STUDY OF CLASSIMAT FAULTS AND THE FACTORS INFLUENCE ON CLASSIMAT FAULTS

A Thesis Submitted To Bahauddin Zakariya University College of Textile Engineering & Technology Multan
By

MUHAMMAD ARIF NAWAZ MUHAMMAD RIZWAN KHAN HINA RUBAB M.NAEEM

08-TE-09 08-TE-31 08-TE-43 08-TE-46

BAHAUDDIN ZAKARIYA UNIVERSITY COLLEGE OF TEXTILE ENGINEERING & TECHNOLOGY MULTAN

May 2012

DEDICATION

This thesis is dedicated to our parents who have supported us all the way since the beginning of our studies.

Finally, this thesis is dedicated to all those who believe in the richness of learning.

ACKNOWLEDGEMENT
In the name of Allah, the Most Gracious and the Most Merciful. Alhamdulillah, all praises to Allah for the strengths and His blessing in completing this thesis.

We would like to express our appreciation to our excellent teachers. We have had more excellent teachers than even extreme good fortune should allow and we are grateful of them and also to the Voice Principal of Bahauddin Zakriya University College of Textile Engineering, Mr. Tahir Bappi for their support and help towards our graduate affairs.

Special appreciation goes to our supervisor, Mr.Furqan Khurshid for his supervision and constant support. His invaluable help of constructive comments and suggestions throughout the experimental and thesis works have contributed to the success of this research.

We would like to pay thanks to Mr.Shoaib Alam General Manager Reliance Weaving Mill Unit # 04, Multan. Who allowed us to work in his esteemed mill. We are also thankful for his valuable guidance during our stay at mill. We are also thankful to all those peoples who helped us during course of this work, especially Mr. Waqas Mill Manager, Mr.Asim Malik Technical Manager.of Reliance Weaving Mill Unit # 04 Multan.

Sincere thanks to all our friends and classmate for their kindness and moral support During our study. Thanks for the friendship and memories.

M.Arif Nawaz M.Rizwan Khan Hina Rubab M.Naeem

08-TE-09 08-TE-31 08-TE-43 08-TE-46

ABSTRACT

It has been widely reported that the defects in cotton yarn are main reason of yarn rejection from weaving mill. The main faults which are undertaken by the weaving mill are classimat, periodic and deviation from the prescribed quality. This thesis has been undertaken to study the various aspects of yarn faults produced in cotton ring spinning mill, its reasons of occurring and prevention from occurring.

Yarn samples were spun on the RX 240 Toyoda ring machine from same fibers properties with different settings on the machine. In addition, samples of roving were taken from simplex and slivers were taken from drawing frame, comber and card with different settings, in order to check the various factors affecting the quality of yarn.

A Classimat yarn fault detection system was developed to find out the defective part in the yarn that mentioned on the Winding/auto Cone machine. It was found that this system is suitable for identifying the source of Classimat fault in the Yarn. Uster Quantum 2 is used for the identification of Classimat Faults on Winding/Auto Cone machine for this thesis.

CONTENTS
CHAPTER 1: INTRODUCTION 1.1 Spinning. 1.2 1.3 1.4 1.5 1.6 1.7 1.8 01

Yarn................................ ........01 Definition of Classimat...............................................01 History of Classimat..01

Scope of Classimat....02

Importance of Classimat......................................................................................04 Classimat Quantum and its possible usage ...06 Distinction between Frequent and Seldom-Occurring Yarn Faults06

1.9 The Scatter plot of Uster Classimat Quantum.....12 1.10 1.10.1 1.10.1.1 1.10.1.2 1.10.1.3 1.10.1.4 Detection of foreign fibers .....................................................................14 Types of Foreign Fibers in the Yarn.15 Foreign Fibers....15 Packing Material .....15 Trash....15 Vegetable matters.....16

1.10.1.4.1 Pieces of Vegetables...16 1.10.1.4.2 Vegetable Packing Material16 1.11 1.11.1 1.11.2 Removal of Yarn Faults...17 Remove Yarn Faults by the Aid of Yarn Clearers....17 Prevent the Origin of Yarn Faults by Adequate Measure.......18

CHAPTER 2: EXPERIMENTAL WORK

2.1 2.1.1 2.1.2 2.2

Material................................................................................................................. 22 Characteristics of Combed Cotton........................................................................ 29 Characteristics of Carded Yarn ............................................................................ 30 Work Place ........................................................................................................... 31

2.2.1 Introduction of Reliance Spinning Mills-4 ........................................................... 31 2.2.2 2.2.3 2.2.3.1 2.2.3.2 2.2.3.3 2.2.3.4 2.2.3.5 2.2.3.6 2.2.3.7 2.2.3.8 Machinery Details ............................................................................................ 32 Machinery Specifications and Settings ............................................................ 34 Blow Room Specification................................................................................. 34 Card Specification ............................................................................................ 39 Drawing specification ....................................................................................... 41 Lap Former Specification ................................. Error! Bookmark not defined. Specification of Comber ................................................................................... 43 Roving Frame Specifications ........................................................................... 44 Ring Frame Specifications ............................................................................... 44 Auto Cone Specifications .................................................................................. 46

2.2.3.9 Specifications of Air Conditioning Department ................................................. 47 2.5 Experiments Conducted....................................................................................... 41

CHAPTER 3: RESULTS AND DISCUSSION

3.1 Effect of Cleaning of Card on Classimat......43 3.2 Effect of Drawing Finisher Guage on Classimat..45 3.3 Effect of Drawing Finisher Break Draft on Classimat..47 3.4 Effect of Simplex Break Draft on Classimat....49 3.5 Effect of Simplex Twist Wheel (T.w) On Classimat...51 3.6 Effect of Simplex Rubber Cots Grinding On Classimat..53 3.7 Effect of Ring Cleaning On Classimat.55 3.8 Effect of Changing the Spindle Speed of Ring Frame on Classimat...57 3.9 Effect of Changing the Break Draft (B.D) of Ring Frame on Classimat.59 3.10 Effect of PENUMAFIL on Classimat.61

CHAPTER 4: CONCLUSION AND FUTURE WORK 4.1 4.2 CONCLUSION & FUTURE WORK ..................... Error! Bookmark not defined. FUTURE WORK ................................................................................................... 65

CHAPTER 5: REFERNCES ..66

INTRODUCTION Spinning
The process for drawing out (cotton) fibers to make into (cotton) threads. Spinning could be done by hand, on a spinning wheel or on a Ring-spinning machine.

YARN
A continuous strand of textile fibers that may be composed of endless filaments or shorter fibers twisted or otherwise held together. It may be made up of vegetable (linen, hemp, jute, sisal, ramie, cotton), animal (wool, mohair, silk), or artificial fibers (gold, silver and other metals rayons, nylon, Orlon). Yarns are utilized in making fabric. Yarn is characterized by its composition, its thickness (or grist or count), number of strands (or plies), direction and degree of twist, and the color. OR A yarn is a constructed assemblage of textile fibers which acts as a unit in fabric formation. OR A continuous strand of textile fibers that may be composed of endless filaments or shorter fibers twisted or otherwise held together. OR Yarn is continuous strand composed of either natural or manmade fibers or filament and is used in weaving and knitting to produce a cloth.

Definition of Classimat
Classimat is used for the detection and classification of faults in the yarn. We can also cut the yarn faults, but this is not done for production point of view.

History
Today, the selection of the right yarn for the right product is crucial for economic reasons. A continuous incoming inspection guarantees a constant satisfactory quality of the end product. In this respect, yarn clearing and classifying systems are playing a very

important role. At the beginning of electronic yarn clearing, the setting of the clearing curve has been quite difficult and has required specialists. In 1968, uster Technologies launched an electronic system by the name of uster
classimat, which was a revolution in yarn clearing at that time. The purpose of the system

was the analysis of seldom-occurring or disturbing thick places and the setting of an optimum clearing curve on the winding machine to eliminate the really disturbing yarn faults and to simultaneously keep the efficiency of the winding machine as high as possible. For this purpose the yarn was classified into four lengths and in four thick place classes. This analyzing system was not only used by spinners. The yarn buyers (traders, weavers, knitters, garment makers, etc) also detected this system as a tool to separate yarns into first grade, second grade, etc, or to establish minimum conditions for the acceptance of yarns. Today with the uster classimat quantum generation, the cleared and unclear yarn can be checked; the classification of thick and thin places, neps and foreign fibers in the yarn can be fulfilled. This system also helps the user in determining the optimal limits for yarn clearing, in analyzing new material, and supports with experience values, which can be used for benchmarking and evaluation. The uster classimat quantum can be used not only as a tool in order to examine the yarns to be purchased for remaining disturbing thick places, thin places and foreign fibers but also as a sophisticated classifying system which can help the user to determine and set his own yarn quality standards.

Scope of Classimat
From a statistical point of view, it is difficult to determine the frequency of yarn faults by testing random samples. Firstly, we are dealing with seldom-occurring events, which mean that a large amount of testing material is required for a statistically reliable measurement result. Secondly, yarn faults are not evenly distributed within a lot. If a yarn normally shows one disturbing fault per bobbin, for example, there will always be individual bobbins with 10, 50 or even more disturbing faults. This means that the faults

are not normally distributed within a yarn lot and that the rules for the calculation of the confidence limits based on the normal

Distributions are therefore not applicable. With the application of the central theorem of limits, we can get around this difficulty, because the theorem says that the mean values of partial groups of a population are normally distributed even if that population as a whole is not normally distributed. It is therefore advisable to divide the test sample of a classification into at least five partial samples of the same size (e.g. 100 km of yarn). Each partial sample is tested separately. The statistical evaluation is carried out automatically by the uster classimat quantum.

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Importance of Classimat
It is still not possible to produce a yarn without faults for various reasons. Stickiness of cotton can contribute to the formation of thick and thin places. Fly liberation in Ring frame department is one of the major reasons for short faults in the yarn because of the fly get spun into the yarn. Hence it is not possible to have fault free yarn from ring spinning, it is necessary to have yarn monitoring system in the last production process of the spinning mill. As physical principle for electronic yarn clearing the capacitive and the optical principle have established. Both principles have their advantages in specific applications. Depending upon the material, the machinery set up, production and process parameters, there are about 20 to 100 faults over a length of 100 km yarn which does not correspond to the desired appearance of the yarn. This means that the yarn exhibits a yarn fault every 1 to 5 km. These faults are thick and thin faults, foreign fibers and dirty places in the yarn. The yarn faults which go into the woven or knitted fabric can be removed at very high costs or cannot be removed at all. Therefore the yarn processing industry demands a fault free yarn. The difference between frequent yarn faults and seldom occurring yarn faults are mainly given by the mass or diameter deviation and size. These faults are monitored by classimat or clearer installation on winding. Each yarn contains here and there, places which deviate to quite a considerable extent from the normal yarn cross-section. These can be short thick places, long thin places, long thick places or even spinners doubles. Even though such events seldom occur, they represent a potential disturbance in the appearance of the fabric or can negatively influence subsequent processing of the yarn. Short thick places are those faults which are not longer than approximately 8 cm, but have a cross-sectional size approx. twice that of the yarn. These faults are relatively frequent in all spun yarns. To an extent they are the result of the raw material (vegetable matter, non-separated fibers, etc). To a much larger extent, these faults are produced in the spinning section of the mill and are the result of spun in fly. Short thick places are

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easily determinable in the yarn. In many cases, they cause disturbances in subsequent processing. Once they reach a certain size ( cross-section and length) , and in each case according to the type of yarn and its application, short thick place faults can considerably affect the appearance of the finished product. Long thick places are much more seldom-occurring than the short thick places and usually have a length longer than 40cms. In some cases, their length can even reach many meters. Their cross sectional size approx. + 40% to +100% and more with respect of the mean cross-section of the yarn. Long thick places will affect the fabric appearance. Faults like spinners doubles are difficult to determine in the yarn, with the naked eye. On the other hand, they can produce quite fatal results in the finished product. A spinners double in the warp or in yarn for circular knitting can downgrade hundreds of meters of woven or knitted fabric. Thick places occur in two length groups. Short thin places are known as imperfections, and have a length approx. three times the mean staple length of the fiber. Their frequency is dependent on the raw material and the setting of the drafting element. They are too frequent in the yarn to be extracted by means of the electronic yarn clearing. Long thin places have lengths of approx. 40cms and longer and a cross-sectional decrease with respect to the mean yarn cross-section of approx.30 to 70%. They are relatively seldom-occurring in short staple yarns, but much more frequently-occurring in long staple yarns. Long thin faults are difficult to determine in the yarn by means of the naked eye. Their effect in the finished product however, can be extremely serious. The quite extensive application of electronic yarn clearing has set new quality standards with respect to the number of faults in spun yarns. It is therefore necessary to evolve a method of yarn fault classification before clearing the faults in winding. The most important aspect is certainly the determination of the fault dimensions of cross-sectional size and length. With such a cross-section and length classification and by means of the correct choice of the class limits, the characteristic dimensions of the various fault types can be taken into consideration, then a classification system will result which is suitable primarily for satisfying the

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requirements of yarn clearing and yet allows, to quite a large extent, for a selection of the various types of faults. The yarn faults are classified according to their length and cross-sectional size, and this in 23 classes.

Classimat Quantum and its possible usage in improving the quality of yarns
The uster classimat quantum is a complex testing system that offers the customers multitude of applications and evaluation possibilities. It can be used for production monitoring or as an analysis instrument for the clearer setting and for the preparation of supply agreements or quality certificates.uster classimat if used in a proper way can increase the quality of the product and also the faulty process can be identified and even the fault producing part can be determined which was not possible a few years ago.. Today with the uster classimat quantum generation, the cleared and unclear yarn can be checked; the classification of thick and thin places, neps and foreign fibers in the yarn can be fulfilled. This system also helps the user in determining the optimal limits for yarn clearing, in analyzing new material, and supports with experience values, which can be used for benchmarking and evaluation.

Distinction between Frequent and Seldom-Occurring Yarn Faults

Fig. shows the position of the frequent yarn faults (imperfections) in comparison to the position of the seldom-occurring yarn faults in the classification matrix. It becomes clear, that both types of yarn faults differ from each other clearly by their size and thus, cannot be compared with each other. In addition, the areas of the clearer settings N, S, L, T, CCp and CCm are indicated in Fig. This shows where the settings are effective.

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A) Random Occurring Faults

Frequently occurring yarn faults are generally given per 1000 m. These faults are generally called IPI.

Thin Places
Thin places are places in the yarn, that are the thinner than -50% or more then the average diameter of the yarn.

Thick Places
Thick place are determined where yarn diameter is in excess of 50% of the average yarn diameter and the length is 8-12 mm.

Neps
A nep is very short thick place in the yarn, a small fault having a length of 2mm dia of 3 times or more at a standard setting of 200%. It can either be a fiber nep, a seed coat nep or a trash particle.

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B) Seldom Occurring Faults

Seldom occurring yarn faults are given generally per 10000m. As mentioned in table.

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Class A Fault - Lengths between 1 mm and 10 mm Nep. A nep is a small accumulation of entangled fibers with a well-defined core.
The diameter of the core is generally of the order of 0.8 mm to 1.5 mm. In general the total length of the nep is from 1.5 mm to 3 mm, and the local count 2 to 5 times that of the average yarn count. The origin of a nep is in the preparation stages, that is, at the top. It can be formed during the scouring of wool, opening and carding processes, and can be removed during combing. The problem could be that the roller beater in the blow-room may not be opening the fibers well enough to remove coils. During carding, 85% of neps should be removed under normal circumstances.

Short Fly. The short fly is a mass of fiber of rather loose structure, generally
loosely adhering to the yarn. The fault is most often shorter than 4 mm. The length of these short fibers does not fall within the range of the fibers being processed. It is easily distinguished from a nep by having a very loose structure, and by the fact that it has no compact core. They are loose because air suction and currents cause them to fly around. The solution is to improve the efficiency of such systems. A powerful extraction system must be kept in place to remove these fibers, ensuring minimal amounts of short fibres in the spinning area. Suction fans should be placed around the spinning area to remove such short fibers.

Class B Faults - Lengths between 10 mm and 20mm Waste. Waste is a compact mass of fibers analogous to a nep but distinctly
larger in size having average adhesion to the yarn. The length of the fault is between 4 mm and 15 mm (more rarely up to 20 mm). The fault in the yarn originates from waste in the top. The faults are formed in the first stages of preparation and may disappear in drawing. Just like neps, the system must be able to extract unnecessary material such as short fibers, twigs, and seeds. Fibers would certainly form around any of these materials.

Fly. A fly is a mass of fiber of rather loose structure, generally loosely adhering to the yarn. The fault is more often between 4 mm and 20 mm long but may reach 70 mm. The increase in local count, and particularly apparent diameter, may sometimes be very large, e.g. 2 to 20 times the average yarn. The increases and decreases in

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thickness at the beginning and end of the fault are not always abrupt. This fault is often formed by bundles of fiber drawn into the yarn during its passage to the winding machine / spinning frame. A powerful extraction system to remove these fibers must be kept in place to ensure minimal amounts of short fibers in the spinning area. Suction fans should be placed around the spinning area to remove these.

Slub. A slub is part of a yarn with a thickness appreciably greater than the
average over a fairly short length, of the order of 10 mm to 40 mm, and characterized by a fairly gradual appearance and disappearance of the thickened place. The local count will be between about 2 and 6 times the average. The corresponding part of the yarn is generally less or much less twisted. The fault is generally produced at the spinning frame by a faulty drafting action at certain times. The sliver then experiences a reduced amount of draft due to poor fiber control, releasing fiber bundles. The solution lies in how efficient the preparation has been, how well the system eliminates dust, and how well the fibres are paralleled. Proper noil removal Bad sliver piecing at any process carding and spinning should be controlled by proper management. control leaking sliver proper gauge of traveler cleaner

Class C Fault Length between 20 and 40mm Long Slub. Part of the yarn with a thickness appreciably greater than the average
over a fairly long length ranging from 40 mm to 160 mm. The emergences and disappearances of the thickness are generally very gradual. The local count may be up to about 6 times the average. The corresponding part of the yarn has generally very little twist. The fault is produced in the spinning frame by a faulty drafting action, but is in general caused by more pronounced mechanical defects, or more pronounced faults in the roving.

Piecing up. Every time an end breaks during spinning, the yarn end of the bobbin is
located, withdrawn and rethreaded, bringing it into close proximity with the strand of

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fibres being delivered from the drafting zone, so that the twist binds the two ends of the yarn together where they overlap. This is called piecing up. Faults arise due to careless piecing at the spinning frame. When the yarn is pulled from the bobbin back to between the drafting rollers, it meets new fibers. The length is between 40 mm and 60 mm (exceptionally up to 200 mm), and the local count between 2 and 6 times greater.

Cracker. Refers to parts of

yarn with a thickness clearly greater than the average,

over a length most often between 40 mm and 60 mm, but different from the long slub fault by having a characteristic spiral appearance, some of the fibres comprising the yarn being wrapped around the other part in a corkscrew fashion. The local count is generally about 2 to 6 times the average; the emergence and disappearance of the thick part are fairly gradual. The fault occurs at the spinning frame as a consequence of the formation in the drafting zone of two parts of the roving which were drafted differently. The part drafted most winds itself round the part drafted least in the manner of a corkscrew. As in the slub, the problem could be that the covering rollers are be worn out at the spinning phase. This problem appears during roving and in the spinning system.

Class D Faults 40~ 80mm Thick Yarn. This refers to part of the yarn with a thickness appreciably greater than
the average (as in the slub), of the order of 160 mm to 1 meter in length (in rare cases up to 2 meters or more), for which the emergence and disappearance of the fault are generally very gradual. The local count is generally between 1.5 and 4 times the average. This fault is generally caused by a thickening similar to a slub present in the finisher roving, where it appears for reasons analogous to those indicated for yarn. Drafted from about 10 to 25 times at the spinning frame, this slub produces long thick places in the yarn, at times up to about 2 meters in length.

Class E Faults 80~ 320mm Double.

Where an end breaks and piecing occurs, a fault is produced by the total or

partial fusion of two ends at the spinning frame. Once inside the rollers and joining new

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fibers, the redundant fiber has to be cut out. If it is left too long, it doubles up because of new roving coming in the ring system. Local count is about 1.5 to 2 times greater than the average. The fault is often quite long, up to several meters.

Class F and G Faults 80~ 320 mm (Long Thick Places) Piecing Up. Every time an end breaks during spinning, the yarn end of the bobbin is
located, withdrawn and rethreaded, bringing it into close proximity with the strand of fibres being delivered from the drafting zone, so that the twist binds the two ends of the yarn together where they overlap. This is called piecing up. Faults arise due to careless piecing at the spinning frame. When the yarn is pulled from the bobbin back to between the drafting rollers, it meets new fibres. The length is between 40 mm and 60 mm (exceptionally up to 200 mm), and the local count between 2 and 6 times greater.

Class H and I FAULTS 80~ 320MM Long Thin Places

Mostly eccentric bobbin of simplex and eccentric spindle of ring fame. Poor handling of material during process. Long thin places (these types of faults are produced by bad piecing of ring simplex and back process. Peeling of sliver and roving

The Scatter plot of Uster Classimat Quantum

The scatter plot is a very important feature of uster classimat quantum which helps the user in analyzing the exact place of each event in the classification matrix and indicates the yarn faults of both the standard classes and the extended classes as points in the classification matrix. The exact length and cross-section increase of the individual yarn faults can easily be determined with the horizontal and vertical scales.

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In order to show the usage of the scatter plots, two yarns of two mills were given (Ne 30, 100% cotton, carded) as an example. 100 km of these two yarns were measured with uster classimat quantum and the neps, short thick, long thick and thin places (NSLT) were counted and classified. In Fig. 3, we can see the scatter plot of a yarn produced in a mill with a good quality management having less number of faults. These faults are shown according to the classimat Classes (NSLT) as green colored points. In Fig. 4 the scatter plot of a low quality yarn is shown having a high number of faults. When we compare these two yarns, for example in the B1 class, the first yarn (left) had only 9 short thick places; Fig. 4 shows, as a contrast, a yarn with 488 short thick places in the same class. The faults in the B1 class can be the result of a wrong raw material, fiber damages in spinning or other processing problems. The difference between these two yarns is enormous, and by the help of the scatter plot the user can analyze and choose the yarn having better quality easily.

Fig. 3 100% cotton, carded, Ne 30, ring spun yarn, per 100 km (low number of faults)

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Fig. 4 100% cotton, carded, Ne 30, ring spun yarn, per 100 km (high number of faults )

Detection of foreign fibers

The yarn of Fig. 4 also has much more faults in the thin place area (part below the zero line of the scatter plot). Foreign fibers are one of the major problems in spinning mills. The global ITMF survey on cotton contamination in 2007 showed that in the perception of spinners from around the world contamination remains a serious problem. During the past 18 years the degree of contaminated cotton bales was increasing steadily from 14% to 22%. Organic matters are still the main contaminants, followed by fabrics of cotton and plastic film, strings of jute and plastic. These fibers can be of different origin, character, structure, or color other than the original fibers of the yarn (for example synthetic fibers in a cotton yarn). There are distinct benefits to early detection and removal of unwanted fibrous material since later processing stages open up and spread out these foreign fibers. This can result in the contamination of many yarn packages. Schenek named that due to the fact that fabrics containing foreign fibers cannot be dyed homogeneously, these fibers can cause a lot of quality problems especially after finishing. Lord mentioned that these foreign fibers

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and materials adversely affect processing and produces error and also affect the properties such as dye uptake, fiber reflectance and the appearance of the final product.

Types of Foreign Fibers in the Yarn Foreign Fibers

Foreign fibers are all kinds of fiber type materials, which cling to the yarn. They can be of different origin, composition, structure and color. They occur as single fibers as well as in fiber bundles. The length of foreign fibers can vary considerably, but hardly exceeds a length of 10 cm. Foreign fibers can be: Plastic, foil Fertilizer bags Strings Feathers Human and animal hair

Packing Material
Cotton bales are often packed in polypropylene bags or other synthetic material after ginning. Other kind of packing material made of natural fibers will not be discussed here. Foreign fibers consisting of polypropylene are often white or without any color and therefore hard to detect by electronic means. First, these fibers do not protrude and are not detected before dying or finishing. Thus, they first become visible in the finished woven or knitted fabric.

Trash
Trash is made up of substances, which adhere to, are spun into or have penetrated the yarn body. The contamination of bales is usually attributed to transport damage, improper storage and print color.

In the spinning mill, trash as a foreign matter can be caused by Lubricant residue on machine parts (grease or oil) A messy working environment with dust and dirt

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Dust or very small particles from rubberized machine parts (e.g. press rollers) or drive belts, which adhere to the yarn. In the yarn, trash appears mostly as dark, brown or gray contaminants. In contrast to many foreign fibers or packing materials, such faults are often very long, for example 10 cm or more. Due to the length and the missing fibrous structure, these faults can usually be clearly identified.

Vegetable matters
With vegetable matter, it is necessary to clearly differentiate between two categories pieces of vegetables vegetable packing material

a) Pieces of Vegetables
Under this term, it is commonly understood: leaves stems bark seed-coat fragments

The color is light to dark brown and the shape is irregular. The foreign matter adheres to or, in some cases, is embedded in the yarn. The frequency of such foreign matter depends on the degree of contamination of the fiber material and on the efficiency of the blow-room equipment. In general, it can be said that the relative percentage of such foreign matter is usually very high. Foreign matter in the form of vegetable pieces is normally brightened up almost completely in the bleaching process. But the effectiveness of the bleaching process depends on the recipe and on the applied technology. Under normal conditions, this type of foreign matter is considered as none disturbing. Experience has shown that vegetables deriving from weeds might remain as dark spots in the yarn after bleaching. The monitoring of such faults is aspired.

b) Vegetable Packing Material

Foreign matter made out of vegetable packing materials is e.g.: Jute fabric or jute-/hemp strings Chemical components based on cellulose material

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The structure of the material is clearly fibrous. The color is usually light to dark-brown and the length is in a short to medium range of approx. 1 to 2 cm. The fibers are extremely rigid and brittle, so that they often protrude from the yarn and rarely cling tightly to the yarn body. Due to the chemical similarity to the vegetable components of the fiber material, e.g. cotton, vegetable packing materials are also affected by the bleaching process, whereby the recipe and the process technology again play an important role. Usually, this type of foreign matter can only be partly brightened through bleaching.

Removal of Yarn Faults

The principles of the spinning process for short- and long-staple yarns remained the same for many decades. Changes took place especially in the field of automation and production quantity per production hour in order to reach the highest production of yarn in a good quality at the least expenses for personnel, capital and energy. Despite this progress and many years of experience in spinning technology, it is still not possible to produce a fault-free yarn straight-off. Depending on the raw material and state of the machinery park, there are about 20 to 100 events over a length of 100 km yarn, which do not correspond to the desired appearance of the yarn. This means, that the yarn exhibits a yarn fault every 1 to 5 km. These kinds of yarn faults are places, which are too thick or too thin. Foreign fibers or dirty places in the yarn are also counted as yarn faults. Yarn faults cause disruptions in the subsequent process stages, which affect production and quality. Yarn faults, which get in the woven or knitted fabric, can only be removed at very high costs or not at all. Therefore, the yarn processing industry demands a fault-free yarn from the yarn producer. The spinner has to fulfill these demands; otherwise he could not sell the yarn covering his costs. . The spinner can fulfill these demands by a combination of two measures: Remove Yarn Faults by the Aid of Yarn Clearers Prevent the Origin of Yarn Faults by Adequate Measure

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Remove Yarn Faults by the Aid of Yarn Clearers

There are two methods two remove yarn faults but capacitive method is more accurate. The Capacitive Measuring Principle

But most common is capacitive in Pakistan industry

The Capacitive Measuring Principle

Fig 1.18 The electrical measuring condenser (1) forms the sensor for the capacitive monitoring of the yarn mass. This is done by two parallel metal plates, the electrodes. In the space in between (2), the two electrodes build an electrical field when putting on an electrical alternating voltage (3). If a yarn (4) is brought into this field, the capacity of the measuring condenser is changed. From this change, an electrical signal, the yarn signal (5) is derived. The change in the capacity depends, besides of the mass of the yarn and of the dielectric constant of the fiber material used, on the moisture content of the yarn. With the capacitive measuring principle, the yarn signal corresponds to the yarn crosssection yarn mass, respectively, which is located in the measuring field. Changes of the yarn mass cause a proportional change of the yarn signal.

Prevent the Origin of Yarn Faults by Adequate Measure

FAULT CLASSIMAT FAULT SELDOM OCCURRING FREQUENTLY OCCURRING PREVENTIVE MEASURES

By controlling IPI in the yarn Proper mixing of raw material Selection of suitable

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of raw material Control Mechanical faults on machine machine setting

should be proper machines and

environment should be clean regularly & properly train people to control Operative faults
IMPERFECTIONS THIN PLACES

Check that auto leveler is working properly. Control single and double roving. Proper gauge. drafting

THICK PLACE

Control

the

top

roller pressures on the simplex frame and zone. Proper cleaning of drafting zone of ring and simplex. Regular protocol test Control the size of the package to ring drafting

remove piecing in draw frame and

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simplex.
NEPS

Check raw cotton Check Trash content in raw cotton Control the Moisture content in cotton Control R.HS% Adequate removal carding clothings( doffer & flats) machine card, waste

control the gauges of top flats in card. Check the effects of grinding on the nep removal.

SPLICE FAULT

Proper

blowing

pressure in splicer adequate splicing Faulty yarn trap

should be eliminated

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CHAPTER 2 EXPERIMENTAL WORK

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2.1 MATERIAL
In this project we were taken such cotton, which were open in the blow room. This was Pakistani cotton. Total cotton consumption was about 72930 bales per year. Carded cotton is taken from the areas of Sadiqabad, Rahim Yar Khan, Liyah, Multan, Shujabad, Khanewal. Comber cotton is taken from the areas of Ali Pur, Muzaffargarh, Jatoi, Sher Sultan and Taunsa Sharif.

2.1.1 Characteristics of Combed Cotton

S.# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Lot 75 80 76 65 18 61 48 49 46 47 45 72 63 70 81 39 84 50 78 62 Moist 9.4 9.2 9.3 9.2 9 9.4 9.1 8.8 9.2 9 9.4 9.1 9.5 9.7 9 9.5 9.2 9.5 9.3 9.6 Mic 3.5 3.6 3.6 3.8 5.2 4.2 3.3 3.4 3.5 3.5 3.6 3.6 3.9 4 3.5 3.9 3.2 3.3 3.3 4.1 Sci 134 150 128 135 125 137 138 146 148 127 133 135 135 137 143 128 136 145 136 136 Length 1.12 1.12 1.13 1.13 1.08 1.15 1.15 1.16 1.17 1.13 1.14 1.13 1.13 1.13 1.18 1.12 1.13 1.14 1.12 1.15 Unf 83 85 82 83 83 84 83 83 84 81 83 83 83 84 83 84 83 83 83 83 Sfi 9.5 7.6 9.8 9.1 8.5 8.7 9.4 8.5 8.1 11 9.6 8.8 9.8 8.3 8.4 8 9.5 8.6 10 8.8 Str 27.5 28.5 26.7 28 30 28.3 27.6 29.4 28.7 27.2 27.6 28.2 27.4 28.6 28.8 27.1 28.4 27.2 28.4 28.4

29

21

66

9.5

4.1

136

1.15

83

27.2

2.1.2 Characteristics of Carded Cotton

S.# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 `25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Moist 9.01 8.95 9.2 9.2 8.6 8.05 8.85 8.95 8.9 9.1 9.15 9.05 9.07 9.5 8.65 9.1 9 9.15 8.9 9.2 9.25 9.15 8.8 8.75 8.4 8.5 9.25 9.1 8.8 8..9 9.2 8.9 8.95 9.25 9.2 9.35 8.8 10.45 8.95 11.55 10.5 Mic 3.91 3.75 3.8 3.83 4.54 5 4.49 4.18 4.04 4.02 4.02 4.05 3.8 4.75 4.89 4.62 4.32 3.69 5.33 5.25 3.93 3.93 3.95 3.97 4.74 4.61 3.82 3.73 3.73 3.79 4.25 4.14 4.64 4.39 4.67 4.86 4.18 4.21 3.64 5.04 4.98 Sci 128 121 118 130 105 127 134 137 138 123 129 123 123 133 132 131 133 135 114 128 121 116 129 122 127 138 112 122 127 125 125 131 116 130 129 125 121 143 136 129 128 Length 1.097 1.109 1.079 1.105 1.04 1.089 1.124 1.135 1.134 1.085 1.097 1.085 1.1 1.101 1.1 1.107 1.11 1.22 1.089 1.086 1.075 1.07 1.109 1.077 1.099 1.128 1.093 1.1 1.008 1.11 1.115 1.07 1.044 1.106 1.087 1.096 1.096 1.159 1.134 1.24 1.128 Unf 82.6 81.8 81.8 83.1 81.2 83.6 83.7 84.2 83.8 82.5 83.1 82.2 82.1 84.2 83.8 84.2 84 83.5 85.1 83.4 82.3 81.5 83.4 82.4 83.1 84.4 80.2 81.8 82.2 81.8 83 83.3 82.1 84.2 83.8 83.2 82.3 84.1 82.5 84 82.4 Sfi 9.6 9.8 10.4 8.5 11.3 8.7 8 8.4 8.6 10 9.6 9.7 10 7.3 8.1 8.2 8.8 9 8.7 8 9.5 10.2 9.4 10 8.7 9 10.8 9.6 10 9.6 9 8.4 9.4 8.5 8.6 8.2 9.9 8 9.7 7.4 7.6 Str 27 25.1 25 26.8 25.3 29.6 29.3 28.3 28.4 26.5 27.7 26.6 26.8 30.1 30.6 28.3 28.3 26.9 29 30.7 26.2 25.8 26.4 26.4 29.2 29.4 25.8 26.1 27.7 27.2 27.1 26.6 27.5 27.6 29.2 29 27 30.3 28.8 29.3 28.6 Grade B B B B A A A B B A B A B B B A A C A A B B B B B A A B D B C B B B A A B A A A A

30

42

9.03

3.38

133

1.124

8.8

27.1

2.2 WORK PLACE 2.2.1 Introduction of Reliance Spinning Mills-4 & Fatima Group of Industries
In start of 2004, a spinning unit named reliance spinning mills unit-4 consisting of 21120 spindles (Toyoda Japan) was set up by Fatima group of industries. In this unit most modern machines were imported from worlds leader manufactures like Rieter, Toyoda and Schalafhorst to provide the customers with state of the art yarn. The yarn produced is of export and local quality, free from all defects and suitable for the manufacturing of all sorts of cloths.

Mills Name CHIEF EXECUTIVE ADDRESS PHONE FAX EMAIL CITY STATE COUNTRY ZIP TYPE UNIT MILL ADDRESS

RELIANCE WEAVING MILLS LTD MR.FAZAL AHMED SHEIKH

2ND FLOOR TRUST PLAZA .L.Q.M. ROAD MULTAN 0092-61-4512031-2-4546238 0092-61-4511677-4584288 Reliance.accounts@fatima-group.com MULTAN PUNJAB PAKISTAN 60000 COMPOSITE UNIT 1,2&4: FAZAL PUR KHANEWAL ROAD

MULTAN MILL PHONE MILL FAX TYPE UNIT 0092-61-6740020-3 0092-61-6740039 SPINNING

31

MILL ADDRESS

UNIT 3&4: MAKHTARABAD, CHAK BELI KHAN ROAD RAWAT RAWALPINDI

MILL PHONE MILL FAX PRODUCTION CAPACITY MILL INSTALLED PRODUCT LINE BRANDS EMPLOYEES CERTIFICATION

0092-5777-4611579-81 0092-5777-4611092 UNIT 1&2: 46 MILLION METERS, UNIT: 3&4 15.30 MILLION KGS YARN 35,520 SPINDLES ,296 AIR JET LOOMS

YARN, GREY FABRIC LUCKY, RELIANCE WEAVING MILLS 2100 ISO 9002 SGS CERTIFIED BY SGS

2.2.2 Machinery Details

MACHINERY COMPANY COUNTRY MODEL YEAR QUANTIY

Blow

room Rieter

Switzerland

2004

2 lines

with chute feed

Card

Rieter

Switzerland

C-60

2004

14 cards

Drawing breaker

Rieter

Switzerland

Sb-2

2004

Lap former

Toyoda hara

Japan

1993

1 m/c

Comber

Toyoda

Japan

Cm-100

1993

6 m/cs

32

Drawing finisher

Rieter

Switzerland

Rsb-d35

2004

Roving frame

Toyoda

Japan

Fl100

2004

Ring spinning Toyoda frame

Japan

Rx240

2004

20

Autocone

Schalafhorst

Germany

338-rm

2004 & 8 &1 2008

Yarn clearers

Uster

Switzerland

Quantum -2

2004

540

Airconditioning

Con air

Pakistan

2004

33

2.2.3 Machinery Specifications and Settings 2.2.3.1 Blow Room Specification

34

1. Uni-Floc A-11 (Automatic Bale Opener and Blender Feeder)

MANUAL LINE TAKE OFF DEPTH 19.7 MM

MIXING BALES LINE

6MM

TRAVERSE SPEED

9.0 M/MIN

6M/MIN

TOTAL HEIGHT

35 M

35 M

ARM LENGTH

2300MM

2300MM

MANUFACTURINGYEAR

2004

2004

2. Metal Detector

COMPANY YEAR OF INSTALATION NUMBER OF MACHINES MEGNET TYPE SENSITIVITY

JOSSI 2004 3 ELECTROMEGNET 60 %

3. Uni Clean B-11

MANUAL MIXING LINE BALES LINE CLEANING INTENSITY 0.5 0.5

35

REALATIVE WASTE YEAR MANUFACTURING BEATER SPEED SPIRAL PATH EFFICIENCY YEAR OF INSTALATION DIA OF BEATER BEATER LENGTH SPIKES TYPES

3 OF 2004

3 2004

650 7 97% 2004 670mm 1400mm U-TYPE

650 7 100%

1. Uni Mix B-70

MANUAL MIXING LINE BALES LINE STORAGE CAPICITY STOP GO RATIO CONVEYOR SPEED 800 KG/HR 95 % BELT 60RPM 97% 96RPM

SPIKED FEED LATTICE SPEED AFTER MIN. LEVEL PRESSURE STORAGE CURRENT PRESSURE YEAR MANUFACTURING

80 RPM

110 RPM

25 KG

25 KG 170PA

FULL 150 PA

120 PA OF 2004

120 PA 2004

36

2. Uni Clean B-60

MANUAL MIXING LINE YEAR MANUFATURING BEATER SPEED PRODUCTION LEVEL STOP GO RATIO CLEANING INTENSITY REALATIVE RATE BEATER TYPE WIRE TYPE WIRE TYPE WIRE TYPE EFICIENCY FEED ROLL SPEED 93 % 96 RPM 92 % 96 RPM 87% 96 RPM GAUGE B/W FEED ROLL 3 MM TO BEATER WIRE ANGLE 10 Deg 3MM 3MM 550 47 87% 0.2 550 45 83% 0.2 1 550 56 94% 0.2 1 OF 2004 BALES LINE 1st 2004 2nd 2004

WASTE 1

REPLACEMENT OF WIRE ON PAK 6000 hr CTN BEATER DIA BEATER WIDTH 388mm 1200mm

37

3. Vision Shield
COMPANY SETTINGS:1. PARTICAL SIZE:PIXELS ( P. SIZE) 80 500 CURRENT SETTING LENGTH THAT REMOVED 0.2mm 4.5mm : 500 (5.0 mm) JOSSI

2.COLOR CONTRAST:SETTING 0 REMARKS OPEN SETTING (DARK COLORED CONTAMINATION REMOVED) 1 2 3 CLOSE SETTING (LIGHT COLORE CONTAMINATION,RESEMBLES COTTON REMOVED CURRENT SETTING : 1 TO

EJECTION

80009000/HR

DETECTION ZONE SPEED PROFILE DUCT YEAR OF MANUFACTURING NUMBER OF MACHINES

150 12M/S 2004 3

38

4. Condenser A-21
MANUAL LINE YEAR OF MANUFACTURING DIA ROTORY SCREEN SPEED 2004 400 MM 60 RPM MIXING BALES LINE 2004 400MM 110 RPM

2.2.3.2 Card Specification

Sr. 1 2 3 4 5 7 8 10 11 12 13 14 SPECIFICATIONS CARD MODEL COMPANY YEAR OF INSTALLATION AMOUNT OF CARD TAKER IN DIA TAKER IN TYPE CYLINDER DIA DOFFER DIA DOFFER SPEED EFFICIENCY %AGE CAN CAPICITY CAN SIZE TROUMPT SIZE 16 17 NO. OF FLATS STATIONARY FLATS C-60H RIETER 2004 14 9 inch PIN TYPE 32 inch 27 inch DEPEND ON PRODUCTION 95 % 39 Kg 40*42 7~8 mm 79 3 AT FRONT 6 AT BACK 18 19 20 21 DISC ROLLER DISTANCE FLATS IN WORKING SLIVER LENGTH CHUTE OPENING ROLLER RPM 9 21 5500 m 1150 rpm

39

22 23 24 25 26 27 28 29

EFFICIENCY SLIVER WEIGHT PRODUCTION PER HOUR DELIVERY SPEED CYLINDER SPEED TAKER IN SPEED FLATS SPEED FEED RATE

95% 100GRAIN/YD 105KG PER HOUR 250 M/MIN 850 1450 0.23M/MIN 600 g/m & 765 g/m

CARD WIRE SPECIFICATION

PARTS WIRE NAME HEIGHT (mm) ANGLE (Degree) COMPANY WIRE DENSITY

CYLINDER DOFFER TOP SETS FRONT STATIONARY FLATS BACK

PK 2040*0.4 M 5030*1.0 M 48/0

2 3

50 40

GRAF GRAF

965 466 480

11 FD-64 -

GRAF 640

T)FD-32

11 -

GRAF

320 140

STATIONARY B)FD-14 FLATS TAKER SEGMENT IN FD-9 7.5

58

GRAF

90

IMPORTANT GAUGES IN CARDING

Sr. NO. 1 2 Feed roll to taker-in Taker-in to Opening the fibers 23/1000 13/1000 SETTING FUNCTION GAUGE

mote Adjusting the amount of waste

40

knife 4.3 Taker-in to taker-in carding before transferring material segment F 13 /1000 B 13/1000

4 5

Taker-in to cylinder Cylinder to

Proper transferring of fibers

5/1000

back Pre Carding action (FD-14) (FD-32) T 13/1000 M 12/1000 M 16/1000 B 13/1000

stationary flats

Cylinder to top flats

Proper Carding action

B 7/1000 M 5/1000 F 5/1000

Cylinder

to

front Post Carding action (FD-64) 8/1000 16/1000

stationary flats

8 9 10

Cylinder to doffer Doffer to striping roll Crush roller

Proper striping action Doffing the web Crushing the contamination

5/1000 6/1000 5/1000

2.2.3.3 Drawing specification DRAWING BREAKER SPECIFICATION

M/C NO. 1 2 3 4. COMPANY RIETER RIETER RIETER RIETER MODEL SB-2 SB-2 SB-2 SB-2 M. YEAR 2004 2004 2004 2004 DRAFTING SYSTEM 4/3 4/3 4/3 4/3

41

DRAWING FINISHER FRAME SPECIFICATIONS A% STOP LIMIT LENGTH CALENDER CLEARANCE ERROR 1.5% 20m DICS 0.904mm AT 0% 1.5% 20m 0.904mm 3.0% 30m 1% 20m 0.569 mm

CV% STOP LIMIT 3.0% THICK PLACE S 25% MASS OF THICK PLACES

1.0% 25%

3%

1.8% 25%

2.2.3.4 Lap Former Specification

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 MODEL COMPANY YEAR LAP WEIGHT DELIVERY SPEED LAP LENGTH LAP SPOOL WEIGHT LAP ROLLER DIA DRAFTING SYSTEM GAUGE RUBBER COTS HARDNESS MAIN PRESSURE ROLLER PRESSURE PRESSURE ON RUBBER COTS DRAFT SET DRAFT WHEEL MOTOR PULLEY DIA MACHINE PULLEY DIA TS-100 TOYODA HARA 1993 650 grain/yd 80 yd/min 160yd 2.5 Kg 600 mm 3/2 10 mm 80 shore 6 bar 5 bar 80 Kg/m 31/50 49T 211 mm 406 mm

42

19 20

LAP WEIGHT TOTAL NO OF SLIVER FEED

15+_0.5 36

2.2.3.5 Specification of Comber

MODEL COMPANY YEAR FEED SLIVER LENGTH NOILS %AGE LAP ROLLER DIA FEED ROLLER DIA CYLINDER DIA BRUSH DIA DIA OF CYLINDER SHAFT DIA OF BRUSH SHAFT GAUGE B/W CYLINDER TO BRUSH DETACHING ROLLER DRAFTING ROLLER DETACHING ROLLER HARDNESS DRAFTING ROLLER HARDNESS GAUGE SLIVER WEIGHT GAUGE B/W TOP COMB TO D.TOP ROLL CM-100 TOYODA HARA 1993 4.69 mm 20~22% 70mm 25.4mm 150mm 110 20mm 30mm (150+110-20-30)/2=105mm 2/2 2/2 60 shore 65 shore 5mm 49 grain/yd 0.6mm range(0.4~1.2) GAUGE B/W TOP COMB TO TOP 0.6mm range(0.4~1.2)

DETACHING ROLL

GAUGE B/W TOP COMB TO BOTTOM 0.5mm DETACHING TOP ROLL

43

CYLINDER TO FEED ROLLER GAUGE B/W DETACHING TO NIPPER TOP COMB DENSITY

0.5mm 6mm,range(4.5~6mm) 54 needle/inch range(54~66)

BRUSH SPEED

1320 rpm

2.2.3.6 Roving Frame Specifications

DRAFTING SYSTEM GAUGE R.COTS SIZE R.COTS GRINDING SPINDLE LENGTH Hanks Roving T.P.I T.M Full Bobbin Length BOBBIN LENGTH WINDING LENGTH RUBBER COTS HARDNESS PK-1500 6.5, 20.5,24 mm 19*28*39mm (B*T*L) AFTER 6 month 16 inch 0.74 0.966 1.122 2100Yds 445mm 380mm 80 shore

2.2.3.7 Ring Frame Specifications

MODEL COMPANY ROLLER SIZE DRAFTING SYSTEM ROLLER GAUGE RX-240 TOYODA 27,27,27mm PK-225 F ) 44 B) 51

44

TOP ROLLER PRESSURE

RED 16lbs /in*in

TOP ROLLER SIZE TOP APPRON SIZE BOTTOM APPRON SIZE SPINDLE WARVE DIA

27mm 43mm 43.2 M/C 1-8 9-20 DIA 19.2mm 19mm

SPINDLE TAPE SIZE BOBBIN LENGTH

2440*13*0.8mm M/C 1-8 9-20 LENGTH 210mm 180mm HEIGHT 8in 7in

LIFT HEIGHT

M/C 1-8 9-20

TIN PULLY DIA RING CUP COMPNY RING LIFE SPINDLE TYPE DRAFTING SYSTEM COMPANY DRAFTING ANGLE COUNT 14/1CDD 16/1CDD

210mm CHINA 1 YEAR ADOPTER TOYODA 60degree 21/1 CDD 20/1 COMB

M/C YARN WT/BOBBIN LIFT LENGTH TOTAL LENGTH LIFT 197mm 183mm 183mm 183mm 80g 60g 46mm 60g 42mm 60g 42mm

CHASE 46mm

45

FULL LENGTH

BOBBIN 1900m

1800m

2200m

2200m

FULL BOBBIN HANK YARN PITCH

2.26hank 1.76mm

2.14hank 1.65mm

2.62hank 1.44mm

2.62hank 1.44mm

2.2.3.8 Auto Cone Specifications

M/C COUNT 1 2 3 4 5 6 7 8 9 COMPANY SCHLAFORST SCHLAFORST SCHLAFORST SCHLAFORST SCHLAFORST SCHLAFORST SCHLAFORST SCHLAFORST CERLIKON MODEL A.C-338 A.C-338 A.C-338 A.C-338 A.C-338 A.C-338 A.C-338 A.C-338 A.C-338 M.YEAR 2004 2004 2004 2004 2004 2004 2004 2004 2005 SPINDLE 60 60 60 60 60 60 60 60 60 SPEED

TOTAL =540

Important Settings in Auto Cone

COUNT BOBBIN COLOR MEASURING HEAD PAPER CONE BLACK COLOR SPEED TENTION LENGTH 28 cN/Tex 24 cN/Tex 24 cN/Tex 32 cN/Tex PAPER PINK TIP GREEN PAPER KHAKI IMK-C-20 YL IMK-C-20 YL IMK-C-20 YL IMK-C-20 YL 16/1 CDD GREEN 20/1 COMB ORANGE 21/1 CDD WHITE 14/1 CDD PINK

46

N% S%/cm L%/cm T%/cm FD%/cm FL%/cm CP%/m CM%/m CCP%/m CCM%/m Jp% Jm% PC PC

250 140/2 35/40 -30/40 20/0.2 0/0.2 15/2 -15/2 35/1 -25/1 90/4 -50/4 35/1 FAULT 8.5

200 120/1.8 30/35 -30/40 25/0.2 0/0.2 15/2 -15/2 35/1 -25/1 90/3.5 -50/4 35/1 8.5

250 140/2 35/40 -30/40 20/0.2 0/0.2 15/2 -15/2 35/1 -25/1 90/4 -50/4 35/1 8.5

250 140/2 35/40 -30/40 20/0.2 0/0.2 15/2 -15/2 35/1 -25/1 90/3.5 -50/4 35/1 8.5

DISTANCE

2.2.3.9 Specifications of Air Conditioning Department

SPLY DUCT BLOW ROOM CARD & COMBER DRAW FRAM &SIPLEX RING AUTO CONE 4 6 6 10 4 RETURN DUCT 1 2 2 8 2

47

2.5 EXPERIMENTS CONDUCTED

In this project, we were carried out different experiments. Which are given below

1. Effect of Cleaning of Card on Classimat 2. Effect of Drawing Finisher Guage on Classimat 3. Effect of Drawing Finisher Break Draft on Classimat 4. Effect of Simplex Break Draft on Classimat 5. Effect of Simplex Twist Wheel (T.w) On Classimat 6. Effect of Simplex Rubber Cots Grinding On Classimat 7. Effect of Ring Cleaning On Classimat 8. Effect of Changing the Spindle Speed of Ring Frame on Classimat 9. Effect of Changing the Break Draft (B.D) of Ring Frame on Classimat 10. Effect of PENUMAFIL on Classimat

48

CHAPTER 3 RESULTS & DISCUSSIONS

49

3.1 Effect of Cleaning of Card on Classimat

Article: CARD (C-60) Material Class: Yarn

Machine: 07 Yarn Count: 16/1 CD WVG Before: Without cleaning AFTER: with cleaning (Taker In, Cylinder, Top Sets, Stationary Flats, Doffer and Coiler).

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

120 100 80 60 40 20 0 N S L T FD Jp YF BEFORE AFTER

50

N BEFORE 10.0 AFTER IMPACT 8.5

S 32.3 28.1

L 11 8.0

T 0.0 0.0

Cp 3.8 2.0

Cm 3.0 2.5

CCp 10.9 8.5

CCm 1.0 0.5

FD 30.2 26.2

Jp 1.9 1.5

Jm 0.6 0.0

YF 115.3 95.7

Remarks:
It is clear from the graph that proper card cleaning (Taker In, Top Sets, Stationary Flats, Doffer and coiler) has a positive impact on Classimat. This experiment relieved that yarn faults (N, S, L, Cp, Cm, CCp, CCm, FD and Jp) were reduced after card cleaning. There is no impact on T and FL yarn faults.

51

3.2 Effect of Drawing Finisher Guage on Classimat

Article: Drawing Machine: 07 Yarn Count: 16/1 CD WVG Before: AFTER: Guage: 3.5-14 mm Guage: 4-13 mm

(RSB-D35)

Material Class: Yarn

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

140 120 100 80 60 40 20 0 N S L T FD Jp YF

BEFORE AFTER

52

N BEFORE 7.0 AFTER IMPACT 7.5

S 37.1 29.5

L 44.2 9.4

T 3.0 0.9

Cp 1.0 1.3

Cm 1.0 0.4

CCp 6.0 2.6

CCm 0.0 0.4

FD 38.2 30.5

Jp 5.0 1.8

Jm 0.0 0.0

YF 137.6 85.3

Remarks:
It is clear from the graph that Guage has a positive impact on Classimat. This experiment relieved that yarn faults (S, L,T, Cm, CCp, FD and Jp) were reduced by increasing Front Guage and decreasing Back Guage of Drawing Finisher. Guage has negative impact on N, Cp and CCm faults. It has no impact on Jm faults.

53

3.3 Effect of Drawing Finisher Break Draft on Classimat

Article: Drawing Machine: 07 Yarn Count: 16/1 CD WVG Before: AFTER:

(RSB-D35)

Material Class: Yarn

Break Draft: 1.16 Break Draft: 1.28

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

60 50 40 30 20 10 0 N S L T FD Jp YF BEFORE AFTER

54

N BEFORE 3.2 AFTER IMPACT 1.2

S 12.3 9.5

L 1.1 0.8

T 0.0 0.0

Cp 0.0 0.0

Cm 1.0 0.4

CCp 0.0 0.0

CCm 0.0 0.0

FD 34.5 31.1

Jp 0.0 0.0

Jm 0.0 0.0

YF 51.2 44.4

Remarks:
It is clear from the graph that Break Draft has a positive impact on yarn clearing. This experiment relieved that yarn faults (N, S, L, Cm, and FD) were reduced after Increasing the Break Draft of Drawing Finisher. It has no impact on T, Cp, CCp, CCm, Jp and Jm faults.

55

3.4 Effect of Simplex Break Draft on Classimat

Article: Simplex (FL-100) Machine: 07 Yarn Count: 16/1 CD WVG Before: AFTER: Break Draft: 1.24 Break Draft: 1.30 Material Class: Yarn

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

90 80 70 60 50 40 30 20 10 0 N S L T FD Jp YF BEFORE AFTER

56

N BEFORE 3.5 AFTER IMPACT 2.9

S 25.5 20.2

L 16.8 19.6

T 1.1 0.0

Cp 0.6 0.6

Cm 0.0 0.0

CCp 10.0 10.3

CCm 0.0 0.0

FD 19.2 19.8

Jp 2.0 1.1

Jm 0.0 0.0

YF 82.9 73.8

Remarks:
It is clear from the graph that Break Draft has a positive impact on yarn clearing. This experiment relieved that yarn faults (N, S, T and Jp) were reduced after Increasing Break Draft of Roving machine. It has no impact on Cp, Cm, CCm and Jp faults. It has negative Impact on L and FD faults.

57

3.5 Effect of Simplex Twist Wheel (T.w) On Classimat

Article: Simplex (FL-100) Machine: 07 Yarn Count: 16/1 CD WVG Before: AFTER: 0.87 T.P.I 0.94 T.P.I Material Class: Yarn

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion

120

100

80 BEFORE AFTER 40

60

20

0 N S L T FD Jp YF

58

N BEFORE 6.3 AFTER IMPACT 2.6

S 38.9 14.6

L 32.0 3.3

T 0.0 0.0

Cp 0.0 0.0

Cm 0.0 0.0

CCp 15.7 0.7

CCm 0.0 0.0

FD 20.7 20.5

Jp 3.8 0.7

Jm 0.0 0.0

YF 114.2 41.7

Remarks:
It is clear from the graph that Twist has a positive impact on Classimat. This experiment relieved that yarn faults (N, S, L, Cm, CCp, CCm, FD and Jp) were reduced by increasing the Twist on Simplex. It has no impact on T, Cp, Cm and CCm faults.

59

3.6 Effect of Simplex Rubber Cots Grinding On Classimat

Article: Drawing Machine: 03, 04 Yarn Count: 16/1 CD WVG Before: AFTER: ONE Month Grinding (machine#04) ONE Day Grinding (machine#03)

Material Class: Yarn

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

140 120 100 80 60 40 20 0 N S L T FD Jp YF

BEFORE AFTER

60

N BEFORE 7.6 AFTER IMPACT 6.3

S 41.1 38.9

L 32.5 32.0

T 0.0 0.0

Cp 3.3 0.0

Cm o.o o.o

CCp 18.6 15.7

CCm 0.7 0.0

FD 19.9 20.7

Jp 10.6 3.8

Jm 0.0 0.0

YF 121.3 114.2

Remarks:
It is clear from the graph that Grinding of Rubber Cots of drafting zone has a positive impact on Classimat. This experiment relieved that yarn faults (N, S, L, Cp, Cm, CCp, CCm, and Jp) were reduced after card cleaning. Grinding has negative impact on FD faults.

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3.7 Effect of Ring Cleaning On Classimat

Article: Machine: 09 Yarn Count: 16/1 CD WVG Before: Without Cleaning Ring (RX-240) Material Class: Yarn

AFTER: With Cleaning (Drafting Roll, Roving guide, Appron, Cradle and Creel)

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

90 80 70 60 50 40 30 20 10 0 N S L T FD Jp YF BEFORE AFTER

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N BEFORE 6.2 AFTER IMPACT 2.9

S 20.3 26.7

L 50.0 9.2

T 0.4 0.5

Cp 2.5 1.0

Cm 0.0 0.0

CCp 7.0 1.5

CCm 0.0 0.0

FD 42.6 23.3

Jp 3.3 1.5

Jm 0.0 0.0

YF 84.0 65.0

Remarks:
It is clear from the graph that proper Ring cleaning (Drafting Roll, Roving guide, Apron, Cradle, Creel) has a positive impact on Classimat. This experiment relieved that yarn faults (N, L, CCp, FD and Jp) were reduced after card cleaning. It has negative impact on S and T faults.

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3.8 Effect of Changing the Spindle Speed of Ring Frame on Classimat

Article: Ring (RX-240) Machine: 09 Yarn Count: 16/1 CD WVG Before: AFTER: Spindle Speed= Spindle Speed = 17900 r.p.m 16900 r.p.m Material Class: Yarn

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

120

100

80 BEFORE AFTER 40

60

20

0 N S L T FD Jp YF

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N BEFORE 6.3 AFTER IMPACT 3.0

S 38.9 75.0

L 32.0 5.0

T 0.0 0.0

Cp 0.0 0.0

Cm 0.0 0.0

CCp 15.7 1.0

CCm 0.0 0.0

FD 20.7 2.0

Jp 3.8 2.0

Jm 0.0 0.0

YF 114.2 86.3

Remarks:
It is clear from the graph that Spindle Speed of Ring Frame has a positive impact on Classimat. This experiment relieved that yarn faults (N, L, Cp, CCp FD and Jp) were reduced by increasing Ring Break draft. It has negative impact on S faults. It has no impact on T, Cp, Cm and CCm faults.

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3.9 Effect of Changing the Break Draft (B.D) of Ring Frame on Classimat
Article: Ring (RX-240) Machine: 09 Yarn Count: 16/1 CD WVG Before: AFTER: Break Draft= Break Draft = 1.29 1.34 (B.D.W=54) (B.D.W=52) Material Class: Yarn

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

120 100 80 60 40 20 0 N S L T FD Jp YF BEFORE AFTER

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N BEFORE 9.2 AFTER IMPACT 6.7

S 43.5 26.7

L 42.2 8.7

T 2.0 0.7

Cp 2.6 2.7

Cm 0.7 0.0

CCp 4.0 1.3

CCm 0.0 0.0

FD 15.8 30.7

Jp 0.0 1.3

Jm 0.0 0.0

YF 113.5 77.3

Remarks:
It is clear from the graph that Break draft of Ring Frame has a positive impact on Classimat. This experiment relieved that yarn faults (N, S, L, T, Cm and CCp) were reduced by increasing Ring Break draft. It has negative impact on Cp, FD and Jp faults. It has no impact on CCm faults.

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3.10 Effect of PENUMAFIL on Classimat

Article: Ring (RX-240) Machine: 09 Yarn Count: 16/1 CD WVG Before: AFTER: With Penumafil Without Penumafil Material Class: Yarn

Classimat Settings:
N S L T Cp Cm CCp CCm Setting 250% 140% 35% -30% 15% -15% 35% -25% PC PP FD FL Jp Jm U Setting Fault Distance=8.5 cm Sensitivity=35% Length=1.0 cm 20% Off 90% -50% 80%

Results and Discussion:

25

20

15 BEFORE AFTER 10

0 N S L T FD Jp YF

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N BEFORE 3.1 AFTER IMPACT 2.1 32%

S 8.3 12.4 49%

L 2.1 2.4 14%

T 2.1 0.4 80%

Cp 0.0 0.0 -

Cm 0.0 0.0 -

CCp 0.0 0.0 100%

CCm 0.0 0.0 -

FD 6.8 5.8 15%

Jp 0.0 0.0 -

Jm 0.0 0.0 -

YF 22.9 9.9 57%

Remarks:
It is clear from the graph that Penumafil has a positive impact on Classimat. This experiment relieved that yarn faults (N, S, T, Cm and CCp) were reduced without Penumafil .It has negative impact on T fault. It has no impact on Cp, Cm, CCp, CCm, Jp and Jm faults.

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CHAPTER 4
CONCLUSION & FUTURE WORK

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4.1

CONCLUSION

Classimat is used for the detection and classification of faults in the yarn. We can also cut the Yarn faults, but it is not done for the production point of view. Today, the selection of right product is essentional for economic reasons. A continuous inspection of product or sample during its manufacture gives the satisfactory quality of the end product. To compete the others and to remain in the market there is need to produce faults free yarn. It is still not possible to produce a yarn without faults for various reasons. Stickiness of cotton can contribute to the formation of thick and thin places. Fly liberation in Ring frame department is one of the major reasons for short faults in the yarn because of the fly get spun into the yarn. Hence it is not possible to have fault free yarn from ring spinning, it is necessary to have yarn monitoring system in the last production process of the spinning mill. As physical principle for electronic yarn clearing the capacitive and the optical principle have established. Both principles have their advantages in specific applications. A yarn fault is an irregularity, which produced difficulties in subsequent process. There are various faults e.g. nep, thick, thin; actually they deviate from the mean diameter of the yarn. They all effects the weaving and processing of cotton in form of low efficiency, high breaking, low production, belly fabric, increases the processing cost due to excessive chemicals or processes. e.g to remove the contamination from the yarn an extra process is actual process. Classimate faults are sub classified in 23 main categories e.g. A1, A2, A3, A4, B1, B2, B3, B4, C1, C2, C3, C4, D1, D2, D3, D4, E, H, I, etc and each class has specific length and dia. There are various instruments which identify the faults; uster tester is used to identify the Thick Places, Thin Places, Neps and Hairiness in the yarn. The uster classimat quantum is a complex testing system that offers the customers multitude of applications and evaluation possibilities. It can be used for production monitoring or as an analysis instrument for the clearer setting and for the preparation of supply agreements or quality certificates. Uster classimat if used in a proper way can

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increase the quality of the product and also the faulty process can be identified and even the fault producing part can be determined which was not possible a few years ago.. Today with the uster classimat quantum generation, the cleared and unclear yarn can be checked; the classification of thick and thin places, neps and foreign fibers in the yarn can be fulfilled. This system also helps the user in determining the optimal limits for yarn clearing, in analyzing new material, and supports with experience values, which can be used for benchmarking and evaluation. There are various variables in the spinning process which are use to control these faults in this project we select the 24 variables which effects the yarn faults. If we will control these variables then we can control the faults. These variables includes beater speed, waste %age in blow room, card production, card gauges and card waste, break draft on breaker finisher, roving and ring frame and speed of ring spindle on ring frame.

4.2

FUTURE WORK

The purpose of this project was to study how yarn faults are classified and the factors influence on Classimat faults. In this project we check the yarn faults classifying system and chek how these faults can be minimized. Our aim was also to check the effect of different process variables on seldom occurring yarn faults. We carried out many practical to minimize Classimat faults .Some project should be carried out on spacer change and Traveller chage effect to minimize these faults.

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CHAPTER 5 REFERENCES

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1. Http://www.llamapaedia.com/wool/glossary.html

2. www.elib.gov.ph/results.php?f=subject&q=Classimat+yarn+faults

3. www.raginiyarns.com/YT.pdf

4Textiletechinfo.com/spinning/winding-2.htm

5. En.wikipedia.org/wiki/Fault_(geology)

6. www.uster.com/en/instruments/fabric.../uster-classimat-quantum/

7. www.uster.com/fileadmin./Yarn/Classimat./CMTQ_TechnData.

8. www.scribd.com/doc/48275627/USTER-Classimat

9. www.fibre2fashion.com/...yarns/trends-in-the-quality-of-cotton-yarn.

10. www.salon.com/1999/08/13/hitchcock_endings/

11. Authenticimperfection.wordpress.com/tag/Socrates.

12. www.jossisystem.ch\meatldetactor

13. Nopr.niscair.res.in/bitstream/.../1/IJFTR%2034(3)%20225-230.pdf

14. Textiletechinfo.com/spinning/processparspinning.htm

15. Classimate Chart Of Faults And Reasons By Ctm#1

16. Application Manual Of Uster Quantum Chapter 1 Uster Technologies Ag Switzerland

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17. www.textilesindepth.com/index.php?page=yarn-faults-clearing

18. www.discogs.com/Andrey...Frequently-Occurring-Fault/.../933246

19. www.scribd.com/doc/49971999/cottonspinning

20. www.elib.gov.ph/results.php?f=subject&q=Classimat+yarn+faults

21. www.fibre2fashion.com/industry-article/.../neps-devalue-cotton . 22. www.tradess.biz 23. Application manual of uster quantum chapter Quality parameters of a yarn Uster Technologies Ag Switzerland

. 24. Www.textiletechnology.com

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