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Page 1

MILL AT A GLIMPSE - AN
INTRODUCTION

 MARKET PROSPECTUS :-
Bhilwara textile market is a rising textile hub with a
present thunder in demand due to recovered goodwill after
the end of the duplicate selvedge production by few business
concerns in Bhilwara. Overall demand is expected to double of
the present demand. “Chhabra Group” is one of those
groups which have established their name in the market with
the concepts of methodical working eminence and services
under their brand names “NEWMAN” and “CITILINE”.

 GENERAL REMARK :-
M/s Chhabra Syncotex Limited, Bhilwara is a fabric
manufacturing unit having its registered office at “Chhabra
Mansion” Opp. Waterworks, Pur raod, Bhilwara and
Manufacturing unit at Biliyan Kalan, Chittorgarh road,
Bhilwara.

The company was incorporated on 3rd august, 1993


and commenced commercial production in the month of
January, 1998.

Further, the company had also established two


“SULZON” make “WIND POWER PROJECTS” having
capacity of 350KW and 600KW at Jaisalmer district
and getting the reimbursement of electricity generated
from Rajasthan State Electricity Board (RSEB) for its
capitive use.
Page 2

 FUTURE PROSPECTUS OF THE COMPANY :-


Looking to the demand of company’s products in the
market, the company has to arrange its production
arrangement through outside various job parties in addition to
its own production capacity to meet out the demand of its
customers. Hence, the company is planning to import and
install more efficient and upgraded weaving machineries and
management is exploring better and high speed looms in the
international market and likely to be import in this current
financial year which also improve company’s profitability.
Page 3
Page 4

Chhabra Syncotex Ltd. , Bhilwara


1 – Main Entrance Gate
2 – Security
3 – Diesel Generator & Power Distribution
4 – Entry Gate
5 – Weaving Preparatory Department
6 – Prashant Gamatex Warping M/c
7 – Prashant Gamatex Warping M/c
8 – Cone Rewinding M/c
9 – Drawing – in Department (Manually)
10 – Raw Material
11 – Weaving Shed
12 – Maintenance office & store
13 – Office
14 – Dobby Card Cutting M/c
15 – Drinking Water
16 – Store Room
17 – Mending Department
18 – Drinking Water
19 – Toilet
20 – Parking

 Weaving M/c Line 1 has 6 SULZER-RUTI PU – 85” & 1 P7100 -85”


 Weaving M/c Line 2 has 6 SULZER-RUTI TW 11 – 85” & 1 P7100-
85”
 Weaving M/c Line 3 has 5 SULZER-RUTI P7100 – 153” (Double
Width)
 Weaving M/c Line 4 has 5 SULZER-RUTI P7100 – 153” (Double
Width)
 Weaving M/c Line 5 has 4 SULZER-RUTI PU-153” & 2 P7100 - 85”
 Weaving M/c Line 6 has 4 SULZER-RUTI PU-153” & 2 P7100 - 85”
 Weaving M/c Line 7 has 4 SULZER-RUTI PU- 85” & 3 P7100 - 85”
 Weaving M/c Line 8 has 4 SULZER-RUTI PU- 85” & 3 P7100 - 85”
Page 5

Staff & Management

Chief Executive - Mr. K.L. Chhabra.


Production Manager - Mr. Jherul Hassan
Maintenance Head - Mr. Madan Singh
Warping Head - Mr. Rewat Singh
Head Supervisor - Mr. Waquar Hassan
Dispatch In-charge - Mr. Pradeep Kumar
Store In-charge - Mr. Vimal Kumar Jain
Page 6

Raw Material & Sales


 Raw material used
• Poly. Texturised Yarn

• 100% Polyester

• P/V-65/35, 70/30, 69/31

• P/W- 85/15

• Count Range- 2/30s, 2/40s, 2/20s, 2/18 s , etc.

• Cone weight- 1.5-3 kg

 Raw material comes from


• Sangam Spinners , Bhilwara

• Shree Rajasthan syn. Ltd., Dungarpur

• Birla Textile Mills, Himachal Pradesh

• Chenab Textile Mills, J&K

• Jagdamba Spinning Mill Ltd., Nepal

• Bhiwani Textile Mill , Harayana

• IndoRama

• Reliance

• Grasim

• Alok Textiles

• DNH Spinners

• Keshar Multiyarn Mill Ltd., West Bengal


Page 7

 Sales :
• all over India through the marketing agents,
• Production- 15 million meter annually(2008),
• 55 lakh meter own production,
• Remaining on order.

 WIND Mill Project –

• Situated at – Jaisalmer

• Make – SULZON
• 0.35 MW (2006) -No of project-1

• 0.65 MW(2007,2008)- No of projects-2

• 3.48 Rs./ unit sells to RSEB

• 3.64 Rs./unit purchase from RSEB

• 3.55 Rs./unit sells to A.K. Spintex ,Bhilwara

Wind –Mill Project ,Jaisalmer


Page 8

Flow Chart of Process


Yarn Cones from
Raw Material
Godown
Page 9

Winding Machine

To weft
Warping
supply
system

Drawing - in

Weaving Machine

WINDING MACHINE
Page 10

 Object :
To make suitable package of warp & weft yarn for
warping & weaving accordingly from the package purchased
from spinning party.

 Technical Specifications
• Make : Peass Industrial Engineering Ltd., Navsari (
Gujrat )

• Model : RECO DA

• Year : 1998

• Speed : 250 – 300rpm

• Total Head : 2 x 30 = 60 heads

WARPING
 Object :
Page 11

1. To prepare continuous warp sheet beam according to given warp


pattern, of required length , width & no. of ends.

2. All of ends must be under uniform tension.

 Machine Allocation :

Sr. No. Make Model Creel Capacity


1. Prashant Gamatex A - 217 384
2. Prashant Gamatex A - 217 384

 Prashant Gamatex High Speed Sectional Warping


Machine

 Technical Specifications.
1. Make: Prashant Gamatex Pvt. Ltd., Ahmedabad.
2. Model : A – 217
3. Creel : 2(side) x 8(vertical) x 24(horizontal) = 384
4. Warping Speed : 0 - 650 meter /min (Maximum )
5. Beaming Speed : 0 -100 meter / min
6. Beaming Diameter : 800 mm – 1000 mm
 Salient Features :

• Reserve cone holders for next programme


• Fixed cone height
Page 12

• Fully machined & Dynamically Balanced Metallic Drum

• Hydraulic Disc Brakes

• Auto Section Advancing

• Accurate Warp density adjustment & Alignment


• Frequency variable A/C Drive

• Micro-Processor based controls

• Electronic length measurement


• Four line display showing continuous monitoring of warp
length speed, section width plus traverse & No. of section.

• Constant warping speed

• Foot operated crawl speed

 Tension level :
Sr.no. Count Tension (gm)
Page 13

1. Coarse up to 18’s 14 – 16
2. Medium , 19’s – 35’s 10 - 12
3. Fine , 36 – 48’s 8–9
4. Superfine, above 48’s 6-8

 Temperature & R.H. of department


• Temperature = 270 – 320 C

• Relative humidity = 60% – 65%

 Warping Defect and Remedies

 High variation in tension within and between ends (slack ends)


For this ensure
1. Change in unwinding dia. and balloon height
2. The number of guide points for the yarn in the creel
3. Due to jerks sometimes the ends come out from the tensioning device
causing slackness
 The surface of yarn building on the beam should be even and free
from ridges from one selvedge to the other.
For this ensure
Page 14

1. Uniform spacing of comb dents,


2. Matching the comb width with the beam width,
3. Minimum variation in tension within and between ends.

CHHABRA SYNCOTEX Ltd. BHILWARA


 Cutting -in of ends at the end of beams-
BEAM CARD
1. This is due to improper flange distance
Lot No. : 2422 Loom
No. : 19

Quality: Smart Cot Prog. No. : 255 Length


: 2000 x 2 mtr

Reed : 52/3 Picks. /inch: 52 ppi Total


Ends:

Avg. Wgt. Reed Space: 65 “


110+4914+110 = 5134

2/30 KesharMulti P/V 4123

Dent x ends

selvedge 2x3 =6
(2/30)

in Patti - light blue 14 x 2 = 28 (2/30)

Pla blue 2 ply 1 x2 =2 (2/30)

mono P. blue 1x2 =2 (2/30)


BEAM CARD: Beam card contains all specification of fabric. It has
monogram
warping details as well as pattern. One example of a lot is given below.

selvedge 8x 1 – 36 ( 72
ends in 8 dents )

Smart Cot by Neuman 1 - 36


Page 15

Drawing in Department
Page 16

In this department the beam from warping machine


comes to the drawing – in department. The beam is kept on
the drawing - in stand and here the person have detail of
Design, Draft & Peg plan. In this way warp ends are drawn
through the reed, drop Pins and heald frame. Now the
beam is ready to be taken to the weaving Machine.

 Types of Heald Wires & Drop Pins

 Heald wire

• Type : C - type and J – type simplex

• Length : 331 mm, flat steel

• Eye let mm : 5.5 x 1.2 mm

• Strip size : 5.5 x 0.30 mm

• Make : Unique Impex , Mumbai

 Drop pins

• Type : Open , electrical

• Size : 165 x 11 x 0.4 mm

• Make : Unique Impex , Mumbai

WEAVING DEPARTMENT
 Machine Allocation

Sr MAKE MODE Reed Space No of wvg


Page 17

no L m/c
.
1. SULZER - RUTI PU Single width 14
85”
2. SULZER - RUTI PU Double width 8
153”
3. SULZER - RUTI TW 11 Single width 6
85”
4. SULZER - RUTI P7100 Single width 12
85”
5. SULZER - RUTI P7100 Double width 10
153”
Total wvg m/c 50

 SPEED AND EFFICIENCY

• Single width = 300-330 rpm

• Double width = 250-270 rpm

• Efficiency = 88 - 91%

 Details of model

1. SULZER RUTI
PU 85 VSD 110 KR D1 F

2. SULZER RUTI
PU 153 ZSD 110 KR D1 F

3.SULZER RUTI
P7100 B190 N4 EP D1
 NOMENCLATURE SYSTEM OF SULZER –RUTI
MODELS
Page 18

SULZER –RUTI has developed a scheme for naming the


models of its projectile weaving machine. Each & every
part of it, tells about a significant machine detail.

A. PU – SERIES

SULZER -RUTI
P U 153 ZSD 110 KR
D1 F

1. SULZER – RUTI : MANUFACTURER


2. PU i) P – Projectile weaving m/c
ii) U - Universal machine
3. 153 : nominal reed space in inches
Other versions are, a) 73 “ - 1894 mm
b) 85 “ - 2200 mm
c) 110 “ - 2830 mm
d) 130 “ - 3340 mm
e) 143” - 3670 mm
f) 153 “ - 3930 mm
g) 183 “ - 4690 mm
h) 213 “ - 5450 mm

4. ZSD : Weft colors change mechanism


Other Versions are ,
Page 19

a) ES - single color mechanism


b) MW - weft mixer
c) ZSD – 2 color machine, color change by
dobby
d) VSD – 4 color machine, color change by
dobby
e) VSK – 4 color machine, color change controlled
by special card cutting unit
f) VSI – 4 color m/c, color change by jacquard
mech.

5. 110 : Picking unit


Other versions are,
a) 110 - for 143 “– 213 “
b) 121 - for 130 “
c) 135 - for 110 “
d) 150 - for 73” -85
6. KR : Shedding Control Device
Staubli Dobby, 18 shaft rotation
principle
Page 20

Other versions are;


a) E 10 - Tappet shedding device (Max. 10
shafts)
b) E 14 - Tappet shedding motion (Max. 14 shafts)
c) J - Jacquard shedding device

7. D1 : Projectile Cycle
for steel projectile with small cross section,
primarily for light & medium quality yarn .
( 73 “ - 153 “ wide loom normally use it)
Other versions are,

D2 - for steel projectile with large cross


section, primarily for heavy & fancy quality yarn .
( 85 , 110 , 130 ,153 , 183 ,213 inches loom used)

8. F : Suffix , used for endless manmade fibre


weft

Other versions are,


a) H - Bast fibres
b) P - Polyolefines
c) R - heavy fabrics
d) G - Terry Weaving
Page 21

B. P 7100 Series :

 Model : P 7100 W 190 N 4 SP D1

• P - Projectile

• 7100 - Model number

• W - Raw material

a) W - Wool

b) B - Cotton

c) S - Synthetic.

• 190 - Loom width in cm

• N - Low built (not for terry)

• 4 - Weft colors

• SP - Shedding device

a) SP - Positive dobby

b) J - Jacquard

c) EP - Positive tappet

• D1 - Steel projectile with small cross section

 Accumulator
Page 22

Types of Accumulators
1. Technomatex – Futura (Switzerland)

2. IWF – Sweden

3. ROJ – Electrotex AT – 1200

4. VIRIEL – Technomatex

 Accumulator Setting :
Electronic head of Accumulator has one ON/OFF switch & 4
settings are there,

1. Setting of winding Speed by a set screw.

2. Intensity of photocell can be changed according to type of


weft yarn Texturized or spun.

3. Amount of yarn wound on winding head by altering the


position of photocell by the help of rotating screw arranged
with Rack-Pinion system.

4. NT / RT setting

• Heald frames

• Make : Grobamextra 4 no. (Sulzer)


Page 23

• Pattern Maker (selvedge)

 Make : YANTAI S & S SCIENCE AND TECHNOLOGY


APPLICATION ENG. CO. LTD , P.R. – CHINA

 Model : SEJ – 159


Page 24

 Specification

• High speed steady operation, reach 600 rpm max.

• Double lift opening

• Lifting needle – 72x1, 72 x 2 head

• Shed height : 58 - 98mm

• Synchronous belt connecting the loom

• Use at rapier, projectile, air-jet and water jet wvg


m/cs.

• Electronic control

• Input from control panel memory (design from floppy)

• Can save many pattern data box (up to 40 files of


3000 pictures.)

 Flow –Chart of Design Interpretation


Page 25

Design on
CAD Copy to Floppy
Software

Copy
Carry to Control
Programs in
panel of Pattern
memory
Maker

Start Process

SORT PARTICULARS
Page 26

Sort Selvedge name of Warp Weft Reed ppi Reed Body Total design
no . fabric count count count space ends sel.
(inches) ends
1. Fighter Newman 2/20 105 D 44/2 40 65 2772 108x2 1/1
P/V P plain
2. Shahi Libas 2/15 105 D 58/4 82 65 6560 119x2 1/1
NT& P plain
RT
3. Enzamimo 2/40 2/70 52/4 58 65 6552 102x2 2/1
Cots Feel P/V P/V twill
4. Soft Touch 2/30 320 52/3 52 65 4914 114x2 2/1
P/V D twill
5. Executive Class 2/18 2/18 42/2 46 65 2646 106x2 2/1
P/V P/V twill
6. Royal Classic 2/30 320 50/3 50 65 4725 114x2 2/1
P/V D twill
7. Challenger 2/15 2/15 36/2 34 65 2268 66x2 1/1
P/V P/V plain
8. Spider Natural 2/18 2/18 40/2 40 65 4725 98x2 1/1
P/V P/V plain

PRODUCTION CALCULATION

Assuming following average particulars,


Page 27

• Machine RPM : 330 rpm

• Picks per inch : 50

• Shift Duration : 12 hrs

• Efficiency : 88 %

Production = Rpm x eff. x 2.54 x 12 x 60 mtr per


shift
ppi x 100

= 330 x 0.88 x 2.54 x 12 x 60


50 x 100

= 106 .21 meter per shift

ABOUT SULZER - RUTI


PROJECTILE WEAVING MACHINE
Page 28

A. PU - Series
• It works on a weft insertion system consisting of unilateral
projection of multiple projectiles.

• Projectile weighing 0.083 lb slithers across guide teeth at


an acceleration of 2200 mt/sec2 .

• Strain energy of a torsion bar hits projectile from 300 to


400 times per minute in PU model.

• Most efficient converter of energy, the picking force is 1/3rd


of machine’s total energy consumption.

• Firing unit is fixed but receiving unit can be brought closer


for narrower width fabrics.

• Minimum fabric width which can be successfully woven is


13”.

• Speed reduction in 4 or 6 color machines are significant as


compared to mono color machine.

• Beam flanges of 800 mm to 1000 mm. accommodate up to


4000 mts. of normal count.

• Gripping force of gripper jaws is 1900 to 2200gms.

• Torsion bars are of three different diameters


15mm/17mm/19mm.

• Torsion bar is free from molecular fatigue. Corrosion free


and a modulus of rigidity 12.106 lb in.
Page 29

• Sulzer projectile machine reduce labor cost up to 60% and


power consumption by 40%.

• Noise level is safe for human audio system i.e. 90dBa.

• Lightest possible gripper shuttle, which will not become


airborne is of 17gm. Mass through, equal in size to 60gm.
D2 model projectile.

• Gripper size is 3.5 “x 0.55” x 0.24 “.

B. P7100 Series

• The machine handles practically all types of yarns: spun


yarn, filament yarn, fancy yarn etc..

• In the weft the machine processes staple fiber yarns from


Nm 0.5-160 and continuous filament yarns from 5000-10.8
denier.

• Weft density is between 0.83-181.5 picks/cm.

• Maximum weft insertion rate 1200 meter / min. and speed


up to 400 rpm.

• Can work for up to four different weft colours.

• Nominal width 190-540 cm.

• Machine design is extremely compact.

Various Mechanisms
Page 30

 SHEDDING

In this machine shedding is done by STAUBLI dobby.

Staubli dobby is one sided dobby provided on one side of


the loom, driven by the cross shaft by chain drive. Dobby may
be turned at the time of pick finding.

 WEFT INSERTION SYSTEM


 The key to the machine is the gripper projectile. In the
picking position it takes over the thread drawn from the
supply package. After picking, it carries the thread into the
shed and is braked upon entering the receiving unit.

 The thread is now taken over by the projectile feeder, held


by the selvedge grippers, cut by the scissors, released
from the projectile and beaten up to the cloth.

 The tucking needles then tuck in the thread ends, forming


firm tucked-in selvedges.

 Finally, the projectiles is ejected from the receiving unit and


taken back to the picking position by conveyer.

 The projectiles are accelerated by a torsion bar. This is


tensioned, storing the energy needed for a flight through
the shed. Following the release of a lock, it accelerates the
projectile smoothly and resumes its initial position at once.

 The flight velocity of the projectile is determined by the


torsion angle of the bar and can therefore be matched
Page 31

without problems to the working width, machine speed and


weft yarn.

 During its flight through the shed the projectile glides in a


rake - like guide, so that the warp threads are not touched
either by the projectile or the weft thread.

 BEAT – UP MECHANISM
Page 32

A double cam assembly is mounted on the main shaft.


Both cams are working counter to each other.

A rocker is resting on cam with anti friction bowl. This is


fasten to sley sword. Sley sword keeps the reed support for
final beat-up.

The cams are so designed that they provide sufficient


dwell (220-250) for the traverse of projectile.

 Take - up Drive
Page 33

Take - up drive of Sulzer draw and winds the cloth


positively. Rate of take up can be adjusted by means or
change wheel. A combination of four wheels A,B,C,D is fitted
with a total of 12 change wheels it is possible to wheel weft
density of 36 to 910 threads/ 10cm and forward up to
1810picks/ 10cm by changing the worm gear.

 Let-Off Drive
Page 34

The purpose of the let- off drive is to pay out the warp
sheet through turning the warp sheet by warp beam and at
the same time keeping the tension on warp constant. The
whip roller plays as the control element. It adjusts its height to
the tension of the warp and control the let-off motion of let-off
drive coupling by means of a bar. As the winding diameter of
the warp beam decreases, the whip roller moves gradually
downwards. As a result of this, the let-off increases and is
matched automatically to the winding diameter of the drum
take-up.
Page 35

 PICK FINDING MECHANISM


When a pick is broken to find its position clutch is
brought to position third and hand wheel pull to out position
and two turns are given to it. Then it is brought to position
second and turn the hand wheel till the clutch returns to
position first. Thus dobby is turned on a pick back.

 Position 1: Clutch two is engaged.

 Position 2: Clutch two is disengaged. The clutch re


engages itself after the machine has been turned by one
pick.

 Position 3: Clutch two is disengaged.


Page 36

 LIGHTS SIGNALS

1) Blue light blinking: - Warp thread breakage.

2) Yellow light blinking: - Weft thread breakage.

3) Yellow and red light blinking: - Shut down via


emergency switch.

4) Yellow light: - Specified length of fabric attained.

5) Red light: - Mechanical fault.

6) Red light blinks when machine is in operation: -


Electronic projectile detector or weft detector shut off.

 SENSORS AND STOP MOTION

• Amount of yarn wound on winding head by altering the


position of photocell by the help of rotating screw arranged
with Rack-Pinion system

• Projectile sensor – It is a metallic sensor situated at the


receiving side and it senses that projectile is reaching at
correct angle or not.

• Let- off sensor – P7100 provides electronic let off. If


tension in warp sheet decreases the sensor senses it by
suitable arrangement and motor regulates warp sheet
accordingly.

• Weft sensor –To sense the presence and absence of weft


supply at receiving side.
Page 37

• Angle sensor- To stop the loom at correct angle at


particular degree.

• Warp stop motion- Electrical warp stop motion work


together with drop pin attachments.

A Study on Fabric Defects

1. Starting mark :

An isolated narrow bar running parallel with the picks,


starting abruptly & gradually shading away to normal cloth.
This is due to abrupt change in the pick spacing followed by
a gradual coming back to normal pick spacing.

Cause:

• Restarting wvg. M/c after pick finding.

• Reed (loom) stops ahead from the place where it


should stop (generally loom stops at 400),so that
sufficient moment is not generated during the next
pick beating and results in starting mark.

2. Weft Bar :

A bar due to difference in material, count, twist,


lusture or shade of the adjacent groups of weft yarns.

3. Reed Marks :

Irregular spacing between the groups of warp yarns


across the width of the fabric. The defect may be caused by
a damaged or defected reed, i.e. dent opened or gap is
more than normal between two dents.
Page 38

4. Missing ends / Ends out / Chira :

This most commonly characterized by a gap of one or


more warp end in the fabric.

The main causes are:-

• The weaver is careless, not mends broken ends


immediately.

• Missing ends in the beams.

• Any end not passed from the heald & reed i.e. not drawn &
remain missed.

5. Patti :

Take up roller jammed or move slowly in between the


regular process due to some mechanical fault than a thick
place or closer pick spacing results known as Patti or thick
bar.

6. Thin :

Due to some mechanical fault take up roller moves


little bit faster, gives a fault known as thin bar.

7. Double pick :

In plane weave if after loom stops due to pick


breaking, loom is not turned back to its initial position than
two pick are comes in the same shed, resulting the defect
named double pick.
Page 39

8. Design Cut :

If the above defect occurs in the dobby design, design


gets disturbed & defect is known as design cut.

Clean Fluffs & use thicker dobby card (250 Microns)


for Sulzer.

9. Temple mark :

Holes or surface disturbances along the selvedge of a


fabric due to bad or improperly adjusted temples.

• Cause: In temples ring are there of different size


according to cloth thickness if ring is not appropriate or
jammed or not working properly than results mark on
emerging out cloth.

Pin Pin type Diameter Application


length
1 mm Pointed 24 mm Spun yarn
1 mm Blunt 24 mm Woollen yarn
0.5 mm Pointed 24 mm Filament yarn ,
fine spun yarn

10. Slub :

Fly accumulated at drop pin or heald wire goes along


with the warp in the fabric create slub in the fabric, gives
defect in finishing if not removed.
Page 40

11. Wrong Weft Pattern :

Hole is not punched properly for weft colour selection


or some mechanical mistake is selection needle, result
something wrong weft to be inserted thus give defect
known as wrong weft pattern.

12. Pattern Break :

Shed not opened properly due to some mechanical


fault, gives pattern break.

13. Broken pattern :

This defect may be due to wrong drawing of threads,


inserting a pick in the wrong shed, incorrect lifting of warp
threads.

14. Cracks :

A narrow streak parallel to the weft due to the


pronounced opening between two adjacent yarns. Any loom
condition that permits erratic operation of the sley or yarn
of its parts will create cracks in the fabric.

A loosed-reed, that is, one that has excess freedom in


the sley, will also caused this defect. A take-up motion
which is sticking may produce cracks in the fabric.
Page 41

15. Floats stitches :

A place in the fabric where warp & weft yarns escape


the required interlacement.

• Main causes are :

Entanglement of warp threads due to delay in


repairing a broken end, knots with long tail ends, breakage
of wire healds on running loom, unsatisfactory working of
warp stop motion. With synthetic yarns, due to static
electricity generation, there is a tendency for the adjacent
ends to roll during weaving, this results floats or stitches
less opening of shed.

16. Stains :

Stains on the fabric are measure serious problems in


textile mills. Majority of the stains occur at loom shed only.
There are various kinds of stains.

e.g. oil, grease, rust, dirt, soil, carbon particles in air, sweat,
crayon, box mark etc.

Most of the stains can be traced back to poor material


handling, lack of care on the part of workers and poor oiling
and cleaning practices. Certain stains can be removed by
solvent but it involves additional cost.

17. Wrong warp pattern:

Wrong order of drawing the ends through the reed or


wrong order of drawing the ends through the healds.
Page 42

MENDING

• Introduction:
Totally fault free fabric cannot be manufactured
on the loom. They are some small or extra faults that occur in
fabric during manufacturing.
But some faults along these could be mendable .They can be
eliminated easily.

• View Of Mending:-

No of Mending Tables – 36
No of workers- 40

The particular fabric incoming from weaving department is firstly


stored in grey mending store. Each fabric piece carries with
there ‘PIECE TICKIT’ which is having various particulars about
fabric. According to date of delivery, fabric pieces are arranged
in sequence systematic manner.
Earlier fabric first took for mending. The fabric piece is
given to mender for mending with its piece ticket.

These are the following faults that will mend by the mending
department:

Broken end/ pick , missing end / pick, reed mark, floating ends,
pattern mistake, contamination, naps, slubs, knots, oily yarn etc.
Page 43

Material Handling of Weaving Shed

Transportation of weavers beam


• Manufacturer- Visco

A trolley which has a curved top so that the beam


does not roll off while being moved from one place to another.
A modern shed warp lifting device with healds is mounting
device has a capacity is used. Hydraulic lifting of heald is done
by foot paddle. Exact positioning of the heald. Shaft is done by
precise delivery system. After heald shaft being lowered, they
are disconnected automatically.

• Transportation of grey fabrics


Fabric should be doffed on a trolley which is then
pulled to the weavers beam trolley having capacity of 8 beams.
This type of trolley is suitable for the carrying up to 600 kg
load.
Page 44

TECHNICAL TROUBLE
SHOOTING

• Machine : SULZER-RUTI PROJECTILE WEAVING


MACHINE

Sr. PROBLEMS ENCOUNTERD CORRECTIVE MEASURES TAKEN


No
.

1. Broken or worn out Grinding or replacement

Projectile feeder

2. Projectile jaw Broken Replace

3. Barley liner worn out Replace

4. Projectile returner Replace

worn out

5. Conveyor jamming Proper cleaning


Page 45

6. Dobby

A) puller, broken Proper cleaning

Traction element & maintenance

B) needle broken or Change the broken element

Jamming

7. Projectile jamming in Proper setting

Picking unit
Page 46

PREVENTIVE MAINTENANCE
ACTIVITIES

Sr MATERIAL PROCEDURE FREQUENCY


.
No

1. PICKING UNIT

A. Projectile feeder, slide Remove parts , 15 days

B. Check selector Clean , and check oil


lubricating nozzle

C. R-h sliding pride


---------------
D. Feeder link do---------------------

E. Upper guide rail -----------------


do----------------------
F. Cover plate
----------------
G. Projectile feeder opener
do----------------------
H. Projectile feeder bar
---------------
I. Picking shoe do---------------------

J. Packing link ---------------


do---------------------
K. Pressure press spring &
thread guide tube ---------------
do---------------------
Page 47

---------------
do---------------------

---------------
RECEIVING UNIT
do---------------------
2. A. Projectile returner 15 days
---------------
do---------------------

B. Returner link

C. Front projectile break

D. Rear projectile break

E. Lower break lining Remove parts, clean, check


grease (white grease)
F. Projectile break cover
---------------
15 DAYS
do---------------------
3. Tucking unit
---------------
do--------------------- 15 days

Scissor & roller ---------------


4.
do---------------------

---------------
do---------------------

--------------- 15 days

Temples do---------------------
5.

Check nylon pins on the


telescope shift and grease

Remove parts clean


Page 48

Check for wear and dirt


(50dg)

Clearance to selvedge

OILING SCHEDULE FOR SULZER RUTI WVG


M/C

Sr. LUBRICATION LUBRICANT FREQUE PROCEDUR


POINT - E
No. USED
NCY

1. PICKING SIDE
A) projectile lifter Metanol - Twice a First clean
link 32 Day By air
Pressure
B)projectile opener Then apply
Link By nozzle

C) projectile feeder
selector link

D) scissor & roller


Page 49

E) projectile feeder
Selection bar

F)weft tensioner link


2.
RECEIVING SIDE
First clean
Twice a
A)front brake link Servo line Day By air
220 pressure
B) rear brake link Then apply
By nozzle
Ones in Spray by air
C) projectile returner Servo a day Pressure gun
Pride 30 Funnel &
Mug

3
6 month Manually
Dobby
Needles & puller Servoline
220
4 Manually
6 month
Sley drive, picking
unit, torsion rod Molybdenum
grease 105

5
3 month
Tension flange
Picking unit (lower White
Part) receiving unit Grease
Let off, take up, Ap-3
clutch
, shedding motion

6 At
Revision
Time
Emery wheel
Page 50

Receiving unit part,