NARAYANAYA

..

ORIENTATION OF PRODUCTION (WEAVING) In

MAHAVIR SPINNINGS LTD (A unit of Vardhman Textile Ltd) BADDI

(H.P.)

SUBMITTED TO SUBMITTED BY,

MR. PRAVEEN KUMAR BHARAT RANA

H.O.D.(DEPARTMENT OF TEXTILE) B.TECH. (TEXTILE ENGINEERING) JAWAHARLAL NEHRU GOVT. ENGG. COLLEGE,

SUNDERNAGAR, MANDI (H.P.)

INDEX

SER. NO. DEPARTMENT (H.O.D.)

1 INTRODUCTION (MR. V.B.KANAUJIA)2 PREPATORY

(MR. P.S.CHATTERJI)3 LOOM SHED

(MR. D.B.PATEL)4 QA/INSPECTION & FOLDING

(MR. SANJEEV SHARMA)

5CPDC

CENTRAL PRODUCTIVE DEVELOPMENT CENTRE(MR. S.S. BAINS)

RAW MATERIAL a) Auro spinning mill, Baddi b) Arisht spinning mill, Baddi c) Arihant spinning mill, Malerkotla d) Vardhman fabrics limited, Budhni. e) VSM, Baddi f) VTL Satlapur, g) Anant unit, BudhniWarp & Weft: 2/40s ET, 30s comp, 50s comp, 60s comp

20k, 80s comp, 30s carded, 32s carded, 40s comb, 40s/2 comb, 20s OE, 2/50s ET, 16s O.E, 16s OE

Selvedge:2/100 CWC, 2/80C

PREPARATORY SECTION

1. WARPING SECTION & REWINDING SECTION

2. SIZING SECTION

3. DRAWING-IN SECTION

WARPING SECTION

DIRECT WARPING SECTIONAL WARPINGDIRECT WARPING SECTION Total number of direct warping machine - 2

PARTICULERS MACHINE NO.1 MACHINE NO.2Machine manufacturer MOENUS SUCKER

GmbH(GERMANY) BENINGER

Model

COMWARP BEN-DIRECT

Year of Manufacture 2005 2004Pressure of wooden roller

800 N 800 N

Max. Speed 800 mpm(100-800mpm)

1200 mpm(50-1200mpm

Operating Speed 700mpm 700 mpm Machine Brake Hydraulic Hydraulic

•AMBIENT CONDITIONS IN WARPING DEPARTMENT

Temperature Range: 27-30°C Relative Humidity: 60-80%

PARTICULERS MACHINE NO.1 MACHINE NO.2Creel:Creel type H-Creel V- creel(moving chain

type)Creel capacity 672 656Pressure operated on the creel

15-20 N 18N

Yarn stop motion Electromagnetic Photocell typeTensioning system Capstan

Tensioners Pre-tensioning

rod{t=t’exp(μθ)}Total drive motor 8 9Creel Threading Horizontal Vertical

PASSAGE OF YARN IN DIRECT WARPING M/C

Creel Package Yarn Tensioners Yarn stop motion

Sensor Yarn guides

Expanding Comb

Guide roller

Warper’s beam

S

SETIONAL WARPING

Each of the Sectional Warping M/c contains:

One Creel One Leasing Reed One Expanding Reed Tapered Drum Sectional Warper’s Beam. Stop Motions.

TOTAL SECTIONAL WARPING M/C: 6

BENNINGER :4 PRASHANT GAMMATEX :2

PASSAGE OF YARN IN SECTIONAL WARPING M/C

MACHINE SPECIFICATIONS :(m/c No.1,2,3,4) MANUFACTURE M/C MODEL

YEAR CREEL

Benninger AG (Switzerland)

Ben-tronic 2005 Ben-creel

M/C COMPONENT TYPEMachine brake HydraulicTensioning system Additive type(spring loaded)Yarn break stop motion Electromagnetic Winding speed 5-800m/min

CREEL:Manufacture Model of creel/ Type Year of manufactureBenninger(Swiss) Ben-Creel/H-Creel 2005Creel threading Horizontal Pitch length of the creel 28cmTotal reeds 2Angle of tapered flange 11.8°Diameter tapered beam 1m( max dia of flange 1.5m)

MACHINE SPECIFICATIONS :(m/c No.5,6) MANUFACTURE M/C MODEL

YEAR CREEL

Prashant Gamatex(Ahmd,India)

ESP 1100 2007 Prashant Gamatex

M/C COMPONENT TYPEMachine brake HydraulicTensioning system Additive type(spring loaded)Yarn break stop motion Photocell typeWinding speed 5-800m/minAngle of tapered flange 10.5°

CREEL:Manufacture Model of creel/ Type Year of manufactureBenninger(Swiss) Ben-Creel/H-Creel 2005

Creel threading Horizontal Pitch length of the creel 28cmDiameter tapered beam 1m( max dia of flange

1.5m)

TENSION IN WARPING SECTION

CALCULATION OF BEAMING TENSION: BEAMING TENSION =

CALCULATION OF YARN TENSION: YARN TENSION = dtex × 0.1cN

Count (Ne) Warping tension Speed (mpm) 16 24 500 20 22 500 30 15 500 40 12 500 50 11 500 60 9 500 70 8 500 80 7 500 2/40 22 500

REWINDING SECTIONObjective:

1.)To utilize the remaining yarn in packages after the completion of warping beam.

2.) 1) To form big packages from small packages for selling purpose.

Total Rewinding M/C: 2Type: Drum Type Winding M/CPackage Produced: Open Wound Package.

Rewinding m/c no. -1,2

PARTICULARS TYPE / VALUE  Made: P.S. METTLER

Year of Manufacture 2006Model RECO DANo of Spindles 60 (ON 2 SIDES)Tensioners Disc type TensionersSpeed 500-550 r.p.m.Stop Motions Mechanical Stop Motion

Package Prepared Open wound package

Weak place Cut end Bad winding Slough off

Cone finish Entanglement Foreign matter Others

WARPING BREAKAGES:

SIZING DEPARTMENT

SIZING SECTIONSIZING KITCHEN

SIZING MACHINE

SIZING KITCHENSize is prepared at the top floor in the sizing kitchen and

transferred to the machine with the help pipes. USE 3 APPARATUS:(1) PREMIXER (2) PRESSURE COOKER (3) STORAGE.

PREMIXER PRESSURE COOKER STORAGE VESSEL

PREMIXEROne for three m/c

• Chemicals are mixed with stirrer for 15 min.• In 665 ltr of water• Then mixture is transferred to cooking vessels

through pipes.

PRESSURE COOKERThree for three m/c

• Set temperature : 120° C• Steam cut of time : 40 min.• Cooking pressure : 1.5 – 2 kg /

cm²(psi)

STORAGE VESSELThree for three m/c

• size is transferred to storage vessel • stored at the temperature of 85 - 90°C • continuous stirring for further transfer to m/c

SIZING MACHINE SECTION

TOTAL SIZING M/C : 31.) Tsudakoma: Only For Direct Beam2.) Moenus Sucker: Both For Direct & Sectional Beam3.) Moenus Sucker: Only For Sectional Beam.

PARTS OF SIZING MACHINE:

--------------------------------------------------------------------------------------------------

SIZING INGRIDIENTS TEXOPLAST WATER KETANOL ANTISTATICSONYCRYL Sizofilm: recently ordered (using)MUTTON TALLOW

1.)Creel Zone

2.) Size box

3.)Drying zone

4.)Waxing

Zone/oiling zone

5.)Splitting Zone 6.)Comb 7.)SIZED

BEAM

SIZING MACHINE SPECIFICATIONSMachine

TSUDAKOMA

Moenus Textilmaschinen GmbH

Moenus Textilmaschinen

Manufacturer TSUDAKOMA Sucker Muller Hacoba Sucker Muller Year

2004 2004 2005

Creel capacity 20 beams 20 beams 1 beamType of creel Vertical creel Vertical creel Sectional CreelM/C speed (max)

7-125 mpm 7-125 mpm 7-125 mpm

No. of size box 2 2 1Drying cylinder 14 (10 Tef,4

steel)14 (10 Tef,4 steel) 8(6 Tef ,2 steel)

Dia. of drying cylinder

800 mm 800 mm 800 mm.

Squeeze roller pressure

5 kN (7m/min) 13 kN (60m/min)

5 kN (7m/min) 13 kN (60m/min)

5 kN (7 m/min) 13kN (60m/min)

Immersion,Feed, Size rolls

2,2,2 2,2,2 2,2,2

Pre drying cylinder temperature

115°C-135°C 115°C-135°C 115°C-135°C

Temp. of size box

80°C-90°C 80°C-90°C 80°C-90°C

PARTICULERS FOR SIZING M/CSIZE PICK UP %Open End Yarn-8%Compact Yarn-12%Carded Yarn- 16%Combed Yarn- 16%PARAMETERS FOR SUCKER MULLERTension (N) =gm/mtr * factor *1.15Gm/mtr = total no. of ends /metric count

FACTORS:Let off tension=6 ( upto 40, 40& above =7)Positive feed tension = 2Wet zone tension=NADry split tension= 12Winding tension = 16Beam pressing or winding tension = (70~100)

DRAWING-IN SECTIONDRAWING-IN DEPARTMENT

MANUAL DRAWING-IN AUTOMATIC DRAWNG-IN WASHING & CLEANING SECTION

Drawing-in is the final preparatory process.

Cleaning & Drying

Drawing-In

--------------------------------------------------!!----------------------------------------------------------

Manual drawing-in Automatic drawing -in

Drawing-in componentsDifferent types of

Healdframes:1) STEEL HEEDLE DELTA2) TOYOTA-230 CM3) GROB-DELTA4) OMNIPLUS HIGH SPEED DELTA5) TSK-ZAX6)VERBRUGGE7) TOYOTA-190 CM8) ZAX-E9) TSK- TSUDOMA10) TSK-ZAX-e

Type of Heald wires: 1) 6.6 mm × 1.8 mm : Simplex 2) 6.4 mm × 1.5 mm : Duplex 3) 5.5 mm × 1.2 mm : Duplex Type of drop pins: 6.5× 1.1× 0.2 : (used for

processing Ne 25 & above) 6.5× 1.1× 0.4 : (used for

Processing Ne 25 & below) Type of Reed: DELTA-110 m.m. (Crank height

4.5cm) ZAX-120 m.m.(Crank height

6 cm)

Auto Drawing-inDRAWING-INAuto drawing m/c: Here drawing is done automatically using rapier

hook.

Manual Drawing-inDone manually to draw warp yarn through

droppins,healdframes,and reed.Two workmen:Reacher-in: puts warp in drawing-in pin or needle.Pinner: Holding drawing-in pin& draws the warp yarns

through drop pins, Healdframes & reed.

Name of Machine Model Year of Manufacture Rapier Traverse Staubli(KOREA) DELTA-110 2005 40-140mpm

Washing ,cleaning and drying m/c

Machine Used: SpaleckSPALECK washing cycle and other settings

Component Washing process Carriage time Drying passes

Heald wire-ZAX 1 100sec 4Heald wire-GAMMAX 1 100sec 4Drop wire 1 200sec 9Gammax reed 1 100sec 2Gtx reed 1 100sec 2ZAX reed 1 100sec 2

LOOM SHED DEPARTMENT

LOOM SHEDTotal loom : 224

Airjet looms : 142 Rapier looms : 82

AIRJET LOOMS (24+118)

TSUDAKOMA ZAX

TSUDAKOMA ZAX9100

Ambient conditions Loom conditions: Room conditionsRelative humidity(%) 75-85 % 68-72 %Temperature(°C) 26-30°C 28-32°C

Passage of weft through airjet loom

Loom specificationsLoom Tsudakoma Tsudakoma Manufacturer Tsudakoma corp

nomachi (Japan)Tsudakoma corp nomachi (Japan)

Year 1999Model Tsudakoma ZAX Tsudakoma ZAX9100Speed 750 rpm Loom 901 rpmReed width 190 cm 150,170,190,210,230,250,28

0,340,360,380cm.Shedding positive staubli positive staubli Max. Heald frame 7 8FDP Pin Present PresentWeft feeling sensor H1 & H2 H1 & H2 Cutter Both cutters are

mechanicalBoth cutters are mechanical

Digital display: Not attached with loom Attatched(navigation system)

Let off Electronic ElectronicShedding Mechanism

+ve cam shedding +ve cam shedding

Loom specificationsLoom type Picanol Picanol DornierManufacture Picanol Machine

(Belgium) Picanol Machine (Belgium)

Dornier Machine

Model

Gammax-6R Picanol –Gtx Dornier

Type Rapier loom Rapier loom Rapier loom

Rapier type Flexible Rapier Flexible Rapier Rigid Rapier

No. of rapier 2 2 2

Reed Width 190cm 190cm 190cmNo. of weft colour insertion 2,4,6 2,4,6 2,4,6

Shedding

Positive staubli Positive staubli

Loom speed 750rpm 550rpm 500rpm

Accumulator type Irostella-290 Irostella-290 Irostella-290

Selvedge cutter Mechanical Mechanical Mechanical

Others Particulars

Knotting: process to join warp of new weaver beam with old warp sheet using knotting machine.

type; grey and dyed yarnm/c used: Staubli knotting machine.Approximate time: 1-1.5hr.Gaiting :is to replace old weaver’s beam, drop wires,

healdwires,reed with new one.m/c used: GENKINGER HOBTEX hydraulic gaiting machine.

Quality assurance/folding department

CLOTH ROLL

Inspection FOLDING

GRADING BALE SORTING BALE PACKING

•Inspection zone.•Bale sorting zone. •Bale packing zone.•MACHINE Number manufacture•Inspection m/c 7 Laxmi m/c manufacture•Mending table 2 Laxmi m/c manufacture•Folding 2 Laxmi m/c manufacture•Rolling machine 1 Laxmi m/c manufacture •Inspection cum Rolling m/c 1 Navjyot m/c works ltd •Bale pressing m/c 1 Laxmi m/c manufacture

VARIOUS INSPECTION SYSTEM 10 POINT INSPECTION SYSTEM, 4 POINT INSPECTION

SYSTEM 4 Point inspection System: 0-3 inches- 1 point 3-6 inches- 2 point 6-9 inches- 3 point 9 inches and above 4 points FAULTS NOTED IN FOLDING Minor faults- this includes slub, stains and

contaminationMajor faults- this includes the faults like bent pick,

double pick, thick place stain mark, oily weft

QUALITY ASSURANCE (PDC)

ResearchSelection of raw materialProcess controlProcess developmentProduct testing Quality assurancesSpecification tests

INSTRUMENTS USED IN R & D LAB Tension meter, Digital thread counter , Weighing scale,

Circular cutter, Stirrer, Tachometer, Shore hardness tester, Yarn appearance tester, Automatic twist tester, Single yarn strength, tester, Bess lay balance, Desiccators, Moisture meter, Tearing strength tester, Lea strength tester, Refractometer.

cpdc: central productive development centre

PDC

• PRODUCT DEVELOPMENT CENTRE

CDC

• CREATIVE DESIGN CENTRE

PILOT PLAN

• PILOT PLAN

CPDC: CENTRAL PRODUCTIVE DEVELOPMENT CENTRE

Queries.???