares.
Allied Bank Limited was the first bank to be established in Pakistan. Today, with its
existence of over 60 years, the Bank has built itself a foundation with a strong equity,
assets and deposit base. It offers universal banking services, while placing major emphasis
on retail banking. The Bank also has the largest network of over 830 online branches in
Pakistan and offers various technology-based products and services to its diverse clientele.
1. Textile Plant 1
2. Textile Plant 2
3. Textile Plant 3
4. Textile Plant 4
Textile plant 1
Constantly upgrading plant and machinery since initial operations in 1980, the
present manufacturing operations of Ibrahim Textile Plant-1 have a total installed capacity
of 54,720 spindles. The project comprises of two units located within the same premises.
Unit I has been upgraded in 2016, consists of 35,280 spindles (21 frames of 1680 spindles
each) from Saurer Zinser Germany with cone-winding of Schlafhorst, Germany.
Unit II consists of 19,440 spindles from Marzoli, Italy with cone winding of Schlafhorst
Germany.
11
Textile plant 2
Textile Plant 2 consists of 40,608 spindles and is further divided into two units:
Unit I has a capacity of 19,008 spindles and Unit II compromises of 21,600 spindles.
Textile plant 3
Textile Plant 3 compromises of 39,168 spindles and is further divided into 2 units:
Unit I consists of 19,968 spindles and Unit II consists of 19,200 spindles.
Textile plant 4
Textile plant 4 is under erection . It has a capacity of 1 lac spindles. 25000 spindles
are ready for production with the capacity of 500 bags per day.
Power generation capacity of these plants is 93.3 MW. These Plants are for the sole
objective of catering to the requirements of the company’s industrial operations for
uninterrupted and stable power supply.
Polyester Plants are based on engineering and technology supplied by Lurgi GMBH
Germany (which is a part of Air Liquide France) who are market leaders in polyester
polymer capacities supplied worldwide representing more than 50% share in the world
market. These plants are equipped with Provox plus Distributed Control System (DCS)
using SRX process controllers providing a foundation for real time, efficient and accurate
control and also monitoring of the process of entire plant through Computer
Sapphire Textiles
Nishat Textiles
Al-Karam Textiles
Arshad Corporation
Chenab Limited
Sadaqat Textiles
Crescent Textiles
Gull Ahmad Textiles
Kohinoor Textiles
13
CHAPTER 2
RAW MATERIAL
2 Introduction
Polyester and viscose are used as a raw material in TP-1. The polyester is from
Ibrahim fibers polyester plant while viscose is imported from Indonesia. Polyester is
supplied on daily basis while viscose is stored in ware house. There are 2 warehouse in
TP-1. The yarn is made by blending of polyester and viscose with the ratio of 80 : 20. For
blending these two manmade fibers , we have to check about there properties. The sample
reports are carried and then we decide the mixing plan.
2.1 Properties
There are the following properties of polyester and viscose fibers.
Length
Length uniformity
Strength
Elongation
Fineness
Color
Moisture
Table 2.1 Properties of polyester and viscose
14
CHAPTER 3
SPINNING PREPARATORY PROCESSES
3 Blow Room
3.1 Objectives
3.1.1 Opening
Opening is the leading operation in the spinning process. It is compulsory in order
to execute all the other processes stages. The aim is always a high amount of openness of
the material with a gentle handling and fiber damage as small as possible. Higher the
degree of opening, higher will be the cleaning. A very high cleaning effect is almost
always purchased at the cost of a high fiber loss. Higher roller speeds give a better
cleaning effect but also more stress on the fibre.
Dust removal is not an easy operation, since the dust particles are completely enclosed
within the flocks and hence are held back during suction (because the surrounding fibers
act as a filter). It is mainly the suction units that remove dust and removal will be more
intensive the smaller the tufts.
15
which results from the combination of a variety of raw materials. Polyester and Viscose
are manmade fibers. The following parameters vary very much between bales.
• Fiber micronaire
• Fiber length
• Fiber strength
• Fiber color
• Fiber maturity
There are 2 blow room lines in Ibrahim TP-1. Mixing is planned in such a way that all the
bales should be consumed evenly from each lot and there should not be any occurrence of
shade variation in the yarn throughout the year. For mixing we have to see the +b value of
bales.
When a lot finishes and a new lot is required in mixing, we have to use the very next lot
whose +b value is almost same as that of +b value of previously working lot. This is the
basic principle of mixing.
AS-2 AS-1
PWSE-4 PWSE-4
PWSE-3 PWSE-3
PWSE-2 PWSE-2
PWSE-1 PWSE-1
FML-2 FML-1
WASTE ROOM
SPEM-22 SPEM-21
MPM 10/1600 MSL-47 MSL-37 MSL-42 MSL-32 MSL-40 MSL-30 MPM 10/1600
POLYESTER
VISCOSE
Fourth row cards 3rd row cards 1st row cards 2nd row cards
FOR POLYESTER
The bales are plucked off to the height set by the control system, when the bales are being
worked off on the right-hand and left-hand side of the machine; it is possible to switch to
the other working area the pivot drive in the turret then rotates the detacher 180 degree
around the vertical axis. Bale opening continues without the machine corning to a
standstill.
Attribute Specification
Total length 25.5 meter
Working Length 23 meter
Traverse speed 16 rpm/m
Production Up to 1500 kg/hr.
Up and Downward Movement 1800 mm
No. of Beater 2
Beater Speed 1400 rpm
No. of Bales Used 38
Continuous power consumption 4KW
Suction air rate min. 5,500 m3/h
Depending on the travel direction of the machine, the opposed opening rolls are lifted,
thus allowing the teeth to work once in and once opposite the travel direction of the
machine. This results in consistent tuft sizes and uniform production distribution between
the rolls.
17
The large working width of the Blendomate of 17,200 mm or 23,000 mm allows lay-down
of up to 150 or 200 and more bales (machine length of 50 m). The Blendomate BO-U can
selectively process bales on one or both sides of the track.
The Extra Precision Weighing Feeder BL-EW is used for low blending ratios. For very
small lots or very low production rates, the Component Balance BL-CB is the most
economical solution. It is also suited for pre-blending.
18
3.5 Tuft Blender (FML)
The tuft size of raw material is reduced in it. One beater is used for the opening purpose.
Speed of beater is about 550 rpm. 7.5 bar pressure is used.
Attributes Specifications
Manufacturer Trutzschler
Total no of machines 2
Model 2004
Production capacity Up to 800 kg/hr.
Machine Width 2.2 m
Machine Length 5.3 m
20
Machine Height 3.7 m
No. of Chambers 10
Compressed Air Consumption 300 pa
Delivery roll/chamber 2
Opening roll/chamber 1
Delivery Roll Speed 672 rpm
Opening Roll Speed 650 rpm
Air Pressure 7 Bar
Trunk Filling Time 3 min
Attribute Value
Opening Roller Speed 680 rpm
FD-O Roll Speed 655 rpm
Fan Speed 2200 rpm
Dust Cage Speed 141 rpm
Suction Pressure 350 Pa
Gauge feed roller to beater 3.5mm
21
3.10 Waste Breaker (Reusable Waste Mixing)
Reusable waste is fed in it. It is directly attached with the scale and scale takes the
material from it according to the blending requirement. It has inclined lattice and evener
lattice. The gauge between them is 10mm.
3.11 Condenser
Table 3.5Condenser Specification
Manufacturer Trutzchler
Maximum Production 1800 kg/hr.
Compressed air requirement 7 bar
Cage dia 490 mm
Fan dia 410 mm
Fan speed 2480 rpm/2930 rpm
Fan motor power 5.5kw/7.5kw
Stripper roller dia 298 mm
Stripper roll speed 438 rpm
No. of fan blades 8
Manufacturer LUWA
Type Rotary
Model No IE1
Air volume handled 140000 m3/Hr.
Air change/Hr. 16.0
Motor 45 KW
Rated output of gear motor, 0.75 KW
Pre filter dia 2200 mm
22
Rpm 10-16
Pre filter cloth mesh 80 mesh/inch
3.13 Maintenance
Preventive Maintenance is done in blow room. Blow room machines work 23
hours in a day a 1 hours/day reserved for a daily maintenance.
In daily maintenance
There is also the maintenance of one machine daily except Friday and Sunday. In that
maintenance the greasing of Barings, inspection of gear box, belt tensions are check.
3.14 Manpower
Table 3.7 Manpower in Blow Room Department
Designation Strength
Foreman 1
Head fitter 1
Fitter 1
Assistant fitter 2
Total 5
Manpower production for 1 shift
Designation Strength
Supervisor 1
Operator 3
Assistant Supervisor 1
Total 5
23
4 Card
Carding is a mechanical process that breaks up locks and unorganized clumps of
fiber and then aligns the individual fibers so that they are more or less parallel with each
other. Carding is one of the most important operations in the spinning process as it directly
determines the final features of the yarn, above all as far as the content of Neps are
concerned.
Manufacturer Trutzschler
Model TC-03
Year 2004
Maximum speed 400 m/min
Maximum production 150 kg/hr.
Total no of cards 36
Waste % 2.2 %
Fly waste 1%
Taker in waste 0.2 %
Efficiency 97 %
Can size 1000mm dia & 1200mm height
Can capacity 10000m
Sliver weight 62 gr/yd. , 65 gr/yd.
Delivery speed 65 m/min , 125 m/min
Production speed 17 kg/hr. , 34 kg/hr.
Installed load Motor 19 KW
No. of motors 16
25
4.5.1 Dia. & speeds of different rollers
Table 4.2 Dia. & speeds of different rollers
Back 14/1000
9 taker in side 1 mm
Cylinder and Under casing Center 1.5 mm
Doffer side 3.5 mm
10 Cylinder and doffer 7/1000
11 Doffer and stripping roller 7/1000
26
4.5.3 Wire specifications
Table 4.4 Card Wire Specification
Taker in wire
PPSI (Points per square inch) of R1 34
Height 5-6 mm
Angle for R1,R2,R3 20o
PPSI (Points per square inch) of R2 164
PPSI (Points per square inch) of R3 210
Taker in wire life 1200 ton
Cylinder wire
PPSI (Points per square inch) 727
Height 4 - 5.5 mm
Thickness 0.40 mm
Angle 30o
Cylinder wire life 1200 ton
Doffer wire
PPSI (Points per square inch) 504
Height 4 – 5.5 mm
Thickness 0.90 mm
Angle 30o
Doffer wire life 1200 ton
Top set
PPSI (Points per square inch) 510
Total flats 84
Working flats 28
Top set life 600 ton
Stationary flats 26
Stationary flats life 400 ton
Manufacturer LUWA
Type Rotary type
Model No 2004
Airflow rate 220000 m3/hr.
Air change/Hr 18.0
Motor 110 KW
Rated output of gear motor, 0.75 KW
Pre filter dia 81 inch
Rpm 10-16 rpm
Pre filter cloth mesh 80 mesh/inch
27
4.7 Maintenance
Preventive Maintenance is done in blow room. Blow room machines work 23
hours in a day a 1 hours/day reserved for a daily maintenance. Cleaning is done daily for
one hour.
There is also the maintenance of one machine daily except Friday. In that maintenance, the
one machine is opened and the wires point, greasing of Barings is checked, belts tensions
are checked.
4.8 Manpower
Table 4.6 Manpower in Card Department
Designation Strength
Foreman 1
Assistant foreman 1
Head fitter 1
Fitter 1
Assistant fitter 1
Total 5
Manpower Production for 1 Shift
Designation Strength
Supervisor 1
Operator 3
Floor cleaner 0
Total 4
28
5 Drawing
Draw frame is a machine for combining and drawing slivers of a textile. Drawing
is the operation by which slivers are blended, doubled and leveled. In short staple spinning
the term is only applied to the process at a draw frame. In drawing slivers are elongated
when passing through a group of pair rollers, each pair is moving faster than previous one.
It is the process of increasing length per unit weight of sliver. It is mainly due to
the difference in the surface speed of the rollers.
• Doubling
The process of combing two or more carded sliver into a single form is called
doubling. In draw frame m/c generally six slivers are fed to convert into one is known as
doubling of six.
• Drawing
One of the main tasks of draw frame is improving evenness over short, medium
and especially long terms. Carded slivers are fed to the draw frame have degree on
unevenness that cannot be tolerated in practice and slivers from the comber contain the
“infamous” piecing. Equalizing is always performed by a first process, namely doubling
and can optionally also be performed by a second process, namely auto leveling. The draft
and the doubling have the same value and lie in the range of 6 to 8.
• Parallelizing
To obtain an optional value for strength in the yarn characteristics, the fibers must
be arranged parallel in the fiber strand. The draw frame has the tasks of creating this
29
parallel arrangement. It fulfills the task by way of the draft, since every drafting step leads
to straightening the fibers.
• Blending
• Dust removal
Dust is steadily becoming a greater problem both in processing and for the
personnel involved. It is therefore important to remove dust to the greatest practical extent
at every possible point within the overall process. Since a large function the smallest
particles adhere relatively strong to the fibers. High performance draw frame is equipped
with appropriate suction removal systems; more than 80% of the incoming dust is
extracted.
30
Table 5.2 Top Roller Specification of Breaker & finisher
Outer dia 34 mm 34 mm
Grinding range 2 mm 2 mm
5.5 Maintenance
5.5.1 Daily
• cleaning of drafting gauges of all machines
• cleaning of coiler tube and trumpet
Daily one machine is opened and the overcalling is done. Checking, greasing, and oiling
of all bearings of check jack box, creel, sliver roller bearing cleaning and greasing.
31
5.5.2 Major parts change schedule
The major changing is rubber cots both in breaker and finisher. Changing is done
according to the lab results. Rubber cots are changed after one year.
5.6 Manpower
Table 5.4 Man power
Designation Strength
Foreman 1
Assistant Forman 1
Mechanical Supervisor 2
Head fitter 2
Fitter 3
Assistant Fitter 1
Total 10
Manpower production for 1 shift
Designation Strength
Production supervisor (3 shifts) 1
Supervisor 1
Operator 4
Bobbin boy 2
Doffer 3
Total 11
32
CHAPTER 04
SPINNING AND PACKAGE WINDING PROCESS
6 Simplex
6.1 Introduction
The draw frame produces a sliver that already exhibits all the characteristics
required for the creation of a yarn, namely an ordered, clean strand of fibers laying parallel
to one another. The roving machine itself is complicated, liable to faults, causes defects,
adds to production costs and delivers a product that is sensitive in both winding and
unwinding.
Drafting
Twisting
Since the resulting fine strand has scarcely any coherence, protective twist must be
inserted in order to hold it together.
Winding
Winding is the process to wind roving to suitable bobbin for easy efficient
transportation. Build the roving on the bobbin such a form which will facilitate unwinding,
handling and transfer to the next process.
33
6.3 Defects And Its Prevention On Roving Frame
Prevention:
For preventive action we should keep the delivery length and the speed difference
constant then the tension in this case will be ideal.
Prevention:
Prevention:
Supervisor should train his workers in a proper way. If end breakage is disturbed
then its treatment should be proper. If piecing will not be proper then it will affect the next
process.
Prevention:
For the proper solution of roving breakage, speed of machine, trained operator and
proper management should be must otherwise it create severe problems in ring section.
Manufacturer Zinser
Model 670 RoWeMat
Total frames 9
34
No. of spindle per frame 144
Total lift of machine Mm
Maximum Delivery speed 80 m/min
Maximum Flyer speed 1500 rpm
Maximum bobbin speed 1800 rpm
No. of turns around presser arm 2 turns
Feed of machine 60 gr/yd.
Can size 600 mm x 1200 mm
Type of roller weighing Spring weighing
Spindle gauge 110 mm
Bobbin rail lift 406 mm
Flyer rpm 1100 rpm
Bobbin rpm 1400 rpm
Drafting system
Model SKF PK-1500
Type 3/3 drafting system
Dia. of bottom rollers 30 mm , 25.5 mm , 30 mm
Dia. of top rollers 34 mm
Gauges
Between front and middle roller 30 mm
Between middle and back roller 39 mm
Apron specifications
Top apron 39.8 x 48 x 1.1
Bottom apron 88 x 42 x 1.1
Life 1.5 year
Top Roller Specifications
Dia. with rubber cot 34 mm
Width 40 Mm
Grinding range 2 Mm
Polish No
Grinding 3 month
35
Life 3 year
2nd roller 20 Pa
Back roller 25 Pa
Spacer
Color Brown
Size 10 mm
Condenser 8 mm
Front Collector 3 mm
Bobbin specifications
Length 445 mm
Dia 56 mm
Weight 200 g
36
7 RTS (Roving Transport System)
The Bobbin transport system provides economic advantage to package handling of
Ring Spinning. It ensures the protection of roving wound around the Bobbin, which is
highly liable to damages during manual transportation. BTS also protects the yarn quality
where the Roving defects are transferred. Bobbin Transport System is certainly the area in
Spinning Mill where the investment in automation is more easily justified due to labour
savings and reduction in yarn faults. Especially in the coarser count spun the labour saving
will be higher.
Attribute Specification
Manufacturer Zinser
Transport system Transport of the trolley trains by means of
stationery wheel and disk drives
No. of trolley trains 64
No. of bobbins per trolley train 288
Gauge of trolley train 180 mm
Stripper working rate 2 bobbins/45 second
Exchanger rate 2 bobbins /45 second
Bobbins preparation for one doff 144 bobbins /54 minutes
Speed of train 16 meters per minute
Storage 24 trains
Number of train movements per transport 2.9 trains/hr. one way
direction & 5.8 trains /hr. two way
37
8 Ring Spinning
Ring Spinning is the oldest of the present day spinning processes. Fiber material is
supplied to the ring-spinning machine in the form of roving. The fiber mass of the roving
is reduced by a drafting unit. The twist inserted moves backwards and reaches the fibers
leaving the drafting unit. The fibers lay around one another in concentric helical paths.
The normal forces encountered by the fibers enhance the adhesive forces between the
fibers and prevent fibers from flying or slipping past each other under the tensile strain.
Ring spinning is a comparatively expensive process because of its slower production
speeds and the additional processes (roving and winding) required for producing ring spun
yarns. Ring spun yarns produce high quality and are mainly produced in the medium
range, with a small amount produced in the coarse count range.
39
Front zone 56.5 Mm
Back zone 73.5 Mm
Bare bobbin dia.
Top 21.22 mm
Bottom 24 mm
Length of bobbin 231 mm
Gauges
Spindle gauge 70 mm
Lappet gauge 20-22 mm
Pressure gauge 3 mm
Traveler clearer gauge 1.5-2.75 mm
Spindle wharve dia. 19 mm
Spindle length 185 mm
Spindle tap thickness 2 mm
Spindle tap width 20 mm
Spindle tap length 138000 mm
Lift of machine 192 mm
Chase length 46 mm , 49 mm
Apron specifications
Top apron 42.1mm x 27.8 mm x 1.0 mm
Bottom apron 79mm x 30 mm x 1.1mm
Life 1.5 year
Top roller specification
Dia. with rubber cot 35 mm
Width 28 mm
Grinding range 2 mm
Grinding 3 month
Life 4 year
40
8.4 Process and quality parameters of product
Table 8.2 Process and quality parameters of product
Count 18 50
Hanks roving 0.95 1.3
TPI 11.29 20.15
Nominal Draft 22.80 40.65
Break Draft 1.14 1.14
Spindle Speed 12800 rpm 15497 rpm
Delivery speed 29.33 m/min 20.17m/min
T.M 2.66 2.85
O.P.S 14.40 3.87
Production 85.7 kg/hr. 23.0 kg/hr.
Efficiency 90 % 96 %
No. of unit 1 2
8.5 Maintenance
The maintenance of different machine parts depends upon the quality results of the
product.
The hardness of rubber cord increases with the passage of time because of friction. The
grinding of rubber cords is done in the maintenance department workshop. The cleaning of
machine parts is done on daily basis for one hour.
8.6 Manpower
Table 8.3 Manpower in Ring Department
Designation Strength
Assistant foreman 2
Head fitter 1
Fitter 2
Assistant fitter 5
Helper 6
Total 16
Manpower Production for 1 Shift
Designation Strength
Supervisor 1
Operator 6
Doffer 3
Total 10
41
9 Cone Winding
Winding department comes after the Ring department. Yarn wound on the Ring
bobbins cannot be put to good use in the subsequent process because Ring bobbins are in
the form of small packages.
This necessitates the preparation of a dense and uniform yarn package of sufficiently large
size which can unwind in the subsequent operations without interruptions. The packages
prepared for warping are normally cross-wound, containing several kilograms of yarns.
This implies that a number of knots or splices are introduced within each final package.
Bear in mind, each knot or splice itself is an artificially introduced imperfection; therefore,
the size of this knot or splice must be precisely controlled to avoid an unacceptable fault in
the final fabric.
42
9.3 Processed material
Input - Yarn (Spinning bobbins)
General
Manufacturer Schlafhorst (AC 6V)
No. of frames 21
Spindles per Frame 60
Doffing and Feeding Automatic
Clearer type Zenit Plus
Cradle type Yoke type
43
Magazine Not available
Suction mouth tip 5 mm
Air consumption for one splice 2.5 Pa
Winding speed 250~2000 m/min
Type of splicer (Air splicer)
Splice length 1.2 inch
Splice strength 92
Pressure on tension disk Electric disc
No. Of Grooves per drum 2.5
Dia of Drum 94 mm
Traverse of Drum 150 mm
Auto doffer per machine 01
Auto doffer speed 42 m/ min
Auto doffer doffing time 7~8 Seconds
Package Diameter 165-300 mm (Maximum)
Count range 15~65 Ne
Staple length range 38~51 mm
Compressed air consumption 450 NL/min
Minimum compressed air Pressure 7 bar
9.7 Manpower
Table 9.2 Manpower in Auto Cone Department
Designation Strength
Foreman 1
Supervisor 4
Fitter 4
Assistant fitter 1
Total 10
Manpower production for 1 shift
Designation Strength
Head Supervisor (3 Shifts) 1
Total 35
44
CHAPTER 05
YARN PACKING
10 Introduction
The last process in the spinning mill is packing. In this department yarn is packed
in to a suitable form of package so it can be identified, protected, stored or staged before
the shipping to the buyer and so it can be sold out in the market. The beg weight is always
kept 100 lbs. this is the net weight of the yarn excluding beg weight. The weight of other
elements i.e. paper cone, sticker, polyethylene packet, polypropylene bag, cartoon and
strips is considered as the tare weight. Packages are sold on the basis of net weight of
yarn.
10.1 Objectives
To protect yarn from environment.
Ease in transport.
Less yarn damage in storage.
Different products are identified easily
45
10.1.3 Pallets packing
For pallets packing a machine [SAN-GRato-CMT-Srl] is used for pallet packing.
Its model 2003. In this packing the same process of stickers, stoppers and poly ethylene
bags are used then pallets packing is done. After packing packages are set.
Robotic arm picks up cones by multi gripper and build up pallets at designated areas and
also puts separators from their respective separator storage between each layer. Once the
pallet is complete, it will be removed automatically.
Pallets from palletizers will be moved by means of a T-car to a transfer roller conveyor.
The same T-car takes empty pallet bottoms from a dispenser and moves them to the
palletizing places. From transfer roller conveyor pallets move to a turntable. This turntable
will rotate at 90° and pass on the pallet to next T-car via roller conveyor.
The second T-car takes the pallets and moves these pallets to one of the de-palletizing
units and also to the storage area. The de-palletizer picks up 5 packages at the same time
and brings these to the in feed line of the sack packing unit.
The pallet has 240 packages of one quality on the pallet, which means the sack packing
unit can produce 10 bags of one quality. When the pallet is empty, the transfer car takes
out the empty pallet and moves a full pallet into the de-palletizer.
From the weighing scale the cones move forward to the sack packing machine, where
every second one will be turned 180 degree in order to receive a nested packing pattern.
Then the cones move through a unit where each cone will be put into a PE plastic bag.
After bagging, the cones will be put into (double) rows by means of a small pusher and
then by means of a big pusher moved into the sack.
47
Figure 11.2 Sack packing machine
The sack packing unit includes fixation the bag automatically. The filling cycle will repeat
until the sack is full. The full sack then will be moved away from the filling table onto a
conveyor. Here the stitching machine closes the sack and moves them further on the
conveyor.
The sack weight will be checked automatically with the help of integrated weighing scale
and moves them further on the conveyor.
48
12 Roller Cover Department
50
12.6 Lubriboy
Lubrication machine.
51
CHAPTER 06
TESTING AND QUALITY CONTROL
13 Introduction
After making yarn it is very necessary to perform certain tests to check whether the
results are up to our expectations are not. In any textile mill the factors which are checked
include yarn strength, elongation, IPI, breaking force and certain other parameters. Several
machines are used for testing and quality purposes.
Ibrahim Fibres TP1 has modern testing laboratory available which is performing its
function efficiently.
13.1 Objectives
To maintain the quality
To obtain the optimum level of product
To control the waste
To maintain the maximum efficiency
To maintain the good check and balance system
U%
CV% (10m, 3m, lm)
Relative count %
Index
For Sliver:
Parameters Mean
U% 1.75
CVm 2.20
CVm 1m% 0.52
CVm 3m% 0.34
Rel. Cnt ± % 0.5
After testing the results were displayed on the printed paper attached to the
machine
For Yarn:
For the testing of yarn, below is the information entered in the UT-4.
It gives the percentage for the mean value of test series performed and their location on the
statistics chart.
Mean value
53
It‟s the average value of test series performed.
If the test is performed, several times for the same material than the results would lie
between ranges of acceptable 95% probability. This gives the mean value for which test
results are within the acceptable 95 % probability.
Max/min value:
It is the highest and lowest sub samples of the test series. It helps to indicate which value
is furthest from the mean value.
Functions:
Count determination of yarns, roving and slivers and the weight per unit area of
55
CHAPTER 7
AIR CONDITIONING SYSTEM
14 Introduction
Air conditioning (often referred to as, AC or A/C) is the process of altering the
properties of air (primarily temperature and humidity) to more favorable conditions,
typically with the aim of distributing the conditioned air to an occupied space to improve
comfort. More generally, air conditioning can refer to any form of technology, heating,
cooling, de-humidification, humidification, cleaning, ventilation, or air movement.
56
14.5 Humidification System
Humidification system without chilling helps to maintain only the RH% without
much difficulty. They can be classified generally as either unitary or central station.
Central system is the most widely used system in the textile industry. The systems
principal components are
Air moving devices- fans
Mixing devices for air and washer- i.e. Air washers
Air moving devices are always broken into two halves,
Return Air fans and
Supply Air fans.
The return air fans return the air to the plant room from where it may circulate or
exhausted in the mill. The supply air fans- supply air to the mill from the plant room.
Air washer is a device for intimately mixing water and air. The intimate contact between
these two elements is best brought about- for this application- by drawing air through a
spray chamber in which atomized water is kept in transit.
Air washer system has water nozzles supply fans and multistage pump in it which
throws water on the plates of washer system. Therefore water becomes cold and supply
fans take humidified air from there and send it to the whole department.
57
2. Lovers
Lovers prevent the airborne particles such like leaf, papers, sand etc., to enter into
the unit and block the filters especially in the heavy dust storm.
3. Water tank
Water tank is present to store water which is supplied through nozzels to increase
the humidity of air.
4. Spray nozzles
Spray nozzles are used to give ideal atomization, ample water volume for efficient
air scrubbing and a stable cone of spray even at high velocity. The high quality of
atomization produces a high surface are of droplets for contact with air which result in
peak humidifying efficiency and also for heat transfer efficiency.
5. Dampers
A damper is a valve or plate that stops or regulates the flow of air inside
a duct, chimney, VAV box, air handler, or other air handling equipment. A damper may be
used to cut off central air conditioning (heating or cooling) to an unused room, or to
regulate it for room-by-room temperature and climate control. Its operation can be manual
or automatic.
Manual dampers are turned by a handle on the outside of a duct. Automatic dampers are
used to regulate airflow constantly and operated by electric or pneumatic motors,
58
6. Fans
Two types of fans are used in air conditioning system which are:
Supply fan
Return fan
Supply fan supplies air from air cooling plant to the whole unit including blow room,
carding, drawing, Drawing/simplex, roving, ring, auto cone and doubling processes. Every
department has its own air conditioning system Supply fan.
Return fan sucks air from inner side of the rotary air filter and it provides required quantity
of air to the air cooling plant and remaining hot air is thrown out.
This equipment is specially designed for handling high volume of air laden with
fiber and dust returning along with the air from the department/ waste recovery equipment.
The fluff, fiber and dust arrested on the filtering media is sucked out by traveling suction
nozzles, moving along the outer surface of the drum and are deposited in collection bags
for easy disposal. The clean air is then either re-circulated or exhausted in to the
atmosphere.
8. Water pump
Water pump is used to fill water tank. When the water in tank becomes muddy or
dirty then it replaced with fresh water for which purpose water pump is installed.
59
Table 14.1 AC stations data
60
Chapter 08
COMPRESSED AIR SUPPLY
15 Introduction
An air compressor is a device that converts power (usually from an electric motor,
a diesel engine or a gasoline engine) into kinetic energy by compressing and pressurizing
air, which, on command, can be released in quick bursts. There are numerous methods of
air compression, divided into either positive-displacement or negative-displacement types.
There are total 5 compressors in Textile Plant-1. Average air consumption for TP-1 is
50,000 c.m/day. Detail of compressors is given below:
15.1 Objectives
There are many uses of compressed air
Cleaning
In cards (to press the web sheet)
Can changing
Draw frame (drafting system)
Ring frame (auto doffing)
Auto cone (cone holding pressure)
Splicing unit
1. Air filter
2. Intake valve
3. Oil separation tank
4. Cooling agent
5. Compressed air after cooler
6. Pressure switch (for output pressure)
7. Oil filter
8. By pass valve
9. Heat exchanger for oil
61
Oil separation tank separates the oil from air and sends it back to the air end. If the
temperature of oil is increased then it is firstly sent to the cooler and then back to the air
end.
When the specified unload pressure is reached the input air valves are closed by the output
pressure and leave them in IDLE condition for giving some rest to the input valves and
also for allowing the oil to cool down by passing many times through the heat exchanger.
In winding machine, compressed air is used for splicing of yarn. Compressed air required
in the mills is at pressures ranging from 4 - 8 kg/cm2. Although, atmospheric air is free, its
compression to the required higher pressure by air compressors is done normally.
I. Auto-cone
Winding department is the biggest consumer of the compressed air therefore in most of
the units the maintenance and overseeing of the installation is done by technical staff of
the winding department. The consumption of compressed air is done at following positions
in a winding head:
Compressed air used for the above mentioned purpose must fulfill the following
requirements for better results:
Air should be clean and does not contain any dust or micro particles
There should be no moisture or oil particles in the air
The air produced, should have low temperature
Pressure should be uniform at all times
There should be as less pressure drops as possible
The cost of producing air should be kept low as regard economic concerns
15.7 Maintenance
For proper and trouble-free operation of pneumatic systems provided for the
machines, it is essential to ensure filtration, pressure regulation and lubrication of the
compressed air. Providing filters in the pipeline after the air receiver ensures that filtration.
These can remove dust particles up to 5 micron size. For reducing friction, wear and tear
and preventing corrosion, proper lubrication of compressed air is necessary. This is
achieved by the “oil-fog” airline lubricator.
64
CHAPTER 09
CONCLUSIONS
I have conducted internship at IFL TP-1 from 19th August to 18th September. It
was very useful and informative regarding textile spinning process. I learned a lot about
the process flow for yarn manufacturing. Environment and culture of IFL is very
appreciable. Especially the uniform segregation between different departments. In
spinning flow process, best raw material is used. The ring spinning machines are operated
at optimum speed to achieve best quality yarn. State of the art equipment and best
environmental conditions allow to achieve best quality of yarn. Besides this, housekeeping
and healthy working conditions provides a reliable environment for workers and employs
to do their jobs at their best. In short, Ibrahim group of companies is well organized group
and the better platform for learning purpose.
65