2012

UPTTI KANPUR,VISIT OF MAHABIR SYNTEX

MANOJ KUMAR SONI UPTTTI,KANPUR 1/7/2012

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A VISIT TO SPINNING MILL

AN EFFORT OF DEPARTMENT OF TEXTILE ENGINEERING U.P.T.T.I. KANPUR

SPECIAL THANKS & SUBMITTED TO: 1. RESPECTED Mr. ARUN KUMAR GANGWAR SIR 2. RESPECTED DEAN Mr. MAHENDRA UTTAM SIR

SUBMITTED BY:
1. MANOJ KUMAR SONI 2. PRABHAKAR SINGH 3.NAVEEN DIXIT 4.RAMKRISHNA MAURYA 5.CHANDU PASWAAN TEXTILE ENGINEERING (B.TECH. IInd YEAR)

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TABLE OF CONTENT
YOUR REMARK IS VALUABLE FOR US

SR. NO.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

TOPIC
INTRODUCATION RAW MATERIAL POLYSTER MANUFACTURING PROCESS VISCOSE RAYON MANUFACTURING PROCESS CUPRAAMONIUM RAYON MANUFACTURING PROCESS TINTING OF MATERIAL BLOWROOM THE CARDING MACHINE DRAWFRAME SIMPLEX RINGFRAME WINDING PLYING PACKAGING & TRANSPORTATION MILL LAYOUT 5 5-6 5-6 7-9

PAGE NO.

REMARK

10-11 11-12 12-13 13-20 21-24 24-25 25-26 27-29 29-30 30-31

~4~ We start our visit at 7/1/2012 under the guidance of honorable general manger Mr. HARIKEASH CHAUDAHRY at MAHABIR SYNTEX, SAHJANVA .our object was to get the knowledge of the advance modern machinery used in modern textile yarn manufacturing. The mill contains the machinery for the blending of viscose rayon fibers with polyester fibers & then spins them to form best quality yarn. Generally the blend ratio is decided by the customer. But as far as quality concerned the blend ratio is taken which have following fractions in a sample of feed to carding machine Polyester fibers Viscose rayon Tint material Sliver waste 16.4kg 7.8kg 1.8 kg 0.7kg

The process contain following stages: 1. Tinting of material 2. Blow room (Opening of viscose rayon) 3. Carding (formation of sliver) 4. Barker draw frame 5. Finisher draw frame 6. Simplex/roving frame 7. Ringframe 8. Autoconer

RAW MATERIAL
POLYSTER: . 1. Polyester filament yarn (PFY) is a long chain or synthetic polymer composed of an ester of a substituted aromatic carboxylic acid such as terephthalicacid. Polyester filament yarns are manufactured in a wide range of deniers and properties to suit virtually all textile requirements.

~5~ 2. Polyester filament yarns are manufactured either from molten polymer or polyethylene terephthalic acid (PET) chips by melt spinning process. In this process molten polymer from a manifold is metered through various spinnerets, having number of holes, to form filaments. These filaments are then solidified by airquenching and wound on take-up winders after application of spin-finish. 3.The yarns manufactured could be UDY (un-drawn yarn), POY (partially oriented yarn) or FDY (fully drawn yarn)depending upon the winder speed and heat setting methods.PET is made by condensation of pure terephthalic acid (PTA) or a derivative such as di-methyl terephthalate (DMT), with Ethylene Glycol (EG). There action involved is direct esterification in case of PTA and trans-esterifi-cation in case of DMT, followed by polycondensation. The reaction is carried out in one or more reactors above atmospheric pressure and at elevated temperature. Excess glycol is used for carrying out the reaction, which is recovered during polycondensation and recycled. Proper control of temperature, pressure, time of reaction and vacuum is necessary for better quality of polymer and for this, different designs of reactors and new and better additives and catalysts are used .Out of the two alternative raw materials i.e. DMT and PTA, it is advantageous to use PTA as it gives 15% higher production and requires less investment in capital equipments; as well as requirement of glycol is lower. In case of DMT, methanol is generated as a byproduct, which is hazardous in nature and requires special plant and equipments. 4. During recent years, almost all new plants all over the world are being put-up with PTA as feedstock but due to availability, the use of DMT is still continuing though its percentage share as a feedstock for polyester is enormously declining.PET was earlier manufactured by batch process having a small capacity of1 to 2 TPD and without close control of process parameters. The spinning process used was based on grid-star melting, with poor control on performance, followed by winding of yarn at low speeds, yielding small packages. 5. over a period of time, developments have resulted into large size of batches and continuous polymerization process giving mass production. Sophisticated instruments and computer controls are used for monitoring.

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VISCOSE RAYON
It is a regenerated cellulosic fiber and cellulose is the raw material for producing this manmade fiber. The raw material is obtained from a special variety of wood called spruce. MANUFACTURING PROCESS 1. PURIFICATION OF CELLULOSE: The manufacture of viscose rayon starts with the purification of cellulose. Spruce trees are cut into timber. Their barks are removed and cut into pieces measuring 7/8" x 1/2" x 1/4". These pieces are treated with a solution of calcium bisulphate and cooked with steam under pressure for about 14 hours. The cellulosic component of the wood is unaffected by this treatment, but the cementing material called lignin, which is present in the wood, is converted into its sulphonated compound which is soluble in water. This can be washed off, thereby purifying the remaining cellulose. This cellulose is treated with excess of water. After this it is treated with a bleaching agent (sod hypochlorite) and finally converted into paper boards or sheets. This is called WOOD PULP, which is normally purchased by the manufacturers of viscose rayon. 2. CONDITIONING OF WOOD PULP: The pulp sheets are cut by a guillotine to the required dimension and are kept in a special room. Air moves freely among the divisors by means of ventilators, the

~7~ temperature is maintained at 30 deg Celsius. In this way the desired moisture content can be had. 3. STEEPING PROCESS: The conditioned wood pulp sheets are treated with caustic soda solution (about 17.5%). It is called mercerizing or steeping. The high DP cellulose (1000) is converted into soda cellulose. The sheets are allowed to soak (steep0 until they become dark brown in colour. This takes about 1-14 hours. The caustic soda solution is drained off and sheets are pressed to squeeze out excess caustic soda solution. 100 kg of sulphite pulp gives about 310 kg of soda cellulose. 4. SHERREDING &CUTTING PROCESS: The wet, soft sheets of soda cellulose are passed through a shredding machine which cuts them into small bits. In 2-3 hours the sheets are broken into fine crumbs. 5. AGEING PROCESS: To obtain almost ideal solution of cellulose, the soda cellulose is stored in small galvanised drums for about 48 hours at 28 deg C. This process is called ageing process.The ageing process is essential. During This process, the DP od soda cellulose is decreased from 1000 to about 300 by oxygen present in the air, contained in the drum. 6. CHURNING PROCESS OR XANTHATION: After ageing, the crumbs of soda cellulose are transferred to rotating, air tight, hexagonal churners or mixers. Carbon disulphide (10% of the weight of the crumbs) is added to the mixer and churned together for 3 hours by rotating the mixers at a slow speed of 2 rev per minutes. Sodium cellulose xanthate is formed during this process and the colors of the product changes from white to reddish orange. 7. MIXING OR DESSOLVING PROCESS The orange product i.e. sodium cellulose xanthate is in the form of small balls. These fall into a mixer called discover which is provided with a stirrer. A dilute solution of caustic soda is added, and the contents are stirred for 4-5 hours and at

~8~ the same time, the dissolver is cooled. The sodium cellulose xanthate Dissolves to give clear brown thick liquor, similar to honey. This is called 'viscose' and it contains about 6.5% caustic soda and 7.5% cellulose. 8. RIPENING PROCESS This viscose solution requires to be ripened to give a solution having best spinning qualities. Ripening is carried by storing the viscose solution for 4-5 days at 10 to 18 degree. The viscosity of the solution first decreases and then rises to its original value. The ripened solution is filtered carefully and is now ready for spinning to produce viscose rayon filaments. 9. SPINNING PROCESS The viscose solution is forced through a spinnerette, having many fine holes ( 0.05-0.1mm) diameter. The spinnerette is submerged into a solution containing the following chemicals. 10% --> sulphuric acid, 18%- Sod sulphate, 1% - Zinc sulphate, 2% glucose, 69% water. The spinning solution is kept at 40-45 deg Celsius. Sodium sulphate precipitates the dissolved sod. Cell.xanthate. Sulphuric Acid converts xanthate into cellulose, carbon disulphide and sod. Sulphate. The glucose is supposed to give softness and pliability to the filaments whereas zinc sulphate gives added strength. The quality of viscose rayon filament formed depends upon: 1. The temperature of the spinning bath 2. The composition of the spinning bath. 3. The speed of coagulation 4. The period of immersion of the filament in the spinning bath. 5. The speed of spinning. 6. The stretch imparted to the filaments. As a number of filaments emerge from the spinnerets, they are taken together to an eye at the surface of the spinning bath and then guided to two rollers from where they are wound on to a spindle.

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MANUFACTURING PROCESS OF CUPRAMMONIUM RAYON Cuprammonium Rayon

Like Viscose Rayon, cuprammonium rayon is also a regenerated cellulose fiber. Cotton linters are used as the source of cellulose for this rayon. Ammonical copper oxide solution is also known as cuprammonium hydroxide solution. Cuprammonium hydroxide solution is a solvent for cellulose. When a solution of cellulose in cuprammonium hydroxide is diluted with water or treated with dilute sulphuric acid, the cellulose is regenerated or reprecipitated. By using spinnerets, filaments of this regenerated cellulose can be produced. MANUFACTURE OF CUPRAAMMONIUM RAYON The source of cellulose for this rayon is cotton linters; the purification of cotton linters is carried out in two stages: a. Mechanical Treatment b. Chemical Treatment a.) MECHANICAL TREATMENT The cotton linters are transported in bales in highly compressed state and the object of the mechanical treatment is to loosen them and to remove mechanically admixed and loosely bound impurities such as dust sand, seed residues etc. b.) CHEMICAL TREATMENT The mechanically opened and purified cotton linters are boiled under pressure for several hours with dilute soda ash (Na2Co3) solution (2%) to which a little amount of caustic soda may be added. The natural fatty matter present in the cotton is converted into soluble substance by the action of soda ash and thus removed from cotton linters.

~ 10 ~ DISSOLUTION OF CELLULOSE In this, a solution of hydrated copper sulphate in 300-400 liters of water is introduced in a vessel at ordinary temperature with stirring. Some sugar is also added followed by caustic soda solution to form copper hydroxide. Ground linters suspended in water are added to the above mixture to form copper cellulose. The copper cellulose is filtered to remove the liquid, well ground and dissolved in a solution of ammonia in water. SPINNING SOLUTION By adding certain compounds to the cuprammonium cellulose solution, the solution is made more suitable for spinning. These compounds include glycerine, glucose, tartaric acid, citric acid, oxalic acid, can sugar etc. STRETCH SPINNING In the spinning process, the cuprammonium cellulose solution is discharged through nozzles (spinnerette) into a solution of sulphuric acid in the form of relatively thick threads which are subsequently pulled (stretched) to very fine filaments.

TINTING OF MATERIAL
Tinting is a process of applying temprerory color in the polyester fibers. CAUSES: 1. It gives the facility to differentiate the tufts of different qualities. 2. At the time of spinning we can keep watch the material of different count. 3. It is a temporary color so does not harm the fiber &easily can be remove after the processing of the yarn with water. In this step we add some amount of the oil which protects fibers from frication. PROCESS: In this process we used the hall rooms for the tint first the tint material are apply on the tufts in haphazard manner. & then it is taken into a room for the

SPRAY=(L.V.40 oil+water*(1.5% of wt. of polyster)/70)

~ 11 ~ spraying of the tint overall the material. The tint material contains the following materials.

BIN TINTING OF VISCOSE RAYON Then put the material in the free environment of mill.

BLOW ROOM
THE PROPER BALE LAYDOWN
1. COORDINATION WITH FIBRE PROPERTIES: More variables in raw stock means more bales needed to lay down must decide which variables have the greatest influence in yarn manufacturing. 2.COORDINATION WITH FIBRE INVENTRY: Lay down should be a "mini representation of the warehouse inventory. Lay down should be as consistent as possible from day-to-day, week-to-week, and month-to-month.

~ 12 ~ The mill contain the blow room line having only one beating point for the opening of the viscose rayon bales into smaller tufts .the blow room is of the Laxmi Rietar first of all we make opening of viscose rayon bale called layering process .& than mix them with polyester flocks in another machine called toppling process .

VISCOSE RAYON

LAYERING

TOPPLING

*Beater speed=630 rpm

*LAYEARING OF VISCOSE

The blow room is fully automatic & can be controlled by inbuilt computer able to give all information about production, speed, power consumption etc. From blow room material is passed to the caring machine pneumatically.

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CARDING

LAYOUT OF BLOWROOM & CARDING

Carding is the process in which sliver is formed from lap by carding m/c. Carding may be defined as the reduction of an entangled mass of fibers to a filmy web working two closely spaced, relatively moving surface clothed with sharp wire points. The carding is the heart of the spinning mill.

OBJECTS OF CARDING
1. OPENING TO INDIVIDUAL FIBRE: The blow room only opens the raw material to flocks where as the card opens it to the stage of individual fibers. 2. ELIMINATION OF IMPURITY & DUST: Elimination of foreign matter occurs mainly licker-in or taker-in region. The card also removes a large proportion of micro-particles. 3. ELIMINATION OF SHORT FIBRES: Short fibers can only be eliminated if they are pressed into the wire points.

~ 14 ~ 4. DISENTANGLING OF NEPS: The card reduces the number of neps from the Blow room. Actually neps are not eliminated at the card, intact they are mostly opened out. 5. FIBRE BLENDING: Intimate fiber with fiber mixing is achieved in carding. 6. FIBER ORIENTATION: The card is often attributed effect of parallelizing. 7. SLIVER FORMATION: Sliver is formed in carding as an intermediate product. Generally, the card sliver hank lies between 4 ktex to 5.5 kilotex.

DIFFERENT ACTION IN CARDING

1. CARDING ACTION When two close surfaces have opposite wire direction and their speed Direction or relative motion is also opposite. Then the action between two surfaces is called carding action. FUNCATION: It is occurred between flats and cylinder. 1. Maximum individualization of fibers is achieved in this region. 2. Naps short fibers dirt and dust are removed by this action. 3. There always should be point against point action. 2. STRIPPING ACTION When two close surfaces have same wire direction and their speed direction or Relative motion is opposite then the action between two surfaces is called stripping action.

~ 15 ~ OBJECT 1. It is occurred between licker in and cylinder. 2. There are should be point against back action. 3. Individualization of fiber is also by this action. 3. DOFFING ACTION When two close surfaces have opposite wire direction and their speed direction or relative mot6ion is also opposite then the action between two is called doffing action. OBJECT 1. It is occurred between cylinder and doffer. 2. Web formation is accrued by this action. 3. There always should be point against point action.

Picture of Carding machine

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FIBRE TO FIBRE SEPRATION IN CARDING

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THE CARDING MACHINE

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INTERNAL DIGRAM (carding)

TECHNICAL SPECIFICATION: OWN COMPANY:LAXMI RETEIR SPEED:150-160rpm PRODUCATION: 149meter/min,can contain 4500m sliver COUNT: 4ktex-5.5ktex

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DRAWFRAME
Drawing is a process of yarn manufacturing in which the sliver is elongated when passing through pairs of rollers, each pair faster than the previous one.

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PICTURES OF DRAWFRAME MACHINE

~ 22 ~ OBJECTS OF DRAWING: To straighten the fibers in the slivers. To make them lie is a parallel to their neighbors and to the sliver axis. To improve the uniformity and evenness of the slivers. To reduce weight per unit length of sliver. To remove dust from sliver. To make perfect blending of the sliver. To reduce ir-regulations of fiber by doubling and drafting. Necessity of draw frame: To parallisation of fiber and blending carded-carded sliver. In carded sliver, fiber present in hook form i.e. trailing hooks and leading hooks. Tasks of draw frame: Equalizing Parallelizing Blending Dust removal Actions involved in draw frame 1. Drafting: The process of attenuating or increasing length per unit weight of sliver. It is mainly due to peripheral speed the rollers. 2. Doubling: The process of combing two or more carded sliver into a single form is called doubling. In generally six slivers are fed and converted into one i.e. six doubling. 3. Drawing: In the cotton industry, the term is applied exclusively to processing on the draw frame, where he operational is one of doubling and drafting.

Drawing = Drafting + Doubling

~ 23 ~ Draw frame is carried out by two processes. One is called breaker draw frame and another is finisher draw frame. In breaker draw frame, 8 or 6 doubling is done. In finisher draw frame finer sliver is produced.

ROVING FRAME (SIMPLEX)

The sliver form after the drawing have non-uniformity in the diameter Hence for providing the sliver uniformity we give it and to decrease the diameter For this we pass the sliver through the feed controlled roller & than wind it precisionally on the bobbin the platform contain the bobbin is moving upward & downward motion for traverse & the yarn is winding at a higher speed .since the feed is regulated hence the sliver is gone winded with a little twist &diameter gone decreases drafting also occurs with uniformity .due to high speed of rotation we also called is speed frame .The final product for is roving . at this stage the count of the yarn got increases .The finer roving is produced collected on the mule cop .

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SPEED FRAME INTERNAL DIGRAM From here the roving is passing to the ring frame.

RING FRAME
We got final package in this step. The package form is delivered to the Winding process. The roving is used as input material. & we provide further twist &drawing in this process to get final yarn. The cloth wrapped roller is used to remove hairyness.

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RING SPINNING

The product obtained is collected in the mule cop or the bobbin & used as a supply package for the autoconar 5 machine for error & fault remover.

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WINDING
After the ring spinning the package form is unable to use at the loom directly due to some faults (thick places, thin places, neps) & not required package density for this reason we used a winding machine in this mill we used autoconer 5 of shalfrost Germany. This process we use surface winding having drum speed 1600 rpm. The bobbin get from the ring spinning is set into the automatic feeder magazine by the worker as the bobbin got empty the next bobbin takes it place. This has following features: 1. PROPACK SYSTEM: This system stops the formation of ribbon .for this it calculate the surface speed & diameter ratio of drum & package as the value reaches to the critical condition than servo motor operating on the principle of the frequency change ,have change its speed by the signal of the computer attach with the machine. 2. CLASSIMATE FAULT REMOVER: CLASSIMATE FAULTS are the faults in the yarn manufacture by the ring spinning process which are undesirable .such as thick places, thin places, neps etc .the yarn is passed through the optical arrangement & the system cut down the faulted portion within 5 seconds splicer splice the both ends & winding again started. 3. KZ-AUTOMATIC AIR SPLICER9606: It was invented by the MURATA TECH., JAPAN .This splicer is very suitable for this process. The yarn got fault is cut & cleared automatically by the knifes, machine stops winding& within 5 seconds splicing operation got done. & machine again started winding. 4. OHTC (over head trash cleaner): It is the two parallel hollow rods passing the hot air on the winding machine & traversing throughout the machine. This keep the machine clean & dust free & free from protruding fibre.

~ 27 ~ 5. AUTO DOFFER: when the package become of desirable weight than the auto doffer system collect it in a bin & transfer to the packaging area automatically. In the winding process package density is depend upon the wind angle. More the wind angle less the package density, Hence a desirable package is Produced which is the end product of the company if plying is not required .if plying is required than the TFO is used.

AUTOMATIC AIR SPLICER

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AUTOMATIC DOFFER

AUTOMATIC FEEDER MAGAZINE

PLYING
Plying is the process use to twist two yarns to give them suitable strength. For plying we use TEXPRO TFO machine it is not fully automatic feed manually the yarn packages are feed on the & the twisted resultant count yarn is obtained. This is again wind & sends to the packaging department.

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TEXPRO TFO MACHINE

PACKAGING
The yarn packages of different counts are taken to the packaging area where the packages of different counts are taken having a certain area for specific count yarn. The package weight by the electronic weighing scale. Pack them in the bags. Now bag is also weight. The weight should be appropriate according to count. The consumer buy the product according to weight .so the package used paper cheese or paper cone having weight of 40 grams maximum. These bags are transported to the next mill

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FINAL PRODUCT
The above shown bag contains 24 cones each of 3 kg having blend of 65% polyester & 35% viscose rayon. Total weight with cone is 73 kg. Without cone package (yarn) weight 72 kg. & count 40s Ne with single ply.

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