ppt on summer training Vardhman's Mahavir Spinning Mills Baddi (weaving devision)
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Transcript of ppt on summer training Vardhman's Mahavir Spinning Mills Baddi (weaving devision)
NARAYANAYA
..
ORIENTATION OF PRODUCTION (WEAVING) In
MAHAVIR SPINNINGS LTD (A unit of Vardhman Textile Ltd) BADDI
(H.P.)
SUBMITTED TO SUBMITTED BY,
MR. PRAVEEN KUMAR BHARAT RANA
H.O.D.(DEPARTMENT OF TEXTILE) B.TECH. (TEXTILE ENGINEERING) JAWAHARLAL NEHRU GOVT. ENGG. COLLEGE,
SUNDERNAGAR, MANDI (H.P.)
INDEX
SER. NO. DEPARTMENT (H.O.D.)
1 INTRODUCTION (MR. V.B.KANAUJIA)2 PREPATORY
(MR. P.S.CHATTERJI)3 LOOM SHED
(MR. D.B.PATEL)4 QA/INSPECTION & FOLDING
(MR. SANJEEV SHARMA)
5CPDC
CENTRAL PRODUCTIVE DEVELOPMENT CENTRE(MR. S.S. BAINS)
RAW MATERIAL a) Auro spinning mill, Baddi b) Arisht spinning mill, Baddi c) Arihant spinning mill, Malerkotla d) Vardhman fabrics limited, Budhni. e) VSM, Baddi f) VTL Satlapur, g) Anant unit, BudhniWarp & Weft: 2/40s ET, 30s comp, 50s comp, 60s comp
20k, 80s comp, 30s carded, 32s carded, 40s comb, 40s/2 comb, 20s OE, 2/50s ET, 16s O.E, 16s OE
Selvedge:2/100 CWC, 2/80C
PREPARATORY SECTION
1. WARPING SECTION & REWINDING SECTION
2. SIZING SECTION
3. DRAWING-IN SECTION
WARPING SECTION
DIRECT WARPING SECTIONAL WARPINGDIRECT WARPING SECTION Total number of direct warping machine - 2
PARTICULERS MACHINE NO.1 MACHINE NO.2Machine manufacturer MOENUS SUCKER
GmbH(GERMANY) BENINGER
Model
COMWARP BEN-DIRECT
Year of Manufacture 2005 2004Pressure of wooden roller
800 N 800 N
Max. Speed 800 mpm(100-800mpm)
1200 mpm(50-1200mpm
Operating Speed 700mpm 700 mpm Machine Brake Hydraulic Hydraulic
•AMBIENT CONDITIONS IN WARPING DEPARTMENT
Temperature Range: 27-30°C Relative Humidity: 60-80%
PARTICULERS MACHINE NO.1 MACHINE NO.2Creel:Creel type H-Creel V- creel(moving chain
type)Creel capacity 672 656Pressure operated on the creel
15-20 N 18N
Yarn stop motion Electromagnetic Photocell typeTensioning system Capstan
Tensioners Pre-tensioning
rod{t=t’exp(μθ)}Total drive motor 8 9Creel Threading Horizontal Vertical
PASSAGE OF YARN IN DIRECT WARPING M/C
Creel Package Yarn Tensioners Yarn stop motion
Sensor Yarn guides
Expanding Comb
Guide roller
Warper’s beam
S
SETIONAL WARPING
Each of the Sectional Warping M/c contains:
One Creel One Leasing Reed One Expanding Reed Tapered Drum Sectional Warper’s Beam. Stop Motions.
TOTAL SECTIONAL WARPING M/C: 6
BENNINGER :4 PRASHANT GAMMATEX :2
PASSAGE OF YARN IN SECTIONAL WARPING M/C
MACHINE SPECIFICATIONS :(m/c No.1,2,3,4) MANUFACTURE M/C MODEL
YEAR CREEL
Benninger AG (Switzerland)
Ben-tronic 2005 Ben-creel
M/C COMPONENT TYPEMachine brake HydraulicTensioning system Additive type(spring loaded)Yarn break stop motion Electromagnetic Winding speed 5-800m/min
CREEL:Manufacture Model of creel/ Type Year of manufactureBenninger(Swiss) Ben-Creel/H-Creel 2005Creel threading Horizontal Pitch length of the creel 28cmTotal reeds 2Angle of tapered flange 11.8°Diameter tapered beam 1m( max dia of flange 1.5m)
MACHINE SPECIFICATIONS :(m/c No.5,6) MANUFACTURE M/C MODEL
YEAR CREEL
Prashant Gamatex(Ahmd,India)
ESP 1100 2007 Prashant Gamatex
M/C COMPONENT TYPEMachine brake HydraulicTensioning system Additive type(spring loaded)Yarn break stop motion Photocell typeWinding speed 5-800m/minAngle of tapered flange 10.5°
CREEL:Manufacture Model of creel/ Type Year of manufactureBenninger(Swiss) Ben-Creel/H-Creel 2005
Creel threading Horizontal Pitch length of the creel 28cmDiameter tapered beam 1m( max dia of flange
1.5m)
TENSION IN WARPING SECTION
CALCULATION OF BEAMING TENSION: BEAMING TENSION =
CALCULATION OF YARN TENSION: YARN TENSION = dtex × 0.1cN
Count (Ne) Warping tension Speed (mpm) 16 24 500 20 22 500 30 15 500 40 12 500 50 11 500 60 9 500 70 8 500 80 7 500 2/40 22 500
REWINDING SECTIONObjective:
1.)To utilize the remaining yarn in packages after the completion of warping beam.
2.) 1) To form big packages from small packages for selling purpose.
Total Rewinding M/C: 2Type: Drum Type Winding M/CPackage Produced: Open Wound Package.
Rewinding m/c no. -1,2
PARTICULARS TYPE / VALUE Made: P.S. METTLER
Year of Manufacture 2006Model RECO DANo of Spindles 60 (ON 2 SIDES)Tensioners Disc type TensionersSpeed 500-550 r.p.m.Stop Motions Mechanical Stop Motion
Package Prepared Open wound package
Weak place Cut end Bad winding Slough off
Cone finish Entanglement Foreign matter Others
WARPING BREAKAGES:
SIZING DEPARTMENT
SIZING SECTIONSIZING KITCHEN
SIZING MACHINE
SIZING KITCHENSize is prepared at the top floor in the sizing kitchen and
transferred to the machine with the help pipes. USE 3 APPARATUS:(1) PREMIXER (2) PRESSURE COOKER (3) STORAGE.
PREMIXER PRESSURE COOKER STORAGE VESSEL
PREMIXEROne for three m/c
• Chemicals are mixed with stirrer for 15 min.• In 665 ltr of water• Then mixture is transferred to cooking vessels
through pipes.
PRESSURE COOKERThree for three m/c
• Set temperature : 120° C• Steam cut of time : 40 min.• Cooking pressure : 1.5 – 2 kg /
cm²(psi)
STORAGE VESSELThree for three m/c
• size is transferred to storage vessel • stored at the temperature of 85 - 90°C • continuous stirring for further transfer to m/c
SIZING MACHINE SECTION
TOTAL SIZING M/C : 31.) Tsudakoma: Only For Direct Beam2.) Moenus Sucker: Both For Direct & Sectional Beam3.) Moenus Sucker: Only For Sectional Beam.
PARTS OF SIZING MACHINE:
--------------------------------------------------------------------------------------------------
SIZING INGRIDIENTS TEXOPLAST WATER KETANOL ANTISTATICSONYCRYL Sizofilm: recently ordered (using)MUTTON TALLOW
1.)Creel Zone
2.) Size box
3.)Drying zone
4.)Waxing
Zone/oiling zone
5.)Splitting Zone 6.)Comb 7.)SIZED
BEAM
SIZING MACHINE SPECIFICATIONSMachine
TSUDAKOMA
Moenus Textilmaschinen GmbH
Moenus Textilmaschinen
Manufacturer TSUDAKOMA Sucker Muller Hacoba Sucker Muller Year
2004 2004 2005
Creel capacity 20 beams 20 beams 1 beamType of creel Vertical creel Vertical creel Sectional CreelM/C speed (max)
7-125 mpm 7-125 mpm 7-125 mpm
No. of size box 2 2 1Drying cylinder 14 (10 Tef,4
steel)14 (10 Tef,4 steel) 8(6 Tef ,2 steel)
Dia. of drying cylinder
800 mm 800 mm 800 mm.
Squeeze roller pressure
5 kN (7m/min) 13 kN (60m/min)
5 kN (7m/min) 13 kN (60m/min)
5 kN (7 m/min) 13kN (60m/min)
Immersion,Feed, Size rolls
2,2,2 2,2,2 2,2,2
Pre drying cylinder temperature
115°C-135°C 115°C-135°C 115°C-135°C
Temp. of size box
80°C-90°C 80°C-90°C 80°C-90°C
PARTICULERS FOR SIZING M/CSIZE PICK UP %Open End Yarn-8%Compact Yarn-12%Carded Yarn- 16%Combed Yarn- 16%PARAMETERS FOR SUCKER MULLERTension (N) =gm/mtr * factor *1.15Gm/mtr = total no. of ends /metric count
FACTORS:Let off tension=6 ( upto 40, 40& above =7)Positive feed tension = 2Wet zone tension=NADry split tension= 12Winding tension = 16Beam pressing or winding tension = (70~100)
DRAWING-IN SECTIONDRAWING-IN DEPARTMENT
MANUAL DRAWING-IN AUTOMATIC DRAWNG-IN WASHING & CLEANING SECTION
Drawing-in is the final preparatory process.
Cleaning & Drying
Drawing-In
--------------------------------------------------!!----------------------------------------------------------
Manual drawing-in Automatic drawing -in
Drawing-in componentsDifferent types of
Healdframes:1) STEEL HEEDLE DELTA2) TOYOTA-230 CM3) GROB-DELTA4) OMNIPLUS HIGH SPEED DELTA5) TSK-ZAX6)VERBRUGGE7) TOYOTA-190 CM8) ZAX-E9) TSK- TSUDOMA10) TSK-ZAX-e
Type of Heald wires: 1) 6.6 mm × 1.8 mm : Simplex 2) 6.4 mm × 1.5 mm : Duplex 3) 5.5 mm × 1.2 mm : Duplex Type of drop pins: 6.5× 1.1× 0.2 : (used for
processing Ne 25 & above) 6.5× 1.1× 0.4 : (used for
Processing Ne 25 & below) Type of Reed: DELTA-110 m.m. (Crank height
4.5cm) ZAX-120 m.m.(Crank height
6 cm)
Auto Drawing-inDRAWING-INAuto drawing m/c: Here drawing is done automatically using rapier
hook.
Manual Drawing-inDone manually to draw warp yarn through
droppins,healdframes,and reed.Two workmen:Reacher-in: puts warp in drawing-in pin or needle.Pinner: Holding drawing-in pin& draws the warp yarns
through drop pins, Healdframes & reed.
Name of Machine Model Year of Manufacture Rapier Traverse Staubli(KOREA) DELTA-110 2005 40-140mpm
Washing ,cleaning and drying m/c
Machine Used: SpaleckSPALECK washing cycle and other settings
Component Washing process Carriage time Drying passes
Heald wire-ZAX 1 100sec 4Heald wire-GAMMAX 1 100sec 4Drop wire 1 200sec 9Gammax reed 1 100sec 2Gtx reed 1 100sec 2ZAX reed 1 100sec 2
LOOM SHED DEPARTMENT
LOOM SHEDTotal loom : 224
Airjet looms : 142 Rapier looms : 82
AIRJET LOOMS (24+118)
TSUDAKOMA ZAX
TSUDAKOMA ZAX9100
Ambient conditions Loom conditions: Room conditionsRelative humidity(%) 75-85 % 68-72 %Temperature(°C) 26-30°C 28-32°C
Passage of weft through airjet loom
Loom specificationsLoom Tsudakoma Tsudakoma Manufacturer Tsudakoma corp
nomachi (Japan)Tsudakoma corp nomachi (Japan)
Year 1999Model Tsudakoma ZAX Tsudakoma ZAX9100Speed 750 rpm Loom 901 rpmReed width 190 cm 150,170,190,210,230,250,28
0,340,360,380cm.Shedding positive staubli positive staubli Max. Heald frame 7 8FDP Pin Present PresentWeft feeling sensor H1 & H2 H1 & H2 Cutter Both cutters are
mechanicalBoth cutters are mechanical
Digital display: Not attached with loom Attatched(navigation system)
Let off Electronic ElectronicShedding Mechanism
+ve cam shedding +ve cam shedding
Loom specificationsLoom type Picanol Picanol DornierManufacture Picanol Machine
(Belgium) Picanol Machine (Belgium)
Dornier Machine
Model
Gammax-6R Picanol –Gtx Dornier
Type Rapier loom Rapier loom Rapier loom
Rapier type Flexible Rapier Flexible Rapier Rigid Rapier
No. of rapier 2 2 2
Reed Width 190cm 190cm 190cmNo. of weft colour insertion 2,4,6 2,4,6 2,4,6
Shedding
Positive staubli Positive staubli
Loom speed 750rpm 550rpm 500rpm
Accumulator type Irostella-290 Irostella-290 Irostella-290
Selvedge cutter Mechanical Mechanical Mechanical
Others Particulars
Knotting: process to join warp of new weaver beam with old warp sheet using knotting machine.
type; grey and dyed yarnm/c used: Staubli knotting machine.Approximate time: 1-1.5hr.Gaiting :is to replace old weaver’s beam, drop wires,
healdwires,reed with new one.m/c used: GENKINGER HOBTEX hydraulic gaiting machine.
Quality assurance/folding department
CLOTH ROLL
Inspection FOLDING
GRADING BALE SORTING BALE PACKING
•Inspection zone.•Bale sorting zone. •Bale packing zone.•MACHINE Number manufacture•Inspection m/c 7 Laxmi m/c manufacture•Mending table 2 Laxmi m/c manufacture•Folding 2 Laxmi m/c manufacture•Rolling machine 1 Laxmi m/c manufacture •Inspection cum Rolling m/c 1 Navjyot m/c works ltd •Bale pressing m/c 1 Laxmi m/c manufacture
VARIOUS INSPECTION SYSTEM 10 POINT INSPECTION SYSTEM, 4 POINT INSPECTION
SYSTEM 4 Point inspection System: 0-3 inches- 1 point 3-6 inches- 2 point 6-9 inches- 3 point 9 inches and above 4 points FAULTS NOTED IN FOLDING Minor faults- this includes slub, stains and
contaminationMajor faults- this includes the faults like bent pick,
double pick, thick place stain mark, oily weft
QUALITY ASSURANCE (PDC)
ResearchSelection of raw materialProcess controlProcess developmentProduct testing Quality assurancesSpecification tests
INSTRUMENTS USED IN R & D LAB Tension meter, Digital thread counter , Weighing scale,
Circular cutter, Stirrer, Tachometer, Shore hardness tester, Yarn appearance tester, Automatic twist tester, Single yarn strength, tester, Bess lay balance, Desiccators, Moisture meter, Tearing strength tester, Lea strength tester, Refractometer.
cpdc: central productive development centre
PDC
• PRODUCT DEVELOPMENT CENTRE
CDC
• CREATIVE DESIGN CENTRE
PILOT PLAN
• PILOT PLAN
CPDC: CENTRAL PRODUCTIVE DEVELOPMENT CENTRE
Queries.???