SPINNING.

Cotton Bales Polyester Bales

Mixing
Mixing

Blow Room Blow Room

Card
Card

Combed Yarn Carded Yarn

Lap Former

Comber

Drawing (Breaker)

Drawing (Inter)

Drawing (Finish)

Simplex

Ring winding

Cone Winding

Packing

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 Spinning:

Introduction.

1. The cotton in the Bale form consists mainly of sand, dust, broken seeds, fragment of
leaves, stalk, twinges etc. These impurities are removed in back process, especially in
blow room under the influence of various opening, beating & cleaning action.
The basic objects of blow room are to remove all the impurities by opening cleaning and
formation of uniform Lap of equal length to produce quality yarn.

2. THERE ARE THREE KINDS OF SPINNING.

(a) Ring spinning
(b) Open end spinning
(c) Air jet spinning

3. BACK PROCESS.
Back process starts from

Mixing Blow Room Card Lap Formation Comber

Drawing Breaker Drawing Inter Drawing Finish Simplex

(A). MIXING.
The objects of mixing are.
i. To make the batch homogeneous cotton lots are mixed manually.
ii. Contamination Sorting.
iii. Conditioning (To increase the moisture level)
iv. Opening to reduce tuft size.

Received bales are opened and manually cleaned and mixed. Mixing will be in
accordance with demand / requirement (Pak cotton lot with pak cotton lot or imported
cotton lot with pak cotton lot). Better mixing is very important, almost sandwich mixing
method is used during mixing process contaminations like color cloths, fiber pieces, hard
straws or metallic pieces are also sorted out for further process of mixing & cleaning it
passes through auto pluckier.

(B) BLOW ROOM

Purposes of the Blow Room.

(i) Opening, it is to reduce the tuft size, auto pluckier is to open the cotton to reduce
it in small tuft size Axi flow also opens & cleans the cotton so when cotton gets
out of the blow room then almost 20 to 30 % individual fibers are there.
(ii) Cleaning heavy particle separator removes the heavy particles & dust; more the
cotton is opened more cleaning is achieved. Almost 60 % trash is extracted.
(iii) To enhance the homogeny.

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 (iv) Feed the card. There are two types, lap feed & chute feed.
Aim is to achieve the objectives with minimum fiber loss / damage.

4. CONDUCT OF OPERATION
(a) Auto plucker opens the cotton in small tuft size because it also has the beaters,
which convert the cotton into small tuft size. Axi flow also opens & cleans the
cotton. There is a heavy magnet, which takes out the metallic particles from
cotton.
(b) Six chamber blenders open & clean the cotton. It has a magnet also to remove the
metallic particles.
(c) Three roller blender / beater.
(d) Heavy Particles separator removes dust, trash & other heavy particles.
(e) Now cotton passes through 4 chamber blender again 3 roller blender / beater
length of the cotton fiber is improved.
(f) Then cotton passes through integrated openers & pin beater then from tower
condenser, reserver and opener. Then it comes to fine beater, which also crushes
& beats the cotton to improve the cotton fiber & its length. At the end it passes
through D-Duster, which removes the dust from cotton.

5. Polyester bales opening & blow room process is very simple.

6. Maintenance.
Machines are over hauled in accordance with their schedule but cleaning of machinery is
carried out on daily basis with air pressure.

7. Different kinds of lubricants are used mostly.

(i) Grease LGMT-3 SKF
(ii) For gear box 220-omala oil
For joints 180 Tulles oil

CARD.
1. Card is most important for the preparation of yarn it requires special attention, in card
unit fibers are separated then they are put into some symmetrical shape. During process
impurities, dust heavy particles are separated because card is cleaning of last stage.
Actually spinning process starts from card unit.
Purpose
Purpose of card is fiber-to-fiber opening & cleaning (almost 90 % cleaning is carried out)
short fiber remover and NEP reduction by 70 % as well as formation of uniform sliver.
2. There are two types of cards
(a) Lap feed
(b) Chute feed (It is used as its production is high as compare with lap feed.)
3. Card machinery. There are number of cards in unit 1 & 2 Name is crosrol MK5C made in
England.

Main components of card.

(i) Cylinder roller
(ii) Doffer roller
(iii) Tecreen ruler
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 (iv) Stripping roller
(v) Crush roller
(vi) High speed ruler
(vii) Feed plate
(viii) Feed roller
(ix) Lap roller
(x) Butter roller
(xi) Chute feed roller
(xii) Top set bar
(xiii) Web unit
(xiv) Coiler head

4. Maintenance
Scheduled maintenance & over hauling is carried out in accordance with Programme but
cleaning with jet air pressure is conducted everyday.

Combing
1. Cotton is combed for the preparation of fine yarn. Comber removes the short fiber, dust
& other impurities specially for best count (count is a number which expresses the
relationship between length & weight i.e. weight in given length in given weight may be
defined as number of hanks per pound. Draft before combing reduces the rate of waste
and does not affect the quality of yarn.
2. Purposes.
(a) To remove the short fiber.
(b) To create the uniformity.
(c) Removal of Noil, neps & foreign objects.
(d) Parallelization and strengthening of long fibers.
(e) Sliver formation.

Drawing
1. Drawing is process where the cotton or polyester or the combination of both passes
through a drawing machine for homogeny, blending, fiber straightening, increase in
uniformity for fine consistency of weight and uniform sliver formation. Drawing machine
mixes the polyester & cotton in given ratio it helps in heaving the long fibers to make the
fine yarn. During the process of drawing trash and other dust particular from the sliver
are removed.
2. Normally drawing process has got three stages although purposes are same yet they firm
three stages.
(a) Drawing breaker
(b) Drawing Inter
(c) Drawing finishing

Simplex.
1. Simplex is necessary event to facilitate, ring feeding. It converts the sliver into roving.
Sliver is fed to simplex frame for drafting twisting. This untwisted strand of fiber is hairy
and tends to create fly. An other reason for using simplex process is that the sliver

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 (drawing) cans are not good mode of transportation and presentation to ring spinning
frame.
2. There are three light indicators to show the working condition of simplex machine.
Yellow. It means roving is broken up.
Green. In case of sliver break green light comes “ON”.
White. It means that doff is completed.
Ring winding.
1. Ring is very important unit in whole of the spinning department the ultimate
final product of the back process i.e. yarn is achieved through this department.
2. The purpose of ring winding.
(a). Drafting, to reduce the linear density up to the desired count of yarn.
(b). Insertion of twist & winding.
(c ).Package formation.

3. The quality, length & finesse of fiber are always necessary factor it requires special
attention to avoid excessive fiber breakage. It almost takes 3 hours and 30 minutes to
complete one ring bobbin.

Auto cone winding

1. The last department of whole spinning yarn is auto cone winding. These cones are made /
winded from the ring yarn bobbins. This process is carried out on auto cone machine. The
yarn is wrapped over cones this preparation also helps in transportation. In auto cone
department humidity is maintained up to 65 %.

2. Purpose
(a) Fault clearing. It is also to make the thread in accordance to desired level.
(b) Conditioning, to maintain the desired moisture level.
(c) Formation of package It is to facilitate packing transportation for further
processing.
(d) Waxing it is optional mostly it is done for hosiery yarn.

Packing
In order to maintain safety of cones proper packing material is used following
steps are to be taken.
(a) Yarn is to be properly stored.
(b) Yarn conditioning is to be taken proper care.
(c) Packing should be properly done.

Yarn cones are wrapped in polythene bags, which are put in propylene bags for further
dispatch. These bags are marked with lot # quality specification.
Because of moisture almost temperature remains 24 c.

Suggestion.
1. Quality of end product also depends on input point. To increase the quality of mixing
present mixing area for unit 1,2 & 3 may be enhanced.
2. 2. To increase quality & production latest, Back process machinery may be explored.
3. Air conditioning system of packing area needs to be improved; replaced for the
betterment and protection of cones.
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Doubling Twisting

Doubling
It is to make double yarn or to make ply according to the requirement. It is a costly item. It is
torque free, ability to fall grace fully, evenness is good. Length of thread is also fixed with
customer demand / requirement.

Formula
Count x Weight x 840 (Hanks)
2 / 1.0936

20 x 4.17 x 840
2 / 1.0936

1 lea = 120 Yard.

1 Hank = 7 leas = 840 yards
Count is number of hanks per pound.

PARTS OF DOUBLING MACHINE.

Name of machine FADIS
Model 1990

(a) Yarn clear

(b) Bobbin pack
(c) Blown control wire
(d) Tension disk
(e) Electronic sensor
(f) Sensor cutter
(g) Traverse guide
(h) Fraction roller
(i) Cradle arm + cradle arm disk
(j) Tension pricket
(k) Spool hanger

Twisting
It is to twist the yarn, which is supplied from the doubling. Twisting is adjusted according to
customer’s requirement. Twist is measure of spiral turn given to a yarn in order to hold
constituent fibers together.

S Twist is clockwise.
Z Twist is anti clockwise

Name of machine Valk man from Germany

Model VST U8 1990
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Total machine 08
Spindle per machine 196

PARTS OF TWISTING MACHINE

1. A creel pipe holder

2. Cradle arm
3. Drafter disk
4. Fraction roller
5. Traverse guide
6. Tail guide
7. Pre take-up roller
8. Yarn guide roller
9. Blown control wire
10. Separator
11. Yarn brake
12. Protection port
13. Valko jet
14. Tension capsule
15. Spindle rooter
16. Spindle booster
17. Foot brake

Aqua Splicer
1. It is automatic air with water, splicer unit which is manufactured by MESDAN
2. It can also be manually operated.
3. It joins linen and cotton yarn single or plied
4. It is fitted on air track supply either ‘C’ or ‘L’ types and enables knot free packages to be
produced on specific range of yarn by means of air & water.
5. Aqua splicer joins linen or cotton in a range of counts by applying appropriate mangling
chamber in accordance with yarn characteristics such as degree of twist rate, direction of
twist, length of staple and types of fiber.
6. To optimize the strength and appearance of junction it has a single adjustment point to
control yarn.

ATS
It is a system, which can be attached to all kind of textile machinery where yarn joining is
necessary. It can move the joint air to the optimum working position conserving time &
energy. It is highly efficient compressed air & water supply system, which ensures reliability
and uniformity of splice result.

OPEN END

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1. Open end is just kike back process. In back process impurities are removed by opening,
beating and cleaning action of intact bales. But in OPEN END instead of cotton bales,
waste cotton is brought from various sources almost 15 kinds of waste cotton or PC waste
brought here through inside tunnel or from outside the tunnel. ?

2. Kinds of waste
(a) Blow room drop
(b) Card drop
(c) Pure polyester fly
(d) Cotton fly, generally all kinds of do have short fibers which is dropped down
from cylinder screen and also get accumulated in open area of carding.
(e) Waste from roving ring & simplex.
(f) Pneumafil
(g) Fan (waste from simplex drawing AC etc)
(h) Sweeping in all the units
(i) Damage cotton.
(j) Noil (from comber)
(k) Chimney (from all kinds of ducts)
(l) Hard waste (Now a days not in practice)

2. Kinds of waste out side material.

(a) Supper drop.
(b) CGL (Crescent Green Wood Limited) waste
(c) Open hard waste.

3. Waste plant
Blow room drop, card drop & cotton drop are re-processed through blow room types lines
then types of waste can be mixed further. Rest of the waste qualities are directly used in
mixing. Roving is also opened in waste plant.

4. Process starts from blow room line to lap formation then goes to card unit where slivers
are made after that it passes through drawing breaker then slivers are put to rotor where
yarn cone paper cheese are formed ultimately packing is ready.

1 Bag is of 100 lbs

Average weight of cone is 2.5 lbs.

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