Warping is the process Where ends form a numbers of cons cheeses are collected to form a sheet of yarn comprising of pre-deter mind numbers , length, tension and with which goes to form the weavers beam. Yarn in the sheet will be of some tension, uniform spacing and parallel to each other and will be wound on to a beam called warpers beam.
Direct Warping Machine Specification
Machine Name : Direct warping machine.
Country origin : West point, USA
Model No. : 701
No. of machine : 01
Creel capacity : 434
Speed of the machine : 600 meters / minute
Production capacity per day: (49X1380X.45) =30429 mts (Considering the product mix 5% of 16 Beam of per set and 95% of 12 Beam per set)
03. Yarn Mending Time 1 Min. (10 Times in 12000 Mts.)
04. Yarn Setup time 60 Min. (Daily one time)
05. Speed Raising time 45 sec (from 0 to 600 Mts.)
Prerequisites for warping process:
The following precautions should be taken during warping process:
To form a precaution sheet of yarn specified length and width the individual end of the sheet should be spaced uniformly across in almost uniform tension.
All the ends in the sheet should be wound all most uniform tensions.
Density of the beam should be controlled not by in creasing yarn tension but by adjusting the pressure roll on the beam.
The yarn sheet of beam should not have fault such as missing ends, slack ends, fluffier wild yarn, high variation in tension between ends, which will causes end breaks or defects at subsequent process.
Equipment used:
Following equipment are used in warp m/c:
The details of Direct warping machine used at Auto Denims Limited are as follows:
Manufacturer : west Point Foundry & Machine Company
Order No. : B. 85648
Creel capacity : 434
Key accessories:
The key accessories used for direct warping machine are as follows
One small weighting scale
60 wrapper beams
Safety:
Following maintain are used in warp section:
Smocking is strictly prohibited in the factory permission
Never touch the machine or its parts while it is running; only the authorized person can operate the machine.
Following the safety instructions mentioned on the machine.
Do not put hands on the beam while running the machine
Do not used compressed air on yourself
Put sign on when the maintenance work of the machine is going on.
Do not operate the machine wearing loose dress that could get entangled in the rotating parts
Put the musk on the nose & mouth while running the machine.
Machine set up:
Set up parameter
Range
Set value
Warping length
1-99,999
Based on yarn count, wrapper beam capacity & order quality
Cone/cheese no. in the creel
325-410
Based on customer’s fabric Construction
Machine speed
1-800
650m/min. based on yarn count and quality.
Stop motion
m-second
Do not need adjustment
Supply Pressure
1-8 bars
5 bars
Beaming Pressure
1-160
30Psi
Press roll Pressure
1-160
30Psi
Carrier roll Pressure
1-160
50/55Psi
Hydraulic Pressure
0-40
16Psi
Operation staff for warping section:
Production Executive
Supervisor
Operator
Helper
Check list before operation following points prior to:
Operator must check quality in teams of count, material, and color, mo mixing in allowed
Count the cone/chesses, weight/length variation and finally set the warping length for minimizing wastage and maximum warping length
Check the supply pressure, beaming pressure, press roll pressure carrier roll & hydraulic pressure
Check the number of ends in the creel
Check the setting of warp length and weft length correction factor.
Check the warping beam & yarn available.
Working Procedure:
Based on the production programs operator collects greige yarn from the store as per requirement count, name of yarn manufacturer, yarn lot & quality
The machine operator, creel men and helpers open/break the yarn cartons/bags and place the cones/chesses on the creel as per program and draw the head end of each cone/chesses through the hole of vertical dise, tension dise, yarn guide, stop motion device and then through expanded, comb of beaming unit.
The creel and Direct Warping Machine setting are done according to the requirement as per operating instruction.
When the reed count is not changed on a specific loom, the ends of the fresh beam are tied with of the exiting one with the help of TODO – knotting machine. The selector no. is set according to the count of warp in the beams. If the counts of warp in the exiting beam and that of the fresh beam are different .The m/c can work at a speed of 200-500 knots /min and it is fisherman knot .Two person set the beam in position while one runs the TODO machine. One knotting machine is sufficient to serve all the 95 looms.
Work load assignment
Total no. of looms: 95
Picanol delta X: 30
Picanol omni: 16
Picanol gamma: 25
Sulzer: 24
Preamle
There are two methods which are followed to prepared the beam for mounting on the loom.
These are:
Warping trying or knotting
Drawing in
Warping trying or knotting
The method has some limitation to used where an exactly same article or quality of fabric is to be made that is already running on the loom before knotting the following points should be consider
The total number of warp ends should be same as that of already running into the loom.
The count of warp yarn and weave design be same.
Drawing in
This method of mounting weavers beam on the loom is adopted when the design and quality differs from the existing one. The yarn as it comes to drawer hook is then drawn through dropper, then through the eye of heald wire. All the warp yarn thus drawn one by one finally pass through the split of the dent of reed is called denting
Equipment Used
For Tying a sized and leased beam with the already running beam in the loom. Following typing of machines are used: Knotex warp typing machine for mono color fabric.
Key Accessories:
Key accessories used for drawing are : Drawer’s hook, Reed knife
Key accessories used for warp tying are: Brush, Leasing band, Stand frame
Safety:
In order to ensure floor and personal safety are instructed to following the safety guideline given bellow:
Smokey is strictly prohibited in the department
Operators are instructed not to touch any rotating or operating parts until the machine comes to complete
Put a sign on the machine when knotting work are progress
Cheek before Production:
Check the correctness of the knots
Check the whether any are crossing
Check whether any empty dropper is left or not
Warp tying process:
The operation procedure for warp tying is enumerated under the following points
The beam is loaded on to a specific loom and mounted on beam bracket. The tying frame is set in the roper position.
The ends of the old beam and the ends of the new beam are accurately brushed and gripped by the frame so that older and new ends makes a upper and lower set of yarn placed in proper tension.
Then warp tying head is mounted over the tying frame
Then machine is started, operator will check the correctness of the knot and start again by switch
Thus knotting will be completed up to the end of set tying upper set of older yarn with lower set of new warp
Thus knotting is completed tying head and frame are removed, the old pieces of knotted yarn is pulled through the frame and thus new warp set is allowed to pass and made reedy for run.
Operation staff for knotting section:
Knotting machine in charge
knotter
Helper
Drawing in process:
The operation procedure for drawing in is enumerated under the following points
Generally for new quality drawing n done on the machine
When article is completed the machine is ready for drawing in
As per quality drawing in charge make a program for drawing in
After drawing in / denting is complete then all frame reed are set in the machine
Then new yarn from the beam pulled and set in the loom with dropper, healds properly positioned and new yarn are tied with the old piece of cloth wrapped around the pressure roller with a small number of kno
Operation staff for drawing section:
Drawing in charge
Drawer
Helper
Process Definition:
Interlacement of two or more yarns/threads warp and weft yarns in a definite order to form a fabric which is suitable for dress material, domestic and industrial purpose is called weaving. The machine used for this purpose is called weaving machine or loom.
Equipment:
The knotting machine used to the purpose of weaving can be categories are as follows:
The key accessories used for weaving are as follows:
Weavers hook
Weaver’s cutter
Pick counting glass
Measuring tap
Check before production:
Operator must be checking the following points prior to operation:
Check safety switch
Check drawing, denting, fabric width, weft density and other fabric defect
Check yarn count and manufacturer
Operation Procedure:
After article is done a new weaver’s beam set on the machine and drawing or tying is done. It is the duty of the loom technician to check and set all necessary setting, gauging and operating values through mechanical means after setting is done. He hands over the knotting machine to beam pieces/ beam fitter
It is mainly used to store the material and removed micro dust. It is also used to get long term blending. It is made up of three parts:
Storage section
Intermediate section
Delivery section
Unimix Machine Specification:-
No. of machine = 3
Make = RIETER
Model = B-7/3S
Production = 500-600 kg/hr.
Process Sequence (Ring Spinning)
RAW MATERIAL IN BALE FORM
↓
BLOW ROOM
↓
CARDING
↓
DRAW FRAME
↓
SIMPLEX
↓
RING FRAME
↓
WINDING (auto corner)
Blow Room
In Ring Spinning Department of Auto INDUSTRY LTD. TRUTZSCHLER B/R line is used.
No. of blow room line -1
Manufacture – TRUTZSCHLER
Temperature and humidity in blow room department:
Temperature – 33.6c
Humidity – 62.7%R.H
Multifunctional Seperator:-
It consists of a suction fan running at a speed of 2900 rpm.
Maxi Flow:-
It consist of –
Beaters – 2
Condenser (suction fan) – 1
Fan speed – 500 rpm
Dust cage – 110 rpm
Beater 1 – 706 rpm
Beater 2 – 712 rpm
Speed Frame
In Ring Spinning Department there are 3 speed frame
Make – ZINSER
Model – SAURER -681
Drafting system – 3 over 3
Spindle machine – 120
Draft – 5 (approx…)
Production – 1600 kg/shift
Efficiency – 85%
Labour – 5 Worker/3 m/c (2 training)
Ring Frame
In Ring Spinning Department there are total 5 RING FRAME.
2 – Lycra
3 – Slub yarns
Make – ZINSER
Model – 351
Spindle /m/c – 1116
Drafting – 3 over 3
TM – 4.6 (slub), 4.2(plain)
Production – 12 ton /day
Efficiency – 93%
Labour – 14 workers
Auto Ltd. is the largest and most versatile business conglomerate in the private sector in Bangladesh. Auto Ltd. is committed to the best human workplace practices. Their goal is to continuously improve their Human resource policies and procedures through education, training, communication and employees involvement. Right from inception the policy of the company has been to provide total customer satisfaction by offering quality woven & knitwear in time. Working on new concepts in styling & content of the knitwear is a continuous activity in Auto Ltd. with an objective to up the quality and the value of merchandise. To meet the manufacturing to quality and promote delivery. Auto Ltd. decided to integrate the manufacturing process in a planned manner. Over the year the entire process has been integrated by importing sophisticated machinery from world-renowned manufacturers. For achieving their goal, Auto Ltd. are textiles graduates. According to their capacity they have an enriched production team which is very rare in other factories of Bangladesh. The working environment of Auto Ltd. is very cordially & friendly. All of the executives & employees of Auto Ltd. are very much cordial & they always appreciate the learners.
In a Industries opening of the cotton bales having weight around 160kg is done with the help of unifloc machine. This unifloc machine consist of a beater which has an excellent opening system after opening at this machine the tufts of cotton are pushed into pipes and are made available for another processes with the help of blower.
MACHINE SPECIFICATION:-
No. of machine = 2 Make = RIETER Model = A – 1/2 Transverse speed = 9.5 mpm Production = 900 – 1000kg/hr.
DUST GAUGE:-
The open tufts of cotton are feed to the dust gauge after opening through unifloc machine with the help of suction. In this section the large dust and small particle are removed from the tufts of cotton.
METAL DETECTOR:-
At this stage any foreign like metals are detected and get separated with the help of the suction from the tufts of cotton. Objective:- Cotton fibres arrives in the mill in hard presses bales. So the objective of the blow room is to properly open this hard presses bale of cotton into small tufts. Opening of fibres in the blow room involves not only breaking the stock into small tufts but also to removes the impurities like dust, seed, metal pieces, pouches, stones etc. Opening of fibres in the blow room is essential to properly carry out the subsequent process of carding, drafting, roving and spinning.
PROCESS SEQUENCE IN BLOW ROOM
Unifloc ↓ Dust gauge ↓ Metal detector ↓ Veriocleaner ↓ Unimix ↓ ERM – cleaner 1 ↓ ERM – cleaner 2 ↓ Condenser ↓ Fan for supplying to card
PROCESS SEQUENCE (ROTOR SPINNING)
RAW MATERIAL IN BALE FORM ↓ BLOW ROOM ↓ CARDING ↓ DRAW FRAME ↓ OPEN END (ROTOR SPINNING)
HUMIDIFICATION SYSTEM:
The humidification system plant mainly comprises of the rotary filter, dampers and humidifier. The micro dust is being transferred to the rotary filter (consisting of a large filtering cylinder) where the micro-dust is retained and dust free air is sucked in with the help of travelling nozzles. The purified air obtained is now transported via a suction fan to the humidifier and dampers. The function of damper is to control the flow of air to the department and also to sense the required relative humidity of the air. In case of low humidity the air is transported to the humidifier where the dry air gets humid and is transferred to the department. Almost all the department in Auto Industry Ltd. employ the system of humidification and sucked in waste is being re-circulated along with proper filtration.
Card specification and running parameters:-
Cylinder speed – 558 rpm Doffer speed – 57 rpm Licker in speed – 1126 rpm Flat speed – 320 mm/min Delivery rate – 254 m/min Hank of sliver delivered – 0.100Ne Efficiency – 85% Total draft – 100 Chute feed air pressure – 276 pas Production – 90kg/hr. Can capacity – 7200mm Card coiler tension – 5% Can changing speed – 50m/min Can diameter – 1000m Temperature in carding department – 35.1 C
The objective of this report is to visit different departments, to learn about their organogram, activities, process flow and so on. After the study I have gathered a brief knowledge about them, which will help me in future to decision making and to do my job properly. There are 6 departments here. They are:
Central store
Fabric store
Cutiing section
Sewing section
Finshing section
R & D department
Central store
Different types of labels are mentioned below:
Care label
Main label
RN label
Bar code label
Country label
Flag label, etc
Categories of label are mentioned below:
Woven label
Shertin label
Paper label, etc
Different types of buttons are mentioned below:
Snap button
Plastic button
Pearl button
Metal button
Pig nose button
Chalk button , etc
Sewing threads are mentioned below:
100% cotton
Filament thread, etc
Needle sizes are mentioned below:
DB- 7
DB-8
DB-9
DB- 10
DB—11
DC- 7
DC- 8
DC- 9
DC- 10
DC-11
DP- 5.9
DP- 5.10
DP- 5.11
DP * 17* 11
DP * 17* 14
VY- 8
VY- 9
VY- 10
VY- 11
Accessories of central store are:
Trim card
Hanger
Button
Shartin Tape
Mobilon tape
Sewing thread
Poly
Gum tape
Scotch tape
Security tape
P belt
Sewing machine troubleshooting:
To check label color-wise and on the basis of order quantity.
Conclusion: The necessary things of 6 departments of the factory are mentioned above. From which one can gain a brief knowledge about them.
Details about process and joining inlay with using needle and possible defects and solution:
Collar joint:
Body inlay
Collar inlay
Used needle
Stitching style
7 MM
7MM
11, 14 –DP/DB
PLAIN MACHINE
Front joint:
Back yoke inlay
Front (upper, lower) inlay
Used needle
Stitching style
9MM
9MM
11 – DB / DP
1/32 Top stc- P/ MACHINE
O/L WIDTH /9MM
O/L WIDTH
11 -DC
Over lock
SLV joint:
Body inlay
Slv inlay
Used needle
Stitching style
6MM
18-19 MM
14
1 cm French seam
9MM
9MM
14 -DC
Over lock
1 CM
1 CM
14 -TV
Feed of the arm
SLV Rolling
slv inlay
Used needle
Stitching style
9 MM
9, 11 – DB / DP
PLAIN MACHINE
5 MM
9, 11 – DB / DP
WELTED – ¼ / 5MM
SLV seam
Slv seam inlay (both end)
Used needle
Stitching style
O/L WIDTH
14 – DC
OVER LOCK
1 CM
14 – TV
FEED OF THE ARM
GENBOL
slv inlay
Used needle
Stitching style
9MM
9, 11 – DB / DP
PLAIN MACHINE
Cuff joint:
slv inlay
Used needle
Stitching style
9MM
11 – DB / DP
PLAIN MACHINE
LOWER
Lower Rolling
Used needle
Stitching style
9MM
11 – DB / DP
PLAIN MACHINE
Front placket:
Front placket inlay
Used needle
Stitching style
1/14 welted – 7-8 MM
14- UO
KANSAI
Side seam:
Back part
Front (up / low)
Used needle
Stitching style
1 CM
1 CM
14 – TV
Feed of the
9 MM
9 MM
14 – DC
Over lock
Slv placket:
slv inlay
Slv placket inlay
Used needle
Stitching style
9 MM
9 MM
9 – DB / DP
PLAIN MACHINE
Pocket:
Pocket inlay
Used needle
Stitching style
8 MM
9, 11 – DB / DP
PLAIN MACHINE
Btm Hem
Btm Hem inlay
Used needle
Stitching style
1.5 CM
14 – DB / DP
PLAIN MACHINE
Back yoke joint
Back part
Yoke (top / inside)
Used needle
Stitching style
9 MM
9 MM
14 – DB / DP
Over lock
NOTE: – DP & DB needle are used for same purpose but btm of DP needle is thick and that’s why according to machine needle adjustment DP is used thick hole of needle setting machine.
Information about bobbin and guide used at sewing machine
Guide
Guide is used according to stc at Gmts.
¼, 1/8, 3/8, 1/16, 1/32 etc and plain guide.
Some time for sewing according to measurement some fid is used at machine.
For lower rolling this is seen and some other if need.
Bobbin
Bobbin is used at machine at inside for lock the top side stc with its strength.
It is used according to machine. Information is given below
Except these mentioned machine bobbin is used for all machine
For check fabric vertical checks are called warp & horizontal checks are called weft.
A zipper has four parts:
Runner
Chain
Fabric (cotton / polyester)
Stopper
Note: fabric use in zipper almost of polyester because of its longer lasting.
Information about front placket
There are three kinds of front placket:
Welted kansai
Frence seam double fold
Hidden placket.
Information about thread for per inch
Conclusion
If S.P.I is 11 then it is calculated that for one inch we need 2.5 inch thread. Tread spin count classification: Two types of spin count: s spin count and z spin count. Sewing machine troubleshooting is important factor for any garments
