Spinning Process of textile industry the comber machine is used to convert combed sliver from lap to produce finer and higher quality yarns. The comber machine improves the uniformity and strength of fibers. The function of combing machine is straightening and parallelizing of fibers and the removal of short fibers and impurities.
Functions of Combing Machine :
A combing machine is a one type spinning machine for spinning process of yarn which has comb to straighten the fibers and extract neps, foreign matter and short fibers. Combing machine is used to produce higher count yarn(stronger , more even, more compact, finer, smother). The yarn which is produced by using combing machine is called combed yarn.This machine produces finer yarn by removing short fibers below a pre-preselected length. It reduces length variation in the cotton mixing for yarn market. It removes neps and foreign matter form the cotton. This machine improves fiber parallelization and straightens of the fibers from spinning wool.
Main Parts of this Textile Machinery:
Parts of Comber Machine
Lap roller
Tension roller
Condenser
Feed roller
Top nipper
Bottom nipper
Top combe
spinning wheel
Bottom comb
Detaching roller
Table
Drafting roller
Cloth cleaner
Belt
Trumpet
Calendar roller
Coiler calendar roller
Coiler head
Feature of Spinning Can for Combed Yarn:
Made to exact dimensions to meet industry requirement’s.
Top quality anti static polyethylene sheet for cans, and strong, uniform “jupee” fiber sheet for fiber cans, ensures uniform quality and thickness of the can wall.
Meets the tough requirement’s of advanced spinning technology.
Spinning can made from special high carbon steel.
Specially heat-tempered for combed yarn can
Coils engineered in varying diameters to nest within themselves, thus providing additional capacity when can is full.
Dimensionally and geometrically accurate; consistent in every respect.
Calibrated for precise silver weight control.
Custom made to each customer individual Spring can system. Pressure and right requirement’s.
All Spring can system design to significantly reduce waste.
High impact on nylon wheel for combed yarn can
Non rotating dusts shields reduce up between
Combed yarn wheels and truck assembly.
Feature of Comber:
In lap preparation, total draft, fibre parallelisation, no of doublings, lap weight etc should be done properly (based on trial).
Higher the lap weights (gm/m) lower the quality. It depends on type of comber & fibre micronaire.
If finer micronaire is used, lap weight is reduced to improve combing efficiency.
If coarse micronaire is used, lap weight is also increased.
If fibre parallelisation is too much, lap sheets sticking to each other is more (It happens if micronaire is very low also). If lap sheets are sticking to each other, total draft between carding & comber are reduced.
If draft is less, fibre parallelisation is also less, hence loss of long fibres in noil will be more.
Top comb penetration should be highest for better yarn quality. But care should be taken to avoid top comb damage.
Damaged top comb will affect the yarn quality very badly.
Setting between unicomb & top nipper should be same & it should be around 0.40-0.5mm.
Feed weight is about 50-58gm for combers like E7/4 & is 65-75 gm for combers like E62 or E7/6.
The lower the feed length, the better the yarn quality. Trials to be conducted with different feed lengths & it are decided based on quality & production requirement.
Required waste should be removed with the lowest detaching distance setting.
For cottons with micronaire up to 3.5, top comb should have 30 needles/cm & for cottons with more than 3.8 micronaire, top comb should have 26 needles/cm.
Trials to be conducted to standardise waste percentage.
Piecing wave should be as low as possible & index should be decided based on cotton length & feed length.
Spectrograms should be attended. Comber sliver Uster should be less than 3.5.
Head to head waste% should be as low as possible.
Variation in waste percentage between combers should be as low as possible(less than 1.5%).
If cotton with low maturity coefficient is used, it is better to remove more noil to avoid shade variation problem.
Specifications of Combing Machine:
[label type=”label” title=”Specifications Name“]
[label type=”label” title=”Specifications Value“]
Product Category
Spinning
Machine Category
Combing Machine
Product Name
Automatic Comber Machine
Product Model
According to Manufacturer
Product Class
New
Origin
China/Others
Brand/Manufacturer
spinning wheel
Agent In Bangladesh
No/Yes
Power
6.85 Kw
Temperature
Normal
Certification
SGS/Others
Production Capacity
73kg/h
Max Speed
300 Neps
Type Of Circle
Single Cylinder Single Coil Forming
Delivery Can Size
24″ X 48″
Spool Size
300 mm
Draw Box Drafting
5/4
Cotton Fiber Length
25-51 mm
Noilage
8-25%
Weight
5250 Kg
Theoretic Output
73 kg
Drafting Ratio
Draft 9.12-25.12
Nipper Rate Nips
500 r/min
Head Number*Head Gauge
8*470mm
Suction
Integral Suction
Compressed Air Pressure
(6-8)*105 pa
Compressed Air Consumption
1.5 Nm³/h
Dimension (L*W*H)
7433*2120*1700 mm
Description
Adopt the combing components those are suitable for combe in the high speed running
Feature of Combing Machine for Combed Yarn:
Lapping Cotton feed automatically in textile industry by Comber machine,
Yarn is combed by Combing Machine
Wide range of raw material available in cotton yarn market and yarn market
Spinning process of yarn combed in spinning mill
Spinning wheel is used in this machine for spinning process.
It works as dust removal equipment and ensure workers health.
Advantages of the Spinning Process:
This machine improves uniformity and strength.
This machine produces higher count of yarn.
It reduces neps in the yarn combe.
It improves smoothness and luster of yarn.
It improves the spinning value of fiber.
It combe yarn.
It produces much clearer yarn and reduces the hairiness of yarn.
Disadvantage of the Spinning Wheel of the Machine:
Better quality fibers are needed.
Produces more wastage than other process.
Combed yarn tendency is high to snarl.
Some Defects of Combed Yarn
Slubs, Thick and Thin Places-
Definition and Causes:This usually appears in yarns of lower quality where open-end spinning methods and inadequate and insufficient combing and /or carding processes are used. Apart from being clearly evident on the surface of the fabric, in some cases they also cause yarn breakage and create holes during the knitting or weaving process.
Preventive Suggestions: During the spinning process, and based on the origin and the quality of the base fibers, appropriate carding and/or combing processes should be used.
Corrective Measures: In plain structures such as Jersey or plain weave poplins and sheetings, etc. this defect will be clearly visible and there are no corrective measures available. In more detailed structures, certain secondary processes such as printing or sueding may cover or reduce the appearance of these areas.
Loop and Weave Distortion-
Definition and Causes: This manifests itself in the form of small multi-directional lines (crinkles) on the surface of the fabric. The main causes are the variation and inconsistency in the twist levels of yarns used. Yarns of different twist levels react in different forms after exposure to water and temperature. As a general rule, higher twist levels produce larger crinkle lines. This principle is often used, purposely, to produce fabrics with crinkle surfaces.
Preventive Suggestions: During the winding process and all throughout the spinning process yarn twist levels must constantly be monitored. Corrective Measures: For this problem, unfortunately, there are no corrective measures available.
Rnags and Picks on the Fabric Surface-
Definition and Causes:This is a common problem with light to medium weight knit fabrics constructed using textured continuous filament yarns with high number of filaments (96 and higher). In woven fabrics this is less evident. This is due to the fact that most knit structures have looser constructions compared to woven fabrics, where the construction is generally tighter. In knit fabrics yarns (and fibers) have more space and can get separated from the stitch when pulled. Generally, as the number of filaments increases, the susceptibility to snagging also increases. With flat continuous filament yarns this problem is less evident.
Preventive Suggestions: During the production process, to the extent possible, the contact with sharp elements must be avoided and eliminated.For dyeing these types of fabrics, dye machineries must be equipped with inner chamber Teflon linings to ensure a smooth circulation of fabric. Other machineries with which the fabric may come in to contact (slitters, tenter frames, etc.) must also be regularly checked for rough and sharp places. The use of silicone softeners must be avoided since these types of softeners tend to increase the slippage of fibers. In cases of very sensitive fabrics, an application of a coating of Sodium silicate in the finishing stage is recommended. Corrective Measures: For this problem, unfortunately, there are no corrective measures available.
The Appearance of Dead / Immature Cotton on the Fabric Surface-
Definition and Causes:During the cultivation and the growth process of cotton, and due to the deficiencies in soil preparation and nutrition, an incomplete growth, in certain portion of the crop, takes place. The incomplete growth causes the outer hard shell to remain with the affected fiber. These unshed outer shells appear on the surface of the fabric in the form of dark specs.
Preventive Suggestions: During the spinning process, an intensified double carding and combing, depending on the severity of the fiber condition, will be required. Most of these impurities will be removed in the spinning process. However, some, after fabric construction (greige goods), will appear on the surface and they need to be cleaned up and removed. In cases where the problem on the fabric is not severe, a process of caustisization or mercerization will be sufficient to dissolve, remove and clean up the surface. In more severs cases, specifically with heavy weight woven fabrics such as Denims, Bull Denims, Canvas, etc. where open-end yarns are used, a pre-scouring treatment using Potassium Hydroxide is recommended. The use of dyestuffs with high dead cotton coverage is also recommended. Corrective Measures: Re- bleaching and Re-dyeing the fabric may be the only solution.
Non-Dyeable Cotton Fibers Due to Soil Contamination-
Definition and Causes:In certain cotton growing regions, such as Southern Brazil and certain regions in Pakistan, the soil is known to be contaminated with metal complex elements. These metals include Iron, Copper, Magnesium, etc. During the growth process some of these elements, Iron in particular, gets absorbed and becomes a part of the chemical composition of the cotton fibers. The presence of these metal particles in the fiber inhibits the fiber’s dye affinity and prevents a complete absorption and exhaustion of certain dyes and optical brighteners.
Preventive Suggestions: Prevention of soil contamination is not yet effectively possible.
Corrective Measures: The fabrics made from these yarns (fibers) are only suitable for dark colors and black. Bleaching the fabric into a bright white color is not always possible since the red or the brown cast of the contaminants is often present. Using these types of fabrics for white, pastel and bright colors should be avoided.
Barre-
Definition and Causes:The horizontal lines, across the knitting courses and with distinctive repeat patterns are referred to as Barre lines. These are as the result of the tension differential in the intake of yarn in to the knitted loops. They could also be the result of the difference in the quality of the yarn cones (or cheese) used. In fabric constructions where spandex yarns, in particular bare or uncovered types, are used the excessive, inconsistent and unregulated stretch could be the cause.
Preventive Suggestions: Regular monitoring of yarn tensions plus ensuring that the yarn cones are from the same production merge will help to minimize or eliminate this problem.
Corrective Measures: Provided that these Barre lines are slight and are not too distinctive, using certain dyestuffs with high level of Barre coverage may be effective in helping to achieve a uniform dyed surface. In severe cases, however, no corrective measures are available.
Color Change Due to the Presence of Optical Brighteners-
Definition and Causes:Certain synthetic yarns, such as Polyester and Nylon, during the Melt-spinning processes, are tinted with optical brighteners. The presence of these brighteners will affect the dye affinity of the yarns and may cause illuminant Metamerism where the intensity and cast of a color appear to vary under different light sources.
Preventive Suggestions: When assigning yarns for production, using an Ultra Violet light source, the presence of these types of tints can be established. Prior to the dye process and in the preparation stage attempts should be made to strip and remove these tints using a strong alkali solution such as Sodium Hydroxide or Soda ash. In certain cases the use of Phosphoric acid is recommended.
Corrective Measures:For a fabric which has been constructed using tinted yarns no corrective measures are available.
Twist Liveliness-
Definition and Causes:Excessive twist levels in the yarn will cause the fabric to have an unstable appearance in the form of curled edges and off-grain and irregular course lines.
Preventive Suggestions:Monitoring and determining yarn’s twist level prior to production is of great importance. It is to be noted that twist level is determined based on the length of the fiber, types of spinning, and the direction of twist(S or Z).
Corrective Measures:With fabrics that are knitted with excessive yarn twist, a hot scour treatment will reduce the instabilities. However, as previously mentioned (in section 1 – C), in severe cases this fiber relaxation may cause crinkles on the fabric.
Conclusion:
In the spinning mills the combing machine is very popular which used to produce smoother, finer, stronger and more uniform yarns. For higher count of yarn this machine must be needed.
Lap Former Machine of spinning mill is used for lapping cotton and forming compact lap from drawn sliver by drawing & drafting to feed the combing machine. The lap of 30 inch wide is wound on to bobbin and cotton wool. The lap former machine is not use in the carded yarn process because it is used for lapping yarn by lapping process. Former meaning make laps of various counts for Carding Machine of textile industry.
Application of Lap Former Machine for Lapping Process:
This machine is used for lapping process wool and further opening and impurity separating cotton human made fibre blend and midlength chemical fibre balow 77mm and making the lap and lap joint of various counts for carding machine.
Lap Former Machine Parts
Specifications of Lap Former Machine:
The specifications of this machine is stated below shortly-
[label type=”label” title=”Specifications Name“]
[label type=”label” title=”Specifications Value“]
Product Category
Spinning
Machine Category
Lap Former
Product Name
Lap Former Machine
Product Model
According to Manufacturer
Product Class
New
Origin
China/India/Others
Brand/Manufacturer
Name of Manufacturer
Agent In Bangladesh
No/Yes
Power
9.7Kw
Temperature
Normal
Certification
SGS/Others
Production Capacity
1000 Set/Sets per Month
Machine Width
1060 mm
Tine Of Lap Forming
365457 min
Output
250 Kg/hr
Pressurizing
Weight
Cotton Diameter
365-457 mm
Punching Diameter
3.18-5.83 mm
Cotton Roller Diameter
230/10-13 mm
Combined-Beater Diameter
406-900 1000 mm
Dimensions (L×W×H)
3745×2710×1520
Weight
4300 Kg
Description
The machine is applicable for the raw cotton of all classes or chemical fiber. It is used for cotton wool
Cotton Lapping Process:
Flow char of cotton lapping process during whole carding procedure is shown below-
First Cotton Bale Process
↓
Blow Room Process
↓
Lap Process
↓
Carding Process
↓
Carded Silver Process
↓
Drawing Process
↓
Drawn Silver Process
↓
Simplex Machine Process
↓
Roving Process
↓
Ring Spinning Process
↓
Spinning Bobbin Yarn Process
↓
Winding Process
↓
Finally Cone Process
Cotton Wool Spots Removing Process:
After making fiber by lapping process the fiber exits some spots. The cotton wool spots removing process are described below-
Sufficient amount of water
↓
Fiber was loaded after lapping process and run for 10 min.
↓
Drain Process
↓
Sufficient amount of water
↓
Acetic acid was included for 4 min.
↓
Wetting agent included for 4 min.
↓
Run for 8 min. at 70 C
↓
Rinse for 10 min.
↓
Drain Process
↓
Required amount of Water
↓
Acetic acid included for P – controlled
↓
Check P at 4.6
↓
Enzyme included
↓
Run for 1 hours
↓
Shade checking process
↓
Rinsing for 10 min.
↓
Anti crease was included up to 5 minute
↓
Leveling agent included for 5 minute
↓
Run for 20 minute at 80 C”
↓
Rinsing up to 10 minute
↓
Acetic acid included for P – controlled
↓
Checking P at 6.5
↓
Softening agent injected for cotton wool spots removing process
Ring spinning machine in the textile industry is an industrial machinery used for spinning process to convert the roving into very fine yarn and then wind it onto bobbins for storage. The operation of ring spinning machine is creeling, drafting, twisting, winding, building and doffing. It is related with Roving Frame Yarn Spinning Machine
Function of Ring Spinning :
Drafting: draft the roving for required fineness.
Twisting:forrequired count and strength, twist thedrafted strand to form yarn.
Winding: wind the twisted to bobbin.
Spin: spinning yarn
Parts of Spinnings Ringe Machine :
Creel
Guide roller
Drafting assembly
Pigtail guide
Traveller
Ring
spinning wheel
Ring rail
Spindle
Spindle tape
Spindle rail
Spindle
Specifications of Spinnings Ringe Machine :
[label type=”label” title=” Specifications Name”]
[label type=”label” title=”Specifications Value”]
Product Category
Yarn
Machine Category
Ring Spinning
Product Name
Spinnings Ringe Machine
Product Model
According to Manufacturer
Product Class
New
Origin
China/India/Others
Brand/Manufacturer
Name of Manufacturer
Agent In Bangladesh
No/Yes
Power
15kw
Temperature
Normal
Certification
SGS/Others
Production Capacity
1500 Set/Sets per Month
Distance Of Spindle
280mm
Spindle Quantity
1008
Dia Of Traveler Ring
204mm
Dia Of Spindle
175mm
Wharve Diameter
22mm
Spindle Gauge
70mm
Lift
180mm
Yarn Count
4.86-97.2tex
Twist
230-1740 T/M
Twist Direction
Z or S
Spindle Speed
12000-22000 rmp
Type Of Creel
one tier hanger, four or sixrows optional
Dimension(L*W*H)
7.07*1.58*2.27m
Weight
6600kg
Description
It should easy to operate and maintain, low noise and power consumption
Example of 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
Features of Ring Frame Machine :
It is an automatic yarn spinning machine.
Duo suction
Servo drive for ring roll
Autodoffer with provision to link corner
T flex drive
Touch screen display
4qm drive for drafting system
It is a conventional spinning machine for spinning wool
This machine has wide scope, because it can produce coarse to very finer yarn.
By this machine, yarn count can be spun 0.3Ne to148Ne or 4tex to 2000tex.
By this machine, operation can be done Creel in, Drafting, Twisting, Laying out, Building, Doffing, and Winding.
Ring frame Feature:
Front zone setting should be as close as possible.
Break draft of 1.14 & back zone setting of 60mm is recommended.
65 degree shore hardness for front top roller.
Buffing should be carried out once in 45 days.
If top roller diameter is less by 1.5 mm from standard diameter, top roller should be changed.
Gap between front top roller & apron nip should be as low as possible (0.5 – 1mm) & if not, it generates yarn imperfections.
Bottom & top aprons should be changed at least once in 1.5 years.
It is better to use lighter travellers instead of using heavier travellers. Enough trials should be taken as traveller size depends on, speed, micronaire, humidity condition, count, ring diameter etc.
It is advisable to use Elliptical travellers for hosiery counts.
Ring travellers should be changed before 1.5% of traveller’s burn out.
Whenever there is a multiple break, ring travellers should be changed.
At any point of time, fluff accumulation on travellers should be less. Ring traveller setting should be close enough to remove waste accumulation but at same time it should not disturb traveller running.
Hairiness variation between spindles should not be high & to achieve it, travellers should be changed in time, bad workings (multiple breaks) should be avoided, rings like Titan (from Breaker) should be used, & damaged rings should be removed.
Ring frame breaks should be as low as possible (less than 10 breaks/1000 spindle hours).
Start up breaks after doffing should be less than 3 %.
Overhead cleaners is a must for processing combed cotton
Exhaust trenches should be between machines & for every 200 spindles there should be a trench.
Ring centring should be perfect. Abc rings & lappet hook centring should also be done perfectly.
If ring diameter is more than 40mm, ring centring plays a major role. If ring centring is not done properly, hairiness variation within cheese becomes very high.
Good quality spindle tapes should be used & changed for every 24 months. Spindle speed variation affects yarn strength, TPI & hairiness.
Advantage of Ring FrameMachine:
Any type of material (fiber) can be spun because it is universally applicable.
Production of very finer yarn
It is easy to operate as compared with other spinning machines of textile industry
Yarn Types
Cotton Yarn
Carded Yarns
Combed Yarn
Ring Yarn
Rotor Yarn
Difference Between Combed & Carded Yarn
Combed
Carded
01. Price Higher
02. Material – Cotton Fiber
03. Surface Smooth
04. Comber machine used
01. Price Low
02. Material – Do
03. Surface Hairy
04. Comber machine not used
Combed & Carded both are cotton yarn.
Long fibers are process to make combed yarn .
Short fibers are remove to make combed yarn.
All fibers are process to make carded yarn ( short & long ).
What is combed yarn ?
The yarn which is produce by using comber machine is called combed yarn.
What is carded yarn ?
The yarn which is produce by with out using comber machine is called carded yarn.
What is comber machine ?
Which is use to remove short fibers to make combed yarn is called comber machine.
What is the function of comber machine?
Ring yarn – The yarn which is produce by using ring spinning machine is called ring yarn.
Rotor yarn – The yarn which is produce by using rotor spinning machine is called rotor yarn.
Short fibers are process in rotor spinning machine.
Short & long fibers are process in ring spinning machine.
An Example:
Auto Apparel Ltd is a wholly owned subsidiary of Auto Ltd. and a value addition to Denim Division of Auto Ltd. It has always been the vision of the Auto Group to be at the top end of the denim market, and Auto Garment joins the spinning and Denim Divisions to complete a vertical supply chain of the highest quality.
Auto Ltd. is India’s leading textile company, world famous for its worsted textiles. It has interest in retailing branded apparel, apparel for exports to major brands world wide, engineering and a recent JV with an Italian major for high value shirting. The group was founded in 1925 and has become a household name in India for quality, excellence and trust.
The denim unit of Auto was founded in 1996 as a joint venture with an Italian denim manufacturer, which bred the Italian fashion denim mindset in a company from the start. With the capacity of 40 million meters per annum, the denim unit has the world class manufacturing facilities including state-of-the-art ring spinning, rope and slasher dyeing, rapier and air jet weaving and the latest in finishing equipment including mercerization and pigment coating.
Auto has now added world-class jeans wear facility, Auto Apparel. Auto is set in 14.5 acres of lush green land, an hour from Bangalore International Airport, with facilities impressive by the best international standards. The current capacity is 3million pieces per annum, and has plans to increase to 12 million pieces per annum by 2007. The plant has computerized cutting, automatic sewing, laser patterning and finishing. The centrally process-controlled laundry is the most modern in India, with all the equipment essential to achieving garments of the highest creativity and specification. The plant is supported by a state-of-the-art design studio and dedicated sample making unit.
Disadvantage of Ring Spinning Machine:
Production rate is low
Due to the high speed of the traveller, it damages the fibers.
Energy cost is very very high.
This machine works as more heat generates.
Conclusion:
Although ring frame has some disadvantage, this machine is very popular in the spinning. Ring frame machine can produce very finer yarn.
Sizing machine is a weaving machine in textile mills and this machine is used by textile manufacturers to apply size material to the warp yarns before weaving. This machine is not necessary for knitting which used for textile sizing . It is used to protect the yarn from abrasion and improve the breaking strength of the yarn of textile world.
Function of of the Machine for Textile Industry Process
Used for shuttle and shuttleless looms length of textile industry process
High speed during textile manufacturing
Best support after sale service for textile sizing
Specification of the machine for textile industry process is given below-
[label type=”label” title=”Specifications Name”]
[label type=”label” title=”Specifications Value”]
Product Category
Weaving
Machine Category
Sizing
Product Name
Sizing Machine
Product Model
According to Manufacturer
Product Class
New
Origin
China/India/Others
Brand/Manufacturer
Name of Manufacturer
Agent In Bangladesh
No/Yes
Power
63KW
Ring size
Normal
Certification
SGS/Others
Production Capacity
30 Piece/Pieces per Month
Range Of Application
6’s—80’s staple yarn in cotton
Weaver’s Beam Width
3200 mm
Warper’s Beam Width
1800 mm
Speed
1200 Crawling speed
Squeezing Pressure
40 kN
Drying Capacity
800 Kg/Hr
Weaver’s Beam Diameter
1000 mm
Warper’s Beam Diameter
1000 mm
Max. Winding Tension
7 kN
Motor
1.6 /2.0 Kw
Dimension
2600*5600*4300 mm
Weight
40 T
Description
With automatic machine for the measurement and control of residual moisture in warp sheet.
Process definition
Sizing is a process by which films of chemicals are applied over the yarn.
To impart more strength in the yarn.
To impart more resistant to abrasion.
To impart flexibility in the yarn.
To reduce hairiness in the yarn.
Process requirement
Direct warp beam sizing machine.
Sectional warp beam sizing machine.
Details of warping machineries
For Head stock-1
Topics
Description
M/c name
BENNINGER Zell sizing machine
Manufacturer
BENNINGER Co. Ltd. Germany
M/c Model
BEN PRO COMB ZB – 20SWA TKE CT 4/4/4
Manufacturing year
1997
Creel capacity
20
Others
Double size box, 10 drying cylinder
For Head stock – 2
Topics
Description
M/c name
BENNINGER Zell sizing machine
Manufacturer
BENNINGER Co. Ltd. Germany
M/c Model
BEN SIZETEK ZB – 20 SWA TKDZT4/6BB
Manufacturing year
1997
Creel capacity
1 Sectional warp beam, Extra – 20 capacity
Others
Single size box, Double dip, 10 drying cylinder
Both the machine is equipped with BEN SIZEMIX size cooking and storage apparatus. A total of 20 (maximum) direct warp beam can be combined and sized to make weavers beam. Moreover an additional unwinding frame provides the facility to size sectional warped beam (beam to beam)
For Head stock – 3
Topics
Description
M/c name
KAWAMOTO sizing machine
Manufacturer
KAWAMOTO system corporation, Nagao, Japan
M/c Model
MBB 923: C14 : SS20 : PSDM 1218X2
Manufacturing year
1990
Creel capacity
21
Others
Single size box, Single dip, Double squeeze 14 drying cylinder.
Key accessories: Refractometer and viscosity cup.
Materials and Chemicals used:
Materials
Chemicals
Adhesive materials: Like modified starch, synthetic chemicals.
Starch – Kottotex T5N
Avetex K
Gem size PS
Tap size 364
Siam modified starch
Anilose – E
Sizeanil LV – 100
Penetrose – 50
Amisol
Wetting agent
Quick solan SPR
Perfectly ASP
Quick solan Pec – 2
Elvanol PVA
Quick solan CMS
Texsolan ASP
Gohsenol
Acrylic sizing agent
Size CA – 20
Multitex – AS30
Trisize SY – 50
Sizetex
Lubricants softener
Solwax – 50
Sizewax – 50
Piniwax – 300
Pinitex – K
Antifoaming agent
Resplimite – BU
Fig. Chemicals used in the size bath
Factor on which recipe depends
Composition of yarn
Yarn count
Total no. of ends
Weight of yarn
Size beam width
X=Total Ends/Ends /inch
If the value of X is more than 60, then the size beam width is 72-74.
If the value of X is lower than 60, then the size beam width is 67.
Machine setup:
Parameter
Machine range
Set values
Sizing speed
1-120 m/min
40-45 fine count yarn
45-50 yarn dyed mtl.
50-70 solid dyed with medium count
Typical size recipe
M/c no – 1 (For Direct warp):
. 50×40
Construction: —————- X 59″
. 133×80
Topics
Specification
Fiber composition
Cotton
Weave
Poplin
Total ends
7980
Warp length
6500m
Beam space
67”
Size
14%
Squeezing pressure
7.5 KN
Pick up
18.6%
Dry temperature
800c
Moisture
6.5%
Starch (T5N)
72 Kg
Wetting agent (PVA)
24 Kg
Size wax
4 Kg
Binder (Tri size)
16 Kg
Water
580 Lt.
M/c no – 2 (For sectional warp)
. 45 x 80/2
Construction: —————- X 59″
. 130×70
Topics
Specification
Fiber composition
CVC
Weave
Poplin
Total ends
7670
Warp length
2548 meter
Beam space
67”
Size
14%
Squeezing pressure
8 KN
Pick up
22.6%
Dry temperature
800c
Moisture
6.5%
Starch (T5N)
73 kg
Wetting agent (PVA)
28 kg
Size wax
4 kg
Binder (Tri size)
13 kg
Water
530 lt.
Practical Yarn Recipe
Practical Yarn Recipe
Size cooking procedure
Water
↓
PVA (10 minute steamed 700c)
↓
Starch (30 minute steamed 900c)
↓
Size + Wax
↓
Steam (20 minute at 900c)
↓
Cooked size
Determination of size% by Refractometer
Take the meter
↓
Cooked size collect
↓
Give on the tip of the matter
↓
Observed the scale inside
↓
Rating find in the scale
Determination of viscosity by viscosity cup
Take the viscosity cup
↓
Collect the cooked size in the cup
↓
Determination the time required to drop out the liquor from the bottom hole of the cup
↓
If 22-30 second required then the viscosity is OK
Sizing fault and their remedies
Fault name
Causes
Remedies
Uneven sizing
a. Worn out pressure roller.
b. Incorrect size level in size box.
c. Higher viscosity.
a. Change or grinding pressure roller.
b. Proper level of size in box.
End missing
a. Weak yarn.
b. Excessive speed.
a. Tension and speed. according to quality.
Joint end
a. Improper leasing.
b. Improper combing.
a. Proper leasing.
b. Proper combing
Excessive dried
a. Low speed
a. Proper speed should be maintained.
Wet warp
a. High speed
a. Proper speed should be maintained
Pattern breaking
a. End missing.
b. Improper leasing.
a. Proper leasing should be controlled
Conical beam
a. Mechanical fault in winding
a. Repair mechanical fault.
Excessive hard or loose beam
a. PVI (Pressure Variable Index) not work properly.
a. Maintenance of the PVI box.
List of Others Weaving machinery
Section
Brand name
Winding section
FADIS Winder
RJK Winder.
HARISH Winder.
METTLER Winder.
Warping section
KAWAMOTO High speed warping m/c
BENNINGER High speed warping m/c
BENNINGER Sectional warping m/c
Sizing section
BENNINGER Zell sizing m/c.
Weaving section
TOYOTA Air jet loom
SOMET Rapier loom
Quality assurance section
Thread counter
G. S. M tester
Measuring tape
Alphatens tensile strength tester
Elmendorf tearing tester 1653
Alphatens seam slippage tester
Nu-Martindle Abrasion & Pilling tester
ICI pilling box
Roaches thermal stability tester
Shirley crease recovery tester
Gyro wash fastness tester
Perspirometer & Carbonile water fastness tester
Perspirometer & Carbonile sweat fastness tester
Light fastness tester
Crocometer
Wascator washing stability tester
Maintenance of sizing machinery
Problem 1: Creel housing vibration.
Solve – Change the key of creel housing.
Problem 2: Pressure does not adjust properly.
Result: Uneven sizing.
Cause: Worn out pressure roller.
Remedies: Grinding the roller/ Change the roller.
Problem 3: Winding tension does not correct
Result: Hard/loose warp beam.
Cause: PVI box does not work correctly.
Remedies: Maintenance of PVI box of Sizing Machine
Jacquard loom is weaving machinery for weaving looms generally used in the weaving of various kinds of elastic jacquard tapes,jacquard fabric etc. The machine should adopts new electronic jacquard and computerized embroidery programming system. It can apply to produce all kinds of elastic and unelastic tapes and these tapes are used as safety belt, shoe, fabric etc.
Function of Jacquard Weaving Looms:
These series needle loom is used to make kinds of elastic and un elastic tapes. As ribbon, webbing, shoe lace, carpet tape, underwear band, seat belt and so on. Custom configured Jacquard Weaving Looms can be used to weave practically all fabrics such as jacquard fabric, linings, labels, dress materials, table cloths, bedclothes, velvets, toweling and carpets. The Jacquard Weaving Looms are designed to fullfill the requirements of textile production and to take account of the weaving parameters for the looms of the styles .
jacquard function
Features of Jacquard Weaving Loom:
Jacquard weaving loom is equipped with new electronic jacquard heads and computer punching systems
Mechanism for fast, precision and easy for procedure
Human based design and large space.
Jacquard weaving loom is safe and easy for operation to increase effectiveness.
Real-time storage system to reduce the loss system
Jacquard weaving loom simultaneously saving more than patterns.
Jacquard weaving loom parts and components are made by high quality materials
Compatibility of parts for easy maintenance and adjusting;
Jacquard weaving loom has excellent lubricating system for easy maintenance.
Specifications of Needle Loom:
[label type=”label” title=” Attribute Name”]
[label type=”label” title=”Value”]
Product Category
Weaving
Machine Category
Needle Loom
Product Name
Jacquard Needle Loom
Product Model
According to Manufacturer
Product Class
New
Origin
China
Brand/Manufacturer
According to Manufacturer
Agent in Bangladesh
No
Power
380v
Temperature
Normal
Certification
SGS/Others
Production Capacity
10000 Sets / Year
Weaving Head
8
Number of Frame
12
Jacquard Hooks
128/192/240/320
Reed Width
45mm
Tape Width
45mm
Pattern Chain
1: 32
Weaving System
Computerized Jacquard System
Pick Per Inch
8.9~93/in
Machine Power
2kw
Motor Power
1.5kw
R.P.M
800-1000
Weight
900kg
Description
To achieve the high speed running necessary for ,two steel bead bearings share the load
Machinery and Equipment of a Weaving Loom:
Comber Boards:
The comber boards are designed and built to order. For example the loom depth is matched to the number of sinker rows, the density, the type of weaving loom thread and their link to heald. An optimized drilling pattern improves the functioning of the loom and weaving process. The comber board frame makes it easier to change the fabrics widths.
Single Thread Link:
Two recesses serve to retain it when removing. The link between the heald and the spring is fitted with damping system to reduce vibration.
Springs:
The new sectional aluminum draw-down frame is suitable for all densities. The fixing strips can be selected with 32,16 or 2*8 suspension elements to suit the various densities. A draw down plate with individual harpoon fixing is available for velour and carpet weaving loom.
Lease:
The lease is fed into the weaving loom threads in the required sequence in our works with complete accuracy and great care. This saves time when it comes to inserting the weaving loom and commissioning.
Double Density:
With a double comber board it is possible to use the same weaving loom for two different densities or to switch from single to double fabric width. Switching is a quick and easy operation and does not change the loom leveling.
Blower:
Some machine manufacturer has developed the automatic blowing device to facilitate cleaning of the loom springs. The blower is located behind the return motion frame. The pneumatic blower reduces the accumulation of dust deposits and facilitates manual cleaning. The blower system compact format makes it compatible with many types of weaving looms.
Wrap Threads into the Healds:
The loom can supply with wrap threads, e.g. with texturized yarn PES 167 dtex S/Z cotton yarn Nm 40/2, cotton yarn Nm168/2 and PA 470 dtex. This makes commissioning of new plant much quicker and easier.
Weaving looms maintenance
Preventive Maintenance:
Preventive Maintenance is a predetermined routine activity to ensure on time inspection / checking of facilities to uncover conditions that may lead to production break downs or harmful depreciation.
Corrective Maintenance / Break down Maintenance:
In this case, repairs are made after the equipment is out of order it cannot perform its normal function.
Schedule of maintenance:-
In AUTO Fashions Ltd. planning and scheduling various maintenance tasks to be carried out on each machine during the course of a year. They are scheduling the right men and facilities at the right place and at the right time.
They maintain following schedule for maintenance:
Daily maintenance.
Weekly maintenance.
Monthly maintenance.
The actions which are carried out in the above three types of maintenance program are discussed below:
Daily cutting table maintenance:-
To cleaning the cutting table before starting fabric lying.
To cleaning after completing the cutting.
To cleaning dust and jhute around cutting table at least three times each day.
Daily sewing machine maintenance:
Machine inside and outside cleaning and checking.
Timing system checking.
Machine adjustment checking.
Power connector and cable checking.
Machines needle plate checking.
Dust collector filter cleaning.
Thread stands checking
Machines Eye guard, Pulley guard, Finger guard and Belt tension checking.
Weekly sewing machine maintenance:
Machine oil check if necessary then refill/change.
Machine stitch plate opening and cleaning.
Machines wheel checking and cleaning.
Machines face plate opening and cleaning.
Weaving machine maintenance after two or three month:
All Electronic components checking and cleaning.
Machines servo motor and control box opening and cleaning.
Machine oil completely might be changed.
Advantage of Weaving Machinery and Equipment:
Computerized system loom weaving is used for jacquard fabric
High quality and carefully optimized components
High quality loom weaving parts of machine.
Rapid installation for the loom weaving
The components are made by stainless steel
Vibration damping and optimized drilling pattern
Compatibility to match various software
Easy for operate weaving machinery for how to make a loom weaving
Low energy consumption fro weaving machinery
[1] Amit Dhalan, B.Tech. in Textile Technology, Merchant at Parvati Fashion, India, Email: [email protected]
