aust fall15 industrial training report

Ahsanullah University of Science & Technology

Department of Textile Engineering

Course no.: Tex-500Course 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 IDMd. ShahadulAlam 09.02.06.050Md. ToufiqNiaz 11.02.06.054Md. Hadi-Arafin-AlamAkash 12.01.06.018ShafayatShahariar 12.01.06.140

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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.

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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.

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TABLE OF CONTENTS

ChapterNo.

Topics PageNo.

1 Factory Profile andManpower Management

9-15

2 Raw Materials, Product Mixing andSequence 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

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CHAPTER – I

FACTORY PROFILEAndMANPOWER MANAGEMENT

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Fig. Outside view of Sinha Textile ltd.

Fig. Sinha Rotor Spinning Ltd.

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Factory Profile

01. Name of the MillSINHA 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 locationSinha 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 capacityCotton yarn 6228 Metric ton /yearLycra 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

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LOCATION OF SINHA SPINNING GROUP VIA GOOGLE MAP

LOCATION OF SINHA SPINNING GROUP VIA SATELLITEVIEW OF GOOGLE MAP

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Organogram

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ChairmanDirectorDeputy general ManagerProd. Dept.Prod. Mng.Assist. Mng.Senior Prod. officerProd. Officerassit. Prod. OfficerM/c operatorHelperWorkerQuality Dept.Quality Mng.Senior OfficerOfficerLab Assist.Lab BoyMaint. Dept.Maint. Mng.Assist. MngForemanFiitterHelperWorkerUtility Dept.Utility Mng.Utility Eng.Sub Assist. EngWorkerStore Dept.Store Mng.Senior officerOfficerHelperWorkerAccounts Dept.Accounts Mng.Accounts OfficerCashierAdmin. Dept.Admin. Mng.Admin OfficerAssist. Admin officerMarketing Dept.Marketing Mng.Marketing officerSecurity Dept.Security OfficerAssist OfficerSecurity Gaurd

Manpower Management

Officers listProductionDepartment

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 AssuranceDepartment

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)

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Workers list

GRAND TOTAL STAFF AND OFFICERS: 820

Shifting Schedulea. 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

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Chapter – II

RAW MATERIALS, PRODUCT MIXINGAnd SEQUENCE of OPERATION

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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

MixingA 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% wastage70% virgin cotton + 30% wastage90% virgin cotton + 10% wastage

100%virgin cotton

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Process flow-chart for Card yarn

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Process flow-chart for Combed yarn

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Process flow-chart for Rotor yarn

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CHAPTER – III

PRODUCTION DEPARTMENT

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Layout Plan

Fig. Layout plan of SRSL

B/R- Blow RoomC51-Carding M/cSB2-Breaker Draw frameE32-Lap formerE66/62-ComberD30-Finisher Draw frameTOYOTA FL 100/Zinser 670-Simplex M/cROTOR- Rotor M/cG33-Ring frameAUTOCONE-Winding M/c

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Machinery list ofSinha Rotor Spinning Ltd

Serial Name of machine Quantity Model Mfg. yearno.01. Blowroom

Unifloc 02 RIETER A11 2000Uniclean 02 RIETER B11 2000Unimix 03 RIETER B7/3 2000Uniflex 03 RIETER B60 2000

Mixing Bale Opener 01 RIETER 3/4 2000Waste Opener 01 RIETER B2/5 2000Mono-cylinder 01 RIETER B4/1 2000

JOSSI Vision Shield 02 JOSSI 2006Bailing Press 02 2006

02. CARDING 21 RIETER C51 200003. DRAW FRAME

(Breaker) RIETER SB2 2000

Finisher) RIETER RSB-D35 2000

04. LAP FORMER 02 RIETER E32 2000

05. COMBER 10 RIETER E62 2000

06. SIMPLEX 03 ZINSER RO- WE- 2001MAT-670

05 TOYOTA FL-100 2000

07. O.E. ROTOR FRAME 4 RIETER R20 2000

08. RING 28RIETER 2000/2001

09. AUTOCONE 07 MURATECH 7V 200001 SCHLAFHORST- 2001

33801 PROCESS 2006

CONER-21C

10. XORELLA yarn 01 XORELLA 2000

Conditioning

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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.

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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 2Model A11Manufacturer RIETERYear 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 mmFrequency 50 HzVoltage 400 VProduction 1400 kg/hr.

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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 2Model B11Manufacturer RIETERYear of manufacturing 1999 & 2000 (Comb Line)Country of origin SwitzerlandPin roller speed Normal: 640 rpm, Actual: 570 rpmCleaning 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 mmCleaning cylinder diameter 750 mm

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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

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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 3Model B60Manufacturer RIETERYear of manufacturing 1999 & 2000 (Comb Line)Country of origin SwitzerlandFrequency 50 HzVoltage 400 VProduction up to 600 kg/hr.Cleaning intensity .8 (0.0-1.0)%Relative amount of waste >6 (1-10)Working width 1200 mmCleaning cylinder diameter 750 mmPined roller speed 960-1300 rpm

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Blowroom line 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

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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 tuftb) Elimination of impuritiesc) Disentanglement of nepsd) Elimination of duste) Producing uniform sliver

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Specification:

Model C51

Manufacturer RIETER


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 12Taker in to mote knife 1 40Cylinder to doffer 0.175 7Cylinder to flat .3, .275, .25, .225, .225 12, 11, 10, 9, 9Cylinder to stationary flat (back) .6, .55, .5 24, 22, 20Cylinder to stationary flat (front) .45, .4 18, 16Doffer to detaching roller .15 6Detaching to cross roller .125 5Top delivery to bottom delivery .25-.3 10-12rollerCalendar roller 1.6 64Cylinder to cylinder under casing .9-1.2 36-48Taker in to taker in under casing .5 20

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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

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Breaker draw frameSpecification:

Model SB-2Manufacturer RIETERYear of manufacturing 1999Country of origin SwitzerlandDrafting system 3 over 3Doubling 6 (max- 8)Sliver length per can 5000 mDelivery speed 650 m/minDrafting zone pressure control hard pressureCot roller diameter 38 mmBottom roller diameter 30 mm(back), 30 mm(middle), 30 mm(front)Feed sliver weight 75 grains/yardDelivery sliver weight 75 grains/yard

Can size 120×600mmCot roller shore hardness Comb- 76-80A, Card- 83Apressure 10 bar

Finisher draw frame

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Specification:

Model RSB-D30

Manufacturer RIETER

Year of manufacturing 2001


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/yardCot roller shore hardness Comb- 76-80A, Card- 83A

Can size 1000×500 mm

Auto leveler system Present

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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


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

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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 E62Manufacturer RIETERYear of manufacturing 2002Country of origin SwitzerlandDrafting system 3 over 5Number of doubling 8Draft 23.1 Delivery speed 130 m/minNips / min 300/minCan feeling 6000 mFeed per nip 4.7Diameter of full lap 520 mmMaximum noil extraction 24%

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Fig. Toyota FL-100

Objectives:

1. To draft the sliver i.e. reduce the weight per unit length of sliver2. To insert small amount of twist to strengthen this roving in order to prevent

breakage during processing3. To wind the twisted strand (roving) on to a bobbin4. 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

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Fig. Zinser 670Specification:

Model: RO-WE-MAT 670

Manufacturer: Zinser


Year of manufacture: 2001


Number of flyer: 96

Maximum flyer speed: 1350 rpm

Doffing system: Automatic

Pressure arm loading: Spring loaded

Maximum roving length: 1400m

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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.

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Machine specification:

Manufacturer: Rieter

Model: G33


Number of spindle per machine: 1008

Country of origin: Switzerland


Spindle speed: maximum 18000 rpm


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

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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

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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

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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

20CW 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

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Rotor

Fig Rieter R 20SRSL ROTOR SECTION

Model: R20

Manufacturer: RIETER


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%

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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

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CHAPTER - IV

QUALITY CONTROLDEPARTMENT

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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 ARTManufacturer: Premier, INDIA

Function: Premier ART is used to test the following physical properties of the fiber. It tests accordingto the HVI calibration.

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Test Result Abbreviation

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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

Uster AFIS PRO

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Fig. Uster AFIS ProManufacturer: 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

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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) Monitorb) Printerc) Computer systemd) Electronic balancee) Sample feed unitf) Different sensor for test the sample

Premier Tester 7000

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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

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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 Dc) Sensor type B (capacitance sensor)d) Conveyore) Absorber type Bf) Computer system (CPU)g) Creel (it can holds 24 bobbin max)

Other parts:

a) UPSb) Monitorc) 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) Imperfectionc) Cut length CV%d) Index of irregularitye) Relative countf) Maximum and minimum mass value of different length

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Tensomaxx 7000

Manufacturer: Premier Polytronics Ltd, India

MODEL:Tensomaxx 7000Serial 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

Test setting: before starting ab=ny test it needs to set the following setting:

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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.

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CHAPTER – V

MAINTENANCE DEPARTMENT

MAINTENANCE

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Maintenance points in Blow Room:

MACHINE NAME MAINTENANCE POINTS WORK TO BE DONETake 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.

Maintenance check list of carding m/c:

MAINTENANCE POINTS WORK TO BE DONEOpening roller Check and clean.

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Lap roller Check and clean.Check and clean. Check and clean.

Licker in Check and clean.

FlatClean properly & check sharpness

of the wire.

All Flat belts Clean, check tension & adjust If requiredDoffer 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 requiredLicker-in to cylinder Check gauge & adjust if required

Maintenance check list of draw frames:

MAINTENANCE POINTS WORK TO BE DONEOuter 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 ifrequired.

Motor, fan, creel light barrier Clean & check by electrical person.Top roller lock, pulley nut-bolt, Check tightness & make perfectcreel nut-bolt, drafting zone nut- tightness if required.

BoltFlat 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.

Maintenance checklist of Lap former:

Maintenance Points Work to be doneWaste suction pipes, motor knives. Clean & check suction properly.

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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 ifrequired.

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 rollerClean 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 rollerV-belt, timing belt and flat belt. Clean all the belt, check tension &

adjust if required.

Feed table, table funnel, calendarClean & check condition if

required.roller and trumpet

Nipper, nipper level on in feed side,circular comb brush

Clean & check condition ifrequired.

Feed roller, nipper lips, top Clean & check condition gauge,detaching roller, guide plate, top adjust if required.

Delivery roller and lap plate.

All gearCheck gear condition & correct if

required.

Oil level in gear box Check oil level and apply oil ifnecessary

Motor, switch, connection board,electronic board, motor fan Clean & check by electronic

person.

Chain tension on turn tableClean & check condition, adjust if

required.

Belt tension roll axles and other Clean & check grease if required.

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greasing points.Beating bush of the top detaching Clean & check grease if required.

RollerDrafting roller, stripe nipper frame, Clean & check grease if required.lower delivery and table calendarTop roller pressure, main gearbox,top comber nipper, all pulley, index Check tightness and make correctwheel, coiler wheel, lap feed plate, if required.

Maintenance checklist of Simplex:

Maintenance point Work to be doneCreel 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

PumpCheck grease level & apply

grease if required.

Top and bottom roller Clean & gauge check & adjustif required.

Condenser assembly Clean & check assembly &adjust if required.

Neck bearing of bottom roller Clean & check & replace ifrequired.

Cradle unitClean & 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 gearClean & check gear-meshing

condition.

Shaft Clean & check condition.

Bobbin rail and sealClean & check the gear

condition.

Outer surface of the machine Clean the outer surfaceproperly.

Auto doffing in machine Auto doffing system is clean bycompressed air.

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Maintenance checklist of Ring frame:

Maintenance area Maintenance point Work to be doneCog 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 apronCleaning & checking condition if

required. 30 daysSpindle & 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 daysrequired.

Ring rail, lappet bar settinggauge Cleaning & checking condition if 120 days

required.Spinning traveler cleaner gauge

Cleaning & checking condition if 120 daysrequired.

Auto doffer, beam & conveyor Cleaning & checking condition if 90 days

belt centre required.

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Roller eccentricity & bearing Cleaning & checking condition if 730 dayscondition check (back & middle

rollerrequired.

Front roller eccentricity, bearingCondition 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 WindingMaintenance point Work to be done

Waxing shaftCleaning & checking any damaged

Pressure forkCleaning & checking any damaged

Yarn trap Remove the yarn accumulationGuide plate Cleaning the wax properlySplice cutter Cleaning and apply RS-400

Prism and its cover Cleaning the prism by compressedair

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 ifrequired.

Cuter Cleaning and apply RS-400Lower 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 belttensioning device of the conveyor

belt & remove yarn jam ifrequired.

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Maintenance checklist of Rotor:

Maintenance point Work to be done IntervalRotor Cleaning by dishwasher. 15 days

Nozzle .Cleaning by detergent 15 daysOpening roller Cleaning by compressed air. 15 daysRotor chamber Cleaning by compressed air. 15 days

Belt, pulleyClean all the belt, check tension & adjust if

required. 15 days

Electrical function To be cleaned & checked by electrical function. 15 days

Gear unitsClean & check gear, vibration, abnormal sound

etc. 15 daysSensor Clean all sensors unit by soft cloth. 15 daysRobot Check & cleaning by compressed air. 15 days

Magazine Check & cleaning by compressed air. 15 days

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CHAPTER – VI

UTILITY DEPARTMENT

Generator

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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


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

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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 Area1 Blow Room2 Carding& drawing (Rotor side)3 Carding, drawing, comber & simplex4 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.

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.

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2. Mixing devices for air and washer i.e. Air washers.

Air moving devices are always two types:

1. Return Air fans2. 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

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.

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ISO Standard # 139 defines Standard Atmospheric Conditions:

Temperature of 68 Relative humidity 75%

RELATIVE HUMIDITY & TEMPERAURE FOR DIFFERENT DEPARTMENT:

Section R.H.% TemperatureoC oF

Blow Room 49.6 38.5 101.3Carding 54.5 37.9 100.22Comber 55.0 37.5 99.5Simplex 60.2 37.7 99.86

Ring 58.3 38.0 100.4Auto coner 63.0 39.0 102.2

Rotor 59.8 39.1 102.38

Boiler

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Fig. BoilerNumber 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

Chiller

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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

Chiller – 2

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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 SSLP/A 20 16P/B 20 16P/C 20 16

CHAPTER – VII of 79

STORE AndINVENTORY CONTROL

Inventory Control

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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 inventory2. Finisher yarn inventory3. Wastage yarn inventory4. 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

Engineering stock or spare:

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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.

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CHAPTER –VIII

YARN MARKETING

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MARKETING

Brand name:

1. Sinha Rotor Spinning Ltd.

Buyer of Product:

1. Denim: Hamim Denim Ltd. Pacific Denim Ltd. Chittagong Denim Ltd. Royal Denim Ltd. Sinha Denim Ltd.

2. Textiles: Sinha yarn dyeing Ltd. Sinha knitting Ltd. Adnan textile Ltd. Asian dyeing Ltd. Dacca Dyeing Ltd. Radiance group. Mascot group. Shirazgonj Check Reja Fabrics Padma textiles All tex Bengal textile

Competitors:

a. Square textileb. Shamim textilec. Ages cottond. Akij textilee. Thermax textilef. Sayham textileg. Nasa textileh. RK textilei. Al-Haj Karim Textile

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Foreign buyers:

H & M Mark Kough Synergies Lee & Fung AMC VF Asia TCP Hanes GAP

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CHAPTER-IX

CONCLUSIONS

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ConclusionsThe 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

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