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SILK WINDING PROCESS AND WINDING MACHINES.pptx

The silk winding process involves unwinding silk cocoons and reeling the silk filament onto spools or bobbins, with crucial steps including cocoon selection, softening, and unwinding. The process ensures that imperfections are removed while maintaining consistent tension and quality through various controls and monitoring. Key aspects of machinery maintenance and operational procedures are also discussed to optimize the winding efficiency and minimize waste.

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SILK WINDING PROCESS AND WINDING MACHINES SE R 311 R A W SIL K T EC H NOL OGY ( 2+ 1) COURSE TEACHER Dr.A.Thangamalar Teaching assistant (Sericulture) Presented by Sridharan S 2021009024
2 SILK WINDING The silk winding process refers to the procedure of unwinding silk cocoons and reeling the silk filament onto spools or bobbins. The main functions of winding process are ▪ To put the yarn in a long continuous length to suit later processes and also to eliminate imperfections such as slubs, weak places, dirt and so on. ▪ Hard gum spots, loose ends and knots are removed in the winding operation.
3 PROCESS 1. Cocoon Selection 2. Softening the Cocoons 3. Locating the End of the Filament 4. Unwinding the Silk 5. Guiding the Filament 6. Winding onto Spools or Bobbins 7. Monitoring and Control
4 COCOON SELECTION • Cocoon Selection: High-quality silk cocoons are carefully selected for the winding process.
5 SOFTENING THE COCOONS • The selected cocoons are softened to facilitate the unwinding of silk filament. This can be achieved by either steaming the cocoons or soaking them in hot water. Softening helps to loosen the sericin.
6 LOCATING THE ENDS OF THE FILAMENT • Once softened, the end of the silk filament is located within the cocoon. This end is then carefully attached to a reel or spindle to initiate the unwinding process.
7 UNWINDING THE SILK • The softened cocoons are placed in a basin or container filled with warm water. As the cocoons rotate, the silk filament unwinds from the cocoon. The unwinding process requires skill and precision to ensure the filament remains intact and doesn't break.
8 GUIDING THE FILAMENT • To ensure smooth unwinding, the silk filament is guided using various mechanisms. This may involve passing the filament through guides or tensioning devices to maintain consistent tension throughout the winding process.
9 WINDING ONTO SPOOLS/BOBBINS • As the silk filament unwinds from the cocoons, it's wound onto spools or bobbins. These spools or bobbins can vary in size depending on the specific requirements of the silk yarn being produced.
10 MONITORING AND CONTROL • Throughout the winding process, parameters such as tension, speed, and temperature are monitored and controlled to optimize filament quality and winding efficiency. Modern silk winding machines often incorporate sensors and automated controls to ensure consistent and high-quality winding.
11 Three zones of winding • 1. Unwinding zone-In this zone silk gets unwounded from hank. • 2. Tension zone-In this zone proper thread tension is maintained for respective type of silk thread. • 3. Winding zone-in this zone silk gets wounded on bobbin. ZONES OF WINDING
12 WINDING MACHINE AND ITS PARTS
13 PARTS OF WINDING MACHINE • Swift/Creel: This is where the silk hank is mounted. The swift is weighted to maintain tension on the silk thread during winding. • Stop Motion Device: This device is crucial for stopping the winding process in case of any irregularities or breaks in the thread. • Thread Guider: Guides the silk thread onto the bobbin evenly, ensuring uniform winding. • Bobbin: The double-flanged bobbin is where the silk thread is wound. It's important for maintaining tension and facilitating even winding. • Feed/Supply Package: This is where the raw silk is fed into the winding machine for the winding process. • Delivery Package: Once the bobbin is full, the wound silk thread is collected here
14 WINDING SPEEDS BASED ON DENIER 12 d & below 110 meters/min 13-18 d 140 meters/min 19 d & above 165 meters/min
15 • HANDLING OF SKEINS • Ensure that the skeins are fully dried and conditioned before winding. Semi dried skeins may result in stretching of silk yarn and tension variations In unwinding during the process that follows. • After mounting, spread the skeins to ensure that the diamond shapes are visisble, cut the lacing thread and pick the true end. Don’t mount the skeins haphazardly, since it becomes difficult to get the true end leading to increased breakage. MAINTENANCE OF SWIFTS Use uniform dead weights for all the swifts to avoid variation in winding tension between the swifts leading to variation in bobbin build and compactness. Maintain the swifts in good condition for smooth rotation. Don’t let the swifts wobble as it creates ridgy bobbins which in turn leads to tension variation during doubling Adjust the circumference of the swift to facilitate tight mounting of hanks.
16 PROPER USE OF BOBBINS • Maintain uniform silk content on the bobbins. Use of varying yarn contents on the bobbin leads to more wastage. • Locate the proper end on the bobbin for knotting in the event of end break. Do not knot onto the wrong end. • Stroke gently on the bobbin surface with middle, ring and little fingers while locating the end and pick the right end by index finger and thumb. • Ensure smooth running of the bobbins without jerks by periodical checks. Otherwise it may lead to ridgy buildup causing variation in unwinding tension. MACHINERY MAINTENANCE Inspect the thread guides for any scratches and replace defective ones. Thread guides with scratches and burns lead to hairiness and end breaks. Wipe the machine to prevent settling of dust .
17 OPERATIONAL ASPECTS • Ensure the correct span of yarn traverse. Any variation in bobbin length may cause jerks in the traverse, leading to improper bobbin build. • Cut the tail end after knotting as close as possible preferably not exceeding 2 mm in length. It is advisable to use CSTRI tail end cutter. Do not leave the tail ends longer than 2 mm. Longer tail ends lead to entanglement during weaving. • Try to make doff time more uniform by having lower initial speed. Winding at very high speed causes more breaks. • Waste generated shall be collected in small cotton bags tied to the waist of the winding operator. • Avoid littering of waste on the floor.
18 REFERENCES SE R I B US IN ES S MA NUA L – A U SE R ’S G U ID E IN E NG L ISH
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