21. CHAPTER - 21 Safety in Textile Industry

8/19/2019 21. CHAPTER - 21 Safety in Textile Industry

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CHAPTER - 21

Safety in Textile Industry

1. Need of Safety in Textile Industry 2. Types of Textile Industry 3. Statutory Provisions :

3.1 General3.2 Health Provisions3.3 Safety Provisions3.4 elfare Provisions3.! "otton Ginnin# $ Pressin#

%a&tories '&t $ (ules4. Indian Standards!. %lo)&harts of Textile Pro&esses :

!.1 "o*posite %lo)&hart !.2 +ther %lo)&hartsShort $ lon# Staple, -is&ose

rayon,Syntheti& /re, Spun $

%ila*ent0arn, ute

. Haards and Safety Pre&autions ofSpinnin# Preparatory and Spinnin#Pro&esses :.1 +penin# and lo) (oo*

5a&hines

.2 "ardin# 5a&hines.3 Sliver and (i//on 6ap5a&hines

.4 "o*/ers and 7ra)in# %ra*es.! (ovin# 8Speed9 %ra*es

. (in# 8Spinnin#9 %ra*es. 7ou/lin# 5a&hines.; (otor Spinnin#

. Haards and Safety Pre&autions ofeavin# Preparatory and eavin#Pro&esses :

.1 indin# 5a&hines.2 arpin# 5a&hines.3 Siin# 5a&hines.4 6oo*s

;. Haards and Safety Pre&autions of

Pro&essin# 8%inishin#9 and%oldin# 5a&hines :;.1 General Pre&autions;.2 lea&hin# Pro&ess;.3 Pro&essin# 5a&hines 87yein#,

Printin# et&.9.2 Health Haards in +ther TextileIndustry 11. =?uent Treat*ent and aste 7isposal

in Textile Industry

1 NEED OF SAFETY INTETI!E IND"STRY

Clothing is the basic need for all of usand with the modernisation a want of

more and more attractive (durable,shining, anti-crease and colourful) fabricsis increasing day by day. Therefore thefoundation of textile industry is very old,ever changing and ever lasting. Thecontinuous blow room line, replacementof mule spinning by ring spinning, rotorspinning, high speed shuttle-less andworkerless looms and computerisedprocessing machinery has rapidlychanged the structure of textile industryand the mills not following such

modernisation and automation are

becoming sick in market competition. etit is a fact that the old textile machinesare still in use in some mills. !rom safetypoint of view, such old and poorlyguarded (and without built-in safety)machinery needs more attention.

"ndian textile industry is the oldestone in the world. Cotton was inventedand planted by #$ruts%ad& #ushi some$%,%%% years ago. arn and threads weremanufactured by hands and cloth waswoven by hand looms. & reference ispublished that a ginning machine made in"ndia was sent to 'ngland. hakas*%al%al& (the thinnest and lightest cloth)was famous. +ritish rulers cut o thepalms and ngers of "ndian weavers sothat they cannot compete with cloth from'ngland. yeing by natural colours was

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THEME


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also in use. ld "ndian garments werewhite and colourful.

The textile mills established during/0th century in 1ancashire and in 2ew'ngland initiated the "ndustrial #evolutionand their cotton fabrics dominated theworld markets for many years. "ndian

textile mill industry is also as old as therst "ndian !actories &ct /33/ and 4u5aratis still leading in textile industries. 6anmade synthetic bres such as polyamidesand polyester are now blended withcotton and a trend of such articialfabrics is increasing.

"n /070 there were /07$3 cottontextile factories working with //87%%%workers and 9$88 wool, silk and syntheticbre factories working with /70%%%workers out of total /9:/79 workingfactories with total workers ;707%%% in"ndia. This gives /%.99< textile (cottonand others) factories and /0.:%< textileworkers.

"n /000 estimated re#istered textilefactories in "ndia and 4u5arat were=/;%%% and 8%%% respectively. >imilarlyestimated textile workers in "ndia and4u5arat were =/8 lakhs and 9.% lakhsrespectively.

Table :./; of Chapter-: gives

following gures of textile factories in4u5arat as on 9%-;-/003.

NIC C'de ('r)in*Fa+t'ries

A,era*e('r)ers

$9 //3/ /$%:$7$8 /7:8 300:%$: /; :%:$; $00 /8338

T'tal 2./ 22.0

This indicates there was /;.89


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accidentsue tounsafeconditions

/9:(83


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and other safety conditions need muchattention. The latest design of textilemachinery having built-in safety, dustsuction device and computer controls haseliminated many haHards of oldmachinery.

2 TYPES OF TETI!EIND"STRY

Cotton being the natural and oldproduct, light, easily compressible,transportable and most suitable forhuman body (particularly for hot days),cotton textile is pioneering and oldestindustry. +ut with inventions of newbres, natural and synthetic, it has, now,become a mixed industry. The industry

includes the spinning, weaving, knittingand nishing of all types of natural,synthetic and articial bres. Themachines vary from handlooms of cottageindustry to very expensive and intricatemodern machines. >ome are onlyspinning mills, weaving units or dyeingand nishing houses while some arecomposite textile mills carrying out alloperations at one place.

& classication of various types of thebres is as follows @

Fi7res

Natural Fi7res

Jegetable rigin

Cotton, !rom >eeds !ruit,Eapok, Coir

Kute, !rom +ast, !lex, Gemp,

#amile, >isal

!rom 1eaf

Ani%al Ori*in

Fool, alpaca, mohair, goat,camel hair

>ilk other lament

8ineral Ori*in

&sbestos

&mphiboles, &ctinolite, &mosite,&nthophyllite, Crocidolite,

Tremolite, >erpentine, Chrysotile

Follastonite

Leolite, >epiolite, &ttapulgite

8an%ade Fi7res

&rticial !ibres (2atural Bolymer)

Jiscose rayon (articial silk)

Cupra rayon, !ilament and

>taple bre

Cellulose ester

Cellulose acetate, Cellulosetriacetate

Brotein bres from milk,seaweed, maiHe-soya ground-nuts

$lass 9 C6e%i+al :7res

4lass bres made from borosilicateor calcio alumina silicate glass(4lass wool)

>ynthetic !ibres (Betrochemicalrigin)Bolyamides (2ylon), BolyestersBolyolens (Courlene),BolypropylenesBolyurethanes (>pendex bres)

Bolyvinyl derivatives (&crylic !ibres)

Bolyacrylonitrile, Bolyvinyl chloride,Bolyvinylidene chloride,Bolyvinyl alcohol,BolytetraIuoro ethylene relatedpolymers (TeIon),Bolyvinylidene dinitrile, Bolystyreneand 6iscellaneous.

&ll these bres are used for variouspurposes such as garments, protective

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/. &rticial humidication is not allowedin spinning or weaving factory whenroom temperature exceeds $0.:%C(3:%!) or when wet bulb reading of thehygrometer is higher than thatspecied in the schedule uMr /0 inrelation to the dry bulb reading of the

hygrometer at that time.$. Brovision of hygrometer.9. Copy of schedule uMr /0 to be a?xed

near every hygrometer.8. Temperature to be recorded in

humidity register (!orm 2o.;) at eachhygrometer.

:. >pecications of hygrometer.;. Thermometer to be maintained in

e?cient order.7. "naccurate thermometer not to be

used without fresh certicate.3. Gygrometer not to be a?xed to wall

etc. unless protected by wood.0. 2o reading to be taken within /:

minutes of renewal of water./%. 6ethod of introducing steam for

humidication (pipe dia O $.: cm ,pressure O : EgMcm$ , 5et pro5ection O//.: cm , insulation thickness P /9mm.)

yssi'n'sis is included in the third

schedule of the &ct as an occupationaldisease due to +'tt'n dust exposures toworkers. "t is reportable uMs 30. !or detailssee Bart /% of this chapter.

!or monitoring and control of *cottondust (T1J ), new schedule $7 is uMr/%$ is added in 4!# vide 2oticationdated . "t reAuires Q

B Add

/.$.

9.8.

ection $/ regarding general machineguarding is application to all textilemachines.

>ection $7 prohibits employment of woman or child in a cotton press roomwhere a cotton opener works. "f feed-end

of a cotton-opener is separated by full

partition, they can be employed on feed-end side. This is due to the risk of moreIying cotton dust on delivery side and hit-in5ury when any revolving beater breaksor any solid material is thrown out ondelivery side.

Goist, lift and lifting machine

provisions are applicable to thosemachines. >ection 9% on revolvingmachinery is applicable to hydroextractorto remove water from wet fabric. The topcover of the revolving basket should beinterlocked and safe working peripheralspeed should not be exceeded.

>ection 9/ and rule ;/ are mostimportant for all pressure vessels to beused in a textile industry. Ket dyeing orbeam dyeing vessels, ager, kier, drumwashers, cooking-pans, drying cylinders,drying range, siHing cylinders, air receivertanks etc. are all sub5ect of this provision.

Their design, construction, use andmaintenance must be safe. They must betested by a competent personperiodically. Their safety devices likesafety valve, pressure gauge, stop valve,drain valve and B#J or pressure regulatormust be provided and maintained in asafe working condition. >team traps andvacuum breakers are also essential.

Brecautions against toxic orIammable gas and re are alsoapplicable to textile processes usingsolvent (eg. blancket cleaning) and cottongodowns.

>chedules " "" for detailed machineguarding uMr :8 are summarised in Bart:.8 of Chapter /8.

Rule 0C@ $FR, provides followingsafety precautions for P'ly%erisin* andCurin* 8a+6ines @

/. Brinted fabrics shall be thoroughlydried before feeding to such machines(to allow less solvent in the mMc).

$. $M9 portion of the exhaust damperMIapshould always be open.

9. "nfrared ray heaters shall be cut o while running the prints.

8. 'lectrical heater should have separatecircuit and switch to isolate it at thetime of emergency.

:. 1eakage of solvent should not come in

contact with the heaters.

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;. 'xhaust fan drive should beinterlocked with main drive of themachine so that when exhaust motorstops, the machine (with heatingdevice) should also stop. ('xhaust fanshould start rst before the fabricmoves into the chamber).

7. Thermostat to regulate thetemperature of the heater, notallowing it to go beyond the presetvalue.

3. 'xplosion Iaps to be provided at top tolet o the fumes in case of explosion.

0. !ilter gauge and exhaust duct shouldbe cleaned weekly. Jee-belt tensionshould be checked weekly.

/%. Trained supervisor to examine themachine. & register to be maintainedto enter all checks.

Fhen t6er%i+ ?uid 6eaters are usedto circulate hot oil instead of steam intextile machines (eg. stenter for clothdrying) rule ;3, 4!#, is applicable. >eepart /% of Chapter-/3 for details.

#ule ;3', reAuires suitable ladders,crawling board and work permit toprevent fall from fragile roofs.

#ule /%$, >ch. $9 reAuires earprotection for noise level above 0% d+&,

and auditory examination every year.Feavers are mostly exposed to highnoise. >ch. $7 reAuires protection fromcotton dust.

8an-%ade Fi7re Cellul'si+ andn'n-+ellul'si+ industry is listed in the!irst >chedule of the &ct as a haHardousindustry. Therefore while manufacturingsuch synthetic bre, Chapter 8& of the&ct and rules ;3E to 2, B and R of the4u5arat !actories #ules are applicable.

These provisions may be referred in

statute books for details. Then >chedule/0 uMr /%$ also becomes applicable forchemical work. >chedule /$ uMr /%$ isapplicable where acids or alkalis are used.

ections 8$ to :%) of the!actories &ct is fully applicable to textilefactory. Fashing facilities, rst-aidappliances, canteen, lunch room and rest

room, crSche and welfare o?cers are

reAuired depending on number of workersemployed.

#ules ;3# to F of the 4u5arat!actories #ules regarding health records,Aualied supervisors, medicalexamination, occupational health centre,ambulance van and safety showers are

applicable to haHardous processes inman-made bre textile industry.


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for ring doubling and twisting frames7;/8, woven fabrics testing 0, $077,70%9, /%/%%, yarn acetate and rayonlament /$$0, blended 73;;, polyesterand polyamide 77%9, 73;7, cotton countdetermination $97, cotton winding cones8333, twist determination 39$, linear

density determination /$$;, textileconditioning ;9:0.

Cotton handloom colour fastness;0%;, residual chlorine $9:%, scouringloss determination /939.

yes fastness /;33, !ibres, methodsof identication ;;7, Iammability andIame resistance test //37/, waterAuality tolerances $%/, textile itemsmade up, glossary /8$3/, processingglossary 0;%9, testing handbook >B@/:,textile terms - wool and animal bres//$%;, mmf /9$8, natural bre $9$,woven fabrics $9;8, textile belting /30/,Ioor coverings, Iame resistance /$7$$,asbestos yarn /99;$, electrical insulationand plastic laminate /9/$3.

. F!O(CHARTS OFTETI!E PROCESSES

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Cotton (with seeds) from agriculture↓

4inning machines (removal of seeds) ↑

↓

Bress (gives bales) 4inning-pressing process↓ ↓

CottonMman-made bre bales ↑

↓

pening, mixing and blow-room machinery (gives lap)↓ >pinning Breparatory Brocess

Carding machines (gives sliver)↓

raw frames (precomb), superlap machine, combers, drawframes (post comb), Iy or roving frames (gives rove yarn),interframes ↓

↓ ↑

#ing frames (gives ne twisted yarn)↓ >pinning Brocess

oubling frames (twisting of double yarns)

↓↓ ↑

Finding machines (give cheese or cone of yarn )↓

Farping machine(gives warpers beam)

Birn winding machine (givespirn, weft for shuttle)

Feaving BreparatoryBrocess

↓>iHing machine (gives siHed warp andweavers beam)

>iHingprocess

↓ (>tarchapplication)

raw frames (gives drawn warp)

↓ ↓

1ooms (give grey cloth) Feaving Brocess

↓ ↑

>hearing >ingeing (gives singed cloth)↓

+leaching (gives bleached cloth)↓

yeing (gives dyed cloth) yeing process↓

Brinting Brinting process !inishing BrocessBolymerising (gives printed cloth) (Brocessing ept.)

↓

>anforiHing (gives sanforiHed cloth) ↓↓ ↑

!oldingMplaiting !olding ept. Cloth 4odown

↓

Cloth bales (fabrics) ↓

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&bove Iowchart is self-explanatory,yet some main processes are explainedbelow @

$innin* @ The bres and the cottonseeds are separated by *gin machines ina ginning factory.

Pressin* 9 alin* @ The ginnedcotton is compressed and packed intobales by cotton presses (mostlyhydraulic) in a pressing factory. 4enerallyginning and pressing factories arecombined and situated in villages wherecotton is collected. The cotton bales aretransported to a spinning mill or acomposite textile mill. The cotton-seedsare separately collected. They are used toextract oil therefrom and also for cattle-food.

>chedule-$, rule :8, 4!# is applicableto ginning and pressing factories while>ch-/ is applicable to following processes.

ale Oenin* and S+ut+6in*@ "n ablow room the bales are opened by baleopeners, sometimes tinted in a tintingroom for Auality separation and mixedwith cotton from other bales or man-made bres through a hopper feeder. +ya moving spiked lattice, beaters and aseries of rolls the bres are thoroughly

mixed, cleaned and further opened byrevolving beaters and air currents againsta grid through which the dirt is separated.& cotton lap is formed and lap-rolls aresent to the carding machines

Cardin* @ The bres are madeparallel to each other, remaining hardtus are broken and short thin bres andimpurities are removed. & sliver (Iatuntwisted rope) is formed and it iscollected in cans.

Sinnin* @ Through pre-comb

drawing frames, sliver lap machines,comber machines, drawing frames andinter frames the sliver is converted intointer-end by drawing, drafting, combingand twisting processes. 6ore slivers arepassed through pairs of suitably spacedrollers, each pair revolving at a higherspeed than the preceding pair. !urtherattenuation of the yarn is accompaniedby ring frames and doubling frames. "nterroving ends are converted into yarn of

reAuired count by drafting and twisting inthe ring frame machines. & new method

known as open-end or rotor spinning ismost suitable for spinning coarse yarnsand can replace not only the ring framebut some other initial processes as well.Texturisin* is done to synthetic yarn toreduce its denier.

(ea,in* Prearat'ry @ "n windingdepartment yarn defect is removed andcheese and beam (by warping machine)are produced. Birn bobbins are lled toput them in shuttles. arn singeing iscarried out to burn o the pro5ected bres(hairs). >iHing (starch) process is carriedout in siHing machines.

(ea,in* @ &fter the weavingpreparatory processes, the warp threads(beams) and weft threads (pirn bobbins)are fed to looms to weave cloth. Jarioustypes of looms are used. 2ew alternationsto the shuttle for weft insertion are -rapier, water 5et, air 5et and ripple orwave shedding. The cloth is sent to thegrey folding department for cleaning,mending, inspection and folding (plaiting)purposes.

&rticial humidication is employed incarding, spinning and weavingdepartments to reduce yarn breakage,because moist thread has relatively

higher breaking strength than a drythread. +ut high humidity causesdiscomfort. Therefore its regulation isreAuired by hygrometers and by rules /0to $0 under the 4!#.

Finis6in* Pr'+esses @ Gere shearing- cropping, cloth singeing, piling,mercerising, drying, washing, desiHing(removing starch by enHymes solution),scouring (removing fats and waxes byhydroxide solution), bleaching (by G$$ orCl$), dyeing (wide range of dyes

available) and printing (screen ormulticolour rotary printing) processes arecarried out in seAuence. The dyed orprinted cloth is dried, smoothed andpressed. "t may also be sub5ected to othertreatments to improve its appearance orwearing Aualities. "t may be madewaterproof, Iame repellent or rotproof.>ynthetic resins are used for thesepurposes. The nished cloth (fabric) issent to nish folding department, for

checking, sample cutting, folding andbaling purposes.


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2ow we shall see the Iowcharts of dierent types of fabrics.

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Combing(with parallelism of the bres and removal of

short bres)

rawing and doubling(several stages with parallelism of the bres,

removal of short bres and roving attenuation)↓ ↓

rawing and doubling (several stages to eectmixing and further parallelism of the bres and

roving attenuation)

>pinning into coarse and medium-ne yarns

↓

>pinning into ne cotton yarns by mule or ring machines and nally winding as cops or on bobbins

Fi* 21orting, selection and blending to suit type of yarn reAuired

pening-out and loosening of bre packages

>couring to remove grease and suint (sheeps dried perspiration)

and carbonisation (if necessary) to remove cellulose impurities

(in roving form)

(in lap form)

(in sliver form) (in sliver form)

(in roving form)


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Carding

+ackwashing (scouring) Condensing

4illing >pinning on mule

machine into )oollen

+ackwashing yarn

4illing

Combing

4illing

Fool tops

rawing and doubling

(several stages)

>pinning by Iyer, cap,ring or mule machine

into )orsted yarn

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FarpingRuilling

>lashing

Feaving

↓ !inishing

"nspection ↑ 1egend

↓ ry Brocessing peration

+urling and 6endingFet Brocessing peration

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< Pr'+ess Fl'+6art 'f ;is+'se Ray'n and Synt6eti+ Fi7re8anufa+ture =

Food Bulp (&lpha Cellulose)

>teeping Bress

#ough Cutter

>hredder &lkali Cellulose FasteC>$

vacuum 600 Chemical Reaction et!een "l# Cell $ C%2

Churn - 350C Uanthate FasteCell &anthate

issolver

+lending !iltration #ipening !iltration Faste

eaeration

Jiscose >torage Tank C%2 ' 2%*haust to chimne+

%pinathaci, 570C

>pinning&cid

#ecovery'vaporation

Crystallisation+y Broduct

2a2>4

#aw Cakes 4odet arnFaste Faste

Fash +leach Burication

Gydro 'xtraction -esulphurisation 800

C

ryer - 7%%C

6oisture Control #oom>pg. >pg.

4odet .arn Cake Backing arn FasteFaste Faste

BackingConning

Conning arn Ganks Gank BackingFaste

Cone Backing arn Faste

Fi*< 21


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5< Pr'+ess Fl'+6art 'f Sun and Fila%ent Yarn =A 8anufa+ture 'f Nyl'n G <

CaprolactumFater >tabiliser

pacier /st #eactor

$nd #eactor

4ranulator

Fashing of Chips

Chip >torage

Compounding products

6elting 'xtrusion

>pinning 4ranules for

BlasticConversion

+atching

!ilament Finding

rawing or Texturising if

necessary

>ale

>aleSinnin* 9 Drain*

2ylon chips

Thread guide

Gopper feeder

!eed rollers

>pinning vessel

Take-up bobbin (>pinning)

'lectrical heater

Thread guides

Bool of molten nylon

"nput feed rollers

>pinning 5et

eIector

6etering pump

utput feed roller

Cold air cross Iow

Thread guide

>team chamber


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Take-up bobbin (drawn nylon)

Fig 21.8 : Process Flowchart of Filament Yarn (Nylon-6)

8anufa+ture 'f San 'r Oriented Yarn !OY@ POY@ HOY 9 FOY =

P'lyesters =

Bolyesters were initially discoveredand evaluated in /0$0 by F.G. Carothers,who used linear aliphatic polyestermaterials to develop the fundamentalunderstanding of condensationpolymerisation, to study the reactionkinetics, and demonstrate that highmolecular weight materials wereobtainable and could be melt-spun intobres.

Bolyethylene Terephthalate (B'T) is abre of great commercial signicance,useful in cordage, apparel fabrics,industrial fabrics, conveyor belts,laminated and coated substrates, andnumerous other areas. Gowever, toengineer specic properties for specialuses, many product variants have beendeveloped and commercialised. Thesevariants include alternative crosssections, controlling polymer molecular

weight, modifying polymer compositionby using co-monomers and using additiveincluding delusterants, pigments andoptical brightners.

Gigh molecular weight polymer isused for high strength bres in tyres,ropes, and belts. Gigh strength andtoughness are achieved by increasing thepolymer molecular weight from $%%%% to9%%%% or higher by extended meltpolymerisation or solid-phasepolymerisation. >pecial spinning

processes are reAuired to spin the highviscosity polymer to high strength bre.1ow molecular weight bres are weak buthave a low propensity to form and retainpills, i.e. fuHH balls, which can be formedby abrasion and wear on a fabric surface.6ost pill-resistant bres are made byspinning low molecular weight bres incombination with a melt viscosity booster.

6ost of the textile bres aredelustered with %./-9.%< wt Ti$ to

reduce the glitter and plastic appearance.

6any B'T bres also contain opticalbrighteners.

8anufa+turin* and Pr'+essin* =

Terephthalic &cid (T&) or dimethylterephthalate (6T) reacts with ethyleneglycol ('4) to form bis ($-hydroxyethyl)terephthalate V0:0-$;-$W (+G'T) which iscondensation polymerised to B'T with theelimination of '4. 6olten polymer isextruded through a die (spinneret)forming laments that are solidied by aircooling. Combinations of stress, strainand thermal treatments are applied to

the laments to orient and crystaliHe themolecular chains. These steps developthe ber properties reAuired for specicuses. The two general physical forms of B'T bers are continuous lament andcut staple.


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Ra 8aterials @

!or the rst decade of B'Tmanufacture, only 6T could be madesu?ciently pure to produce highmolecular weight B'T. &fter about /0;:,processes to purify crude T& by

hydrogenation and crystallisation becamecommercial. "n Kapan, oxidation conditionsare modied to give a medium purity T&suitable to manufacture B'T, providedcolour toners such as bluing agents oroptical brighteners are added duringpolymerisation. Compared to 6T,advantages of T& as an ingredient arelower cost, no methanol by-product, lowerinvestment and energy costs, higher unitproductivity, and more pure polymerbecause less catalyst is used. Catalystsare used in the transestericationreaction of 6T with '4 and inpolycondensation. 6any compounds havecatalytic activity. ivalent Hinc andmanganese are the prevalenttransesterication catalysts. &ntimony,titanium and germanium are thepredominant polycondensation catalysts.Dp to 9< delusterant is added to manyB'T bre products to make them moreopaAue and scatter lightX titanium dioxide

is the most common delusterant. B'Tbre blended with cotton for apparelfreAuently contains small amounts of Iuorescent optical brighteners addedduring polymerisation.

Commercial production of B'Tpolymer is a two-step process carried outthrough a series of continuous stagedreaction vessels. !irst, monomer isformed by transesterication of 6T orby direct esterication of T& with '4.

"n general, esterication is conducted

in one or two vessels forming lowmolecular weight oligomers with a degreeof polymerisation of about / to 7. Theoligomer is pumped to one or two pre-polymerisation vessels where highertemperatures and lower pressures helpremove water and '4X the degree of polymerisation increases to /: to $%repeat units. The temperatures arefurther increased and pressuresdecreased in the nal one or two vessels

to form polymer ready to spin into bre.!or most products, the nal degree of

polymerisation is about 7% to /%% repeatunits. &verage molecular weight is about$$,%%%X weight average molecular weightis about 88,%%%.

Sinnin*=

B'T bres are made either by directlyspinning molten polymer or by meltingand spinning polymer chips. & special,precise metering pump forces the moltenpolymer heated to about $0%%C through aspinneret consisting a number of smallcapillaries, typically %.$ to %.3 mm indiameter and %.9 to /.: mm long, underpressures up to 9: 6Ba (:%%% psi). &fterexiting the capillary, laments areuniformly cooled by forced convectionheat transfer with laminar-Iow air.

!ollowing solidication, the threadlineis passed over a nish applicator andcollected. & spin nish is applied toreduce friction and eliminate staticchange.

"t is convenient to classifycommercial B'T spinning processesaccording to the degree of molecularorientation developed in the spun ber.4enerally, the classication is a functionof spinning speed. 1ow oriented yarn

(1) is spun at speeds from :%% to $:%%mMminX partially oriented yarn (B) isspun at $:%% to 8%%% mMminX highlyoriented yarn (G) is spun at 8%%% to;:%% mMminX and fully oriented yarn (!)is spun at greater than ;:%% mMmin.

Drain* and Sta7ilisati'n =

rawing is the stretching of loworientation, amorphous spun yarn (1) toseveral times their initial length. This is

done to increase their orientation andtensile strength. rawing in two or morestages is useful to optimise tensileproperties and process continuity.>tabilisation is heating the ber torelease stress within the molecular chainsmelt and reform crystals and increase thelevel of crystallinity in order to stabilisethe bre structure.

Stale Pr'+esses =


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"n staple processing, the containers of combined spun ends are furthercombined to form a tow band and fed to alarge drawline. The tow band is spreadout into a Iat band tracking over multiplefeed and draw rolls. Cri%in* is theprocess by which two dimensional

conguration and cohesive energy isimparted to synthetic bres so they maybe carded and converted to spun yarns.

The tow band is cut to precise lengthsusing a radial multiblade cutter, normally9% to 8% mm for blending with cotton, :%to /%% mm for blending with wool and upto /:% mm for making carpets. Cut stapleis packaged in up to :%% kg. bales atdensities greater than %.:gMcm9.

Safety and En,ir'n%ental Fa+t'rs =

Healt6 9 Safety @ B'T !ibres poseno health risk to humans or animals.!ibres have been used extensively intextiles with no adverse physiologicaleects from prolonged skin contact. B'Thas been approved by the D.>. !ood andrug &dministration for food packagingand bottles. B'T is considered biologicallyinert and has been widely used in medicalinserts such as vascular implants and

articial blood vessels, articial bone andeye sutures.

En,ir'n%ental Fa+t'rs @ B'Tmaterials are not dangerous to theenvironment and cannot contaminatesurface or ground water. uring

polymerisation, non-condensible organicby-products are stripped from the processoutIow streams and burned. 4lycol andwater are separated by rening. Thewater is treated in a standard water sprayfacility. The glycol is reused. The methodfrom the 6T transesterication isrened and reused. 1ike all materials,polyesters should be disposed of properlyto avoid litter and can be disposed of bylandll or incineration.

& key environmental advantage forB'T materials is the ability to recycle.Bolyester materials, especially bottles,can be separated from contaminatedmaterials such as aluminium caps andpaper labels and remanufactured bydirect remelt extrusion into bres forlling products or carpets or into layeredconstructions for good-gra,e ottles

" loc# ,iagram of aove mentione, processis sho!n in ig 21/

T&M6T>torage

4lycol !eed

Catalyst #ecycle

!eedBreparatio

n Tank

4lycol-water

>eparationColumn

4lycol GotFell

&dditivesBreparatio

n

'steri-cation

ligomer!ilter

Brepoly-merisation

!inisher 4ear Bump

BelletiHing >pinning >taple !ibre

1 B G !


20/45

Fi*< 21ometimes sodium alkyl phosphate(Teepol) is also used. This process isknown as *batching.

&fter preparation, the bres arecarded or combed, drawn and spun.

Then cop and spool winding, weaving,nishing, croppong, cutting and lappingcomplete the processing.

+leaching and dyeing of 5ute is alsopossible. yestus used for cotton, arealso useful for 5ute. The bre has aspecial a?nity for basic dyes, whichprovide brilliant eects even on

unbleached base. The increaseddemand for rugs, mats and carpets

reAuire dyed 5ute yarns and fabricssuitable for these applications. &Hoic

and vat dyes give very bright and fastresults but their high cost limits theiruse with 5ute. The tendency of 5ute toturn brown in sunlight is a permanentdisadvantage.

Haards and C'ntr'ls =

6achinery haHards are high as incase of cotton textile machinery. 6aindrives, gears, in-running nips of rollersor bowls, spindles and shafts, knivesand cutters, Iying shuttles etc. neede?cient guarding.

!ire may occur due to friction andheat. Fater hydrants are necessary.Besticides used in cultivation of 5utemay cause poisoning. ust is given o in bale opening and spinning. 1ocalexhaust ventilation is a must.ermatitis gives skin trouble due todust, batching oil, dyes etc. 'xcessivenoise in weaving operation may cause

hearing loss. 'ar protection isnecessary. Carrying heavy loads maycause strains. 6edical examination of workers is necessary.

HAJARDS AND SAFETYPRECA"TIONS OFSPINNIN$PREPARATORY ANDSPINNIN$ PROCESSES

upercleaner, Cotton opener - Borcupineor Chrighton opener, #oving wasteopener, >cutcher, Combinedopener and >cutcher, >cutcher and

1ap machine, &xi-Io, hopper feederetc. Tinting room is used to colour


21/45


22/45

. D'er 9 C'%7 lade @ (i) Coverson doer wheels should be closed.(ii) Fork at or near the doer coverand doer comb blade must bedone with care and properlysupervised.

;. Hi*6 Seed Cardin* %a+6ine @

The in running nip between crossrolls should be securely guarded.

. !'+al Ex6aust ;entilati'n @6odern card machines have built-inlocal exhaust system with dust

collection chamber to extract thecotton dust generating in themachine and to prevent its exposurein the work environment. Thissystem should be e?cientlymaintained.

liver lap, lap mMc or lap-former,erby doubler, #ibbon lap mMc etc. The main and counter drive shall besecurely guarded.

2. Ni between the lap forming rollers(lap roller and Iuted roller) should beguarded. "t is desirable if it isinterlocked (#. :8, >ch. ").

3. Ri77'n la %K+ @ The lap drum andcalendar drum gap should beinterlocked.

4. Sli,er la %K+ @ 2ip guard at theintake end of the calendar rollersnecessary.

!. The carding slivers should be madeparallel and combined to form a lapsheet suitable for feeding to acombing mMc.

. "nsafe a+ti'ns @ Care must betaken during operations such ascleaning cap bars of a lap mMc,placing laps on lap rack, putting alap rod on a lap stand, removing thechain drive from lap forming mMc,cleaning the ribbon of lap mMc andputting a lap end around a spool.


23/45

2. The head stock gearing (5ack boxwheels) should be interlocked. (#.:8, >ch " 4!#).

3. Slu77er Fra%es @ (i) The drivingbevel and bevel wheel should beguarded. (ii) The spindle shaft wheelshould be guarded. (iii) +obbin and

spindle bevel gears should beguarded. (iv) The ratchet wheelshould be guarded. (v) Fork close torevolving Iyers should be done onlyafter stopping the Iyers. "t should besupervised so. (vi) Care should beexercised while handling of rollersand weights.

4. Inter Seed Fra%es @ (i) Theguard of the head stock gearingshould be adeAuate or interlocked(ii) The stacking of bobbins on creeltop should be done in safe manner.(so that the bobbins may not falldown) (iii) The height of creel topshould be proper. (so as to reacheasily). "f not suitable, foot boardsand hand holds should be provided(iv) Fork close to rotating Iyersshould be done after stopping them(v) raft rolls, draft gears, intergears (5ack box), cone drive andmain drive should have guards.

The new open end or rotorspinning system eliminates somesteps of the spinning preparatoryoperation and reduces manyaccidents. >ee Bart ;.3.

uitable knee-brake for each spindleto stop it. The height of this brakeshould coincide with the knee of theworker. This is the design(ergonomic) aspect.

3. Stru+) a*ainst ,ari'us %K+arts @ (i) The sharp edge of aprotruding metal sheet on the frameand broken edge of a ring frame maycause struck in5ury. >uch damagedcomponents should be replaced. (ii)Care should be taken while creeling,de-creeling, piecing, cleaning rollers,

cleaning cotton Iu, stoppingbobbins for piecing, xing bobbins onspindles, do?ng and ad5usting arborso as not to be struck against rollers,their supporting brackets or rollerbeamsX work near lappet rail, lter-box, lappet middle-rollers, top armand cradle and middle arbor andcradle assembly, pocker rod, tubebracket and dashing against theframe of the machine whileattending to dierent 5obs. Broper

supervision necessary.4. Fall 'f 7'77ins fr'% +reel t' @ (i)

>tacking of bobbins on creel topshould not be haphaHard. nly onerow of bobbins should be stacked. (ii)>afe means of access i.e. suitablefoot-boards and hand-holds shouldbe provided for climbing up.

!. Fall 'f r'llers @ (i) !all of clearerrollers and dead weight rollers occurin the course of operations such as

releasing auto-lever, piecing,removing the rollers or holding them


24/45

for cleaning. Care is necessary. (ii)6echanism holding the rollers inposition should be maintained ingood condition.

. Aut'-le,er @ (i) Care should betaken while releasing or replacingthe auto-lever. (ii) Condition of the

saddle should not be defective.. Rin* tra,ellers @ These can Iy and

in5ure persons unless there is aneective system of periodicalreplacement. &lso the travellersshould be of good Auality andproperly tted.

;. D'Ln* 7'xes @ (i) The hook on thedo?ng boxes for placing them on therail should be proper. (ii) >plinteredcondition of the boxes and theprotruding metal band may causeaccident. Their periodical inspectionand repair is necessary.


25/45

;. 'xcellent dyeability with whiteshades.

7. +lend homogenation.3. 4reater production economy.0. "ncreased Auality of rotor-spun yarn./%. #educing access to dangerous

machine parts, thus increasing

safety.//. #eduction in dust amount.

6ain three bre length groups are @

/. >hort staple upto ;% mm.$. 6edium staple, ;/ to /$: mm.9. 1ong staple, /$; to $%% mm.

&ll the three types of staple groupscan be processed by rotor spinningsystem. "ts ma5or use is for short staple(cotton) sector.

The >ualitati,e r'erties of rotor-spun yarn are much better thanthose of carded short staple cotton. "t ismore regular, has fewer naps, hasfewer thick and thin places and hasbetter weaving and knitting properties."t is possible to use much lower Aualityof cotton with the rotor spinningtechniAue with one precondition that awell drafted sliver - highly clean and

regular - is reAuired.!i%itati'ns of this open endsystem are Q

/. "t is not possible to spin combedyarn.

$. >livers should be free of foreignmatter in order to operate 'system eectively.

9. Bower consumption increases withthe increase in spun yarn count.

8. !or longer staple, larger rotor is

reAuired, which in turn reduces themaximum turbine speed and thusthe productivity.

:. The yarn counts are lower than 8%(/8.3 tex) which limits their use toheavier, coarser fabrics such asdenims, towels, some poplins andinterlinings.

;. The spun yarn is weaker due to theircoarseness.

The characteristics of newdevelopments in cotton blow room are @

/. "ntensive removal of dust by meansof special condensers (dust can onlybe extracted by suction).

$. Jery ne opening of the tufts withsimultaneous cleaning to removethe smallest trash particles.

T6e 7asis of this rotor technologyis the simultaneous opening andcleaning processes and separation of micro dust consisting of ne seed andbre fragments.

1ow Auality cotton (i.e. with highdust content) reAuires more cleaning byextra condenser with reserve chute.

That will do more dust extraction. The card, a cleaning device to

eliminate small and very small trashparticles, should be eective to havesuccessful rotor spinning. 6any rotorspinners have recognised that thetandem card seems to be the bestsuited for good parallelisation and aclean and regular sliver.

1imits of yarn manufacturingprocess have been increased due torotor speed.

#otor spinning has the widesteconomic and technical application

range. &ll purpose capability of rotorspinning provides a universal spinningprocess. "t is technically possible to spinyarns in metric counts ranging from 2m/ to /%% by the rotor system.

#otor machine fulls the spinnersreAuirement of - ro,uctivit+ ro,uctualit+ an, conom+

4 HAJARDS AND SAFETYPRECA"TIONS OF

(EA;IN$ PREPARATORY AND (EA;IN$PROCESSES

4


26/45

motor, timer drive, cam drive,traveller pulley and track nip andconveyor drive. Enotter-carriageassembly spindle assembly shouldhave cover.

$. The gap between the moving partsof conveyor and xed parts should

be checked all along its length andreduced to the minimum by suitablecoversMguards.

9. +obbinsMsleeves used on the mMcsshould be inspected for brokenedges, burrs etc. as also for theirproper tment on driving spindles.

8. Gaste in loading spindles with emptybobbins should be avoided. &lso,dust and other extraneous materialson spindle and moving yarn shouldnot be removed while they are inmotion. ust collecting blower andbag are useful.

:. &utomatic winders like cone winderand spoolers prevent hands reachingnear the rotating drum and arepreferable.

4top motion indicator lamp is useful.. Fheels of moveable stands should

have guards.

;. rum drive motor pulley, beam drivechain, beam ends and sectionwarping gears should be guarded.


27/45

its 6aximum Bermissible ForkingBressure.

4huttle Iightmay be caused by warp breakage,broken or improper heald (heddle)wires, slackness in pickingmechanism and other causes.>huttle less looms (auto looms) isthe best remedy for shuttle Iights,but it is not economical. Therefore,

the practical remedy is the shuttleguard. The shuttle guards beproperly provided. "t should extendsu?ciently forward and the gapbelow it should not be too much.+ecause of possibility of change inthis gap and despite the guard theshuttle can Iy and hit. Certainly theyprotect the upper body of a workerfrom hitting. (ii) To protect fromin5ury due to shuttle Iying from thead5acent loom, every loom must be

eAuipped with barrier guard placedclose to each end of the slay beam.>uch guards of strong wire netting orsimilar material are advisable. (iii)#easons for shuttle Iights should beproperly recorded, investigated andremoved.

3. S6uttles @ (i) >huttle receptacleshould be provided near each end of the slay to place the shuttle properly.(ii) #emoving empty pirn (bobbin inshuttle) and loading wound pirn intothe shuttle may cause in5ury. &lsocare should be exercised whileplacing shuttle on the slay. (iii)&utomation of process of lling upthe empty shuttle can reduce thesehaHards where a pirn battery loadsthe shuttle as soon as the weft yarnon it is exhausted. This device of modern looms is advisable.

4. Pi+)in* sti+) asse%7ly @ (i)Jertical picking stick is less

dangerous than horiHontal one. Fork

near the proximity of the stick shouldbe done carefully. (ii) >pacingbetween two looms should be atleast :: cm measured from thefarthest pro5ecting point of anad5acent loom or wall. The aisles(alleys) should atleast be one meter

wide. "t is so desirable for safemovement. (iii) Bicking stick (arm)should be securely guarded along itsxed path of movement so thathitting by it can be avoided. (iv) Theloom spindle on which the pickermoves may crack or Iy out and hit.efective spindle should be foundout and replaced. (v) Bicking springshould be inserted in positioncarefully (vi) The picking wheelshould be guarded. (vii) &ll parts of picking mechanism and heald frameshould be sound for proper tment,wear and tear.

!. ea% (ei*6in* @ (i) Compoundlever should be adopted for beamweighing wherever possible. Theshape of the weights should be suchthat they would not come o thelever and hit. Feights of shape *3should be preferred to those of shape *C. Feights must be

harnessed to the beam by strings orstraps of adeAuate strength (ii)>pring loaded mechanism used forbeam weighing should be inspectedat least once in a week and defects,if any, rectied. efects of spring,lever handle, threads used if any,should be found and removed.

. Cl't6 and E%ery r'lls @ (i) Thesupport brackets of the cloth rollshould be examined once a week forany defects to ensure that the cloth

roll sits tight in the brackets. (ii) Careshould be taken from hitting thecloth or emery rolls while walkingnear them (iii) Geavy cloth rollsshould be handled mechanically orby more workers. (iv) 4uards shouldbe provided on emery roll and guideroll, crank tappet gears, take-upgears, bottom cam drive gears,motor drive, shedding motion etc.

. Slay 7ea% @ (i) The slay moving

towards and away from the weavermay hit the hand and ngers may


28/45

get trapped between the movingslay and the front rest head frame,temples etc. Gands should not beplaced on the slay or at places nearits path. (ii) Clearance between theslay bolts of two ad5acent loomsshould be adeAuate. (iii) >etting of

the weft fork holder and hammershould be proper. (iv) #emoving Iu or wastes and attending to minorad5ustment on the loom must bedone only after stopping the loom.

;. Du+) 7ill and Hitter @ The duck billand hitter should be guarded onevery loom to prevent contact withsharp edges of these moving partsor being trapped between them.>uch guards can be in the form of close pitched springs surrounding theduck bill and extending 9 to : cmbeyond so that approach to thesharp edges from the sides isprevented.

pare pirns and theirboxes should be examined for theirbroken edges etc., and should berectied. (v) The operators must bealert to 5oin the broken ends. Theyshould be 5oined only after stoppingthe loom. (vi) !all of variousimproperly tted loom parts onworkers while cleaning, oiling etc.,

dashing against loom parts, gettingcaught between loom parts due toaccidental starting, striking weft boxwhile loading or unloading pirns,striking heald wire while drawingends or doing ad5ustments nearbyetc., may cause accidents. Careshould be exercised and supervisedin such operations. (vii) >uctiondevice for pirn-battery return airsystem, diusers, sprinklers,

hydrants, re extinguishers etc.should be in good working order.

1>. N'ise @ Gearing loss is possible dueto high noise in loom shed. 2oiselevel should be below 0% d+&.>huttle less loom gives less noise.4ood lubrication and maintenance,proper tuning, Auick replacement of damaged parts of picking

mechanism and stroke resistors helpto reduce noise. Forkers should wearear protection.

0 HAJARDS AND SAFETYPRECA"TIONS OFPROCESSIN$

FINISHIN$ ANDFO!DIN$ 8ACHINES

0hearing, singing, washing,bleaching, kiers, yarn and clothdyeing, printing, polymerising,sanforising, stentering, padding,nishing, folding, bale (cloth)pressing machine etc.

$. T6e in-runnin* nis betweenrollers and similar parts, unless thenips are inaccessible, should besecurely guarded with nip guards(bars) along the whole length on theintake side (#ule :8, >ch ", 4!#).

9. "n dryers and similar machineswhere there is a risk of access fromthe sides to nips referred to in item($) above and driving gears shouldbe guarded to prevent such access.

8. ther machine parts such as mainand counter drive, belts, pulleys,shafts, gears and Iappers should be

guarded.:. #emoving crease from the cloth on

rollers should never be done whenthe machine is in motion.

;. iling, greasing, ad5ustment orrepairing near dangerous partsshould not be done with the machinerunning.

7. Threading of tape or xing lappingon cylinders should not be carriedout while the rollers are in motion.

The motion which may be necessaryshould be provided either manually


29/45

or by provision of inchingarrangement.

3. 'ntanglement with the cloth inprocess is a serious haHard in someof the machines. Fhile working here,care should be exercised andsupervised.

0. To the extent possible, splash guardsshould be provided for containing thelikely splashes of chemicals and hotliAuids at those parts of machinewhere splashes generally occur.

These would also facilitate keepingthe Ioor free from spillage.

/%. Fherever risk of splashes fromchemical or hot solutions exists,operators should be provided withBB' such as face shields or goggles,hand gloves, aprons and gum-boots.

//. Fherever persons have to reachand work at parts of machinesituated at heights, suitable meansof access in the form of catwalks andplatforms should be provided.Fherever these are not provided dueto infreAuency of the operations orany other reason, alternativearrangements such as scaolding orsafe ladder should be provided andthe operations carried out conrming

to standard safe practices./$. ismantling and tting of heavyparts of machine should be donewith care. To the extent possible,mechanical handling devices shouldbe used for the purpose.

/9. &cids, alkalis, bleach liAuors orwhitening agents, dyestus andsolvents are used for process orcleaning purpose. Their storageshould be kept away in a separateroom. They should be handled in

small containers with lids. Theirspillage or leakage should beavoided and cleaned immediately.>olvent cleaning is risky. >ource of ignition must be avoided while usingsolvent to clean printing machine,vessel, container etc. Then nearbyelectric tting should be Iameproof or switched o. rdinary short-circuithas caused many accidents.

>chedule /$ and /0 uMr /%$, 4!#

should be followed while handlingacids, alkalis and other chemicals.

#ule ;3 should be followed forusing hot oil circulation in stenteretc. through thermic Iuid heaters.

0ee Bart /;.7 of Chapter-/3 for chlorine safety.

pen bleaching tanks should havefencing to prevent fall inside.

+leaching machine should havefume exhaust device. +leaching rangeshould have nip guard on rolls.

0


30/45

acidproof lining if acidMalkali is used.(vi) Clean overIow pipe with watertank (vii) 2ip guard on draw nip(viii) &ir regulator for pneumaticloading of rolls (ix) 4uards on chaindrives of nip rolls (x) oors on soaptanks (xi) safety of steam lines and

(xii) 4uard on chain drive of aplaiter. (xiii) 2ip guard on paddingmangle.

2. (as6in* Tan)s @ Burpose is towash the cloth. (i) #ailing near hotwater tanks to prevent falling into it(ii) rain pipes and valves to drainhot water from the tank. >implehole, cotton plug (stopper) andbamboo use is an unsafe practice.

3. Hydr'extra+t'r @ Burpose is toremove water from wet cloth. (i)"nterlock basket cover (ii) !ixedguard on pulley-belts (iii) +rake tostop basket.

4. i**er %a+6ine @ Burpose is tocolour the cloth in open tub (i.e. nopressure). (i) 2ip guards on rollersand gears (ii) >plash guards shouldbe provided on each of suchmachines to minimise chances of chemicals and colour solutionssplashing on persons. (iii) &prons

and chemical goggles should begiven to workers (iv) Beriodicinspection and maintenance of theIoors. They should be free fromwater and solution so as not to keepit slippery. (v) Bneumatic valve tocontrol steam Iow (vi) Cover onmotor pulley belt drive and gearbox(vi) #oll motion controller.

!. Calendar %a+6ine = "ts function isto give ne nish (ironing) bypassing the cloth through calendar

rolls or bowls. (i) &uto temperaturecontrol to prevent over heating (ii)2ip guards on in-running nips (iii)4uards on main motor drive andreduction gears. (iv) Geavy rollsshould be handled mechanically (v)Contact with hot rolls may causeburn in5ury. Care should be takenwhile working at heights (vi) Fhensteam pressure is aboveatmospheric pressure, #ule ;/ 4!#

should be complied with. &ll safety

devices should be properlymaintained.

. Dryin* %a+6ines @ Burpose is todry cloth. (i) 2ip guards on rotatingrolls and mangle rolls. 4uards onchain, bevel gears, winch drive andstack drive. (ii) Blatform, foothold

and handhold to work at heights (iii)Got cylinders of drying range maycause burn in5ury. Care and eectivesupervision (iv) !or pressure control,follow #ule ;/, 4!#.

. Miers and A*ers @ Burpose isheating by steam pressure. (i) Fhiletightening the eye bolts of kier, barsused should be of such constructionthat they hold the eye bolt securelyand do not slip o. (ii) Catwalks andplatforms to work on the top of theEier (iii) Care form coming intocontact with the hot parts of thekier (iv) Bressure reducing valve,safety valve, pressure gauge, stopvalve etc. should be properlymaintained for the safe workingpressure inside. >afety valve andpressure gauge should be providedon 5acket also (v) Gydraulic pressuretest at every two years (vi) Chainpulley block or hoist to lift heavy

parts.;. Stenter %a+6ine @ Burpose is todry cloth by passing it through heatchambers. Badding mangle, feedingHone, heating Hone (chambers),batching and plaiting are maindivisions (i) 2ip guard between in-running rolls and rollers of thepadding mangle, guard on uncurlernip, main drive and bevel gears (ii)Catwalks or platforms for working atheights. (iii) Temperature control

devices (iv) 'ective exhaust hoodand chimney for removal of fumesfrom the machine. (v) 'ective andsu?cient exhaust fans in theworkroom (vi) >couring process i.e.oil removal from fabric beforefeeding it to the stenter machine toreduce the oil fumes. (vii)

Textometer to detect moisturecontent. (viii) Covers on roll drivechain box, overfeed chain drive,

batching and plaiter drive (ix) 9-way


31/45

pneumatic oil Iow control valvewhere oil heaters are used.

. et Dyein* %a+6ines @ Burpose is

to colour the cloth under steampressure. (i) B#J or pressureregulator in pressure feed line (ii)&deAuate safety valve and rupturedisc Q both of at least /.: inch (dia)siHe and in parallel on the top of thevapour cell (iii) Gigh pressure alarmand automatic or manual de-pressure (venting) device to operateat that alarm (iv) Dse of heat-exchanger for indirect heating andcooling (v) Beriodical hydraulic testsand 2T for corrosion eects (vi)2on-corrosive metal, 5oints andbody parts (vii) !lap guard nearlter cover at the bottom andinternal disc to restrict outIow (viii)

Temperature gauge near thepressure gauge on the vessel (ix)Fater, steam and air control valves(x) 6anhole cover interlocked with

depressure device (xi) 6aximumpressure indicator and automaticpressure controller (xii) Trainedoperator (xiii) 'ective supervisionand auto programming.

11. Dru% as6er @ "t is a washingmachine under steam pressure. (i)!ixed guards on belt and chain drive(ii) Bressure #educing Jalve, >afetyJalve and Bressure 4auge on steamsupply line (iii) rum motion xingdevice (locking) while loading and

unloading. "nternal drum should notrotate while loading or unloading it."t should be mechanically locked.Bower should also be de energisedat that time.

12. Exander %a+6ine @ (i) 2ip guardon rollers and between the cloth inprocess and the rollers (ii) Barts of machine should be periodicallyexamined to detect defectiveconditions such as protruding nails.

13. Stit+6in* and sein* %a+6ine @(i) 4ap between the needle and the

machine table should be guarded toprevent access to this Hone. (ii)'lectric earthing should be properand '1C+ should be provided inpower supply line.

14. Printin* %a+6ine @ Burpose is toprint the cloth by machine. Jarious

types of machines are in use. (i) 2ipguards on the printing roller, clothroller and on the lapping and a roller(ii) Fhile removing a heavy roll fromthe machine, care should be takenor the mechanical handling shouldbe used. (iii) Care should beexercised while changing a designroller otherwise a hand may becaught between the design rollerand control roller (iv) Care should betaken while turning a handle toapply pressure to the printing rollersotherwise a worker may slip and fallfrom height (v) The doctor blade of the machine should be removedcarefully otherwise it may slip andits sharp edge may cause in5ury. (vi)!ixed guards on pulley-belt drive,sector, connecting (eccentric) rod,repeat-setting device and undertable rollers (vi) >afety whilecleaning blanket.

1!. Stret+6in* %a+6ine @ 2ip guardbetween running cloth and roller.1. P'ly%erisin* 'r +urin*

%a+6ine @ >ee part 9.9 and 0 of this Chapter.

1. $asKEle+tri+al Sin*ein* %a+6ine@ >ee part 0 of this Chapter.

1;. S6earin* and Cr'in* %a+6ine@ (i) #otating cutters should beinterlocked by a transparent cover.(ii) 4uards on main drive, suctionblower and dust chamber and (iii)

6etal detector are necessary.1


32/45

gears, mangle roll gears, chainreturn wheel, sAueeHe roll beltdrive, sAueeHe rolls, impregnator nipbetween Ioat roll and top roll,stabiliHer-tension roll and top roll nipand splash guard on caustic tankare necessary.

21. Car7'nisin* unit @ "ts function iscarbonising i.e. acid burning of cotton bre of the blended cloth. (i)&cid bath (7%< G$>8) should havesafe overIow device and splashguards on both sides (ii) 2ip guardon sAueeHe rolls (iii) !#B tray andacid-proof Iooring, BJC valves foracid use and use of BB' and safetyshower by workers.

22. F'ldin* %a+6ine @ (i) The crank-wheel and reciprocating arm shouldbe guarded to prevent hit in5ury. (ii)!ixed guard on main drive.

23. T'el +uttin* %a+6ine @ Cuttingedge should be guarded at thefeeding end of towel.

"n addition to above textile machineguarding, general safety measures formetal working machinery, liftingmachines, material handling, handtools, hand trucks, chemicals, Iooring,

re and health haHards, must also beprovided and maintained. Felfarefacilities of canteens, lunchMrest room,ambulance room, crSche, welfare andsafety o?cers should also be provided.>ee Bart-9 for statutory provisions.

3 FIRE AND EP!OSIONHAJARDS AND

CONTRO!S

& booklet *!ire Brevention in Textile"ndustry, "nstructions for >upervisorspublished by the 1oss Brevention&ssociation of "ndia 1td., 6umbai - /(4u5arati copy is also available), ">@9%70and $/0% are most useful to understandand control reMexplosion haHards intextile industry.

Cotton dust is not ne enough tocause dust-explosion but it maycertainly cause re if any spark is

available. Exl'si'n haHard lies withpolymerising or curing machine where

Iammable liAuids are used andtherefore explosion relief doors arereAuired. !ire haHard is more in blow-room and spinning sections due to looseand Iying cotton and in processingdepartment due to solvents andchemicals.

The main cause of re in textilemills can be attributed to the failure of electrical eAuipment, sparks fromforeign material carried along withcotton stock, friction, hot bearings dueto inadeAuate oiling and attention,presence of excessive Auantities of Iyand dust in the department and the useof Iammable liAuids and processing of cloth at high temperatures.

uildin* C'nstru+ti'n @ Textilemill buildings are classied as *reproofX*non-re proof and *inferior. "n order tominimise the risk of re, all millprocesses and storage buildings mustbe of re proof construction of at least ;hours grading. The behaviour of astructure when sub5ect to re stressesmust be taken into account at thedesign stage.

4odowns for cotton and nishedproducts shall be essentially singlestorey structures and located at least

9% mt away from the spinningdepartment. "n textile mills, thedepartments that reAuires separationby perfect party walls in order to reducethe re loads are @ (a) +aled cottonwarehouses, cotton mixing and blowingroomsX willow and thread extractorroomsX waste opening roomsX cardingroomsX speed and ring framesX mulespinning departmentX preparatorysections and loom sheds, clothprocessing houses with re walls around

special haHard processes such as*singeing and *cloth raising. (b) +oilerhouses and ring places must beseparated from all process and storebuildings except the engine rooms andthe like. (c) 'lectric generating stationsand transformer houses must be citedat least /% mt away.

Cotton and yarn drying chambersmust be constructed of incombustiblematerials and tted with thermostat

controls in order to cut o the source of


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heat supply at predeterminedtemperatures.

(are6'uses and St'res @ (a)+reakage of cotton bale hoops causessparks and subseAuent res (b) !aultyelectrical eAuipment, both for lightingand bale stackers may cause re. (c)

1ots of baled cotton must be stacked inan orderly manner away from godownwalls to prevent spread of re andassist re ghting and salvageoperations. (d) &deAuate drainage of godown Ioors is necessary in order toprevent excessive water damage of lower layers.

&ll sources of ignition likemechanical sparks due to friction,electrical spark, spark from welding orcutting, prismatic eect of sunrays fromglass window on cotton bales, use of naked Iames, heated lamp or metalparts, oil dripping and electrical loosewiring or electrically heated metal partsshould be avoided by promptsupervision. !ire hydrants should bekept nearby.

C'tt'n 8ixin* and l' R''%s @(a) 4eneration of sparks from foreignmatters, particularly pieces of metalcarried along with cotton stock through

metal rollers and spiked lattices of opening and blowing lines. 1oose rivetsand short ends of hoop iron are themain causes which could be eliminatedby providing suitable magneticseparators which should be cleanedduring each shift. (b) 6achines withhigh speeds are more prone to res.6achines with higher capacities areexposed to large Auantities of loosecotton and hence res in such machinesare carried faster and at longer

distances (c) &ll cotton opening andcleaning machines with spiked latticesand rollers must be sprinkled.

Cardin* Deart%ent @ Cotton inthe carding machines being still in theloose stage is susceptible to re due tofriction between metallic parts,particularly llets, licker-ins and grinds.

Sinnin* Fra%es @ (a) !reAuentres occur due to heated spindlebearings of those of the rollers driving

them (b) 1int and Iy cleaner units of spinning frames cause re due to

improper conductor or collector shoecontacts with the open bus bars runningthe entire length of the machines. Theuneven contacts of the collector shoescause sparking which ignite the Iu collected around the buses. (c)4eneration of static electricity is

generally encountered in the spinningof rayon yarn particularly in the cardroom and it is safer to ground allmachines and to provide suitablehumidication system to eliminatestatic charges.

!''% S6ed @ The pickingmechanism usually gets 5ammed due toaccumulation of Iu which causes respreading and droppings below theloom or at times to the warp beams.

Pr'+essin* Deart%ent =

1< Cl't6 and Yarn Sin*ein*7urnin* 7y fuel :re @ ue tothe presence of open Iames andIammable gases, res are freAuentin singeing rooms but these couldbe avoided by the use of properelectrical eAuipment and electricalinterlocked seAuence in order toprevent the machine being started

up before the exhaust and gasblower fans are brought intooperation. &ll control gear in suchcase must be mounted externallywith vapour-proof lighting xtures.

>olenoid valve on the fuel line isessential to stop fuel supply in theevent of power or mMc failure. Thiswill prevent stationary fabricundergoing singeing and from beingignited.

1B4 and air pipe lines should becolour coded. 2#J to prevent Iashback, gas burner control, nosmoking notice and ready reextinguishers are reAuired. 1B4safety rules should be followed.

!uel (petrol) control valve oncarburettor (petrol vaporiser),temperature control on air heater,suction hood, duct and dustchamber, Iameproof electric tting,

guards on nip rolls and batch drive,brush rolls and roll drive, water


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cooling of the guide rolls nearburner and safety ladder to fueltank are also important.

2< Ele+tri+ally 6eated YarnSin*ein* 8a+6ines @ &ninterlocking arrangement is

necessary to ensure that theheating elements cannot beswitched on while the yarn isstationary in the machine. nlywater washed fabric should pass.>olvent may cause haHard.

< P'ly%erisin* 'r Curin*8a+6ines @ "ts function is to dry (byheating) the printed cloth. >everalexplosions and res have occurredin polymerising machines in textilemills due to the mixture of organicsolvents in the printing pigments.

Pre+auti'ns to eliminateaccidents are @ (/) Bre-drying of printed fabric over drying ranges toremove most of the solvent outsidethe machine. ($) 1ock the exhaustopenings in top of curing machine atleast $M9 full opening. (9) 'lectricheaters must be provided withthermostat controls andsynchronised with the exhaust fan

and machine main drive so that inthe event of accidental failure of exhaust fan motor, the entiremachine stops along with theheating elements. (8) Brovision of safety Iaps on the tops of polymerising machines which wouldopen out automatically in case of explosion. (:) &ir circulation fanlter gauHe must be regularlycleaned as poor circulation wouldcause localised pockets of solvent

vapour. (;) 'xhaust duct must beregularly cleaned every week andextended outside the work room. (7)"nterlocking of exhaust fan withfabric motion so that the fans willstart before fabric is fed into thechamber.>ee Bart 9.9 for #ule ;3C 4!#.>team curing is safer.

5< Cl't6 Raisin* Deart%ent @ Gereres are freAuent due to passage of

foreign materials between lletedrollers and it is necessary that the

cloth be inspected before passingthrough the machine. The machinemust be regularly cleaned of Iu accumulation.

.< Ele+tri+al Installati'n@ 'lectricaleAuipment must comply with'lectricity &ct and #ules (>ee Bart

$.7 $.3 of Chapter-$3), relevant"ndian >tandards and installed andmaintained in safe condition.1ighting xtures in places whereconsiderable dust and Iu accumulate and godowns must be of dust-proof type, wired in screwedconduits and switchgear must bemounted externally. >top motiondevices on machines must be dust-proof, wired in conduit and checkedregularly. verhead electric lines incompounds should also be cleanedregularly.

Fire Extin*uis6ers =

!ire ghting arrangementsconsisting of portable appliances, waterhydrants and automatic sprinklers mustbe designed and laid in accordance withrelevant "> >pecications.

The automatic sprinkler system

discovers re, sounds alarm andextinguishes the smallest re. "nsprinkled building, water damage willbe less because the amount of waternecessary for extinguishing is smaller,hence all mill buildings must be*sprinkled. >uch installations areexpensive but their worth is 5ustied.Gigh pressure automatic sprinklers of special design must be provided ingenerating stations, transformer housesand oil godowns. They should be used

after power is switched o. & trainedre ghting sAuad shall be maintainedround the clock within the millpremises.

$eneral Safety Pre+auti'ns =

6ill compounds must be regularlycleaned and housekeeping both insideas well as in the yard should be of goodorder. verhead structures in all

departments must be regularly cleanedand Ioors swept during each shift.


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'lectrical eAuipment shall besatisfactorily maintained and periodiccheck-up is necessary. #isk of overheating can be reduced byproviding e?cient lubrication and day-to-day maintenance of all machines,bearings and moving parts. &deAuate

guarding for machines should beprovided particularly on blowing andcarding machines. >moking should beprohibited within ; mt of process andstorage blocks and it is advisable toprovide smoking booths.

1/ HEA!TH HAJARDS ANDCONTRO!S

>ome important health haHards in a

textile industry are as follows @&ccidents to ngers, hands and

other body parts are due to a variety of textile machinery and their hundreds of moving parts. Constant machineguarding is the best solution. 2oise andvibration are incidental haHards.yssi'n'sis is a lung disease due toprolonged exposure to highconcentration of cotton dust. 'xtractionand suppression is the best remedy.>ch. $7, #ule /%$, 4!# reAuires this.

"ncreased humidity andtemperature cause discomfort toworkers. 1imits of dry and wet bulbtemperatures should be maintained.Fell designed and maintained &C plantsare more comfortable.

1/chedule of the !actories &ct prescribes %.$mgMm9 lint free raw cotton dust. "1prescribed cotton dust values are asunder @

TF& >G& Q- %.$ mgMm9 in yarn manufacturing.- %.: mgMm9 in other operations.- %.7: mgMm9 in slashing and

weaving.>T'1 &C4"G Q %.; mgMm9

"1G Q %.: mgMm9

Jacuum stripping and suctionexhaust arrangement attached tocarding machines, lint and dustcollectors and general exhaustventilation are necessary tominimise the Iying cotton dust.Broper dust mask or cotton cloth

should be given to workers.

yssi'n'sis is an occupationaldisease caused to many mill workersby the cotton dust. This name wasgiven by Broust in /377. "t is a lungdisease like T+ or &sthma andreduces working capacity of aworker. &fter working for : to /%years in cotton dust area, respiratoryproblem starts. "nitial symptoms arecough or bronchitis, chest pain,

breathlessness, emphysema andphlegm. Dltimately the lungs aredamaged. The victim gets exhaustedsoon by a small work. Ge feelsenergy loss and becomes unt towork. "ts ma5or haHard area isspinning department, though it canhappen to winders and weavers andalso to Iax, hemp or 5ute workers.Dnder section 30 and the Third>chedule of the !actories &ct,

/yssionosis is a notiableoccupational disease and the


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medical practitioner noticing thisdisease has to report to the"nspector of !actories, otherwise heis liable for penalty.

!or its diagnosis (/)ccupational history of the workerand ($) 1ung function test are

reAuired. The eected worker isexamined on the rst day after hisholiday and also at the end of hisshift after working. Gis loss of working capacity is measured.Forkman Compensation is availableunder FC &ct or '>" &ct.

!actory 6edical ?cer shouldcheck such workers periodically. Gisworkplace must be changed soonafter the rst detection. U-ray andgradation reports should bemaintained.

There is no medical remedy forthis disease. Therefore its preventionis the only best solution. 1ocalexhaust ventilation attached withmachine, room exhaust ventilation,water sprinklers and use of cottondust mask or respirator are theeective remedial measures.

Forkers engaged in cleaning of cotton dust or in its high

concentration must be provided withair line respirator and hood ore?cient face mask. "nstead of broom-stick cleaning, vacuumcleaning machine should be used tominimise the Iying particles.

2. Heat and Hu%idity@ Gighertemperature due to closedoperations and work rooms, humidity(to reduce thread breakage), heatgenerating processes such as siHing,

kiers, drying range, stenter, hotdyeing, singeing, polymerising orcuring, steam and oil heaters, hot airdryers, boilers etc., create highertemperature in spinning andprocessing departments which if exceeds $0.:%C (3:%!) (threshold oreective temperature), or humidityis increased, causes discomfort andfall in productivity. Therefore theroom temperature must be

controlled = $:.: to $0.:%

C (73 to3:%!) by good natural and

mechanical ventilation (>ee Chapter/%). Forkers should be relieved atshort interval from high temperatureHone. &ir conditioning is desirable.Got metal parts should be insulated.

< N'ise @ Gigh noise in weaving andring frame department causes

mental stresses and may result in ahearing loss which is an occupationaldisease under the !actories &ct.Bermissible limit of 0% d+ for 3 hr.working should not be exceeded.

ne survey in a mill at +ombayindicated the noise levels in >pinningept. - 0;.: d+, oubling machines -07.; d+, Finding machines - 03.:d+, &uto loom shed - 00 d+ and 2on-auto loom shed - /%$ d+. Dse of sound absorbing material is eectivebut expensive. Dse of ear mus orear plugs (glass wool) is the mostpractical remedy and the workersmust be trained to wear them. "n2igeria, it was observed that due touse of ear protection individuale?ciency was increased by /$< andoverall production by /ch. $9, rule /%$, 4!# is

applicable.5< (ea,er&s C'u*6 @ This is caused byinhalation of siHing materials, :%< of which comes out during weaving. &sthe name suggests the workers of loom shed are prone to it. 4oodventilation dilutes the eect.

.. Can+er and C'r'nary diseases @ These diseases like bladder cancer,chrome ecHema or chromepoisoning, dermatitis are caused dueto the chemicals like lead chromate,

potassium or sodium bichromate,toxic solvents, titanium dioxide,hydrogen sulphide, sulphur dioxideand trioxide. 1ocal exhaust systemnear toxic fume generation, chemicalrespirators, gloves, aprons etc. areuseful. 2on or less haHardoussubstitutes should be utilised.6edical health check-ups and adviceshould be followed. Training andsupervision will also help.

< 8a+6inery 6aards = !oregoingparts ; to 3 have classied and


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explained process-wise machinehaHards in textile industry. 2ewermachinery has reduced many of these haHards. The most dangerousparts of textile machines are mainmotor and gear drives, head stockgearing of spinning frames, revolving

beaters of blow-room machines, cardcylinder, Iying shuttles and loomgears, picking stick and in-runningrolls of processing machinery.>pecic haHards of 5et dyeing andother pressure vessels have alsocaused many accidents. The xedguards, interlocked guards, nipguards and other safety devicesshould not be tempered with or keptopen while machinery is in motion.

4< 8aterial 6andlin* = Geavy rollsand other machine parts and bulkcontainers are to be handled intextile industry. 'xcessive weightsmay cause health in5uries, strain andpain. 6echanical aids should be usedto lift, carry and handle such heavyloads.

0< P''r li*6tin* = 6any textileprocesses reAuire high standards of illumination, such as drawing inthreads through healds and reed,

weaving and processing of colouredcloth, 5acAuard (design) weaving,fabric defect checking, folding andpacking etc. Boor lighting on suchprocesses causes eye strain. Boorlighting in passage ways, corners,stairs, platforms, conned spaces,tanks, pits and vessels, unguardedmachinery and slippery surfacesmay cause accidents. Therefore inaddition to providing su?cientlighting (see Bart : of Chapter-0),

window glasses, lamps and tubesshould be regularly cleaned and locallighting should be provided wherereAuired.

3< S6uttle Missin* = >uction shuttlesof ordinary (non-auto) looms needthread (weft) sucking by mouththrough shuttle eye (small hole) andpirn bobbin many times during a day.irt, dust or broken bre ends aredrawn into the throat. The same

shuttle may be used by dierentworkers in dierent shifts. Therefore

this is unhygenic and infectiousmethod. 2on-suction shuttle or pirnbobbin battery reAuiring no kissingby mouth is the only remedy.

1/< O,erti%e 'r) = 1egal limit of 3hours a shift is hardly followed inthousands of small and medium

scale textile industries. /$ hours ashift has become a routine working.

This certainly causes health haHards. This causes more harm to womenand child workers. 6ore workinghours cause physical, mental andnervous strain and result in moreaccidents and sickness rates. !ull co-operation of employers andemployees can solve this problem.

11< (elfare r',isi'ns = 1arge scalefactories have lunch room, restroom, canteen, ambulance room,creche, washing facilities, freemedical examinations, transportfacilities etc. +ut ma5ority of smalland medium scale factories do nothave such facilities. This aects thehealth and general well being of theworkers.

12< Fire and Exl'si'n 6aards =Cotton is easily combustiblematerial. >olvents used in processing

department can cause re andexplosion both. !or details see part 5ust following.

1/, C>$,C;G;, acetic acid etc. should bereduced by local exhaustventilation. Forkers should be givenrespirators.


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>pillage of water and othersolutions may cause slippinghaHards. Brotective clothing isnecessary for wet processes.6achine guarding to machineries issimilar to cotton industry.

4lass wool manufacturing

induces infrared emissions frommolten glass. Geat absorbing screenis reAuired. !lying or breaking glassparticles may cause skinpenetration. #esins, hardeners andaccelerators may cause skinirritation. Brotective clothing, goodhygienic practices and medicaladvice are necessary. ust fumesneed local exhaust ventilation.

Synt6eti+ :7res are madefrom chemicals or petrochemicals.2ylon, polyester, polyolens,polypropylene, polyurethane etc.are welknown. 6achine guarding isreAuired as in case of other textilemachines. The large Auantities of solvent vapours given o duringspinning and extrusion pose re,explosion and poisoning haHard andneed local exhaust with safedischarge and respiratoryprotection. elivery of toxic and

Iammable substances throughpumps and pipes reduces haHards of manual handling and directexposure. T1J, 1'1 and other safelimits must be maintained. >parksshould be eliminated. 'lectriceAuipment should be Iameproof.'ective earthing to machines andvessels shall prevent dangerousspark. >tatic charge eliminators tomachines are necessary. Forkersshould wear footwear with rubber

soles.$. Flax 9 !inen industry @ The bres

of Iax plants are used to make linencloth, towels, nets and ropes. Thebre is light, strong and absorbent."ts strength increases on wetting.

6achine guarding on rollers,pulley-drives and other movingparts is essential. !lax dust maycause 6ill fever and Feaverscough, chronic bronchitis and

byssionosis. &n "1 report (/0;:)

gives following gures for Iax dustlevels and byssionosis prevalance @

Process Mean total!st

concentration

mg"m

#yssionosis$re%alence

(& all

graes)re preparers

67 440

repares 27 300

etfinishers

06 36

otherfinishers

14 07

ust measurement at ; monthsinterval by a trained industrial

6y*ienist is useful. !ine dust isremoved by passing air throughcanvas lter. Coarse dust isextracted by a cyclone extractor.Gackling machines and cardingengines need hood enclosure andexhaust system at the sources of generation.

!or noise reduction, soundabsorption treatment to walls,ceiling and Ioors and isolatingmounts to machines are necessary.

Brocess segregation by separaterooms of heavy partition walls andear mus to workers reduce noiseproblem.

9. ute industry @ >ee Bart :.$8. Sil) industry @ >ilkworms were

reared in homes where Cpoisoning was noticed in Kapan. "nreeling raw silk, dermatitis wasnoticed. Gandling raw silk mayproduce skin and respiratory allergy.

Jery good lighting is reAuired inthe weaving of coloured silk yarn. Temperature, ventilation andhumidity control are important at allstages. #eeling bath temperatureshould be lowered to control skineect. 'xhaust ventilation on bathand freAuent replacement of waterare necessary. 6achine guarding isreAuired as in case of textileindustry.

>ee also Bart 99 of Chapter-$9.


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:. (''l industry @ 1ike cotton textilemachines, wool textile machineryalso needs eective machineguarding and spacing. Ant6rax ispossible to wool sorters. Chemicalsused may cause poisoning, eyeburning, gassing etc. >election of

less harmful chemicals, localexhaust ventilation, good washingfacility, BB' and strict personalhygiene are necessary. ust,temperature and noise control arealso necessary.

11EFF!"ENT TREAT8ENTAND (ASTE DISPOSA!IN TETI!E IND"STRY

Textile eNuents are generallycoloured and contain soluble (organicand inorganic) and insoluble(suspended) impurities and possesshigh + and C. Therefore theirtreatment and safe disposal arenecessary and statutory.

Ee+ts 'f textile euents =

1 On (ater +'urses =

I%urity C'ntent Ee+t/ Colour yes Colouricatio

n.Bhotosynthesis is aected.

$ >uspendedimpurities

Colloidal suspendedparticles

Turbidity of receivingwater.

9 pG &lkalis &lkalinitydisturbsaAuatic life.

8 ils 4rease

6ineral oils !orm blanketand prevent$ entry inwater.

: issolvedminerals

"norganicsodiumsalts

"ncreasesalinity of water.

; Toxicchemicals

Chromium,sulphide,chlorineand anilinedyes

Toxic eect tosh andmicrobialorganisms.

7 xygen >tarch, emand $

depletion dextrin,sulphide,nitrite etc.

from waterand aectsaAuatic life.

2 On !and =

The excess content of sodium and

boron of textile wastes adverselyaects crops. Gigh sodium alkalinitycombined with salinity impairs thegrowth of plants. >uspended solids andsodium prevent root penetration in landand soil texture is spoiled.

On Air =

Continuous addition of C$ andother particles due to fuel (coal, 1,gas) burning in boilers and stenters,and toxic fumes of chlorine, acids, G$$and Iammable vapours from volatilesolvents pollute the air and surroundingenvironment.

Euent Fl'+6art =

& Iowchart of eNuent generationduring cotton textile processing isshown in !ig $/./%.

#aw Cotton

Cottonopening

Carding

Combing

>pinning

>iHing

Feaving

4ray Cloth

esiHing

>couring

+leaching

ffluent

ffluent

ffluent

ffluent

ffluent


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6erceriHing

Brinting yeing

!inishing

!inished goods

Fi* 21 $80% (Bart / to /%) and >chedule" J" uMr 9 9& of the 'nvironment(Brotection) #ules, /03;, prescribetolerance limits applicable to textileeNuents.

Characteristics of raw (untreated)eNuent and reAuired parameters of process houses are shown in the table.

Pr'+ess H'use EuentC6ara+teristi+sN'<

Para%eter

ef'reTreat%en

t

Re>uiredafter

Treat%ent

/ pG ;.;-3.% ;.:-3.:$ Color /%%%-/:%%

unit/%% unit

9 >uspended>olids

;%%-0%%ppm

/%% ppm

8 Total

issolved>olids

/%%%%-

/8%%% ppm

$/%% ppm

: il 4rease

$%-$: ppm /% ppm

; + :%%-;%%ppm

9% ppm

7 C /;%%-$$%%ppm

/%% ppm

3 &mmonical2itrogen

%-: ppm :% ppm

ffluent

ffluent


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Fl' dia*ra% of eNuent treatment plant in textile processing industry is given in !ig.$/.//.

'Nuent↓

il 4rease Trap↓

Collection Tank!e>8M&lum ↓ Brimary Treatment

1ime !locculatorBolyelectrolite ↓

1ammella(>olid >eparation)

↓

&eration Tank#ecycle ↓ >econdary Treatment

1ammella(>econdary)

↓

>and bed↓ Tertiary Treatment

Carbon bed↓

!inal disposal

Fi* 21tatutory provisions for safetyin textile machinery.

9. !low chart of a compositetextile processes.

8. !low chart of spinning andweaving # !inishing

processes.:. !low chart of long staple

nishing processes.;. !low chart of synthetic bre

manufacture.7. !low chart of !ilament yarn

(2ylon Q ;)3. !low chart of riented yarn

(1, B etc.)0. 6anufacturing process of span

(oriented) arn ( B, ! etc.)

/%. The merits and demerits of rotor spinning.

//. GaHards and safety precautionsof +low room machinery.

/$. GaHards and safety precautionsof Carding machines.

/9. GaHards and safety precautionsof >liver and #ibbon lapmachines.

/8. GaHards and safety precautionsof Combers and raw frames.

/:. GaHards and safety precautionsof >peed frames.

/;. GaHards and safety precautionsof #ing frames.

/7. GaHards and safety precautionsof oubling machines.

/3. GaHards and safety precautionsof Finding machines.

/0. GaHards and safety precautionsof Farping machines.

$%. GaHards and safety precautionsof >iHing machines.

$/. GaHards and safety precautions

of power looms.


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//. #ule ;/ (3) for thin wallpressure vessels is applicableto siHing cylinders.

/$. Jertical picking stick is lessdangerous than horiHontalpicking stick of a loom.

/9. Gydro-extractor does not need

interlocked top lid./8. Kigger machine needs splash

guards./:. Calendar machine needs safety

valve./;. >tenter machine needs exhaust

fans./7. Ket dyeing machine needs de-

pressure device./3. rum washer needs B#J and

safety valve./0. >anforiHing needs steam line

safety.$%. Towel cutting machine needs

guard on delivery end of towel.$/. Gigh noise area in a textile mill

is its cloth department.$$. KacAuard (design) weaving

reAuires better lightingcondition.

$9. 6mf manufacture has toxichaHards.

$8. "n silk industry dermatitis is not

possible.$:. 4lass wool processing has dusthaHard but no infrared radiationhaHard.

$;. !lax dust cannot cause+yssionosis.

$7. 'mployment of "ndustrialhygienist is 5ustied in a textilemill.

$3. 'xplosion is possible in apolymerising machine.

$0. Cotton mixing room does not

pose re haHards.9%. >olenoid valve is essential on

fuel supply line of a singeingmachine.

9/. !lameproof e

21. CHAPTER - 21 Safety in Textile Industry

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Transcript of 21. CHAPTER - 21 Safety in Textile Industry