Automatic Sample Loom Number of frames: 16 or higher
Sheaabigsystem: Dobby
Pneumatic lifting/lower of frames
Mannual picking and beating up
Warping beam capacity: 3 metres or higher
Loom Factory Visit
Then we knew about all to our honorable instructor. She has given us some tips for making our project work theoretically. Then we started our work by internet. But some days later our honorable instructor went to Mirpur 11 at Behari Polly with our students. She searched also about our project Carpet manufacturing there. And finally she was success and she informed us that night. According to her address we went there and got some Carpet manufacturers at Millat camp in Mirpur11. The Biahari people were, made carpet in Bangladesh from 1948 after Second World War. There have 4 looms of carpet. They made carpet in small amounts. Fardin carpet was one of the carpet exporters in Bangladesh. But now they are not involved with carpet exporting due to many reasons. Read also Sample Rapier Loom
Custom made carpet in the early 80’s for the Convention
Center and Grand Ballroom at the Concorde Lafayette Hotel – 75017 PARIS Over
3500m² of broadloom Axminster contract carpet.80% wool / 20% nylon
Following so a strong family tradition related to the
textile industry the “Agence CHOLLETON” started to operate 25 years
ago and was quickly known and recognized as a specialist for quality axminster
contract carpets and jacquard wilton woven bespoke carpeting plain or
patterned, available from stock ranges or custom made, as for stairs carpet
runners and bespoke hand tufted rugs.
As you may see from our project list our references are
various and prestigious in France and Europe as in many countries worldwide
especially into the Middle East and Africa. Agence CHOLLETON has been involved
over the last 25 years into major export projects for contract carpeting all
around the world, with some of the best contract carpets manufacturers such as
Trafford Carpets or Couristan carpets.
We also known about “Society
Handicrafts” from Bihar peoples. Bihari
peoples have given us location of Society Handicrafts. But that was not right
location. We went first at Saver bus stand and searched in many places but not
found the address of Society Handicrafts. We searched more than 05 hours in
different places of Savar. At the last moment of the day we found an address
from a man he told us in Nama Genda there have a people who make some carpet
and gave them products in “Aarong”. His name is Ali Akbor. Then we went before
evening at Nama Genda in Savar. Finally we found his factory and visit factory
more than 2 hrs with Ali Akbor. He is really an energetic and skilled man. He told us his history of regarding
carpet. We visited and known about
carpet manufacturing, raw materials, how to store carpet, how to receive an order
etc system.
A prepared sample of fabric is subjected to a tumbling
action against a known abrasive pad. Pile loss is then assessed.
APPARATUS
AATCC “ATLAS” Accelerator, Model AB-7 fitted with 108mm S-Shaped rotor with specimen viewer
Ceramic abrasive lining ring
Rubber based adhesive
Method for removing loose fluff, I.e. vacuum cleaner or brush
Circular cutter 11.28cm in diameter giving a resultant sample area of approximately 100 sq cm.
PROCEDURE
Calibrate accelerotor
Cut two 300mm x 300mm samples
One sample to have appropriate cleaning treatment (as garment care label using appropriate method
Cut the following samples:
Original – four samples, three to test, one kept as original
After Cleaning – cut three samples for test
Glue outside of circle with rubber based adhesive. Fray loose shorter threads to a depth of 2-3 mm (woven fabrics).
Once the adhesive is dry, condition the samples for a minimum of 4 hours at 65 +/- 2% rh and a temperature of 20 +/- 2 degrees C. Testing must also take place in a conditioned environment.
Number and weigh accurately, both original and cleaned samples. This initial weight is now referred to as ‘X’.
Fold one sample in half, place it across the top rotor in the accelerotor and close the door.
Test specimen at appropriate time and speed, initially 3000rpm quickly reducing to 2000rpm after rotor has begun to spin and maintain that speed throughout the test cycle.
Examples as guide:
Velvet 3 mins @ 2000rpm
Corduroy 5 mins @ 2000rpm
Velour 5 mins @ 2000rpm
Remove specimens from accelerotor
Remove all loose fibre from both the sample and accelerotor using vacuum cleaner or brush.
Condition the sample for a further 4 hours, as previously.
Weigh accurately the tested sample. (This weight is now referred to as ‘Y’)
Repeat process e. to I. on both original and cleaned samples saving one original sample for comparison.
SAMPLE DISPLAY & GRADING
Use the following formula to calculate the percentage weight loss of each sample (both original and cleaned):
X – Y x 100 = Result X
X = Weight before testing
Y = Weight after testing
Visually assess each sample comparing with the initial appearance to the original untested sample and grade these samples according to the following assessment table:
Grade : Visual Assessment
NO CHANGE : No change in appearance
NEGLIGIBLE :No obvious loss of individual pile tufts and/ or slight negligible narrowing of the cord wale
SLIGHT :Limited small areas of pile loss and/ or slight narrowing of the cord wale
SIGNIFICANT: Considerable pile loss and/or significant narrowing of the cord wale
DISTINCT : Extreme pile loss causing half or more of the base cloth to be visible and/or distinct narrowing of the cord wales
Retain samples
REPORT
Average percentage weight loss for each set of both original
and cleaned samples, quoting ‘original’ or ‘cleaned’ as appropriate.
It consists of three roller beater which helps in opening and removing of dust and waste.
MACHINE SPECIFICATION:
No. of machine = 1
Make = LAXMI
Model = LB9
Production = 1000kg/hr.
OPEN END SPINNING
In Auto INDUSTRY LTD. the final product is denim which requires coarser yarns (5.6s, 6.1s, 8s, 9s, 10s, 12s, 16s). For the production of these counts open end spinning is preferred instead of ring spinning. Here three models of RIETER ROTOR FRAMES are used and these are:
RU-14
R-1
R-20
Altogether the RU-14 rotors one is having the special attachment for slub yarns another is having attachment for producing mixed count yarns. All these rotors are equipped with automatic piecing robot which helps in increasing machine efficiency and production.
PRINCIPLE AND WORKING:-
In open end spinning the fibre stand i.e. sliver being opened to individual fibre at a predetermine position usually by mean of an opening roller, rotating at a very high speed.
The constant stream of separated fibre is allowed to flow into a high speed rotating disc with the help of draw off roller and tube. The fibre rotate in rotating disc rotor against the wall by the high force and separation point therefore rotates with in the rotor. Each revolution of the yarn at this point inserts one twist in the yarn. The yarn so produced is drawn out with the help of draw off rollers and is easily wound on the package with the help of winding drum.
There is only one winding machine ,which is used only optionally i.e. when the package supplied from the spinning machine are in a deform shape , improperly wound or when there is more than 150 m of yarn left in the package used for ball warping . These packages are taken for rewinding and cones are made on this machine.
The different characteristics and parameters of this winding machine are:
Maker —–Auto industries , Ahmedabad
Type ——grooved drum winding machine
of winding heads—–60
Winding speed——-300
Drum diameter——-4
of crossing per double traverse——-5
Package conicity—–5o57’
Winding angle——-340
The path of the yarn is shown in figure .An patterning device is attached with the driving arrangement, which works on the principle of intermittent disengagement of the drive from the motor.
PASSAGE OF YARN THROUGH MACHINE
Creel
↓
Guide
↓
Tensioning device
↓
Slub catcher
↓
Stop motion
↓
Winding drum
↓
Cone or
QUALITY ASSURANCE
This department takes care of the quality aspect of the raw materials (fibre and yarn) and other auxiliaries for processing of the material, either produce from outside or that being produced over here ( at different stages of the processing) . it also looks after the various processing parameters and the extent of utilization of resources. It comprises of two departments, one the physical testing lab and the other is chemical testing lab.
Testing
Stretch property tester-
For 3 pound –half an hour
For 5 pound-two hour
Sample size -2”width
And length -50 cm
Tearing strength
Sample size -4×8”
Stiffness
Sample size-4×8”
Rubbing
Weight – 9
Diameter – 16mm
Dry and wet both testing has been done
Wet -60%
Dry -100%
Tear strength – washed fabric
Sample size-63 x100mm, warp and weft side
Tensile tester
Sample size – 4×8”
Stretch %
Example of Production
In Ring Spinning Department there are many winding m/c.
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.
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.
