What is Direct Warping Machine? How It Works?

What is Direct Warping Machine? How It Works?

Direct Warping Machine

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

  1. Machine Name : Direct warping machine.
  2. Country origin : West point, USA
  3. Model No. : 701
  4. No. of machine : 01
  5. Creel capacity : 434
  6. Speed of the machine : 600 meters / minute
  7. 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)

Down Time:

01.  Beam load and unload 5 Min (After 12000 Mts.)
02.  Knotting Machine Time 30 Min. (After 4 Beam) 
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 parameterRangeSet value

 

 

Warping length1-99,999Based on yarn count, wrapper beam capacity & order quality
Cone/cheese no. in the creel325-410Based on customer’s fabric Construction
Machine speed1-800650m/min. based on yarn count and quality.
Stop motionm-secondDo not need adjustment
Supply Pressure1-8 bars5 bars
Beaming Pressure1-16030Psi
Press roll Pressure1-16030Psi
Carrier roll Pressure1-16050/55Psi
Hydraulic Pressure0-4016Psi

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.

What is Knotting Machine? How it Works?

What is Knotting Machine? How it Works?

Knotting Machine

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:

Name o loom

 

 

No of loom

 

 

Type of settingWeft insertion capacityRPM
Tsudakoma air jet loom

 

 

56cam shedding

 

 

2Up to 650

Key accessories:

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

What is Unimix Machine? How it Works?

What is Unimix Machine? How it Works?

Unimix Machine

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:

  1. Storage section
  2. Intermediate section
  3. 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:

  1. Temperature – 33.6c
  2. 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.

What is Unifloc Machine? How it Works?

What is Unifloc Machine? How it Works?

Unifloc Machine

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

Unifloc machine is group of spinning machine

Define Sewing Machine Defects and Troubleshooting

Define Sewing Machine Defects and Troubleshooting

Sewing Machine Troubleshooting

Metal room- garments are received from sewing

Sucker machine- To remove the dusts

Ironing   ffff

Quality check- Inspection

Measurement

Getup check

Poly table- Color separation

Size separation

Hang tag add

Care label check

Folding/ hangering

Adding sizer to hanger

Body stickering

Poly insert

Poly close

Packing

Assort type:

There are 4 types of assort. They are:

Solid color & Solid size

Assort color & Assort size

Solid color & Assort size

Assort color & solid size

Department Objective

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

  1. 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 inlayCollar inlayUsed needleStitching style
7 MM7MM11, 14 –DP/DBPLAIN MACHINE

Front joint:

Back yoke inlayFront (upper, lower) inlayUsed needleStitching style
9MM9MM11 – DB / DP1/32 Top stc- P/ MACHINE
O/L WIDTH /9MMO/L WIDTH11 -DCOver lock

SLV joint:

Body inlaySlv inlayUsed needleStitching style
6MM18-19 MM141 cm French seam
9MM9MM14 -DCOver lock
1 CM1 CM14 -TVFeed of the arm

SLV Rolling

slv inlayUsed needleStitching style
9 MM9, 11 – DB / DPPLAIN MACHINE
5 MM9, 11 – DB / DPWELTED – ¼  /  5MM

SLV seam

Slv seam inlay (both end)Used needleStitching style
O/L WIDTH14 – DCOVER LOCK
1 CM14 – TVFEED OF THE ARM

GENBOL

slv inlayUsed needleStitching style
9MM9, 11 – DB / DPPLAIN MACHINE

Cuff joint:

slv inlayUsed needleStitching style
9MM11  – DB / DPPLAIN MACHINE

LOWER

Lower RollingUsed needleStitching style
9MM 11 – DB / DPPLAIN MACHINE

Front placket:

Front placket inlayUsed needleStitching style
1/14 welted – 7-8 MM 14- UOKANSAI

Side seam:

Back partFront (up / low)Used needleStitching style
1 CM1 CM14 – TVFeed of the
9 MM9 MM14 – DCOver lock

Slv placket:

slv inlay Slv placket inlayUsed needleStitching style
9 MM9 MM9 – DB / DPPLAIN MACHINE

Pocket:

Pocket inlayUsed needleStitching style
8 MM9, 11 – DB / DPPLAIN MACHINE

Btm Hem

Btm Hem inlayUsed needleStitching style
1.5 CM14 – DB / DPPLAIN MACHINE

Back yoke joint

Back partYoke  (top / inside)Used needleStitching style
9 MM9 MM14 – DB / DPOver 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

Name of machineBobbin
Plain machine-chain stcNot use
Over lockNot use
Feed of theNot use
KanchiNot use

Warp & Weft

For check fabric vertical checks are called warp & horizontal checks are called weft.

A zipper has four parts:

  1. Runner
  2. Chain
  3. Fabric (cotton / polyester)
  4. 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:

  1. Welted kansai
  2. Frence seam double fold
  3. 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