RSWM spinning some overview, production capacity, product variants, technologies used, and how to calculate the basic terms in textiles.

2. Presented By
Mahesh
Ladha
Manish
Gupta
Suraj
Gupta
Prashant
Srivastav
Guddu
Prasad
Project
Production
Yarn Business
Greige(grey) / Dyed)

3. Pramod
Mahipal
Satyakam
Srivastava
Sunil
Rai
Rajendra
Sankhkla
Project
Production
Yarn Business
Greige(grey) / Dyed)

4. RSWM JOURNEY
1960 – Company incorporated and in 1961 established a spinning unit at Bhilwara.
1973 - Second plant commissioned at Gulabpura. Later, Bhilwara plant was spun off as independent
Company (Bhilwara Spinners Ltd.)
1989 - Established grey yarn spinning unit at Banswara.
1994 - Established Melange Yarn manufacturing unit at Mandpam, Bhilwara
2003 - Acquired Rishabhdev plant from HEG Ltd.
2005 - Acquired Jaipur Polyspin Ltd, Reengus and Mordi Textiles & Processors Ltd. Banswara
2011 – 2012 Executed another expansion plan with capital outlay of Rs. 400 Crore. Expanded capacity at
Kharigram (SJ-11), Banswara (Rotors), Denim (Spinning), Mordi (50 Looms).
2014 - Established a Green Fibre manufacturing unit at Reengus with capacity of 18000 MTs p.a.
2015 – Added another Melange Yarn unit at Kanyakheri, Bhilwara.
2017 – Installation of Sheet Dyeing facility at Denim
2017 - Commissioned 3.3 MW Rooftop Solar Power Plant at Mandpam and Kanyakheri.
2018-19 – 18.7 MW Solar Power Plant and 25000 MTs p.a. Green Fibre
2019-20 – 3.3 MW Solar Power Plant

5. RSWM REENGUS
Synthetic yarn Effect yarn
Polyester Viscose Blended Slub Effect
Viscose 100% Injection Slub
Polyester 100% Roving Grindle
Polyester Acrylic Blended Melange
Polyester Cotton Blended
Spindles : Synthetic 32736
Production
Capacity
33 MT/Day
Count range 8s to 40s

6. RSWM RISHABDEV
Spindles
Production
Capacity
50.7 MT/Day
52704
Count range 8s to 40s
Synthetic yarn Viscose yarn Special fibre Effect yarn
Viscose 100% Viscose Blended Viscose with
Modal,
Tencel,
Bamboo,
Excel
Viscose Linen Slub
Polyester 100% Polyester Blended Cationic Injection Slub
Neppy Slub
Lycra

7. RSWM KHARIGRAM
Spindles : Synthetic
Production
Capacity
136 MT/Day
167136
Count range 6s to 60s
Synthetic yarn Dyed yarn Effect yarn
Acrylic 100% Acrylic blended Poly Viscose Slub
Viscose 100% Viscose Blended Poly Cotton Core spun
Polyester 100% Polyester Blended 100% Polyester Neppy yarn
100% Acrylic Roving Grindle
D/F Grindle

8. RSWM BANSWARA
Spindles : Synthetic
Cotton
Production
Capacity
99 MT/Day
63600
31104
Count range 6s to 60s
Synthetic yarn Cotton yarn Special
fibre
Effect yarn
Acrylic 100% Acrylic blended Cotton 100% Coolmax Slub
Viscose 100% Viscose Blended Cotton with
Modal,
Tencel,
Bamboo
Thermolite Injection Slub
Polyester 100% Polyester Blended Siro
Lycra
Rotors 3140

9. A SHORT INTRODUCTION OF TEXTILE FIBRE

10. TEXTILE FIBRE
NATURAL FIBRE MAN MADE FIBRE

11. VEGITABLE FIBRE
NATURAL FIBRE
Cotton Jute Linen

12. ANIMAL FIBRE
NATURAL FIBRE
Wool Silk

13. SYNTHETIC FIBRE
MAN MADE FIBRE
Acrylic Polyester Nylon Spandex

14. SEMI SYNTHETIC FIBRE
MAN MADE FIBRE
Viscose

15. SYNTHETIC RECYCLE FIBRE
MAN MADE FIBRE
PET bottles PET flakes PET fibre

16. YARN COUNT ( FINENESS OF YARN ) AND VARIOUS
SYSTEMS OF YARN COUNT

17. YARN COUNT ( FINENESS OF YARN )
AND
VARIOUS SYSTEMS OF YARN COUNT
THE FINENESS OF YARN IS KNOWN AS COUNT OF YARN , ALSO KNOWN AS LINEAR DENSITY
OF YARN.
THE COUNT OF THE YARN IS EXPRESSED IN THE FORM OF NUMERICAL NUMBER,
DIFFERENT SYSTEM ARE USED AT VARIOUS REGIONS OF THE WORLD TO EXPRESS YARN
COUNT.
ALL SYSTEM FOLLOW THE PRINCIPLES GIVEN AS BELOW .
DIRECT SYSTEM : HERE THE LENGTH OF YARN REMAINS CONSTANT AND THE WEIGHT OF
YARN VARIES ACCORDING TO THE FINENESS OF YARN .
AS THE NUMBER ( COUNT ) OF YARN INCREASES , THE YARN BECOME
COARSER.

18. INDIRECT SYSTEM : IN THIS SYSTEM OF YARN COUNT , THE WEIGHT OF YARN REMAINS
CONSTANT AND THE LENGTH OF YARN VARIES ACCORDING TO THE
FINENESS OF THE YARN. AS THE NUMBER ( COUNT) OF THE YARN
INCREASES THE YARN BECOMES FINER.
TEX : THE WEIGHT IN GRAMS OF 1000 METER OF
YARN IS CALLED THE TEX OF A YARN , WHEN
THE TEX OF YARN INCREASES, THE YARN
BECOME COARSER.
DENIER : THE WEIGHT OF YARN IN GRAMS OF 9000
METER OF YARN IS CALLED DENIER OF A
YARN
FOLLOWING YARN SYSTEM ARE BEING USED TODAY

19. THE NUMBER OF HANKS OF 840
YARDS IN A POUND IS
THE NEW ENGLISH COUNT
NEW ENGLISH COUNT ( Ne)

20. THE LENGTH OF YARN IN METER OF ONE GRAM OF YARN
OR
LENGTH OF YARN IN KILOMETER OF ONE KILOGRAM OF YARN IS CALLED NEW
METRIC COUNT ( Nm).
NEW METRIC COUNT ( Nm )
THE YARN BECOME
FINER WHEN
Nm INCREASES.

22. PREPARATORY SECTION
BLOW ROOM Section:
Production starts at Blowroom,
Fibres are
Opened,
Cleaned
and Mixed.

23. PREPARATORY SECTION
CARDING
Heart of spinning,
Individualization of fibres ; i.e.
separation of fibres from each others
To produce thick rope form of fibres
called slivers which is suitable for
subsequent processing.

24. PREPARATORY SECTION
DRAWFRAME
This ensures a high level of sliver
quality due to precise sliver scanning
process and the dynamic auto
leveling function.

25. ROVING FRAME
It is an intermediate process in
which fibers are converted into low
twist lea called roving. It’s purpose is
to prepare input package for next
process.
PREPARATORY SECTION

26. SPINNING SECTION
RINGFRAME
Ring spinning is a method of producing
yarn from fibers like cotton, wool,
flax etc. It is mostly used in yarn
manufacturing.

27. POST - SPINNING SECTION
WINDING
It is process of creating large yarn
packages called “cone” from a
number of small yarn packages (ring
cops).
The Winding process not only make
bigger yarn packages, it also corrects
spinning faults like neps, hairiness,
and waxes.

28. POST - SPINNING SECTION
Two for one Twister
Assembly Winder
Cotton & all synthetics Yarn Parallel
Assembly Winding Machine for 2 ply, 3 ply
& 4 Ply yarns & all kinds of Threads for
prepare feed package for TFO & Doubling.
Two-For-One (TFO) is a two-stage process
where the yarns are doubled and then
twisted. In TFO process two or more single
yarns are twisted in order to enhance the
properties of the end-products such as
strengthening the yarns.

29. POST - SPINNING SECTION
SSM WINDER The key features are:
SSM XENO - the new modular winding machine platform,
available with all three leading winding technologies.
 Precision winding
 Digi Winding &
 Soft package winding
 This is only one m/c , we have to produce 25 mm to 270
mm traverse wound in one segment.

30. POST - SPINNING SECTION
SSM WINDER The key features are:
Types of winding DIGICONE® 2 or precision
Mechanical speed
up to 2000-2500 m/min (process speed
depending on process parameters)
Package shape freely programmable
Traverse length 25mm ...270 mm electronically adjustable
Take-up package diameter up to 300 mm
Package weight up to 10 kg
Supply package diameter
2-plies up to 280 mm / 3-plies & more ply
up to 280 mm (with balloon separators)
Yarns
staple yarns, monofilament, textured
filaments, medium count technical yarns
(on request: flat or twisted filament
Count Ne 1.5...240 / 10...4000 dtex (final count)
Technical data XENO-YD

31. POST - SPINNING SECTION
Carton strip machine
Type of packing
Mainly 3 type of packing used in textile Industries Packing
Bag Packing :- Use for Domestic packing.
Carton Packing :- Used in Domestic & Export packing &
Pallet Packing :-Mainly used for Export packing
BAG
PACKING
CARTON
PACKING

32. POST - SPINNING SECTION
Pallet Warp machine
Specifications
Production speed 15 - 25 pallets / hour
Pallet size 1200 x 1200 mm
Pallet height 2600 mm
Max. weight / pallet 2000 kg
Turn Table Diameter 1500 mm
Turn table height 80 mm
Turn table speed 1 - 10 rpm
Max.powered stretch 300%
CAPACITY
MACHINE

33. Technology Comparison
Old
Technology
Latest
Technology
Less
power & Air
consumption
Production
increased by 6% &
HARD Waste
reduce by 0.3%

34. YARN SPINNING
CONVENTIONAL AND NEW TECHNOLOGY

35. TYPES OF SPINNING
CONVENTIONAL NON CONVENTIONAL

36. TYPES OF SPINNING
Ring
spinning
Conventional
spinning

37. TYPES OF SPINNING
Compact
spinning
Fancy
conventional
spinning

38. Siro
spinning
TYPES OF SPINNING
Fancy
conventional
spinning

39. TYPES OF SPINNING
Core spun
yarn
spinning
Fancy
conventional
spinning

40. TYPES OF SPINNING
Rotor
spinning
Non
conventional
spinning

41. TYPES OF SPINNING
Airjet
spinning
Non
conventional
spinning

42. TYPES OF SPINNING
Non
conventional
spinning
Friction
spinning

43. RING SPINNING
YARN PROCESS FLOW
DRAWING
(Homogenising
fibre)
LAP FORMER
COMBER
RING FRAME
(Yarn
creation)
ROVING
FRAME
DRAWING
(II Passage)
AUTOCONER
(Final
Package)

44. ROTOR and NON CONVENTIONAL
SPINNING YARN PROCESS FLOW
ROTOR
MACHINE
(Final
package)
DRAWING
(Homogenising
fibre)

45. COMPARATIVE
YARN
STRUCTURE
OF
DIFFERENT
SPIINNING
SYSTEM

46. YARN PROPERTIES
CLOSED LOOP
(RING SPINNING)
OPEN LOOP
(ROTOR SPINNING)
STRENGTH
UNIFORMITY (EVENNESS)
PRODUCTION
PRODUCTION COST
DYEABILITY
FABRIC TYPE
GOOD FOR FINER FABRIC,
WIDE RANGE OF APPLICATION
ONLY FOR COARSE FABRIC
LIKE DENIM, FURNISHING ETC.
FIBRE LENGTH REQUIRED FOR PRODUCTION LONGER SHORTER
FABRIC FEEL SOFT HARSH

47. PRODUCTION CALCULATION

48. PRODUCTION CALCULATION
PRODUCTION IN KG / DAY / (SPINDLE or ROTOR or Machine head)
Delivery speed
(840 yards x 0.914)
(453.6 gms)
1000 x count of yarn
min
meters
xnumber of shiftx hours
shift
x minutes
hour
x 1
x
OR
Delivery speed
min
meters
x count of yarn
1
x 0.85

49. PRODUCTION CALCULATION
for Ring spinning frame
We require
Spindle speed
Twist multiplier
16000 rpm
3.8
Count 20
We calculate
FRS( front roller speed) =
Spindle speed
Turns per inch
Turns per inch = Twist multiplier X 𝐶𝑜𝑢𝑛𝑡 = 16.99
= 941 inch/min
(or Delivery speed)

50. PRODUCTION CALCULATION
for Ring spinning frame
Spindle Speed x No of Spindle x Efficiency x 60 x 8
Production per Shift =————————————————————————————————
TPI x Yarn Count x 36 x 840
In lbs (pounds)
1 Pound(lb) = 453.6 Gram
Conversion:
1 Meter = 39.37 Inch
Yarn Count means the number of 840 yards length that weight exactly 1 pound (lb)

51. PRODUCTION CALCULATION
for Rotor spinning frame
We require
Rotor speed
Twist multiplier
100000 rpm
4.8
Count 20
We calculate
Delivery speed(in m/min) =
Rotor speed
Turns per meter
Turns per meter = Twist multiplier X Count X 39.37= 845
= 118 m/min

52. PRODUCTION CALCULATION
for Rotor spinning frame
Del Speed x no. of rotors x Efficiency x 0.28
Production per Shift = ————————————————————————————
Yarn Count
In Kgs per 8 hours of shift

53. WAY FORWARD
DIFFERENT BLENDING PROCESS/TECHNIQUES
FOR DIFFERENT FIBRE
CHART FOR COUNT CONVERSION FROM DIRECT
TO INDIRECT SYSTEM
GENERAL THUMB RULE FOR SELECTING FIBRE
DENIER TO COUNT OF YARN
1
2
3

54. DIFFERENT BLENDING PROCESS/TECHNIQUES
FOR DIFFERENT FIBRE
Blowroom Blending Drawframe Blending

55. Blowroom Blending
Laydown Method
(fibre in bale form is laid in pattern
to achieve blend%)
Manual Weighing
Method
(balance is used to weigh
various component)
Automatic Weighing
Method
(machine equipped with auto
weighing system)

56. Drawframe Blending
Alternative sliver of polyester 100% and Cotton 100% component is used
to blend material on drawframe.

57. Thumb rule selection for fibre denier with
respect to count
Fibre Count Range
Blend Denier Length
100% polyester
1.0 34 24 and finer
1.2 38 from 10 to 24 only
1.4 40 coarser than 10
100% viscose
1.2 38 20 and finer
1.5 44 coarer than 20
Poly viscose blend
1.5 44 poly from 24 to 34
1.5 44 vis

58. Basic Count conversion calculator with formula for conversion
To work the calculator kindly double tap to activate on attached Excel

59. THA N K Y O U