Internship presentation on spinning factory.

1. Presentation on
“INTERNSHIP”
AT
ZABER SPINNING MILLS LIMITED

2. Prepared By
Yarn
Manufacturing
Textile
Engineering
7th Batch
NITER

3. CONTENTS
1. Introduction
2. Manpower
3. Machine Description
4. Raw Material
5. Production Plan
6. Quality Control
7. Maintenance
8. Store
9. Utility
10. Cost Analysis & Marketing
11. Conclusion
3

4. Zaber Spinning Mills Limited
North Mawna, Sreepur, Gazipur
4

5. Zaber Spinning Mills Limited
North Mawna, Sreepur, Gazipur
 Spinning factory
 A sister concern of “Noman Group”
 Year of inauguration 2006
 108 Ring frames (78608 Spindles), 6 Rotor
Frame (1728 Heads)
5

6. FACTORY LAYOUT
6
Total Unit – 3
Ring spun unit – 02
Rotor Unit – 01
Recycle unit

7. PRODUCTS
7
Ring spun yarn of different count
Rotor yarn
Fig: Ring spun yarn Fig: Rotor yarn

8. 8
SEVERAL DEPARTMENTS OF THE FACTORY
➢ Production Department.
➢ Quality Control Department.
➢ Maintenance Department
➢ Machine Tools Workshop
➢ Electrical & Utility
Department
➢ Administration
➢ Administration Section
➢ Accounts Section
➢ Store Section
➢ Medical Service

9. 9
PHYSICAL INFRASTRUCTURE OF ZSML

10. ORGANOGRAM
10

11. DEPARTMENT-WISE MAN POWER
SL No Department No of Post
1 Production 1550
2 Quality 40
3 Maintenance 47
4 Utility 20
5 Administration 80
Total 1737
11

12. 12
Process
Carded
yarn
Combed
yarn
Rotor
yarn

13. 13
Bale Blowroom Lap
Lap Carding m/c Card sliver
Card Sliver Breaker Draw Frame Breaker Drawn Slier
Breaker Drawn Sliver Finisher Draw Frame Finisher Drawn Sliver
Finisher Drawn Sliver Simplex Roving
Roving Ring Frame Yarn (bobbin)
Yarn (bobbin) Auto coner Cone
Carded Yarn Process Flow Chart
Input Machine Output
Conditioning
Packing Bag

14. 14
Bale Blowroom Lap
Lap Carding m/c Card sliver
Card Sliver Breaker Draw Frame Breaker Drawn Slier
Breaker Drawn Sliver Lap Former Lap
Finisher Drawn Sliver Simplex Roving
Roving Ring Frame Yarn (bobbin)
Yarn (bobbin) Auto coner Cone
Combed Yarn Process Flow Chart
Input Machine Output
Lap Comber Comb Sliver
Comb Sliver Finisher Draw Frame Finisher Drawn Slier
Conditioning
Package

15. 15
Bale Blowroom Lap
Lap Carding m/c Card sliver
Card Sliver Breaker Draw Frame Breaker Drawn Slier
Breaker Drawn Sliver Finisher Draw Frame Finisher Drawn Sliver
Finisher Drawn Sliver Rotor Rotor yarn
Rotor Yarn Process Flow Chart
Input Machine Output
Packing bag

16. 16
Blowroom Machineries
Blendomat
(BDT)
•Bale
opener
Condenser •Filter
SP EM
•Electronic
metal
separator
CL-P •Pre
Cleaner
MX I6 •Multi
Mixer
CL C3 •Cleaner
SP FP
•Foreign
part
separator

17. 17
Blowroom Machineries
Fig: Blendomat
Fig: Condenser
Fig: Pre Cleaner

18. 18
Blowroom Machineries
Fig: Multi Mixer
Fig: Cleanomat
Fig: SP FP

19. CARDING
• Individualization of the fibers
• Parallelizing the fibers
• Elimination of impurities and neps
• Fiber blending and orientation
19

20. DRAW FRAME
 Input draft
 Doubling
 Reduce irregularities of fibers
 Remove remaining dust
20

21. LAPFORMER
The lap former has the task of forming lap for comber
21

22. COMBER
 Remove short fibers
 Remove neps and foreign matter
 More straighten and parallisation.
22

23. SIMPLEX
Operation involved
 Creeling
 Drafting
 Twisting
 Winding
 Building
 Doffing
23

24. RING FRAME
 Draw the roving to it’s final count
 Impart tenacity by twisting
 Wind up the resulting yarn to suitable
form
24

25. AUTO CONE
25
HEAT SETTING

26. RAW MATERIAL
26
 Natural fibers: Pima USA , CIS Turkey , Indian,
India , Zimbabwe, Mali, Benin, BCI India,
Brazil Senegal, Guinea, Cameroon, Chad, Greek
 Man made fibers
 Wastage from production

27. QUALITY CONTROL EQUIPMENT
27
USTER HVI 1000
 MIC, Length, Maturity, Strength, SFI,
Moisture, Rd, +b, Color-grade Trash area,
Trash grade
USTER AFIS PRO
 Neps(Cnt/gm), Nep (μm),
SCN(Cnt/gm), UQL, SFC, L(n) (mm)
USTER TESTER-5
 Unevenness, Imperfections, Hairiness

28. QUALITY CONTROL EQUIPMENT
28
USTER AUTO SORTER
 Used for count test of carded sliver,
drawn sliver, combed sliver, roving, yarn
WRAP REEL
 Make yarn sample
LEA STRENGTH TESTER
 Test yarn lea strength

29. QUALITY CONTROL EQUIPMENT
29
AUTO WINDER
 Prepare spun single yarns appearance
boards for the grading
TECHO METER
 Check spindle speed of ring
machine

30. MAINTENANCE
30
Types of
Maintenance
Preventive Break Down

31. UTILITY SERVICES
31
Departments No of Machine
AC Plant 09
Chiller 08
Boiler 03
Compressor 08
Dryer 08
Power Generation 11
Control Panel 11
Cooling Tower 10

32. STORE & INVENTORY CONTROL
32
Finished
Goods
Store
Raw
Material
Store
Spare
Parts
Store

33. COST ANALYSIS
33
Production Cost for 40 Ne Yarn per kg
Production cost – 231.39 bdt
Operating cost – 33.81 bdt
Total cost – 265.20 bdt or 3.6 doller

34. COST ANALYSIS
34

35. MARKETING
DIFFERENT CUSTOMER
35
Sufia Fabrics Ltd
Noman Fabrics Ltd
Noman Weaving Mills Ltd
Talha Fabrics Ltd
Saad Saan Apparels Ltd
Zaber & Zubaer Ltd
Local Markets
Fashion Houses

36. CONCLUSION
36
The industrial training gave us the opportunity to work in the mills.
This training gave us actual picture of man, machine, materials,
method.
During training period we visited all department.
We believe that this experience will help us in professional life in
different ways.

37. THANK YOU!
GROUP OF YM-05