Square Textiles Ltd: A Practical Industrial Attachment Report

1 SQUARE TEXTILES LTD
Introduction
Industrial attachment is an essential part of four years course of B.Sc. in Textile
Engineering Bangladesh University of Textiles. I had the opportunity to perform the industrial
attachment at SQUARE TEXTILES Ltd. During 2 months long attachment, I studied the man,
machine, material aspects, quality control section, planning section, utility section, maintenance
section of the mill. There I learn about how a factory runs smoothly. How an administration
should be in factory also its environment how it affects workers work mentality. At SQUARE we
acquire our required knowledge about different yarn production process and Quality control,
From its raw material to dispatch. Various kind of yarn like normal card , normal comb, rotor
yarn, siro, inject, mélange , compact, organic, PC, CVC, white, double yarn, neppy, core spun,
slub yarn.Which gives us vast practical knowledge as a student of Yarn Manufacturing
Engineering .There I saw modern equipment of quality control like HVI, USTER, AFIS,
Tensojet, Autostretch 5C, Mesdanlab, NTDA. There I learn about different M/C and its
maintenance which is very much helpful to avoid Industrial Hazards. I also saw safety
measurement taken at the factory.
By achieving practical knowledge it is possible to apply the theoretical knowledge in the
Engineering field. For any Engineering study, practical experience is almost equally necessary in
organization with the theoretical knowledge. The industrial attachment is the most effectual
process of achieving the practical experience. It provides me sufficient practical knowledge
about production management, productivity, evaluation, work study, efficiency, industrial
management, production planning & control, production cost analysis, inventory control,
purchasing, utilities and Maintenance of machinery and their operation technique etc.
According to my studies there I have prepared the following report and would like to
present.

PROJECTDESCRIPTION
2.1. Project:
Name of the Project: Square Textiles Ltd. & Square Yarns Ltd.
Type: 100% Cotton and blend Yarn Manufacturing.
Year of Establishment:
There are 4 Unit which are situated inside the factory .They were established in different time.
Unit-01: 1995
Unit-02: 1998
Unit-03: 2000
SYL : 2006.
Address:
Corporate Office:
Square Centre
48, Mohalhali Commercial Area
Tel: 02-8817729-38 & 02-8827729-38
Email: Textiles@Squaregroup.Com
Factory:
Vill-Saradaganj, Post-Kasimpur, Thana: GazipurSadar
Dist: Gazipur
Tel: 02-7701232, Fax: 02-7701321
Head Office:
Mascot Plaza (10thFioor), 107/A, Sonargoan Janapath Road, Sector-07,
Uttara , Dhaka-1230.
Tel:02-8916163-65,02-8951101-8, Fax: 02-8916520.

Fig : 2.1 Location map of Square Textiles

Sponsors:
• Samuel S. Chowdhury, Chairman.
• Mrs. Ratnapatra, Vice Chairman
• Tapan Chowdhury, Managing Director.
• Mrs. Anita Chowdhury,Director
• AnjanChowdhury, Managing Director.
Banks:
1. Standard Chartered Bank
SCB House, 67 Gulshan Avenue
Dhaka.
2. Bank Al Falah Limited
5, Rajuk Avenue, Dhaka
3. HSBC Ltd.
Anchor Tower
1/1 –B Sonargaon Road, Dhaka
Insurers
1. Pioneer Insurance Co, Ltd.
10, Dilkusha C/A
Dhaka.
2. Pragati Insurance Co. Ltd.
20-21, Kawran Bazar
Dhaka
Listing
1. Dhaka Stock Exchange (DSE)
2. Chittagong Stock Exchange (CSE

Fig: 2.2. Master plan of STxL

2.2. Product Mix:
Unit -01:
Card Hosiery & Comb Hosiery, organic, siro, slub, melange, inject, 100%
manmade(viscose ,modal , polyester).
Unit -02:
Card Hosiery & Comb Hosiery, compact, organic & rotor card woven.
Unit -03:
Rotor Card Woven, knit slub
SYL:
Blended (PC, CVC, melange, combed), double yarn, neppy, 100% polyester
Number of Spindle
Unit 1: 36288
Unit 2: 23184
Unit 3: 3192
SYL: 31248
2.3. DIFFERENT DEPARTMENT:
 Department
 Production Department.
 Quality Assurance
Department.
 Utility Department
 Maintenance Department
 HR &Administration
Department
 Civil Department
 Store Department
 IT Department
 Marketing Sales Department
 Planning &Procurement
Department
 Finance & Accounti
Remarks:
Square Yarns Limited is a well known export oriented spinning industry in our country. They
process many goods and their project is a big amount.

ManpowerManagement
3.1. Manpower management is the means of manpower control to ensure the most efficient
and economical use of available manpower.
Manpower Planning which is also called as Human Resource Planning consists of putting
right number of people, right kind of people at the right place, right time, doing the right things
for which they are suited for the achievement of goals of the organization. Human Resource
Planning has got an important place in the arena of industrialization. Human Resource Planning
has to be a systems approach and is carried out in a set procedure. The procedure is as follows:
 Analyzing the current manpower inventory
 Making future manpower forecasts
 Developing employment programmes
 Design training programme
3.2. ManagementSystem
Definition:
A management system is the framework of processes and procedures used to ensure that an
organization can fulfill all tasks required to achieve its objectives.
For example, an environmental management system enables organizations to improve their
environmental performance through a process of continuous improvement. An oversimplification
is "Plan, Do, Check, Act". A more complete system would include accountability (an assignment
of personal responsibility) and a schedule for activities to be completed, as well as auditing tools
to implement corrective actions in addition to scheduled activities, creating an upward spiral of
continuous improvement.

3.2. Organogram of different section
Table: 3.1
Organogram of different section
Adminstration Production Quality Utility Maintenance
M.D G.M. A.G.M D.G.M Manager
E.D D.G.M Sr.Manager Sr. Manager Asst.
Manager
D.G.M A.G.M Manager Asst.
Manager
Sr. Executive
Factory
Manager
Sr.
Manager
Asst.
Manager
Sr. Executive Executive
Sr. Manager Asst.
Manager
Sr.executive Executive Sr.
maintenance
officer
Asst. Manager Sr.executiv
e
Executive Sr.asst.
officer
Maintenance
officer
Executive Sr.
Prodution
officer
Qua;ity
Officer
Asst. Officer Assit. Officer
Officer Production
officer
Sr.
Asst.Officer
Utility officer
Junior officer Worker Asst. officer
Sr. officer asst Lab assistant
Officer asst.

3.4. Management Apparatus in STxL
Board of Directors:
Mr. Samuel S. Chowdhury Chairman
Mrs. RatnaPatra Vice Chairman
Mr. TapanChowdhury Managing Director
Mrs. Anita Chowdhury Director
Mr. AnjanChowdhury Director
Mr. M. Sekander Ali Independent Director
Mr. Syed AfzalHasanUddin Independent Director
Audit Committee:
Mr. M. Sekander Ali Chairman
Mrs. RatnaPatra Member
Mr. AnjanChowdhury Member
Management Committee
Mr. Tapan Chowdhury Chairman
Mr. Anjan Chowdhury Member
Mr. Mostaque Ahmed Siddiqui Member
Mr. Md. Kabir Reza Member
Mr. Md. AlamgirHossain Member
Company Secretary
Mr. KhandakerHabibuzzaman

Management Team
Mr. Mostaque Ahmed Siddiqui Chief Operating Officer
Mr. Md. AlamgirHossain Chief Financial Officer
Mr. Md. AbdurRashi Head of Factory
Mr. Md. Idris Ali Head of Utility
Mr. MajiburRahmanBhuiyan Head of Internal Audit
Mr. Sayeed Ahmed Chowdhury Head of Procurement & Planning
Mr. Mohammad Shohel Anwar Head of Quality Assurance
Mr. Md. NaziburRahman Head of Marketing
Mr. Md. Adam Ali Khondoker Head of HR & Admin
Mr. Tazul Islam Head of Maintenance
Auditors
M/s. Das Chowdhury Dutta & Co.
Chartered Accountants
Well Tower, 1st Floor, Flat-A/1
12/APuranaPaltan Line, Dhaka
In SQUARE TEXTILES LTD. the management system is
Intercom telephone
Fax and E-mail
Written letters and
Oral
Shift Change:
There are three shifts in the industry. So the shifts are changed after 8 hours. There are
A shift: 6:00 am to 2:00pm
B shift: 2:00pm to 10:00pm
C shift: 10:00pm to 6:00am
General shift: 8:00am to 5:00pm

3.5. Responsibilities of a Production Officer:
In the Back Process:
A production officer should enter the mill before 15 minutes of the shift starting for taking
over the shift. He needs to look at and assure the following things:
 Stock of Mixing and Stock of Lack
 Availability of Stock for the next shift
 Humidity and Temperature
 Doffer speed of Carding to face the shortage of feed material of the next process
 Carding and Simplex should be in running condition always to ensure the feed material of
next process
3.6. Manpower arrangement in different section (unit-01)
Table: 3.2
Section designation No of
machine
Shift Total
G A B C
Mixing Mixing man 4 59 59
FDP operator 4 - 5 5 5 15
Blow room operator 2 - 4 4 4 12
Carding operator 20 - 3 3 2 8
Drawing operator 15 - 5 5 6 16
Unilap operator 2 - 1 1 2 4
Comber operator 12 - 3 3 2 8
Simplex operator 8 - 7 7 6 20
Ring(male)
Ring(female)
Doffer
operator
72 - 39
50
39
51
38
51
116
152
Winding(male)
Winding(female)
B.shorter
operator
12 - 16
47
16
47
16
47
48
140
Packing(male) - 2 2 2 6
Packing(female) - 5 4 5 14

3.7. Training & Development
Training is the process of enhancing the skill, capabilities and knowledge of employees
for doing a particular job. Training process moulds the thinking of employees and leads
to quality performance of employees.
Training is crucial for organizational development and success .The benefits of training
can be summed up as Improves morale of employees ,less supervision ,fewer accidents
,chances of promotion, increase productivity. SQUARE TEXTILES LTD company is
following the above theme for training & development .
3.8. Remuneration
Remuneration provides basic attraction to an employee to perform job efficiently and
perfectly. Salaries constitute an important source of income and determine their standard of
living. In Square Textiles Limited , employees get a standard figure of salary. They got their
salaries at the beginning of the month.
Remarks:
Manpower Planning is a two-phased process because manpower planning not only
analyses the current human resources but also makes manpower forecasts and thereby draw
employment programs. Manpower Planning is advantageous to firm. By using a proven
management system one can able to continually renew his mission, strategies, operations and
service levels.

Machine Description
4.1. Machine :
A machine is a device that applies force, changes the direction of a force, or changes the
strength of a force, in order to perform a task, generally involving work done on a load .
Machines are often designed to yield a highmechanical advantage to reduce the effort needed to
do that work.
A simple machine is a wheel, a lever, or an inclined plane. All other machines can be built
using combinations of these simple machines; for example, a drill uses a combination of gears
(wheels) to drive helical inclined planes (the drill-bit) to split a material and carve a hole in it
"Machines are worshipped because they are beautiful and valued because they confer power;
they are hated because they are hideous and loathed because they impose slavery" [Bertrand
Russell Sceptical Essays: Machines and the Emotions]
Machine description: square Textiles Ltd. use Rieter blow room line. The figure of the blow
room line of the mill is given below-
Fig 4.1 : Rieter Blow Room Line

4.2. Machine description:
Square Textiles Ltd. use Rieter blow room line. The figure of the blow room line of the mill is
given below-
4.2.1. Blowroom:
4.2.1.1. Unifloc:
The foundations for yarn quality and thus the quality of the textile end product are laid in the
blow room process. Square uses unifloc A10 for unit-1 & unit-2 and unifloc A11 for unit-3 &
syl. The Unifloc A10 &A 11 processes the fiber material gently and efficiently into micro tufts,
from which impurities can be removed very readily in the subsequent processes. This effectively
supports the quality and economic efficiency of yarn manufacture.
Table 4.1
MODEL A10 A11
BRAND RIETER RIETER
ORIGIN SWITZERLAND SWITZERLAND
PRODUCTION 1100 Kg/hr 1200 kg/hr
m/c speed 5-20 m/min 5-20 m/min
Take up depth 4-10 mm 4-10 mm
Fig 4.2: UNIFLOC A11

4.2.1.2. Uniclean:
Square mainly uses B10 and B11 type machine. The UNICLEAN pre-cleaner cleans the micro
tufts in the first cleaning stage immediately after the Unifloc . This enables machine output of up
to 1100 kg/h to be achieved. Cleaning is performed without nipping and is therefore very gentle
to the fibers and at the same time efficient. This ensures a high level of raw material utilization.
M/C specification of B11 model is given below:
Table 4.2
Fig 4.3 : UNICLEAN B11
Model B11
Brand RIETER
Origin Switzerland
Cleaning
intensity
0-1
Relative
waste amount
1-10
Production 1100 kg/hr

4.2.1.3. Unimix:
The mixing machine guarantees homogeneous, intimate mixing of the bale feed in a minimum of
space, even with unfavorable bale lay-down. The unique 3-point mixing process is equally
suitable for cotton and man-made fibers. 6 mixing chambers ensure not only effective mixing,
but also high production performance. The large storage volume of the Unimix provides the ideal
preconditions for a high degree of operating autonomy in the blow room.
Table 4.3
Model B7/3 B70
Brand Reiter Reiter
Origin Switzerland Switzerland
Production 500 kg/hr 500 kg/hr
Mfg year 1996 2006
Effeciency 75% 80%
Fig 4.4 : UNIMIX B70

4.2.1.4. Uniflex :
Thus a very homogeneous batting laydown is formed both lengthwise and crosswise. The
adjustable chute depth determines the lap weight required depending on production and type of
fiber. The material is carried further by a perforated drum and a plain drum. The machine is
equipped with automatic lap intake, thus no manual intervention is needed when starting up the
fine cleaner. The feed roll supplies the material to the opening cylinder. The opening cylinder,
which is available in different versions depending on the requirements of the material, takes over
the material. The spinner can set the rotation speed of the opening cylinder according to his
objectives and raw material.
Table 4.4
Fig 4.5: UNIFLEX B60
Model B50 B60 LB5/6
Brand RIETER RIETER LAKSHMI
Origin Switzerland Switzerland India
Mfg year 1996 2006 1996
Production 450 kg/hr 500 kg/hr 450 kg/hr
Efficiency 75% 80% 75%

4.2.1.5. THE COTTON SHORTER
The cotton shorter in general detects differentiation in color, regardless of the material.
Therefore paper, tar, dark cotton tufts, colored synthetic material are recognized with high
accuracy.
Due to the color differentiation of cotton, The cotton shorter automatically recognizes and
optimizes after machine start the color grade of the cotton tufts. Hence, even contamination with
a similar color like the cotton tufts will be detected and ejected.
Table: 4.5
Model Sp-Fpu HRS-120 ED-351-
1200T
Brand Truttzschler loptex Jossi
Origin Germany Ittaly Switzerland
Mfg year 2012 2011 2006
production 400 kg/hr 400 kg/hr 400 kg/hr
Fig 4.6 : SP-FPU

4.2.1.6. Condenser :
Furthermore, the condensing process enables yarn hairiness to be reduced quite dramatically,
especially of hairs longer than 2 mm (Fig. 75), i.e. those hairs which cause the main problems in
downstream processing.
The condensing process also enables the abrasion resistance of the yarns to be improved.
This not only results in much better yarn abrasion test values, but also considerably reduces
deterioration in yarn quality during winding. All these quality advantages can be exploited by
spinning mill operators. In most cases even yarn twist can be reduced, resulting in higher
delivery speeds on the spinning machine.
Table :4.6
Model LA5/6 A20 A21
Brand LAKSHMI RIETER RIETER
Origin India Switzerland Switzerland
Fig 4.7 : Condenser-A21

4.2.2. Carding Machine
Carding may be defined as the reduction of an entangled mass of fires to a filmy wed by working
between two closely spaced, relatively moving surface clothed with sharp wire point. It is the
heart of spinning.
Table: 4.7
Gauge of carding m/c
Feed plate to feed r/r = .15mm
Feed R/r to licker in = .9mm
Licker in to first knife = .35mm
Licker in to 2nd knife = .45mm
Linker in to cylinder = .25mm
stationary back to cylinder = 0 .35mm
Flat to cylinder = .35/.35/.3/.3/.3mm
Front plate to cylinder= 1mm
Back(top) plate to cylinder = 1.2mm
Front stationary to cylinder = .3/.3
Front knife = .3mm
Doffer to cylinder = .175mm
Doffer to stripping R/r = .15mm
Stripping R/r to delivery R/r = .15mm
Delivery to delivery R/r= .15-.125mm
Cleaning brush of flat = .15mm
Licker in dia = 253mm
Cylinder dia = 1290mm
Doffer dia = 500mm
Model C50 C51 C60
Brand RIETER RIETER RIETER
Origin Switzerland Switzerland Switzerland
Production
Cylinder
speed
Rpm 473 rpm 504 rpm
Flat speed 0.29
m/min
0.29 m/min 0.22 m/min

Fig 4.8 : carding m/c C 60

4.2.3. Breaker Draw Frame
Modern high-performance draw frames are currently equipped with highly efficient extraction
systems which reliable remove a substantial proportion of the dust still present in the fiber
material. Dust, fiber fragments and trash are effectively separated from the fibers by fiber/fiber
friction during the drafting process in the draw frame and can thus very easily be removed by the
extraction system
Table: 4.8
Fig 4.9: Breaker Draw Frame
Model SB-2 RSB-1 RSB-951 SB-D-10 SB-D-40
Brand RIETER RIETER RIETER RIETER RIETER
Origin Switzerland Switzerland Switzerland Switzerland Switzerland
Drafting 4 over 3 4 over 3 4 over 3 4 over 3 4 over 3
Doublingrati 5:1 8:1 8:1 6:1 6:1

4.2.4. Finisher Draw Frame :
Modern high-performance draw frames are currently equipped with highly efficient extraction
systems which reliable remove a substantial proportion of the dust still present in the fiber
material. Dust, fiber fragments and trash are effectively separated from the fibers by fiber/fiber.
Table: 4.9
Fig 4.10 : finisher Draw Frame
Model RSB-1 SB-2 RSB-D40 RSB-D45
Brand RIETER RIETER RIETER RIETER
Origin Switzerland Switzerland Switzerland Switzerland
Doubling 8:1 5:1 8:1 8:1
Delivery 700 650 700 700
Bottom R/r
dia
F-40mm,
M-30mm,
B-30mm
F-40mm,
M-30mm,
B-30mm
F-40mm,
M-30mm,
B-30mm
F-40mm,
M-30mm,
B-30mm

4.2.5. Unilap: A machine which produce lap from sliver.
Table: 4.10
Fig 4.11: UNILAP E 5/3
Model E5/3 E30 E32
Delivery
speed
100m/min 100m/min 100m/min
Doubling 24 24 24
Drafting R/r 30mm 30mm 30mm
Calendar R/r 50mm 50mm 50mm

4.2.6. Comber:
Combing may be defined as the removals of short fibers, neps, and remaining impurities of
card sliver by using comber machine.
Table: 4.11
Model E60H E62 E65
Feed/nip 360
Nip/min 5mm
Doubling 08 08 08
Drafting sys 3over3 3over3 3over3
Noil % 8-15 8-15 8-15
Lap length 230mm
Lap wt 1000gr/yds
Delivery/ m/c 01 01 01
Efficiency 90% 90% 90%
OTHER SPECIFICAION
Comber brush dia: 85-110mm
Detaching R/r dia: 23-24.5mm
Delivery R/r dia: 45mm
Funnel: 3.5-7 mm(inner dia)
Calendar R/r dia: 45mm
Feed amount teeth: 17-22
Drafting R/r: 42-45mm
Fig 4.12 : comber m/c

4.2.7. Simplex: Simplex is the machine involved next to the drawing operation, where the sliver
is subjected to one or more attenuating process and the attenuated sliver receives a small amount
of twist and is then wound on a bobbin.
Fig 4.13: Simplex Electrojet

SPECIFICAION OF SIMPLEX
Table: 4.12
Model FL-16 FL-100 ELECTROJET
Brand TOYOTA Marubeni
Corporation
Tokyo
Electrojet
Origin Japan Japan Spain
Flyer rpm 1100 1100 1100
No. of flyer 120 120 120
Full bobbin dia 152mm 152mm 152mm
Top R/r dia 19mm 19mm 28.5mm
Bottom R/r d 28.5mm 28.5mm 28.5mm
Condenser 12-15mm 12-15mm 12-15mm
Apron (top) 38.8x40x1.4
mm
38.8 x 40 x1.4 mm 38.8 x 40 x1.4 mm
Apron(bottom) 37 x 40 x 1 mm 37 x 40 x 1 mm 37 x 40 x 1 mm
Wighting arm TexpartsPK-
1500-110938
Texparts PK-1500-
110938
Texparts PK-1500-
110938

4.2.8. Ring Frame:
It is the final step of produce yarn. Where feed material is roving and final product is yarn.
the main operation are involved in there are creeling, drafting, twisting, winding, building,
doffing, etc
Table : 4.13
Fig 4.14 : Ring m/c
Model FA-507A RX-240 LR60/AX
Brand ERFANJI TOYOTA LAKSHMI
Origin China Japan India
Spindle speed 18000rpm 18000rpm 18000rpm
No. of
spindle
128 128 120

OTHER SPECIFICATION:
Spindle to spindle distance: 70mm
Spindle wharve: 18.5mm dia
Spindle dia:
Cot R/r dia: 27-29mm
Arbar: 25mm
Creel: 27mm
Bottom R/r: 27mm(all)
Ballon control ring: 46mm
Ring cup: 38-40mm
Tin pulley: 200mm
Juki pulley: 70mm
Tap length: 2455mm
Tap thickness: 0.7mm
Bottom shaft: 40mm
Flange width: 1.5mm
Front to middle R/r dist.: 45mm
Middle to back R/r dist.: 57mm
Lappet hook dia: 3mm

31 SQUARE TEXTILES
LTD
Roller pressure: It may be different types. These are below-
Traveler number: It may be different types. These are below-
Front Middle Back
Green 14 kg 10 kg 12 kg
Red 18 kg 14 kg 16 kg
Black 10 kg 10 kg 10kg
arn count Tr. No. M/c speed
36/1 CH 4/0 16500
30/1 CH 3/0 17500
32/1 KH 3/0 17500
30/1 KH 3/0 15100
26/1 KH 2/0 16500
18/1 CH 1/0 16000
20/1 KH 1/0 16000

32 SQUARE TEXTILES
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Spacer of ring frame:
Spacer is important parts of ring frame . it is place between middle of top and bottom
apron. It creates gap between two apron.
Selection of spacer:
For same count different color spacer is used then check performance (ends break rate,
quality criteria ) .Select spacer for this count which show opimum performance.
Ring cops:
Ring bobbin is a importants parts of ring frame.Yarn are winding here, so for better
winding it is important.
Colour of ring cops:
For separation of count different color of ring cops are used.
o Red old
o Red new
o Yellow old
o Yellow new
o Teya
o Green
o Chocklate
o Orange
o Black
o Sky
o Light blue
o Deep blue
o Ash
o Firoza
Spacer colour Spacer size (mm)
Red 1.8
Yellow 2.2
Lilac 2.5
White 2.8
Black 3.8
Beige 4.8
Green 5.5

33 SQUARE TEXTILES
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4.2.9. Winding m/c:
It is used for re-wounding of yarn into required suitable package.
Table: 4.14
Model AC 338 Savio polar Muratec Orion M
Brand Schlafthorst Savio polar Muratec
Origin Germany Ittaly Japan Ittaly
No. of drum 60 64 60
Drum speed
Splicing sys Automatic Automatic Automatic Automatic
Efficiency 60% 65% 65% 60%
Fig 4.15: winding m/c

34 SQUARE TEXTILES
LTD
4.2.10.Rotorframe:
The rotor spinning machine is the first final spinning machine to be practically fully
automated. Rotor spinning frame is a double sided spinning machine and works according to
the open end processing. The machine works with a discontinuous process. The rotor
spinning machine is also an excellent recycling device.
Table: 4.15
Model BT-903 Autocoro 288 Autocoro 360
Brand RIETER Schlafthorst Schlafthorst
Origin Switzerland Germany Germany
Fig 4.16 : Autocoro AC-288

35 SQUARE TEXTILES
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Main parts of Auto coro:
1) Drive unit
2) M/c section
3) End unit
4) Spinning position
5) Spin box
6) Automatic piecer carriage
7) Pacakage doffer top cone
8) Starter supply carriage
9) Starter winder
1)Drive unit:
 Informater
 Corolab control component
 Yarn guide drive
 Left hand rotor drive
 Combing roller drive
 Auxiliary shaft drive
 Changing gear drive
 M/c control component
 Frequency convertor
 Starter winder
3)End unit:
 Suction generator
 Right hand motor
 Trash removal drive
 Package conveyor drive
 Auxiliary yarn guide drive
5)Spin box:
 Sliver feeding
 Combing roller
 Rotor
 Take up drive

Other parts of Auto coro:
 Naval
 Coupling gear
 Flexible coupling
 Adapter
 Washer
 O.ring
 Torque stop
 Twin disc
 Drum drive
Rotor type:
There are different type of rotor are used for different yarn count
Table: 4.16
Rotor type Count (Ne)
T-533 12-14, Slub
T-540 7-10
TT-540 7-16, Slub
T-546 6
Material passage:
Sliver can
pre condenser
condenser
feed roller
combing roller
fibre channel
adapter
naval
rotor
take up device

4.3. Heat setting:
This machine is used for increasing yarn moisture content. In Square Yarns Limited, There have
only one machine for doing this.
Machine name Heat setting
Brand name Elgi Electric
Origin India
Main specification:
Heat set time 55 minute
Temperature 600c
Pressure 5 kg/cm2
Fig 4.16 : Heat Setting Machine

4.4. Machineries: Machineries used in square Textiles Ltd. For processing fibres into yarn are:
Table 4.17: Machinery Of Unit-1
Sl. Machine Name Type/Model Installation
Date
Quantity Mfg. By
1 Unifloc A 10 1996 1 Rieter Machinery
Ltd.
Switzerland.
2 Uniclean B 10 1996 1
3 Cotton Sorter SP-FPU 2012 1 Truttzschler,Germany
4 Unimix B 7/3 1996 3 Rieter Machinery
Ltd.
Switzerland.
5 Uniflex B 50 1996 2
6 Condenser LA 5/6 2007 1 Lakshmi,india
7 MBO LB 3/6R 1996 1
8 Carding C50 1997 19
Rieter Machinery
Ltd.
Switzerland
9 Carding C51 2000 1
10 Breaker Draw Frame SB2 1996 1
12 Breaker Draw Frame RSB1 1996 1
13 Breaker Draw Frame SB D40 2006 1
14 Unilap E 5/3 1996 1
15 Unilap E 32 2000 1
16 Comber E 60H 1996 6
17 Comber E -62 1996 4
18 Comber E-65 2006 2
19 Finisher Draw Frame RSB D40 2006 6
20 Simplex FL 16 1995 8
21 Ring Frame FA507A 1995 72 ERFANAJI, China
22 Winding Machine Autoconer
338
1996 5 Schlafhorst, Germany
23 Winding Machine Savio Polar 2012 6 Savio Polar , Ittaly
24 Winding Machine Muratac 2002 1 Muratac , Japan

Table 4.18 : Machinery Of Unit-2
Sl.
No.
Machine Name Type/Model Installation Date Quantity Mfg. By
1 Unifloc A 10 1998 1 Rieter
Machinery Ltd.
Switzerland.
3 Verio Clean LB 9/2 19/7/12 from unit 2 1 Lakshmi,india
4 Cotton
Sorter(Loptex)
HRS120 16/11/11 1 Ittaly
5 Cotton Sorter SP-FPU 23/5/12 1 Truttzschler,Ger
many
6 Cotton Sorter Vetal Scan 9/10/12 from U-3 1 Lakskmi,India
7 Unimix B 7/3 1998 3
Rieter
Machinery Ltd.
Switzerland.
8 Uniflex B 60 1998 2
9 Finecleaner B 50 9/10/12 from U-3 1
10 Mixing Bale Opener B ¾ 1998 1
11 Condenser A 21 27/2/13 1
12 Carding C51 1998/A18,2000/A19,2002 15
13 Carding C51H 1998 4
14 Aerofeed A70 1998/A18,2000/A19,2002 19
16 Finisher Draw Frame RSB-D30 1998/2001 6
17 Finisher Draw Frame RSB-1 1996 1
18 Finisher Draw Frame RSB-D45 A1-13/3/13 from U-4 2
19 Unilap E 30 1998 1
20 Unilap E 32 1/5/10 From U-4 1
21 Comber E65 2009
A1&A2,4 /7/11 From U-4
7
22 Comber E62 2006 A8&A9-9/7/12
From U-1
4
23 Comber E60H 1998 3
24 Simplex FL 100 19998 A5-2007,A6-2008 6 Marubeni
Corporation
Tokyo,Japan
25 Ring Frame LR60/A
X
A1-11/9/12& A2-04/9/12 2 LMW,India
26 Ring Frame RX-240 1998 21 Toyota, Japan
27 Rotor BT 903 1998 4 RIETER
ElitexCzeck
Republic
28 Autoconer AC 338 1998 6 W.Schlafhorst
AG.&CO.
Germany

Table 4.19 : Machinery Of Unit-3
Sl.
No.
Machine Name Type/Model Installatio
n Date
Quantity Mfg. By
1 Unifloc A 11 2000 1 Rieter Machinery Ltd.
Switzerland.2 Uniclean B 11 2000 1
3 Cotton Sorter ED-351-
1200T
2006 2 JOSSI,Switzerland
4 Unimix B 7/3 2000 2
Rieter Machinery Ltd.
Switzerland.
5 Uniflex B 50 2000 3
6 Condenser A 20 2000 2
7 Condenser A 21 2006 1
8 MBO B 7/3 2000 1
9 Carding C51-H 2000 15
10 Breaker Draw
Frame
SB D10 2000 6
11 Finisher draw
Frame
RSB D30 2000 7
12 Finisher draw
Frame
RSB D45 2011 1
13 Rotor Autocoro 288 2000 10 W.Schlafhorst AG.&CO.
Germany14 Rotor Autocoro360 2002 1

Table 4.20 : Machinery of SYL
Sl.
No
.
Machine Name Type/
Model
Installatio
n
Date
Quantity Mfg. By
1 Unifloc A 11 2006 1
Switzerland.
3 Unimix B70 2006 2
4 Uniflex B 60 2006 3
5 Cotton Shorter ED-351-
1200T
2006 3 JOSSI,Switzerland.
6 Condenser A 21 2006 1 Rieter Machinery Ltd.
Switzerland.
7 MBO 1 Laxmi,India.
8 Card C50 2006 14 Rieter Machinery
Ltd. Switzerland.
Switzerland.
9 Breaker Draw
Frame
10 Unilap E32 2006 2
11 Comber E60H 2006 8
12 Finisher Draw
Frame
RSB D40 2006 6
13 Simplex Rovemati
CAF
2007 7 Electrojet ,Spain.
14 Ring Frame LR 6/A 2006 26 Laxmi,India.
15 Ring Frame EJM138JLA 2006 5 Erfangi,Shanhai,China.
16 Winding
Machine
Orion M 2009 3 Savio,Ittaly.
17 Winding
Machine
Autoconer,
AC 338
2009 6 W.Schlafhorst AG.&CO.
Germany.
Remarks: Square Textiles Ltd. Uses modern machines for thinking of quality. They also have a
developed testing laboratory equipped with latest developed m/cs

Raw materials
5.1. Raw material: A raw material is the basic material from which a good product is
manufactured or made, frequently used with an extended meaning Raw material is goods or
products which are used in manufacturing or unprocessed products which are used in the creation
of some final product. For example, the term is used to denote material that came from natureand
is in an unprocessed or minimally processed state, a raw material is the wood that is used to
make furniture, fibers to make yarn etc.
5.2. Raw material used in STxL
1.Naturalfibre
 Cotton
 Flax
 Pima
 CIMA
 BCI
 Organic
2.Regenerated cellulose
 Viscose
 Modal
 Tencile
 Excel
 Promodal
 Micromodal
3.Man madefibre
 Polyester
 Lyra
 PVA
 Acrylic
5.3. Name of fibre importer country
1.Cottonfibre
 U.S.A
 Brazil
 Argentina
 Mexico
 India
 Pakistan
 CIS
 Africa
 Arbia

Cotton Supplier
 Delco international
 Sunny texim
 Dewou international
 Olam international
 Cargil cotton
 Four star group
Man madefibre
 China
 Korea
 Malaysia
 Indonesia
 Thiland
5.4. Weight of Different cotton bales
Table: 5.1
Name of origin Weight in kg
U.S.A 230 -250
C.I.S 230 -250
Brazil 230 -250
Organic 230 -250
PIMA 230 -250
India 150 -160

5.5. Description of Cotton bale: Normally cotton bale contains cotton fibers, without
cotton fibers cotton bale also contains some contaminations. Following information is found in a
bale-
 Binding material used for bales: Steel wire
 No of binder: 10
 Bale size: 95 cm x 80 cm x 59 cm
 Bale weight: 220 kg
 Tare weight: 2.6 kg
 Bale loading & unloading system: It is done by FORKLIFT.
 Capacity of raw cotton go down:20000-40000 bales
 Bales used in per lay down: 28 bales
 Bales consumption/day: 84 /unit
5.6. Contaminations of raw cotton : In raw cotton without cotton fibre all the material present
is called contamination.The contamination present in the raw cotton is given below:
• Black cotton
• Piece of cotton cloth
• Color thread
• Piece of polythene
• Piece of white cloth
• Piece of plastic
• Polypropylene
• Wooden piece
• Bale covering cloth
• Color cotton
• Jute
• Hair and Wool
• Others

5.7. BALE FORMATION AT MILL:
Cotton fiber originated from seed, which is called seed cotton. In cotton plant several cotton pot
or ball produced. Cotton growing origins are USA, CIS countries, Egypt, Africa, Australia,
China and also India and Pakistan. In our country cotton is mainly imported from huge cotton
grower USA, CIS, Australia, Africa, Egypt etc. because cotton of India and Pakistan fails to meet
our demand from view of quality and quantity. During harvesting seed cotton pots are collected
from the plant which is known as picking of cotton. Picking can be done manually and
mechanically. Manual picking can ensure cotton pot selection, segregation and collection
separately. So manual picked cotton is less trashy but collection/production is very low. Again in
mechanical picking, production rate is very high but have no choice. Big cotton growing
countries like USA use mechanical picking which in the other hand reduce cost of cotton. After
picking seed cottons, fibers are separated from seed by ginning machine for subsequent
processing. Seedless cotton fibres are then compressed to bales of around 500 lbs for easy
shipment to users. Seed cotton process flow and a typical bale size (95cm*59 cm*80 cm)is
shown as below. inSquar Textiles Ltd.J-34(Indian) cotton is used.
Spinning mill purchase those cotton bales under contract of some fibre property like fibre length,
fineness, strength, trash content etc. But modern spinning mills test all fiber properties for each
and every bale under Id. no. prior use taking representative samples of about 4 ounces from both
side of each bale. For this, thousands of bales need to be tested within very short time where HVI
has no alternatives. HVI i.e. High Volume Instrument offers all possible fibre property tests at a
very high speed.
5.8. BALE MANAGEMENT:
Bale Management is a process of inventory control and selection of Bales of Fibers according to
their properties and also to mix the Fibers homogeneously to get consistent production and
quality of yarn, which is extremely important for production of knitted yarn. For Bale
Management, all of the Bale samples are tested and Bales with almost similar category are
arranged for homogeneous mixing.

5.9. Procedure of Bale Management:
Step-1: Bales provided by the vendor, are received in the plant, and Identification number is
given on each Bale, sample is taken from each of the Bale for testing, a number is added to each
similar to that provided on the bales. The bales are stacked in the storehouse.
Step-2:100% of the bale samples are tested on the fineness tester.
Step-3: A status report is prepared based on the MIC value of the tested sample.
Step-4:Range of MIC values are selected for specific count of Yarn. Generally MIC value 4.0 to
4.5 consider for hosiery .
Step-5:Production Department prepares a table for the Bales of similar category to be mixed.
Step-6:Bales are then transferred to Blow room Line, placed horizontally and mixing is done by
manually(stack mixing).
5.10. Quality of raw material:
Quality of cotton fiber is given below-
Table 5.2: Properties of cotton fiber
R/C Type Mic Mat Len SCI Str Unf SFI Elng CG Rd +b Moist.
Indian 4.12 0.88 25.67 133 29.4 80.2 11.2 6.0 31-3 68.0 8.8 6.2
CIS 4.58 0.90 28.11 135 31.2 82.8 8.9 5.6 21-3 79.1 9.2 6.5
USA 3.97 0.88 29.56 149 34.0 83.7 8.1 6.6 43-3 69.4 8.9 8.3
Remarks: Raw materials of any process are very important. Because the quality of final product
depends on the raw materials. For this reason better quality raw materials should be selected. For
smooth running of a factory uninterrupted supply of raw materials is very essential.

Production Planning And Sequences And Operations
6.1. Production planning:
Production planning is the manufacturing process of preparing and producing goods and
services for use by consumers and other businesses. Depending on the size of the company,
production planning can be a detailed and lengthy process. Production planning has evolved over
the past several decades as business technology has increased the amount of information
businesses can use for production planning. This information has led companies to create
detailed production planning, which includes the use of schedules and electronic information for
producing goods and services.
The administrative process that takes place within a manufacturing business and which
involves making sure that sufficient raw materials, staff and other necessary items are procured
and ready to create finished products according to the schedule specified. Atypical large
manufacturing business engaging in production planning will aim to maximize profitability
while maintaining a satisfied consumer base.
The function of a manufacturing enterprise responsible for the efficient planning, scheduling,
and coordination of all production activities. The planning phase involves forecasting demand
and translating the demand forecast into a production plan that optimizes the company's
objective, which is usually to maximize profit while in some way optimizing customer
satisfaction. These twin objectives are not always synonymous. During the scheduling phase the
production plan is translated into a detailed, usually day-by-day, schedule of products to be
made. During the coordination phase actual product output is compared with scheduled product
output, and this information is used to adjust production plans and production schedules.
If the production or manufacturing process is viewed as an input-output process, then the
production planning function can be viewed as a control process with feedback .The control is in
The form of schedules and plans, while the feedback results from the comparison of the
production reports with the production schedules.

6.2. Flow Chart of Carded, Combed and Rotor Yarn Manufacturing process:
A flowchart is some such pictures from which it is understood that to solve the problem how
successively we have to move forward. The flowchart of carded, combed and rotor yarn
manufacturing process is given below:
Carded (Ring) Combed (Ring) Rotor
Carding
Ring
Simplex
BreakerDraw Frame
Packing
Heat Set/Conditioning
Winding
Marketing
Blow Room
Rooomroo
m
BlowRoom
Rooomroo
m
Blow Room
Rooomroo
m
Carding Carding
BreakerDraw FrameBreakerDraw Frame
FinisherDrawframe FinisherDraw frame Unilap
comber
FinisherDrawframe
Simplex
Ring
Winding
Packing
Marketing
Marketing
Rotor
Packing

Table 6.1
Process flow chart of PC(KH), CVC (KH) and Melange yarn:
PC(KH) CVC (KH) MELANGE
Hand mixing Hand mixing Hand mixing
MBO MBO MBO
Uniclean Uniclean Uniclean
Unimix Unimix Unimix
Uniflex Uniflex Uniflex
Condenser Condenser Condenser
Carding Carding Carding
Breaker Drawing Breaker Drawing Breaker Drawing
Finisher Drawing Finisher Drawing Finisher Drawing
Simplex Simplex Simplex
Ring Ring Ring
Winding Winding Winding
Heat Setting Heat Setting Heat Setting
Packing Packing Packing
Core Spun Yarn:
Core spun yarn are consist of two portion one is core portion and another is sheath portion.
Normally sheath are consist of natural or manmade fibre and core is consist of filament or
elastomeric fibre. Normally we use Lycra as an elastomeric fibre.
Process Sequence of core spun yarn :
This process is as like as ring yarn but here core portion like lycra introduces in ring
section at front zone.

Table 6.2 :core draft
Count (Denier ) Core Draft
40 3.2-3.5
70 3.5-3.8
Compact Yarn:
Compact Yarn is a yarn which has lower hairiness means there is less no of protruded fibre
and C.S.P is higher compare to normal yarn .
Process Sequence of Compact yarn:
This process is as like as ring yarn but here after front roller of ring frame extra Elite
unit is introduced. By this triangles are reduced and maximum fibre are participate during
twisting which reduced the hairiness.
Specification of Elite unit :
Elite Cot dia : 37 mm
Front Cot to Elite cot : 1.88mm
Latice apron length: 39mm (Susan)
Compact Spinning angle: 00/900
Elite air suction: 36 P.S.I
SlUB Yarn:
Slub yarn is a yarn which has various thickness at its length.
Process of producing slub yarn:
It is same as Ring yarn production but here SERVO motor is introduced in ring frame which
control the feed roller speed. Its creates various speed to the feed roller which various draft. It is
the reason for its different thickness
Point should be considered during Slub attachment:
1) Slub length
2) Slub dia
3) Interval length

How can we measure slub dia:
If slub length is 5 cm . Then we cut 10 slub parts length 4 cm (for actual length) and 10
sample for interval length. Then we weight individual sample . If slub sample weight is two
times than interval sample then it is called Slub dia two times .
NOTE: Slub count determined including both slub and interval yarn
Table 6.3 : Slub Attachment
Count Slub
Length
(cm)
Interval
Length(cm)
Dia% T.M
Weaving Slub
10 2.5-5.5 40-60 1.60 5.12
20 3-5 10-25 1.75 5.02
Knit Slub
24 3.5-6.0 25-40 2.0 4.3
30 3.5-6.0 20-60 2.0 4.55
Process mapping :
Process mapping means how a new process are running in the production floor.For
separation of different process different color can and bobbin brand, cops are used.
Flow chart of process mapping
Name of m/c Remark
Blow room Line -1
Carding 8-14, green elastic of can brand
Breaker draw frame 1-2, red elastic brand
Unilap 1, require blue mark
Comber 7-14, light blue elastic
Finisher draw frame 4-5, light blue elastic
Simplex With out cap
Ring frame 1-11, red cops
Winding 7 (1-26 head), with steaker

6.3. Production Parameters:
Production parameter of different machine is given below-
Blow room Line:
No. of blow room line = 3 ( U-1,U-2,U-3,U-4)
In every unit there are two line starts with unifloc and the third line is start with Mixing Bale
Opener
Production Capacity of Blow room:
Line 1 :500 – 600 kg per hour
Line 2 : 500 – 600 kg per hour
Cleaning efficiency of Blow room : 75%
Wastage : 4%
6.4. Process parameter for different process running in different Unit:
In Unit-1 mainly 100% cotton, Blended (e.g. 50% modal+50% Cotton), 100% Moadal, 100%
polyester
In Unit-2 mainly 100% cotton, Rotor (OE,super,normal,knitting)
In Unit-3 mainly Rotor (OE,super,normal,knitting)
In Unit-4 mainly Blended (PC, CVC, PV),100% viscose , Cotton Millange, Grey Millange
produced

Process parameter for different process running in different Unit is discussed Below
Process Parameter (cotton) Table 6.4:
M/C Parameters Setting
Stxl unit-1 Stxl unit -2 SYL
Uniclean Cleaning Intensity 0.7 0.5 0.5
Relative Waste Amount 8 6 6
Uniflex Cleaning Intensity - 0.6 0.3
Relative Waste Amount - 7 6
Carding Sliver Ktex 5.2 5.2 7.5
Delivery Speed 54.6kg/hr 54.6kg/hr 75kg/hr
Cylinder Speed 480 480 850
L-in Speed 1500 1500 1400
Flat Speed 0.24 0.23 0.37
Gauge 0.25/0.225/0.20 0.25/0.225/0.20 0.25/0.225/0.20
SB2/
Breaker
Sliver Ktex 4.9 4.9 4.9
Delivery Speed 750 750 700
Zone Setting 39/44 39/42 39/44
Condenser 4.2 4.6 4.6
Web Funnel 8 11 8
Unilap Sliver ktex 80 75 75
Zone Setting 44/48 42/44/46 45/48
comber Sliver ktex 4.9 4.9 4.9
Main Distance 42 41 45/50
Nip/min 300 350 400
Feed/Nip 4.7 4.7 4.7
Finisher Sliver Ktex 4.9 4.9 4.82
Delivery Speed 500(c)/650(k) 450 500
Zone Setting 39/45 40/44 40/45
Web Funnel 4.2 4.2 4.2
Condenser 8 10 8
Scanning Roller Load 320/320/320/200 120 6mbar/120
Simplex Roving Hank 0.69 0.8 0.79
TPI 1.05 1.07 47(TPM)
Spacer Green Cream Cream
Zone Setting 37.5/49.5/55.5& 37.5/49.5/54 48/50/54
Back draft 1.19 1.19 1.17
Arm Pressure Red Green Green
Ring Zone Setting 44/54 44/54 44/57&42.5/60
Back draft 1.30 1.29 1.3&1.24
T.M/TPI(30Ne) 3.64 6.64 3.75&6.65
Arm Pressure Green Green Green

Process Parameter (Modal/Viscose) Unit-1
Table 6.5 :
M/C Parameters Setting
100% Modal/Viscose 50% Modal/Viscose
Varioclean Grid bar setting 5/5/5/5 9/9/9/9
Opening roller RPM 800/600 700
Grid Bar
Angle
MBO 1 3
Unimix 2 3
Carding Sliver Ktex 6.5 4.9
Delivery Speed 35kg/hr 45kg/hr
Cylinder Speed 390/300 480
L-in Speed 980/450 1500
Flat Speed 0.24 0.24
Gauge 0.25/0.25/0.25/0.30/0.30 0.25/0.225/0.20
SB2/
Breaker
Sliver Ktex 4.9 4.9
Delivery Speed 500 500
Zone Setting 46/46 46/46
Condenser 4.6 4.6
Web Funnel 11 11
Unilap Sliver ktex - -
Delivery Speed - -
Zone Setting - -
Comber Sliver ktex - -
Main Distance - -
Nip/min - -
Feed/Nip - -
Finisher Sliver Ktex 4.9 4.9
Zone Setting 45/49 45/49
Web Funnel 10 10
Condenser 4.6 4.6
Scanning Roller Load 380/380/320/200 380/380/320/200
Simplex Roving Hank 0.90 0.90
TPI 0.766 0.908
Spacer Blue Green
Zone Setting 40.5/49.5/60.5 40.5/49.5/60.5
Back draft 1.26 1.19
Arm Pressure Red Red
Ring Zone Setting 44/54 44/54
Back draft 1.39 1.30
T.M/TPI(30Ne) 3.40 3.70
Arm Pressure Green Green

Parameters For Winding Speed (m/min)
Table 6.6 :
Count(Ne) Normal/Blended:
Process : 100%
Cotton+
Blended
Modal,Viscose
Slub :
Cotton+BlendedSlub
100%
Modal/Viscose
Lycra Yarn
7 850 800 800 800
9-10 1000 850 950 900
12-14 1100 950 1050 950&1000(14Ne)
16 1300 1050 1250 1000
18 1400 1100 1350 1050
20-22 1450 1150 1400 1100
24-26 1550 1200 1500 1100
28&above 1600 1200 1550 1100
Yarn Tension Control in winding M/C
Table 6.7 :
Process Count(Ne) Pressure Min. Pressure Doffing Cycle
Tension
PC/CVC/100%
cotton
7 54 24 20
10-16 52 22 20
18-20 42 16 20
22-38 35 12 20
40-60 35 5 20
MH/CM 10-16 52 22 20
18-20 42 16 20
22-38 40 15 20
40&above 15 5 20
PV/PVC 10-18 30 10 20
20-40 25 8 20
100% PSF 10-18 30 10 20
20-40 20 7 20

6.5. Attachment For Diversified Product:
( 1) Slub attachment:
( a) R/F-01 , ( 8-24 ) , ( 47-48 ) , ( 51-53 ) => Bea Electronics
( b) R/F-( 25-28) , ( 39-45 )=>Caipo,Itali
( c ) R/F-(49-50)=>Pinter, Spain
Total Slub Attachment=> 23+12+2=37
( 2 ) Core Yarn Attachment:
( a ) R/F-( 25-26 ) , (29-32)=>Capio,Ittali
( b ) R/F-( 25-28)=>Pinter, Spain
Total Lycra (Core ) Attachment=> 6=6=12
( 3 )Lycra (Core ) Slub Attachment:
( a ) R/F-( 25-26 ) =>Capio,Ittali
(4 ) Inject Yarn Attachment:
R/F- ( 01-07)=> Bea Electronics , India
(5 ) Inject Slub Attachment:
R/F-01 Bea Electronics,India
( 6 ) Siro : R/F : 57

6.6. Production planning:
For production of 25 ton 30 Ne carded cotton yarn firstly it is required to take 29.0699 ton raw
cotton. Because 3o Ne carded yarn production 14 % wastage will occur. As each bale weight is
220 kg so 132.13 bales are required for this amount of yarn production. In Square Textiles Ltd.
each lay down contains 20 bales. So 6.6 ~7 lay down is required. Square Textiles Ltd. produce
20 ton/day, so 30 hours is required to produce 25 ton yarn.
6.7. Description of production process:
First the raw materials of the final product are taken. If mixing is necessary it is done. If
carded yarn is produced then the raw materials is passed through the blow room line m/c, carding
m/c, breaker draw frame, finisher draw frame m/c, simplex m/c, ring frame m/c and finally
winding m/c. Then the yarn is conditioned by Heat set m/c .If combed yarn is produced then two
extra m/c named Lap former m/c & Comber m/c is used between breaker and finisher draw
frame m/c in the carded process.
Monthly average production: 577748 Kg/Month
Monthly efficiency: 85%
Remarks: Production rate of any mill is important. Because the economic condition of the mill
depends on the production rate.

Quality Assurance System
7.1. Quality assurance
The quality of yarn produced should conform to the quality norms specified by the customer. It
is equally important that:
Quality assurance (QA) refers to the systematic activities implemented in a quality system so that
quality requirements for a product or service will be fulfilled. It is the systematic measurement,
comparison with a standard, monitoring of processes and an associated feedback loop that
confers error prevention. This can be contrasted with quality control, which is focused on process
outputs.
7.2. Quality Assurance Procedure:
Two principles included in QA are: "Fit for purpose", the product should be suitable for the
intended purpose; and "Right first time", mistakes should be eliminated. QA includes
management of thequality of raw materials, assemblies, products and components, services
related to production, and management, production and inspection processes.
this should be achieved without making any compromise in productivity, which otherwise affects
the yarn costing. Quality Control is concerned with sampling, specifications and testing as well
as the organization, documentation and release procedures which ensure that the necessary and
relevant tests are carried out, and that materials are not released for use, nor products released for
sale or supply, until their quality has been judged satisfactory. The Quality Control Department
as a whole will also have other duties, such as to establish, validate and implement all quality
control procedures, keep the reference samples of materials and products, ensure the correct
labeling of containers of materials and products, ensure the monitoring of the stability of the
products, participate in the investigation of complaints related to the quality of the product, etc.
All these operations should be carried out in accordance with written procedures and, where
necessary, recorded

7.3. Controlling quality:
i) Cotton & Raw Material Testing (Bale Management)
Cotton samples received will be tested against mill norms and a decision regarding purchase of
the lot or rejection will be taken. Lots which fulfill the quality norms will be purchased, and
100% testing of the bales from the lot will be carried out Bale Management should be strictly
followed.
ii) In-Process Testing & Process Optimization
In-process material at every process stage must be checked and wherever deviations are
observed, the process must be optimized by conducting trials.
iii) Finished Product Testing
Before the final product is being dispatched to the customer, the same should be checked against
the norms specified by customer. Non-conforming product must be packed separately and given
separate lot/batch number.
iv) Calibration of Testing Equipment
To arrive at reliable results, the testing instruments must be calibrated (Internally or by service
engineer as the case may be) as per the prescribed method and schedule.
There are four unit known as STxl 1; STxl 2; STxl 3; &SYL.The 1 st three unit STxl 1; STxl
2; STxl 3; which are certified by ISO 9001.

7.4. Quality control equipment:
List of quality control equipment is given below-
Table no. 7.1 :
List of quality control equipment
Serial
no.
Machines name Quantity Manufacturer WORK
01. Uster HVI Spectrum 1 Uster Technologies,
Switzerland
Raw cotton
inspection
SCI;
Mic;SFI;Str;Elg;Rd;
+b; C Grade;
Trcnt
02. Uster HVI 900
(Zellewegeruster)
1 Uster Technologies,
Switzerland
Upgrade version of
(1); maturity &
moisture extra
03. Uster tester 5 1 Uster Technologies,
Switzerland
Yarn & sliver
inspection;
Unevenness ; thick
thin; hairiness; neps
04. Covatest (techno textile
testing technology)
1 Germany Same as uster 5
05. Uster AFIS Pro 1 Switzerland Raw material &
sliver inspection
Upgrade version of
UsterAfis ; length;
UQL(w)mm; SFC;
spun length; (2.5%,
5%); IFC; maturity;
Nep; SCN; NRE;
TRASH
06. Uster AFIS 1 Switzerland SAME as 5

07. Dynajet(textechno
textile testing
technology)
1 Germany Yarn’s weak point
test
08. Ustertensojet 1 Switzerland Single yarn strength
tester
Tenacity
;elongation;
breaking force
09. Zweigle G566” 1 Switzerland Yarn inspection
Full COPS
Hairiness
10 Eureka EY12 (Eureka
Precision Instrument
Company)
1 South India Warp reel ;yarn
count
11. Mesdanlab 1 Italy Yarn twist tester
12. NTDA (MAG SITRA
Ele Trash)
1 Germany Raw material
inspection
Neps; Trash; Dust
analyse
13. Board Wrapping
(MAG)
1 India Same as 10
14. Auto stretch 5C 1 India Yarn lea strength
15. HVI Rapid
Conditioning Cabinet
(SDL)
1 Switzerland Raw material
inspection
Cotton conditioning

Table 7.2 :Quality control system;
PROCESSI
NG STAGE
ONLINE QUALITY
CONTROL
OFFLINE QUALITY
CONTROL
EQUIPMENTS
RAW
COTTON
VARIOUS FIBER
PROPERTIES
HVI SPECTROG
SHORT
FIBRE%,NEPS,UM%
VARIATION AFIS.,A
BLOW
ROOM
FIBER CLEANING
EFFICIENCY
CARDING SLIVER WT/YD,CV% SHORT
FIBER%,NEPS,UM%,PERIODIC
VARIATION
AFIS, AFIS PRO
TESTER 5
DRAWING SLIVER
WT/YD,CV%,SPECTROGRAM
NEPS,UM%,PERIODIC
VARIATION,SPECTROGRAM
AFIS.,AFIS PRO
TESTER 5
LAP
FORMER
LAP WT/YD,NEPS AFIS.,AFIS PRO
COMBER SLIVER
WT/YD,CV%,SPECTROGRAM,
NEPS,COMBER WASTE%
AFIS.,AFIS PRO
TESTER 5
ROVING
FRAME
CV%,SPECTROGRAM USTER TESTER
RING
FRAME
HAIRINESS AAND
BALLON SHAPE
SPECTROGRAM YARN
COUNT,U%,CV%,
NEPS,THICK,THIN
USTER TESTER
REEL & BALANCE
WINDING SHORT THICK,LONG
THICK,NEPS,COUNT
VARIATION,CLASSIMATE
FAULT
U%,CV% USTER TESTER
PACKING CARTOON WEIGHTENING BALANCE

7.6. There is four minilab at each unit. Here is the list of the equipment
Unit 1
1. Eureka ( warp reel)
2. Optical yarn reader (Sub meter, thick, thin)
3. Fabric inspection
4. Fibro block(roving, sliver length measurement)
5. Merlin-spa 1803 ( spindle 18,lycra attachment)
Unit 2
1. Eureka (warp reel)
2. Fibro block ( sliver, roving length measurement)
Unit 3
1. Eureka (sliver, roving length measurement)
2. Eureka (warp reel)
3. Zwigle ( Germany, Type G-585/1 sub test)
Unit 4
1. Eureka ( sliver, roving length measurement)
2. Ele warp 10 ( warp reel, yarn count test)
3. Fibro block (India) ( roving , sliver length measurement)
4. MAG (solvics)
5. Statex ( Auto twist tester)

7.7. USTER HVI SPECTRUM:
1)Name of the equipment: Uster high volume instrument(HVI)
2)Objectives: To measure
MIC,length,maturity,strength,SFI,elongation,moisture,Rd,+b,colorgrade,trash area, trash
grade,uv.
3)Testing type
a)System testing
b)Module testing
 Length and strength module
 Micronaire module
 color and trash module
4)Operating procedure:
a)Switch on the power of the machine.
b)Calibrate the color,mic, length, trash.
c)At first mic of the fibre sample is carried out followed by the color, length strengtest.
d) The print out of test result is obtained.
5) Pocedure method:
(1) Visual inspection of the printed individual and summery results.
(2) Bale management is carried out with Bias from these results.
Details about three modules:
a) Micronaire module:
I. Working principle- Air flow method
Fiber thickness, inter space, air pass, mic , fineness
II. Sample weight- 8.5 to 11.5 gm.
III. Application range of mic- 2 to 7

7.8. Color and trash module-
Working principle- Electro optical method
Colour grade is determined by combination of Rd and +b.
Rd-:
 Expresses degree of brightness
 More Rd more brightness
 Application range of Rd- 35 to
90%
+b:-
 Express degree of yellowness
 More +b more white cotton
 Application range of +b 4 to
18%
Leaf grade-
 Trash is expressed by leaf grade.
 Application range of leaf grade- 1 to 7.
Working principle- for length : photo electric cell
For strength- Pneumatic
Length measurement:
UR= 50% span length/2.5% span length *100%
UI = ML/UHML*100%
Fibre length and uniformity is related to short fibre content.
SFI= 122.56-(12.55*UHML)-(1.22*UI)
7.9. USTER AFIS PRO :
Name of the Equipment :Uster Advanced Fibre Information System (AFIS)
objectives: To measure following fibre properties-
 Nep (Cnt/gm)
 Nep (um)
 SCN (Cnt/gm)
 SCN (um)

lxix SQUARE TEXTILES LTD
 L(W) (mm)
 L(W) (%cv)
 SFC (W) (mm)
 SFC (W)
(%<12.7)
 UQL (W)
(mm)
 L (n) (mm)
 L (n) (%cv)
 SFC (n) (%
<12.7)
 IFC (%)
 Maturity Ratio
Technical data :
Application range-
 Number of fibres: maximum-1000 & default-3000
 Sample weight-0.5 gm
 Sample length : 30
Modules Testing:
 Multidata testing module : UQL, SFC, Fineness, IFC, M.R Neps,
SCN, Dust, Trash, VFM.
 Neps module- neps, SCN
 Length &Dia module: UQL, SFC, IFC, M.R, Fineness
 Trash module : Dust, Trash, VFM
Operating Procedure:
 Switch on the power of the m/c
 Select measurement from the main menu.
 Select module
 Select identifier

 Select sample type
 Input filename
 Press start button.
 Feed the prepared samples in the feed nozzie
 The print out of the tested results could be obtained after the test.
Report Type:
 AFIS quality report
 results of each tested sample
 Summary of the results with statistics
 Graphical representation of each and every parameters e.g
histogram etc.
Inspection :
 Visual inspection of the printed individual and summary test
results.
 Raw cotton selection is done from the measured neps, SFC,
Maturity Ratio etc.
 Test results help to select proper process parameter.
AFIS TEST SUMMARY
Table :7.3
Process Lay
down
After
Unifloc
After
Uniclean
After
Uniflex
Card
mat
Card
sliver
Sliver
(B/F)
Sliver
(F/F)
Ro
ving
Neps/gm 242 231 256 281 309 74 71 67 50
NRE% 4.55% 10.82% 9.96% 9.96% 76.05% 4.05% 5.63% 25.37%
UQL 28.52 31.3 29.6 30.9 30.2 30.5 30.8 31.2 31

7.10. USTER TESTER-5:
Name of the Equipment : Uster tester-5 (UT-5)
Objectives : To test.
Thin -50% /km
Thick +50% /km
Neps +200% /km
U%
CVm
CVm 3m
CVm 10m
Hairiness
Number of Slots:
For Slivers: 1 Slot
For Roving:1 Slot
For Yarn : 2 Slot
Measuring Principle :
 Electronic Capacitance Method.
Testing speed :
 For Yarn: 400 m/min
 For roving:50 m/min
 For Sliver : 50 m/min
Quality parameters:
a) Unevenness- (Um%, CVm%) at different cut length
Cut length- For Sliver : 20 mm
For roving : 12mm
For yarn : 8mm
a) Imperfection index:
Thin place/km : at- 30%, 40%, 50% & 60% Sensitivity
Think place/km :at + 35%, +50%, +70% & +100% Sensitivity
Neps/km : at +140%, +200%, +280% & +400% Sensitivity

b) Hairiness (at different cut length and CV% of hairiness)
c) Periodic faults (mechanidal)
Operating System :
Switch on the power of the machine.
Select “Test Program” and then press recall button.
Write the changeable parameter through keyboard and start the test with
start button.
Feed the test sample manually through the proper guide. No interruption is
valid during test period.
The printer automatically prints a report along with diagrams just after a
test is being completed.
Electronic Capacitance Method.
7.11. Uster Classimate :
In the production of spun yarn, faults such as slubs, spun-in fly, hard piecings, long thin
Places result. These faults are to be avoided for two reasons: firstly, they cause breaks during
post spinning operations like winding, warping, weaving & knitting and secondly, they detract
(take away from) the aesthetic (relating to principle of beauty, taste & art) appeal of the fabrics.
Table: 7.4
Cross Section Length
0.1~1cm 1~2 cm 2~4cm Over 4 cm
A B C D
+100% and
above
A1 B1 C1 D1
+ 150% and
above
A2 B2 C2 D2
+ 250% and
above
A3 B3 C3 D3
+ 400% and
above
A4 B4 C4 D4

7.12. Classification of Classimat Faults
The faults : A1, A2, A3, B1, B2, C1, C2, D1 & D2 are dependent on raw cotton and hence called
Raw material faults.
Determination of Classimat faults. It is recommended to test 300 km of yarn on the Classimat
system to determine the frequency of faults and express the results as number of faults per 100
km.
7.13. Quality Assurance Department
Table: 7.5
Short
Abbreviation
Of Uster
Statistics
Standard as per Uster Statistics, 2001
Meaning
Ne 30 KH Ne 30 CH
5%USL 25%USL 5%USL 25%USL
CVm Co-efficient of
variation of mass per
1m length
13.4 14.55 11.38 12.06
Thin/km Thin place(-50%) in
one km of yarn
4 8 0.9 1.25
Thick/km Thick place (+50%) in
one km of yarn
85 150 12 20
Nep/km Neps (+200%) in one
km
140 200 29 42
IPI Imperfection Index. It
is sum of. Thin, thick
&neps
229 358 41.9 63.25
Hairiness (H) Total length of
protruding fibres per
unit length of yarn. So,
the hairiness ‘H’ is the
ratio of two length &
therefore in
simensionless.
4.8 5.35 4.3 4.6
CV-T Co-efficient of
variation of count in
he same bobbin.
1.45
CV-B Co-efficient of
variation of count in
different bobbins.
1.1 1.45 0.90 1.27
CSP Product of Count
(Ne) &lea Strength in
Ibs
2250 2250 2250 2250

7.14. ELECTRONIC TWIST TESTER:
Name of the equipment : Twist Tester
Machine specification :
 Sample clamp
 load adjusting cursor
 Scale
 MAINTENANCE Level adjusting screw
 Plum bob
 Change leaver of untwisting direction ‘S’ and ‘Z’ twist.
 Sample elongates and revolve chack
 Handle for move the revolve chack.
Operating procedure :
 Set the reference length (e.g. 10 cm) in the twist tester.
 Adjust deflecting needle deflection ‘O’ degree as weight free.
 Select proper weight from weight table.
 Adjust deflecting needle again to the centre of the graduated scale
(i.e deflection ‘O’ degree)while attaching the sample yarn with real
end by fixed and rotating jaw.
 Rotate the wheel against the twist in the yarn allowing the
deflection needle to move not or more than three graduations.
 Rotate the wheel until deflection angle becomes ‘O’ degree again.
 Report type : Calculation of twist per inch or cm from display
counter
 Inspection: Check the twist variation and variation and take
necessary action.

7.15. Quality Reports:
Category of Waste Cotton
Table: 7.6
Name of waste
Cotton
Recovery
On
Consumption
Where To
Found
Remarks
Hard Waste 1.00% Autoconer This waste Could not be
recycled. It incurs
production cost at per that
of yarn production. So it
tells upon productivity
very adversely.
Pneumafil
Waste
2.0% Ring Spinning
machine
It incurs the same cast
as Hard waste but it is
recyclable. Usable for
Open End Spinning.
Dropping # 1 3.0% Blow
Room/Compactor #
2 & 4
Saleable. Good for Quilt
making.
Dropping # 2 3.0% Taker-in
dropping/Compact#
2 & 4
Saleable, Good for Quilt
Making.
Flat Strip/Card Fly 2.0% Carding (Flat tops) Saleable. Good for Quilt
making.
Sweeping Waste 0.80% All Sections. When Cotton is dropped
on floor, becomes
sweeping waste. In most
of the case, they are good
cotton but completely
unusable owing to soiling.
Salable
Filler Waste 0.50% A/C Fitters &Vouk
drawing’s Filter
box.
Salable
Roving 0.20% Simples Speed
frame & Ring
Frame
Usable For Open End
spinning.
Comber Noil 16.0% Comber Filter Usable For Open End
spinning.
Dust 0.50% In All Filter’s Completely Unusable.

Remarks: Customer buy justify product by the quality of the product. So quality of the product
should be maintained carefully. For this quality is checked in every step properly and advanced
quality assurance device should be attached in the processing machineries. . Quality assurance is
the link between production and customers, by which the desired quality can be produced which
meets the specification. Research and development can help for value addition through product
development, which can face competition in global market and satisfy the customers.

Maintenance
8.1. Maintenance :
Maintenance is a procedure by means of which we can maintain active functioning in operation
according to the behavior utility of a particular elements/substance. Machine, building and other
service facilities are subjected to deterioration due to their use and exposure to environmental
condition. Process if deterioration if unchecked culminates in rendering these facilities
unserviceable and bring them to a standstill. Industry therefore has no choice but to attend them
from time to times to repair and recondition them so as to elongate their life to the extent it is
economically and physically possible to do so. This is called maintenance that elongates machine
life and helps the machine to run smoothly. It is in this in the context that maintenance assumes
importance as an engineering function. It is made responsible for provision of a condition of
these machines, buildings and service that will permit uninterrupted implementation of plans
requiring their use.
8.2. Objectives of Maintenance:
There are many objectives of maintenance. These are -
 To keep the factory plants, equipments, machine tool etc. in an optimum working
condition.
 To ensure accuracy of products and time schedule to delivery to customers.
 To keep the downtime of machines to the minimum thus to have control over the
production program.
 To keep the production cycle to the stipulated range.
 To modify the machine tools to meet the need for production.
 To improve the productivity of existing machines and to avoid sinking of additional
capitals.
 To reduce the maintenance costs as far as possible thereby leading to reduction in factory
overheads.
 To prolong the useful life of the factory plant and machinery.

8.3. Types of Maintenance:
Preventive maintenance: Preventive maintenance is a predetermined routine activity to ensure
on time inspections or checking of facilities to uncover conditions that may lead to production
break downs or harmful depreciation.
Break down maintenance :In this case, repairs are made after the equipment is out of order and
it can not perform its normal functions.
Maintenance Procedure:
At the beginning of the maintenance operation, all the cover of the machines are opened and
machine is cleaned with a cloth internally. This is called general cleaning.Inside the machine all
machine parts, conveyor belt, spike lattice, different roller and gear are checked. At first find out
the problem and rectify problem.All the gears and chain of the machine are cleaned with oils or
lubricants as instructed by the manufacturer. Chain box is checked and jam is cleaned if
necessary.
Lubricant: GRXP 460(Used in PBL gear box)
Omella 320(Used in PIV gear box)
Maintenance carried out in the blow room:
Periodic maintenance: After 10 to 15 days.
8.4. Maintenance ofcarding machine:
Carding machine maintenance consists of following tasks-
 Schedule maintenance
 Find out the problem
 Way of rectify
 Setting adjustment
 Existing setting check
 Carding maintenance sequence after 18 days.

Schedule maintenance:
Schedule maintenance of carding machine consists of following tasks-
 Cleaning the machine and machine parts by compressed air
 Cleaning the cylinder by compressed air
 Cleaning the flat by compressed air
 Cleaning the doffer by compressed air
 Cleaning the fixed carding segment
 Find out the problem of different gear and belt
Grinding:
Grinding of carding machine is done according to the following-
 1st grinding after 90 tons production
 2nd grinding after 80 tons production
 3rd grinding after 70 tons production
 4th grinding after 60 tons production
 Normally 4 times grinding possible
 IGS grinding machine use doffer and cylinder
 Emery fillet grinding machine use for flat
Grinding system: Table: 8.1
Flat Cylinder Doffer
Emery TSG TSG
stone Stone Stone
IGS IGS

Mounting:
 Life time of wire approximately 300-350 ton production
 Remove the faulty wire
 Remove the rust by emery cloth
 Wash by acetone
 Wire mounting by mounting machine
 Lakshmi mounting machine use for flat mounting
 Graft mounting machine use for cylinder , doffer and T-in.
Wire company: Normally following company wire is used in carding machine-
1. Graf
2. Trutzschler
3. Beakerf
4. Toshin
5. ICC(Indian)
6. ECC(England)
Wire specification:
P-2040S×0.4-B8R
Here,
20 = height of wire
40 = angle of wire
0.4 = thickness of wire

8.5. Lubricating schedule of carding machine:
Lubricating points Lubricant Time interval
Flat tops driving gear box Omala 460/ Grxp-460/ Castrol Sp-460 3 years
Coiler driving gear box Omala 460/ Grxp-460/ Castrol Sp-460 3 years
Feed roller driving gear Omala 460/ Grxp-460/ Castrol Sp-460 3 years
Cylinder drive idler Ls-3 / KluberStaruragsNbu 12/300kp 3 years
Flat stripping motion gear Ls-3 / KluberStaruragsNbu 12/300kp 3 years
Coiler drive bevel gear box Ls-3 / KluberStaruragsNbu 12/300kp 3 years
Coiler head gear box Ls-3 / KluberStaruragsNbu 12/300kp 3 years
8.6. Maintenance of Lap former machine:
Lap former machine maintenance consists of following tasks-
 Way of rectify
 Lap former maintenance sequence comes after 30 days.

Schedule maintenance :
In schedule maintenance following works are done-
 Cleaning the different gear and belt
 Cleaning the top roller, feed roller, calender roller, conveyer belt
 Cleaning the all cot rollers and all coil spring
 Clean winding drum, lap plate, weighting plate, cut plate and table
 Clean all cotton gears for cotton lapping
 Clean fluted air pipe for air blowing in the winding zone
 Clean top and bottom side of the conveyer belt
 Clean all air piping
 Clean all flexible suction line
 Check tightness of gear fixing belt
 Clean all suction duct line
 Check the different gear and belt
 Check the drafting zone
 Check the all nuts ant bolts of the machine
 Find out the problem of different parts
 Rectify the problem
 The whole machine is set sincerely
8.7. Lubrication schedule for lap former:
Lubricating Point
Lubricants Frequency
Bearing Part
Alvania Grease EP-2 15 Days
Open Gear Cardium compound D 15days
Roller Chain Tallus Oil –C-150 15 Days

Bearing Part Alvania Grease Ep-2 9 Months
Differ. Gear
Omala-150 6 Months
Differ.Gear Omala-150 6 Months
Reduction Gear Tellus-68 3 Months
8.8. Maintenance of Comber machine:
Comber machine maintenance consists of following tasks-
 Way of rectify
 Comber maintenance sequence comes after 15 days
The schedule maintenance tasks are-
 Cleaning the different gear
 Cleaning the top detaching roller
 Cleaning the bottom roller
 Cleaning the delivery plate
 Cleaning the drafting zone
 Cleaning the brush
 Check the cylinder clothing
 Inspection the top comb clothing

 Inspection of different setting
 Feed plate to detaching roller
 Steel detaching to top comb
 Depth of top comb
Change/Replacement:
Following parts are changed regularly-
 Cylinder clothing(Normally one year)
 Combing brush(After 6 month)
 Top comb(Normally one year)
8.9. Lubricating schedule of Comber machine:
Lubricating points Lubricant Time interval
Can Bottom Chain
OMALA 150/ GRXP-150/
Castrol SP-150
1 Months
One way clutch Alvania grease ep2/
Castrol ap-2
5 months
Worm gear box for can Omala 150/ grxp-150/ castrol
sp-150
5 months
Gear end box Tellus-68/ castrol aws-68 5 months
Gear box for drawing Tellus-68/ castrol aws-68 5 months

8.10 Maintenance of draw frame machine:
Draw frame machine maintenance means-
 Way of rectify
 Draw Frame maintenance sequence comes after 15 days
 Schedule maintenance :
Schedule maintenance means-
 Cleaning the top roller(Petrol cleaning)
Special works:
Some special tasks are done in draw frame ,these are-
 Top cot roller grinding(after 2 months)
 Replacement of top cot roller(after 18 months)

8.11. Lubricating schedule of draw frame:
Lubricating points Lubricants
Frequency
Gear end Box Tellus-68 180 days
Reducer Gear Box
Omela-320
120 Days
Spiral Gear Box Omela-320 120 Days
Ball Bering
Alvania Grease-EP2 15 Days
Neddle Bering/End Bush Alvania Grease-R2 7 Days
8.12. Maintenance of Simplex machine:
Simplex machine maintenance means-
 Way of rectify
 Simplex maintenance sequence comes after 15 days
Schedule maintenance consists of following tasks-
 Cleaning the top roller
 Cleaning the cradle
 Cleaning the guide

 Check the different adjustment
 Pressure arm cleaning
 Apron resetting
 Top roller resetting
 Different gear oiling
Change/Resetting:
Following works are done after certain period of time-
 Cot change (Normally one year)
 Cot mounting by cot mounting machine (Short press)
 Cot grinding by grinding machine
 Berkolizing after grinding
8.13. Maintenance of Ring frame machine:
Ring frame maintenance means-
 Way of rectify
 Ring Frame maintenance sequence comes after 30 days

 Cleaning the top roller
 Cleaning the cradle
 Check apron, cradle damage
 Pressure arm cleaning
 Apron resetting
 Top roller resetting
 Different gear oiling
Change/Resetting:
Some changes are done after certain period of time in the ring frame machine, those are-
 Cot change(Normally one year)
 Cot mounting by cot mounting machine(Short press),
 Cot roller grinding by grinding machine,
 Berkolizing after grinding,

 Ring gauging(After 2 month),Bottom roller gauge –6 month.
 Spindle gauging(6 month),
 Lappet gauging(monthly),
 Traveler clearer setting(2 month),
 Spindle oil change(After 4 year).
8.14. Maintenance of Rotor spinning machine:
Rotor spinning machine maintenance consists of following tasks-
 Way of rectify
 Rotor machine maintenance sequence comes after 30 days
 Inside plate ,separator, naval clean by corium.
 Central suction line open and clean.
 Different gear oiling-The whole machine is set sincerely

Special works:
Some extra work is done without above. those are-
 Oil change after 1 Year.
 Comber gauge and Separator gauge used when Rotor unit resetting.
8.15. Maintenance of Winding machine:
Winding machine maintenance means following tasks-
 Way of rectify
 Winding machine maintenance sequence occur after 15 days.
 General cleaning every shift.
Schedule maintenance consists of following tasks-
 Cleaning the bobbin chute
 Cleaning the bobbin magazine

Setting adjustment: Following setting are adjusted-
 Suction arm to cone holder (Normally 6-10mm,Empty cone).
 Paper cone to drum: 2mm.
 Bobbin to fixed belt cone: 8-10mm.
 Bobbin peg central sensor to bobbin: 25-30mm.
 Tension setting
 Bobbin ejection setting
 Bobbin angle setting (Normally 90o)
 Length correction setting
 Air pressure
 Splicing setting
 Blast time : (Normally 10-15 mile sec.)
Lubrication of Ring, Rotor and winding machine: Staburags NBU12,Polylub GA
352P,Kluberplex BE31222,Silicon oil 1000 are used for lubrication of Ring, Rotor and Winding
machine.
8.16. Maintenance tools and their functions:
Serial
no.
Tools name Function
1 Spanner To provide grip to apply torque o turn objects
2 LMT
3 Screw driver To drive screws or bolts with special slots through
mating drive system
4 Hammer To deliver an impact to an object
5 Torque Wrench To preciously apply a specific torque to a fastener
6 Adjustable wrench To be used with different size of fastener head

7 Combination Spanner To preciously apply a specific torque to a fastener
8 Open end Spanner To be used with different size of fastener head
9 Ring end spanner To be used with different size of fastener head
10 Cir-clip plier Used to hold object firmly for physical compression
11 Nise plier Used to hold object firmly for physical compression
12 Allen key (Star) Used to drive bolt and screw
13 Allen key (Special) Used to drive bolt and screw
14 Allen key (T-type) Used to drive bolt and screw
15 Allen key (Socket) Used to drive bolt and screw
16 Ratchet To move mechanical ports in one direction
17 Socket (Box) Used to fit different size of nuts & bolts
18 Puller Used to pull elements
19 Grease Gun To provide grease on required place
20 Flat file Used to cut something very slightly
21 Square file Used to cut something very slightly
22 Tumbler file Used to cut something very slightly
23 Round file Used to cut something very slightly
24 Flat level Used to level
25 Vernier calipers Used to measure little length
26 Filler gauge Used to adjust double seamer
27 Leaf gauge Used to adjust double seamer
28 Block gauge Used to adjust double seamer
29 Dial indicator To accurately measure small distance
30 Pressure gauge To measure pressure
31 Saddle gauge To maintenance saddle roller
32 Scanning roller gauge Used to scene roller shape and dia
33 Comber Special tools Used to comber maintenance

8.17. Cot grinding machinaries:
Cot grinding m/c is used for grinding of cot roller of different spinning m/c.For better
performance of cot roller after a certain period cot roller should be grinding.Machnaries used for
cot grinding is given below-
1)Berkol cot grinding m/c :By this m/c cot are grinding.
Specification of Berkol cot grinding m/c:
Origin: Switzerland
Per grinding reduce : 0.02 mm
Stone dia at frist: 200 mm
Stone dia when out: 150 mm
Stone auto cleaning: after 100 grinding
Stone is dressing: after 1000 cot grinding
Grinding rate: 3 cot/ minute
Fig. 8.1 cot grinding m/c
Grinding cycle:
Type of process Duration (months0
Lycra 2
Normal 3

2)Heat setting m/c:
Name of m/c:Berkol azing
Origin: Switzerland
Conditioning time: 3 minutes
Temperature: At starting- 37◦c Up to- 63-65◦c
3)Eccentricity and Taper tester:
Here two side of cot roller dia is measured and difference is measured.
Origin: India
Tolerable range: 0.5 mm
4) Sarbar cot grinding m/c:
Sarbar is cot grinding m/c by which draw frame, comber and unilap cot roller is grinding.
Here grinding is done by traversing of stone roller.
Table 8.2 Cot roller maximum and minimum dia
M/c name Maximum dia (mm) Minimum dia(mm)
Ring (ERFANG RFA-
507 )
29 27
Rotor (BT-903 ) 40 36
Auto coro 28.5 24.5
TFO ring (RY-2) 30 27.5
Ring (lakshmi ) 30 27.5
Compact (elit cot ) 29
40
26.9
37.1
Simplex 28 26.5
Drawing 38 36.5
Comber drafting (E 60,
E60 H,E 62)
45 42
Comber drafting (E 65 ) 39 36
Comber detaching 24.5 23
Unilap 39 36

Remarks: The maintenance department of SQUARE Textiles Ltd. is well equipped. It has
sufficient maintenance manpower including mechanical and electrical engineers. They do the
maintenance of the m/c even during the Eid vacation. Otherwise, they do the breakdown
maintenance. To increase the lifetime of the machineries and ensure the proper running of the
machinery.
Machine longevity depends on the proper maintenance. So maintenance of the machine should
be done timely and care.

Utility Services
9.1. Utilities:
Utilityisan organizationthatmaintainsthe infrastructure fora publicservices (oftenalsoprovidinga
service usingthatinfrastructure). Utilitiesare subjecttoformsof publiccontrol andregulationranging
fromlocal community-basedgroupstostate-widegovernmentmonopolies.(Commonargumentsin
favorof regulationinclude the desire tocontrol marketpower,facilitate competition,promote
investmentorsystemexpansion,orstabilize markets.Ingeneral,regulationoccurswhenthe
governmentbelievesthatthe operator,lefttohisowndevices,wouldbehave inaway that iscontrary
to the community'sbestinterests.)
The term utilities can also refer to the set of services provided by these organizations consumed
by the public: electricity, natural gas, water, and sewage .
9.2. Utility facilities :
Utility facilities are given below-
Table 9.1 Utility facilities
Utilities
Electricity (PDB and
Generator)
15 M.W.
Steam (Boiler) 3000kg

9.3 Utility Department UTILITY
Electrical section Power house A/C, Chiller, Boiler
Utility (Elec+A/C, Chiller, Boiler, Generator) Maintenance
D.G.M
Sr. Manager (Electrical) Sr. Manager
Dy. Manager(P/H)
D.G.M.
Sr. Manager Dy.Manager
U-1 U-2 U-3 SyL Executive Executive
(electrical)
P/H-1 P/H-2 P/H-3 P/H-4 H.F.O
(At all unit there are Exe/ Sr. M.O / M.O)
A/C + Chiller + Boiler
(Sr. Executive)
Head of Mechanics, Helper(Unit wise)
Unit-1 Unit-2 Unit-3 SyL
1. Exe 1.Sr.Exe 1.Ass.Manager 1.Exe
2.Exe 2.Exe 2.Exe 2.Exe
3.Sr.M.O 3. M.O.3.Sr.M.O
4. M.O.4.M.O

Total manpower of utility:
1. Unit 1- 10 person
2. Unit-2 – 10 person
3.Unit 3 -13 person
4.Unit 4 (SyL)-10 person
9.4. Air compressor:
Compressed air:
Compressed air is required in the spinning section mainly for control purpose through valves
and cylinders. With the latest machinery and increased automation, use of compressed air has
increased substantially. In winding machine, the use of compressed air is for the purpose of
splicing of yarn.
Although, atmospheric air is free, its compression to the required higher pressure by air
compressors costs money as the compressors are operated by electric motors. With the rise in
power cost, it has become necessary to optimize compressed air consumption so that compressor
usage is curtailed thereby saving electrical power.
Type of Air Compressor Capacity Range
Table: 9.2
Reciprocating Compressor,
Single Stage
Upto 50 cfm
Reciprocating, Two Stage 50-600 cfm
Screw Compressors 150-2500 cfm
Centrifugal Compressors 2000-4000 cfm

Ring frame section:
 SCD (Stationary cop doffing)
 Tray moving
 Cop gripping
 Doffing bar in and out
9.5. Dryer:
It is to dry compressed air. Actually if wet air goes to
pneumatic system pneumatic valve, solenoid valve will be
defective frequently. Besides yarn quality may decrease.
Table: 9.3 Air Dryer
M/C
name
Model Brand Year Qty Capacity
– m3/min
Air
Dryer
TE
121
KAESER 1998/2010 5 12
Air
Dryer
TF
171
KAESER 1999 1 17
Air
Dryer
TE 91 KAESER 1997 1 9
Air
Dryer
DB
115
BOGE 2006 4 11
Air
Dryer
DS
120
BOGE 2010 1 12
Air
Dryer
DS 95 BOGE 2012 1 9
Winding section:
 Cradle lifting
 Suction mouth lifting
 Retie pipe lifting
 Tension device

9.6. Generator:
To provide the large amounts of steady power demanded by modern societies, large power plants
have been built. Most power plants make electricity with a machine called a generator.
Generators have two important parts: a) Engine/ Prime mover
b) alternator.
Generators use the principle of electro-magnetic induction, which exploits the relation between
magnetism and electricity. In large AC generators, an outer shell with powerful magnets rotates
around a stationary "armature" which is wound with heavy wire. As they move, the magnets
induce an electric current in the wire
9.7. Principle of generator:
Engine/Prime mover takes fuel (gas) then runs. Rotor of alternator is coupled with shaft of
engine. So when engine shaft rotates power is generated in alternator output terminal.
Fuel, Gas Engine(Mechanical
Energy)
Generator
(Electrical
Energy)

Table: 9.4
In Square there is four power house in four unit and 1 HFO plant
Name of content Power house 1 Power house 2 Power house3 Power house 4
No of generator 4 3 3 3
Model G3516 G3516
Company Waukesha Caterpillar Waukesha Caterpillar
Power generate 920 1025 1100 1950
KVA 1281 1370 1288
KW 1025 1100 1030
Frequency 50 50 50
Phase 3 3 3 3
No of wire 6 6 6
Excitation 33volts
7.2amp
19volts
5 AMPS
Generation 400 VA
1849
400 volts
1859 AMPS
No of frame 806 697
Rev/min 1000 1500 1000 1500
Max temp rise 105 ͦ C 105 ͦ C
Ambient temp 40 ͦ C
Insulation type Class f

Fig9.1: generator
9.8. HFO PLANT:
HFO means heavy fuel oil or Furness oil
Type : 4.1 MW Man Gegilski power plant
Company : MAGNUS Power PVT ltd
Capacity : 4.1 MW
Engine type : V type
No of cylinder: 16
There is 5 oil tank in HFO plant
1. Storage tank
2. Buffer tank
3. Day tank
4. Diesel tank
5. Sludge tank.

Fig9.2 : MW Man Gegilski power plant

Processhow it run
by diesel engine runs and stop
HFO purification system
Day tank ( pure oil) and Sludge tank(
sludge)
ENGINE
Engine pure oil from day tank
Engine produce 11KV
Step down transformer makes it 440 volts
HT
LT
Distribution Board

Flow chart of powerhouse:
9.9. Cooling tower:
Main parts:
1. Housing
2. Fan
3. Motor
Main function:
Main function is to cool water. From Generator/ Chiller water driven to the
cooling tower by pump. After cooling water comes to engines. Thus it helps Generator / Chiller
in cooling system
CT1
CT2
Generator/Chiller

9.10. A/C plant:
Air conditioning is the process of treating air also as to control simultaneously its temperature,
humidity, cleanliness and distribution to meet the requirements of "conditioned space". An air
conditioning system may use heating, cooling, humidifying, de-humidifying and filtering units of
combination of these depending upon the outside weather.
. Air conditioning plants are installed to maintain correct ambient condition for spinning process
to work smoothly. Norms of temperature and relative humidity for textile mills are established
through controlled experiments in laboratories and mills.
At SQUARE all A/C type is same
Brand: LUWA
Origin: Switzerland
Quantity :
Unit 1 Unit2 Unit 3 Syl
7 set 6 set 4 set 4 set
Type: All induced forced type
Capacity: 350 TR; 700 TR
Water in: 28 m3/min
Water out : 33m3/min
Motor capacity: 7K.W.
Mfg. Company: Singapour
Colling water punp specification:
Motor capacity: 45 K.W.

At
1. UNIT 1 8 A/C
2. UNIT2 4 A/C
3. UNIT3 4A/C
4. SYL 4A/C
Necessary information about A/C plant:
A/C number Supply Section
01 Carding m/c & Blow room
02 Blow room
03 Ring Frame
04 Ring Frame
05 Ring Frame
06
07
08
Ring Frame
Ring Frame
Winding/ Finishing

9.11. Chiller:
A chiller is a device that removes heat from liquid using vapor-compression technology.
Chillers reduce the temperature of liquids (often water though other liquids can also be
cooled by chillers) for industrial applications. Chillers utilize four main components: a
compressor, an evaporator, a condenser and a metering device. Chillers operate with a
closed-loop system, which means that the coolant remains in the chiller and is recycled
across many uses. Closed-loop chillers contain a separate tank that filters and cleans the
coolant before returning it to the main storage area for re-use.
In Square textiles ltd Unit 1, 2 &3 the chiller use is given below
Unit1: There is 3 Chiller
Model: PHE0874444
Company: Macquee
Origin: U.S.A
Capacity: 400 ton of refrigerant(TR)
Type: centrifugal
Gas type: R134A
Bearing type: Sleepy type
Fan : induced force type
Consume: electric power
Nos: 3
No of cycle :1
Unit2: There is also three chiller
1. Vapor absorption Chiller
2. Steam fired Chiller
3. Hot water absorption chiller (Thermax)
Steam fired chiller:
Model: DW500

Company: Thermax
Origin: India
Capacity: 500 TR
Consume: Steam
Nos: 2
No of cycle :3
Dilute solution in absorber: Distilled water and lithium provide
Hot water chiller:
Model: LT525
Company: thermax
Origin: India
Capacity 320TR
Unit 3: there is one HOT Water Chiller and two Steam fired Chiller
Capacity: 260 TR
Company: Thermax
Origin: India
nos: 2
SYL unit: Absorption chiller consumes exhausted gas directly
9.12. Boiler:
A boiler is water containing vessel which transfers heat from a fuel source (oil, gas, coal) into
steam which is piped to a point where it can be used to run production equipment, to sterilize,
provide heat, to steam-clean, etc.
InSquare the boiler use is
Exhaust gas boiler
Capacity: 2.5 ton
Consume: Natural gas

Safety valve: 2
Wt of safety valve: 9.5 kg/ cm2
Cell & tube type : in cell there is water & in tube hot water
Exhaust temp: 450/500 ͦ C
Out temp: 200 ͦ C
9.13. Water softening system:
Water softening system makes hard water into soft water. It can be done by de mineralized
process
Benefits of water softener:
Many industries require softened water for such uses as processing . Water softening systems are
installed in some municipal water systems for the dual purpose of protecting the plant equipment
and better serving industrial and residential users
Generato
r Boiler Chiller
Coolingtower Cold
water
Raw
water
Resin+
softening
Softwater
tank
Softwater
pumpto M/C
Hot
water
fromM/C

There is 3 vessel among them
1st vessel is sand vessel
2nd vessel is resin vessel (softener)
3rd vessel standby vessel
Water Softening plant :
Treatment Capacity : 30 m3/hr
Pressure Filter Tank Size:
Height : 2133mm
Diameter : 914 mm
ResinTank Size :
Height : 2133 mm
Diameter : 914 mm
Brine Tank Size:
Height : 1219 mm
Diameter : 609 mm
Regeneration Period: 2 hr 10 min
Regeneration Time :
Overflow : 30 minBackwash : 30 min
Type Of Resin: 540 g ,740 g
Salt consumption per resin : 100 kg

9.14. Other electrical equipment mostly use
Fig. 9.3 . Other electrical equipment
PLC( Programmable logic controller ):
It has some input output port. It sends an out signal to the SCU from specific input signal.
For example if door is open the respective limit switch or proximity switch give an input signal
to the PLC and PLC give an output signal to the SCU. Then SCU process the data and stop the
M/C showing the error. Safety circuit open or door open etc show on the display. In this case if
we by pass that limit switch or proximity, safety of that door only will not work.
Motor:
It converts electrical energy into mechanical. It is used to drive any rotating part like
cylinder ring shaft etc.
Frequency inverter:
It is used to vary the speed of the motor and also as motor saver , energy saver
.

CKT Breaker:
To supply and cut the power and also to protect the over current. Normally it is operated
manually.
Magnetic contact:
It makes contact between power sources (Breaker) to load (Motor, Coil etc). It is operated with
control CKT ( Push button switch, selector switch etc).
Overload:
To protect over current.
Thermostat:
To protect machineries from overheat. Normally used motor, dryer, refrigerator etc.
UPS( Uninterrupted power supply):
It is power supply to provide power without interruption.
Power Unit:
It’s function is to supply to control power of M/C to SCU and different switches.
Operating panel:
To perform M/C operation or to set up data initial start up everything is done by it. On/Off
switch , jogging switch different key are mounted on it .
Limit switch:
It is used to control the operation of M/C. It has two types of contact NO/NC. In case of any
movement of it’s limit bar . It’s NO contact becomes NC and NC becomes NO.It’s movement is
done by M/C’s door or any of the mechanical part.
Proximity switch:
It is used to control the operation of M/C . It has two types of contact NO and NC. IT sense the
presence of metallic item and when it sense some ones presence it’s NO contact becomes NC.
And NC becomes NO. It can be replacement of a limit switch.
Auto Leveling system:
The carding auto leveling system collects medium term variation by means of a micro computer
. At the in feed a measuring device detects cross sectional variation in the feed .Then the

microprocessor vary the speed of the feed roller, so that the variation of the feed is corrected. A
pair of stepped roller sense the cross section of the delivered sliver . Microprocessor compares
this measured value with selected nominal value and correct any deviation again by varying the
feed roll speed.
Spark detector:
IT is designed specially for detection of fast moving particles. The capacity of the detector
depends on distance, speed and size of the particles
minimum spark size: 3mm at .5 m
6mm at 1 m
Metal detector:
It is used to find any metal in pipeline and separate from cotton. The ejection of the product
takes place after the metal detector goes off
Pressure Switches: It is a switch which is controlled by pressure( suction or compresses air) . It’s
NO/NC contact becomes NC /NO after getting specific pressure.
Light barrier/Photocell:
It is used to control the operation of machine. It has two part receiver & transmitter and NO
/NC contact in it’s receiver part. Transmitter transmits ray beam to the receiver in normal
operation . When this ray beam is disturbed by something it’s NO contact becomes NC and NC
becomes NO.
LED:
(Light Emitting Diode): It is one kind of signal lamp to show the condition of machine.
Fuse:
When over current flows through the wire of M/C then the coil melts and it’s protect the M/C
from accident .
Remarks: SQUARE Textiles Ltd has good facilities for UTILITY department. It has well
established building, equipment, manpower to run the factory. Each and every section of utility
are well maintained and workers are well trained so the facilities can run smoothly.

Store And Inventory Control
10.1. Store and inventory control system:
A store is a place where things are stored, e.g. a ship's paint store.
An inventory control system is a set of hardware and software based tools that automate
the process of tracking inventory. The kinds of inventory tracked with an inventory control
system can include almost any type of quantifiable good, including food, clothing, books,
equipment, and any other item that consumers, retailers, or wholesalers may purchase. Modern
inventory control systems are almost exclusively based on barcode technology. Though barcodes
were initially developed to automate the process of grocery store checkout, their ability to
encode a wide variety of alphabetic and numeric symbols makes them ideal for encoding
merchandise for inventory applications. Inventory control systems work in real-time using
wireless technology to transmit information to a central computer system as transactions occur.
10.2. Classification of store:
Store
10.3. Raw materials store:
All the raw materials are stored in godown, near the blow room section. The raw materials are:
 Cotton
 Flax
 Fleece
 Polyester
 Modal
 Viscose
 Tencel
 Organic
 Lycra
Raw material & wastage Finished yarn General (spare and packing material)
store )store

10.4. Spares:
In this mills required amount of spears of different machine are stored in mechanical store room.
All the shares are listed in a sheet which is controlled mechanical and maintenance personal.
Spares are arranged in store room according their size, quantity and requirements. There are
selves in store room to keep small spare parts. Different stationary used in the mill are given
below:
Sticker, formatting book, register, Raw cotton, wastage, yarn, chalan, quality
certificate,(MRR),gate pass, file, paper, pen, marker, calculator, paper connect.
10.5. Spare parts:
In Square Textiles differernt types of belt, bearing, bobbin holder, ring cup, knee break, apron,
top roller, gear, sensor, motor , diode, cable, bulb spark plug etc.
10.6. Finished goods:
Normally Spinning mill supplies its finished yarn to different fabric manufacturing industry. So
package yarns are stored for short time in the finishing section.
 KH
 CH
 Inject
 Siro
 Neppy
 Melange
 Organic
 Compact
 White
 100% polyester
 Blended (viscose, modal )
 Rotor
 PC
 Core spun
 CVC
 Viscose
 Slub

10.7. Others:
Packing materials: Poly bag, Poly rope, Sticker, Sacks.
Remarks: SQUARE Textiles Ltd has individual stores for raw materials, finished goods etc.
There is enough space to store the finished goods. It has well security system and now it is
increasing the store area. The store for inventory control is satisfactory.

Square Textiles Ltd: A Practical Industrial Attachment Report

Square Textiles Ltd: A Practical Industrial Attachment Report

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Square Textiles Ltd: A Practical Industrial Attachment Report