INDUSTRIAL TRAINING REPORT 2011, Textile college Berhampore
1. INDUSTRIAL TRAINING REPORT 2011INDUSTRIAL TRAINING REPORT 2011INDUSTRIAL TRAINING REPORT 2011INDUSTRIAL TRAINING REPORT 2011
GIMATEX INDUSTRIES PVT. LTD
(WANI UNIT)
7 KM MILE STONE, NH-7, VILL- WANI, TAH- HINGANGHAT
DIST- WARDHA, MAHARASTRA-442301
SUBMITTED BY
ARUP NANDY
SUDIPTA DAS
JISHU RAJ MURMU
SUBHAJIT KARMAKAR
FAKHRUDDIN ALI AHMED
PRASANTA KUMAR GAHANA
GOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY, BERHAMPOREGOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY, BERHAMPOREGOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY, BERHAMPOREGOVT. COLLEGE OF ENGG. & TEXTILE TECHNOLOGY, BERHAMPORE
WEST BENGALWEST BENGALWEST BENGALWEST BENGAL
2. All through the days we passed at GIMATEX, we could always remember ourselves
and our training associated with a number of names. These were the names of people
responsible our Industrial Training-2011 which improved us technically as well as,
prepared us mentally for our personal industrial experiences. This report would be
incomplete without the mention of at least some of those people.
Firstly, the person who was responsible for our training schedule- Dr. Chakradhar
Dutta and Mr. Debraj Sarkar. They have always lent us their helping hands when we
needed them the most. They have been our greatest inspirations.
Secondly, we must thank Mr. Gautam Kumar Dhang, Vice President (Weaving) who
helped us out whenever we faced a problem inside or outside the mill complex, even being
strict in his command. We want to specialy thank Mr Shyamal Ganguly, Sr. Manager(
Weaving).
There are numerous other names which come to our minds, Mr.Umesh Singh, Mr
B.Basu Purkayasthya, Mr.Rajesh Rajput, Mr. Ramesh Yadav, Mr. Daaga, Mr S. Dey and
Mr. A. Ghosh being a few of them.
We express our heartfelt gratitude for these people and wish people like them stay
in the industry forever and make the industry a wonderful place to survive.
4. BOILER DEPARTMENT
Aim of the department:-
To supply steam in different departments.
Area:-It is just beside the weaving department.
No. of boilers:- There is one boiler
Capacity of the boiler: - 3 Ton/hrs (Steam)
Temperature of the boiler: - 1800
C
No. of workers: - There are three workers.
Name of the boiler m/c: - Thermax
Name of the boiler company:-Boiler tech Engineers.
Running time:-24 hrs.
Type of Raw material:-Coal and Husk (commonly used)
5. DIFFERENT TYPES OF YARN & YARN SUPPLIERS IN YARN GODOWN
Yarn Godown is a dept where yarns from different supplier are stocked. Properties of yarn vary in count,
blend, structure & packaging.
YARN PROPERTIES CHART OF DIFFERENT SUPPLIERS
LENGTH OF A STD YARN PACKAGE (eg: PATSPIN, count: 50/2, wt: 1.875kg)
1) COUNT= 50/2
2) Wt OF 1 CONE=1.875 kg
= 1.875*2.2 lb
LENGTH OF 1 lb= 840*50 yard
1.875*2.2 lb= 840*50*1.875*2.2/2 yard
= 86625 yard
=79 km (yard to meters multiple factor 0.9144)
SUPPLIER PACKING CARTOON NET
WT:
(KG)
COUNT STD CONC
WT(KG)
1 GIMATEX CARTOON 45.36 50/2 Ne 1.89
2 TRIDENT CARTOON 45.36 40/2 CW 2.52
3 ETCO SPINNING
LTD
SACK 60 24 KW 2.54
4 DAMODAR CARTOON 35.36 290 DEN 1.97
5 RAJVIR IND LTD CARTOON 45.36 60 Ne 1.89
6 RAJVIR IND LTD SACK 38.50 50 Ne 0.96
7 RELIANCE CARTOON 61.42 5.11
8 ANNUR SATYA
TEXTILE LTD
SACK 60 40 Ne P/C 2.5
9 VARDHMAN CARTOON 34.02 30/1 CW 1.89
10 INDO RAMA CARTOON 32.75 5.45
11 PATSPIN CARTOON 50.4 70/1 1.52
12 MARUTI GTex CARTOON 45.28 40/1 CW 1.88
13 NSL TEXTILE
LTD
CARTOON 45.36 60/1 CW 1.89
6. WARPING
Introduction: Warping is a department, where single warp ends are combined into parallel sheets of ends.
Objective of warping:
1) Removal of yarn-faults and foreign matter, which are the main causes of warp breakage.
2) Making warpers’ beam, which are used in sizing.
WARPING
DIRECT WARPING SECTIONAl WARPING
DIRECT WARPING:
Direct warping is a warping process, where warps are prepared from V-creel simultaneously.
M/c name: BENINGER BEN-DIRECT
M/c DETAILS:
CREEL CAPACITY 784
SPEED RANGE 500-1200 rpm
PRESSURE(WARPING) 35 bar
PRESSURE(CREEL) 5 bar
TEMP, RH 34ᵒC, 64.9%
COUNTWISE SPEED AND TENSION CHART.
COUNT SPEED(mpm) PRE-TENSIONER SETTING
20ˢ O.E 1000 12 mm
2/40 C, 2/40 ELI 1000 10 mm
2/50 C, 2/60 C 1000 10 mm
2/80 PC, 2/80 C 1000 6 mm
20ˢ 1000 8 mm
30ˢ 900 4 mm
40ˢ, 40 PC 800 2 mm
45 PC, 50 PC,60 C 700 0 mm
80ˢ 600 0 mm
7. WARPING CHECK REPORT
SORT NO: 12360 BLEND: 100% COTTON SUPPLIER: GIMATEX
NO OF CREEL: 1 DATE: 14/06/11 TENSION: 12mm
COUNT: 20ˢ O.E LOT NO:52080012
Sl.
No.
SPEED
(M/min)
NO:
OF
CONE
LENGTH FOREIGN
MATTER
WEAK
PLACE
CUT
CONE
SLUGG
OFF
BAD
WINDING
CONE
FINISH
ENTANGLEMENT
1 900 754 8470 1 12 24 1
2 700 752 10 1 2 1
3 700 752 1 15 1
4 900 752 8 1
5 900 752 5 1
.
TIME TAKEN FOR M/C STOP & CREEL CHANGE TOTAL TIME TAKEN FOR WARPING
EVENTS TIME BEAM COMPLETE
TIME(min)
RUN TIME
(min)
FAULT
REPAIR
OLD CREEL END
CUTTING
20 sec 1 60 12 18
CLEANING 15 min 2 30 12 21
REVERSING CREEL 2 min 10
sec
3 33 10 13
DRAWING
THROUGH SENSOR
11 min 4 23 10 15
DENTING 10 min 5 25 10 14
8. SECTIONAL WARPING
INTRODUCTION; Sectional warping is a warping m/c, where warp yarns of different quality are used for stripe or
other warp variation in weavers’ beam. Direct weavers’ beam is created for loom-shed.( Sectional warping is
preferred for strong yarns).
M/C manufacturer name: BENINGER KARL-MAYER
M/C model: ERGOTECH 2200
CREEL MODEL: HGP-W/ISOTENS-880
Creel capacity: 880
M/C DETAILS:
DETAILS DATA DETAILS DATA
SORT NO: 14223 WORK ORDER S22
NO OF CREEL 1 SECTION WIDTH 54.28
BEAM NO: P405 COUNT 40 SLUB
DATE 13-06-11 TOTAL END 5796
NO. OF SECTION 35 SECTION LENGTH 200mm
7 LEASE YES X LEASE YES
CENTRE LEASE YES DENTING ORDER 4.4.4.3
CREEL END 166 REED SPACE 1900mm
9. SIZING
Objective: Sizing is specially applied to the woven fabric for the following purposes:
1) Increase it’s weavability
2) Increase the yarn strength
3) Reduce the yarn hairiness
4) Minimize the abrasion between warp threads and various loom parts, and between threads
that are adjacent to each other.
M/C NAME: BENINGER BEN-SIZETEC
No. of machines: There is basically one sizing machine. There is a Separate part beside the machine known as
Kitchen. It consists of:-
• Premixer: Here basically the size ingredients are mixed with water.
Total capacity= 56 inch (first 6 inch = 100 L, 1inch=25 L)
• Cooker: Here the mixture is whirled around so that the size ingredients are properly mixed
with each other. Temperature maintained is 1200
C and the material is processed here for
30min.(same capacity)
• Storage unit: The mixture is stored here and sent to the main unit when necessary. The
material is kept here at 90c.(approximately same capacity
Optimum size percentage
The percentage size to be applied to a warp in order to achieve a minimum number of end-breaks during
weaving is dependent mainly on:
• The end density, as this will affect the amount of end-to-end abrasion that will take place;
• The linear density of the warp, which greatly influences the strength of the yarn and will also
affect the amount of abrasion; and
• The pick density, which will affect the amount of abrasion between the warp ends and the reed
as it reciprocates.
There are other factors which may also need to be taken into consideration, such as the
fibre type, the yarn type, the yarn structure, the type of size and the type of loom.
10. DETAILS DATA
CREEL CAPACITY 16×2=32
2 (for sectional)
NO. OF SIZING BATH 2
CAPACITY OF SIZE BOX 12 inch (FIRST 6 inch 100L, then 25L/inch)
TEMP. OF SIZE BOX 90ᵒC
NO. OF DRYING CYLINDER 4+4+4=12
FLOW CHART OF SIZE PASTE:
FLOW CHART OF SIZING PROCESS:
SIZE COOCKER
WARPERS'
BEAM
SIZE BOX
PREMIXER
SIZING M/C DETAILS:
DETAILS
6×2=32
2 (for sectional)
MAXIMUM SPEED
OPTIMUM SPEED
12 inch (FIRST 6 inch 100L, then 25L/inch)
TEMP OF DRYER
4+4+4=12
STORAGE CHAMBER SIZE BOX
CYLINDER
DRYER
LEASE ROD COMB
DATA
120-160 m/min
80-100(for coarser)
50-60 (for finer)
120ᵒC
SIZE BOX
COMB
WEAVERS'
BEAM
WATER
STEAM
11. DIFFERENT TENSION ZONES OF SIZING
TENSION ZONES: Tension imparted on warp yarns are implemented on different zones in sizing m/c. There are 5
zones in sizing m/c. Each zones have unique multiple factor, which are used to calculate the warp yarn tension.
WARP TENSION:= g/m*TENSION FACTOR
G/M = Total ends/ (1.693*count)
DETAILS OF TENSION ZONES IN SIZING M/C
ZONES ZONE NO: MULTIPLE FACTOR TENSION(N)
CREEL ZONE Z-1a, Z-1b 5-6 G/M*(5-6)
SHOW BOX ZONE Z-2a, Z-2b STRETCH
CYLINDER ZONE Z-3a, Z-3b 12 G/M*12
LEASING TENSION ZONE Z-4 12-13 G/M*12-13
WINDING ZONE Z-5 16 G/M*16
PRESSURE ROLLER Z-6 14 G/M*14
12. SIZING RECIEPE: Sizing recipe is the amount of chemicals used for sizing in sizing box.
COTTON 40 S COTTON 20 O.E
CHEMICALS TOTAL WEIGHT( kg) CHEMICALS TOTAL WEIGHT(kg)
ALPENAL JV 100 MAIZE STARCH 75
KETANAL 15 NIPPASOFT 4.5
NIPPA SOFT 4.5 WATER 28”
WATER 25” TOTAL VOL 31”
TOTAL VOL 28” TIME 10+35
TEMP 135’C TEMP 135’C
FINAL VOL 31” FINAL VOL 31”
ANTI STATIC 1 SOLID PERCENTAGE 71%
SOLID PERCENTAGE 12% VISCOSITY 6 sec
VISCOSITY 15 sec
TIME 10+35
60 VISCOSE 60 COMP
CHEMICALS TOTAL WEIGHT( kg) CHEMICALS TOTAL WEIGHT( kg)
ALPENAL JV 75 SIZANIL LV-100 100
KETANOL 12 KETANOL 21
NIPPA SOFT 6 NIPPBOND 21
WATER 33” NIPPASOFT 8
TOTAL VOL 36” WATER 27
TIME 10+30 min TIME 10+30 min
TEMP 130’C TEMP 120’C
FINAL VOL 38” FINAL VOL 36”
SOLID % 78% SOLID% 12%
VISCOSITY 6 sec VISCOSITY 9 sec
13. SIZE PICK-UP PERCENTAGE CALCULATATION
SIZE PICK UP PERCENTAGE: Size pick-up percentage is the amount of size paste attached to yarns
after yarn is released from squeezing rollers.
SIZE PICK UP % =[weight of size material /( Weight of unsized yarn)]×100
CALCULATION: Net weight(sized yarn) =Gross weight – Tare weight
= 619.5 – 191.0 kg
= 428.5 kg
Weight of unsized yarn = (lengtht×otal ends)/1693/avg Ne
= 4508×6090/1693/45.96
= 352.82 kg
Pick up percentage = [(428.5 – 352.82)/352.82]×100
= 21.4%
SIZING M/C TENSION CALCULATION
Sizing tension is calculated by multiplying factors of zone with gm/m. Calculated tension can be adjusted by
50N from fixed value.
Gm/m = Total ends/1.693/count = 42.15
• WINDING ZONE TENSION: gm/m*16 = 575N (fixed = 680N)
• CREEl ZONE = gm/m*6 = 252.9N (fixed = 300N)
• PRESS ROLL = gm/m*14 = 590 (fixed = 590)
14. DRAWING-IN
Introduction: Drawing-in is a dept. where warp ends are inserted through heald wires and reed dent with different
denting orders from weavers’ beam according to the required quality.
No of Drawing-in stand: 10
No of worker required/stand: 2
Different reed count used: 72/4, 67/5, 70/5, 80/3, 72/5, 66/5, 68/5 etc
DRAWING -IN CHART FOR DIFFERENT QUALITY
SORT NO. 14278 27206 110203
ENDS 6350 5852 5796
REED COUNT 96/2 88/2 86/2
REED SPACE 66.1” 66.5” 66.5”
TIME FOR DRAWING (hr) 5 hr 30 min (approx) 5 hr (approx) 5 hr (approx)
DENTING ORDER 1,2,3,4 1,2,3,4 1,2,3,4
ENDS/HEALD WIRE 1 end/heald wire 2 end/heald wire 1 end/heald wire
15. LOOM-SHED
Introduction: Loom shed is the department where fabric is weaved in loom. Warp yarns are taken from
weavers’ beam and weft yarns are inserted from another package.
FABRIC PRODUCTION PROCESS
DESIGNING DEPT.
Fabric pattern, denting order and
pegging plans are made.
SAMPLING DEPT.
A sample fabric is produced with
given preference, for testing
PREPARATORY DEPT.
Warping, Sizing and leasing process
are done to assist weaving
LOOM-SHED
Fabric produced by interlocking
warp and weft yarns. Drawing &
knotting will be required before
fabric produced sometimes for
different quality
INSPECTION & DESPATCH.
After production inspection for
fabric faults are done and mended.
After that fabric is dispatched
DRAWING-IN DEPT.
Warp ends are inserted through
heald wires & reed according to
denting order
16. DETAILS OF LOOM-SHED
There are two loom-sheds. Four types of air-jet looms are there:
1) PICANOL OMNI PLUS (sumo motor function) - 50 looms
2) TOYATA JAT710 – 56 looms
3) SULZER TEXTIL L5400 - 13 looms
4) SULZER TEXTIL L5500 – 1 looms
Three types of shedding mechanisms are used:
1) STAUBLI CAM SHEDDING
2) STAUBLI DOBBY SHEDDING
3) FILTEXTILES DOBBY
Two types of knotting m/c are used:
1) TODO - 2 m/c
2) STAUBLI -1 m/c
Working patterns:
1) PLAIN -1/1
2) TWILL- 2/1
3) OXFORD- 3/1
4) SATIN- 4/1
Compressor used for pressure supply in looms
1) SAMSUNG
2) ATLAS COPCO.
17. DETAILS OF EACH LOOM
STAUBLI TYPE starting with 1 (eg: 1661) indicates Cam shedding, and starting with 2 (eg: 2871) indicates
DOBBY shedding.
NO OF LEVERS indicates no of heald frames.
PREWINDER indicates no of weft accumulator.
R.S means reed space.
LOOM NO. STAUBLI
TYPE
NO.OF
LEVERS
PREWINDER
LOOM TYPE
R.S.
(CM)
1,2,3,4,5,6,7,8,9,10,11,12,13,
14,15,16,17,18,19,20,21,25,
26,27,28,29,30,31,32,33,34,
35,36,37,38,39,40,41,42,43,
44,45,46,47,48
1661 7 2 TOYOTA 710 190
22,23,24 2871 16 4 TOYOTA 710 190
49,51,52,53,54,56 2861 16 4 TOYOTA 710 210
50,55 2861 16 6 TOYOTA 710 210
57,58,59,60,61,62,64,71,73,
74,75,76,78
1661 8 4 SULZER 5400 190
63 FILMTEXTILES NOT FROM
STAUBLI
6 4 SULZER 5500 190
65,66,67,68,69,70,72,113,
114,115,116,117,118,119,
120
1661 6 2 PICANOL 190
77, 2871 10 2 PICANOL 190
79,80,81, 2871 12 2 PICANOL 190
82,83,84,85,87,88 2871 16 2 PICANOL 190
86 2871 13 2 PICANOL 190
89,97,100,110 1761 6 2 PICANOL 190
90,91,92,104,111 1661 7 2 PICANOL 190
93,107,108,112 1661 7 4 PICANOL 190
94,96,98,101,102,103,105 1661 6 2 PICANOL 190
95,106 1661 4 2 PICANOL 190
99 2861 14 2 PICANOL 190
109, 1761 6 4 PICANOL 190
19. LOOM MECHANISMS
Primary motions: 1) SHEDDING 2) PICKING 3) BEAT UP
Auxiliary motions: 1) TAKE-UP 2) LET-OFF 3) WARP STOP 4) WEFT STOP
PRIMARY MOTIONS
SHEDDING: Shedding is done either CAM or DOBBY mechanism. Shedding shaft gets movement from SUMO
MOTOR(Picanol) or Main motor(Toyata, Sulzer). Heald frames are set as some difference for staggering.
PICKING: Picking is done by air-jet. Weft yarns are inserted by air pressure. There are two main valves and relay
nozzles for continuity of jet integration. Main and relay valves are connected with main nozzles and relay nozzles.
BEAT UP: Beat-up mechanism get motion from crank drive connected by gear with main motor.
AUXILIARY MOTION
TAKE UP: Take-up motion is controlled by individual motor. Fabric is rolled on a cloth roll which is surface driven
LET OFF: Let off motion get control by individual motor. Let-off motion is assisted with easing motion where feeler
rollers are vibrated to adjust warp tension.
WARP STOP: If warp ends get broken loom is automatically stopped by hydraulic brake. Warp stop motion is
controlled by drop pins, when a warp breaks drop pin fall on a electrode, completing the circuit and making loom
stop.
WEFT STOP: Weft stop motion is controlled by two filling detector (FD1 and FD2).
RELAY NOZZLE SETTING FOR DIFFERENT LOOMS
TYPE OF LOOM DISTANCE
FROM
LEFT OF REED
TO 1ST
RELAY
NOZZLE
DISTANCE FOR
SUBSEQUENT
RELAY NOZZLE
FROM ONE
ANOTHER
5 OR 6 RELAY NOZZLE
AT RHS. FROM ONE
ANOTHER
DISTANCE FROM FD1 TO
FD2
PICANOL OMNI
PLUS
15 MM 74 MM 37 MM 100-120 MM
SULZER TEXTIL 30 MM 65 MM 35 MM 90-120 MM
TOYOTA J710 20-25 MM 60-65 MM 35-40 MM 90-110 MM
VALVE PRESSURE: Pressure in main valve should be 6 bars.
SELVEDGE : In air-jet loom dummy selvedge are used with leno selvedge. There is a leno box for every loom.
REED: For air-jet looms profile reeds are used for jet integrity.
20. LOOM PRODUCTION
Loom production determines the total production of weaving. Loom production data is stored and updated on
spreadsheet and informed to MIS. Main hurdles of loom production are beam gating, knotting and warp stop and
weft stop motion.
TOTAL PRODUCTION OF LOOM-SHED: 37,000 meters/day
AVERAGE PRODUCTION
LOOM TYPE TOYATA PICANOL
AVG. PICKS/INCH 84 PPI 83 PPI
AVG. RPM 830 785
NO. OF M/C 64 56
PRODUCTION/ DAY 20, 000 METERS/DAY 16, 000 METERS/DAY
EFFICIENCY 88% 85%
PRODUCTION IN METERS / SHIFT /m/c: (RPM *60 * 8 * EFFCIENCY %) / 3937 /PPI meters/shift
PRODUCTION IN gm / SHIFT / m/c: (Production in meters/shift/ m/c * FABRIC WIDTH * GSM) gm
Fabric width in meter, GSM= gram weight of one square meter fabric
AVERAGE BEAM GATING TIME / m/c: 3-4 hr (approx.)
AVERAGE KNOTTING TIME / m/c: 1hr- 1hr 30 min
21. LOOM SETTINGS
LOOM TIMING DIAGRAM: Loom timing diagram is the timing settings of all motions of a loom. As for better
production and m/c stability and less wear and tear perfect loom timing diagram is essential.
PICKING PATH OF AIR-JET LOOM
MOTION STARTING (DEGREE) STOPING (DEGREE)
BEAT UP 0
CUTTER 5
SHED OPENING 10 60
DWELL PERIOD 61 319
SHED CLOSING 320 360
PICKING 80 300
FILLING DETECTOR 1 210 290
WEFT YARN PRE-WINDER PFT TENDOM
NOZZLE
MAIN
NOZZLE
WEFT
CUTTER
RELAY
NOZZLE
SELVEDGE
CUTTER
RHS
22. GREY INSPECTION & DESPATH
INTRODUCTION: Inspection is the department, where fabrics are checked after production for faults and mended. In
this department grey fabrics are graded according to American 4 point checking system.
NO OF M/C: There are 4 types of inspection m/c and 4 handmade mending frames.
1) SHREETEX – 3 M/C
2) YASH – 2 M/C
3) NEW BHAGWATI VIJAY ENG – 1 M/C
4) B.TEX TEXTILE MACHINERY – 2 M/C
Make of the m/c: Indiana Euro, Shreetex (Silvasa)
Motor rpm: 1415
Motor hp: 1.0
Power consumption: 0.75 KW
Length of the beam: almost 70”
AMERICAN 4 POINT SYSTEM PENALTY POINTS FOR DEFECT
WARP DEFECTS
UP TO 3 INCH 1 POINT
3 INCH TO 6 INCH 2 POINT
6 INCH 9 INCH 3 POINT
9 INCH TO UP 4 POINT
WEFT DEFECTS
UP TO 3 INCH 1 POINT
3 INCH TO 6 INCH 2 POINT
6 INCH TO HALF WIDTH 3 POINT
HALF WIDTH TO FULL WIDTH 4 POINT
1) No one meter should be penalized more than 4 points.
2) Fabric shall be inspected on one side.
3) Total no of points allowed in 100 linear meter are 24 points.
4) Deviation of 10 points per linear meter allowed.
23. DIFFERENT FABRIC FAULTS
QUALITY NO FABRIC FAULTS
14292 STARTING MARK, BREAKING END, BROKEN PICK, DOUBLE PICK, THICK PLACE
16239A WEFT DISTORTION,
12361 BUMP MARK, OIL STAIN,
110203 LOOSE WEFT, WARP SLUB, STICHES,
14534 DOUBLE END, THICK PLACE, STARTING MARK, LOOSE WEFT
SOME OTHERS FAULTS:
SELVEDGE DEFECT, LOOPS, SIZE PATCH, BROKEN PATERN, COARSE PICK, THIN PLACE, MISSING END, WEFT SLUB,
CONTAMINATION, HOLE/CUT/TEAR, MISSING PATTERN, WRONG DENTING
SOMETHING ABOUT THE SECTION
Each fault is given a marking. This marking technique varies from mill to mill. Here the
marking technique is shown below.
Maximum points given to a fault = 4.There are corresponding marking of 1, 2 & 3.
Maximum allowable points to consider a fabric as “A” grade is 24 within 100metres of
fabric, for “B” grade this range varies for 24 - 90 within 100 meters of fabric. Above this it is
considered as “C” grade fabric.
24. MAINTAINANCE SHEDULE
MAINTAINANCE SCHEDULE FOR DIRECT WARPING M/C( 500 hr service) SIZING M/C WEEKLY MAINTAINANCE SCHEDULE
CLEAN MACHINE CLEAN THE COMPRESSOR FILTER
CLEAN WINDSHIELD CLEAN THE OIL LEVEL
CLEAN GUIDE ROLL CLEAN THE BEAM SHAFT
CLEAN PRESSURE ROLL CLEAN THE AIR FILTER AND AIR SILENCER
CLEAN TRAPEZOIDAL THREADED SPINDLE AND
LIMIT SWITCH ASSEMBLIES
CLEAN THE ALL VALVE POSITION
CHECK OIL LEVEL CLEAN THE ALL SAFETY GUIDE POSITION
CHECK SCREWED LEVEL CHECK THE ALL MANDI PUMP POSITION
CHECK DRIVE LEVEL CHECK THE ALL BEARING POSITION
RESET MAINTAINANCE INTERVAL ALL M/C GEAR BOX POSITION
LUBRICATING QUILS CHECK ALL THE NUT BOLT
CLEAN / BEAM POSITION CHECK CREEL BELT POSITION
CLEAN / LUBRICATE TRAPEZOIDAL THREADED
SPINDLE
ALL M/C GREASING
CHECK WARP BEAM STEAM LEAKAGE PROBLEM
CLEAN / LUBRICATE COMB TRAVERSE CHAIN
GREASE CYLINDER PRESSING DEVICE
RESET MAINTAINANCE INTERVAL
OIL CHANGE: REPLACING OIL FILTER
INSPECT/ REPLACE BRAKE PADS
REPLACE DRIVE BELTS
CHECK BEAM CLAMPING AXIAL PLAY
CHECK COMPENSATING SPRING
REPLACE PRESSURE ROLL BEARING
REPLACE GUIDE ROLL BEARING
REPLACE QUILL ROLL BEARING
REPLACE BRAKE CALIPER SEALS
25. TOYATA AIR-JET MONTHLY CHECK LIST
1. CLEANING
2. WEFT PASSAG, LEAF SPRING, TENTIONERS
3. EDP, MEASURING BAND, WINDING ARM
4. ABS, TANDOM NOZZEL, MAIN NOZZLE 180’
5. FILLING CUTTER LHS(25’-30’)
6. REED TIGHTNESS (5.9 – 6.9 Nm)
7. SUB NOZZEL PIPES
8. RHS CUTTER
9. WEFT FEELERS,(WF1 &WF2) STRCHING NOZZEL TIGHTNESS
10. BEAM LOCKING AREA
11. BACK REST BEARING AND BACK REST PLAY
12. LENO DEVICES, LENO SHAFT, WHEEL
13. EASING RAD, BEARING
14. HEALD FRAMES, SIDE SUPPORTS AND BOLT TIGHTNESS
15. WARP STOP MOTION SENSOR, SERRECTED BAR
16. TEMPLE RING CONDITION
17. TAKE UP ROLL,GEAR, PRESS ROLL
18. CATCH CORD SET
19. TAKE UP, DRIVE MOTOR, GEARS, CHAINS
20. TAPPET CAM BOX AREA & BELT TENSION
21. UNDER MOTION, JACK LEVERS
22. MAIN MOTOR AREA AND BELT TENSION
23. CONTROL PANEL
24. AIR PRESSURE AND REGULATOR AREA
25. AIR FILTER, OIL FILTER AND GREASE FILTER
26. CLUTCH GAP UP TO 0.6mm
27. OTHERS
TOYATA AIR-JET SIX MONTHLY CHECK LIST
ALL THE MAINTAINANCE PROGRAM OF 1MONTH CHECK LIST ARE INCLUDED
1. BACK ROLLER RELATED COMPONENTS IN THE LET-OFF MOTION
2. INDIRECT TAKE UP ROLLER CHAIN AND TENSION PLATE
3. FOR GLASS FIBER M/C MAIN NOZZELS
4. CENTRALIZED LUBRICATION SYSTEM
5. EASING LEVER PIN & BUSH
6. TAKE UP, DRIVE MOTOR, GEARS AND CHAINS
7. AIR AND OIL FILTER
8. OTHER DAMAGED PARTS
9. MAIN BRAKE (<0.5)
10. MIDDLE METAL SELECTION
11. BEAM HOUSING AND BEARING
27. The days we passed at Gimatex taught us a wonderful lesson in
our lives. Gimatex taught us to survive even in the most competitive
situations against the most powerful competitors. The lesson we
learnt is an experience of a lifetime. None of us has enough of
oblivion to forget it.
