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ppt on summer training Vardhman's Mahavir Spinning Mills Baddi (weaving devision)

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ppt on summer training Vardhman's Mahavir Spinning Mills Baddi (weaving devision)

  1. 1. MAHAVIR SPINNINGS LTD (A unit of Vardhman Textile Ltd) BADDI (H.P.)SUBMITTED TO SUBMITTED BY,MR. PRAVEEN KUMAR BHARAT RANAH.O.D.(DEPARTMENT OF TEXTILE) B.TECH. (TEXTILE ENGINEERING) JAWAHARLAL NEHRU GOVT. ENGG. COLLEGE, SUNDERNAGAR, MANDI (H.P.)
  2. 2. SER. NO. DEPARTMENT (H.O.D.) 1 INTRODUCTION (MR. V.B.KANAUJIA) 2 PREPATORY (MR. P.S.CHATTERJI) 3 LOOM SHED (MR. D.B.PATEL) 4 QA/INSPECTION & FOLDING (MR. SANJEEV SHARMA) CPDC 5 CENTRAL PRODUCTIVE DEVELOPMENT CENTRE (MR. S.S. BAINS)
  3. 3. a) Auro spinning mill, Baddi b) Arisht spinning mill, Baddi c) Arihant spinning mill, Malerkotla d) Vardhman fabrics limited, Budhni. e) VSM, Baddi f) VTL Satlapur, g) Anant unit, BudhniWarp & Weft: 2/40s ET, 30s comp, 50s comp, 60s comp 20k, 80s comp, 30s carded, 32s carded, 40s comb, 40s/2 comb, 20s OE, 2/50s ET, 16s O.E, 16s OESelvedge:2/100 CWC, 2/80C
  4. 4. 1. WARPING SECTION & REWINDING SECTION 2. SIZING SECTION 3. DRAWING-IN SECTION
  5. 5. DIRECT WARPING SECTIONAL WARPING DIRECT WARPING SECTION Total number of direct warping machine - 2 PARTICULERS MACHINE NO.1 MACHINE NO.2Machine manufacturer MOENUS SUCKER BENINGER GmbH(GERMANY)Model COMWARP BEN-DIRECTYear of Manufacture 2005 2004Pressure of wooden 800 N 800 NrollerMax. Speed 800 mpm(100-800mpm) 1200 mpm(50-1200mpmOperating Speed 700mpm 700 mpmMachine Brake Hydraulic Hydraulic
  6. 6. PARTICULERS MACHINE NO.1 MACHINE NO.2Creel:Creel type H-Creel V- creel(moving chain type)Creel capacity 672 656Pressure operated on 15-20 N 18Nthe creelYarn stop motion Electromagnetic Photocell typeTensioning system Capstan Tensioners Pre-tensioning rod{t=t’exp(μθ)}Total drive motor 8 9Creel Threading Horizontal Vertical •AMBIENT CONDITIONS IN WARPING DEPARTMENT Temperature Range: 27-30°C Relative Humidity: 60-80%
  7. 7. Creel Package Yarn TensionersYarn stop motion Sensor Yarn guides Expanding Comb Guide roller Warper’s beam
  8. 8. SETIONAL WARPING TOTAL SECTIONAL WARPING M/C: 6 PRASHANT BENNINGER :4 GAMMATEX :2Each of the Sectional WarpingM/c contains:One CreelOne Leasing ReedOne Expanding ReedTapered DrumSectional Warper’s Beam.Stop Motions.
  9. 9. MANUFACTURE M/C MODEL YEAR CREEL Benninger AG Ben-tronic 2005 Ben-creel(Switzerland) M/C COMPONENT TYPEMachine brake HydraulicTensioning system Additive type(spring loaded)Yarn break stop motion ElectromagneticWinding speed 5-800m/minCREEL:Manufacture Model of creel/ Type Year of manufactureBenninger(Swiss) Ben-Creel/H-Creel 2005Creel threading HorizontalPitch length of the creel 28cmTotal reeds 2Angle of tapered flange 11.8°Diameter tapered beam 1m( max dia of flange 1.5m)
  10. 10. MANUFACTURE M/C MODEL YEAR CREELPrashant ESP 1100 2007 Prashant GamatexGamatex(Ahmd,India) M/C COMPONENT TYPEMachine brake HydraulicTensioning system Additive type(spring loaded)Yarn break stop motion Photocell typeWinding speed 5-800m/minAngle of tapered flange 10.5°CREEL:Manufacture Model of creel/ Type Year of manufactureBenninger(Swiss) Ben-Creel/H-Creel 2005Creel threading HorizontalPitch length of the creel 28cmDiameter tapered beam 1m( max dia of flange 1.5m)
  11. 11. CALCULATION OF BEAMING TENSION: BEAMING TENSION =CALCULATION OF YARN TENSION: YARN TENSION = dtex × 0.1cN Count (Ne) Warping tension Speed (mpm) 16 24 500 20 22 500 30 15 500 40 12 500 50 11 500 60 9 500 70 8 500 80 7 500 2/40 22 500
  12. 12. Objective:1.)To utilize the remaining yarn in packages after the completion of warping beam.2.) 1) To form big packages from small packages for selling purpose.Total Rewinding M/C: 2Type: Drum Type Winding M/CPackage Produced: Open Wound Package.
  13. 13. PARTICULARS TYPE / VALUEMade: P.S. METTLERYear of Manufacture 2006Model RECO DANo of Spindles 60 (ON 2 SIDES)Tensioners Disc type TensionersSpeed 500-550 r.p.m.Stop Motions Mechanical Stop MotionPackage Prepared Open wound packageWARPING BREAKAGES: Weak place Cone finish Cut end Entanglement Bad winding Foreign matter Slough off Others
  14. 14. SIZING SECTIONSIZING KITCHEN SIZING MACHINE
  15. 15. Size is prepared at the top floor in the sizing kitchen and transferred to the machine with the help pipes. USE 3 APPARATUS: (1) PREMIXER (2) PRESSURE COOKER (3) STORAGE. PREMIXER PRESSURE COOKER STORAGE VESSEL • Chemicals are mixed with stirrer for 15 min. PREMIXER • In 665 ltr of water • Then mixture is transferred to cooking vessels One for three m/c through pipes.PRESSURE COOKER • Set temperature : 120° C • Steam cut of time : 40 min. Three for three m/c • Cooking pressure : 1.5 – 2 kg / cm²(psi)STORAGE VESSEL • size is transferred to storage vessel • stored at the temperature of 85 - 90°CThree for three m/c • continuous stirring for further transfer to m/c
  16. 16. TOTAL SIZING M/C : 31.) Tsudakoma: Only For Direct Beam2.) Moenus Sucker: Both For Direct & Sectional Beam3.) Moenus Sucker: Only For Sectional Beam. PARTS OF SIZING MACHINE: 4.)Waxing 1.)Creel 2.) Size 3.)Drying Zone/oiling Zone box zone zone--------------------------------------------------------------------------------------------------5.)Splitting Zone 6.)Comb 7.)SIZED BEAMSIZING INGRIDIENTS TEXOPLAST WATER KETANOL ANTISTATIC SONYCRYL Sizofilm: recently ordered (using) MUTTON TALLOW
  17. 17. Machine TSUDAKOMA Moenus Moenus Textilmaschinen GmbH TextilmaschinenManufacturer TSUDAKOMA Sucker Muller Hacoba Sucker MullerYear 2004 2004 2005Creel capacity 20 beams 20 beams 1 beamType of creel Vertical creel Vertical creel Sectional CreelM/C speed (max) 7-125 mpm 7-125 mpm 7-125 mpmNo. of size box 2 2 1Drying cylinder 14 (10 Tef,4 steel) 14 (10 Tef,4 steel) 8(6 Tef ,2 steel)Dia. of drying 800 mm 800 mm 800 mm.cylinderSqueeze roller 5 kN (7m/min) 5 kN (7m/min) 5 kN (7 m/min)pressure 13 kN (60m/min) 13 kN (60m/min) 13kN (60m/min)Immersion, 2,2,2 2,2,2 2,2,2Feed, Size rollsPre drying 115°C-135°C 115°C-135°C 115°C-135°CcylindertemperatureTemp. of size box 80°C-90°C 80°C-90°C 80°C-90°C
  18. 18. SIZE PICK UP %Open End Yarn-8%Compact Yarn-12%Carded Yarn- 16%Combed Yarn- 16%PARAMETERS FOR SUCKER MULLER Tension (N) =gm/mtr * factor *1.15 Gm/mtr = total no. of ends /metric countFACTORS:Let off tension=6 ( upto 40, 40& above =7)Positive feed tension = 2Wet zone tension=NADry split tension= 12Winding tension = 16Beam pressing or winding tension = (70~100)
  19. 19. DRAWING-IN DEPARTMENTMANUAL DRAWING- AUTOMATIC DRAWNG- WASHING & IN IN CLEANING SECTION Drawing-in is the final preparatory process. Cleaning & Drying Drawing-In --------------------------------------------------!!---------------------------------------------------------- Manual drawing-in Automatic drawing -in
  20. 20. Different types of Healdframes: Type of Heald wires:1) STEEL HEEDLE DELTA 1) 6.6 mm × 1.8 mm : Simplex2) TOYOTA-230 CM 2) 6.4 mm × 1.5 mm : Duplex3) GROB-DELTA 3) 5.5 mm × 1.2 mm : Duplex4) OMNIPLUS HIGH SPEED DELTA Type of drop pins:5) TSK-ZAX 6.5× 1.1× 0.2 : (used for processing6)VERBRUGGE Ne 25 & above)7) TOYOTA-190 CM 6.5× 1.1× 0.4 : (used for Processing8) ZAX-E Ne 25 & below)9) TSK- TSUDOMA Type of Reed:10) TSK-ZAX-e DELTA-110 m.m. (Crank height 4.5cm) ZAX-120 m.m.(Crank height 6 cm)
  21. 21. DRAWING-IN Auto drawing m/c: Here drawing is done automatically using rapier hook.Name of Machine Model Year of Manufacture Rapier TraverseStaubli(KOREA) DELTA-110 2005 40-140mpm Manual Drawing-in Done manually to draw warp yarn through droppins,healdframes,and reed. Two workmen: Reacher-in: puts warp in drawing-in pin or needle. Pinner: Holding drawing-in pin& draws the warp yarns through drop pins, Healdframes & reed.
  22. 22. Machine Used: SpaleckSPALECK washing cycle and other settingsComponent Washing process Carriage time Drying passesHeald wire-ZAX 1 100sec 4Heald wire-GAMMAX 1 100sec 4Drop wire 1 200sec 9Gammax reed 1 100sec 2Gtx reed 1 100sec 2ZAX reed 1 100sec 2
  23. 23. Total loom : 224 Airjet looms : 142 Rapier looms : 82 AIRJET LOOMS RAPIER LOOMS (24+118) (6+74+2) TSUDAKOMA ZAX PICANOL GTX TSUDAKOMA ZAX9100 PICANOL GAMMAX DORNIER GPXAmbient conditions Loom conditions: Room conditionsRelative humidity(%) 75-85 % 68-72 %Temperature(°C) 26-30°C 28-32°C
  24. 24. Loom Tsudakoma TsudakomaManufacturer Tsudakoma corp nomachi Tsudakoma corp nomachi (Japan) (Japan)Year 1999Model Tsudakoma ZAX Tsudakoma ZAX9100Speed 750 rpm Loom 901 rpmReed width 190 cm 150,170,190,210,230,250,280,340,36 0,380cm.Shedding positive staubli positive staubliMax. Heald frame 7 8FDP Pin Present PresentWeft feeling sensor H1 & H2 H1 & H2Cutter Both cutters are mechanical Both cutters are mechanicalDigital display: Not attached with loom Attatched(navigation system)Let off Electronic ElectronicShedding Mechanism +ve cam shedding +ve cam shedding
  25. 25. Loom type Picanol Picanol DornierManufacture Picanol Machine Picanol Machine Dornier Machine (Belgium) (Belgium)Model Gammax-6R Picanol –Gtx DornierType Rapier loom Rapier loom Rapier loomRapier type Flexible Rapier Flexible Rapier Rigid RapierNo. of rapier 2 2 2Reed Width 190cm 190cm 190cmNo. of weft colourinsertion 2,4,6 2,4,6 2,4,6 Shedding Positive staubli Positive staubliLoom speed 750rpm 550rpm 500rpmAccumulator type Irostella-290 Irostella-290 Irostella-290
  26. 26. Knotting: process to join warp of new weaver beam with old warp sheet using knotting machine.type; grey and dyed yarnm/c used: Staubli knotting machine.Approximate time: 1-1.5hr.Gaiting :is to replace old weaver’s beam, drop wires, healdwires,reed with new one.m/c used: GENKINGER HOBTEX hydraulic gaiting machine.
  27. 27. CLOTH ROLL Inspection FOLDING GRADING BALE SORTING BALE PACKING•Inspection zone.•Bale sorting zone.•Bale packing zone.•MACHINE Number manufacture•Inspection m/c 7 Laxmi m/c manufacture•Mending table 2 Laxmi m/c manufacture•Folding 2 Laxmi m/c manufacture•Rolling machine 1 Laxmi m/c manufacture•Inspection cum Rolling m/c 1 Navjyot m/c works ltd•Bale pressing m/c 1 Laxmi m/c manufacture
  28. 28. VARIOUS INSPECTION SYSTEM10 POINT INSPECTION SYSTEM, 4 POINT INSPECTION SYSTEM4 Point inspection System: 0-3 inches- 1 point 3-6 inches- 2 point 6-9 inches- 3 point 9 inches and above 4 pointsFAULTS NOTED IN FOLDINGMinor faults- this includes slub, stains and contaminationMajor faults- this includes the faults like bent pick, double pick, thick place stain mark, oily weft
  29. 29. Research Selection of raw material Process control Process development Product testing Quality assurances Specification testsINSTRUMENTS USED IN R & D LAB Tension meter, Digital thread counter , Weighing scale, Circular cutter, Stirrer, Tachometer, Shore hardness tester, Yarn appearance tester, Automatic twist tester, Single yarn strength, tester, Bess lay balance, Desiccators, Moisture meter, Tearing strength tester, Lea strength tester, Refractometer.
  30. 30. • PRODUCT PDC DEVELOPME NT CENTRE • CREATIVE CDC DESIGN CENTRE PILOT • PILOT PLAN PLANCPDC: CENTRAL PRODUCTIVE DEVELOPMENTCENTRE

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