A

SUMMER INDUSTRIAL TRAINING

REPORT

SARLA FABRICS PVT. LTD.

30/2 LONI ROAD, MOHAN NAGAR,

DISTT:GHAZIABAD( U.P. )

SUBMITTED BY

NAROTTAM KUMAR

MAYANK SRIVASTAVA

AKANKSHA ARYA

ANSHUMA SRIVASTAVA

CHANCHAL

PRAGYA DIXIT

RUCHIKA RAZDAN

UTTAR PRADESH TEXTILE TECHNOLOGY INSTITUTE

KANPUR

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 ACKNOWLEDGEMENT

We acknowledge our deep gratitude towards SARLA FABRIC PVT. LTD. and

our college authority for providing us this one month in-plant training.

We are very grateful to Mr. DEVANSHU NARANG (C.EO.) for allowing us to

under go in plant training at this mill as well as our college Director Mrs. Dr. Anita

Niskam & training officer Mr. V.K. Malhotra for the correspondence.

We are thankful to Mr. Michael ( General Manager ) , Mr. R.K.Agnihotri (Head

Preparatory ), and other members of this mill who directly or indirectly helped us

during our training.

Yours Sincerely,

NAROTTAM KUMAR

MAYANK SRIVASTAVA

AKANKSHA ARYA

ANSHUMA SRIVASTAVA

CHANCHAL

PRAGYA DIXIT

2
RUCHIKA RAZDAN

U.P.T.T.I. ( Formerly known as G. C. T. I. ) , Kanpur

(2005-2009)

1.1 MAJOR HIGHLIGHTS OF THE COMPANY

• Largest dyeing & printing capacity of fabric.

• Largest range of textile products. .

• Collaborations with specialists worldwide.

• Installation of state of art machine from Switzerland,

Germany, South Korea, Japan and Italy.

• Exporting to the countries with the most stringent quality

standards requirements like Hong Kong, Switzerland,

Germany, South Korea, Japan and Italy.

• Winners of the maximum export achievement awards.

1.2 GROUP PHILOSOPHY

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• Faith in core competence in textile business.

• Customer orientation for a quick and positive response to

the customer's need.

• Production of the best quality of premium market segments

through TQM and zero defect implementation.

• Global orientation targeting at least 20-25% production for

export.

• Timely delivery with consistent standards.

• Productive approach to the benefits of R&D and modern

technology.

• Targeting excellence through continuous functional

developments and innovations.

• Unflinching faith in individual's potential his growth and

respect for human values.

• Developing relationship for benefit with business partners

and dealers.

• Believing that trust is the foundation for durable relationship

between the employer and employee.

• Acceptance of change as a way of organizational growth.

4
1.3 GROUP QUALITY POLICY

• Quality should be built into company's products to not only

meet customer requirements continuously but also exceed

them. The company shall achieve this through an interface

with the market place, access to state of the art technology,

R&D process development and adoption of innovative

manufacturing and marketing strategies.

• The quality policy shall be implemented through a network

of systems and procedures understood and followed

throughout the company.

• The quality policy shall be integrated with the company's

main objectives :

1. To remain market leader in the quality.

2. Increase market share with focus on niche

segments.

3. Improved productivity.

4. Cost reduction.

5. Reduction in percentage of seconds.

• The management shall be committed to provide capital and

human resources to achieve the above objectives. A

5
 Company wide quality culture shall be created through

training and motivation of people at all levels of

organization.

2.1 SARLA FABRIC PVT. LTD. GHAZIABAD (AT A GLANCE)

Sarla fabric Pvt. Ltd., a weaving subsidiary of Sahi export

house Faridabad has now a days emerged as one of the

premium quality greige and dyed fabric fabric manufacturing

companies in India.

Sarla fabric Pvt. Ltd. had started its journey in the year

1994 in a very humble way with mere dyeing range100000

mtr./day and print up to 40000myr./day

Benninger Ben-Direct 1000 warping machine was installed

in the year 2006-2007.Simultaneously, with the installation of 54

Toyota Air Jet (Delta and Omni Model) and JAT710 model with

Staubli Dobby attachments) Looms company had revolutionized

its production capacity (45,000 meters) and products range (7's

to 2/120's). In the year…. the company was honored with the

ISO-9002.

Moving with the modern world, company had accepted the

new philosophy of quality improvement like Quality Circles, TQM

6
 Warping
Bottom cones

etc. Its international customers are like GAP WALMART, H&M,

MARKS & SPENCERS, POLO, AMERICAN EAGLE etc.

2.2 PROCESS FLOW IN SARLA FABRIC PVT. LTD.

Raw material

(Warp yarn)

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 Sizing
Rewinding
Drawing & Gaiting
Knotting

2.3 ORGANISATIONAL STRUCTURE

Loom shed

Inspection and folding

CEO

Dispatch

GENERAL MANAGER

MANAGER

SHIFT OFFICER

M4(Chief Manager)

M3(Sr. Manager)

M2(Jr. Manager)

M1(Dept. Manager)

E2(Master)

E1(Astt. Master)

02(Shift officer)

S4 S3 S2 S1 (Supervisor)

8
Worker

9
2.4 RAW MATERIAL

SARLA FABRIC PVT. LTD. is buying most of the raw

material from Vardhman Group, Nahar Group, Aditya Birla

Group, Trident, and some of the raw material mainly of O.E. yarn

of coarse count from other suppliers.

• 100% cotton yarns for warp, weft and catch cord.

• Polyester cotton blended yarns.

• Cotton Lycra blended yarns.

• Polyester filament yarns for leno selvedge.

• Open end yarn

• Compact yarn

• Eli yarn

2.5 YARN SUPPLIER

• Auro Spinning Mills Baddi

• Arihant Spinning Mill Malerkotla

• V.S.G.M. 100% E.O.U. Baddi

• Arist Spinning Mills Baddi

• V.M.T. Spinning Co.

• Pratap Industries Ltd. (7s, 10s, 14s, 16s, O.E.)

• Fertichem Cotspin Ltd. (7s, 10s, 14s, 1s, O.E.)

• Indo Rama Industries Ltd. (Polyester Yarn)

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 • Glofame Spinning.

• Nahar Group

• Arti international ludhiana

• Dhar Industries

• VTM Ludhiana

• Shivatex

• Vaibhav

• Nitin spinners

• Shrivishnu

• Sandhya

• Rajapalayam

• Aruntex

• S. Lalitha

• Thanjavar

• Rajapa

3. PREPARATORY DEPARTMENT

Preparatory department provides weaver's beam (sized) for

loom shed. It consists of the following processes:-

Warping

Sizing

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 Drawing - in

Rewinding

3.1 PROCESS FLOW IN PREPARATORY DEPARTME

3.2 Gray yarn from godown

Creeling

Direct Warping

Bottom Cones

Rewinding

Sizing

Drawing in

Loom shed

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3.2 WORK ALLOCATION

Manager

Three executives

Four shift officer

Workers

Warping

One warper and one creel boy per machine per shift.

Yarn trolley man two per shit.

Sizing

One sizer and one back sizer per machine per shit.

Beam carrier two per shift.

Mixing man two per shit.

Drawing in section

One drawer and one reacher per stand per shift.

Rewinding section

Two rewinder per shift

Floor cleaner

Morning shift - 2

Evening shift - 1

Night shift - 1

Maintenance

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One feater per shift.

3.3 WARPING

Warping is a process of making warper's beam of specified

number of ends, pattern and width from uniform cones/cheeses

of specified count. All the ends in sheet should wound at almost

uniform tension. The density of wound yarn beam should be

uniform across the width & from start to end of winding sheet.

This beam further goes for sizing.

3.3.1 AMBIENT CONDITIONS IN WARPING DEPARTMENT

Temperature Range 27 C to 32 C

R.H. 60% to 66%

R.H. = 98.4 (Dry bulb temperature - Wet bulb X

- temperature) 100

Wet bulb temperature

3.3.2 TYPES OF WARPING PROCESSES

Warping is divided into two types:-

a. Direct warping

b. Sectional warping

a. DIRECT WARPING :-

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 It consists of preparing number of full width warping beam

with required length, called as one set. The total no of ends

warped in number's of beam depending on the capacity of creel.

These all beams of one set put together on sizing creel for the

sizing process, which result in formation of weaver's beam.

USE OF DIRECT WARPING :-

Direct warping is used for the prepare a set of one color,

either grey or dyed yarn.

To prepare large set length i.e. to take large length of yarn

in each warping beams of the set & prepared number of small

length sized beam from this set which reduce the warping and

sizing machine down time.

Multi-color warps with complicated patterns can be formed

successfully on this type. It gives one set so less inventory and

handling of beams is there.

b. SECTIONAL WARPING:-

If forms section by section on to the section drum of

specified no of ends and width. After completion of these

sections, drum is unwound on the warper's beam that is then

sent to the sizing department.

USE OF SECTIONAL WARPING

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 Multicolored warp with complicated pattern like checks

and strives etc. can be successfully prepared. Only one beam is

needed in one set, so less inventory & handling of beam is need.

3.3.3 WARPING MACHINES

Preparatory department has one direct warping machine.

A. Direct warping machines

a. One Benniger Wpg. M/c (Ben- Direct 1000).

3.3.3.1 Direct warping machine

a. BENNINGER WARPING MACHINE BEN-DIRECT

1000

MAKE :- Ben-direct 1000

Benninger uzwill schwetz.

Benninger co. ltd. uzwill Germany

MODEL :- 2007

SPEED :-

Maximum running speed - 1200 mpm

Normal running speed - it depends on the count of yarn

Yarn count Running speed

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 7s, 10, 14s, 16, 20s 800 m.p.m.
2/30s, 2/40s, 2/20s 800 m.p.m.
40s, 50s, 60s and above 600 m.p.m.
Crawl speed (inching) 20 mpm

Type of creel V creel

Creel capacity 704

Weight of a cone 1.5-2.5 kg

Total guide bars 88

Overhead cleaning By suction pipes

Machine cleaning By compressor air.

Brake system Hydraulic braking system

(Braking pressure 5.8 bar)

Direct drive from motor

positively driven from spindle and

belt)

M/c height 1800mm

M/c Width useful width+1900mm

M/c Weight 3500kg

M/c Length 2120mm

Air pressure 8-5 Bar

Air consumption 3 m3/n at 5-bar

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Ambient Temperature- 10-40 deg centigrade

M/c to Creel Distance 4000mm

Over all yarn tension 450 N

Normal efficiency 94%

Breaking Moment 1600Nm

Sound Level less than 80 dB normal

Density in g/dm3 =warp length in m * No. of ends *

dtex * 400

Warp Width* (D²–d²) *3.14

WARPER”S BEAM : Beam can be classified in different types-

1-Beam with serrated cones for centering and driven shape “c”

2-solid flange

3-Ribbed flange

4-Dyeing beam

Beam diameter

maximum minimum Empty(barrel weight

)
Other beam- 1250kg(full
beam)
1000-1016mm 800mm 300mm 800kg
(800mmdia.)
Dyeing beam-

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520mm 300mm 150mm

Beam length = 1800 mm

Maximum breaking torque = 8500

Nm/flange

Creel measurements

Height between two packages = 27.2 cms

Horizontal distance = 24.5 cms

Fluff removal: - Internal blower

a(2).YARN PASSAGE

Cone à balloon breaker à tension bars à yarn stop motion à

zig-zag comb à measuring roller à press roller à warper's

beam.

a(3). DRIVE TO VARIOUS PARTS

• To warpers's beam

Main motor à pulley à weaver's beam (attached to pulley)

There is clamping and declamping device attached to pulley

which get the drives through motors attached on each side.

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Apart from this there is presser roll which is given drive by

hydraulic system. This roller provides pressure to beam

essential for proper winding. Friction drive is not given as it may

damage the yarn.

• To comb

Motor à through chain to shaft à comb attached on shaft.

The comb has a zig zag shape (9 ends, 13 ends) and it

moves to and fro as well as up and down. The main function of

the comb is proper beam formation i.e. close packing and also

separation of threads. To and fro movement ensures the close

packing of ends while up and down movement is to evade reed

damage by friction.

Comb is driven by three motors one for to and fro motion,

one for up and down and third one for controlling the comb dent

density.

• Pre tension settings - here setting of tension rod depth is

done through scale on the creel. Screw is set at the

required scale and then the shaft containing tension rod is

engaged to the screw and then the shaft containing

tension rod is engaged to the screw and then the machine

runs. The tension rods are actuated mechanically It is

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 actuated 3 sec after the machine starts.

a(4). TENSION KEPT FOR DIFFERENT COUNTS :-

COUNT (Ne) PRETENSION SETTING (mm)

14s K, 16s K, 20s K 10-20

40s C, 50s C, 60 C 0-2

2/40s C, 2/60s C 7-11

a(5). OTHER IMP. PARTS

• Yarn stop motion - this machine have electronic

(capacitance based) type of yarn stop motion. It actuated

after 5 sec of machine start running.

• Pressure bar - to maintain tension in the yarn ends when

the machine stops and during running it releases its

pressure.

• Yarn cutter - after finishing warping the ends are cut by a

running yarn cutter which moves horizontally in a slot.

• Fluff removal - by internal blower system.

• Microprocessor control and display system.

Creeling time :-

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Yarn passed through pretension rods, drop wire time taken is 30

minutes Time for combing is 10 minutes so total time taken in

creeling is 50 minutes.

b(4) TENSION CONTROL OF WARP :-

count tension setting (mm)

20, 16, 14 4mm

30k, 30c 4mm

40c, 50c 2mm

2/40c, 2/50c 8mm

b(5). FEATURES:-

• Advanced microprocessor than Ben-1000 and touch screen

type of control panel and display screen.

• Monitor on the creel front to show the exact position of the

broken end otherwise total no. of ends in the creel should
be checked.

• Yarn passage and drive system same as Ben-dir 1000.

• Yarn stop motion is electronic with sensors.

• Pre tensionar settings are done on computer.

• Number of ends fed in the computer = no. of end stop

motions.

• Advanced microprocessor display mechanism.

• Highly efficient brake system (with very small time). So

the broken end doesn't wind on the beam.

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 • Lay panel.

3.3.4 WARPER'S CHECK REPORT

The warper working on the beam is required to fill the

report, which includes the data like beam no., warper's name,

no. of cones, length and the record of no. of breakage of each

kind.

3.3.5 REASONS OF END BREAKAGE

End breakage may occur due to following reasons:-

• Spinning faults :- weak places, soft places, slubs, foreign

matter (plastic/hair)

• Winding faults: - slough off, cut cone, entanglement,

bad winding.

• Warping faults: - faulty stop motions, faulty thread

passage, entanglement.

• Miscellaneous faults: - cone finish, others.

According to norms breakage in warping should not be more

than 0.2 breaks per 400 ends per 1000 m.

3.3.6 WARPING CALCULATIONS

REMANANT %

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It is defined as the percentage ratio of remaining avg. length on

the bottoms to the length one a full cone. Generally 100 bottom

cones are taken for this purpose but it is always better to take

max. Number of bottom cones.

Remnant %age should be kept below 2%.

FORMULAS

 Nm=Ne*1.693

 Tex=590.5/Ne

 Ne=5315/Denier 1 yard = .91437 meter

 Warp weight = Total Ends. * warping length (Yards) /

840 * count * 2.205

 Warp weight = Total Ends. * warping length (meter) /

1693 * count

 Weft weight = Reed space* picks per meter* cloth

length/1693* count

 Length of yarn in a cone = count * wt of yarn content

on cone * 1693 meters

A. FOR DIRECT WARPING

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Calculations for set length and no. of beams:-

Suppose the given parameters are

Yarn count = 40s

Width of the cloth = 63 inches

Ends/inch = 132

Ordered length = 50000 m.

Total number of ends = 132*63 = 8316 ends

If creel capacity is 642

Then the minimum no. of beams required = 8316/642 = 12.95

Suppose we choose to make 14 beams of each of 594 ends.

Length of yarn in a cone = count * wt. of yarn content on cone *

1693 meters

Now at count 40s the cone length = 40 * 2.255 * 1693 = 1,

52,700 m

If we use set in 1 creel i.e. 14 beams from 1 creel then set

length will be = 1, 52,700/14, = 10,900m

Consider shrinkage is 10% and packing is 98%

Warping length = (5000 * 1.10) /0.98 = 56122.45 meter.

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Minimum no. of creel sets required will be =

56122.45/10,900=5.15 i.e. we need 6 creel sets.

Set length of beam in each creel set = 56122.45 / 6 = 9353.75m

So we can prepare warper's beam from 6-creel set each making

14 beams each (of 594 ends each).

Example 2

Considering sort:-

Count = 20 Ne

Construction = 108*56

Required Grey width = 63"

So total no. of ends = EPI * width = 108 * 63 = 6804

Suppose max creel capacity = 576

So no. of beams = 6804 / 576 = 11.8125

So we can make 12 beams each of 567 ends

Length of cone = 20 * 2 * 1693 = 67720 m

On using 12 beams from 1 creel, the set length will be =

67720/12

= 5644 m

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(app)

In 2 creels = 67720 / 6 = 11286.6 m

C. CALCULATION OF YARN REQUIREMENT (WARP AND

WEFT)

Consider a sort:-

Warp & weft count = 50 Ne

Construction = 144 x 80

Require Grey width = 63"

Requirement = 25000 m plain poplin

Warp Requirement

Total ends = 144 x 63

= 9072

Fabric required = 25000 m

to be sized = 25000 x1.1

= 27500 m (10% increased due to

shrinkage)

Hence warp required = (total ends x to be sized) / (1693 x

count)

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 = (9072 x 27500) / (1693 x 50)

= 2947319 Kg

Required = 2947.19 + 3.1% (According to packing &

wastage) = 3035.6 Kg

Weft Requirement

Reed space = (total ends*2)/(reed count *ends per dent)

= (9072) / 140

= 65" (app.)

Weight of weft = (reed space * ordered length *PPI) / (1693 *

count)

+ 3% = 1581.5 Kg

Total yarn requirement = weight of warp + weight of

weft

= 3035.6 + 1581.8

= 4617.4 Kg

4.0 REWINDING

Bottom cones are rewound to get full cones and can be used in

selvedge purpose of other. One rewinding machines (drum

28
driven) with over head blowing/cleaning system.

Rewinding m/c no.1

Make - RJK

No. of spindles - 32 (16 on each sides)

Tensioner - spring type

Speed - 500-1000 rpm

Stop Motion –electrical type

4.1 Passage of yarn through m/c :-

Creel à guide à tensioner à stop motion à winding drum

à package

There is a wet splicer for joining the broken ends.

5.0 SIZING

Object of sizing is to increase weaveabilty of warp yarns by

improving their abrasion resistance and strength which plays

major role during shed formation at loom.

Good sizing depends upon three very import factors i.e.

• Size paste composition

29
 • Method of preparation

• Its application to the warp yarns

The sizing paste should have film forming property on the yarn

which increases its strength, decreases its abrasion resistance;

is still flexible on drying and which can be easily washed out

(desized).

5.1 SIZE PREPARATION

Size is prepared at the first floor and transferred to machine

with the help of pipes. Size preparation includes following steps

Pre-mixer à cooking vessel à storage vessel à sizing

machines (through pipes)

1. Pre-mixer - First all the chemicals are mixed here

with the help of stirrer for 5 - 10 min. Then mixture is

transferred to cooking vessels through pipes. There

is one premixer for all cooking vessels. It has

capacity of 1595 liters.

Bottom 5" have capacity of 110 Litre then

capacity/inch is 29 Litre .

2. Cooking vessel - There are 2 cooking vessels each

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 with a max.Capacity of 1200 litre mfd by Karandas

Becharadas & Sons (Ahamedabad). Cooking is done

through direct and indirect steam for 45 minutes.

The conditions inside cooker are :

Pressure = 2.5-3 kg

Temperature = 130-1350C

Capacity: bottom 5" is of 90 litre then 27 litre

per inch.

3. Storage vessel - From cooking vessel size is

transferred to storage vessel where it is stored at the

temperature of 85-90 C and with continuous stirring

for further transfer to machine according to the

requirements.

Supervisor checks the viscosity and solid content before

transferring the prepared size to machine.

5.2 SIZE INGRADIENTS :-

• Maize starch :- It is an adhesive and exhibits all the

properties of native starch. It is non foaming.

• P.V.A. Evanol: - Better binder and suitable in case of P/C

blends as it has affinity for polyester also.

31
 • Sico-12:- It is also an acrylic binder generally used for

finer count Apart from these antistatic agents, antifungal

agents are also used. Antistatic agents are used for P/C

blended yarns and antifungal used if the beam is to be

kept for longer duration.

Yarn Count Size vol. Per Size conc. Final vol. of Std. size
1000 kg wp Solid % Size/batch pickup

14s PC 1420 ltrs 12.07 850 18

16s, 20s, K 1200 11.56 840 11.5

30s, 40s, C 1300 12.08 860 15

40s comp 1200 13.00 900 14.5

50s C 1300 12.76 900 16

Sec wpng 1200 13.00 900 14

5.4 SIZING MACHINES

1. Benninger (Ben-sizetec) sizing m/c (one)

5.4.2 ABOUT BENNINGER SIZING MACHINE

Made = 2007

Capacity = 16 beams with 1 sectional beam

Size boxes = 2 (if cover factor is<50 than use only

32
one size box otherwise 2)

Squeeze rolls = 2 in each size box

Size rolls = 2 in each size box

Emerson roll = 2 in each size box

Feed roll = 2

Maximum running speed = 1235 mpm

Operative running speed = 80 mpm

Drying cylinders = 4+4+2+2+2=14

Teflon coated cylinders = 4+4+2=10

Cylinder's dia. = 800 mm

Cylinder's length = 2000 mm

Beam width = 1800 mm or 70.8"

Barrel dia. = 178 mm

Cylinder temperature for zone 1 = 1450C

For zone 2 = 145 0C

For Zone 3 = 1350C

For Zone 4 = 1350C

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 For Zone 5 = 1350C

It is always recommended to keep temperature of each zone

lesser by 200C

Size box temperature: 900C

Beam stretch: 0.5-0.7/100m (fine)

0.8-1/100m (coarse)

Beam pressure: 1710 N (14 X…..gm/m)

Creel tension: 800 N (5 X…..gm/m)

Leasing tension: 11.5 X……gm/m

Winding tension 16 X……gm/m

Braking motion: Pneumatic auto control

Moisture regain: 7 (cotton)

4 (polyester/cotton)

Size level control: automatic

5.4.2.a. SOME IMPORTANT POINTS

• Single dip single nip system, hence more chances of yarn

being left unsized.

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 • Though it has system for sectional beam but generally not

preferred as single dip doesn't give better pick up thereby

increasing the chances of ball formation during weaving.

• All the drying cylinders are Teflon coated except the last

two, as yarn dries completely before reaching the last two

cylinders.

• Brake is applied on the creel (beam) through belts.

• There is stretch encoder at feed roll, size roll, dryer motor,

drag roll motor (i.e. Headstock) and winder motor, which

calculates the speed in each zone thereby giving stretch

value in each zone (generally 0.1-0.2%).

5.4.2.b. TENSION CALCULATION FOR BENNINGER ZELL

Tension (N) = gms/mt * factor *1

Gms/mt = total no of ends / Nm; [Nm = Metric count = Ne *

1.693]

Type of tension Factor for ring spun Factor for open end

Let off tension 0.5 0.5

Positive feed stretch 0.145. for fine 0.2 for coarse

Wet zone stretch 0.1 for fine count 0.2-0.3 coarse

Dry split tension 1.2 1.3

Winding tension 1.8 1.8

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 Beam pressing 1.5 1.5

5.4.2.c. PICK UP FOR DIFFERENT COUNTS

count pickup % age

16s OE 8

20s OE 12

30s, 15

40s, 16-17

50s 17

80s 18

5.4.2.d. SIZE RECIPE FOR DIFFERENT COUNTS

Sr.n Sizing. Ingredient 7s 16 20 30 40 50 60 70 2/40s

o o.e. o.e. s s s s s s
-
1 P.V.A. - - 12 8 20 9 16 20

2 Sico 12 - - - - - - - - 1.6

DRAWING IN

4500 ends are drawn/shift/2 operative for plain sorts.

PASSAGE
Beam –guide bar- comb -warp stop pin- steel heald wire- profile
reed - comb fixed with parallel to heald.

HEALD WIRE SPECIFICATION

1.2 –Thin for fine count

1.8 –Thick for coarse count

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If machine condition will be good then, it can be used till 15-20
years.
MATERIAL USED
Steel-tempered stainless steel

REED
Profile reed – Mayur (left hand side greater width and RHS
Smaller width)
-Takayama-(same width)
DROP PIN
Type- Closed type drop pin
Material used-Copper
TYPE-YKC-11122
SIZE-0.3*11*165
MANUFACTURER-Yosinaka

COLOUR SPECIFICATION
White-Fine count (1.2)
Brown-Coarse count (1.8)

6.0 LOOM SHED

Here only one loom shed having a total of 54 looms.

Looms are air jet Toyota JAT 710.

Loom no. 1-48 are cam shedding & loom no.49-54 are E-

Shedding.

6.2 REQUIREMENT FOR AIRJET LOOM

1. Warp beam and weft packages.

2. Maintained air pressure.

3. A pre-measuring device

4. A short quick air blast with nozzles to guide the weft.

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5. A suction device at the receiving end.

6 A take up & let off combination which is properly

controlled.

7 Warp stop & weft stop devices.

8 A dobby (+ve or -ve) to lift the heald frames.

10. Proper temple to grip the fabric.

6.3 MAIN FEATURES OF AIR JET LOOMS

1. The loom is compact without usual race board or bobbin

change mechanism.

2. The m/c is provided with buttons for inching & reversing.

3. Cloth roll can be doffed while the m/c is running.

4. Microprocessor (information board) to indicate, stops,

efficiency, reason of stop, no of picks / min., loom speed,

production in meters, loom angular motion, channel

settings, various loom timings.

5. 4 colors lamp indication system to indicate reason of m/c

stoppage.

Indication lamp Specification

Lamp color White Red Green Yellow
Condition Stop switch Warp and Weft stop Leno
pressed- waste selvedge,

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 Beam selvedge Electrical
doffing, stop problem
optical
safety
sensor,
RH cover
sensor

*There can be 6 color used for showing the cloth beam and other
warp beam.
6. Cam shedding motion to raise and lower heald frames.

7. Drum pool system to wind 1 pick length extra over it.

8. Leno selvedge motion to bind up the fabric & prevent its

unwinding.

9. Take up in some m/c is electronic otherwise a combination

of 2 gears decide take up speed.

10. Let off is electronically controlled and is provided with a

servo motor.

11. Easing motion is provided in some looms to compensate

for the difference in tension during open and closed shed.

12. The range of pick density is 20 to 200 but used range is

50-140 .

13. It contains a completely enclosed, 3 phase induction motor

with the built in D.C. single plate excitation brake.

STUDY OF JAT710 LOOM

39
6.4.1Shedding Mechanism:

In 1 to 48 looms has + ve shedding mechanism by cam and 49

to 54 looms are-Shedding (electronic shedding)

6.4.2Weft insertion

In air jet looms pick is inserted by the compressed air pressure

and requires measuring and storage control devices. To ensure

of smooth picking, the required weft for the next pick is wound

in advance on prewinder. While the loom is running, the weft of

corresponding length of one pick is supplied to FDP & storage is

controlled in the FDP.

One pick length of weft is measured by releasing or hooking

solenoid pin electrically. There are two timings, one is for the

first pick (at the start) & other is for running looms.

Nozzles In weft Insertion

1. Tandem nozzle : provide yarn to main nozzle

1. Main nozzle : provides drag for pick insertion.

2. Sub nozzle maintains the drag.

3. Stretch nozzle : keeps pick straight and stretched.

Weft package- accumulator(measuring drum)-tandem nozzle-

main nozzle-sub nozzles-stretch nozzle

6.4.3Selvedge Formation

It has full leno selvedge on both sides. Discs of leno assembly

40
rotate once in every two picks. Leno yarn used is 80 den.

Polyester filament yarn to give a strong and fine selvedge.

6.4.4Weft Stop Motion

Two electrically controlled weft stop feelers Wf1 & Wf2 are

set on right side of the loom. The distance between them is 125

mm. wf1 puts check on short pick and wf2 on long pick. Std.

Sensitivity of feelers-wf1-4 & wf2-8

6.4.5Catch Cord

Picks on right side are interwoven with catch cord mechanism

which gives smooth selvedge and avoids tucking in of the right

side picks into the fabric. 2/40s yarn is generally used and is

brought wpg. dept. as bottoms.

6.4.6Weft cutting motion

Weft is cut on either side by a pair of scissors. On left side it cuts

the continuous when it's been laid. On right hand side it cuts the

catch cord to the waste bin.LH cutter timing-25-30 deg

6.4.7Beating up :-

Done by the reed which is of tunnel type (profile reed) in

crank angle 340 deg

6.4.8Take Up Motion:-

Mechanical type of + ve take up motion where a pick change

41
wheel is changed according to the requirement.

SINGLE BEAM LET-OFF MOTION

An electronically controlled let-off motion detects the warp tension
applied to tension roller with load cell(set at the right side of the
m/c),and then the difference between the detected tension and
the pre-set tension is calculated on the computer in order to
control the speed of the servo motor.

LET OFF TYPE STD. LOW

DENSITY(PPI<240) DENSITY(PPI<100)
Warp beam flange 800 1000 800 1000
diameter
Barrel no 150 210 150 210
No of teeth on the 120 136 120 136
beam
Warp tension at 37 30 16 13
900 rpm

WARP TENSION SETTING

YARN TYPE TENSION SETTING
SPUN YARN AND +EASING STD DENSITY-30-500
LOW DENSITY-10-150
FILAMENT(-EASING) 30-300

CALCULATION OF WARP TENSION

WARP TENSION
(For spun yarn) = TOTAL No. ENDS * COEFFICIENT
YARN NO. COUNT

COEFFICINT OF SPUN YARN

STRUCTURE COTTON AND MAN –MADE SPUN
BELENDED YARN
PLAIN (1/1) 1.0 1.1
TOP WEAVE (2/1, 0.55 0.65 if Ne <10(thick)
2/2, 3/1) 0.6 0.7 if 10<Ne<20
0.7 0.8 if 20<Ne<30
0.8 0.9 if 30<Ne(thin)
BACK WEAVE, 0.6 0.7 if Ne <10(thick)
SATEEN WEAVE 0.7 0.8 if 10<Ne<20
(1/3,1/4,1/2) 0.8 0.9 if 20<Ne<30
0.9 1.0 if 30<Ne(thin
DOBBY WEAVE 0.9 1.0
Jacquard Weave 0.8 0.9

42
Warp tension
(For filament yarn) = TOTAL WARP ENDS*D*Coefficient
1000

COEFFICIENT FOR FILAMENT YARN

STRUCTURE WARP TYPE COEFF.
1/1 Acetate 0.20-0.25
Bamberg
2/1,2/2,3/1 Grey yarn 0.20-0.25
Finished yarn 0.30-0.35
Hard twist yarn 0.20-0.25

POSITIVE EASING MOTION-it correct the warp tension difference

caused at shed opening and closing, by tension roller adjustment
positively. It is used for spun yarn weaving.

Easing amount: distance b/w the positions (shed closing

&opening time) of tension roller.

Table for std easing timing according to fabric texture, shed close
timing &shed angel for spun yarn for
Shed angle-32deg

Item Cam shedding motion Crank Dobby

shedding
motion
Shed 1*2 300
close 3*4
timing Twill/sateen

310
290
290

310 deg
Easing 6 Plain-6
amount 6 Twill-1
1

6
Easing 290deg 300deg
timing 290deg
290deg

290

Spun warp high density fabric

43
Item Cam shedding motion
Shed 1*2
close 3*4
timing
290deg
310deg

Easing 6
amount

Easing 310deg
timing

Filament yarn for shed size 24 deg

Item Cam shedding motion Crank Dobby
shedding
motion
Shed plain 345
close twill
timing
345
345

345 deg
Easing 3 Plain-3
amount 1 Twill-1

3
Easing 345deg 345deg
timing 345deg

345

NEGATIVE EASING MOTION: it correct the warp tension

difference caused shed opening and shed closing by negative
adjusting tension roller with buffer spring. It is used for filament
yarn weaving.
* In filament weaving shed size and warp tension difference
is less than spun yarn weaving.

Smallest------effective no. of turns in buffer spring -------Largest

(3turns) (9
turns)

44
small Shed size large
high Warp tension low
high M/c speed low

6.4.11 TOYOTA LOOM CYCLE

• pin = 80-200

• Ist = 90-200

• Fill first = 90-200

• Main = 90-176

• Ist = 100

• Fill first = 100

• Aux. = 94-170

• Main Ist = 104

• Fill Ist = 104

• sub #1 = 90-170

#2 = 100-180

#3 = 120-200

#4 = 140-220

45
 #5 = 160-250

• Shed opening = 60-65

• Shed crossing = 320

• Pick arrival = 240

6.4.12 JAT 710 SALIENT FEATURES

• Single back rest

• Positive shedding device, staubli with hydraulic leveling.

• Lip in the reed system : good for filling stops

: good for

corrugation/stop mark.

• Speed up to 1200 rpm (max.)

• Suitable for fine to coarse type of fabrics. [cover factor up

to … in plain]

• Automatic jet control [pick arrival steady]

• Single hole nozzle (relay), 3 ht, 20 nozzle angle.

• Mechanical take up having large range of pick density.

• + ve let off, electronically controlled.

46
 • + ve easing motion.

• Electrical warp stop motion with six serrated bars.

• Max. 6 frame designs can be woven in cam shedding and

maximum 12 frame designs can be woven in e-shedding

• Suitable for basic weave.

It is a modern high speed weaving m/c with an innovative

system of weft insertion via air nozzle in order to provide

drastically improved productivity, saved labour & improved

working environment.

The air which is expelled by the main nozzle during its

movement extrains the weft & drags it through the warp sheet

6.4.13 TOYOTA JAT 710 DIMENSIONS

Size = 398cm * 200cm * 165cm

Net weight = 2850 kg

Gross weight = 3000 kg

6.4.14 CAPACITY

One these looms, the pick density ranges from …. ppi, but in this

unit only ppi ranging from ….. are inserted and for this, they use

pick wheels (B) ranging from … teeth.

47
Standard wheel (A) is changed depending upon ppi.

A = 56 teeth, B = 50-100 teeth, ppi = 34.02 - 68.04

A = 28 teeth, B = 50-115 teeth, ppi = 68.04 - 156.4

6.4.16 M/C SPECIFICATIONS

 Pneumatic provision

TYPES OF MAIN NOZZLE SUB NOZZLE LH CUTTER

NOZZLE
AIR PRESSURE 0.2-0.3mpa 0.2-0.3mpa 0.15-0.2mpa

 Allowed uncleanness

Compressed air specification

Oil free - max. 0.005 - 0.01 ppm

Moisture free - max. 0.7 gm water vapour / m3 at 7 bar & 20C.

Dust free - particles less than 5 mm.

6.7.3 MECHNICAL SETTINGS ON TOYOTA LOOMS

Back roller and related parts

Fabric Graduation Front - Drop Heald Shed

texture on back rear(incremen pin frame size

roller t with 50mm (droppe height heigh

respect) r box) t
Plain- 0 3 0

48
1/1,twill-

2/2
2/1, 3/1, +1 3 +1

4/1
1/2, 1/3, -1 3 -2

1/4
dobby 0 5 0

6.7.5 SETTING DONE ON MACHINE GATING

a. Red dent in line with reed holder
b. Feeler I on right hand side of the loom should be at 5 mm
distance from fabric width or reed space.
c. The distance between feeler I & feeler II should be 125 mm.
d. Prewinder dia and turns. Pick adjustable according to reed
space.
e. Cloth bar is set initially when the loom is set
6.7.6. BEAM DIA FOR PICANOLGTX
Beam dia =2+11.5+27/3.14
= 31.75 inch
=802.6 mm
7.0 MAINTENANCE SCHEDULE

1 FOR JAT710 LOOMS

Monthly

a. Cam box oil level

b. Oil filter cleaning

c. Working of central lubrication system

Three monthly

a. Shock absorbed step change.

49
b. Main cuter & selvedge cutter working.

c. Cloth pressure roll rubber strip condition checked.

d. R.H.S. planetary shaft play.

Yearly

a. Take up motion full maintained.

b. Shedding cam lever single roller double roller alignment

c. main cutter selvedge drive checked

d. Grease pipe line checked.

e. Air filters condition.

Two yearly

Top lever fully maintained.

Pneumatic maintenance included all solenoid valve cleaning

relay nozzle condition direction & height checked& adjusted,

pipe condition checked.

Both side planetary motions.

Back rest cleaning and full maintenance of drive..

8.0 FOLDING

The main function of this department is fabric inspection and

folding of rolling of fabric.

8.1 PROCEDURE

Cloth- Inspection machine – Folding machine – grading packing

(bale formation )

Mending (reworking)

50
8.2 VARIOUS INSPECTION SYSTEM

• 10 points system (Japanese system).

• 4 Point system (America system).

Here the system used is 4 point. IN this system the faults are

catalogued on the basis of fault length as shown below.

0-3 inches- 1 point

3-6 inches- 2 point

6-9 inches- 3 points

9 inches and above 4 points

Hence according to the length of the faulted each is assigned

respective points. A total o f38 points per 100 m of cloths are

acceptable. The piece with more than 18 points per 100 m is

rejected. The faults with 4 points are considered as major

damage and that with single points are considered as minor

damages. S in 100 of cloth 4 major and 22 minor damages

are the acceptance limit beyond which the piece is rejected.

8.3 GRADING

Here the fabric is graded according to the fault in the fabric.

A. Fresh piece
B. Fresh piece
C. Domestic
D. Rejection
E. Cut piece, rags and chindi

51
8.4 MACHINE IN FOLDING

a. Inspection machines- there are total 9 inspection machines

for he fabric inspection, Manufacture is Almac. The speed of the

inspection is kept 20-25 mpm.

b. Folding or flatting machines- There are 2 folding

machines used for forming the bale of the fabric.

c. Rolling machine- there is one rolling machine for forming

the roll of the cloth

d. Bale pressing machine- There are 2 bale pressing machine

for pressing the bale.

e. Mending table- There mending tables for reworking i.e. for

mending the damages if possible.

8.5 FAULTS NOTED IN FOLDING

• Minor faults- this includes slub, stains and contamination

• Major faults- this includes the faults like bent pick,

double pick, thick place stain mark, oily weft

8.6 MENDABLE DAMAGES

The damages which could be reworked include pick, snarling,

ball formation and double ends.

After packing most of the fabric is then send for dyeing and

finishing in AURO TEXTILE

52
9.0. QUALITY ASSURANCE (R& D DEPARTMENT)

The work of R&D department is research and development of

processes for controlled and better efficiency and quality of

weaving and also to check the quality of the raw material and

the processes.

9.1 THE MAIN FUNCTION OF THE DEPARTMENT

 Research

 Selection of raw material

 Process control

 Process development

 Product testing

 Quality assurances

 Specification tests

9.2 INSTRUMENTS USED IN R & D LAB

1. Tension meter- it is used to study warp tension during

warping beam tension on loom. Standard tension is l cN/tex.

2. Digital thread counter (Make - paramount) – It is used for

counting EPI & PPI.

3. Weighing scale- There are two weighing scales

i) Make- Atco

Capacity- 2.4 kg

ii) Make- Ohaus

Capacity- 210 g

53
1. Circular cutter- It is used for measuring the GSM of

the fabric.

2. Stirrer- It is used for stirring the solution for checking

the viscosity.

3. Tachometer- It is used for measuring rpm.

4. Shore hardness tester- It is used to check the

hardness of cone and cheese.

5. Yarn appearance tester- Make is Kamal Metal Ltd. It

is used for checking yarn appearance

6. Automatic twist tester- It is used to determine the

twist (or TPI) of to yarn.

7. Single yarn strength tester- It is used to measure

the strength of the single yarn.

8. Besslay balance- Make is paramount. It is used to

check the count of the yarn.

9. Moisture meter- It is used to measure the solid

content percentage of the material.

10.Tearing strength tester- It is used to measure the

tearing strength of the fabric in both weft and warp

direction. The sample to be tested is cut with template

of came size and the mounted between the jaws. After

release of the quadrant scale the reading is noted a

soon as cloth tears completely.

11. Lea strength tester- It is used to measure the lea

strength. First the lea of 120 yards is made, weighed

and then the breaking load id measured with the help of

54
 the instrument. Also the CSP of the lea could be

determined with the help of the formula.

CSP =avg. actual count* avg. actual strength.

12.Refractometer- It is used the solid content in sizing/

other sizing chemicals

9.3 SIZE INGREDIENT TEST

Some of the tests of the size ingredients preformed are:-

1. Solid ingredient percentage test- It is done with the help

of analyzed.

2. Viscosity- It is measured with the help of the BITRA CUP and

the stopwatch.

3. pH- It is measured with the help of the pH paper.

4. Ash percentage- It is measured using the muffle furnace.

The following formula is used to calculate the ash %:

Ash % = weight of ash * 100/ weight of material

5. Size pick up % -It is measured by weighing the sized sample

and then desizing and weighing again. Then the pick up % is

given by:

Pick up % = (sized weight – unsized weight) *100/ sized weight.

55