Spinning Machine

Spinning machine of cotton spinning mill which made by textile machine manufacturers for manufacturing fiber and yarn. There are a lot of machines are used in spinning factory like lapping machine, simplex machine, porcupine Opener, mono cylinder beater, draw frame, lap former, comber machine etc.

List of Spinning Machine for Cotton Spinning Mill:

Textile machine manufacturers make different types of machine for cotton mill-

• Mixing or Blending Machine
• Hopper bale breaker or Hopper bale opener
• Axo Flow Cleaner
• Bale Opener Machine
• Crighton Opener or Vertical Opener
• Step Cleaner or Ultra Cleaner
• S.R.L.L Cleaner
• R.N Beater
• Porcupine Opener
• Rotor Spinning Machine
• Mono Cylinder Beater
• Hopper Feeder
• Bladed Beater
• Krishner Beater
• Carding Machine
• Draw Frame
• Lap Former
• Comber Machine
• Roving Frame or Simplex
• Coconut fiber making machine for industrial automation
• Ball Fiber Making Machine  for  garment industry
• Polyester Fiber Making Machine for  textile manufacturing
• Water jet loom polyester fiber making machine for apparel industry
• Cotton fiber making machine for  textile manufacturing
• Maize Fiber making machine for textile industry
• Recycled cotton fiber making machine for textile industry
• Polypropylene staple fiber making machine for textile industry
• Non woven fabric making machine for apparel industry
• Woven fabric making machine for  textile manufacturing for apparel industry
• Coir Fiber rope making machine for apparel industry

Automation of Cotton Spinning Mill :

For producing technology in textile industries  of yarn ring frame is one of the best important component during the last two and half decades components of ring spinning machines have been greatly improved, drive systems and robotics have enabled large gains in productivity, flexibility and quality. Most of the technical spreads in ring spinning were aimed at improving the performances on the present  technology. These are all achieved to the  automation.

Advantages of Spinning Machines:

The advantages of the spinning machines made by textile machine manufacturer-

1. Very trustworthy system of these electrical machines
2. Maximum machine  is controlled by servomotor
3. Expensive to implement
4. Enhancing manufacturing by  textile machine manufacturers capacities.
5.  Textiles equipment are made by textile machine manufacturer
6. Accurate result for cotton on
7. Automatic Doffe system
8. Reduced Manpower from the industry
9. Increase more  productivity than manual system.

Flowchart of Wool Finishing Process:

Finishing process of Wool in textile world is given below-

Greasy Wool

↓

Sourcing

↓

Staple Dyeing / Oiling Carding / Drawing / Combing

↓

Silver Pre Dyeing Treatments

↓

Dyeing Vigoureux / Printing

↓

Recombing Drawing Spinning

↓

Yarn Pre-Dyeing Operation

↓

Weaving Knitting

↓

Dyeing

↓

Printing

↓

Finishing

↓

Inspection

Spinning Production Planning And Control (PPC) 

• Design a system and plan, by which production may be carried out in order to meet promised delivery date consistent with minimum cost and quality standard.
• Ensure efficient utilization of production facilities.
• Coordinate production activities of different departments.
• Maintain an adequate and not excessive stock of raw materials; work -in-progress and of finished goods to meet production requirements and delivery schedules at the most economical level.
• Ensure production of right product in right quality at the right time.
• Maintain flexibility in manufacturing jobs, to accommodate rush jobs or to meet
• Contingences manner.
• Ensure smooth flow of materials by eliminating, bottlenecks, if any, in production.
• Establish targets and check them against standards.
• PPC guides production department by preparing and manufacturing orders.

Spining Plan: 

In spinning, preparation of spin plan is an important component of PPC work. First we have to decide the type, quantity and quality of yarn. Then an allocation of various machinery is calculated in the spin plan. Product Detail:-

• 20s Carded yarn
• Blends of cotton and manmade fiber or other (e.g. 65/35 PV,70/30 PC,93/7 CV…….etc)
• Process flow:  blowing…..Carding…..1^st Passage…..2^nd Passage…Roving….Ring

Mill Details:

Blow room with chute feed to cards

• Marzoli
• Reiter
• Trutzschler

Cards: 

• Marzoli CX300(8 heads)
• Reiter C4-A and C4 (7heads)
• Trutzschler TC 03 (6 heads)

Draw frames: 

• DO6: 6 machines
• RSB 851 : 5 machines
• SB2 : 2 machines
• VOULK : 4 machines
• Melanjor : 1 machine

Unilap:

• Vouk (RD300/2T): 1 machine

Comber:

• Vouk (CM400/S) : 5 machines

Fly frames:

• F1/1A:5 machines
• F5:2 machines
• F1/1:2 machines

Ring frames:

• G5/1 (14 machines having 768 spindles)
• G5/11 (16 machines having 1008 spindles)
• CSM (6 machines having 1088 spindles )

Winding machines:

• Murata (7-II)…..5 machines having 60 spindles
• Murata (V-SS)……5 machines having 60 spindles
• Schalafhorst……….2 machines having 60 spindles

Steamer machine: 

• Mill works for 6 days a week; 24 hours a day.

Production Required: 

100% cotton carded or mélange 20s:  4000kg/day

(The above production figures are arrived based on orders)

Process Parameters: 

The following table gives the process parameters for the counts that have been given under Production required.

Machine	Count	Speed	Hank	TM	Efficiency	Other Factors
Card	20s	130 m/min(truszschler)	0.12	–	90	Doffer speed;27″   ;1.5Tension draft
Draw frame	20s	400m/m	0.13	–	85
Fly frame	20s	1000 rpm(F1/1A)	0.9	1.47	85	120 spindles per machine
Ring frame	20s	11000rpm (G5/11)9000 rpm (G5/1)	—	4.64	88.085	1008 Spindles per m/c768 Spindles per m/c
Winding machine	20s	1000 m/min	–	–	75	60 drums

Waste Levels: 

Ring frames: 

• Pneumafil – 4.0% (reusable)
• Hard waste – 0.2%

Fly frames: 

• Roving waste– 0.3% (Reusable)
• Sliver waste – 0.2%

Draw frames: 

• Sliver waste- 0.2% (reusable)
• Suction waste – 0.8%

Cards: 

• Card waste – 4.8%
• Sliver/web – 0.2% (Reusable)

Blow room: 

• Blow room waste: 4.0%
• Reusable waste: 0.2% (Reusable)

(All percentages on ring frame production)

Balancing Machine :

Ring Frames (G5/11): 

Production per spindle per 8 hours for balancing machine  (in grams):

7.2*Spindle Speed(rpm)

——————————* Efficiency

Count *TPI

Production per spindle per 8 hours (g):

20s: 169.40grams.

Number of spindles allotted

= 7669.3spindles

Number of ring frames = 7.6 8

Fly frames for balancing machine : 

Production per fly frame per day:

20s: 4.5*120*3 = 1620.0 Kg

Number of fly frames allotted:

Production in ring frame+Ring frame waste+ Roving waste

———————————————————————

Production per fly frames per day

= 2.7 3 Fly frames.

Finisher draw frames: 

Production per shift per machine (kg)

(0.286*L*eff*Nd

———————-

Ne

(0.286*400*0.85*1)

= ———————

0.12

=810.3 kg

Production of Finisher Draw frame per day per machine:

20s: 810.3*3 = 2430.9 Kg

Number of finisher draw frames allotted:

Breaker draw frames:

Production per shift per machine (kg) for balancing machine

(0.286*L*eff*Nd)

=————————

Ne

(0.286*400*0.85*1)

=————————–

0.12

= 810.3kg

Production of Breaker Draw frame per day per machine:

20s: 762*3 = 2430.9 Kg

Number of Breaker draw frames allotted:

Production in FD frame +FD frame waste +bDF waste

—————————————————————-

Production per BD frame per day

Production in BD frame per day =2*2430.9= 4861.8 Kg.

Roving waste = 4214.2*0.3/100

=12.6 kg

Sliver waste = 4214.2*0.2/100

=8.4 kg

Suction waste = 4214.2*0.8/100

=33.7 kg

So, Number of finisher D frames allotted

4680+12.6+8.4+33.7

=————————–

2430

= 2.02  2 FDF

Carding Spinning Machines:

Production per shift per machine (kg)

(0.286*L*eff*Nd)

=———————

Ne

(0.286*130*0.9*1)

=———————–

0.12

=278.8 kg

Production of Carding per day per machine:

20s: 278.8*3 = 836.5 Kg

Number of carding machine allotted:

Production in BD frame +  Bd frmae waste +Card waste

—————————————————————–

Production of carding per day

Production in BD frame per day =2*2430.9= 4861.8 Kg.

Sliver waste = 4214.2*0.2/100

=8.4 kg

Suction waste = 4214.2*0.8/100

=33.7 kg

Card waste  = 4214.2*4.8/100

=202.3 kg

So, Number of carding machine allotted

4861.8+8.4+33.7+202.3

= —————————–

836.5

= 6.1  6 Card, since we do have excess quantity in draw frames no need to approximate to 7 carding machines.

Bales required: 

Blow room waste = 4214.2*(1 + 4/100) =168.6 kg

Reusable waste = 4214.2 *(1+0.2/100) =8.5 kg

Total card production =6*278.8

5019 kg +8.5 +168.6

=————————-

230

=22.6, approximate to 23 bales

Autoconer winding spinning machines:

Production per drum per day =  0.2836*m/min*eff*Nd/Ne

= 10.6 kg

TOTAL production per machine per day =10.6*60*3

=1908 kg

Hard Waste = 4214.2*(1+2/100) = 84 kg

No of autoconer required

Ring production – Winding waste

= —————————————–

Winding m/c kg per day per m/c

4214.2 -84

=————-

1908

=   2.16 ≈3 Winding machines

Conclusion:

Number of machines calculated above for achieving production balance in cotton spinning (short staple plant) is summarized below:-

• Ring spinning unit =8064 spindles i.e. 8 G5/1 machines (1008 spindles)
• Simplex frame, 3 Roving (120 spindles)
• Draw frames,(2 passage), 4 single delivery drawing frames
• Carding machines, 6 Cards
• Blow room, cleaning line of machines with chute feed system.
• Winding, 3 machines (60 drums)
• Balancing machine is the key factor for quality production.

[1] Ovi Islam, B.Sc in Textile Engineering- PUB Email: ovislam@ovi.com

[2]Wondwossen Seyoum, Planning Head in Saygindima Textile Share Company. BSc, in Textile and Leather Engineering