1. 1
Ahsanullah University of Science & Technology
Department of Textile Engineering
Course no.: Tex-500
Course Title: Industrial Training
Session: Fall-15
Report on Industrial Training
at
SINHA ROTOR SPINNING LIMITED
Supervised by:
Dr. Md. Ismail Chowdhury
Associate Professor
Submitted by:
Name ID
Md. ShahadulAlam 09.02.06.050
Md. ToufiqNiaz 11.02.06.054
Md. Hadi-Arafin-AlamAkash 12.01.06.018
ShafayatShahariar 12.01.06.140
6. Page 6 of 78
ACKNOWLEDGEMENT
At first we would like to express our gratitude to Almighty Allah for his kindness to enable
us to complete the industrial training successfully at SINHA ROTOR SPINNING
LIMITED.
We take this opportunity to express our deepest gratitude and special thanks to the Prof. Dr.
Ahmed Jalal Uddin, Head of the Department of Textile Engineering, AUST for his
great support and valuable advice and co-operation.
We are grateful to our project supervisor Dr. Md. Ismail Chowdhury, Associate
ProfessorDepartment of Textile Engineering, AUST for his logical guideline, constant
inspiration, necessary instruction and proper supervision that have led us to complete the
industrial training successfully.
We also express our deepest gratitude to Dr. AftabuddinHossainChowdhury, Director of
SRSLand Mr. MasudurRahman, General Manager of SRSLfor their supervision,
support and guidance throughout the training.
Finally we would like to thank all the officers, staffs and technicians of SINHA ROTOR
SPINNING LIMITED who have helped us to overcome different problems in different
situations on the successful completion of our industrial training.
7. Page 7 of 78
INTRUDUCTION
As we know, Internships provide real world experience to those looking to explore or gain
the relevant knowledge and skills required to enter into a particular career field. Internships
are relatively short term in nature with the primary focus on getting some on the job training
and opportunity to apply our classroom knowledge to the real world.
The SINHA ROTOR SPINNING LIMITED is truly an excellent industry from our point of
view. Various types of modern technology are available here. Every section of the mill
helped us so much by giving information during our training period.
During the 8-week long training we were allowed to gather information from different
sections of the mill such as raw materials production department, quality assurance
department, operation and maintenance of various machines, utility department etc.
We tried our best to learn about the mill which will be very helpful in future.
8. Page 8 of 78
TABLE OF CONTENTS
Chapter
No.
Topics Page
No.
1 Factory Profile and
Manpower Management
9-15
2 Raw Materials, Product Mixing and
Sequence of Operation
16-20
3 Production Department 21-45
4 Quality Control Department 46-54
5 Maintenance Department 55-62
6 Utility Department 63-69
7 Store and Inventory Control 70-72
8 Marketing 73-76
9 Conclusion 76-77
9. Page 9 of 78
CHAPTER – I
FACTORY PROFILE
And
MANPOWER MANAGEMENT
10. Page 10 of 78
Fig. Outside view of Sinha Textile ltd.
Fig. Sinha Rotor Spinning Ltd.
11. Page 11 of 78
Factory Profile
01. Name of the Mill
SINHA ROTOR SPINNING LIMITED
(SRSL)
(A Concern of Sinha Textile Group)
02. Project owner Md. AnisurRahmanSinha
03. Contact address House # 368, Road # 28, New DOHS,
Mohakhali, Dhaka, Bangladesh
04. Project location
Sinha Textile Group Complex, Post:
Kanchpur,
PO: Sonargaon, Dist: Narayanganj,
Bangladesh
05. Final product Cotton Yarn
06. Spinning system Ring Spinning & Rotor (OE) Spinning
07. Installed machine capacity 28224 Ring Spindle & 960 Rotor Head
07. Production capacity
Cotton yarn 6228 Metric ton /year
Lycra yarn 225 ton / year
08. Raw materials 7474 Metric ton/year
Aim of the Project:
Production of export quality yarn
Production of 100% Cotton yarn
Providing employment to the local people
Earning foreign exchange for our country
Provide an efficient backup to other sectors e.g. knitwear, denim, weaving in Sinha
Textile Group
Physical Infrastructure:
SINHA ROTOR SPINNING LIMITEDis organized into three major parts: Factory, Sales &
Procurement (S&P) department, Finance department and Account department. Among these
three, the Factory consists of five departments namely Production, Maintenance, Quality
Assurance, Administration and Information Technology
12. Page 12 of 78
LOCATION OF SINHA SPINNING GROUP VIA GOOGLE MAP
LOCATION OF SINHA SPINNING GROUP VIA SATELLITEVIEW OF GOOGLE MAP
14. Page 14 of 78
Manpower Management
Officers list
Production
Department
Deputy General Manager (1)
Assistant Manager (2)
Sr. Production Officer (6)
Production Office (10)
Assistant Production Officer (13)
Store Department Assistant Manager/ Store Officer (1)
Assistant Sr. Officer (2)
Jr. Executive ( 1)
Quality Assurance
Department
Sr. Quality Assurance Officer (2)
Quality Assurance Officer (5)
Utility Department Deputy Manager (1)
Assistant Manager/ Sr. Engineer (3)
Assistant Engineer (14)
Maintenance
Department
Assistant Manager (1)
Engineer/ Assistant Engineer (2)
Accounts Department Deputy General Manager (1)
Sr. Accounts Officer (1)
Assistant Accounts Officer (1)
Marketing Department Assistant Manager (1)
Assistant Marketing Officer (1)
15. Page 15 of 78
Workers list
GRAND TOTAL STAFF AND OFFICERS: 820
Shifting Schedule
a. General shift 09 am to 06pm
b. A shift 06 am to 02 pm
c. B shift 02 pm to 10 pm
d. C shift 10 pm to 06 am
e. Working hour 08 hours per
day, 48 hours
per week
f. Over time 02 hours per
day, 12 hours
per week
g. Weekly
holiday
Friday or any
other day in a
week
16. Page 16 of 78
Chapter – II
RAW MATERIALS, PRODUCT MIXING
And
SEQUENCE of OPERATION
17. Page 17 of 78
Raw materials
SINHA ROTOR SPINNING LIMITED (SRSL) produces only cotton yarn. As cotton is not
grown in our country enough to fulfill the demand, so it is imported from other countries.
Sinha rotor spinning mills has used several types of cotton, which are imported from
different countries of the cotton growing area.
The following cottons are used by mills in the last months:
Brand name Country of origin
USA PIMA USA
CIS Turkiministan
CIS Tazakistan
Burkina Faso Burkina Faso
Benin Benin
SANKAR-6 India
Mixing
A systematic mixing plan by maintaining the lowest possible variation in cotton quality
parameters ensures trouble-free yarn production with consistent yarn quality. Mixing
planning is a very important function for spinning operation and investing the time and skill
for systematic mixing plan pays good returns such as consistency in productivity and quality.
For the rotor unit, there are various types mixing are available,
They are:
50% virgin cotton + 50% wastage
70% virgin cotton + 30% wastage
90% virgin cotton + 10% wastage
100%virgin cotton
18. Page 18 of 78
Process flow-chart for Card yarn
19. Page 19 of 78
Process flow-chart for Combed yarn
20. Page 20 of 78
Process flow-chart for Rotor yarn
21. Page 21 of 78
CHAPTER – III
PRODUCTION
DEPARTMENT
22. Page 22 of 78
Layout Plan
Fig. Layout plan of SRSL
B/R- Blow Room
C51-Carding M/c
SB2-Breaker Draw frame
E32-Lap former
E66/62-Comber
D30-Finisher Draw frame
TOYOTA FL 100/Zinser 670-Simplex M/c
ROTOR- Rotor M/c
G33-Ring frame
AUTOCONE-Winding M/c
24. Page 24 of 78
BLOWROOM
Blowroom is the first processing stage in yarn manufacturing process. It performs the actions
of opening, cleaning, dust removal, sometimes blending and accelerates even feed of the
material to the card. The blowroom section of SINHA ROTOR SPINNING LTD. is a
sophisticated one, equipped with modern machines which are suitable for quality production.
In order to produce carded, combed and rotor yarn- the blowroom section is divided into two
parts or lines reffered to as combined line and rotor & card line.
25. Page 25 of 78
Unifloc machine
Fig. Unifloc A11
The automatic bale opener opens fibers to very small size tufts. It can process up to 180 bales
per laydown.
Specification:
Number of machine 2
Model A11
Manufacturer RIETER
Year of manufacturing 1999 & 2000 (Comb Line)
Country of origin Switzerland
Traverse drive speed:
.8 m/min (min.) to 12.0 m/min.
(max)
Take off depth .8 to 20 mm
Frequency 50 Hz
Voltage 400 V
Production 1400 kg/hr.
26. Page 26 of 78
Uniclean machine
Fig. Uniclean B11
Course cleaner works on double roll cleaning principle and suitable for very heavily contaminated
raw materials.
Specification:
Number of machine 2
Model B11
Manufacturer RIETER
Year of manufacturing 1999 & 2000 (Comb Line)
Country of origin Switzerland
Pin roller speed Normal: 640 rpm, Actual: 570 rpm
Cleaning intensity .3 (0.0 - 1.0)
Relative amount of waste 6 (1-10)%
Grid angle 15.00
Production up to 1200 kg/hr.
Working width 1600 mm
Cleaning cylinder diameter 750 mm
27. Page 27 of 78
Unimix machine
Fig. Unimix B73
Multi-mixer is used for homogenous mixing. It has 6 chamber and it generally combined with
cleaners.
Specification:
Number of machine 3
Model B 7/3
Manufacturer RIETER
Year of manufacturing 1999 & 2000 (Comb Line)
Country of origin Switzerland
Production up to 800 kg/hr.
Working width 1200 mm
No. of blending chamber 6
28. Page 28 of 78
Uniflex machine
Fig. uniflex B60
Fine cleaner is used at the last stage of blowroom. Generally a vision shield is attached with the
machine which is used to detect foreign fibres.
Specification:
Number of machine 3
Model B60
Manufacturer RIETER
Year of manufacturing 1999 & 2000 (Comb Line)
Country of origin Switzerland
Frequency 50 Hz
Voltage 400 V
Production up to 600 kg/hr.
Cleaning intensity .8 (0.0-1.0)%
Relative amount of waste >6 (1-10)
Working width 1200 mm
Cleaning cylinder
diameter 750 mm
Pined roller speed 960-1300 rpm
29. Page 29 of 78
Blowroomline for Comb line
Unifloc
Uniclean
Unimix
Uniflex
Chute feed
For combed yarn
Blowroom line for Card and Rotor line
Waste opener
Unifloc Mixing bale opener
Uniclean
Unimix
Uniflex
Vision shield
Chute feed
For Rotor
yarn
Unimix
Uniflex
Vision shield
Chute feed
For Card
30. Page 30 of 78
CardingSection
Carding is the process in which fibers are opened, parallelized and removal of dust,
impurities, neps, short fibers are done to produce a continuous strand of fibers called sliver of
uniform weight per unit length.
The carding machines available at SINHA ROTOR SPINNING LIMITEDis well equipped
with high performance machinery suitable for constant production at a high rate. In order to
produce both carded and combed yarn simultaneously, the card line is divided into two lines.
Objectives:
a) Individualization of fibers from tuft
b) Elimination of impurities
c) Disentanglement of neps
d) Elimination of dust
e) Producing uniform sliver
31. Page 31 of 78
Specification:
Model C51
Manufacturer RIETER
Country of origin Switzerland
Total number of machine 21
Production capacity Up to 90kg/hr.
Feed roller diameter 120 mm
Taker in diameter 253 mm
Taker in speed 1800 rpm
Cylinder diameter 1290 mm
Cylinder speed 450-550 rpm
Doffer diameter 500 mm
Doffer speed 51-55 rpm
Total draft range 85-250
Different gauge (settings) of the carding machine:
Setting
points Distance (mm) Distance (thou)
Taker in to cylinder .3 12
Taker in to mote knife 1 40
Cylinder to doffer 0.175 7
Cylinder to flat .3, .275, .25, .225, .225 12, 11, 10, 9, 9
Cylinder to stationary flat (back) .6, .55, .5 24, 22, 20
Cylinder to stationary flat (front) .45, .4 18, 16
Doffer to detaching roller .15 6
Detaching to cross
roller .125 5
Top delivery to bottom delivery .25-.3 10-12
roller
Calendar roller 1.6 64
Cylinder to cylinder under casing .9-1.2 36-48
Taker in to taker in under casing .5 20
32. Page 32 of 78
Drawing Section
The draw frame is an essential section in any spinning mill. The process by which a number
of carded sliver are combined to produce a regular and uniform drawn sliver by drafting and
doubling is known as drawing.
Objectives:
Strengthening and parallelization of fibers
To facilitate blending of the fibers
To remove hook fibers
To reduce irregularities of fibers by doubling
Types of draw frame: There are mainly two types of draw frames used in Sinha textile mills.
They are mentioned below:
a) Breaker draw frame b) Finisher draw frame
33. Page 33 of 78
Breaker draw frame
Specification:
Model SB-2
Manufacturer RIETER
Year of manufacturing 1999
Country of origin Switzerland
Drafting system 3 over 3
Doubling 6 (max- 8)
Sliver length per can 5000 m
Delivery speed 650 m/min
Drafting zone pressure control hard pressure
Cot roller diameter 38 mm
Bottom roller diameter 30 mm(back), 30 mm(middle), 30 mm(front)
Feed sliver weight 75 grains/yard
Delivery sliver weight 75 grains/yard
Can size 120×600mm
Cot roller shore hardness Comb- 76-80A, Card- 83A
pressure 10 bar
34. Page 34 of 78
Finisher draw frame
Specification:
Model RSB-D30
Manufacturer RIETER
Year of manufacturing 2001
Country of origin Switzerland
Drafting system 3 over 4
Doubling 6 (max 8)
Sliver length per can 3000m
Delivery speed 700 m/min
Drafting zone pressure control compressor
Cot roller diameter 38 mm
Bottom roller diameter
30 mm(back), 30 mm(middle), 40
mm(front)
Feed sliver weight 75 grain/yard
Delivery sliver weight 75 grain/yard
Cot roller shore
hardness Comb- 76-80A, Card- 83A
Can size 1000×500 mm
Auto leveler system Present
35. Page 35 of 78
LapFormer
Purpose of lap former:
Fibers in the pre-comb sliver are blended and mixed. Thus blending provides a
degree of compensation of raw materials variation.
It helps in arranging the fibers with better orientation.
It helps in better parallelization of the fibers
The tailing hooks in pre-comb sliver is reversed to leading ones here, which
ensures less fiber damages during combing.
Specification:
Model E32
Manufacturer RIETER
Year of manufacturing 2000
Country of origin Switzerland
Drafting system 3 over 3
Number of doubling 26
Draft 1.746 (front), 1.062 (back)
Delivery speed 110 m/min
Top roller diameter 42 mm
Lap weight 20 kg (1 meter= 80 grams)
Lap length 270 m
36. Page 36 of 78
Comber
Objectives of combing:
Elimination of precisely pre-determined quantity of short fibers
Elimination of remaining impurities
Elimination of large proportion of the neps in the fiber material
Formation of sliver having maximum possible evenness.
Specification:
Model E62
Manufacturer RIETER
Year of manufacturing 2002
Country of origin Switzerland
Drafting system 3 over 5
Number of doubling 8
Draft 23.1
Delivery speed 130 m/min
Nips / min 300/min
Can feeling 6000 m
Feed per nip 4.7
Diameter of full lap 520 mm
Maximum noil extraction 24%
37. Page 37 of 78
Simplex
Fig. Toyota FL-100
Objectives:
1. To draft the sliver i.e. reduce the weight per unit length of sliver
2. To insert small amount of twist to strengthen this roving in order to
prevent breakage during processing
3. To wind the twisted strand (roving) on to a bobbin
4. To make conical or taper shape of bobbin
Number of simplex machine in SRSL: 8
Specification:
Model: FL-100
Number of machine: 5
Manufacturer: Toyota
Year of manufacturing: 2000
Drafting system: 4 over 4
Number of flyer: 108
Maximum flyer speed: 1205rpm
Bobbin length: 452mm & 445mm
Lift length: 390mm & 384mm
38. Page 38 of 78
Fig. Zinser 670
Specification:
Model: RO-WE-MAT 670
Manufacturer: Zinser
Number of machine: 3
Year of manufacture: 2001
Drafting system: 3 over 3
Number of flyer: 96
Maximum flyer speed: 1350 rpm
Doffing system: Automatic
Pressure arm loading: Spring loaded
Maximum roving length: 1400m
39. Page 39 of 78
Ring frame
Fig. Rieter G33
Ring spinning is a universal spinning system. Higher count, quality yarn can be achieved
by this machine. The processes involved in the ring are creeling, drafting, twisting,
winding & doffing.
Objectives:
To draft the roving feed to the ring frame from the simplex roving.
To insert the necessary amount of twist in the yarn.
To wind the twisted yarn on a cylindrical bobbin.
40. Page 40 of 78
Machine specification:
Manufacturer: Rieter
Model: G33
Number of machine: 28
Number of spindle per machine: 1008
Country of origin: Switzerland
Year of manufacturing: 200
Spindle speed: maximum 18000 rpm
Drafting system: 3 over 3
Ring cup diameter: 38mm, 40mm, 42mm & 45mm
Bobbin length: 190mm, 200mm, 210mm, 230mm
Top apron origin: Germany
Top apron size: 39.2mm×30mm×1.1mm (L×W×T)
Bottom apron origin: Germany
Bottom apron size: 72.5mm×30mm×1.1mm (L×W×T)
Manufacturer of apron: ACOTEX
Cot roller size: 30mm×28mm×19mm (L×W×T)
Particulars obtained:
Process name Machine no.
Compact yarn 15-20
Lycra yarn 1,2,5,13,14 & 15
Slub yarn 2,3,4,6 & 22
Normal yarn Rest of the machines
41. Page 41 of 78
Cot roller shore hardness:
Roller Shore hardness
Front 65A
Middle 80A
back 75A
Spacer size (mm) Color
2.50 Chocolate
2.75 Ash
3.00 White
3.25 Yellow
3.50 Black
4.0 Orange
4.5 Red
5.0 Blue
42. Page 42 of 78
Winding
Fig. Winding machine
Winding is considered as an integral part of the spinning process. Winding not only
improve the quality of the yarn but also step up production at the later process, i.e.
weaving, knitting & Yarn dyeing.
Winding machine commonly used for all types of fibers (100% cotton, MMF, blended
yarn).
Function of winding machine:
To make a suitable yarn package from ring bobbin.
Yarn clearing and splicing
Waxing
Machine details:
Number of drums per machine: 60
Speed range: 800-1300 m/min
Groups per machine: 6
Length of yarn per package: 74000 m (avg.)
Package mass: 2-3 kg
Bobbin mass: 54 g
43. Page 43 of 78
Winding machine:
Name or model of m/c Number of m/c
MuratecMachconer No. 7-V 7
Process ConerMuratec No. 21C 1
SchalfhorstAutoconer 338 1
Total: 9
Winding speed:
Yarn count Process Winding speed(m/min)
14 KW slub 900
14 KW 1200
20
CW 1250
20 KW 1250
20 KW slub 950
20 CW 1200
23.7 CH 950-1250
32 CW 1300
32 CW 1250
32 KW 1250
32 CW compact 1300
50 KW compact 1200
44. Page 44 of 78
Rotor
Fig Rieter R 20
SRSL ROTOR SECTION
Model: R20
Manufacturer: RIETER
Year of manufacturing: 2000
Country of origin: SWITZERLAND
Number of rotor frame: 04
Number of rotor head per frame: 240
Rotor RPM: 60000-1400000
Rotor diameter: 31mm, 32mm, 35 mm, 40 mm Feed roller RPM:
Feed roller diameter: 35 mm
Opening roller diameter: 80 mm
Opening roller RPM: 6500-8500
Draft range: 50-120
Delivery speed: 145m/min
Count range: 6-20 Ne
TPM: 450-800
Package weight: .5-4 kg
Shape of yarn package: cylindrical
Machine efficiency: 75-100%
45. Page 45 of 78
Heat setting
Fig. Heat setting machine
Heat setting is an important finishing of yarn. For heat setting, one room is provided and
required temperature and humidity are supplied to the room. The package of yam is placed on
the creel for the specified time. After the pre-selected time the yarn are taken out from the
machine.
The advantages of heat setting:
Increased strength of yarn
Increased elasticity of yarn
Set the twist
Increased the weight of yarn (1-2%)
Machine specification:
Brand: Xorella AG
Model: CH-5430 WETTINGEN
Type: CONTEXXO
Manufacturer: peterhans AG 5605 Dottikan
Country of origin: Switzerland
Production no./ year: 2010630/2000
46. Page 46 of 78
CHAPTER - IV
QUALITY CONTROL
DEPARTMENT
47. Page 47 of 78
Quality Assurance Department
In SINHA ROTOR SPINNING LIMITED, quality assurance department is well equipped
with various types of yarn testing instrument. Actually it is a quality based mill. They are
careful about the quality of the product with production. All information related to yarn
process are controlled from this department.
List of the machines which are used in QAD laboratory: Sinha Rotor Spinning Ltd. Is
enriched with the following instrument:
I. Premier ART
II. USTER® AFIS PRO
III. Premier tester 7000
IV. Premier TENSOMAXX 7000
V. WIRA yarn reel
Premier ART
Fig. Premier ART
Manufacturer: Premier, INDIA
Function: Premier ART is used to test the following physical properties of the fiber. It tests
accordingto the HVI calibration.
48. Page 48 of 78
Test Result Abbreviation
Spinning Consistency Index SCI
Micronaire Mic
Maturity Index Mat
Upper Half Mean Length UHML
Uniformity Index Unf
Short Fiber Index SFI
Strength Str
Elongation Elg
Moisture Moist
Reflectance Rd
Yellowness +b
Color Grade CG
Trash Count Trcnt
Trash Area Tr area
Trash Grade Tr grade
Fluorescence UV
Neps Nep
49. Page 49 of 78
Uster AFIS PRO
Fig. Uster AFIS Pro
Manufacturer: ZellewegeUster, Switzerland
Model: AFIS PRO
AFIS modules:
NC modules:
The USTER® AFIS PRO comes with different modules enabling a customized
configuration for each plant.
The NC module is included in the base configuration of the USTER® AFIS PRO. It stands
for nep classification and measures the amount and the size of neps and seed coat neps in
raw cotton, card mat and sliver.
Test result Abbreviation
Nep count per gram Nep Cnt/g
Nep size Nep size µ
Seed coat nep count per gram SCN Cnt/g
Seed coat nep size SCN size µ
50. Page 50 of 78
The L&M module measures fiber length and maturity in raw cotton, card mat and sliver.
The lengthis measured on single fibers in order to get a true fiber length distribution within
a cotton sample. The USTER® AFIS PRO is the only instrument that measures the maturity
of single fibers, resulting in a true distribution of maturity within a cotton sample.
Test result Abbreviation
Mean length by weight L (w)
Upper quartile length by UQL (W)
Weight
Short fiber content by
weight SFC(W)
Mean length by number L (n)
Length variation L (n) CV%
Short fiber content by
number SFC (n)
Fineness (millitex) FINE (mtex)
Maturity ratio MAT
Immature fiber content (%) IFC %
Test setting: Different setting points are to be set before starting the test. These are shown
below.
Identifier
Location
Test module
Weight: weight of the sample must be in between 0.4-0.6gm
Main parts of the machine:
a) Monitor
b) Printer
c) Computer system
d) Electronic balance
e) Sample feed unit
f) Different sensor for test the sample
51. Page 51 of 78
Premier Tester 7000
Basic installation: module to test evenness properties
Additional properties:
To measure the hairiness index
12-40 ktex for coarser sliver
Application range:
Yarn, roving and sliver
4 to 12 ktex
Fig. Premier Tester 7000
Measuring principle:
Evenness – capacitance sensor
Hairiness – optical sensor
Test condition:
Test time up to 20 min
Test speed up to 400m/min
52. Page 52 of 78
Test speed:
Speed (m/min) Generally used for
400 Yarn
125 Sliver and roving
100 Sliver and roving
50 Roving
Main parts of the machine:
a) Hairiness sensor (optical sensor)
b) Tensor type D
c) Sensor type B (capacitance sensor)
d) Conveyor
e) Absorber type B
f) Computer system (CPU)
g) Creel (it can holds 24 bobbin max)
Other parts:
a) UPS
b) Monitor
c) printer
Sensor type B (capacitance sensor) has four slots for evenness testing. These are shown
below:
Slot no. Used for
1 Sliver
2 Roving
3 Yarn (less than 30Ne)
4 Yarn (more than 30Ne)
Output parameters: premier tester 7000 tests the following parameters of the materials.
a) Unevenness (U%) & Co-efficient of variation (CV%)
b) Imperfection
c) Cut length CV%
d) Index of irregularity
e) Relative count
f) Maximum and minimum mass value of different length
53. Page 53 of 78
Tensomaxx 7000
Manufacturer: Premier Polytronics Ltd, India
MODEL:Tensomaxx 7000
Serial no: P64
Fig. PremierTensomaxx 7000
Description: Premier TENSOMAXX 7000 is a single yarn strength tester; it works on
constant rate ofelongation (CRE). It determines the tensile characteristics of yarn. This tester
tests the following properties of yarn.
Breaking tenacity
Breaking force
Force elongation
Graphical results
Output parameters: after testing yarn premier TENSOMAXX 7000 gives some results.
These aregiven below:
Breaking time
Breaking force
Breaking tenacity (RKM)
Breaking elongation
Breaking work
It also gives the mean value, CV% minimum & maximum value of them
54. Page 54 of 78
Test setting: before starting ab=ny test it needs to set the following setting:
Test ID
Sample (yarn)
Material (cotton)
Speed: 5000.00 mm/min
Length: 500.0 mm
Pre-tension: .50 CN/tex
Wrap reel
Fig Wira wrap reel
Manufacturer: WIRA WIRA yarn reel: 5-SKRM-36 Serial no. 100110024 Country of
origin: UK
Function: to make lea (120 yards) of yarn.
55. Page 55 of 78
CHAPTER – V
MAINTENANCE
DEPARTMENT
56. Page 56 of 78
MAINTENANCE
Maintenance points in Blow Room:
MACHINE NAME MAINTENANCE POINTS WORK TO BE DONE
Take off Unit Clean properly by compressed air.
Take off roller Check & clean properly by compressed air.
Unifloc A11 Retainer roller Check & clean properly by compressed air.
Conveyor belt Check & clean properly by compressed air.
Sensor Lenses to be cleaned by soft cloth.
Cleaning cylinder Properly clean & check any damage.
Uniclean B11 Cleaning grid Check any damage & position.
Gear and drive motor Clean properly.
Sensor Lenses to be cleaned by soft cloth.
Chamber Clean properly by compressed air.
Blending roller Properly clean & check any damage.
Unimix B 7/3 Take off roller Properly clean & check any damage.
Sensor Lenses to be cleaned by soft cloth.
V-belt pulley Clean, check belt & chain tension.
Lamellar chute Cleaned by soft cloth & compressed air.
Perforated roller Check & clean properly by compressed air.
Uniflex B 60 Opening &cleaning Properly clean & check any damage.
Cylinder
Cleaning grid Check any damage & position.
Gear and drive motor Clean properly.
Sensor Lenses to be cleaned by soft cloth.
Tube light Clean by soft cloth.
Jossi CCD camera Lenses to be cleaned by soft cloth.
Sensor Lenses to be cleaned by soft cloth.
Maintenance Tools for blow room to carding machine:
Duration of maintenance for carding machine : 2.5 to 3 hrs.
Duration of maintenance for blow room : 3.5 to 4 hrs.
57. Page 57 of 78
Maintenance check list of carding m/c:
MAINTENANCE POINTS WORK TO BE DONE
Opening roller Check and clean.
Lap roller Check and clean.
Check and clean. Check and clean.
Licker in Check and clean.
Flat
Clean properly & check sharpness
of the wire.
All Flat belts Clean, check tension & adjust If required
Doffer Clean properly & check sharpness of the wire.
Detaching roller Check and clean.
Delivery roller Check and clean.
Calendar roller Check and clean.
Pneumatic system Check and clean.
All suction points Check and clean.
Cylinder Clean properly & check sharpness of the wire.
Feed roller to licker-in Check gauge & adjust if required
Licker-in to cylinder Check gauge & adjust if required
Maintenance check list of draw frames:
MAINTENANCE POINTS WORK TO BE DONE
Outer surface of the whole
Machine Clean properly by compressed air.
Pressure bar, dead weight,
condenser, trumpet. Clean properly check its condition.
Top roller Cleaning by washing powder &
grinding after 5000 hour.
Bottom roller Clean & check its gauge, reset if
required.
Motor, fan, creel light barrier Clean & check by electrical person.
Top roller lock, pulley nut-bolt, Check tightness & make perfect
creel nut-bolt, drafting zone nut- tightness if required.
Bolt
Flat belt, V-belt, timing belt Clean all the belt, check tension
adjust if required.
Filter box, filter screen, fan blade Clean properly filter & blade
condition.
Can plate Check & clean properly.
58. Page 58 of 78
Maintenance checklist of Lap former:
Maintenance Points Work to be done
Waste suction pipes, motor knives. Clean & check suction properly.
Filters Clean & check condition.
All belts and chains Clean, check tension, greasing &
apply grease if required.
Guide rolls, sliver guide Clean properly & check setting.
Top cleaning device & bottom Clean & check its physical condition.
cleaning device
Top and bottom roller Clean & check gauge reset if
required.
Setting gear Clean & check gear, vibration,
abnormal sound etc.
All sensors unit Clean all sensor unit by soft cloth.
Safety switch, pneumatic switch Check safety device.
Main gear box, drafting gear box,
lap Tightness check & make correct if
plate etc. required.
Main motor, electronic board, To be cleaned & checked by
connection board etc. electrical function.
Main gear box, drafting gear box Check oil level & put oil if required,
and all greasing point also check greasing.
Maintenance checklist of Comber:
Maintenance points Work to be done
Top bottom and stripping roller
Clean Properly & check physical
condition if required.
Top comb and circular comb setting Gauge check & adjust if required.
and condition.
Nipper feed plate, nipper gauge,
Gauge check & adjust if required.
bottom detaching roller
V-belt, timing belt and flat belt. Clean all the belt, check tension &
adjust if required.
Feed table, table funnel, calendar
Clean & check condition if
required.
roller and trumpet
Nipper, nipper level on in feed side,
circular comb brush
Clean & check condition if
required.
Feed roller, nipper lips, top Clean & check condition gauge,
detaching roller, guide plate, top adjust if required.
Delivery roller and lap plate.
All gear
Check gear condition & correct if
required.
Oil level in gear box Check oil level and apply oil if
necessary
Motor, switch, connection board,
electronic board, motor fan Clean & check by electronic
person.
59. Page 59 of 78
Chain tension on turn table
Clean & check condition, adjust if
required.
Belt tension roll axles and other Clean & check grease if required.
greasing points.
Beating bush of the top detaching Clean & check grease if required.
Roller
Drafting roller, stripe nipper frame, Clean & check grease if required.
lower delivery and table calendar
Top roller pressure, main gearbox,
top comber nipper, all pulley, index Check tightness and make correct
wheel, coiler wheel, lap feed plate, if required.
Maintenance checklist of Simplex:
Maintenance point Work to be done
Creel Clean & check bearing
condition.
Sensor Clean by soft cloth.
Balancing spring and chain Clean & check greasing.
Creel chain Clean & check greasing.
Rack groove Clean & check greasing.
Grease level in the grease
Pump
Check grease level & apply
grease if required.
Top and bottom roller Clean & gauge check & adjust
if required.
Condenser assembly Clean & check assembly &
adjust if required.
Neck bearing of bottom roller Clean & check & replace if
required.
Cradle unit
Clean & check & replace if
required.
Pressure arm Check height gauge & readjust
if required.
Top and bottom apron Clean properly by detergent &
replace if required.
Flyer cap Clean set properly.
Flyer and its gear
Clean & check gear-meshing
condition.
Shaft Clean & check condition.
Bobbin rail and seal
Clean & check the gear
condition.
Outer surface of the machine Clean the outer surface
properly.
Auto doffing in machine Auto doffing system is clean by
compressed air.
60. Page 60 of 78
Maintenance checklist of Ring frame:
Maintenance area Maintenance point Work to be done
Cog belt tension Cleaning & checking condition if 30 days
required.
Bottom apron tension bracket Cleaning & checking condition if 30 days
required.
Type tension roller condition Cleaning & checking condition if 30 days
required.
All type of timing belt condition Cleaning & checking condition if 30 days
for head stock & tail stock required.
ROBO doff, lifting rod, drive Cleaning & checking condition if 30 days
required.
Brushes of servo discs Cleaning & checking condition if 30 days
required.
Cot roller Cleaning & checking condition if 30 days
required.
Top & bottom apron
Cleaning & checking condition if
required. 30 days
Spindle & spindle break Cleaning & checking condition if 30 days
required.
Pneumatic line, mono meter & Cleaning & checking condition if 240 days
pressure regulator required.
Pressure hose condition Cleaning & checking condition if 30 days
required.
Gripper membranes condition Cleaning & checking condition if 30 days
required.
Filter box, filter cloth, seal of Cleaning & checking condition if 240 days
filter drum required.
Suction tube gauge 1mm Cleaning & checking condition if 30 days
required.
Sensors Cleaning & checking condition if 30 days
required.
Ring cup, balloon control ring &
lappet guide Cleaning & checking condition if 120 days
required.
Ring rail, lappet bar setting
gauge Cleaning & checking condition if 120 days
required.
Spinning traveler cleaner gauge
Cleaning & checking condition if 120 days
required.
Auto doffer, beam & conveyor Cleaning & checking condition if 90 days
belt centre required.
61. Page 61 of 78
Roller eccentricity & bearing Cleaning & checking condition if 730 days
condition check (back & middle
roller
required.
Front roller eccentricity, bearing
Condition Cleaning & checking condition if 365 days
required.
Driving shaft eccentricity & Cleaning & checking condition if 730 days
bearing condition check required.
Machine leveling Cleaning & checking condition if 730 days
required.
Maintenance checklist of Winding
Maintenance point Work to be done
Waxing shaft
Cleaning & checking any damaged
Pressure fork
Cleaning & checking any damaged
Yarn trap Remove the yarn accumulation
Guide plate Cleaning the wax properly
Splice cutter Cleaning and apply RS-400
Prism and its cover Cleaning the prism by compressed
air
Untwist nozzle Clean/wash by petrol & brush,
checking the position.
Clamping guide Cleaning by cloth.
Feeder guide Checking the position.
Rubber sleeve Cleaning & checking.
Sensor Cleaning carefully & adjust if
required.
Cuter Cleaning and apply RS-400
Lower end sensor Cleaning the sensing area.
Package adapter Check for unobstructed rotation.
Sliding part (cradle) Cleaning and apply silicon oil.
Cradle sensor Check its cover and screw.
Circular magazine Check, clean and re fixing.
Elector Cleaning and movement check.
Bobbin peg Cleaning.
Tensioning device
Remove cover from the belt
tensioning device of the conveyor
belt & remove yarn jam if
required.
62. Page 62 of 78
Maintenance checklist of Rotor:
Maintenance point Work to be done Interval
Rotor Cleaning by dishwasher. 15 days
Nozzle .Cleaning by detergent 15 days
Opening roller Cleaning by compressed air. 15 days
Rotor chamber Cleaning by compressed air. 15 days
Belt, pulley
Clean all the belt, check tension & adjust if
required. 15 days
Electrical function To be cleaned & checked by electrical function. 15 days
Gear units
Clean & check gear, vibration, abnormal sound
etc. 15 days
Sensor Clean all sensors unit by soft cloth. 15 days
Robot Check & cleaning by compressed air. 15 days
Magazine Check & cleaning by compressed air. 15 days
64. Page 64 of 78
Generator
Sinha spinning mill generate its own power. It has six generator in .The generator specifications
are given below:
Fig: JENBACHER generator
Generator of SRSL:
Name: JENBACHER Engine
Model: JGS 320
Country of origin: Austria
Year of manufacturing: 2000
65. Page 65 of 78
Necessary information:
Number of Generator: 6 (5 generator runs for power supply and 1 stand by)
Capacity: 1006 Kw
Production requirement: 60-70% of capacity
Type of Generator: Gas Generator
Synchronizing system: Auto synchronizing system
Controlling system: PLC (Programming Logic Control) Controlling system
Number of cylinder per generator: 20
Gas source: TITAS Gas
Gas line pressure: 14.5 PSI
Voltage: 415
Frequency: 50Hz
Gas consumption per day: 18000-20000m3
A/C plant:
The factory consists of five A/C plants in SRSL and the two A/C plant in SSL. The A/C plant in
SRSL for
Blow room
Carding
Simplex
Rotor
Ring
AC Number Use for the Area
1 Blow Room
2 Carding& drawing (Rotor side)
3 Carding, drawing, comber & simplex
4 Ring (East & West side)
5 Rotor & Auto cone
The A/C plant in SSL is for
Rotor
The manufacturer of A/C plant for SRSL is BEST AIR.
66. Page 66 of 78
The main task of A/C plant is to maintain specific humidity in the factory in the shed, for
this it circulates the cooling air. A/C plant without chilling helps to maintain only the RH%
without much difficulty. They can be classified generally as either unitary or central station.
Central system is the most widely used in the textile industry.
The systems principal components are:
1. Air moving devices-fans.
2. Mixing devices for air and washer i.e. Air washers.
Air moving devices are always two types:
1. Return Air fans
2. Supply Air fans
The return air fans return the air to the plant room from where it may circulate or exhausted in
the mill.
The supply of air to the mill from plant room.
Air washer is a device for intimately mixing water and air. The mixing water and air supply by
nozzle.
Importance of RH% and Temperature:
The atmospheric conditions with respect to temperature and humidity play very important
part in the manufacturing process of textile yarns. The properties like dimensions, weight,
tensile strength, elastic recovery, electrical resistance, rigidity etc of all textile fiber whether
natural or synthetic are influenced by moisture regain.
Moisture regain is the ratio of the moisture oven-dry weight of the material expressed as
percentage. Many properties of textile materials very considerably with moisture regain,
which in turn is affected by the ambient Relative Humidity (RH) and Temperature. If a dry
textile material is placed in a room with a particular set of ambient conditions, it absorbs
moisture and in course of lime, attains equilibrium.
Some physical properties of textile materials which are affected by RH is given below:
Strength of COTTON goes up when R.H.% goes up
Strength of VISCOSE goes down when R.H.% goes up
Elongation% goes up with increased R.H.% for most textile fibers
The tendency for generation of static electricity due to friction decreases us RH goes
up
At higher levels of RH, there is also a tendency of the fibers to slick together
67. Page 67 of 78
Temperature alone does not have a great effect on the fibers- However the temperature
dictates the amount of moisture the air will hold in suspension and therefore, temperature and
humidity must be considered together.
ISO Standard # 139 defines Standard Atmospheric Conditions:
Temperature of 68
Relative humidity 75%
RELATIVE HUMIDITY & TEMPERAURE FOR DIFFERENT DEPARTMENT:
Section R.H.% Temperature
oC oF
Blow Room 49.6 38.5 101.3
Carding 54.5 37.9 100.22
Comber 55.0 37.5 99.5
Simplex 60.2 37.7 99.86
Ring 58.3 38.0 100.4
Auto coner 63.0 39.0 102.2
Rotor 59.8 39.1 102.38
68. Page 68 of 78
Boiler
Fig. Boiler
Number of boiler: 1
Capacity: 10 Kg/hour
Production: 5.6 Kg/hour
Source of heat: Exhaust of generator
Temperature raised: 550oC (Maximum)
Steam pressure: 405 Kg/cm3
Manufacturer: Hurst Boiler, India
Serial no: BA.BO. 2332
69. Page 69 of 78
Chiller
Fig. Chiller
The main purpose of chiller is to supply chilled water to the A/C plant. Here three chiller in
SRSL
Chiller – 1
Manufacturer: Thermax Ltd, India
Type: DE
Model: EW 770V
Serial no: 18
Manufacturing date: August, 2000
70. Page 70 of 78
Chiller – 2
Manufacturer: Thermax Ltd, India
Type: Hot water
Model: THW-LT/16
Serial no: 2
Manufacturing date: October, 2000
Fire Fighting System:
Cotton fiber catches and spreads fire very rapidly. So any kind of accidents related to fire
generation can turn into a devastating calamity in cotton spinning mill. That is why the factory
has a well-equipped firefighting system. Water lines are spread throughout the factory. External
and internal firefighting groups are always ready to action. Some workers practice to go out
quickly from the factory during fire alarm is start. It helps to make any action against fire and
reduce any kind of injury.
Number of fire fighters:
Shift SRSL SSL
P/A 20 16
P/B 20 16
P/C 20 16
71. Page 71 of 78
CHAPTER – VII
STORE
And
INVENTORY CONTROL
72. Page 72 of 78
Inventory Control
Raw materials:
Import processing by head office
Physical received by stock spare LC or invoice as bale or Kg.
The raw materials are provided for lay down according to lay down plane given from
Q.C Department.
The inventory systems are divided into four groups:
1. Raw cotton inventory
2. Finisher yarn inventory
3. Wastage yarn inventory
4. Spare parts & materials inventory
The inventory is maintained in first in first out system. When store keeper receive some goods,
they write a note in the receive book. They also inform inventory related department. Then the
department made MRR (Material Receiving Report). They made BIN card which contain its
name, amount and other necessary information. Then the materials are stored in the store.
1. Raw cotton inventory:
In case of raw cotton inventory, QAD department sampling every bale and numbering the bale
according to micronaire value.
2. Finished yarn inventory:
Different lots of finished yarn are given to the production department by Transfer Memo. The
store produces its daily, monthly production report based on the yarns are delivered to order of
the marketing department, the yarns are delivered to the buyers.
3. Wastage yarn inventory:
Different wastage produces from different department. Such as hard waste, pneumafil, FS,
dropping etc. They are measured even day and transferred to store same procedure.
4. Spare parts and materials inventory:
Different type machine parts are stored in the store. When any kind of machine parts broken,
damage etc then this machine parts collect from store.
Finished Yarn: 1) Received from production department
2) Delivered to customer
3) Count, Lot or LC
73. Page 73 of 78
Engineering stock or spare:
All kind of spare parts are received and stocks are maintained.
At first received by reporting system
Stock purchase required
Material receiving report (MMR)
Posting to bin card
Issue
Balance position
N.B: Gate pass is required for receiving or delivery.
78. Page 78 of 78
Conclusions
The eight-week long industrial training truly helped us to reduce the gap between the theoretical
and practical knowledge. It also hasraised our confidence to face any industrial environment in
future. During training period we learnt about the management, human resource, production
process, quality control and many other things of spinning mill. It is true that within this short
period it is quiet impossible to achieve 100% success. However as a whole the training was very
satisfactory.
After a lot hard work we think that we achieved the objectives of the Industrial training to a great
extent which will be of much use in our future career.
The End
