CHAPTER III

FUNCTIONAL DEPARTMENT ANANLYSIS

PRODUCTION DEPARTMENT
STRUCTURE OF PRODUCTION DEPARTMENT

PRODUCTION MANAGER

SPINNING MASTER

ASSISTANT ASSISTANT
PRODUCTION MAINTENANCE
MANAGER MANAGER

PROCESS FLOW CHART

SUPERVISOR

Mixing & Blending

WORKERS

Blow Room

Combed Yarn

CARDING

Silver Lap Drawing

Ribbon lap Lap Former

Combing
OPERATIONS
PRODUCTION

The head of the production department is mill manager; the planning and
control of production are done by the mill manager. He gives necessary instruction to spinning
master for doing the desired objectives. He gives necessary instruction to spinning master for
doing the desired objectives; the deputy spinning master also helps the master for his work.
These plans are implemented through the shift supervisor.

STRUCTURE OF PRODUCTION DEPARTMENT

Mill Manager

Spinning Master

Deputy Spinning Master

Shift Supervisor

Skilled Worker
CAPACITY & PRODUCTIVITY OF THE MILL

The production of QCSML started 13-02-1986. But the whole operation

was commenced by the end of the financial year 86-87. In 98-99 the QCSML couldn’t use the
whole plant capacity because of the absenteeism of workers and power failures.

PRODUCTION OF COTTON YARN IN THE MILL

The mill adopts the ‘production to stock’ method. In this method they produce goods according
to demand for the product. According to the demand of the product the production process will
vary. During the working condition the tem is maintained at 34 Degree C, otherwise the yarn will
be broken during the process. The quality controller the quality of goods, during production and
after production.
As per the requirement of QCSML, first of all tenders are invited from suppliers and purchase
order is given to the suppliers. The payment to the suppliers are done, 20% will be made within
30 days, balance within 3 months.

PRODUCTION PROCESS

Mixing

Blow Room

Carding
Draw Frames

Fly Frames

Ring Frame

Winding

Reeling

Doubling

Packing.
MIXING:
In this department cotton are graded according to various fiber properties like length, strength,
fineness, color etc. Properties vary with different varieties of cotton. The working of blending
different cotton together is done in the departments, where the different varieties are taken in
required proportions and arranged on the lattice of the blenders or bale plungers of the blow
room machinery. Sometimes useful wastes are also mixed.

COTTON MIXING
Cotton is a hygroscopic material, hence it easily adapts to the atmospheric air conditions. Air
temperature inside the mixing and blow room area should be more than 25 degree centigrade and
the relative humidity (RH %) should be around 45 to 60 %, because high moisture in the fibre
leads to poor cleaning and dryness in the fibre leads to fibre damages which ultimately reduces
the spin ability of cotton. Cotton is a natural fibre. The following properties vary very much
between bale (between fibres) fibre micronaire fibre length fibre strength fibre color fibre
maturity. Out of these, fibre micronaire, color, maturity and the origin of growth results in dye
absorption variation. Therefore it is a good practice to check the maturity, color and micronaire
of all the bales and to maintain the following to avoid dye pick up variation and barre in the
finished fabric.

BALE MANAGEMENT:

In a particular lotMicronaire range of the cotton bales used should be same for all the mixings of
a lot Micron ire average of the cotton bales used should be same for all the mixings of a lot
Range of color of cotton bales used should be same for all the mixings of a lot Average of color
of cotton bales used should be same for all the mixings of a lot Range of maturity coefficient of
cotton bales used should be same for all mixings of a lot.
Average of maturity coefficient of cotton bales used should be same for all mixings of a lot
Please note, in practice people do not consider maturity coefficient since Micronaire variation
and maturity variation are related to each other for a particular cotton.

If the cotton received is from different ginners, it is better to maintain the percentage of cotton
from different ginners through the lot, even though the type of cotton is same. It is not advisable
to mix the yarn made of out of two different shipments of same cotton.
For example, the first shipment of west-African cotton is in January and the second shipment is
in March, it is not advisable to mix the yarn made out of these two different shipments. If there is
no shade variation after dyeing, then it can be mixed.
According to me, stack mixing is the best way of doing the mixing compared to using automatic
bale openers which picks up the material from 40 to 70 bales depending on the length of the
machine and bale size, provided stack mixing is done perfectly. Improper stack mixing will lead
to BARRE or SHADE VARIATION problem. Stack mixing with Bale opener takes care of short
term blending and two mixers in series takes care of long term blending.

Tuft sizes can be as low as 10 grams and it is the best way of opening the material(nep creation
will be less, care has to be taken to reduce recycling in the inclined lattice)contaminations can be
removed before mixing is made The raw material gets acclimatized to the required temp and
R.H.%, since it is allowed to stay in the room for more than 24 hours and the fiber is opened , the
fibre gets conditioned well.
DISADVANTAGES:
 more labour is required
 more space is required
 mixing may not be 100% homogeneous( can be overcome by installing double
 mixers)

If automatic bale opening machine is used the bales should be arranged as follows let us assume
that there are five different micronaires and five different colors in the mixing, 50 bales are used
in the mixing. 5 to 10 groups should be made by grouping the bales in a mixing so that each
group will have average micronaire and average color as that of the overall mixing. The position
of a bale for micronaire and color should be fixed for the group and it should repeat in the same
order for all the groups
 It is always advisable to use a mixing with very low Micronaire range. Preferably.6 to
1.0. Because it is easy to optimize the process parameters in blow room and cards
drafting faults will be less dyed cloth appearance will be better because of uniform dye
pickup etc
 It is advisable to use single cotton in a mixing, provided the length, strength micronaire,
maturity coefficient and trash content of the cotton will be suitable for producing the
required counts. Automatic bale opener is a must if more than two cottons are used in the
mixing, to avoid BARRE or SHADE VARIATION problem.
 It is better to avoid using the following cottons with inseparable trash (very small size),
even though the trash % is less sticky cotton (with honey dew or sugar)cotton with low
maturity co-efficient
 Stickiness of cotton consists of two major causes. Honeydew from Whiteflies and aphids
and high level of natural plant sugars. The problems with the randomly distributed honey
dew contamination often results in costly production interruptions and requires
immediate action often as severe as discontinuing the use of contaminated cottons. An
effective way to control cotton stickiness in processing is to blend sticky and non-sticky
cotton. Sticky cotton percentage should be less than 25%.

BLOWROOM
Basic operations in the blow room:
 opening
 cleaning
 mixing or blending
 micro dust removal
 uniform feed to the carding machine
 Recycling the waste
Blow room installations consist of a sequence of different machines to carry out the above said
operations. Moreover Since the tuft size of cotton becomes smaller and smaller, the required
intensities of processing necessitates different machine configuration.

TECHNOLOGICAL POINTS IN BLOWROOM

 Opening in blow room means opening into small flocks. Technological operation of
opening means the volume of the flock is increased while the number of fibres remains
constant. i.e., the specific density of the material is reduced.
 The larger the dirt particle , the better they can be removed
 Since almost every blow room machine can shatter particles, as far as possible a lot of
impurities should be eliminated at the start of the process. Opening should be followed
immediately by cleaning, if possible in the same machine.
 The higher the degree of opening, the higher the degree of cleaning. A very high cleaning
effect is almost always purchased at the cost of a high fibre loss. Higher roller speeds
give a better cleaning effect but also more stress on the fibre.
 Cleaning is made more difficult if the impurities of dirty cotton are distributed through a
larger quantity of material by mixing with clean cotton.
 The cleaning efficiency is strongly dependent on the TRASH %. It is also affectedly the
size of the particle and stickiness of cotton. Therefore cleaning efficiency can be different
for different cottons with the same trash %.
 There is a new concept called cleaning resistance. Different cottons have different
cleaning resistance.
 If cotton is opened well in the opening process, cleaning becomes easier because opened
cotton has more surface area, therefore cleaning is more efficient
 If automatic bale opener is used, the tuft size should be as small as possible and the
machine stop time should be reduced to the minimum level possible
 If Manual Bale openers are used, the tuft size fed to the feed lattice should be as small as
possible
 Due to machine harvesting, cotton contains more and more impurities, which furthermore
are shattered by hard ginning. Therefore cleaning is always an important basic operation.
 In cleaning, it is necessary to release the adhesion of the impurities to the fibresand to
give hte particles an opportunity to separate from the stock. The former is achieved
mostly by picking of flocks; the latter is achieved by leading the flocks over a grid.
 Using inclined spiked lattice for opening cotton in the intial stages is always a better way
of opening the cotton with minimum damages. Of course the production is less with such
type of machines. But one should bear in mind that if material is recycled more in the
lattice, nets may increase.
 Traditional methods use more number of machines to open and clean natural fibres.
 Mechanical action on fibres causes some deterioration on yarn quality, particularly in
terms of neps. Moreover it is true that the staple length of cotton can be significantly
shortened.
 Intensive opening in the initial machines like Bale breaker and blending machines means
that shorter overall cleaning lines are adequate.
 In a beating operation, the flocks are subjected to a sudden strong blow. The inertia of the
impurities accelerated to a high speed, is substantially greater than that of the opened
flocks due to the low air resistance of the impurities. The latter are hurled against the grid
and because of their small size, pass between the grid bars into the waste box, while the
flocks continue around the periphery of the rotating beater.
 By using a much shorter machine sequence, fibres with better elastic properties and
improved spin ability can be produced.
 Air streams are often used in the latest machine sequence, to separate fibresfrom trash
particles by buoyancy differences rather than beating the material against a series of grid
bars.
 There are three types of feeding apparatus in the blowroom opening machines two feed
rollers( clamped)feed roller and a feed table a feed roller and pedals
 Two feed roller arrangements gives the best forwarding motion, but unfortunately results
in greatest clamping distance between the cylinders and the beatingelementfeed roller and
pedal arrangement gives secure clamping throughout the width and a small clamping
distance, which is very critical for an opening machine In a feed roller and table
arrangement, the clamping distance can be made very small.
 This gives intensive opening, but clamping over the whole width is poor, because the
roller presses only on the highest points of the web. Thin places in the web can be
dragged out of the web as a clump by the beaters Honeydew (sugar) or stickiness in
cotton affect the process very badly.Beacause of that production and quality is affected.
Particles stick to metal surfaces, and it gets aggravated with heat and pressure. These
deposits change the surface characteristics which directly affects the quality and running
behavior.
 There are chemicals which can be sprayed to split up the sugar drops to achieve better
distribution. But this system should use water solutions which are not recommended due
to various reasons. It is better to control the climate inside the department when sticky
cotton is used.
 Low temperature (around 22 degree celcius) and low humidity (45% RH). This requires
an expensive air conditioning set up.
 The easiest way to process sticky cotton is to mix with good cotton and to process
through two blending machines with 6 and 8 doublings and to install machines which will
segregate heavier particles by buoyancy differences.
 General factors which affect the degree of opening, cleaning and fibre loss are,
 Thickness of the feed web density of the feed webfibre coherencefibre alignment size of
the flocks in the feed (flock size may be same but density is different)the type of opening
device speed of the opening device degree of penetration type of feed (loose or
clamped)distance between feed and opening device
 Type of opening device
 Type of clothing
 Point density of clothing
 Arrangement of pins, needles, teeth
 Speeds of the opening devices
 Throughput speed of material
 Type of grid bars
 Area of the grid surface
 Grid settings
  Airflow through the grid
 Condition of pre-opening
 Quantity of material processed,
 Position of the machine in the machine sequence
 Feeding quantity variation to the beater
 Ambient r.h.%
 ambient temperature

BLOW ROOM:
The main purpose of blow room is opening, closing and cleaning or cotton in this department
the cotton is fed at one end and the output is achieved at a sketcher, which is the last machine in
the sequence of machinery of the blow room in the form of a lap. A lap is a sheet of cotton fleece
rolled around an iron rod inserted in the lap spindle. When the full lap is removed from the full
sketcher, the spindle is pulled out and the lap remains around the iron rod. The lumps of cotton
are gradually broken down to smaller size by the process of trembling, beating action etc. of the
spiked roller, lattice and beaters of the blow room machinery.

BLOW ROOM:
Blow room is one of the most important parts of textile spinning sector. It is consists of a number
of machines which are sued in succession to open and clean the cotton fibre according to the
required amount of degree. In blow room section, normally 40-70% trash is removed.
 Blow room section in spinning
BLOW ROOM SECTION:
It is that kinds of section where the supplied compressed bales are opened, cleaned and mixing or
blending for making uniform lap of definite length. The range of blow room cleaning efficiency
is 60-65%. It should be noted here that, blow room is the first section of spinning line for
producing cotton yarn.

BASIC OPERATION IN BLOW ROOM:

The below operation has don main blow room section of a spinning line:
 Opening,
 Cleaning,
 Mixing or blending,
 Lap forming.
All the above operations have explained in the following:
1. Opening:
Here, the compressed bales of fibres are opened for making the cotton tuft in a small size (as
much as possible).

2. Cleaning:
This operation is used to remove dust, dirt, broken leafs, broken seeds, stalks and other foreign
materials from the fibres.

3. Mixing or blending:
Mixing or blending process has performed for producing higher quality yarn by reducing
production costing which is only possible by mixing different grade of fibres.

4. Lap forming:
 This operation has done due to the below reasons:
 It is done to transfer the opened and cleaned fibres into a sheet form of specific width and
uniform unit length which is termed as lap.
 It is also used to roll the lap of predetermined length into a cylindrical shape around a lap
pin.
 It is also used to transfer the lap from the lap pin int a rod to suitable handle and feed it to
subsequent processing carding machine.
CARDING
The blow room lap, which is still in the form of small tuff in the lapis brought to this
department and fed to the carding machines. These are opened to the stage of single fibre on the
card by means of carding action between pointed wires mounted in the surface of licker in,
cylinder and plates. The opened fibres are collected by the doffer comb in the formals of a web.
This web is then passed through the trumpet to give to the shape of a rope and coiled inside a can
by means of a coiler.

Carding
Carding is one of the most important operations in the spinning process as it directly determines
the final features of the yarn, above all as far as the content of neps and husks are concerned.
There are many objectives of the carding process and these can be summarised as:
 Opening the tufts into individual fibres;
 Eliminating all the impurities contained in the fibre that were not eliminated in the
previous cleaning operations;
 Selecting the fibres on the basis of length, removing the shortest ones;
  Removal of neps;
 Parallelizing and stretching of the fibre;
 Transformation of the lap into a sliver, therefore into a regular mass of untwisted fibre.

The carding operation is carried out by the card, a machine that in practice is a system of rotating
organs, mobile and fixed flats, covered with steel spikes that go by the name of wiring. It is a
good idea to know what the wiring and its functions are before going onto a description of the
card.

Wiring and Clothing

 There are different types of cylinder wiring, in particular:
 rigid wiring, for rotating parts;
 elastic clothing, for mobile flats;
 Clothing for fixed flats.
The most common on the machine are the wiring type. They are made up of a steel wire with
sharp cutting teeth, the saw tooth like edge of the wiring is hardened in order to better resist wear
caused by the abrasive action of the fibers. The base of the wiring is thicker than the toothed
parts, both to guarantee support to keep the teeth in a vertical position, as well as to prevent
lateral contact between the teeth and to permit the necessary momentary penetration of fibre into
the wiring.

The sizes of the teeth vary notably and depend on how compact the material is, on the quantity
and on the fineness of the fibre. The parameters which permit one type of wiring to be
distinguished from another are:
Concentration, meaning the number of teeth in a square inch of the wiring (for the various
devices of the card the concentration is different and is strictly linked to the type of fibre used;
for fine fibre, for example, wiring with a high concentration is used);

The height of the teeth, which can vary according to the wired element;
 The angle between the teeth and the base in a longitudinal sense.
 It is a known fact that a wired element moves in:
  a positive way when it moves in the same direction as the inclination of the teeth;
 a negative way when it moves in the opposite direction to the inclination of the teeth
 The fibrous material is found between the two wired elements which, by moving, act on
the fibre in an alternate manner: first they trap it then they remove it. Depending on the
layout of the teeth, the direction travelled and the speed of the devices, two conditions are
possible, called:
 Carding position which is obtained when the teeth of the wired elements are inclined in
an opposite direction and their movement occurs with a certain speed and in a direction
that permits reciprocal grasp of the fibre and then the disentangling of the neps and
elimination of trash and dust.
 Position of cleaning or brushing, which is obtained, on the other hand, when the devices
have converging teeth and their movement occurs with such a speed and in such a
direction to permit the passing of fibre from one organ to another.

DRAW FRAMES:

The card silver lacks on regulating the fibres and the fibres are also in a crisis condition. In
order to spin and even and regular yarn the silver for better control of the fibres during drafting
in succeeding process and also for obtaining better strength of yarn spinning. The evenness of
silver and parallelization of fibre is achieved at the draw frame when 6-8 more silver are again
fed to another draw frame. The finished draw frames are transferred to fly frame.
DRAW FRAME
Drawing is the operation by which slivers are blended, doubled and leveled. In spinning the term
is only applied to the process at a draw frame. In drawing slivers are elongated when passing
through a group of pair rollers, each pair is moving faster than previous one. This permits
combing, drawing and elongating of several slivers to make them strong and uniform.In most
modern worsted drawing sets there are 3 passages of pin drafting and roving process.

OBJECTS OF DRAWING

 To straighten the crimped, curled and hooked fibers.

 To make the fiber parallel to their neighbors.
 To improve uniformity of fibers by drafting and doubling.
 To reduce weight per length unit of sliver.
 To remove dust from slivers.
 To blend raw material of same hank perfectly.
IMPORTANCE OR NECESSITY OF DRAW FRAME IN YARN PRODUCTION
 To parallelization of fiber and blending the carded sliver, draw frame is needed.
 In carded sliver, fibers are present in hook form i.e. trailing hooks and leading hooks. To
parallel these hooks raw frame is used.
  Majority of the fiber hooks in a carded sliver are trailing hooks while leading hooks are
comparatively less.
 Trailing hooks are also known as major hooks, while leading hooks are known as minor
hooks.
 What should do for better performance of drawframe:
 Always keep a watch on humidity and temperature as it affects the working.
 Keep a watch on stop motions and ensure that no singles or doubles are fed to drafting.
Ensure machine stopping before a broken sliver entering drafting zone.
 Verify the trumpets size as per the hank, and ensure in good condition.
 Keep a watch on the surface of the top rollers and pressure on top roller

FLY FRAMES:

The silver from draw frame is fed to fly frames. The silver is drafted and reduced
in diameter and slightly twisted and wound on the bobbin by means of the flyer.
SPEED FRAME:
Simplex is an intermediate process in which fibers are converted into low twist lea called roving.
The sliver which is taken from draw frame is thicker so it is not suitable for manufacturing of
yarn. Its purpose is to prepare input package for next process. This package is to prepare on a
small compact package called bobbins. Roving machine is complicated, liable to fault, causes
defect adds to the production costs and deliver the product. In this winding operation that makes
us roving frame complex. There are two main basic reasons for using roving frame.
 Speed frame
 Necessity of Speed Frame:
 The first reason is related to the required draft. Sliver is a thick, untwisted strand that
tends to be hairy and to create fly. The draft needed to convert this to a yarn is in the
region of 300-500.
 Thedrafting arrangements of ring spinning machines, in their current forms, are not
capable of processing this strand in a single drafting operation to create a yarn of short-
staple fibers that meets all the normal demands on such yarns.
 The fine , twisted roving is significantly better suited to this purpose.
 The second reason is that draw frame cans represent the worst conceivable mode of
transport and presentation of feed material to the ring spinning frame.
OBJECTS/ FUNCTIONS OF SPEED FRAME
 Attenuation of drawn sliver to form roving of required count by drafting.
 Insert small amount of twist to give required strength of roving.
 Wind the twisted roving on to the bobbin.
 Build the roving in bobbin such a form which will facilitate handling, withdrawing &
transfer to the next process.
OPERATIONS INVOLVED IN SIMPLEX MACHINE:
 Cree ling
 Drafting
 Twisting
 Winding
 Building
 Doffing
CREELING:
To feed the sliver by the help of several rows of driver rollers to the machine.
 Creel draft
 Creel Stop motion
 Block creeling
DRAFTING:
To reduce the wt/unit length of sliver to make it suitable for ring spinning system.

TWISTING:
To insert small amount of twist to give required strength of roving.

WINDING :
To win the twisted roving on to bobbin

BUILDING:
To build the roving in bobbin such a form which will facilitate handling, withdrawing & transfer
to the next process.
DOFFING:
To replace an empty bobbin at the place of full roving bobbin.
 RING FRAME:
The roving wound on the bobbins at the fly frame is fed to the ring frame creel. The
bobbin is drafted to the fineness to the required and is twisted as it is delivered from the nip of
the front roller pairs. It is wound on the bobbin or spindle through the traveler which rotates
along the flange of the ring. The difference in the speed of the spindle and the traveler results in
the winding of the yarn in the bobbins.
INTRODUCTION
The ring spinning machine was invented in the year 1828 by the American Thorp. In 1830, another Amer
contributed the traveller rotating on the ring. In more than 150 years that have passed since that time, the m
experienced considerable modification in detail, but the basic concept has remained unchanged. Fig. 1 shows a t
frame.

Fig.1 : Typical view of a Ring Frame

The long central section of the machine, on which production is actually carried out, consists primarily of lo
members in the form of spindle rails and drafting rollers extending over the complete machine length.
These longitudinal members are secured to intermediate sections arranged at short intervals along the machine l
sections also serve as supports for the creel .
The ring spinning machine has been the most widely used form of spinning and it will continue for some more tim
it has unique advantage over new spinning technologies:

 It is universally applicable, most of the textile fibres can be spun to required fineness.
 The yarn spun from this machine demonstrate excellent quality features like uniform structure a
strength.
 It is easy to operate as compared to other spinning machines.
 The “know-how” for operation of the machine is well established.
 It is flexible as regard to quantities in terms of blend and lot sizes.

For these reasons, new spinning processes (with the exception of rotor spinning) have difficulty in gaining w
acceptance.
Disadvantages associated with ring spinning are:

 More process stages. Roving stage exists as an extra process compared to the other systems.
 Yarn breakages are more frequent as a result of ring traveller friction and yarn to air drag forces. Interr
broken ends and piecing up problems exist because of the yarn breakages.
 The high speed of the traveller damages the fibers.
 The capacity of the cops is limited.
 Energy cost is very high.
 Low production rate.

In long term, the ring frame can survive in longer term only if further success is achieved in automation of the rin
process. Also, spinning costs must be markedly reduced since this machine carries significant cost factor in spinni
Operation of the Ring frame
Task of the ring spinning

  Attenuate the roving until the required fineness is achieved

  To impart strength to fiber strand by twisting it
  To wind up the resulting yarn in a form suitable for storage, transportation and further processing

Principles of operation
Fig. 2 shows the operating parts of the ring frame and the principle of operation is explained below:

Fig.2 : Operating Parts of Ring Frame

 The roving bobbins (1) are creeled (A) in appropriate holders (3). Guide rails (4) lead the rovings (2)

drafting arrangement (5) which attenuates them to the final required count.
  The drafting arrangement (B) is inclined at an angle of about 45 – 600. It is one of the most im

assemblies on the machine since it has considerable influence on irregularities present in the yarn.
 After the drafting arrangement, the machine have twisting and winding zone (C).
 Upon leaving the front rollers, the emerging fine fiber strand (6) receives the twist needed to give it s
 This twist is generated by the spindle, which rotates at high speed. Each revolution of the spindle imp
turn of twist to the fiber strand. Spinning of the yarn is thus complete.
 In order to wind up the twisted yarn to bobbin mounted on Spindle( 8) , a traveller (9) is required to co

with the spindle. The traveller moves on guide provided on the ring (10) encircling the spindle.
 The traveller has no direct drive; instead, it is carried along by the yarn it is threaded with. The spee

traveller is lower than that of the spindle owing to significant friction generated between the traveller and
 This difference in speed enables winding of the yarn to bobbin.
 Winding of the yarn on to the bobbin is done by raising and lowering the ring rail. The traverse strok
 ring rail is less than that of the bobbin height. The ring rail must therefore be raised by small amount af
layer of coils.

Cross-section of the machine

Fig. 3 shows the cross-section of a typical ring spinning machine. The ring frames are two sided machines with th
positions located on both sides of the machine. Each spindle is a spinning position. The spindle rail houses the sp
creel housing the feed roving bobbins are arranged in two rows on each side of the machine. The drafting arra
carried on the roller beams. Each intermediate section stands on two feet adjustable in height by means of screw
permitting easy leveling of the machine.
Fig.3 : Cross-section through the machine

In modern machines, an auto-doffer is also provided. Including the auto-doffer, the width of the machine varies f
1000 mm (up to 1400 mm when the doffer arm is swung out). Today, the machine length can reach 50 m. Spin
usually lie between 70 and 90 mm.

Sources :
WINDING:

The yarn spin at the ring frame and double yarn from doubling frame is wound on the
bobbin; this is a very small package. The cheese produced at the winding machine is either fed to
double when yarn is to be doubled or sent to the packing department. The main function of
winding machine is changing the yarn useful to power looms.

Winding is the process of transferring yarn or thread from one type of package to another to
facilitate subsequent processing. The re-handling of yarn is an integral part of the fiber and
textile industries. Not only must the package and the yarn itself be suitable for processing on the
next machine in the production process, but also other factors such as packing cases, pressure
due to winding tension, etc., must be considered. Basically, there are two types of winding
machines: precision winders and drum winders. Precision widers, used primarily for filament
yarn, have a traverse driven by acam that is synchronized with the spindle and produce packages
with a diamond-patterned wind. Drum winders are used principally for spun yarns; the package
is driven by frictional contact between the surface of the package and the drum.
 Yarn Winding Package
Types of Winding:
 Precision Winding
 Non Precision Winding

PRECISION WINDING

By precision winding successive coils of yarn are laid close together in a parallel or near parallel
manner. By this process it is possible to produce very dense package with maximum amount of
yarn stored in a given volume.

FEATURES OF PRECISION WINDING

 Package are wound with a reciprocating traverse

 Patterning and rubbing causes damage of packages
  Package contains more yarn
 Package is less stable
 The package is hard and compact
 The package is dense
 Rate of unwinding of package is low and the process of unwinding is hard
 The unwound coil is arranged in a parallel or near parallel manner
NON PRECISION WINDING
By this type of winding package is formed by a single thread which is laid on the package at
appreciable helix angle so that the layers cross one another and give stability to the package. The
packages formed by this type of winding are less dense but is more stable.

FEATURES OF NON PRECISION WINDING

 Only one coil is used to make this packages

 Cross winding technique is used
 The package density is low
 Minimum number of yarn is wound
 The package formed is soft and less compact
 The stability is high
 Flanges are not required
 The rate of unwinding is high and the process is easy
 The packages formed have low density

REELING :
The yarn is to be supplied to in the form of hanks. The bank yarn is produced in the reeling
machine. The hanks are wound from bobbins.
 Reeling
 Reeling or making of hanks
 Watch video here
  The Reeling is a procedure which converts yarn into commerically portable form. The
outcome of reeling is called hanks or skeins. It is normally done after twisting/Winding to
wrap yarn carefully for processing in hank form and unwinding it later. The reeled yarn is
carefully tie-banded to control fibres during handling, scouring, Dyeing and unwinding.

These machines are used to convert the yarn in hank form .The hanks produced as per the quality
of yarn ,further processing facility such as dyeing, drying ,hank to cone winding etc.
Mail characteristics of hanks are
o Hank diameter
 Hank weight
 Hank traverse
 Crossing angle such as diamond.
 Formation of hank such as rectangular ,trapezoidal, cop built or lea hanks.

MAIN FEATURES OF A REELING MACHINE

1.SWIFT AND ITS CIRCUMFERENCE SETTING
 Hanks of various sizes such as weight ,circumference, width and make up are used
depending upon the substrate quality (cotton, viscose, silk, wool, acrylic etc ), physical
and aesthetic features of the yarn, end use ,further processing machinery set up such as
mercerizing, dyeing ,hydro extraction , drying and hank to cone winding. Generally 54
“(1370 mm) to 90 “(2286 mm) circumference hanks are used
  In most of the cases the swift of the machine is adjustable to accommodate the different
circumferences or swift sets are available for particular ranges such as in crune luke
machines 3 different sets are available
 swift circumferences:
1. Size 1 1.350 – 1.524 mm
2. Size 2 1.500 – 1.905 mm

• Size 3 1.800 – 2.337 mm

2.Yarn guide system

The yarn laying system has thread guides which are controlled electronically for changing the
hank features , type of hanks and to select different crossing angles.
3.Hank doffing system
The doffing could be manual or automatic after the completion of hanks.

4. Hank parameter setting or type of hank

Different types of hank formation or lay out can be made depending upon the type of yarn and
further processing machinery such as,
 rectangular
 trapezoidal
 cop-built

lea-hanks
A trapezoidal or tapered end hank
5. Hank positions
It is the number of hanks which can be made on the full machine ,with a particular set of
parameters. The hank positions are less when the hank width or traverse is more.
6.Leasing system

Leasing is tying the hanks at various places(1-6) with stronger threads or yarns by inserting the
thread throughout the traverse at selected points. Generally leasing in the hanks is done manually
to keep them intact in the further processing such as mercerizing, dyeing, hydro extraction,
drying and to facilitate efficient and trouble free hank to cone winding. There are different
systems for leasing as shown below double eight one and a half eight single eight

in crune luke machine automatic leasing system CLT is available.

7.Length measuring system
Modern reeling machines are equipped with length measuring devices to keep the yarn length
constant from one hank to another, to get a uniform hank weight for better results in further
processing such as dyeing and to make uniform size packages in hank to cone winding.
8.Hank width setting or traverse
The traverse or width of hanks is important for a particular hank weight to get uniform results in
further processing; generally a range from 80 mm to 380 mm is available from the different
manufacturers.
9. Yarn tension control system
The yarn tension from the feed package is regulated to get the uniform reeling results and precise
winding in all the hanks. Modern reeling machines are equipped with automatic yarn tension
control system
10. Reeling speed and maximum obtainable hank weight.
The reeling speed depends upon the number of factors such as type of yarn and required hank
weight and circumference. The machines are available with a maximum winding speed up to
1500 m/min. Hank weight is also decided by the set up of further processing machinery as well
as the type of yarn processed . The maximum hank weight as per the different manufacturers is
up to 2.5 kg . For mercerized cotton yarn a weight of 1-1.5 kg is generally adopted.
11. Crossing angle and diamond

It is distinct characteristic of hank for uniform dyeing and efficient hank to cone operations. It
could be selected in a step less manner or diamond formation as shown below from 1:1 to 1:6.
12. Splicing and yarn clearing system
To avoid the manual knotting in case of yarn breakage and yarn faults to be carried forward in
further processing.
DOUBLING:

In the doubling process two single yarns are twisted together to give a Double yarn.
This increase the strength of the yarn. If two single yarn of 10s count are doubled,
Resulted yarn will be 2/10s count.

PACKING :

The yarn is sold in hank form or as cones. Hanks are packed as bundles. One bundle
contains 4.5Kg of 20 or more hanks. Cones are packed in bags. One bag contains 40 cones of
which one cone weight 1.25Kg. During the time of production and after the production, the
quality is checked by the quality controller
Grading of the product

In QCSML grade of the cotton are measured in count and they are as follows. 20’s,40’s,
50’s, 60’s, 80’s 120 count is the best count but in this mill 40 count is used. This mill produces
mainly 2 types of cotton yarn namely, Cons and Hanks. Now a day it also produces polyester
yarn. The working condition is always maintained at 34degree C tem else the yarn will be broken
during the procedure

WASTE
The production process creator 2 types of waste. They are usable, and saleable .usable wastes are
again sending to the production process of mixing and blowing. Saleable wastes are sold and
scrap value is obtained.

SOURCE OF PURCHASE

The purchase is made from the cotton producing federators. But now the mill
management is going for private suppliers and individual agents. Because their suppliers found
to be high cost, low quality etc.
SUPPLIERS OF RAW MATERIAL

 Private parties.
 Vijay Lekshmi Enterprises- Kundara
 Sreenivas- Kundara
 L. Davarajan and co-Coimbatore.
 Arakal cotton co-Thrichur
 Chaithanya cotton concern- Kundara
 P.K. Sumbramanyam- Coimbatore

QUALITY CONTROLL DEPARTMENT

This department refers to the systematic control of various factors that

affect the quality of the end product. The quality of the end products depends on the quality of
the raw materials used, manufacturing equipments the degree of skill and proficiency of the
workers etc. During the time of production and after the production the quality controller
checked the quality of the product. It will help to eliminate the weaving mistakes. Now a days
the mill started computer testing labs for checking the quality of yarn at each machine. Then they
can produce good quality products.

In every organization production department is concerned with the activities related to the
production process carried on by the organization. Production process includes the process of
converting raw materials &other inputs in to usable out puts. i.e., as final finished product which
in return produces profit for the organization? .
FUNCTIONS INVOLVED
 Fixation of the standard upon which yarn must be produced, ie. It is usually represented
as Hank.
 Operation of purchase and storage of materials.
 Planning and controlling the operations.
 Inventory and qualitative control.