High-tech spinning process optimized for quality yarn production
1. INTERNSHIP
REPORT
ABSTRACT
Process of making yarn using high tech technology
and experienced engineers team for better quality,
high production.
Pankaj Yadav
Mechanical engineer
2. Contents
Topics:
1) Introduction of an organization
2) Structure of an organization
3) Spinning
4) Layout
a) Plant layout
b) Process layout
5) processing of yarn
6) maintenance of plant
3. Reliance spinning mills ltd. Is joint venture between Golyan
Group & Maliram Siv Kumar (MS) Group. Located in khanar (sunsari
district of Nepal).reliance spinning is a high tech spinning plant
with machinery from world renowned textile machinery
manufacturers such as Lakshmi machinery works, savior, and
schlahorst saurer.
Reliance spinning has the workforce of over 5000 people, making
it largest employer in Nepal.
4. Structure of an organisation:
Production
shlew pratap
(Sr.s/o)
Manoj Katial
(sr.prod. Mang)
Deputy
manager
V.K.
Bajpayee
Devendra
katiyar
Bipin
Yadav
Ashish
singh
Puspendra
prakash
D.P Mishra (GM)
D.K Singhal
(Sr.v.p.p)
Production Maintainance
D.B.Tiwari
(joint v.p.Admin)
Mahesh pokhrel
(Sr.manager admin)
6. What is spinning?
Spinning is the major parts of textile industry.it is the part of textile manufacturing
process where three types of fiber are converted into yarn, then fabrics which
undergoes finishing process such as bleaching to become textile .The textile are then
fabricated into cloths or products .there are three industrial process available to spin
yarn, and a handicraft community who use hand spinning techniques. Spinning is
twisting together of drawn strands of fibers to form yarn.
In simple words, spinning is process in which we convert fiber by passing through
certain process like blow room, carding, drawing, combing, simple, ring frame and
finally winding into yarn. These yarn are then wound into cones.
Types of fibers:
1) Artificial fibers
2) Natural fibers
Artificial fibers
Are made by extruding a polymer through a spinneret into medium where its hardens. Wet
spinning uses conjugating medium .in dry spinning (nylons and polyesters) the extruded polymers is
coiled in gas or air and sets. All these fibers will be of great length, often kilometer long .all these
fibers will of great length, often kilometers long.
Natural fibres
Natural fibers are either from animals (sheep, goat, rabbit, silkworm), mineral (asbestoses) or from
plants (cotton, fax, sisal).these vegetable fibers can come from the seed (cotton), the stem (known as
blast fibers: flax, hemp, jute) or the leaf (sisal). Without exception, many process are needed before a
clean eve staple is obtain each with a specific.
Plant layout
7. Process and product
layout
Blow room:
It consists of swift floc and unimix. Swift floc is machine used for sucking the fibers .sucked fiber is sent into
vacuum pipe where negative pressure of about 100-200 Nm2 is maintained. This fiber passes through tube to
unimix on the way to unimix it also passes through metal and fire diverter. The product of unimix is feed to the
carding machine through automatic feed line.
8. Carding:
It is mechanical process that disentangles, clean and intermix fibers .Produce continuous web or sliver suitable
for subsequent processing .this is achieved by passing between differently moving surfaces covered With card
cloths .it break up locks and unorganized clumps of fibers and aligns the individuals fibers to be parallel with each
other.
LD/2:
Sliver is feed into draw frame, 8 slivers ropes is mixed to form 1 rope. Output of the LD/2 is feed into can which is
further transferred into LD/1 machine for similar operation .these processing is done for uniform mixing of sliver.
Speed frame:
Output of LD/1 is feed to the speed frame, where roving is further twisted and wrapped in the bobbin. Bobbin
nearly contains about 7000-8000 m. filled doffers transferred to the ring frame No of spindle in the speed frame is
160. Speedframe runs at 1200rpm.The efficiency of this speed frame is about 80-85% & output of this machine is
called roving .this machine is also known with another name like simplex, fly frame.
Ringframe:
The output of the speedframe is feed to the ringframe to form yarn. It’s wrapped in the bobbin. The number of
spindle in the ring frame is 1440. Total number of workers required for handling is 25.output of this machine is
nearly 800kg/8hrs.
9. Autoconer:
This is machine which is used for making bundles of yarn. This machine is automatic which also lift the produced
yarn bundle. Finally the product are ready andare sold as per the orderof the customers.generaly theyarn made
here is of 28,30,15 counts of polyster and 20,15,18 counts of viscous.production ofan autoconer isnearly
850kg/8hr.there are 8 autoconer in the polyser line and 6 in p/v line.
10. MAINTAINANCE
It is process in which machines are maintaned for effective production of yarn. There are 4 types of maintainance:
1) Day to day maintainance.
2) Preventive maintainance.
3) Scheduled maintainance.
4) Breakdown maintainance.
Day to day maintainance:
Under this maintainance following opertaion were done in industry.they are as
a) Cleaning internal parts using air pressure
b) Gauging
c) Lubricating
d) Machine surface cleaning
Preventive maintainance:
Under this maintainance following opertaion were done in industry.they are as
a) inspecting the movement of gears and pinions.
b) Observing the quality of yarn produced
c) Cheking the fults in machine and removing it’s fults if present.
Scheduled maintainance:
Under this maintainace overhuiling and changing of parts are done in particular interval of time for effective
operation of industry. This maintainance plays vital role in industry for good production as all machinary are
checked .this maintainace was found to done in every 2 months. This maintainance is also done as per the
instruction given in the user manual.
Breakdown maintainance :
Under this maitainance machine parts are replaced frequently after brakedown.this is the last maintainance
activity done in industry.Breakdown maintainace is not good for industry .
