yarn-II Note

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Chapter 1

Speed Frame

Speed Frame : Speed frame is the m/c where the sliver is subjected to one or more attenuating
process and the attenuated sliver receives a small amount of twist and is then wound on
bobbins suitable for creeling at next process.
It is a conventional process where generally three passages are required .
They are as below –
Sliver ------- Sliver frame ------ Slubber bobbin ( draft change 3-5 )
Slubber bobbin ----- Intermediate frame ------ Coarse roving ( d.c. 3-5)
Coarse roving ---- Fire roving frame --- Fore roving ( draft change 3-5)

Object / Function of speed frame:


1. Attenuation of drawn sliver to form roving of required court by drafting.
2. Insert small amount of twist to give required strength to roving.
3. Wind the roving in bobbin such a form which will facilate handling , transfer and
feeding to ring frame.
4. Build the roving in full length of bobbin.

Need to use Speed Frame / Necessity of Speed Frame :


1. The first reason for speed frame related to the required draft. Slivers from the draw
frame are generally too coarse in hank number for intermediate presentation in the Spg
frame for drafting and twisting to yarn.
To convert this to a yarn , required 100-500 draft . But the drafting arrangement of ring spg
m/c are not capable of processing sliver in a single drafting operation to create a yarn of
short staple fibre.
2. The second reason is that , the drawn frame cars represent the worst conceivable mode
of transport and presentation of the feed material to the ring frame.
Operation involved in Speed Frame :
1.) Creeling: Sliver feeding with the help of several rollers. 40 drawn slivers can be
creeled at a time.
2.) Drafting: To reduce wt per unit length of roving in speed frame so that produces
roving can be converted into yarn easily with draft in drafting Zone. For this normally
3 pairs of rollers are used.
3.) Twisting: To insert small amount of twist to get required strength of roving . so that
not breakage of yarn and possible to wind of roving in convenient package. Usually 30-
65 turns per m which are created by flyer. But twist in roving are given such that the
fibres hold its constituent fibres together and not create hinder during drafting in Ring
frame.
4.) Winding: To wind the roving on to a suitable bobbin which will facilate handling ,
transfer and feeding to ring frame. Due to winding , as dia of bobbin is gradually
increased, the speed of bobbin is continuously decreased with the help of building
motion so that not breakage of %%%% too much tension. And as a result roving is
wounded on bobbin.
5.) Building : With the help of building motion , the correct or proper shaped package is
made by winding of roving on bobbin in some consequent process and the two ends of
package is formed tapered so that not with drawn of roving.
6.) Doffing : To replace empty bobbin at a place of full bobbin.

Conventional speed frame :


1. Slubing frame : In this first conventional process , the slivers from the can placed back
of the m/c are attenuated by the drafting rollers and attenuating roving pass through
the flyer cop, flyer leg and eye .
Draft Range : 4-5
Drafting system : 3 over 3.

2. Intermediate frame : Two slubbing bobbin are creeled for each spindle on the
Intermediate frame and the resulting roving is finer than that of slubbing.
Draft Range : 5-6
Drafting system : 3 over 3.
3. Roving Frame : Roving frame is the next m/c which doubles two of the intermediate
bobbins and offers finer hank roving.
Draft Range : 5-6
Drafting system : 3 over 3.

4. Fine roving frame : For very fine counts spinning , attenuation is done again on fine
Roving frame / jack frame where two roving bobbins are creeled for one spindle.
Draft Range : above 7.
Drafting system of Simplex / Speed Frame :
1. Conventional drafting system : 4 over 4 without apron
2. Modern drafting system : 4 over 4 with apron
I SKF Pk 1600
II SKF Pk 1500
1. Conventional 4 over 4 drafting system :

Features :
1. Draft range --- 6 ---10
2. Less middle %one draft ( about 1.05)
3. Roller weighting by dead weight and hook arrangement.
4. Nip point is in the vertical line of the roller centre.
5. After passing the nip point , fibre is not controllable.
6. Nip to nip distance is higher than fibre staple length.
7. Pressure system is dead wt and hook arrangement.
8. .Top Rollers are rubber coated & Bottom are steel and flutted.
Advantage : → Flutted rollers causes of less slippage and synthetic rubber coating prevent
more fibre damage .
Disadvantage : → No arrangement for properly fibre control.
 Irregular draft distance.
 Time required for changing nip t nip distance.
 Found more irregularity.
 Thick and thin places produce.
 The roller setting distance should be changed for even
 Very small change in fibre staple length.
 Less production due to more time required .

Modern drafting system :


 SKF PK1500
SKF drafting 
SKF PK 1600
1. SKF PK – 1500 drafting system :

Feature :
 It is 3 over 3 drafting system.
 Draft range – 10-15 and break draft range form 1.05-1.15
 Apron is used in front %one and thickness of apron is 1 mm and aprons is
shorter and lower apron is longer.
 Cradles are long continuous sheet used in double apron system.
 Top roller weighting is by spring or pneumatic.
 Roller setting is not necessary for small change of fibre length.
 Roller Pressure : Front pair → 20-30 daN, Middle Pair 20- 25 daN, Back pair
15-20 daN.
 Hardness of top roller 80-88 shore and hardness of bottom roller is about 60
shore , & Back –85-80 and Front 80-75 .
Roller dia
Front Middle Back
Top—28 mm 25 mm 28 mm
Bottom—30-32 mm 25-27 mm 30-32 mm

Advantage
 Regular and uniform draft distribution .
 Better fibre control.
 Roller setting is not always necessary.
 Better roving evenness.
 Less influenced by change in staple length of fibre.

Disadvantage :
 If draft is below the lower limit , then drafting operation becomes difficult to
control.
 Cracked open , badly joined leather apron produce bad roving.
2. SKF PK – 1600 drafting system :

Feature :
 Draft range – Max 20 Normally 10-15
 Roller dia slightly change .
 All bottom roller dia ---- 28.0 mm
 Top roller dia--- Back 28, 3rd---28, 2nd—25 , front ---28 mm.
 For middle zone, draft distribution easily.
 More wider roller setting.
 Double apron is used and thickness 1 mm.
 Top roller hardness is 80-85 shore.
 Roller setting is not necessary for small change of fibre length.
 Roller weighting by spring or pneumatic.
 Condenser in middle %one to hold the fibres in one place.
Roller setting :
Front range : ---------- Staple length +1/16~1/18”
Middle range : -------- Staple range + 2/16~3/16”
Back range : -------- Staple range + 4/16~5/16”
Advantages :
 Regular and uniform drafting is possible.
 Roller setting is draft %one for dust and fly fibre suction.
 Pneumatic suction in draft %one for dust and fly fibre suction.
 Less irregularity.
 Roller setting is flexible.
 Better controlling and guiding of fibre occurs .
 Capability of giving high range of draft.
 Less tendency of roller lapping.
Disadvantage :
 When draft is below the lower limit then drafting is difficult to control.
 Cracked apron , badly joined leather apron produce bad roving and end
breakages.
Factors consider for Roller Pressure and Hardness :
1. Bulk of the mtl : Bulk →  , Pressure 

2. Amount of draft : Draft → , Roller Pressure 

3. Type of fibre : Polyester and acrylic is bulk fibre As a result required higher roller pressure
then cotton .
Factors considered for Roller setting :
1. Bulk of the mtl  R/r setting 
2. Amount of Draft  R/r setting
3. Type of fibre Staple length  R/setting 
Difference between Conventional and Modern Drafting system :
Conventional Drafting system Modern drafting system
1. Roller draft method. 1. Apron draft method.
2. Apron is not used. 2. Apron is used for better drafting.
3. Not fibre control. 3. Better fibre control.
4. Roller weighting by dead weight 4. Roller weighting by spring and
and hook arrangement. pneumatic.
5. Draft range 6-10. 5. Draft range 10-15 Maximum 20.
6. Less tendency of roller lapping and
6. More tendency of roller lapping end breakage rate.
and end breakage rate.
7. Spindle speed is very high.
7. It is possible to apply very less 8. Able to more production.
speed in spindle.
8. Not able to more production. 9. Various staple length fibre can be
9. Various types of setting is needed treated in same roller setting.
to various staple length of fibre. 10. Less time required.
10. More time required to change of
roller setting. 11. Not.
11. Nip points in the vocational line of
roller centre.
12. Irregular draft distributes. 12. Regular draft distributes.

Apron : Apron is an endless sheet of synthetic rubber , Over which fibre can free movement . It
may be of short or long and the thickness is about 1 mm. The aprons are held out by tensioning
devices.
Objects :
 To reduce the less of short fibre .
 Control the floating fibre.
 Prevent foreign matters.
 Help regular drafting by alignment of fibre..
Twisting :
Twisting is one of the main operation involved in speed frame. The process of giving
spiral rotation in the drafted mtl along its axis is called twisting. .
Twist helps to bind the fibres together to give a desired strength to the drafted strand just
sufficient to enable it to build up in the form of bobbin and easy with draw for the next process.
Importing Twist :
The flyer inserts twist . Each flyer rotation creates one turn in the roving. Twist per unit
length of roving depends upon the delivery rate of front roller.
RPM of flyer
Turns per inch =
Front roller delivery ( inch / min )
High level of roving twist represent production losses and also draft problem in the ring
spinning m/c. But low twist levels can cause roving breaks during bobbin winding and
unwinding.
Spindle :
The spindle is simply support and drive element for the flyer without any ancillary
function. It is a long steel shaft, mounted at its lower end in a bearing and supported package
tube acting as a neck bearing. The spindle tip is and provided with a slot .When the flyer is set
on the spindle a pin on the flyer projects into the slot so that the flyer and spindle are converted
into a unit for drive purpose.
The Flyer :

Flyer is an essential part pf a speed frame, By this Twist are given an roving , without
any current resistance . Flyer hold the roving and pass the roving through hollow legs also
maintain uniform tension during bobbin building.

The second full flyer leg serves to balance the grooved leg .
Mainly three types of flyer --------
1. Spindle mounted flyers ( conventional)
2. Top mounted flyer ( Modern)
3. Closed mounted flyer
Flyer speed ---- 80-1200 rpm.
Function of flyer :
 To import twist on roving. It gives one twist on roving per revolution.
 Guiding the roving in proper place over the bobbin during winding.
 The pressure of the flyer on the roving helps to produce a compact bobbin.
 Helps in winding.
 Protects the weak roving from resistance of air.

Factors consider for selection of twist in Roving :


1. Staple length of fibre : For higher staple length, lower TPI because of it gives sufficient
strength to roving.
Staple length ↑ sufficient strength ↑ Twist ↓ Production ↑
2. Fire ness of fibre : Fineness ↑ TPI ↓
3. Hank of roving : For fibre hank roving , TPI ↑
4. Type of fibre : Poly long staple , uniform fibre, Twist ↓ Polyester→ twist ↓ Cotton -----
Twist

Yarn count Roving Hank T.M


6-40 0.8-1.0 1.3-1.1
40--+ 1.0-3.0 1-.9
Winding Principle: In speed frame , normal drum winding or Cross-winding is not possible
at high speed, because of its softness and low strength. It is wounded by the help of flyer.
There are two winding principle :
1) Bobbin leading principle ( for cotton )
2) Flyer leading principle ( for jute )

1. Bobbin leading principle :


1) In order to wind the roving on to bobbin , the bobbin speed must be higher than the
flyer/ spindle speed at all winding period.
2) With the increase of bobbin dia , the bobbin speed must be decrease.
3) The variation of bobbin speed with the increase of bobbin dia must be constant.

Nb

Mathematical Expression ----


Let front Roller delivery = l inch/min.
Bobbin dia = d inch
Bobbin speed = Nb rpm
Spindle / flyer speed = Ns rpm
Bobbin circumference = ∏ d.
And winding on speed (Nw) = L/∏d rpm.
Again , Nw = Bobbin speed –Flyer speed/spindle speed.
= Nb-Ns
So , L/∏d = (Nb-Ns)
L = ∏d(Nb-Ns)
Bobbin dia increase , the bobbin speed must be decrease.
2. Flyer leading principle :
1. In order to winding the roving on the bobbin , the flyer speed must be higher than the
bobbin speed at all point of winding.
2. With the increase of bobbin dia , the bobbin speed must be increased.
3. The variation of bobbin speed is constant with the increase of bobbin dia.

Nb

Mathematical Expression ---


Let, Front roller delivery = L inch/min
Spindle / flyer speed = Ns rpm
Bobbin speed = Nb rpm
So, bobbin circumference = ∏d
Winding on speed = L/∏d
Again Nw = Ns-Nb
L/∏d = Ns-Nb
L = ∏d (Ns-Nb) if L, ∏, Ns are constant with the increase of bobbin dia , the bobbin speed must
be increased.

How to change bobbin speed?


 When the builder motion shifts the cone belt, the rotation rate of the lower cone is
changed.
 This continuously reducing rotation rate is transmitted via gearing to the
differential and is there superimposed on the constant speed of the main shaft.
 Further gearing then transmits the resultant movement arising in the differential
to the bobbin drive.
Building Motion : The task : / Function :
This device has to perform three important tasks during winding operation: -
1) Shift the cone belt corresponding to increase in the bobbin dia.
2) Reverse the direction of movement of the bobbin rail at the upper and lower ends of the
lift stroke.
3) Shorten the lift after each layer to form tapered ends on the bobbins.
1) Shifting on the cone belt :

 The m/c part that induces all changes is the change over mechanism , which
comprises metal brackets (3/7) and rods (5/6)
 This mechanism is secured to the bobbin rail and is raised and lowered as a unit with
the rail.
 A stationary pin is struck by one of the rods (5/6) on the upward stroke and by the
other on the downward struck.. and each time a micro switch (4) emits a pulse.
 Each pulse from micro switch causes operation of a release mechanism to permit
rotation of the ratchet wheel through one half tooth.
2) Reversal of the bobbin rail movement :
 Reversal of the rail movement originates from the reversing gear.
 An electrically operated valve pressurizes the left and right chambers of the double
acting cylinder (9) alternately.
 Thus the left hand clutch and right hand clutch are operated successively so that the
pinion is meshed either with. gear wheel 1 or gear wheel 2.
 The shaft on which gear wheels 1 and 2 are mounted , always rotates in the same
direction.
 Accurately , operation of clutch ( 1)or ( 2) causes left or right hand rotation of the
pinion and shaft.
 The bobbin rail is correspondingly raised or lower via the bevel gear, pinion ,
sprocket and lifting chain.
3) Shorting of the lift :

 Rods 5 and 6 are inclined. The inclination is adjustable and corresponds exactly to
the taper of the bobbin ends (α)
 During winding of a package , the ratchet is rotated at every change-over and also
the micro switch is gradually shifted further to the right on a slide .
 The rods engage the micro switch steadily earlier in the lift stroke and reversal
occurs correspondingly earlier.
 This gives a continuous reduction in the lift of the rail.
 The bobbins are thus built with a taper.

Break draft : The greater portion of draft in speed frame is obtained between middle and front
roller. But the draft between back and middle roller varied from 1.03-1.5 which is known as
break draft.
Function:
 To prepare the processed sliver for final drafting in the front zone.
 Engage to break the twist in the curled mtl to prepare it for final drafting.
 Helps to acquire higher draft between middle and front roller.
Excessive break draft are undesirable from evenness and quality point of view. The twist of the
speed frame roving is well broken in the break draft field, so that the roving , enters the main
draft zone , is in sufficient loose condition.
List of break draft of different fibres for different back zone setting :

Efficiency loss for different types of stoppage :


1. Roving breakage
2. Roller lapping in drafting roller
3. Power failure
4. Mechanical fault.
5. Electrical fault.
6. Unskilled worker.
7. Workers regularly.
8. Doffing.
9. Creeling.
10. Piecing.
11. Can shortage.
12. Sliver shortage.
13. Sliver breakage.
14. Bobbin shortage.
Recent development of speed Frame :
1. Improved drafting system : By Improved drafting system, 6-20 Draft can be imported to
sliver. SKF pk 1500, SKF pk 1600, SKF pk 5000 etc. give better controlling to fibres.
2. Higher spindle speed : Range 1400-1500 rpm which gives up to 50% increased
Production.
3. Plastic flyer : Lighter in wt and less power consumption.
4. No spindle present , flyer gets drive from the top.
5. Auto stop motion :
1) At creel : When slivers breaks or slivers can is empty.
2) At front Roller : When roving breaks.
3) Auto doffing : Full bobbin is ejected and empty bobbin is replaced automatically.
6. Gearing in the oil bath : Smooth running of the m/c and high production.
7. Inching motion : This involves in turning the flyer to correct position for piecing when
m/c stops for any end breakage and important due to relationship between bobbin dia
and winding speed.
8. Monitoring system : Includes
 Process setting
 Drive setting
 Production report
 Efficiency
 Speed of flyer
 Quality monitoring
 Stoppage time.
9. Auto tensioning device : To determine tension on roving and send this data to inverter
motor . If tension is more , decreases motor speed and vice – versa.
10. Cone belt returns automatically.
11. Suction in drafting zone.
12. Inverter motor :
 Decrees speed of bobbin with the increase of bobbin dia.
 Controls traversing motion.
 Controls tension on roving.
 Controls the fast wheel directly.
13. Improved roving quality.
14. Wide range of roving court ( 0.5-2.5 Ne)
15. Can changing.
Differential motion : Differential motion is actually the resultant of two different
motion’s namely ---
The const motion of main shaft driven from motor.
The variable motion of cone drum ( particularly bottom can drum)
Differential; motion is generated in differential box and get the output motion from the last
wheel.

Function or necessity of differential motion : Necessity of differential motion is very much.


→ For winding roving on to bobbin we have to keep bobbin speed more than flyer speed .
This excess speed of bobbin is controlled by differential motion.
→Bobbin dia increases after winding every layer of roving onto it. So to keep constant
winding on speed (ie difference between bobbin and flyer speed ) we have to decrease
bobbin speed. For this purpose differential motion is used.
→ Differential motion helps to transmit the variable speed of bobbin cone drum to bobbin
with the increase of bobbin dia.
So its necessity is very much for winding operation of speed frame.

Change wheels in speed frame:


1. Draft change pinion. (DCP)
2. Draft constant change pinion (DCCP)
3. Twist change pinion (TCP)
4. Twist constant change pinion (TCCP)
5. Lifter change pinion( LCP)
6. Ratchet wheel.
7. Spindle speed change pinion.
8. Pooker whelel (PW) / Taper wheel (T.W)

Effect of roving hank change :


1. Draft change pinion :
→ The amount of draft is changed by changing DCP.
→ Controls the speed of bach rollers/ drive position.
→ If DCP is longer in size then back roller speed will increase and more mtl will be feed.
But front roller speed remains unchanged. So draft will reduce.
F.R. Speed
Draft =
B/R speed
DCP  DRAFT  Roving hank 

2. Draft constant change pinion (DCCP) :


 Draft constant can be changed by changing DCCP.
 If DCCP is larger in size then constant increases and vice versa.
 When required DCP (teeth) is not available then DCCP is used to change or to
obtain required draft and ultimately it increases drat constant.
DCCP  , Draft constant 
If used of DCCP of required teeth , get required draft .

3. Twist change pinion :


→ TPI is changed by changing TCP.
→ If the no of teeth in TCP/ it is larger in size , the front roller delivery and bobbin speed
increases, but TPI decreases.

Flyer speed/ spindle speed


TPI=
Front roller delivery.
&TPI = TM Roving hank
If TPI is More then roving hank More.
TCP  TPI  Roving hank 
TCP creates no effects on draft because of same delivery ratio of front roller and back roller.
4. Twist constant change pinion (TCCP) :
→ Twist constant is changed by TCCP.
→ Twist Const increase with the increase of the increase of the teeth of TCCP.
→ When required TCP is not available , then TCCP is changed to get required TPI. TCCP
Twist constant
5. Lifter change pinion :
 Lift speed of bobbin rail or rate of lift is determined by LCP.
 It determines the coil per inch in roving.
 In case of not changing the bobbin speed , if LCP is large in size the speed of
bobbin rail or rate of lift will be increase As a result , Coil/ inch will be
decrease. i.e. LCW increase , Rate of lift increase and coil / inch decrease.

1 1
LCP  and & LCP
 Coil / inch Roving hank

 LCP , coil / inch ↓ , Roving hank ↓


6. Spindle speed change pinion :
 Spindle speed is controlled by ( SSCP )
 If the increase in no of teeth of SSCP , decrease the spindle speed.
 Production will decrease if spindle speed decrease
 SSCP  , Spindle speed ↓ , production ↓
7. Ratchet wheel : Ratchet wheel is directly related with roving Hank , bobbin dia ,
bobbin speed and cone drum belt movement.
 Quicker movement of ratchet wheel , cone drum belt moves quickly.
 Ratchet wheel makes a ½ teeth movement after completing winding of one
layer of roving on to bobbin.
 The movement of cone drum belt after winding one layer depending on
bobbin dia.
 For fibre roving , the movement of cone drum belt less, the pitch of RW is less
I e no of teeth more.
 For coarse roving , the movement of belt is more the pitch of ratchet wheel
should be more I e no of teeth less.
 When circumference of ratchet wheel is fixed , then the no of teeth in ratchet
wheel will be decrease i.e. pitch increase.
 R.W ↓ Pitch of ratchet  teeth of ratchet ↓ Roving hank ↓ bobbins ↓

8. Tappet wheel / Poocker wheel :


 H controls tapering of bobbin.
 If no of teeth of P.W is more , increase of tapering on bobbin.
 Taper wheel ↑ Tappet ↑
9. Bottom cone drum change pinion : ( BCDCP)
 If BCDCP is large in size , winding will be very tighter
 H determines the primary speed of bobbin.
10. Spoor wheel change pinion (SWCP) :
 It controls instead of ratchet wheel.
 For finer count.
Inching Motion : The motor mechanism has been improved by fitting an inching motion.
The inching motion involves in turning the flyer to correct position for piecing when the
m/c steps for any end breakage.
This is important because there is a relationship between robbin dia and winding on
speed.

Problems
Problem -01 : Find out the Production / frame / Shift of a modern speed frame at 85%
efficiency to produce 1.5 hank roving.
Assume necessary parameters .
Given , Efficiency = 85%
R.H = 1.5 Ne
Let , TM = 1.1
TPI = TM R . Hank = 1.1 1.5=1.34
No of spindle = 120
Spindle speed = 1200 rpm
Spindle speed * no of spindle * 60* 8 * 0.85
Production = lb
TPI * 36 * 840 * 1.5
= 96.6 lb / shift.

Problem 02 : In speed frame spindle speed =1200, No of spud =120. Roving Hank =1 , TPI =
1.3 , Effy = 85% , cale production lb/hr.
120 * 120 * .85 * 60
Production =
1.3 * 1 * 840 * 36
= 186.81 lb / hr.

Problem 03 : Find out the DCP required to produce 1.5 Hank roving from the sliver of 60
grains / yd. When,
Present DCP = 60 , Roving hank = 0.74
Present sliver = 68 grain /Yd.
R.H = 1.5 Ne
Sliver hank = 60 grain /Yd.
Present DCP = 60
Present roving hank = 0.78
Present sliver = 68 gram/ Yds.
Present DCP * present Draft = Required DCP * Required draft
Delivery Hank
Now, Present draft = ------------(1)
Feed Hank
Delivery Hank = 0.74
Feed Hank = 68 grains / Yd.
= 0.1225 Ne
L w 1 1

W l 68
 840
7000
 0.1225 Ne
0.75
Present draft = =6.03
0.1225
= 6.03
delivery Hank
Required draft =
Feed Hank
1.5
= = 10.8
0.13
Present draft * Present DCP
Required DCP =
Required draft
6.03*60
= = 33.5 = 34 teeth.
10.8

Problem no 04: Present R.H = 1.2 Present hank = .014, Required R.H = 1.1 , Required sliver
Hank = 0.12 , Present DCP = 60 , Required DCP = ? Ans :
56.14 ~ 57.0

Solve:
Present R.H = 1.2 Required RH = 1.1
Present Sliver Hank = 0.14 Required Sliver Hank = 0.12
Present DCP = 60 Required DCP = ?

Draft 1 * DCP 1 = Draft 2 * DCP 2


Draft1 * DCP 1
DCP 2 = (1)
Draft 2
Present R Hank 1.2
Draft 1 = =
Present sliver 0.14
1.1
Draft 2 =
0.12
1.2/0.14 * 60
DCP 2 = = 56.10 ~57. Ans.
1.1/0.12

Problem 05 : Front roller dia = 1.125” , Front roller rpm = 185, If Roving Hank is 0.8 Ne , find
out production in lb per hr.
 * Front roller dia * N * 60
Production in lb/ hr =
36 * 0.8 * 840
 * 1.125*185*60
=
36 * 0.8 * 840
= 1.62 lb/hr.
Production with 85% efficiency = 1.62 * .85 = 1.38 lb/hr.
Problem no 06 : Find out the production less / shift in lbs of a speed frame was stopped for
40 mins due to roving breakage (Assume necessary parameters)
Solve :
Here data given , time of stoppage = 40 mins
Let number of spindle =120 , Production in 03 per spindle = 160
Now Production loss in spindle –hr = No of spindle * time in hr
= 120* 40/60 = 80
OPS * spindle -hr 160 * 80
Production loss in lb per shift = =
16 * 8 16*8
= 100
Production loss 100 lb / shift (Ans)
Chapter 2
Comber

Combing : Combing may be defined as to removed of short fibres , reps and remaining
impurities of card sliver by using comb with the help of knives , brushes and rollers.
Objects of combing :
1. To remove short fibres below a pre elected length so that the spinner enable to produce
finer / better yarn.
2. To remove reps and foreign matter from the cotton / sliver.
3. With the help of drawing and doubling , combed sliver is uniform and the fibre are
straight and parallel.
Combing for finer / better yarn :
Why combing is necessary for finer / better yarn :
1. For finer count , high draft is required but draft irregularity for presence of short fibre .
After combing short free product ( sliver / Roving) is ready for higher draft .
2. Longer fibres are finer than short fibres. After combing higher count is possible to keep
minimum no of fibre in yarn dia.
Ring spinning system at least 60-65 no of fibre.
Rotor Spinning system more than 80 no of fibre.
Length ↑ → Yarn dia ↓
Length ↑ → yarn dia ↑
3. Long fibre yarn has less hairiness but more luster.
4. Combing is necessary for better yarn appearance and regularity.
5. Less twist for finer yarn but more twist required in present of short fibre. To remove
this.

Contribution of combing to yarn quality :


1. Improve the spinning value of fibre.
2. Better twist distribution improve the strength of yarn.
3. Improve uniformity , smooth and luster of yarn.
4. Reduce yarn hairiness and imperfection .
5. Produce short trash free clear yarn.
6. Improve efficiency in the next process.

Objects / Necessity of lap former :


1. To reduce the strain to delicate comber reduce.
2. To reduce fibre damage.
3. To reduce chance of good fibres waste.
4. To reduce short fibres.
5. To reduce thick and thin places in the sliver.
6. To control wastage.
7. To parallel and straight of fibre in corded sliver by changing pushing of fibres .
8. Not freely opening of fibre from sliver.

M/c’s used for lap preparation :


1. Conventional system –
i. Sliver lap m/c.
ii. Ribbon lap m/c .
2. Modern System –
1) Super lap former.
Super lap Former : Modern lap former M/C :

Feature :
 Three sliver creel for one m/c.
 Every creel can accommodate 20 cans of sliver .
 The sets of 20 ends are separated into 2 sets of 10 sliver are passed through the
detecting roller and draft together by vertical arrangement drafting system.
 2 over 3 Drafting system.
 After drafting the web are led through the calendar roler and finally made indo lap.
 Separated indicator and stop motion for all rollers.
 Fully automatic doffing.

M/c specification :
Speed → 80-120 m/min.
Production → 300-350 kg/hr..
Maximum 8 comber → 1 lap former
Lap wt → 700-1200 grains / Yd.
Waste → above 20 %

Advantage :
 Increase wt / unit length
 Regularity maintained in wt/ unit length.

Additional feature :
 Auto grain adjuster.
 Auto lap carrying device.
 Lap length measure device
 Auto stop motion
 Fault indicating lamp.
Sliver lap machine:

Object of this machine is to produce a narrow lap from a number of card slivers or draw frame
slivers. The machine is made to take 16-20 slivers depending upon the width and weight/yard
of the lap required to be produce.
Machine Description and material passage: in this machine material i.e. sliver are passes
through the following passages:-
1. Each sliver passes through a hole in the guide plate placed at the back end to the
machine.
2. Then they are passed over special spoons.
3. Then the slivers are guided over a v-shaped feed table which brings them together in
the order in which they lie in the lap.
4. Then the slivers are passed through 3 pairs of drafting rollers.
5. Due to draft in the drafting zone the fibers become straightened as all slivers pass
side is side creating web.
6. After leaving the web table the lap sheet runs through 2 pairs of calendar rollers
which compress it in to a sheet.
7. The sheet of cotton is then wound onto a wooden spool bobbin with the help of two
fluted lap winders.
8. During winding on spool bobbin considerable pressure is applied so that a long
length of compressed lap can be obtained.

Ribbon Lap Machine: The machine description and material passage of ribbon lap machine is
mentioned below:-
1. The lap from the sliver lap machine is creeled here. This lap is unwound and fed to
drafting rollers.
2. Ribbon lap machine is actually used to increase wt/unit length and uniformity of the lap
obtained from sliver lap machine.
3. IN ribbon lap machine 6-8 laps are fed. They form a web of same width but more
thickness then doubling and drafting is done.
4. Two wooden fluted feed rollers are used to unwind the lap.
5. Generally 3 over 3 or 4 over 4 drafting system are employed in this machine.
6. After drafting the lap is emerged out in web form passes via deflector plate’s web tables
and calendar rollers.
7. Here 2 pairs of calendar rollers are employed to compress the lap.
8. Thus comber lap is obtained and it is rolled on a spool bobbins Two fluted rollers are
responsible to obtains a compact lap bobbin.
Basic principle of combing / Sequence of combing : Cycle :

a) Lap feed by the feed roller : The feed rollers S move the sheet W forward while the
nippers Zo/Zu are held open.
b) Lap nipping by nipper : The upper nipper plate Zo is lowered onto the cusion plate
Zu so that the fibres are clamped between them
c) Combing by the cylinder : The combing segment (k) mounted on rotating cylinder
(Z) sweeps its needle or saw-teeth through the fibre fringe (B) and carries away thing not
held by the nippers.
d) Nippers forward : The nippers open again and move towards the detaching rollers
(A).
e) Web return : Meanwhile the detaching rollers A have returned part of the previously
drawn of stock (web v) by means of a reverse rotation so that the web protrudes from
the back of the detaching device.
f) Piecing : In the coarse of the forward movement of the nippers the projecting fibre
fringe B is placed upon the return web V.
g) Detaching : The detaching rollers begin to rotate in the forward direction again and
draw the clamped fibres out of the sheet W held fast by the feed rollers S ( Detaching ) .
h) Combing by the top comb : Before the start of the detaching operation , the top comb
F has thrust its single row of needles into the fibre fringe , As the fibres are pulled
through the needles of the top comb during detaching , the trailing part of the fringe is
combed thus making up for the inability of the cylinder combs to reach this part of the
fringe.
i) As the nipper assembly , is retracted , the nippers open for the next feeding step . The
top comb is with drawn . A new combing cylinder begins.

Comber lap specification :


Lap Dia → 650 mm
Lap width → 300 mm
Lap weight → 18-20 kg
Lap Hank → 0.0075-0.009
Lap wt/Yds → 700-1100 grain
Lap wt / mitre → 50-65 gm / m.

Line diagram of combing M/C :

M/C specification :
Nip / min → Max 450
Feed /nip → 4.3-5.9 mm
Drafting system → 3 over 3 or 3 over 5
Noil → 8-25 %
Draft → 9-20
Sliver Hank → Max 0.24 Min 0.16
Production → 66 kg/hr.
Parameters Influence the combing operation :
1. Raw material :
→ Fibre type
→ Fibre length
→ Uniformity of fibre length
→ Fibre Stiffness.
→ Moisture content.
2. Material preparation :
 Parallelization of the fibre.
 Sheet thickness.
 Sheet evenness.
 Orientation of the hook.
 Tailing hook → 50%
 Leading hook → 15%
 Straight fibre → 20%
 Both end hook → 15%
3. Factors associated with the m/c :
 Condition of the m/c.
 Condition of the can.
 Speed.
 Orientation of the comb.
 Accuracy of the setting.
 Drafting arrangement and draft.
4. M/C setting :
 Feed distance
 Type of feed
 Detachment setting.
 Point density of the comb.
 Depth of penetration of the top comb.
 Piecing.
5. Atmospheric condition :
 Relative Humidity ( R.H)
 Moisture Regan ( MR)
 Room temperature .
 M/C.
Index wheel : In comber outside the cylinder shaft , a wheel is attached with 40 equal parts
names as Index wheel.
H is always change during working of comber . There is a pointer on it to indicate the index
number.
Various motion of comber m/c and its timing such as nipper , cylinder , top comb, roller and
different setting and adjustments are done by different index number.
With the reference of index number , Nipper comb , cylinder and conjugative position , motion
and adjustment limit are selected.

Function of index wheel :


1. The consecutive position , motion and adjustment limit of nipper , comb, cylinder etc are
selected with the reference of Index number.
2. Different settings of comber are arranged with the reference of index number.
3. Top detaching roller weighting is also selected with reference to index wheel.
Combing cycle with reference to Index wheel : Timing diagram :
Combing cycle :
1. Combing by the cylinder :
Start → 33 and close → 5
2. Nipper movement :
Start → 7 and close → 30
3. Forwarding roller movement : 6 ~ 14.
4. Top comb timing : 13-27 (Normally)
5. Detaching Roller movement :
Start = 39
39-8 = backward
8-22 = Forward
22-39 = Still remain.
Detaching distance : The distance between nipping points of the nipper and the detaching
roller ( nip point ) when the nipper is in its foremost position.
Production calculation :
Production = Feed/Nip * Nip / min * Waste%
Problem 01 : Feed/ nip = 5 mm & Nip/ Min = 350 , waste → 20%
Production of comber = F/N * N/ Min * waste
5*350*100-20
= mm/min
100
Recent development of comber:
1. Higher production rate(100/250 nips/min to 500/600 nips/min)
2. Higher lap wt can be used(700-800 grains/yds)
3. Improved modern drafting system is used(2 over 3)]
4. Larger can size(20 inch*20 inch)
5. Auto lubricating system
6. Auto can changing system ---auto doffing
7. Higher rate of the noil extraction(5 -25%)
8. Auto stop motion for sliver breakage, feed and roller lapping
9. Noil measuring system
10. Production and quality monitoring system
11. Fault locating system
12. Diagnosis of m/c stoppage
13. Gearing in oil bath
14. Timer belt drive
15. Improved piecing mechanism

Combing improved spinning value:


spinning value indicates that up to how much finer yarn(finer count yarn) can be produced
from existing fibre. i.e. average length after spinning
1. To produce finer yarn ,high draft is required .but if there remains short fibre in fibre
strands .high draft can not be imparted .so by combing process short fibres ,hooked
fibres etc are removed. thus the strands becomes prepared to be imparted higher draft
2. For producing finer yarn, the staple length of fibre should be more by combing process ,
short fibre below a pre selected length are removes. by the remaining longer fibres, finer
yarn production become possible
3. For finer yarn count , better and higher twist distributions necessary . as weight
increases yarn strength .but short fibres can not contain more twist .so by combing these
short fibres are removes
from the above discussion , it is clear that combing process increase the spinning value of fibres
Neps removal efficiency:
neps removal efficiency is expressed as NRE%
-sliver neps +laps neps Neps removes from
NRE%= 100=  100
neps remain in lap Neps remaining in lap
lap/neps remaining in lap *100
the amount if neps are determined by AFIS. if in the combing ,neps removal efficiency is less
then 50% then it is considered that there is problem in m/c setting .so it should be more than
50%
in carding , neps removal efficiency should be more than 50%
in carding , neps removal efficiency should be more than 70%
NRE is the performance of comber
medium degree of combing (25-44Ne NRE%40; fine (45- 75Ne) --50%
super (>=76NE) -- 60%; double cpmbing : 75%
Different setting gauge:
1. gauge for setting cylinder to detaching roller
uses:
a. fasten the cylinder to their shafts
b. fastening the screws and the cylinders in the middle of each head.
2. Step gauge of setting feed plate to steel detaching rollers and nippers knives
uses:
a. noil extraction will be more
b. combing cycle will be done
1
3. inch trowel gauge for setting top detaching rper parallel to the top comb
32
4. 25/100 inch trowel gauge for setting nipper knives to cylinder needle
5. Uses a combing cycle.
6
6. inch gauge for setting depth of top comb needle
1000
7. Top comb angle setting gauge
8. Distance setting gauge for setting brash shaft to cylinder shaft
1
9. gauge for setting top cam needles to steel detaching roller
16

Degree of combing:
The amount of noil (short fibres ,neps or impurities) extracted during combing expressed in
percentages is called degree of combing
Degree of combing depends on the end use of yarn
types of combing on the basis of degree of combing:

I 1 Half combing --------noil % up to 9%


II 2 Ordinary combing -------noil% 10 --18
III 3 full combing -----noil% 18 --25
IV 4 double combing noil% above 25%

factors of degree of combing or noil extraction:


1. amount of short fibre in the raw cotton:
if the row cotton contains a huge amount of short fibre , a high degree of combing
becomes necessary to get a high amount of noil extraction for good quality yarn
2. quality of yarn required:
for good quality of yarn , the amount of noil should be present in limited range. but
passing lf range of noil , not found of good quality yarn. up to 25% noil , yarn strength ,
lusture are gradually increased but after that not increase of strength
3. cost of yarn product:
higher degree of combing removed higher noil % where production becomes slow at the
same time the production cost be come higher

Main setting points of comber :


1. Nipper and detaching roller
Function: control waste %
effect of change:
for wider setting -------waste increase but the wt od produced sliver reduced and
quality good
for narrow setting: -----waste reduce but wt of produced sliver increase and
quality comparatively reduce
2. Cylinder needle and nipper:
function: combing operation
effect of change:
for narrow setting ------fibre embedded to cylinder needle
3. Top comber gauge:
a. Top comb and detaching roller function: combing operation
for wider setting: ----- waste reduced quality hampered
for narrower setting ----waste increased but quality is good
b. Top comb & Nipper:
For wide Noil extraction quality high, production hampered.
4. Brush setting:
function: extraction of waste actually
Effect of change:
for wider setting ----------- increase tendency to be blont
for closer setting------- reduce the tendency of the blunt
Effect of comber setting on noil extraction
1. Effect of detachment setting:
the distance between thee leading edge of the feed plate and the nip of the detaching roller close
setting for the same staple length will reduce the noil extraction% and vice versa .when the
setting is wider for the particular type
2. Effect of top comb setting:
the amount of waste extracted can also be adjusted by alternating the position of top comb,
combing operation will be proper and the noil extraction will be high.
if it is set closer to the nippers , the waste extraction will be lower
Factors influences the comber setting:
1 staple length of fibre (+) feed plate and detaching roller distance higher
2 noil extraction% (+) top comb and detaching roller distance less
3 production rate(+) if noil mtl feed rate (feed/min) is higher
4 production quality(+) if the noil extraction%(+) , production rate(-)
Maintenance of comber:
1. Frequency of resetting:
if the comber is used under constant . combing condition s for long runs, the setting should be
checked and adjusted if necessary
resetting may be done as follows
a. for 1 shift -----------every 12 month
b. for 2 shift------------every six month
c. for 3 shift ---------every three month
2. Lubrication:
To obtain the best result from the m/c, it is essential to establish on efficient system if clearing ,
oiling and maintenance
lubricating system depends on the following factors
a. condition of the mtls
b. quality of the fibres
c. available of man power.
d. no of m/c3 care of needles:
3. Care of needles: all the needles should be inspected every seven says. needle that are
bent can be straightened with a pair of flat nosed pliers. needles should be changed after
production of 800—1000 tons
4. care of detaching rollers: A part from the accident ,roller covering should remain
serviceable for several thousand hours. covered rollers that appear to be soft and flabby
should be sent immediately for recovering to avoid inferior work and to reduce
excessive waste
Combing Fault:
1. Cutting Across : thick and thin place across the width of the web
Causes:
 Incorrect roller setting, excessive draft, roller slip or loose drafting roller
 Incorrect timing of detaching rollers
 Top comb set deeply
 Top comb touching the back detaching roller
 Requirements of lubricating in top detaching roller
 Stretching on the web in the sliver condensing plate
2. Curling: when group of the fibres curl as they leave the detaching roller
Causes:
 Incorrect timing of detaching roller cam
 Faulty top detaching roller covering
 Dirt in flutes of the steel detaching roller
 Excessive air current
 Excessive brush speed
3. Cotton coming through at one head:
Causes:
 Improper gearing of pawl with ratchet
 Ineffective bite between nippers
 Requirements lubrication on back covered detaching roller
 Foreign matter accumulation in nipper jaws
4. Detaching roller lapping:
Causes:
 Oil on roller
 Sticky dirt on roller
 Defective roller setting
 Improper Atmospheric Condition
5. Irregular sliver:
 Defective wearing or cylinder or top comb
 Variation of noil extraction
 Improper pressure in drafting roller
 Improper setting of drafting zone
 Diameter variation of r/r
6. Long fibre in the waste:
 Faulty pre comber draft
 Faulty lap preparation method
 Improper nipping
 Defective back covered detaching roller
 Foreign matter wedge between nipper jaws
7. Waste flocking on needles :
 Brush loose on shaft
 Brush set too far from cylinder
 Bent of cylinder needle
Reasons:
1. Long fibre in the noil /waste:
Causes:
 If cylinder needle performs combing before holding of feed lap in the nipper
 Proper speed adjustment a of cylinder and detaching roller ie when the 1st comb
detached fringe goes backward for mixing with the new fibre fringe ,it incomes in
contact with cylinder needle .as t a result , long fibre is found in the noil waste
 If more amount of trailing hook in feed fibre fringe, nipper can not catch it, as a
result ,in spite of long fibre , come to the noil
 If proper or not parallel gripping of nipper and cushion plate
 For defect back over of detached roller, detaching roller can not hold the fibre
fringe. As a result , during top combing , some long fibres come in noil
2. Short Fibre In Combed Sliver
Causes:
 Fibre breakage during detaching
 If excessive amount of short fibres in feed sliver , these can not controlled
properly during detaching
 If the gripping of cushion plate and nipper is not parallel during detaching , for
warding can hold the short fibres .as a result , these short fibre goes to the
comber sliver
Object of pre comb drawing:
 To parallelize the hooked fibres
 To reduce the loss of long fibres
 To convert the leading hook into trailing hook
 To remove short fibres
Backward feeding:
the lap is fed whilst the nipper is rocking backwards i.e. after detaching but before the circular
comb the fringe of fibre
immediately after detaching , the length of the fibre fringe protruding from the nipper amount
to L mm. the length of the fringe p is increased further by the amount A fed before the action of
the circular comb .thus a fringe measuring L +A and consequently not presented to the circular
comb
theoretically all fibres shorter than L+A and consequently not gripped by the nipper should
now extracted by the circular comb and subsequently passed in to the waste
when the nipper rocks forward again , the length of the fringe is not altered in any way so that
all length of the fringe longer than L are sized by the detaching roller when the nipper is in the
foremost position
the waste percentage may thus be calculated as following
(L + A /2 ) 2
P% =  100
F2

Forward feed:
The mtl is feed during the forward motion of the nipper towards the detaching roller during
detaching. the fringe of the fibres producing from the nipper has a length L when the nipper
moves backward . there fore all fibres are shorter then L are extracted by the circular comb and
subsequently passed in the waste. the mtl is feed as the nipper swings forwards again and
during detaching roller and pass into the sliver
the calculation of the waste percentage of therefore performed according to the following
formula
A 2
(L- )
P%= 2  100
F2
here, F= maximum fibre length
P%=wastage percentage
A= feed per nips
L=detaching distance
Difference between forward feed and backward feed :

FORWARD FEED BACKWARD FEED


1. the mtl is feed during the forward 1. the lap is feed whilst the nipper is
motion of nipper towards the rocking backwards i.e. after detaching
detaching roller during detaching but before the circular comb combs
2. all the fibres shorter than L are 2. all the fibres shorter than L+A are
extracted by the circular comb and extracted by the circular comb and
subsequently passed into waste passed into waste
3. all the fibres longer than L+A are 3. all the fibre longer than L are sized by
seized by the detaching roller and the circular comb and passed into the
passed into the sliver waste
4. less waste percentage(8--16%_ 4. more wastages(24.5%)
5. 5 it not produce a cleaner sliver 5. it produces a cleaner combed sliver
6. feed amount 4.9 and 5.2 mm 6. 6.0 and 6.5

(L-
A 2
) (L+A/2) 2
7. equation P%=  100
7. equation P%= 2  100 F2
F2

Difference Between Carded Yarn And Combed Yarn:


Carded yarn Combed yarn
1. carded yarn is obtained without 1. combed yarn is obtained by combing
combing
2. short fibre is more in carded yarn 2. short fibre is less in yarn
3. irregular fibre 3. regular fibre
4. low smooth ness 4. strength is high
5. quality of carded yarn not better than 5. better yarn
combed.

Difference between blow room lap and comer lap:


Blow room lap Comber lap
1. Short fibre high 1. Short fibre low
2. Uniformity low 2. Uniformity high
3. Trash high 3. Trash low
4. Impurities high 4. Impurities low
5. Lap length ------ 50-60 yds 5.
6. Lap wt 40-50 lb 6. Lap wt 18-20 kg
7. Lap hank .0011-.0019 Ne 7. Lap hank .0075 -.009
8. Lap wt /yds 12-16 ounce 8. Lap wt /yds 700-1100 grains
9. Lap width 1m 9. Lap width 300 mm
Mechanism of comber:
1. Feed mechanism
2. Nipper movement mechanism
3. Top comb mechanism
4. Top detaching roller movement mechanism
Properties of fibre:
1. Fibre length
a. Staple length
b. Effective length
c. 2.5% effective length
d. 50% effective length
e. Uniformity ratio
f. Mean length
g. Uhml
2. Fibre strength: psi---- 70000--110000
3. Fineness: mic ---3.5--5
4. Colour:
Rd-----yellowish
B+ ----whiteness
5. Trash content : 1 - 8% avg 6%
6. Maturity.
7. Fibre elongation.

Problem
Problem 1: if nip/min= 220, no of head=8, feed/nip =7mm, lap wt =1000 grains/yds,eff% =
90% , noil =15%. calculate pro/day/comber=?
solve:
100-15
production =nip/min * feed/nip* no of head*feed lap wt*eff * *60*24
100
7*220*8*1000*.90*(100-15)*60*24
=
7000*100*10*2.54*36
= 2120.315 LB/DAY
Problem : 2
Calculate the production per day of a combing m/c running with following particulars -- feed
lap wt= 1100 grains/yds, nips/min = 400 ,no of combing head = 8, noil extraction = 17%,
feed/nip = 5 mm , eff% =90%
solution:
400*5*8*1100*(100-17)*.9*60*24
Prodution
100*10*2.54*7000*100*36
= 2957.75 lb/day
Problem 03: Find out the no of comber m/c to produce 10000 lb/day of 40 count semi combed
(50:50) yarns when nips /min =380; feed nip =8; lap wt= 1000 grain/yds, no of head /frame = 8:
noil% =15; effy =90%
380*5*1000*8*100-15*.90
production =
10*2.54*36*7000*100
=2615.97 lb/comber/day
no of comber required= 10000/2615.97
=3.82=4
Total 4 comber will be required
problem 04: find the no of modern comber that feed by a lap former having the particulars lap
production rate = 5000 lb/yda;;ap wt = 1000 grain /yds; nips/min = 400, length feed/ nip = 4.8
mm, assumed all the other parameter
solution:
let,
efficiency = 90%
waste/noil =
extraction= 15%
400*4.8*0.9*100-15*8*1100*60*8
production =
7000*10*2.54*36*100
=921.28
no of comber=5000/921.28
=5.15=5
Problem 05: find out the production per hour at a combing running particular nips/min=300,
feed/nip= 5.4 mm, lap feed= 64 k tex, no of head=8, noil extraction= 16%; effy= 85%
solve: =852.79 kg/day =35.53 kg/hr
Problem 06: Find out the production per hy at particular
nip/min=180; feed/nip=4.8 mm; feed lap hank =0.0095, no of head= 8; effy =85%, noil %= 15
180*60*4.5*.85*100-15*8
solution=
0.0095*840*10*2.54*36
=
Problem 07: Find Out required DCP to produce 3.4 ktex sliver from 64 ktex comber lap,the
comber m/c particulars are as the following , no the head =8, no of delivery =2; noil extraction =
15%, draft constant=1696
solution:
delivery count*no of doubling
Actual draft=
feed count *no of delivery
65*8
=
3.4*2
=75.3
mechanical draft =actual draft* 100-15/100
=64.43
draft canstant = mechanical draft*DCP
so, DCP =1696/64.43 =26T
Chapter 3
Ring Frame

Function or task of ring frame:


 to attenuate the roving to form yarn of the required count/ fineness of yarn by
drafting
 to impact strength to the fibre strand by twisting
 to wind up the resulting yarn on to bobbin
 to build up the yarn on to bobbin in form of a suitable for storage, transportation
and processing
Operation involved in ring frame
The Following Operation Are Involved:
I Creeling
II Drafting
III Twisting
IV Winding
V Building
VI Doffing
I Creeling
Roving bobbin is fitted on the top of the m/c on the creel on both sides of the m/c. creel helps
to freely rotate of roving bobbin and hold such that roving feed to the drafting zone on tension
Two types of creel
I Umbrella types
 Ball bearing is used for smooth running.
 Mostly used.
 Modern type creel.
 Useable to double roving.
 Large size package used.
II Skewer type:
 Conventional type creel
 Risk of roving breakage
 Rotate easily and negatively driven
Drafting
drafting operation reduces wt per unit length of roving . roving comes from the bobbin are
passed through the drafting zone which may be of apron drafting system . in apron drafting
system , fibre controlling system is better so it is widely used
draft = break draft*draft bet middle and front roller
=draft between B&F roller
= S.S. of front roller/ S.S. of back roller
Twisting: Spiral turns are inserted along the fibre axis .it increase yarn strength .the traveler
which helps to insert twisting yarn , gets drive indirectly from spindle
Winding: After twisting the yarns are wound on a suitable package , layers of yarn are wound
properly are above another on the package . It should be suitable for unwinding
Building: For proper size and shape of the package the bobbins are lifted gradually. The
resultant bobbins are conical shape full bobbin
Doffing: After the required length of yarn is wound on the package , the m/c is stopped .
Doffing is wound on the package ,the m/c is the process of replacing the full bobbin by an
empty bobbin
Block creeling: The num of the spindles or the positions of spindle may be 480 or 540(short
length) and 1008 to 960 (long length) and t he number of creek must be 2-3% .if all roving
bobbins , fitted on the creel are of same size i.e. of same length . the bobbin will be exhausted at
he same time which will cause m/c stoppage and production will become low
In block creeling arrangement , the total numbers of creel are divided into several no of groups .
then each group contains roving bobbin of same length but differs from adjacent group or
blocks .
example:
block or groups length of roving
1st 500 yds
2nd 600 yds
3rd 900 yds
thus all bobbin will not exhausted at the same time .so there id no m/c to stoppage and
production goes on smoothly
Advantage
 To avoid m/c stoppage
 To save the time
 To save man power

Mordern Drafting System

SKF PK 225/2025 drafting system:


1. roller diameter:
front back middle
Top rollers 28 mm 28 mm 25 mm
Bottom 28 mm 25 mm 25-27 mm

2. roller pressure:
front pair 10-18 dan
middle pair 10-14 dan
back pair 12-16 dan
To increase fibre gripping , roller pressure should increased

3. top roller pressure system is pendulum arm with pneumatic weighting /spring loaded
or magnetic weighting system
4. Roller setting distance:

apron cradle hf(mm) vf(mm) gf(mm) fibre length


short 44 50-60 40
medium 53 60-70 maxm 143 51
long 68 maxm 60
5. total draft: up to 60
6. amount of break draft 12-14
7. apron always exit in front zone
8. better fibre controlling is obtained
Advantages
No change of roller setting distance is required for any small change (2-3 mm) in fibre
length

 Factors of drafting arrangement on yarn quality:


 Type of drafting arrangement
 Its design
 Precise setting
 Selection of correct individual elements
 Choice of appropriate draft
Cop building :/general formation of a ring frame:

yyarn guiding device:


1. Lappets
2. Balloon control
3 separators
Thread guide or lappets:
Lappet is mounted directly above each spindle . It is designed to lead the yarn centrally over
the spindle axis .the lappet consist of a thread guide or a snail wire and a pivot able the length
of the m/c. During winding yarn, the rail along with lappet is raised and lowered to control
balloon size. This traverse of lappet rail .also facilities the easy passage of yarn form the front
roller to the bobbin

Function:
 To maintain security of yarn
 To prevent yarns collision
with adjacent yarns
 To prevent rubbing of yarn
 Easy passage of yarn from
the front roller to the bobbin
 To control balloon size
Balloon control ring:
The spindles used for yarn winding are relatively long. The spacing between the
ring and the thread guide is correspondingly long. Thus it gives a high balloon. This high
balloon causes space problem and excessive yarn tension due to high air drag

To avoid this problem, balloon control rings are used between lappet and ring. This balloon
control rings divides the bigger balloon into too smaller sub-balloons
The surface of balloon control rings should be very smooth otherwise yarn hairiness
increases. This balloon control ring should also participate in up and down traverse
movement with ring rail but with a shorter stroke length
Separators:
Ring:
The rings are made of low carbon steel i.e. soft steel or of ceramic in the form of a bar which
modeled into ring shape either by bending and welding or by piecing and rolling the
desired projection termed as ring
Function of ring:
I Ring circular run of the traveler
II It acts as a high speed bearing surface of traveler
III It also acts as a track of traveler
Feature of a good ring:
A good ring should have the following feature
I Best quality row mtl
II Good but too high surface smoothness
III An even surface
IV Exact round ness
V Good running condition
VI Good, even surface hardness, higher then traveler
VII Good operating lifetime
VIII Correct relationship between ring and bobbin tube diameter
IX Horizontal disposition
X It should be exactly centered relative to the spindle
Material for the spring:
The ring should always be tough and hard on its exterior. The surface layer must have high
and even hardness in the range 800-850 Vickers. the traveler hardness should have lower
650-700 Vickers
surface smoothness is also important . it should be high or not too high since otherwise a
lubricating film cannot build upon it.
The following mtls are used
 Flame or induction hardness steel
 Carbo-nitrided steel
 Nitrided steel
 Chrome steel
Classification Of Steel
1. basic forms
a. Lubricated rings (in woolen / worsted spg )
b. Un lubricated rings
i. Single side ring
ii. Double side ring
2. Anti-wedge shaped ring
3. The low-crown ring
4. Su-ring

Single sided rings:


single sided rings must be replaced by new ones after they have been worn down

Double Sided Rings


they worn on one side can be turned over and used on the second side .the latter serves for
mounting of the ring while the first side is acting as traveler guide
2. Anti wedge ring:

 High performance ring


 Enlarged flange inner side and flatted on its upper surface
 The change of form permitted use of traveler with a lower centre of gravity
and precisely adopted bow(elliptical traveler) which in term allowed
operation at higher speeds
3 Low crown ring:

 upper surface flat


 more space for the passage of yarn so that the curvature of the traveler can also
be reduced
 the centre of gravity is lowered
 it is today the most widely used ring form
 all current traveler s shapes can be applied

4. Su – ring:

 higher traveler speeds but slight reduced in a traveler wear


 This ring is a Russian development.
 Large surface of contact for the travelers on the inner flange and a degree of
compensation of forces acting on the travelers.

Factor Consider For Selection Of Ring Size/Dia


1. yarn count :Higher the yarn count , lower the ring dia .
for coarse count; bobbin dia(+), ring dia(+)
for fine count; bobbin dia (-) ,ring dia(-)
2. empty bobbin dia:
(size of the bobbin) larger the empty bobbin dia ,larger the ring dia
3. spindle speed: higher the spindle , higher the yarn tension. hence smaller should be
the ring dia, other wise yarn breakage takes place
4. end use: for weft yarn , smaller ring dia for warp yarn, larger ring dia
5. lift of bobbin :the higher the bobbin lift , ring dia will be larger
6. spindle gauge : spindle gauge(+) ,ring size(+)
7. for the presence of separator in the frame , ring dia will be 1inch smaller them the
m/gauge and for absence of separator , ring dia will be 1.5inch smaller than the
m/c gauge

Selection of ring dia smaller :


Advantages
 Gives higher spindle speed so higher production
 Smaller gauge , more spindle per frame
 Lighter traveler used as an frictional resistance reduced.
 Used for higher count yarn
Disadvantages:
1. smaller yarn package
2. more doffing
3. more cost winding
4. more knot
larger size ring
Advantages:
 larger package
 less doffing
 less cost
 less knot
Disadvantages:
1 less spindle speed
 Less spindle speed.
 Higher gauge.
 Less spared/hr.
 Used for known lever count.

Traveler:
Traveler is the most tiny part made up of metal or plastic through which yarn passes on its
way form balloon controlling ring to the yarn package surface in ring spinning m/c.
It is mounted on the ring and is dragged round by the yarn. During its rotational
movement on ring it impart twist on yarn
Function of traveler:
1. Twisting the drafted strand of finer through the front roller
2. Winding of the yarn on the bobbin in proper way
3. Maintaining winding tension of the yarn by the friction al resistance between the
ring and traveler
4. It acts as thread guide
5. It performs the functions of building motion and also maintains spinning tensions
Types of travelers:
a. According to a c-traveler
b. Flat- traveler
c. Elliptical traveler
d. N traveler
According to x-section of wire
1. A round traveler
2. Flat traveler
3. Semi circular traveler

Wire profile of the traveler:


wire profile influences both the behavior of the traveler and contain yarn characteristics
such as
 Contact surface of the ring
 Smooth running
 Thermal transfer.
 Toughening effect.
 Hairiness.

For cotton , flat wire types are preferred because a good seating on the ring is achieved and
the yarn is cleaned

For cotton only, best remedy for hairiness yarns and bobbins
for cotton , extremely wide traveler resulting in a very good guidance , the large , surface
allowing heat to be conduced away rapidly for high performance

for synthetic and blends. profile keeps yarn free from damage

for synthetics

for wool and synthetics, travel with around wire profile do not roughen the yarns

for wool and synthetics


Traveler mass:
Traveler mass determine the magnitude of frictional forces between and the ring and these
in turn determine the winding and balloon tension
If traveler mass is too small ,the balloon will be too big and the cop too soft .an unduly high
traveler mass leads to high yarn tension and may end breaks
count traveler number iso/ mass of 1000 traveler in gms
120 9
100 14
75 20
60 26
35 45
30 56
20 90
16 100
The material of the traveler / good traveler :
the traveler should be
 generate as little heat a possible
 quickly distribute the generated heat from the area where it develops over the
whole volume of the traveler
 transfer this heat rapidly to the ring and the to air
 be elastic so that the traveler not break as it is pushed on the ring
 exhibit high wear resistance
 be some what less hard then the ring because the traveler must wear away in use
in preference to the ring.
Optimal Running Conditions of Ring And Traveler Depends on:
 Mtls of the ring and traveler
 Surface characteristics
 The forms of both elements
 Wear resistance
 Smoothness of running
 Running conditions
 Fibre lubrications

Factors considered for selection of a traveler:


1. Yarn count: finer the yarn count, lower he traveler weight i.e. Traveler weight 
tensioncount traveler
2. Spindle speed: if the spindle is higher then the yarn tenting will be high so lighter
tension should be used to minimize the tension i.e. Spindle speed, yarn tension 
traveler 
3. Ring dia : for same spindle speed and yarn count , ring dia increases , yarn tension high ,
frictional area so traveler should be lighter ring diabobbin diayarn tension 
traveler
4. Empty bobbin dia: when empty bobbin dia increases ,winding angle increases , hence
yarn tension decrease . Is a heavy traveler should be used
5. Lift of the bobbin : for same count and spindle speed , if the bobbin lift is higher ,the
bobbin length is higher and yarn tension increase hence traveler wt should be less
6. Cross section of traveler:
for flat , frictional area traveler wt
for semi circular; frictional areatraveler
for circular , frictional area  traveler
7. Ring condition: if the ring is old or bad. Then traveler wt should ne less band and old
ring traveler wt
8. M/condition: if the m/c is oils then the m/c will be vibrate then traveler wt 
9. Traverse length: traverse length  balloon loomyarn tension traveler weight.
Variation in the speed of the traveler:
The wing dia in ring spg frame changes continuously with raising and lowering in the ring rail.
The traverse must have different speed at the base and tip
Assuming for example:
Speed of spindle =13500 rpm
Deliver of spindle =15 m/min
Traveler speed at the base will be
15000
n T =13500- =13396/min
46
And at the end of the tip
15000
n T =13500- =13309/min
25
In comparison with the speed of the spindle , the traveler has a difference of 0.77-1.14
spindle :

spindle is the third most important machine element following the draft arrangement and
the ring /traveler combination. the spindle is capable of speeds up to 28000 rev/min but
this maximum speed can not be exploited commercially because of the limited traveler
speed
parts of spindle:
 spindle blade performs conjunction between spindle and bobbin is placed on
spindle 1 blade
 lock prevents the spindle from coming out with bobbin
 wharves is the place of the spindle, connected to ropes or belts or any other
driving mechanism to get drive
 insert or bolster is the lower part of spindle which is connected with bearing
and acts as a bearing of spindle blade
 bearing helps to move the spindle smoothly
 bolster case is used for containing lubrication agent
I to reduce the friction from metal to metal
II to avoid the damping effect
Function of spindle:
I To hold the bobbin tightly to prevent slacking during its revolution.
II To help in winding on to bobbin.
III To help in twisting yarn .
IV Capacity of ring frame mainly determined by the no of

Spindle drive: basically three type spindle can be distinguished


1. Tape drive
2. Tangential belt drive
3. Direct drive
1. Tape drive: tape drive can be further considered under the heading single spindle
drive and group drive in four spindle tape drive two spindle on one side of the m/c
and a further two spindle on the opposite sides , in running form the one m/c side
to the other, the tape passes around a drive pulley one or two tension rolls ensure
even firm tension of the drive tape
2. Tangential drive : in this drive a belt extends from the suspended motor past the inner
side of each spindle . The pressure of pressure roller ensures even pressure of the belt
and each spindles. There may be single belt , double belt and group drives in single belt
drive , one endless belt drives the spindles on both m/c sides in double belt drives, two
belts are provided , a first belt to drive the spindles on one side and a second belt to
drive the spindles of the other side. The double belt systems gives better evenness of the
spindle revolutions
3. direct drives:
mechanical direct drives are no longer used to day . individual motor drives (one motor
per spindle) were introduced by SKF company as an expt. direct drives may be of two
types
a. individual mechanical drives
b. individual motor drives
Essential qualities of spindle:
1. The spindle must be perpendicular to the rail bar on which the rings are mounted.
Both spindle and the ring should co centric to one another
2. The spindle blade should never be allowed to run with defective insert t /bolster
3. It should not vibrate during running
4 It should run with minimum friction
5 It should be well balanced
6. It should have precise construction with minimum tolerance to ensure smooth and
vibration free running ever with variable laids on the bobbin as the yarn is wound
on it under tension
End breakage rate:
It is experienced as no of end break /100 spindle per hour
Cause of end breakage:
A. Technical causes:
1. Excessive yarn tension
I. Excessive traveler wt
II. Eccentric spindle
III. Excessive ring dia
2. Excessive irregularity of yarn
i. Thick place less twist
ii. Thin place higher count
iii. Excessive short fibre in the roving
iv. Roving irregularity
3. Excessive twist in roving:
v. 1 improve selection of tpi in roving
vi. 2 less amount of break draft
4. Excessive spindle speed:
The more spindle speed, the higher production as a result yarn tension increased .as a
result due to increase of spindle speed , end breakage rate increase
5. Incorrect roller setting:
vii. The fibre breakage due to closer roller setting
viii. The uneven yarn due to wider roller setting
6. Incorrect break draft:
ix. Not proper opening twist of roving due to less break draft
x. The reverse twist due to excessive break draft
7. Incorrect bare bobbin dia : yarn tension increase due to lower bare bobbin dia as a
result of yarn breakage
8. Faulty drafting system:
xi. Bad quality apron
xii. Cracked roller system
xiii. Improper selection of spacer
9. Stretched roving:
xiv. Bad creel
xv. Faulty roving guide
xvi. Faulty building of roving package
10. Traveler flying out:
xvii. worn out of traveler
xviii. Improper flange selection
xix. Higher spindle speed
11. Improper atmospheric condition: the std R.H. for the spinning mill is 55-60% and
temp 27-30 degree Celsius
If R.H. %is lowered then std value , static electricity form . If R.H. % increased, roller
lapping forms. So improper R.H. %is a cause of end breakage
(B) Mechanical cause:
1. Faulty drafting system
2. Worn out ring , traveler
3. Faulty gear and wheels
4. Worn out top roller coats
5. Faulty apron
6. Spindle vibrate
7. Eccentric ring
8. Unbalance bobbin
9. Faulty setting of lappet and rings
10. Faulty roller covering
11. Slip of spindle tape
Limitation of ring frame:
1. Technical limits:
2. Economical limitation: in the ring spinning , testing and winding are done
simultaneously winding on the speed is the difference between spindle speed and
traveler speed so in ring frame winding speed =spindle speed -traveler speed
though less rpm is required for winding on both spindle and traveler rotated at
high speed for twist insertion
Hence , target power consumption.
Mathematically, spinning power is proportional to the cube of spindle speed
as the spindle speed increase power consumption increases
assume , front roller delivery= 50 inch/min
TPI = 30
so traveler speed required = 500*30 =15000rpm
let bobbin circumference = 2 inch
winding on speed = 500/2 =250 rpm
so spindle speed = (winding on speed required + traveler speed) =250+15000=15250
though for winding only 250 rpm was enough , it is increased to 15250 due to twist
insertion
Parameters:
I excessive spindle speed
II lower yarn delivery rate
III excessive traveler speed
IV end breaks rate
V m/c stoppage hour
VI wastage
Relation Among Ring Dia Bobbin Dia And Angle Of Pull
There is a relation ship between angle of pull and bobbin dia and ring dia. Smaller the
bobbin dia , smaller the angle of pull . As the angle of pull changes , the spinning tension
also changes

in the figure , ON= radius of ring


OM = radius of bobbin dia
 = angle of pull
N= position of traveler
MN= yarn path form traveler to bobbin
now in the triangle MNO
OM
sin  = bobbin radius/ring radius =bobbin dia/ring dia =
ON
=Dr/Db
here, Dr =ring dia
Db = bobbin dia
so  =sin inverse (Dr/Db)
this is the relation among them. the angle of pulley generally lies between 25-27 degree for
appropriate spinning tension
Two for one twister:
In two for one twist m/c one revolution of spindle imparts two twist on yarn. So in two for
one twister, get increased production ie more production ten ring twisting
The main construction points of the m/c shown above . The yarn is passed through a
rotating spindle and then through a yarn guide
In one revolution of rotating spindle ,the yarns imparted the first twist in MN region and
the 2nd twist by one revolution of the rotating spindle . The cone holder is used to hold the
cone and finally the yarn is wound on another cross wound package which is indirectly
driven by the contact of yarn
Ring data:
Ring data system is an additional software attachment for data collection . The m/c
manufactures offers the buyers the options of purchasing or not purchasing the ring data
system attachment the data collected and shown by the ring data system are
1. Production data(ops, gsm, total data of previous 3 shifts)
2. End breakage rate
3. TPI
4. M/c efficiency
5. Patrolling time
6. Doffing time
7. No of doff
8. M/c stoppage time
9. Yarn count
10. yarn lot
11. Fibre type
12. M/c number
13. Spindle speed
The data can be collected
1. Individual m/c wise
2. Count wise avg
3. Lot wise avg
Recent development of ring frame:
1. Improved drafting system
2. Higher no of spindle about 1008 spindles
3. Higher draft range about up to 100-200
4. Data collection system , ring data system
5. Spindle winding system after spg the ring bobbins are transferred to winding
selection through conveyer belt
6. Grooved t- in cylinder :it reduce t-in cylinder
7. Tangential belt drive : a belt drives many spindles
8. Inverter speed controller
9. Auto doffing
10. Auto piecing: 60-70% piecing
11. Direct two ply in the oil bath
12. Higher spindle speed
Flow chart of yarn from yarn form marketing:
Ring Yarn
For single yarn:
Cone winding.

Inspection.

Packing  Labeling
Marketing


Marketing.
For double yarn:
Cone winding.

Doubling

Ring twisting
Twisting
Two for one twister.

Cone winding

Packing

Marketing.

For hank form Marketing.


Cone winding.

Reeling.

Bundling.

Bailing.

Marketing.
Reeling:
1. Used to produce hank
2. Similar to warp reel
3. In 60 position , we can produce hank(840 yds)
4. Circumference of reeling m/c is 1.5 yds
6 So to produce a hank it requires 560 rev.

Problems
1. In a ring frame 30 Ne carded yarn is to be spun in which spindle speed is 17000 rpm and
there are 504 working spindles. If the m/c runs at 95% efficiency and twist multipller is
4.6. Find out its production in lbs/shift.
 Solution: Here, data given,
Yarn count=30 Ne
Spindle speed =17000 rpm
No Of working spindle=504
M/C efficiency=95%
Twist multiplier=4.6
Now we know T.P.I  Twist multiplier count in indirect system

T.P.I=4.6 30
Spindle speed x no of spindle x 60 x 8 x.95
 Production in lbs/shift=
T.P.I x 840 x 36 x Yarn count
17000 x 504 x 60 x 8 x .95
= lbs/shift
25.195 x 840 x 36 x 30
Production = 170.93 lbs/shift.
2. A ring frame was stopped for 30 minutes due to block creeling. Find out production loss
in lbs and spindle –hr for block creeling. Let Ops =4 and no of spindle =504.
 Solution:
Here, data given,
Ounch per spindle production=4
No of stoppage=30 minutes.
Production loss in spindle-hr=no of spindle x time in hr
30
=504 x
60
=252 spindle-hr
ops x spindle - hr
Production loss in lbs =
16 x 8

4 x 252
=
16 x 8
=2.1 lbs (Ans)
3. Problem: Production requirements of 30΄s combed woven cotton yarn is 2000 lbs/shift.
Now many ring frames to be run meeting this requirement. (Assume necessary
parameter).
Solution: Here, date given.
Production in lbs/shift=2000
Count of yarn = 30 ΄S a(combed)
We know,
Production in lbs/shift
Find out the production of a Ring Frame in ops which is running with the following parameters –
spindles speed= 1700 rpm, yarn conut = 40 Ne carded yarn efficiency =95%.

Solution: Here data given,


Spindle speed = 17000 rpm.
Yarn count =40 Ne carded woven
Efficiency =95%
Spindle speed
We know production=
T.P.I
Now T.P.I=4.2 count(Ne)

 4.2 40
=26.57
17000x60x8x.95x16
Production in ops with 95% efficiency = =3.85 ops /shift
26.57x36x840x40
Production will be 3.85 ops /shift

If we assume that there were 1008 spindles in that ring frame then,
Production=(3.85x 1008) Ounce /shift/frame

Find out the production in ops per shift of a ring frame having 480 spindles and running with
folloeing parameters. Spindle speed =15000 rmp; count=30 Ne ; Twist multiplier 4.4; Efficiency
=92%

Solution:
Here data given,
Time =shift ie. 8 hours .
No of spindle=480
Spindle speed =15000
Count =30
Twist multiplier=4.4
Efficiency=92%

Now, T.P.I =Twist multiplier count(Ne)

 4.4 30
=24.1
Production in ops per shift /frame with 92% efficiency
spindle speed x no of spindle x 60x8x.92x16
=
T.P.I x 36x840x30
=4.845 ounce
Find the number of spindles if yarn count =30 Ne ; production =2000 lbs /shift ; Assuming ne
Solution: necessary parameters.

Solution: Here data given,


Yarn count=30 Ne
Production=2000 lbs/shift
T.P.I =4.2 count (Ne)
 4.2 30
=23

Let, Efficiency =90% ; spindle speed =15000 rpm


spindle speedx no of spindle x 60x 8x .9
Production =
T.P.I x36x 840x 30
Let,
No of spindle = x ;
15000X x 60 X 8 X .9
 2000=
23X 36X 840X 30
23 x 36x 840 x 30 x 0.9
x=
23 x 36 x 840 x 30
x=6441.2
 6442 spindle will be required.
6442
i.e.  13 ring frame will be required. (each having 504 spindle)
504

Production requirement of 40 Ne cotton yarn is 3000 lbs /day. How many ring frames and
simplex machines will be required to fulfill this requirements ? Assuming necessary parameters.

Solution:
Here data given,
Yarn count =x ;
Spindle rmp=17000
Wastage of ring frame=3%
spindle speed x no of spindle x 60 x24 x o.95
Production =
T.P.Ix 36x840x40
1700  x  60  24  0.95
 3000 
28  36  840  40
3000  28  36  840  40
x
17000  60  24  0.95
 x  4369.04  4370
4370 spindles will be required and if there are 504 spindle/ring frame and if there are 504
4370
spindle/ring frame then  866 x 9 ring frames will be req.
504
9 ring frames are needed (Ans)
Now, wastage in ring frame= 3%
3000  103
Production of speed frame= lbs
100
=3090 lbs.
Let, Spindle speed of speed frame = 1200
 Roving T.P.I.=T.M. R.Hank
Twist multiplier= 1.3
  1.3 0.75
Roving hank = 0.75 
1.125

No. of spindles/speed frame=120


Efficiency=90%
Spindle speed  total no. of spindles  60  24  0.9
 Production=
Roving T.P.I  Roving hank  840  36
1200  x  60  24  0.9
 3090  x=50.69  51
1.125  36  840  0.75
51
 No. of speed frame required= 1
120
 1 Speed frame will be required.  Ans.

Problem: Find out the required T.C.P. to produce 40 Ne carded woven yarn when twist
multiplier is 4.6, existing T.C.P. is 48 T and existing T.P.I. is 21.7
Solution:
Here data given,
Existing T.C.P. = 48 T
Produced yarn count=40 Ne (Carded)
Twist multiplier= 46
We know,
Existing (T.C.P X T.P.I)…………….(1)
Now, Required T.P.I.=Twist multiplier Count in Ne.
 4.6 40
 29
From (1) we get,
existing (T.C.P X T.P.I)
Required T.C.P.=
Req.T.P.I.
48X 21.7
  35.8  36T
29
 A pinion with with 36 Twill be required as T.C.P.  Ans.
Jute
Chapter 1
Drawing Frames

Objects of jute drawing frames:


 Straightening of fibres in the in the silver
 Parallelization of fibres in the silver
 To reduce the weight per unit length of sliver
 To reduce the thick & thin places in the sliver
Main functions of drawing frame:
 Drawing. The regular & uniform elongation of the sliver is called drawing. Drawing
takes place between retaining roller & drawing roller.
 Doubling: To produce one sliver from two or more sliver is called doubling. It is done by
doubling plate.
 Drafting: Ratio of the surface speed of deliver (drawing) roller & feed (retaining roller is
called-drafting.
Definition terms:

A. Reach: The distance between the center of the front back roller (retaining) to the bite of
the front (drawing) & front pressing roller is known as reach of the drawing frame. The
reach should be slightly longer than the longest fibre in the sliver.

B. Nip: the distance between the foremost gill where the pins leave the sliver and the bite
of the front pressing roller is called “Nip”. The distance should be as short as possible.
C. Pitch of faller: the distance between the one row of pins of one faller bar to pins of next
faller bar is called pitch of faller.
D. Lead% : The difference in the surface speed of fallers over surface speed of retaining
roller to give sufficient tension to the sliver is known as lead percentage. This lead
should not be more or less .
S.S. of faller - S.S. of retaining roller) X 100%
Faller bar lead % =
S.S. of retaining roller.
This faller bar lead% is generally 10 – 15%.

Desirable features is any type of drawing frame:


 An ideal method of pinning the slivers that is the gill pins must enter and leave the
sliver as nearly perpendicular as possible.
 Small lead of gills or fallers to avoid undue tension on the sliver between the faller bars
and retaining rollers.
 Shortest possible nip to give maximum possible control of fibres in drafting
 Freedom of movement of fibres in the drafting zone.
 Reliability of the working parts.
 High speed of fallers permitting maximum production
 Less noise of fallers when working
Effect Of Draft And Delivery Speed:
Since the object of any industrial process is to achieve a high production rate at an acceptable
quality level as economically as possible it is desirable of be able to run machinery at high
speeds. The highest speed at which gill drawing frames can be operated is given by the
equation (). Where () is the number of faller drops per minute, v is the delivery speed per
minute, and d is the machine draft.
In practice there is an upper limit to f, the faller drops per minutes, imposed by two factors. The
first of these is the ability of the fallers, as machine components, to withstand the forces
involved in their propulsion without excessive amounts of wear and tear, the second factor is
the ability of the gill-pins to strike into the sliver and control fibres movement during drafting.
With regard to the mechanical aspects the fallers on spiral drawing frames, with their sudden
drop-out at the drawing roller and their rise at the feed rollers are subjected to greater strains
that those of push-bar types. The pitch of the faller-bars is closely related to the maximum speed
of the gill-sheet, for the smaller the pitch p, the finer must be the bars, pins screws, etc., and the
more expensive the mechanism becomes. There is obviously a lower limit beyond which the
materials used and the manner of construction becomes so refined that the cost becomes
prohibitive. On jute frames the faller bar pitch is between 6/8 and 3/8 inch and as far as the
user is concerned, this can be regarded as being fixed by the machine designer. Control over the
number of faller drops per minute, therefore, devolves on making adjustments to the speed of
the whole machine by a series of speed pinions on the main drive and selecting a suitable draft.
Fig shows how draft and delivery speed combine to give a series of different faller drops per
minute on a sacking weft push-bar first drawing frame. In this case if it is desired to work at the
upper limit of faller drops for this type of machine (850 per minute) and the faller pitch is 0.5 in,
then, v =425 in./min. and if the draft is changed at any time the delivery speed should be
altered also to ensure that relationship holds and the machine is run at its maximum speed
compatible with freedom from mechanical trouble and correct pinning of the sliver.

Arrangement of drawing frame:


Some arrangements of drawing and doubling section for sliver spinning are mentioned below:
1. Hessian warp and weft and sacking warp yarns of 7 lbs/spindle and above:
Flow chart is mentioned below.

1st drawing frame: Push bar-high speed type.



2nd drawing frame: Double threaded spiral

3rd drawing frame: Triple threaded spiral.

Spinning

2. Sacking weft yarn of 20 lbs/spindle and above:

The flow chart for this type is mentioned below:



1st drawing frame: Push bar –high speed type.

2nd drawing frame: Double threaded spiral.

Spinning

Setting Changes in the 1st Drawing Frames


(A) Speed Change:
Speed change pinion is a driver pinion. Therefore, a bigger speed pinion means more speed of
all the part of the machine giving more production per unit time but less control of fibres in the
machine.
(B) Draft change:
The draft change pinion or DCP is a driven pinion. Therefore, a bigger pinion means slower
feed speed, more draft, less material fed per unit time in the machine.
(C) Faller change:
This is driver pinion. Therefore, a bigger pinion means more speed of the , faller bars, increased
percent lead of faller bars over back roller surface speed.
(D) Variable V-Pulley:
This is a driver pulley through which motion is transmitted to the fluted feed roller of the roll
feed. Therefore, if pulley diameter is bigger roll feeder speed will be increased.

Pitch of faller -0.5´´


Two faller bars per tooth space of the faller bar carrier wheel
Reach of 1st D/F = 13´´
Production /Hour = 600 to 650 lbs.
Auto stop motions:
1. Feed end – serrated com type
2. Delivery end – Feeder type
Types of drawing frames: The jute drawing frames can be classified as below:
1. Conventional Draw Frame: Conventional jute drawing frames are all alike in regard to the
arrangement of essentials. According to faller bar propelling mechanism there are 2 types of
drawing frames.

 orthodox type
i. Push bar type drawing frame 
high speed type
Double threaded sprial draw frame
ii. Spiral drawing frame 
 Triple threaded sprial draw frame
2. Modern Draw Frame: There are two type of modern jute drawing frame, namely-
i. Variable draft draw frame.
ii. Gardella 18-M model.
Push Bar Draw Frame (Feature and types): In push bar drawing frames the fallers have
specially cranks ends which run in slides on the machine frame. The fallers are driven by a large
carrier wheel at the back of the machine. In modern frames the bear across the full width

1. Orthodox type d/f: The features of orthodox type drawing frame are mentioned below:
i. Orthodox type drawing frames have 2 carrier sheets
ii. Their speed is moderate(faller bar speed)
iii. 10-15 % faller bar lead is necessary for good pinning.
iv. Wide nip.
v. Used as 1st drawing frame.
vi. Faller bars are propelled by carrier wheels both at back and front.

2. High Speed Type: The features of high speed draw frame are mentioned below:
i. They have one carrier wheel.
ii. Faller bar speed is high.
iii. Maximum control over entire drafting zone on fibres of faller bar.
iv. Short nip.
v. Low draft and noiseless running.
vi. 1st drawing frames are normally high speed type.
vii. Faller bars are propelled by carrier wheel only at back side.
Mack High Single Crank Push Bar First Drawing Frame:
This is a high speed type push bar 1st drawing frame having 2 heads, 4 sliver per head, 2
deliveries per head, doubling 2:1. the propelling mechanism of ½´´ pitch faller bar “F” are
controlled by faller carrier wheel or sprocket “E” at the back of the machine. Thus, a faller bar is
pushed forward by the other behind it and the fallers leave the sliver at the front of the machine
almost vertically.
The faller bars “F” are controlled by a single crank at one end and are arranged in the machine
alternately right & left handed. The fallers travel under full control through out the entire path
of fallers. Production of 3 finisher card can be processed by 2 first drawing frames. The machine
is normally roll-delivery type.
The rolls of finisher card delivery sliver is fed on the bottom fluted feed roller. The sliver is
passed over the back plate “A” side by side, then under back retaining roller “B”, over the slip
roller “C” and then under the front retaining roller “D”. The slivers then pass over the moving
gills “F” being embedded in their pins. After necessary drafting, the slivers passes between the
drawing (front) roller “H” and front pressing roller “J” to the guide plate “K”. in front of the
guide plate, there is doubling plate “L” where the slivers are grouped in equal numbers for
doubling and then delivered between the delivery roller “M” and delivery pressing roller “N”.
Due to the effect of draft that is higher speed of drawing & drawing pressing roller ten the
retaining rollers. The fibres held by the gill pin bed, become straight, reduce weight per unit
length of the sliver. Due to doubling, irregularity of the sliver is reduced to a great extent.
Jute 2nd Draw Frame (Spiral type double threaded):
This is a drawing frame having 3 head, 6 slivers per head and 2 deliveries per head. So here
doubling ratio is 3:1 i.e. here 3 slivers are doubled into one.

This drawing frame has derived its name from the fact that the faller bars (N) are propelled
along the spiral screws (F)
On each head there are two sets of top slides(p) along which the faller bars(N) travels. These top
slides are supported by two top spiral screws(F) when moving in forward direction.
Each of the top screws has two cams attached at the forward end set at 180° apart from each
other. For one revolution of top screws the two faller bars drop down. Because the fallers have a
travel equal to the lead of screw or twice the pitch of faller bar.

As each faller comes to the forward end of the top slide the guide spring (H1) is pushed away
from the slide P. This allow the faller bar N to pass down between the end of slide P and spring
H1 on to the bottom slide S. This downward peerage of faller bar is assisted by cam
arrangement. The back journey of the fallers are preformed by two bottom S to support the
fallers.

But here the bottom screws have courser pitch than the pot screws.
When a faller on the bottom screws reaches its back most position, it presses the guide spring
H2 which allow it a passage for raising to the top screws E. This lift of the fallers from bottom to
top is assisted by cams.
The passage of slivers from the feed end is over the conductor roller (A), under the back
retaining roller (B), over the slip roller (C), under the front retaining roller on to the gills (N).
After required drafting the slivers are passed between delivery pressing rollers then over
Screw Gill Triple thread finisher Drawing Frame:
By-James Mackie & sons Ltd. (For light Yarn)

This type of triple thread spiral drawing frame produces slivers of desired weight for spinning
into yarn by a light yarn spinning frame. On account of triple thread screw high delivery speed
for drawing frame is possible. The length of the machine varies according to the number of
heads but a 5 heads machine is very popular having 8 slivers/head, 4 deliveries per head,
doubling 2 ends into.

¼’’ to 3/8’’ wide crimping box is fitted to each delivery to import crimps to the delivered sliver.
This crimp gives cohesion to individual fibres and thus adds strength to the light and delicate
slier which will have to pass over the back of the spinning frame to the top or retaining rollers
there without breakage crimping in the finisher drawing frame delivered sliver is essential.

In this drawing frame, there is no doubling plate. Doubling at this stage in creases regularity of
the delivered slivers and therefore doubling is done by passing 2 slivers side by side through
harrow guides at the back of the frame and passed on to the drafting field as one sliver.

Crimps to the slivers are added in the crimping boxes, one box being fitted to each delivery at
the position where the sliver emerges from the delivery roller. The crimping box consists of an
oblong box made of cast iron or some other light metal. The delivered sliver keeps filling the
space inside the crimping box until the sliver forces the weighted lid of the crimping box
upward. The lid is heavy enough to slightly resist the pressure imparted by the sliver but at the
same time the weighted lid does not stop the flow of the sliver from the delivery roller. This
resistance compresses the sliver whit e filling inside the box and imparts a wavy or crimped
shape the sliver which greatly assists in keeping the fibres tightly together in the delivered
sliver.

Crimping may be added to slivers delivered by all the drawing frames but it is essential in the
finisher drawing frame delivered slivers.
Working principle
The working principle of this drawing frame is similar to that of the double thread screw
gill second drawing frame in their faller bar propelling mechanism.

On each carriage or head, there are two 2 sets of top slides along which the faller bars
travel and are supported when driven by 3 top screws in the forward direction, one screw at
each side. Each of the top screws has 3 cams attached at the forward end set at 1200 apart from
each other. For one revolution of the top screws 3 fallers drop down, fallers having a travel
equal to the lead of the screw or thriee the pitch of the faller bar. As each faller bar comes to the
forward end of the top slide, the check or guide springs is sufficiently pushed away from the
slide ot allow the faller bar to pass down between the end of the slide and the springs on to the
bottom slide. The downward passage of the faller bars being assisted by the cam attached to the
forward end of the screw.
The back journey of the fallers are performed by two bottom screws which have their
won slides to supports thee fallers. The top screws have the fine pitch whereas the bottom
screws have coarse pitch.
When a faller on the bottom screws reaches its backmost position, it presses the guide
springs which allow it a passage for rising to the top screws. The lift of the fallers from the
bottom to the top screws is assisted by cams attached to the back end of the back end of the
bottom screws. The bottom screws having coarser pitch quickly return the faller bars to the top
screws for re traverse.
doubling plate and crimping box. At last it is collected in sliver can in rope form. This sliver os
fluffy and lighter than the ribbon form sliver of 1st draw frame.

Topics 1st draw frame 2nd draw frame 3rd draw frame

1. No of head 2 3 5
2. No of sliver 4 6 8
feed/head
3. No of delivery 2 2 4
/head
4. Doubling ratio 2:1 3:1 2:1
5. Deliver sliver 3-5 5-7 7-9
weight Comparison between
6.Crimping Absent Present Present push bar and spiral
arrangement
draw frame:
7. Concentrated Absent Present Present
can packing Push
Spiral
arrangement. Topi bar
8. Faller bar ½” ½” 3/8” draw
c draw
pitch. frame
frame
9. Production/ 600-650 lbs 600-650 lbs 400-450 lbs
hour/m/c Falle Faller Faller
10. DoublingAt delivery At delivery At feed end. r drops drops
process. end end
drop up to in
Auto stopAt both feed At feed end. At delivery
motion. and delivery end. 850/m doubl
end in e
12. Change Surface Surface speed Surface speed screw
pinions in m/c. change, draft change, draft change draft
up to
change, change. change.
variable v- 400
pulley. drops
/min
and
triple
screw
up to
650
drops
/min.
Lead Faller Faller
bar bar
lead lead
over 1.5-
retaini 4.5
ng
rollers
4-10
Sou No Noisy
nd sound
while
runnin
g
Clea Tends Self
ning to clog &Clea
with ning
dirt becau
se of
the
jerk at
each
drop.
Pinn In Excell
ing moder ent
n type laps
m/c,
pinnin
g is
good.
lapp Laps Seldo
ing occasi m
onally, laps
Special
ly with
light
slivers
Dra 1st 2nd
w draw and
fram frame 3rd
e is push draw
bar frame
s are
spiral
type.

Crimping Box in Draw Frame: In 2nd and 3rd drawing frame of jute we see that there is a
crimping box after the sliver emerges out the delivery rollers.
Necessity Of Crimping Box: In case of cotton we see that cotton has some natural convolutions.
So it needs not to be crimped. But in case of jute we see that jute has no natural crimp. So as the
draw sliver of jute comes out from flaw frame its count is reduced and it becomes mare and
more fragile when it emerges out from the finisher draw frame, it is in so tenuous form that it
becomes impossible to handle and it can not be carried up to the back of the spinning frame.
So to overcome this problem, the sliver is crimped to give a certain amount of cohesion and
strength to the strand. This crimping is imparted to the draw sliver by crimping box.

Crimping Process: In this figure below a crimping box is shown which is attached to the
delivery of a finisher drawing frame.
The sliver leaves the nip of the drafting rollers and passes down the sliver plate into the nip of a
pair of fluted delivery roller. The upper roller is spring loaded and positively driven through a
wide pitch gear from the lower one.
The sliver is driven into a box where it meets a metal finger or lid which is hanging down into
the box. The finger hinders the motion of sliver and the box is filled quickly. When more sliver
entes the back of the lid of the box. The sliver is forced up by the mass of sliver in side the box.
So the sliver at the front of the box comes out.
This is a continuous process. During its sojourn in the box the fibers of the sliver becomes
concertina and take on a permanent crimp or wave.
The time of staying the sliver inside the box can be regulated by means of a small weight which
can be added to the finger. A heavy weight on the finger required greater mass of sliver to lift
the finger up and hence develops greater amount of crimp in the fibers.

Trends of development of modern draw frame:


The modern draw frames are developed for obtaining the following basic objects:
 Uniform linear density of sliver
 Higher sliver quality
 Higher rate of production
 Higher draft range in a single draw frame(3-9)

Variable Draft Draw Frame: Variable draft draw frame is a modern type of jute drawing frame
which Produces regular sliver with constant weight /unit length.
Here a variable draft draw frame is described which is developed by B.J.T.R.A
Here the in feed sliver passes through a measuring sensor which is a capacitance type evenness
tester.(Like Uster evenness tester). This evenness tester measures the weight /unit length of
sliver and sends it to standard signal. In standard signal previously the standard or desired
weight /unit length of sliver is set.

So the two values are compared and sent to the memory. The memory collects the information
for certain time and then transmits it to the variable speed motor so that the motor can act at
proper time. This variable speed motor changes the speed of drawing and delivery rollers so
that the sliver can get required amount of draft. As a result the output sliver obtains long term
regularity.
Thus the thick place of in feed sliver get more amount of draft and thin places get less amount
of draft. As a result the sliver becomes even and regular with desired wt/unit length.
GARDELLA “18-M DRAW FRAME”:
Gardella is an Italian company which has developed this model of modern jute draw frame. The
basic improvements added in this draw frame are mentioned below:
i. Faller bars of conventional draw frame had single row of pins where as in
GARDELLA “18-M draw frame there are double rows of pins.
ii. Pneumatic drafting system is included here.
iii. During processing faller pins are continuously cleaned by rotating brush.
iv. Drafting and delivery pressing roller are covered with special rubber sleeve. This
result in less wears out of covering and less slippage of roller.
v. Wide range of speed and draft. Here in every d/f draft range is 3-10.
vi. Mono head (conventional had 2,3 and 5 heads)
vii. All machines are similar in design. That is to say the design of m/c parts of 1st ,2nd
and 3rd d/f of this made are the same. So parts replacement is possible.

Basis Of Fixing Reach:-


The distance from the center of the front retaining roller to the nip point of the drawing and
drawing pressing roller is called the “Reach” of drawing frame. Reach is adjusted with fiber
length and it must be wider than fiber length.
The jute sliver enters the m/c through the nip of the feed or retaining rollers. Because of the
grater linear speed of drawing rollers the material becomes drafted. The exact amount of
drafting being determined by the relative surface speeds of the two sets of rollers. This distance
between two sets of rollers. This distance between two sets of rollers is longer than the fiber
being drafted; if it were not so then the fibbers would be gripped by both sets of rollers and be
broken.
The reach of different draw frames is as below:
1st drawing frame: 13”
2nd drawing frame: 12”
3rd drawing frame: 13”
It should be 10-15. If the reach is wide than the largest fiber in the sliver the loose and short
fibers will remain uncontrolled in drafting zone. So irregular sliver will be produced.

Drafting leading to greater irregularity of the weight of sliver-Explain it.


A desirable property of jute drawing frame is a constant front reach. But it can not be obtained.
The variable distance of front reach causes uncontrolled drafting and formation of faller bar
slubs (Slubs is a thick clump of fibers in a sliver or yarn). These faller bar slubs can not be
eliminated but they can be kept small by keeping correct density of pinning. As the sliver count
becomes smaller the gill pins require to be finer and more closely set.
Drafting is closely related to sliver regularity and because of variable fiber length in sliver and
imperfections of draft control mechanisms each drafting operation increases the amount of
irregularity present.
If the in feed sliver contains a weight irregularity with a wave length or 4 inches and it is
drafted 4 times then the delivered sliver will have an irregularity with a wave length of 4X4 =16
inches.
The action of drafting will impose further irregularities on material and there will be minor
irregularities added to basic wave length. Thus as the sliver progresses through drawing stages
its irregularity pattern becomes more and more complex and it is reduced as much as possible
by doubling.

Doubling leads to a greater uniformity of sliver-Explain it.


Drafting of sliver tends to increase irregularity and this is reduced by doubling.
In jute, slivers count varies from place to place in each strand of sliver and it also varies from
sliver to sliver. These differences in count can be defined statistically by the Normal
Distribution.
If one took a length to sliver and cut if up into sections one would find that the distribution of
count of the cut pieces followed a bell shaped pattern as in figure (a) below.

If one takes two or more such slivers whose weight varies according to normal distribution and
doubles them together then the variation is the count on the resultant product (i.e. sliver) will be
less than that of the individuals. The amount by which the variation falls depends upon haw
many slivers are doubled together. In fact the variation falls according to the square root of the
number of doublings. This is shown the narrower and taller the bell shaped the better and more
uniform the sliver.
Doubling is highly advantageous but it should not be forgotten that to reduce the count of the
material drafting must predominate over doublings and that drafting increases the variability of
weight’s as the material passes over drawing stage two matters happen simultaneously
doubling lending to greater uniformity and drafting leading to greater irregularity of weighty.

Utility of faller bar drawing: The reach is always larger than the jute fiber being drafted. For
this reason there is always a large no of fibers which are gripped neither by the retaining rollers
nor by the drawing rollers. These are called floating fibers. For ideal drafting each fiber should
move with the same speed as the back rollers until their leading ends enter the nip of drawing
rollers. In practice a fleeting fiber is held by the entanglement of if with neighboring fibres and
with inters fiber frictional forces. When a long fiber has its tip gripped by the drawing rollers it
immediately accented rate to the speed of these rollers and because of these fiber entanglements
and inter fiber friction. Some of the fiber lying alongside will be dragged forward and
prematurely drafted. This process is cumulative. So that a clump of short fiber is drafted too
soon, producing a thick place in the sliver. So this is the problem with only two sets of rollers
and if no attempt is made to control the movement of floating fibers the resulting sliver will by
highly irregular. For this reason in jute drawing frame short fiber controlling is obtained by
means of moving sheet of pins which carry the sliver up to the nip of drafting rollers. The pins
provide sufficient restraint to stop most of the short fibers being drafted prematurely but at the
sometime do not interfere with the normal process of drafting near the nip of drawing rollers.
So this type of drafting named faller bar drawing is applied to jute sliver.
Chapter 2
Jute Spinning

Essential Tasks of Spinning Process: The three essential tasks of spinning process are
1. Drafting
2. Twisting
3. Winding –On
Drafting is carried out by the usual arrangement of retaining rollers and drawing rollers where
drawing rollers rotate faster than retaining rollers
After emerging out from the nip of drafting rollers the thin ten-uous sliver passes down to the
top of the flyer goes through its hollow leg and wound onto the bobbin. During flyer ration it is
imparted necessary amount of twist.
Winding on function is carried out by builder mechanism. As the builder moves up and down
the bobbins alternatively rise into and withdraw from the flyers and thus winds yarn on the
bobbin in a continuous spiral.
Type of jute spinning: There are two types of jute spinning process according to Yarn
Manufacturing Process, namely-
1. Sliver Spinning
2. Roving Spinning
Now they are shortly described below:-
1. Sliver Spinning:-Here yarn is produced from the sliver of finisher drawing frame. Sliver
spinning is used to produce coarser inferior quality yarn. Here the count of yarn
produced range from 10-200 lbs/spindle. Sliver spinning is used mostly all over the
world. The process flow chart of producing span by sliver spinning is mentioned below.
Input Out put
Sliver Sliver from 2nd or 3rd drawing  Sliver.
Frame.
Sliver Sliver Spinning  Yarn
There are 2 types of sliver spinning namely-
I Slip draft sliver spinning
II Apron draft sliver spinning.
2. Roving Spinning :-In roving spinning yarn is produced from rove of roving frame. So
by roving spinning we can get finer and superior quality jute yarn. Here the count of
yarn produced ranges from 5-10 lbs/spindle. The flow chart of producing yarn by
roving spinning in mentioned below:-
Input Out put
Sliver  Sliver from 3rd or 2nd drawing  Sliver
Frame
Sliver  Roving frame  Rove
Rove  Rove Spinning  Yarn

Drafting Systems Used in Jute Spinning:-


The following drafting systems are used in both sliver and roving spinning process of jute.
1. Breast Plate Type
2. Breast plate and intermediate
3. Grooved intermediate roller type.
4. Faller bar type.
5. Single apron and intermediate roller type
6. Double apron and intermediate roller type.
1. Breast Plate Type: It is a conventional drafting system used in rove spinning.
The reach of this spinning frame is as usual slightly longer than the length of the longest fiber in
the material. Situated between the drawing and delivery roller pairs is a smooth metal plate
called breast plate. This plate is fixed and it does the function of to it. Immediately beneath the
breast plate there is a small conductor roller to lead the fibers right into the drafting nip. This
conductor roller does not rotate but can be adjusted inward and outward.
The delivery pressing
roller is synthetic rubber coated and rotates in surface contact of delivery roller. Both the
delivery and drawing rollers are positively driven.
Draft range of this system lies between (15-20).

2. Breast Plate and intermediate roller type:


Breast plate and intermediate roller type drafting system is used in sliver spinning system. This
drafting system is most common in conventional sliver spinning frame.
Here in between the delivery and drawing roller pair there is a pair of intermediate roller pair
and a breast plate. Breast plate is a small semicircular outward concave plate which moves
bodily inward and outward.
The intermediate roller pair is just after the breast plate. The lower intermediate roller is
positively driven and the upper one rotates in surface contact. Both of them are deeply fluted.
In this drafting system pre-opening of sliver is far better than breast plate type drafting system.
So it can be regarded as an improved version of breast plate type drafting.
3. Grooved intermediate roller type:
It is a conventional drafting system which is used for sliver spinning to produce coarser count
jute yarn (for example rope yarn) or heavy yarn.

Here the sliver passes down over a series of smooth surfaced intermediate rollers. Each of them
deeply grooved. The placing of the lower rollers can be adjusted to impart a greater on lesser
tension in the sliver. The roller of grooved roller series is self weight.
4. Faller bar or Gill pin type drafting system:

The gill pin /faller bar type drafting system is very similar to the gill drawing frame. This is a
conventional type drafting system which is used for producing coarser and heavier yarn like
rope yarn, carpet yarn etc.

This system offers a lower draft range. The faller bed is inclined at 45˚ angle. On the faller bed
the gill pins are fine and densely set. The faller drops per minute is about 500 and the spirals are
usually 1/4˝ pitch triple screw type.
5. Single Apron and Intermediate roller type:

This is a modern drafting system found in modern sliver spinning frames. This is sued for
producing better quality and finer yarns. Here the breast plate is replaced by an endless rubber
apron.
The fibers leave the nip of the retaining rollers or drawing rollers and then pass onto the surface
of a rubber apron. As they move down this they meet a slip roller which is pressing gently into
apron. Below the apron there is a conductor just before the drafting nip.
6. Double Apron and Intermediate Roller Type:
Double apron drafting system is a modern type drafting system which is used for producing
finer count jute yarn in sliver spinning.
This type is a more recent development of apron and intermediate roller type. Here the slip
roller contains another apron above the lower one. The lower apron is given tension by a dead
weight. This lower apron is driven by a grooved wheel at its upper end and its lower end is
made to turn sharply round a small adjustable plate.

The upper apron is driven by surface contact of the lower one. In this way the two aprons are
brought very close to the nip of drawing rollers and a positive grip is maintained on the short
fibers as late as possible.
Apron Draft Sliver Spinning Frame
 Apron draft sliver spinning frame is the modified version of slip draft spinning
frame
 It is capable of producing a yarn with improved quality at a higher rate of
production.
 Drafting of material in the machine is by means of a moving apron which provides
a very good control of material through out the entire drafting zone. As a result,
the yarn produced is more regular than a conventionally spun yarn. This
regularity in the yarn brings in good appearance and increased strength.
 Apron drat spinning are of two types that in 4 -1/4” frame and 4 – ¾:” frame of
100 spindles and 80 spindles respectively. In 4 – ¼” pitch frame, the bobbins used
has a capacity of 12 ozs of yarn and bobbin size being 6 ½” x 3”, and flyer speed of
4750 rpm. In the 4 ¾” pitch frames, the bobbin capacity is 20 ozs, the bobbin size is
7 1/2” x 3 ½” and flyer speed is 4500 rpm.
 Control draft not only brings yarn regularly, increased strength and better
appearance but also reduce the number of the number of ends breaks per unit
time. This reduced breakage of sliver during spring helps increased production
and decreased work load on the spinner. The bobbin capacity to hold more yarn
mean less numbers of doffs per unit time and the consequence more running time
to help increased production from the machine.
 The apron draft sliver spinning frame has an automatic cleaner which traverses
full length of machine and thus increases yarn cleanliness reducing operator work
load. The apron is removable to cleaning and replacement of new apron if
necessary. All rollers are mounted on ball and roller bearings to allow smooth
running, reliability and durability. The flyer has been newly designed keeping in
view the increased speed of flyer.
Study of yarn auto – stop mechanism.
Automatic (Sliver) stop motion cuts off the supply of the material for any one flyer when the
yarn breaks without affecting the rest of the frame. This result in considerable saving of waste,
and also reduces the chance of fly – over flowed by two ends spinning into types:
Weight operated.
Power operated.
The power operated stop motion is more definite in action when it acts but the weight operated
stop motion is much quicker in action and is also safer to work. In mackies weight operated
stop motion is fitted and in FLCB frames power operated stop motion is fitted.
When a yarn breaks or a sliver runs out, the yarn stop detector J swings up and its tail operates
necessary motion which releases the weight lever W2 which than falls down at this the sliver
nipping pawl Q mounted near the fulcrum point F2 of the weight lever W1 pusher beak the
retaining pressing roller B1. Thus onward passage of sliver is stopped.
The pressure on the retaining –pressing roller is applied by means of a dead weight W2 hung at
the end of the lever S fulcrummed at F3.

Slip Draft Jute spinning frame


The essential feature of the spinning process are drafting, twisting and winding on. All jute
spinning frames have two sets of rollers extending along the whole length of the machine – the
retaining rollers and the drawing roller. Each of these sets consist of a positively driven member
and a pressing member, between which fibres are gripped. The draft operates in the usual way
by attenuating the material and reducing its weight.
The reach of the frame is as usual, slightly longer than the length of the longest fibres in the
material. Situated between the retaining and drawing roller is a smooth metal plate called the
breast plate. This plate projects forward slightly from the line joining the nip of the two sets of
rollers in order that it may play its proper part in the control of short fibre movement. The
function of the breast plate is to determine where the sliver will begin drafting. This it does by
virtue of its position. Because of drafting a slight tension develops in the sliver which presses
the material more firmly on to the plate. The tension below the plate is greater than that above
the plate and since inter – fibre movement occurs at the point subjected to the greatest tension, it
is here that drafting takes place.
The draft is controlled by the combination of breast plate position and the setting of the plate.
Immediately beneath the breast plate there is a small conductor for leading the fibre right into
the drafting nip. It also can be adjusted in ward or outward.
The yarn passes down from the drafting nip to the top of the wharf cap where it enters a central
hole and continues down through the wharf. There two flyer legs are screwed on to the wharf.
At the end of the leg there is a flyer eye, through which the yarn passes on to the bobbin.
The amount of twist is depend on flyer speed and front roller delivery.
T=N/V
N= Flyer rpm
V= Front roller delivery in inch per minute.
Twisting Mechanism:
Flyers are used to insert twist in the jute spinning frame. Flyers are situated in front of the
machine about waist height suspended over the bobbin. There is no positive drive to the
bobbins and the bobbins are made to rotate by the yarn pulling them round. Figure shows the
twisting arrangement. The flyers are carried on ball – bearing wharves. The part of the wharves
projecting above the mounting assembly is called the “Cap” and plays an important part in the
actual operation of the frame. The wharves are driven by a cotton or nylon tape from the main
cylinder of the machine.
The yarn passes down from the drafting nip to the top of the wharve cap where it enters
through a central hole and continues down through the wharve. At the exit of the a ceramic
disk is cemented to protect the metal from the abrasive action of the yarn. The flyer legs are
screwed on to the wharve so that they may replaced if necessary. The legs themselves are
tapered forwards their tips to reduce centrifugal “through – out”. The flyer legs have a small
“eye” at the foot through which the yarn passes on to the bobbin. As the flyers designed to run
at high speeds they must be dynamically balanced otherwise any eccentricity would ultimately
damage the hole assembly and could cause a serious accident.
n
The simplest relationship between flyer speed (n), delivery speed (v) and twist (t) is: t 
v
This equation needs, modification due to twist take – up. Where twist take – up is expressed as
percentage
Untwisted length - Twisted length
(T) Twist take up= X 100
Untwisted length
Normally twist take – up percentage (T) varies from 2 to 3 % depending on count of yarn. Thus
the formula needs correction as follows:
n(100+T)
i=
100v
k
T.P.I for any particular count of yarn is determined by the use of the formula, T.P.I.=
count
Where K is called the twist factor or K – factor. The value of K varies from 10 to 13, for finer
yarns, the value of K will be higher & for coarser yarns the value of K will be lower.

Winding in spinning frame:


Winding in jute spinning frame is performed by flyer leading principle. Here flyer speed ie rpm
is more than that of bobbin. Both of them rotate in same direction.
For correct winding the equation is as follows:-
V= π db(n-b)
Where, (n-b)=Winding on speed;
V =Drawing roller surface speed;
db=Bobbin diameter(Changeable)

n=Flyer rpm (fixed)


b=Bobbin rpm (Changeable);
As the delivery speed of drawing roller (v) is fixed by the T.C.P. of the frame and flyer rpm is
fixed by gearing from above equation we can see that with the increase of bobbin diameter (db)
the value of (n-b) i.e. winding on speed must be reduced.
To perform this, bobbin speed must be increased as the flyer speed is constant. From the graph
bellow
It is obvious that as bobbin diameter increases bobbin speed also increases. The requirements of
winding motion may by summarize below:-
i. .It must increase bobbin speed as bobbin diameter
ii. It must slow the builder down as the bobbin fills
The second requirement is performed to wind as much yarn as possible on a package.

Yarn Tension Control: The yarn will break if the tension in it is greater than the strength at its
weakest point. On the other hand if tension is too low ballooning effect is seen. When
ballooning occurs the yarn strikes the adjacent flyer and breaks. So control of yarn tension is
necessary to avoid excessive spinning breaks and tension should be as low as practicable.
The spinning tension is a balance between two extremes.
The upper level of tension is determined by the ability of yarn to spin successfully.

The lower level of tension is set by ballooning phenomenon.


The yarn tension in jute spinning frame is controlled by altering the position of the felt bobs.
Placed under the bobbin carrier. By altering the position of felt bob the frictional radius is
altered which in turn control tension.

The four-pad type gives a method by which the frictional radius can be altered. But this change
in frictional radius can not be done during spinning rather it should be ste when the bobbins are
not in use. Each small pad is mounted upon a short spring arm which can be put into one of the
three positions.
i. Inner
ii. Middle
iii. Outer
When the bob is in outer position the distance between the centre of the bobbin and the centre
of the felt bob becomes more and hence the radius increases and as a result tension increase. On
the other hand when the felt bob is in innermost position the frictional radius is small and the
tension is low. So the felt bobs are placed at the inside position for spinning lighter count yarns
and that are placed at the outside position when yarns are to be spun.
Bobbin building Mechanism: In jute spinning frame, flyer is fixed in its position. For
building a bobbin the bobbin rail along with bobbin carrier and bobbin moves up and down.
This is called builder traverse motion.
Building Mechanism in the figure below the arrangement for building motion is shown.
The horizontal lever is fulcrum med at A and in its middle position there is a bowl the lever
moves up and down at a uniform rate due to the action of a heart shaped cam. This heart
shaped cam is driven by gearing from the retaining roller shaft of the spinning frame. When the
nose of the cam touches the bowl the lever moves upward and in other positions it goes
downwards. The stud has a connecting rod at its end. To the lower end of the connecting rod a
chain is fastened which is fixed to the circumference of the quadrant. With the help of this chain
the up and down movement of the rod is turned into a backward and forward movement of the
quadrant. The quadrant is keyed to one end of the builder shaft. So the builder pulleys also
rotate in backward and forward direction alternately to correspond to the motion of quadrant.

This backward and forward rotation of builder pulley makes the bobbin rail to move upward
and downward as it is connected to it via guide pull
Further the backward and forward movement of builder shaft from the same up and down
motion of builder will depend on the size of build pulley.

Causes of end breakage:-


The causes of end breakage in sliver spinning frame can be divided into 3 major types as
below:-
i. Machine factors
ii. Process or yarn factors
iii. Other factors
Now they are separately described below:-
1. Machine factors: The machine factors are:-
 Defective flyer: Worn-out flyer, sharp edge due to passing of yarn through a particular
path for a long time.
 Defective auto stop motion: The auto stop motion stops sliver feeding in corresponding
head after any sliver /yarn breakage. If the auto stop motion is faulty yarn feeding
continues even after end breakage. So roller lapping occurs.
 Dirty drag pad or felt bob:- In case of dirty felt bob tension on yarn increases as the
bobbin carrier does not rotate smoothly.
 Wrong setting of felt bob:- The position of felt bob should be adjusted carefully
according to required yarn tension. If it is improper yarn breakage may occur or the
package may be soft.
 Defective type joining:- In case of defective tape joining where the defected part will
pass the spindle wharves or t-in cylinder a jerking will occur.
 Eccentric spindle:- The spindle should be vertical with respect to bobbin rail, otherwise
problem may arise.
 Wrong adjustment of bobbin building mechanism: It causes faulty traverse length on
bobbin.
2. Yarn or process factor: Among process factors the following are main-
 Excessive flyer speed >Yarn breakage will occur frequently.
 Wrong T.P.I selection > either end breakage for more T.P.I.
 Wrong draft selection > Draft  irregularity increases.
 Too high or too low moisture regain in sliver.
Other problem: Among other factors the followings are mentionable:-
 Improper RH % and temperature in factory (standard RH % is 55-60% and
temperature is 30-35˚C.)
 Workers overload
 Workers inefficiency and lack of skill ness.
Faults in yarn:
The following faults are found in jute yarn after spinning.
viii. Slub
ix. Dust slub
x. Blow –in
xi. Slack twist
xii. Bad piecing
Now those are shortly describe below:-
i. Slub: Slubs
ii. are abnormally thick place in yarn. This generally occurs due to uncontrolled fibbers
in rove in spinning frame drafting zone.
iii. Dust slub : Blow in is the term used to express jute yarn hairiness. Hairiness in
measured by CVm and CVT, temperature, short fibres, relative humidity, closer
setting of rollers, worth out m/c parts etc are some causes of blow in.
iv. Zweigle Company makes the latest m/c which measures yarn hairiness. It shows the
no of hairs in yarn per unit length (i.e., per 1 mm, per 2 mm, per 3 mm, up to per 25
mm) and the type of yarn hairiness.
v. Slack Twist: Slack twist is the variation of number of twist per unit length in jute
yarn. Up to 2% variation of twist is acceptable. It occurs due to displacement of layer
driving belt and slack tape.
vi. Bad Piecing: - During piecing the two broken ends should be overlapped along a
small length of yarn. But if it is done along a larger length it is called bad-piecing. It
looks like a long thick place which occurs due to workers inefficiency.

Modern spin guard sliver spinning frame:-


Spin guard sliver spinning frame is the latest development of jute spinning frame which is
manufactured by an Italian company named Gardella.
The main features of this spinning frame are mentioned below:-
 It uses centrifugal type of spinning. Here centrifugal force is applied on yarn by rotating
traversing tube and it also helps in twisting the yarn.
 It has draft range up to 80
 It gives twist up to 15 TPI
 It produced yarn with count range 2-48 pound/spindle. This 2 lbs /spindle jute yarn is
the finest jute yarn which can be produced be any spg. frame. It is mentionable that in
apron draft sliver spinning frame we can produce fine yarn up to 7 lbs/spindle.
 Twisting speed i.e. Rpm of spinning pot is 9600
 No spinning tension during spinning. So end breakage rate is almost nil.
 Auto Doffing.
 The machine contain 40-50 or 96 delivery
 Yarn is wound on pot and automatically stops when the pot is full of yarn. Here no
bobbin is used for yarn to be wound on.

Mechanism: The arrangement of this spinning frame is similar to apron draft sliver spinning
frame up to delivery roller. The only difference up to delivery roller is that here double apron
drafting is used in place of single apron drafting as in apron draft delivery roller is shown
below:-
The yarn is taken inside the traversing tube by strong air suction. When it is deposited in from
traversing tube which traverses up and down during winding. The yarn descends into a rapidly
rotating pot. When it comes against the inner surface of the pot it simultaneously becomes
twisted and wound-on by centrifugal force. The yarn continues to wind the package from the
outside to the inside. When the package is full a spring cage rises into the pot and withdraws
the yarn.

The only disadvantage of this winding is that here no package bobbin is used. So the package is
not stable. And in this type of package unwinding problem arises due to missing the end of
yarn.

Problem 01: 3 finisher cards supply sliver to 2 1st D/F; Calculate the speed of the back rollers of
the drawing frames required to keep the cards and drawing frames in balanced. Each finisher
card produces 400 lb/hr of 16 lbs /100 yds sliver. Drawing frame has 2 heads, 2 delivery/head,
doubling 2:1.
Solution:
Production of 1 finisher card = 400 lb/hr.
Production of 3 finisher card = 400X3 =1200 lb/hr.
1200 lbs/hr is fed at 2 Drawing frame.
1200
So, Amount of fed of each drawing frame= lbs / hr .
2
=600 lbs/hr.
600  100
Length of feed in each D/F = yds / hr .
16
600  100  3
 ft / min  187.5 ft / min .
16  60
As the finisher cards & the drawing frames are in balanced so, feed = Delivery.
187.5
The speed of back roller = ft / min .
2X 2X 2
=23.437 ft/min. Ans.
Problem 02: A high speed push bar D/F with 2 heads, 2 delivery/head, doubling 2:1, produces
600 lbs/hr of 8 lbs/100yds sliver. Draft = 4, pitch of the faller bar = ½”, faller bar lead =10%;
Calculate the faller bar drops/min.
Solution:
100 x100 600 x100 x3
Length of Production= yds / hr  ft / min
8 8 x60
600 x100 x3 x12

8 x 60
 4500 inches/min.
4500
Sliver length production per delivery roller = inches / min .
2 x2
=1125 inches/min.
10
Surface speed of faller sheet = 281.25+ 281.25 X
100
=300.375
we know, Faller bar S.S.=Faller drops/min X Pitch.
Faller bar S.S.
Or faller drops/min =
Pitch.
309.375
=  618.75 Ans.
1
2
Problem 03: Calculate lbs/100 yds sliver from the D/F with particulars: F/C delivered
sliver……………..lbs/100 yds.
D/F draft ………………….4
D/F doubling ………….2:1.
Solution:
D/F doubling
lbs/100 yds from D/F = lbs/100 yds from F/C X
D/F drafting
2
 16  8 Ans.
4
Problem 04: A high speed type push bar 1st d/f 2 heads, 2 del per head, doubling 2:1 is being
fed with 16 lbs/100 yds sliver. If d/f draft is 4 and the back roller surface speed of d/f is 23.44
ft/min, Calculate,
a. lbs/100 yds from the d/f.
b. Production per hr of the d/f.
Solution:
2
a. lbs/100 yds from the d/f=16 8
4
Delivery roller S. Speed
we know, Draft=
Retaining roller S. Speed
or, Delivery roller S. Speed= Draft X Ret. R/r S. Speed.
=4X23.44X ft/min ( for one sliver)
=4X23.44X2X2 ( for 2 head each of ft/min. 2 delivery sliver
)
4  23.44  2  2
 yds / hr .
3
4  23.44  2  2  60
 yds / hr.
3
Now, wt of 100 yds sliver = 8 lbs.
4  23.44  2  2  60  8
So, delivery wt =
3 100
=600..64 lbs/hr.
b. Production per hr of the d/f.
Problem 04: A 1st D/F, 2 heads, 2 del/head, doubling 2:1 Producer 600 lbs per hr. The m/c is
fed with rolls of sliver from the F/C. Each roll wt is 30 lbs of lbs/100 yds sliver. S. Speed of back
roller is 30 ft/min. Find out the eff of the m/c (d/f).
Solution:
Actual production=600 lbs/hr.
Each roll wt= 30 lbs.
30  100
Length of each roll=  214.28 yds  642.857 ft.
14
Surface speed of back roller= 30 ft/min.
642.857
So, time required to finish a fed roll =  21.428 min .
30
There are 8 rolls of sliver ( i.e. 2X2X2)
So, total wt = 8X30=240 lbs.
240
So, wt feed per min = lbs.
21.428
240 X 60
And wt feed per hr=Calculated production:  672lbs
21.428
600
So, efficiency =  100  89.28%
672
So, Calculate lbs/100 yds from 2nd D/F.
3:1 Doubling of 2nd D/F.
6 Draft of 2nd D/F.
Solution:
3
lbs/100 yds from 2nd D/F= 8   4 Ans.
6
Problem 05: Calculate prod/hr of Double thread screw gill drawing frame from particulars:
Back R/r S. Speed = 15.52 ft/min.
Draft = 6
Delivered sliver = 4 lbs/100 yds.
5 heads, 2 del/ head, eff= 90%.
Delivery roller S. Speed =15.52 X 6 = 93.12 ft/min.
Total length of delivery =93.12 X 5 X 2 ft/min.
93.12  5  2  60
yds / hr .
3
 lbs / hr.
=
93.12  5  2  60  4  90
 lbs / hr[at 90% eff]
3  100 100
=670 lbs/hr.
Problem 06: On a spiral D/F, Drawing roller dia 2 ½” & its speed 78.5 ft/min. Draft =6; The
faller speed 320 faller drops/min; Faller lead 2%; Find the pitch of screw; Find r.p.m of 2” dia
retaining or back roller.
Solution:
S. Speed of Drawing roller=78.5 ft/min.
Draft=6
78.5
So, S. speed of ret roller or back roller=  13.08 ft/min.
6
=13.08 X 12 inches/min.
=157 inches/min.
Dia of ret roller = 2”
157
So, r.p.m. of ret R/r=  24.98 25 Ans.
2
Again,
Faller bar S. Speed = Ret R/r S. Speed + Ret R/r S. Speed X lead%
2
=157+157 X
100
=160.14 inches/min.
Faller drops/min X Pitch.
Faller bar s. speed 160.14
 Pitch=   0.5inches. Ans.
Faller drops/min. 320
Problem 07:
For 1st D/F
2 heads.
2 del/heads.
del speed 127 ft/min.
delivered sliver 8 lbs/100 yds.
For 2nd D/F
Draft 6
eff =90%
Loss=1%
And head= 5
2 del/head.
Doubling 3:1
S. Speed of the back roller=?
Prod/hr of 2nd D/F = ?
Solution:
Total length of delivery of 1st D/F= 127X2X2 ft/min.
=508 ft/min.
508
S. Speed of 2nd drawing back roller= ft / min .
5X 2X 3
508 100
  ft/min.[At 90% eff]
523 80
=18.82 ft/min.
Delivery roller surface speed=6 X 18.82 ft/min.
So, Total length of delivered sliver of 2nd d/f=6X18.82X5X2 ft/min [At 100% eff]
6  18.82  5  2  90
 [ At 90% eff]
100
6 18.82  5  2  90
= [ yds / hr ]
100  3
3 99
lbs/100 yds of 2nd D/F delivered sliver= 8   =3.96 lbs/100yds.
6 100
618.825290603.96
So, Prod/hr of 2nd D/F=  804.89 805lbs
10031000

Drawing
1. Calculate lbs/100 lbs sliver from the drawing frame with particulars as below:
Finisher card delivered sliver =16 lbs/100yds.
Drawing frame draft =4
Doubling at drawing frame 2:1
Doubling at D/F
finisher card sliver wt=16  Drawing frame sliver wt.
Draft at D/F
2
 Drawing sliver wt=16  8 lbs/100yds.
4
2. 3 finisher cards supply slivers to supply slivers to 2 first drawing frames calculate the
speed of back roller of the drawing frame in Balance. Each finisher card produces 400
lbs/100yds sliver; Drawing frame 2 heads, 2 deliveries/head, doubling 2 each into 1.
2 1st D/F = 3 finisher card produ/hr.
=3 X 400=1200 lbs/hr.
1200
=1 1st d/f prod/hr=  600 lbs/min.
2
600
1st d/f feed/min=  10 lbs/min.
60
Total no. of sliver feed at d/f
=2 head X 2 delivery/head X 2 doubling
=2 X 2 X 2 Slivers
Length of Sliver available /min to feed.
100
 10  yds/min
16
to each d/f
10  100  3
= ft/min.
16
10  100  3
Surface speed of Back roller=   2 2 2
16
 23.44 ft/min. Ans.

Spinning
1. Time = 8 hr.
Spindle no. =100
Flyer R.P.M.=3301
T.P.I = 3.35
Sliver from finisher D/F = .5 lbs/100 yds
Spinning frames draft = 9
Spinning frame efficiency = 80%
Production=?
Solution:
Sliver from finisher D/F = 0.5 lbs/100 yds.
0.5X144
So, Spinning count=  8 lbs/spyndle
9
3301 X 60 X 8 X 80 X 100 X 8
 lbs/8hr.
Production 3.25 X 100 X 14400 X 36
=583.92 lbs/8hr. Ans.
2. Present form:
8 lbs/spindle Hessian warp = delivery count.
72 lbs/spindle sliver =feed count.
D.C.P=27
T.C.P=32
T.P.I=4
72
Solution: Draft= 9
8
Draft constant= Draft X D.C.P = 9 X 27 = 243.
Twist constant= T.P.I. X T.C.P = 4 X 32 = 128.
Required formula:
10 lbs spindle sacking warp = delivery count.
120 lbs/spindle sliver = feed count
T.P.I. = 4.4
D.C.P.=?
T.C.P. = ?
120 243
 12  required D.C.P. = 20.2520T
10 12
Draft =
128
required T.C.P. =  29.09 29T
4.4
3. Prepare a spin plant to produce is tons/day Hessian yarn.
Spinning frame:
Assumptions:
Spyndle speed=4000
Yarn count = 8 lbs/spindle.
Twist factor, K = 12
Efficiency= 90 %
Wastage = 2 % ( Sliver )
No. of spindles per frame=100
Calculation:
k
T.P.I=
count
12
  4.24.
8
4000 1 90 8
Production/spindle/day=   60    24
4.24 36 100 14400
=18.867 lbs.
15  2240
No. of spindles required =
18.867
=1780.88
1780.88
No. of spinning frames required=
100
=17.80
18
3rd Draw frame:
Assumption:
Delivery speed= 150 ft/min.
Sliver weight= 1 lbs/100 yds.
Efficiency = 70 %
Draft = 9
No. of delivery per machine=20
Wastage=2 %
Doubling = 2 : 1
Calculation
100
Required production of 3rd Draw frame  15   15.306tons / day tons/day.
98
150 1 70
Production of 3rd Draw frame   60  24  
3 100 100
=504 lbs/delivery
15.306  2240
No. of delivery required =
504
=68.02
68.02
No. of 3rd Draw frame required=
20
=3.4
4
2nd Draw frame:
Assumptions:
Delivery speed = 90 ft/min.
Efficiency = 70 %
Draft = 6
Doubling= 3:1
Wastage=2%
No. of delivery per frame= 10
Calculation:
100
Required production of 2nd Draw frame = 15.306   15.618 tons/day.
98
Sliver wt of 2nd draw frame delivery:
lbs/100 yds of feed of 2nd draw frame
Doubling
  lbs /100 yds of delivery of 3rd draw frame.
Draft
9
lbs/100 of feed 3rd D/F or sliver wt. Of 2nd draw frame delivery  1
2
=4.5 lbs/100 yds*
90 4.5 70
Production =  60  24  
3 100 100
=1360.8 lbs/day/delivery
15.618  2240
No. of 2nd draw frame =
1360.8
=25.7
25.7
Required no. of 2nd draw frame =  2.57 3
10
1st Draw frame;
Assumption:
Delivery speed= 110 ft/min.
Efficiency = 80 %
No. of delivery per frame = 4
Draft = 4
Doubling= 2:1
Wastage=2.5%
Calculation:
100
Required production of 1st draw frame=15.618   15.936 tons/day.
98
Sliver wt of 1st draw frame delivery:
Doubling
Sliver wt of feed of 2nd D/F X  Sliver wt of delivery of 2nd D/F
Draft
6
Sliver wt of feed of D/F or sliver wt of 1st draw frame =4.5 
3
9 lbs/100yds.
110 9 80
Production of 1st draw frame/delivery=  60  24  
3 100 100
=3801.6 lbs/day.
15.636  2240
Required no. of delivery =
3801.6
=3801.6 lbs/day
15.936  2240
Required no. of delivery=
3801.6
=9.389
2.389
Required no. of 1st draw frame 
4
=2.34=3
Finisher card:
Delivery speed= 140 ft/min.
Efficiency =80 %
Wastage = 4%
Draft = 15
Doubling= 11 : 1
Calculation
100
Required production of finisher card=  15.936   16.344 tons/day.
97.5

Sliver wt of finisher card delivery:


Doubling
Sliver wt of feed of 1 D/F  Sliver wt of delivery of finisher card Sliver wt of feed of 1st
Draft
4
draw frame or sliver wt of delivery of finisher card= 9 
2
=18 lbs/100 yds.
140 80 18
Production of finisher card =  60  24    9678.8 lbs/day
3 100 100
16.344  2240
Req. no. of F/C=  3.78  4
9676.8
Breaker card:
Assumption:
Delivery speed= 150 ft/min.
Efficiency=80%
Wastage=5%
Calculation:
100
Req production of breaker card = 16.344   17.025 tons/day.
96
Sliver wt of B/C delivery:
Doubling
Sliver wt of feed of finisher card = = sliver wt of delivery of F/C
Draft
Sliver wt of feed of finisher card or sliver wt of delivery of B/C=
15
18   24.54 lbs/100yds.
11
150 80 24.54
Production of B/C   24  60    14135.04 lbs/day
3 100 100
17.025  2240
Req no. of B/C m/c=  2.69 3
14135.04
Softener M/C:
Assumption:
Production /softener/hour=1 ton.
Calculation:
100
Req production of softener m/c= 17.025 
95
=17.92 tons/day
17.92
Req no. of softener m/c= =0.74=1
24  1
Emulsion m/c:
Required no. of emulsion m/c=1
Say, emulsion pick up=25%
Emulsion req for 17.92 tons of jute=4.48 tons
‘OD’ batch mixer produces 1 batch (100 liters)
in 3 ½” minutes 4 minutes.
4 min 100 liter.
60 min 1500 liter equivalent to 1 ½ tons
24 hours  36 tons
.5
Spg frame = =0.05 lb/100 yds.
10
Flyer R.P.M.
Prodn/hr=
T.P.I.
3000 93 0.05
  60  8   lbs / shift.
3.35  36 100 100
1. What will be the prodn for 8 hrs working of a spg. Frome of 100 spyndles with
particulars as below:
R.P.M. of flyer =3300; TPI=3.35,
Sliver from finisher drawing frame 0.5 lbs/100yds.
Spg. Frame efficiency = 80%
14400
Solution: Spg count = 0.5   8 lbs/spyndle.
9  100
3300  60  8  100  8  0.8
 prod n / shifts  =583.747 lbs Ans.
3.35  36  14400
2. Find out the required input sliver in lbs of a jute spg mills having 10 Apron draft
sliver spinning frame to produce 10 lbs/spindle Hessian warp yarn (Assume
necessary parameters)
Soln:
Here, no. of Apron draft sliver spg frame = 10
Hessian warp yarn count = 10 lbs/spindle.
Let, spindle speed= 4000 rpm, K factor=12
No. of spindle=100
Wastage = 2%, Efficiency = 90 %
12
TPI =  3.8
10
 prodn / spg frame/day in lbs,
4000  60  24 10 100  .90 10
=
14400  3.8  36
 100+L 
 input sliver in lbs=26315.78947   .
 100 
 26842.10526 Ans.
3. Find out the faller bar surface speed from the following data; Drawing roller
speed=150 ft/min, Doubling = 3%
Draft = 5, Faller bar lead%=10 %
Drawing r/r speed
Solution: We know, draft =
Ref r/r speed
 Ret. r/r speed =30 ft/min.
Faller bar speed-Ret r/r speed
Again, FBL%=  100
Ret r/r speed
Faller bar speed - 30
 10   100  Faller bar speed=33 ft/min.
30
4. Find the prodn /shift of 8 hrs of a jute mill having 28 frames of 100 spindles each
running with the following particulars
Flyer speed=3800 r.p.m.
T.P.I=3.2
Count=8.6 lbs/spindle, Eff=84%
Comment on the quality of the yarn produced if 10% root cutting are used in the mixing
along with good fibre,
Solution:
3800  60  8  8.6  .84  100  28
Prodn /Shift=  22240.566lbsAns
3.2  36  14400

5. Find out the no. of jute spg frame required 10 produce 15000 kg/day of jute yarn of
Hessian warp quality (Assume all necessary datas )
Let, Hessian warp yarn count = 8 lbs/spindle
Required production= 15000 kg/day,
Spyndle speed =4000 rpm, no. of spindle=100
Wastage =2 %, Eff=90% K. factor=12;
12
T.P.I. = =4.24
8
400  60  24  100  8  .90
 Prodn/frame/day in Kg=
4.24  36  14400  2.204
 856.075  17.52 18 Ans.

6. A high speed type push bar 1st drawing frame is being fed with 16 lbs/hr. Sliver if
the back rest, r/r. S.S is 23.44 ft/min. Calculate prodn /hr in lbs of the frame
(Assume all necessary parameters).
Soln:
93.76  60  0.8  2  2  8
Prodn/hr in lbs=
3  100
=480 lbs/hr. Ans.
Let, draft= 4
7.
Drawing r/r s.s.
 4=
Ret. r/r s.s.
Drawing r/r s.s.
4
23.44
Drawing r/r s.s. = 93.76ft/min.
eff=80%
No. of head=2
del/head=2
feed sliver wt XDoubling
1st drawing sliver weight =
Draft.

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