This presentation shows staple fiber processing through various machines employed in the spinning hall with technical acess to m/c parameters.

1. SPINNING WITH
TECHNICALACESS
BY ESHAN BANSAL
DEPARTMENT OF TEXTILE ENGINEERING
GZS PTU CAMPUS
BATHINDA

2. SPINNING
Spinning is a process of conversion of fibers (raw
material) which possess certain characteristics into
yarn of desirable characteristics through various
stages involving preparatory stages and ring
spinning stage.

3. STAPLE FIBER PROCESSING
BLOWROOM
CARD
PRECOMBED
DRAWFRAME
UNILAP
COMBER
FINISHER
DRAWFRAME
SPEEDFRAME
RINGFRAME
AUTOCONER
PACKING

4. RAW MATERIAL SPECIFICATIONS
Sr. No. PARAMETER J-34 (100%)
1. Length 29.4mm
2. Micronaire 4.2
3. Strength 30 g/tex
4. Trash 4.8%
5. Maturity Ratio 0.92

5. LIST OF MACHINES
Sr. No. MACHINE NAME MACHINE
MANUFACTURER
MODEL NO OF M/C
B/R LINE-1&2
1 BLENDOMAT TRUETZSCHLER BDT-019 1
2 CONDENSOR TRUETZSCHLER LVSA-375
3 SECUROMAT TRUETZSCHLER SC-154 1
4 UNICLEAN RIETER B-11 1
5 MULTIMIXER TRUETZSCHLER MCM-6 2
6 CLEANOMAT TRUETZSCHLER CVT-3 2
7 CCS-BASIC SIEGER 2
8 DUSTEX TRUETZSCHLER DX385 2
CARD
1 CARD TRUETZSCHLER DK-803 17
2 CARD TRUETZSCHLER TC-03 1
BREAKER D/F
1 DRAW FRAME RIETER SB-2 2
2 DRAW FRAME LAKSHMI LD0/6 1
UNILAP
1 UNILAP RIETER E-30 2
2 UNILAP LAKSHMI LH-10 1
COMBER
1 COMBER RIETER E-62 8
2 COMBER RIETER E-60H 3
3 COMBER LAKSHMI LK-64 3
FINISHER D/F
1 DRAWFRAME RIETER RSB-D851 5
2 DRAWFRAME RIETER RSB-D30 3
SPEED FRAME
1 SPEED FRAME LAKSHMI LF-1400 7
2 SPEED FRAME LAKSHMI LF-1400A 4
RING FRAME
1 RING FRAME RIETER G 5/1 20
2 RING FRAME LAKSHMI LR 6/S 9
AUTOCONER
1 AUTOCONER SCHLAFHROST 338 5
2 AUTOCONER SCHLAFHROST 5 3
T.F.O
1 T.F.O VEEJAY LAKSHMI VJ-150-HS 4
2 T.F.O VEEJAY LAKSHMI VJ-190 2

6. BLOWROOM
The basic purpose of Blow room is to supply
• small fibre tufts
• clean fibre tufts
• homogeneously blended tufts if more than one variety of fibre is
used
to carding machine without increasing fibre rupture, fibre neps, broken
seed particles and without removing more good fibres.
The above is achieved by the following processes in the blow room
• Pre-opening
• Pre-cleaning
• Mixing or blending
• Fine opening
• Dedusting

7. BLENDOMAT
BDT O19
• It can be freely programmed
to allocate up to 3 bale
groups, to feed up to 3 blow
room lines.
• Bales of varying heights can
also be easily processed.
• It is very sturdy and robust
machine capable of
producing production up to
1200 kgs/hr.
• The penetration control
mechanism avoids reversal
of rotation direction of the
opening roll and avoids the
wear intensive braking and
acceleration after each
passage of bales.

8. UNIQUE INVERSION
MECHANISM
• The blendomat is equipped with two
opening rolls rotating in opposite
direction.
• Depending on the direction of travel
one roll is always working against the
travel and one with the travel.
• The one which is operating in
opposite direction to the travel, is
raised by up to 10 mm by means of a
motor.
• The roll which operates in the same
direction as the travel penetrates
more deeply into the bale.
• The result is the even distribution of
production from both rolls and equal
tuft sizes from both rolls.
• TECHNICAL DATA
Production- 900 – 1000 kg/hr
Efficiency- 88.6%
Traverse drive speed- 11.6 m/min
Rpm of take-off roller- 1500 – 1800 r.p.m
Nominal take off depth- 2.5- 3 mm
Beating Points – 0.5

9. LVSA 375
The purpose of the condenser is
twofold:
• To transport cotton and synthetic
fibers pneumatically in the form of
tufts
• To de-dust these tufts at the same
time.
The fan (7) produces the air current
required to transport the material. The
stock is separated from the transporting
air by the perforated drum (3) and
removed from the drum (3) by the
take-off roller (9). The exhaust air (5)
is deflected to the filter unit.
• TECHNICAL DATA
Diameter perforated drum- 480 mm
Diameter take-off roller- 300 mm
Diameter fan wheel 50 Hz- 528 mm
Speed perforated drum- 80/min
Speed take-off roller- 410/min
Speed fan wheel 50 Hz- 1410/min
Production- up to 1200kg/hr

10. SECUROMAT
SC154
Its objectives are:
• To separate the metal
particles especially iron
particles from the raw
material.
• To feed the material to the
next machine for further
processing.
Basically, electronically
controlled metal separation is
carried out from the raw
material so as to protect the
cleaners and cards from metal
parts. It requires no exhaust
air and filter capacity.

11. UNICLEAN B11
• It is used for cleaning and extracting dust from
cotton of any origin and blends of cotton/man-
made fibers very gently and effectively.
• The raw material is fed without nipping.
• The guide plates (14) carry the tufts in a spiral
manner over the grid (11) seven times.
• The combination of cleaning intensity and waste
rate ensures efficient cleaning with few good fibers
in the waste and no crushed waste particles.
• Waste is removed periodically via the air lock
roller (9) and the conduit (2).
• TECHNICAL DATA
Diameter of pin roller 750 mm
Diameter of lock roller 350 mm
Speed of pin roller 480 – 960 rpm
Speed of lock roller 16 – 19.2 rpm
Electric cylinders per m/c 2
Shearing force 2000 N
Lift 100 mm
Lifting speed 5.6 mm/s
Beating Point 1.0
Grid angle 4.40

12. MULTIMIXER
MCM6
• To blend different varieties of cotton in order
to achieve maximum homogeneity of the
mix.
• It acts as a storage unit to feed raw material
to the card uniformly in case of any
malfunction in the pre-process.
• There are six reserve trunks which comprises
of reserve trunk flap (3), perforated partition
wall and light barrier for minimum filling
level monitoring.
• Each trunk is filled until the set pressure is
reached.
• When the pressure is reached, the controller
identifies the trunk as full and the next trunk
is filled.
• The trunk is ready to receive the material
again only when the calculated filling level
has fallen to 75%
• If all the trunks are ready to receive material,
the system switches to next trunk after a
maximum of one min even if the changeover
pressure is not reached.
• TECHNICAL DATA
Storage volume per trunk 1.38 – 2.58 m3
Reserve capacity per trunk 41.4 – 77.4 kg
Opening roll speed 1000 rpm
Delivery roll speed 0.05-0.83 rpm
Tray suction fan speed 2860 rpm
Conveyor belt speed 1.8-35.5 rpm

13. CLEANOMAT
CVT3
• It is a combination of one spiked roll and
two saw-tooth rolls which ensures high
degree of opening and cleaning
especially of medium grade cottons.
• These rollers work in combination with
mote knives and suction hood to remove
fine trash impurities in all types of cotton
very effectively.
• Roll 1 has two separating wings. A
carding segment is installed after the first
wing. Waste is extracted directly from
the separating wings, via suction hood
i.e. a continuous suction flow removes
all contamination produced by
separation.
• Before the second separating wing, a
guide wing is situated which can be
steplessly adjusted during production. In
this way, the quantity and composition of
the waste can be regulated.
• Roll 2 (6) runs faster than roll 1 and
receives the material. Roll 2 is equipped
with a guide wing, a carding segment, a
separating wing and a connected suction
hood (7).
• Roll 3 (8), which in turn runs faster than
roll 2, is also equipped with a guide
wing, a separating wing and a connected
suction hood (9). From here the material
is extracted to the next machine.

14. TECHNICAL
DATA
Figure: Roll 1
Figure: Roll 2
Figure: Roll 3
Speed of feed belt- 0.757 -15.15 m/min
Speed of roll 1- 1244rpm
Speed of roll 2- 1864rpm
Speed of roll 3- 2968rpm
Beating point- 1.0

15. DUSTEX
DX385
• It ensures effective
dedusting which results
in thoroughly dedusted
slivers which ensure
optimized running
behaviour during yarn
formation.
ADVANTAGES
• Higher efficiency rates
• Longer lives of clothing
and spinning
components
• Better running
behaviour of the
spinning machines
• Clean ambient air

16. CARDING
DK803
• The function of the carding machine is to open
the tuft web coming from the tuft feeder into a
fiber web, to card (parallelize) the fibers, to
extract the waste particles (dust, trash, etc.), to
form the carded web into the sliver and to feed
this to the coiler for being deposited in a can.
The main components of the card DK 803 serving
for this function are:
• Tuft feeder DIRECTFEED DFK
• Feed roll
• SENSOFEED
• Deflector blades, mote knives with suction
hoods and carding segments
• WEBFEED
• Precarding segments and suction hoods with
mote knife- WEBCLEAN-
• Flats cleaning device
• Cylinder covering segments with suction hoods
and mote knives
• Revolving flats
• Cylinder
• Suction hoods with mote knives and post
carding segments- WEBCLEAN-
• Doffer
• Cleaning roll
• Stripping roll
• Squeezing rolls
• Calendar rolls with can changer

17. OPERATING
ZONES
• The feed roll seizes the web, condenses it
and forwards it to the L-in.
• The feeding system (SENSOFEED)
enables the web being clamped and
measured section by section.
• The function of the WEBFEED is to
open the web supplied from the feed roll,
to clean and feed it to the cylinder.
• The main cleaning is performed on the
first roll (1). Fine trash particles and dust
are extracted on the second and third
roll.
• The extraction quantity is determined by
a corresponding setting of the deflector
blades (7).
• Carding-parallelization-cleaning and
opening into individual fibers takes place
between the clothing of the cylinder and
the revolving flats.
• The clothing of the revolving flats are
designed to pick up short fibers and
impurities in the form of strips.
• The clothed doffer carries the fiber web
over the web guiding section to the
stripping roll (1).
• The WEBSPEED brings the web
together.
• In the web trumpet the card sliver is
formed from the web, and the sliver is
drawn off by the calendar rolls and
orderly deposition of the sliver into the
can takes place.
Fig: Tuft feed direct
feed DFK
Fig: Feed Zone
Fig: WEBFEED
Fig: Web doffing unit, WEBSPEED
calendar unit

18. AUTOLEVELLERS
IN CARD
1. CORRECTACARD
(CCD)
• This serves for a long term
levelling and monitoring of
the sliver count.
2. CORRECTAFEED
(ICFD)
• This serves for levelling of
the sliver count (CV-
value). The levelling
system works already
from a sliver length of 1
m.

19. TECHNICAL DATA
Feed roller-L-in- 35 thou
L-in-L-in- 7 thou
L-in-cylinder- 8 thou
Cylinder-flat- 8 thou
Cylinder-doffer- 5 thou
Knife-cylinder- 21.6 thou
1st Knife-doffer- 11.8 thou
2nd knife-doffer- 9.8 thou
L-in 2- Graf: K 50 20 X16 VG
TCC: T 50 20 160 0164 35/V
L-in 3- Graf: N 50 20 B16 VG
TCC: T 50 20 160 210 35/VB
Cylinder- Graf: R 20 30 X0.5
TCC: T 17 30 050 0860 05/X1
Doffer- Graf: N 40 30 X0.85
TCC: T 40 30 090 0367 31/BRZ
Flat tops- Graf: Spacetop 55
TCC: Novotop 55
Fineness- 0.125 Ne
Draft- 104
Target pressure DFK- 300 Pa
Diameter of L-in 1- 172.5 mm
Diameter of L-in 2- 172.5 mm
Diameter of L-in 3- 172.5 mm
Diameter of cylinder- 1287 mm
Diameter of doffer- 700 mm
Speed of cylinder roll- 560 rpm
Speed of L-in 1- 1152 rpm
Speed of L-in 2- 1788 rpm
Speed of L-in 3- 2343 rpm
Speed of feed roll- 10.9 rpm
Speed of flats- 400 mm/min
Speed of DFK beater roll- 830 rpm
Web thickness- 1.03 mm
Balancing value CCD- 5.70 mm
Total no of flats- 84
No. of flats in working position- 30
Delivery speed- 184 m/min
Production- 52.1 kg/hr
Efficiency- 96.3%
SETTINGS
WIRE SPECIFICATIONS

20. BREAKER DRAWFRAME SB-2
Its objectives are:
• Equalizing i.e. through doubling the sliver are made even.
• Parallelizing i.e. through drafting the fibers get parallelized.
• Hooks created in the carding machine are straightened.
• Dust removal.
Doublings – 7
Drafting arrangement – 3/3
Type of weighing – Spring loaded
Type of coiling – Over coiling
No. of deliveries – 2
Diameter – Top (mm) Bottom(mm)
Front 26 40
Middle 29 30
Back 38 30
Hardness of top roll – 830 shore
Roller gauge – 40/42
Break draft – 1.4
Main draft – 3.78
Total draft – 5.3
Hank fed – 0.125
Hank delivered – 0.094
Delivery speed – 750 m/min
Efficiency – 85%
Auto can changer – Yes
Auto leveller – No
Sliver monitor – No
TECHNICAL DATA

21. UNILAP E30
Its objective is:
To form a lap of desired fineness, weight, length and fiber orientation to be fed
to the comber for effective combing operation.
Doubling – 22
Drafting system – 3/3
Type of loading – Pneumatic
Lap length – 230m
Lap wt. – 80 g/m
Hank fed – 0.094
Hank delivered – 0.007
Efficiency – 82.2%
Total draft – 1.64
TECHNICAL DATA

22. COMBER E62
Its objectives are:
• Elimination of a precisely pre-determined quantity of short fibers.
• Elimination of remaining impurities.
• Elimination of a large proportion (not all) of the neps in the fiber material.
• Formation of a sliver having maximum possible evenness.

23. SEQUENCE OF
OPERATIONS
• Feed rollers (S) move lap sheet (W) forward
by a small amount ,while nippers (Zo/Zu)
are held open (feed).
• Upper nipper plate Zo is lowered onto
cushion plate (Zu) so that the fibers are
clamped between them (nipping).
• Combing segment (K), mounted on rotating
cylinder (Z), sweeps saw-teeth through fiber
fringe (B) and carries away anything not held
by the nippers (rotary combing).
• The nippers open again and move toward
detaching rollers (A) (nippers forward).
• Meanwhile detaching rollers (A) have
returned part of the previously drawn-off
stock (web V) by means of a (partial) reverse
rotation, so that the web protrudes from the
back of the detaching device (web return).
• In the course of the forward movement of the
nippers the projecting fiber fringe (B) is
placed on the returned web (V) (piecing).
• The detaching rollers begin to rotate in the
forward direction again and draw the
clamped fibers out of web (W) held fast by
feed rollers (S) (inside the nippers)
(detaching).
• Before the start of the detaching operation,
top comb (F) has thrust its single row of
teeth into the fiber fringe, (passive combing
by the top comb).
• As the nipper assembly is retracted, the
nippers open for the next feeding step. The
top comb is withdrawn. A new combing
cycle begins.

24. SETTINGS
TECHNICAL DATA
Feed/nip 5.2 mm (S= 18)
Nips/min 400
Lap wt. 80 g/m
Dia of full lap 550m
Noil % 18.60
Batt tension 9%
Type of feed Concurrent feed
Point density of top comb 32 needles/cm
Drafting arrangement 3/5
Type of weighing Pneumatic
Break draft 1.36
Main draft 10.22
Total draft 13.9
Hank fed 0.007
Hank delivered 0.115
Doublings 8
No. of deliveries 1
Delivery speed 167.1 m/min
Efficiency 90.8%
Can filling 6000m
Noil index- 24-40
Nipper-cylinder comb- 0.3 mm
Nipper-bottom detaching roller- 8 mm
Cylinder- brush- 18 mm

25. FINISHER DRAWFRAME RSB851
Its objectives are:
• To control the count variation within the sliver by using auto
levellers.
• To make the required hank of sliver for feed to the speed
frame.

26. AUTOLEVELLER
TECHNICAL DATA
Doublings – 6
Drafting arrangement – 3/3
Type of weighing – Spring loaded
Type of coiling – Over coiling
No. of deliveries – 1
Diameter – Top (mm) Bottom(mm)
Front 38 40
Middle 38 30
Back 38 30
Hardness of top roll – 830 shore
Roller gauge – 39/41
Break draft – 1.28
Main draft – 4.61
Total draft – 5.9
Hank fed – 0.115
Hank delivered – 0.120
Delivery speed – 400 m/min
Efficiency – 82%
Auto can changer – Yes
Auto leveller – Yes
Sliver monitor – Yes

27. SPEEDFRAME
LF1400
Its objective are:
• Attenuation of the draw frame
sliver.
• Insertion of protective twist.
• Winding of the roving into a
package which can be
transported, stored and donned
on the ring spinning frame.
The building motion performs
three essential functions during
the winding operation:
a. Shifting of the cone belt
corresponding to increase in
the bobbin diameter.
b. Reverse the direction of the
bobbin rail at the upper and
lower ends of the lift stroke.
c. Shorten the lift after each
layer to form tapered ends on
the bobbins.
(a)
(b)
(c)

28. TECHNICAL DATA
Drafting arrangement- 3/3
Type of drafting system- Pneumatic
Apron size- Bottom apron Top apron
76*65*1.02 42*38*1.02
Diameter- Top (mm) Bottom (mm)
Front 19 27
Middle 29 27
Back 38 27
Roller gauge- 45/50
Saddle gauge- 52/48
Break draft- 1.01
Main draft- 7.75
Total draft- 7.83
Hank fed- 0.120
Hank delivered- 0.90
Flyer speed- 980 rpm
Delivery speed- 450m/min

29. RING FRAME G 5/1
Its objectives are:
• Attenuate the roving until the
required fineness is achieved.
• To impart strength to the fiber
strand by twisting it.
• To wind up the resulting yarn in a
form suitable for storage,
transportation, and further
processing.
WINDING MECHANISM
This has to perform two movements:
a. Continuous rising and lowering in
order to apply alternate main and
cross windings (layering traverse)
and
b. A continuous ascent in very small
amounts after each layering
traverse in order to fill the cop
(switching traverse).
(a)
(b)

30. TECHNICAL DATA
Drafting arrangement- 3/3 double apron
Type of drafting arrangement- Pneumatic
Diameter- Top (mm) Bottom (mm)
Front 19 27
Middle 30 25
Back 28.5 27
Roller gauge- 42.5/60
Saddle gauge- 50.5/62
Ring dia- 42mm
Total draft- 26.67
Hank fed- 0.90
Hank delivered- 24s COM
No of spindles- 864
Spindle speed- 14600
Traveler speed- 32 m/sec
Tpi- 17.34
Production- 252.60 g/shift/spindle

31. AUTOCONER SCHLAFORST 338 TYPE RM
Its objectives are:
• To make a bigger package which has much higher content of
yarn than bobbin.
• To remove the faults that are generated in spinning i.e., thin,
thick and weak places
No. of machine sections- 6
No. of winding drums per section- 10
Total no. of winding drums on machine- 60
Creeling- Manual into circular magazines (6
pockets)
Winding speeds- 1650 m/min
Diameter of drum- 95 mm
TECHNICAL DATA

32. CONDITIONING AND PACKING
Fig: Contexxor conditioning process by xorella
Its objectives are:
• To improve the physical properties of yarn like strength, elasticity etc.
• To minimize monetary loss by selling yarns with standard moisture content.
After this, the cones are brought in the packing department where they are weighed, the
cartons are marked accordingly to yarn counts and then the cones are packed in cartons
to export.
Temperature 550 C, 650 C (depending
on the type of yarn being
processed)
Pressure 130, 140 mBar
TECHNICAL DATA