JAIPUR ENGINEERING COLLEGE & RESEARCH CENTRE, JAIPUR

DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGINEERING

BY-
MR. ANKUR GANGWAR
MR. BHOOPESH KUMAWAT
MR. NARESH KUMAR
Assistant Professors, Dept. of ECE
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The main objective of the Textile Mill is to produce Yarn (Thread) from
the Raw Cotton which requires six stages of process. These are discussed
briefly for readers understanding. The Textile Mill can be split into three
systems namely, Card Sliver, Combed Sliver and Ring Spinning System.
 The Card Sliver system consists of blow-room and carding machine,
which does the function of removing the foreign particle from the raw
cotton and convert the same into thick yarn (sliver).
 The Combed Sliver system consists of draw frame and comber
machines, the draw frame machine ensures the uniformity in
thickness of the sliver and comber machine removes the unwanted
short fibre in the sliver.
 Ring Spinning system consists of Speed frame and Ring frame
machine, which does the conversion of sliver (thick thread) into yarn
(thin thread). Ring frame is the final product of the spinning mill. 2
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In Spinning Machinery Process, various levels are added to convert fiber
(Cotton/Wool) into Yarn to process it further for textile products. This
transformation goes through various levels such as:
 Step 1: BlowRoom process
 Step 2: Carding
 Step 3: Combining
 Step 4: Drawing
 Step 5: Roving
 Step 6: Cone winding

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 BLOWROOM PROCESS

 BlowRoom indicates place processing “Air Flow”. Blow Room
consists of various machineries to conduct the objectives of
BlowRoom. Here, the cluster of cotton brought is changed into
miniature material. Simply, in blow room section, the compressed
bales are opened, cleaned and blended/mixed according to particular
length to form a specific size of lap.
 CARDING
 Carding is known as heart of spinning process as it defines the
concluded features of yarn. The lap produced in BlowRoom is then
shifted to carding machine for production of Carded Sliver. Here the
bales processed are opened up in single fiber. Apparently, it make
easier to remove the left impurities on the surface of fiber making it
straight and separating the short fiber. 4
 COMBINING

 As yarn is arranged in parallel manner, it is straightened again in
stage of combining. On the other hand, the left short fiber is
subtracted completely from longer Staple Fiber. This results in
stronger and smoother Staple Fabric having higher demand in
market.
 DRAWING
 This is a device in which Drafting and Drawing are carried out.
Doubling is the application of feeding several intermediate strands
into a Single Strand. Drafting is carried out to lessen fiber laps to
slivers. The carded silver is drafted between roller to produce Drawn-
Sliver.
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 ROVING/RING FRAME

 The yarn produced is processed into a Speed Frame to attain Roving
Yarn. This is the initial step where twist is inserted for giving hold to
the fibers in a Spinning Mill. The Roving Yarn is of little larger
diameter as compared to the Final Yarn. Similarly, Ring Frames are
used to produce finished yarns from obtained Roving Yarns. Yarn is
resulted having good amount of strength through these ring frames.
 CONE WINDING
 Cone Winding is just a simple packaging process functioning as a link
between last stages of yarn manufacturing and initial stages of fabric
manufacturing process. It is important to utilize the winding devices
properly to avoid the loss of spinning mills as well as consumers.
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 SPINNING is the process of winding together of drawn-out strands
of fibers to form a yarn and is a major part of the textile industries.
Spinning is used in manufacturing various textile fibers.
 Ring, Rotor, Air Jet are different types of spinners used in the textile
industries.
 THE PROCESS: The polymer is first converted into the fluid state. A
thermoplastic polymer is melted, other polymers are treated
chemically or dissolved in a solvent to form thermoplastic
derivatives. The fluid polymer is then passed through the spinneret.
The polymer forms a rubber-like material on cooling and solidifies.

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TYPES OF SPINNING
There are four main types of Spinning Method:
 DRY SPINNING
 This type of spinning is used for fibers formed in a solution. The
polymer is solidified by evaporation. The solvent gets evaporated by
the stream of inert gas or air.
 This process is used for manufacturing Spandex, Acetate, Triacetate,
Acrylic, etc.
 WET SPINNING
 This is an old process used for fiber forming substances dissolved in a
solution. This is known as a wet method because the polymer
solution is pushed through directly into the precipitating liquid. It is
used to produce Acrylic, Rayon, Modacrylic, Spandex, etc. 8
 MELT SPINNING

 The fiber forming substance is melted and pushed through the
Spinneret. It is then solidified by cooling. This method is used to
produce Nylon, Olefin, Saran, Sulfur, etc.
 GEL SPINNING
 In this, the polymer is not in the true liquid state during extrusion. It
is used to obtain high strength fibers.

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 Description
Blowroom
Carding
 Installed, kW
58.78
327.6
Total load, %
2.39
13.32
Drawframe 61 2.48
Comber 59.23 2.41
Speed frame 68.32 2.78
Ring frame 1,158.88 47.12
Autoconer 196.35 7.98
Winder 26.4 1.07
Humidification plant 284.3 11.56
Waste collection 45.48 1.85
Buffing 7 0.28
Compressor 93 3.78
Lighting 35.15 1.43
Seawage plant 7.25 0.29
Water pump–hostel 18.7 0.76
Admin office, QC, hostel 11.84 0.48
Total power 2,459.28 100 12
Power Distribution including Productive and Non-Productive Machines
 Specialized Field Fuel
Electricity Total % Share

Dyeing 37,661 28,412 66,073 25

Fibre Production 32,551 21,498 54,049 21

Spinning 3,224 44,262 47,480 18.4
Weaving 4,467 24,848 29,315 11.4
Clothing
8,240 15,420 23,660 9.2
Manufacturing
Knitting 4,059 11,709 15,858 6.1
Twisting 219 1,660 1,879 0.7
Textured Yarn
120 1,543 1,663 0.6
Production
Others 5,959 12,000 17,959 7
Total 96,500 161,442 257,942 100.0
Unit: million Rs. 13
Energy Consumption Share of Each Specialized Technical Field in the Textile Industry
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From this data it is evident
that the major power saving
regions are Preparatory
Process, Ring Frame,
Humidification Plant and
Compressor. Apart from the
above, cable loss and power
factor also plays a major
task in textile mills to
conserve the energy.

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For Fuel Conservation, some of the measures are mentioned below:

 Human Factor Management  Alternate Sources of Fuel

 Fuel Selection  Renovation/Replacement of
 Fuel Handling and Storage existing Plants
 Fuel Combustion  Process Modification
 Steam Generation
 Steam Distribution
 Steam Utilization
 Maintenance of Machines
 Waste Heat Recovery
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