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ADVANCED SHORT STAPLE SPINNING
Contents
Foreword
Preface
Author
1 Process control in mixing
Significance of process control in mixing
Fiber quality index
Essential properties of fiber
Fiber length
Fiber strength and elongation
Fiber fineness and maturity
Trash color
Neps
Properties of cotton: global scenario
Process sequence: short staple spinning
Bale packing and dimensions
Bale management
Selection of cottons for mixing
Points to follow for effective bale management
Bale lay down planning
Procedure for bale lay down planning
Linear programming technique for cotton mixing
Formulation of LPT model
LPT in the optimization of cotton mixing
Cotton property evaluation using HVI and AFIS
High volume instruments
Modules of HVI
Advanced fiber information system
Cotton stickiness
Effect of stickiness on various processes
Ginning
Spinning
Effect of stickiness on weaving
Stickiness detection and measurement
Contamination and its impact
Effects of contamination
Measures to reduce contamination
Contamination cleaning methods
Hand picking method
Blow room equipped with contamination detection
And ejecting units
Soft waste addition in mixing
References
2 Process control in blow room
Significance of blow room process
Intensity of fiber opening
Cleaning efficiency
Determination of cleaning efficiency
Points considered for attaining better cleaning efficiency
Neps in blow room
Lint loss
Blending homogeneity
Fiber rupture and its measurement
Microdust
Classification of dust
Problems associated with microdust
Microdust extraction
Lap uniformity
Technological developments in blow room machinery
Automatic bale openers
Openers and cleaners
Blenders or mixers
Contamination sorting
Chute feed system and its control mechanism
Process parameters in blow room
Defects associated with the blow room process
Lap licking
Conical lap
Soft lap
Soft lap
Curly cotton
Nep formation in blow room
High lap C.V% or tuft size variation
Other defects
Work practices in blow room
General considerations in blow room process
References
3 Process control in carding
Significance of the carding process
Neps in carding
Nep monitoring and control
Influence of licker-in zone on the carding process
Feeding
Licker-in: opening and cleaning
Quality of blow room lap
Influence of the carding zone on the carding process
Cylinder
Flats
Precarding and postcarding segments
Doffer zone
Fiber transfer efficiency
Sliver formation
Wire geometry in licker-in, cylinder,flats,and doffer
Point density
Wire point profile
Wire angle
Tooth angle
Tooth depth
Basic maintenance of card wire
Grinding
Stripping
Stationary flats
Auto leveler in carding
Benefits associated with autoleveler
Process parameters in carding
Defects associated with the carding process
Patchy web
Singles
Sagging web
Higher card waste
Low nep removal efficiency
Higher unevenness of silver
Higher sliver breaks
Ambient conditions
Cleaning efficiency and lint loss%
Control of waste
Control of waste
Control of nonusable waste
Control of soft waste
Automatic waste evaluation system
Productivity and quality for different end uses
Points for effective control of quality in the carding process
Technological developments in carding
Developments in rieter card: C70
Developments in trutzschlerTC11
Developments in marzoli C701
References
4 Process control in drawing
Significance of the drawing process
Fundamentals of drafting system
Fiber control in roller drafting
Doubling
Influence of draw frame machine elements on process
Creel
Drafting zone
Bottom drafting rollers
Top rollers
Top roller weighing system
Web condenser
Coiler trumpet
Roller setting
Top roller maintenance
Measurement of shore hardness
Berklization of top roller
Testing of top roller concentricity and surface roughness
Draw frame: speeds and draft distribution
Count C.V% and irregularity U%
Causes and control of U% in draw frame
Auto leveler
Defects associated with draw frame process
Roller lapping
Sliver chocking in trumpet
Creel breakage
More sliver breakages
Improper sliver hank
Singles
Process parameters in draw frame
Work practices
Technological developments in draw frame
Rieter draw frame
Trutizscler draw frame
References
5 Process control in comber and its preparatory
Significance of combing process
Lap preparation
Lap preparation methods
Precomber draft
Degree of doubling
Factors influencing the combing process
Fiber properties
Lap preparation
Machine factors
Setting points in comber machine
Feed setting
Type of feed
Amount of feed per nip
Detachment setting
Point density and wire angle of comb
Top comb parameters
Timing
Nips per minute
Piecing
Draft
Noil removal
Combing efficiency
Degrees of combing
Nep removal in combing
Hook straightening in comber
Sliver uniformity
Control of feed lap variation
Defects and remedies
Inadequate removal of short fibers and neps
Short-term unevenness
Hank variations
Higher sliver breaks at coiler
Coiler chocking
Web breakages at drafting zone
Breakages in comber heads
Excessive lap licking and splitting
Technological developments in comber and its preparatory
Rieter comber and lap former
Trutzschler comber
Marzoli comber
Toyota comber
Work practices
References
6 Process control in speed frame
Significance of speed frame
Tasks of speed frame
Importance of machine components in speed frame
Creel zone
Drafting system
Bottom rollers
Top rollers
Aprons, cradle, condensers, and spacer
Top arm loading
Flyer and spindle
Daft distribution
Twist
Bobbin formation
Tapper formation
Quality control of roving
Ratching
Procedure to determine ratching% in roving
Roving strength
Count C.V%
Unevenness
Defects in roving
Higher roving breakages
Soft bobbins
Lashing-in
Hard bobbins
Oazed-out bobbins
High roving count C.V%
Roller lapping
Slubs
Technological developments in speed frame
References
7 Process control in ring spinning
Significance of ring spinning process
Ring spinning machine
Influence of ring spinning machine components on spinning process
Creel
Roving guide
Drafting elements
Bottom rollers
Top roller cots
Top arm loading
Spacer-apron spacing
Lappet
Balloon control ring
Ring and traveler
Load on ring and traveler
Shape of the traveler
Traveler friction
Traveler mass
Traveler speed and yarn count
Traveler and spinning tension
Traveler clearer
Prerequisites for smooth and stable running
Of traveler on ring
Traveler and spinning geometry
Traveler fly
Impact of ring and traveler on yarn quality
Roller setting
Top roller overhang
Spinning geometry
Spindle and its drive
Spindle speed
Ring spinning empties or tubes
End breakage rate
Developments in rieter spinning machines
Developments in Toyota spinning machines
Developments in zinser spinning machines
Compact spinning system
References
8 Process control in winding
Significance of the winding process
Objectives of winding process
Types of wound packages
Cross-winding technology: terminologies
Demands of cone winding process
Quality requirements of ring bobbins for winding operation
Bobbin rejection in automatic winding machine
Acceptable deterioration in quality from ring bobbin to cone
Factors influencing process efficiency of automatic winding machine
Winding speed
Slough-off in high-speed unwinding zone
Yarn tension
Tension control in unwinding zone
Tension control in winding zone
Package density of cone
Yarn clearing
Yarn faults
Yarn cleaners
Yarn cleaner setting in automatic winding machine
Waxing
Factors influencing properties of spliced yarn
Package defects in winding
Missing tail end
Cut cone
Yarn entanglement
Hard waste/bunch
Stitch/jail formation
Patterning/ribbon formation
Sloughing off
Wrinkle/cauliflowers-shaped cone
Hard/soft cones
Double end
Missing end/cob/web
Drum lap
Ring in cone
Oily/greasy stains on cone
Determination of shade variation in yarn package
Control of hard waste
Practices to be adopted to control hard waste
Wrong work practices in the winding department
Poor work practices in manual winding process
Poor work practices in automatic winding process
Yarn conditioning
Benefits of yarn conditioning
Technological developments in winding machine
Antirbboning or ribbon breaker mechanism
Hairiness reduction
Tension control
References
9. Process control in rotor spinning
Significance of rotor spinning
Tasks of rotor spinning machine
Raw material selection
Fiber strength
Fiber fineness
Fiber friction
Sliver preparation
Influence of machine components on rotor spinning process
Opening roller
Opening roller: wire profile
Opening roller: speed
Rotor
Rotor diameter
Rotor groove
Rotor speed
Slide wall angle
Navel or withdrawal tube or draw-off nozzle
Winding zone
Tension zone
Tension control
Cradle pressure
Stop motion
Ribbon breaker
Draft
Twist
Doubling effect
Winding angle
Waxing
End breakage in rotor spinning
Relative humidity in rotor spinning process
Defects associated with rotor spinning process
Neppy and uneven yarn
Stitches
References
10 Energy management in the spinning mill
Significance of energy management in the spinning mill
Manufacturing cost of yarn in spinning mill
Energy distribution in ring spinning process
Calculation of energy consumption of ring frame machines
Energy management programs
Energy conservation in the spinning mill
Spinning preparatory process
High-speed carding machine
Installation of electronic roving end-break stop-motion
Detectors instead of pneumatic systems
Ring frame
Energy conservation in postspinning process
Intermittent modes of the movement of empty bobbin
Conveyors in autoconer/cone winding machines
Two for one twister
Yarn conditioning process
Energy conservation in humidification system
Replacement of aluminum fan impellers with
High-efficiency FRP fan impellers in humidification
Plants and cooling tower fans
Installation of variable frequency drive on
Humidification system fan motors for flow control
Other areas in humidification system
Overhead traveling cleaners
Attachment of control systems in OHTC
Provision of energy-efficient fan instead of blower fan
In OHTC
Electrical distribution network
Cable losses
Power factor
Lighting
Replacement of T-12 tubes with T-8 tubes
Replace magnetic ballasts with electronic ballasts
Optimization of lighting in production
And nonproduction areas
Optimum use of natural sunlight
Compressed air system
Energy demand control
Calculating the load factor
Motor maintenance
Energy-efficient motors
Rewinding of motors
Motor burnouts
Power factor correction
Minimizing voltage unbalances
References
11 Humidification and ventilation management
Importance of maintaining humidity in spinning process
Humidification: terms
Humidity and working conditions
Humidity and yarn properties
Humidity and static electricity
Humidity and hygiene
Humidity and human comfort
Humidity and electronic components
Humidity and dust control
Moisture management in ginning
Humidification management in spinning mill
Air washer
Determination of department heat load
Solar heat gain through insulated roof
Heat dissipation from the machines
Heat of air
Heat load from lighting
Occupancy heat load
Determination of supply air quantity
Water quality
Types of humidifiers
Stream humidification
Atomizing humidifiers
Air washer humidifiers
Conventional humidification system
Merits
Demerits
Modern humidification system
Merits
Demerits
References
12 Pollution management in spinning mill
Significance of pollution in spinning mill
Types of pollutant in the spinning process
Cotton dust
Classification of cotton dust
Types of dust
Generation of the cotton dust during manufacturing
Health hazards associated with cotton dust exposure
Byssinosis
Permissible exposure limits for cotton dust
For different work areas
Medical monitoring
Environmental exposure monitoring
Vertical elutriator
Dust control measures
Preventive measures to be followed during manufacturing process
General practices
Work practices during material handling and cleaning
Pollution in cotton cultivation and processing
Impact of chemical used in cotton cultivation
Cotton usage
Organic cotton
Necessity to shift to organic production
Comparison of conventional cotton and organic cotton
Production
Limitations of organic cotton production
Significance of noise pollution
Noise: terminologies
Ambient air quality standards in terms of noise
Perceived change in decibel level
Noise in the textile industry
Method of noise evaluation
Effect of noise pollution
Suggestion to eradicate noise pollution in textile industry
Preventive measures to control noise pollution
References
13 Process management tools
Significance of process management
Process management in spinning mill
Process management tools
5S
Application of 5S in spinning mill
Bale godown
Preparatory department
Spinning department
Maintenance department
Advantages of 5S
Implementation program of 5S
5S radar chart
Total productive maintenance system
TPM: definition
Objectives of TPM
TQM versus TPM
Different modules in the implementation of TPM
In a spinning mill
Preparatory module
Introduction module
Implementation module
Eight pillars of TPM
Lean manufacturing: definition
Principle of lean manufacturing
Goals of lean manufacturing
Lean concepts in the spinning mills
Implementation of lean concept
Lean manufacturing tools
Advantages of lean manufacturing
14 productivity waste management and material handling
Productivity in the spinning process
Factors influencing productivity of a spinning mill
Productivity measurement
Production per spindle
Labor productivity
Operatives per 1000 spindles
Measures to improve productivity in the spinning mill \
Yarn realization
Measures to improve yarn realization
Waste management in spinning mill
Waste investigation
Recording of waste
Waste reduction and control
Invisible loss
Material handling
Principles of material handling
Factors governing selection of material handling equipment
Material handling equipment in spinning mills
Bale godown
Mixing and blow room department
Trolleys used in carding, drawing, and comber
Roving bobbin trolley
Winding and packing
Automation in roving bobbin transportation
Automation in ring bobbin transportation
References
15 Case studies
Mixing-related problems
Higher needle breakage in knitting
Barre effect in the woven fabric
Poor fabric appearance due to black spots in the knitted fabric
Higher sliver breakage in carding
Higher roller lapping in spinning preparatory process
Higher polypropylene contamination in yarn
Blow room-related problems
Higher sliver breakages in card sliver
Higher end breakage in rotor groove
Holes in the blow room lap
High short thick places in yarn
Carding-related problems
Higher yarn imperfections
Higher creel breakages in drawing
Draw frame-related problems
Poor fabric appearance
High yarn count C.V%
Comber
High yarn unevenness
Speed frame
High level of thin places in the yarn
Ring frame
Higher hard waste in winding
Shade variation in cone
Higher yarn breakages in weaving
Barre in fabric
Bibliography
Index…..