O

Ravi Shekhar SEM-V, NIFT DELHI Auro Spinning Mills Hall 5

TABLE OF CONTENTS ACKNOWLEDGEMENT 1 VARDHMAN GROUP 2 INTROUCTION 2.1 MANUFACTURING 2.2 PORTFOLIO 2.3 ADMINISTRATION 2.4 QUALITY POLOCY 2.5 PHILOSOPHY 2.6 AURO SPINNING MILLS 3 PRODUCTION DETAILS 3.1 AURO LAYOUT 3.2 RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3 PROCESS FLOW 3.4 BLOWROOM 3.5 CARDING 3.6 DRAWING 3.7 LAP FORMER 3.8 COMBING 3.9 FINISHER DRAW FRAME 3.10 DRAW FRAME 3.11 SPEED FRAME 3.12 RING FRAME 3.13 WINDING 3.14 PACKING 3.15 SPIN CALCULATION & PLANNING PRODUCTION 4 GOAL OF THE PROJECT 4.1 THE PROPOSAL 4.2 AN INTRODUCTION TO NEW SYSTEM 4.3 ASSESMENT OF CURRENT SYSTEM 4.4 SILENT FEATURES OF NEW SYSTEM 4.5 TECHNICAL REQUIREMENT FOR NEW SYSTEM 4.6 DEVELOPERS REQUIREMENT 4.7 DATA FLOW DIAGRAM 4.8 UNIT CONVERSION AND SPIN CALCULATION 4.9 MAINTENANCE : UPDATION & SUPPORT 4.10 SNAP SHOTS 4.11 BIBLIOGRAPHY 5 2 3-6 3 3 5 5 6 6 7-27 7-8 9 10 11 12-15 16-17 18 19 20-21 22 23 24 25 26 27 28-46 28 29 30 31 33 34 35 36 37 44 45 47

ACKNOWLEDGEMENT | This Internship Proved to bridge the gap between the theoretical and Practical Aspects of textile Field. It was a great pleasure to be part of Vardhman Group. All Thanks to my institute NIFT, New Delhi for providing me the opportunity for getting the practical knowledge at such an eminent company. I am also greatly thankful to my subject faculty Dr. Senthil Venkat for the full support and step-by-step assistance. I am also Thankful to my Internship Mentors Dr. Noopur Anand and Ms. Suruchi Mittal. I am very thankful to the whole Vardhman Group for providing me the best possible facilities and good environment during the period of my internship. I acknowledge deep gratitude towards each and every employee of the Auro Spinning Mills, Baddi for providing me with their valuable time. I would also like to express my gratitude towards my mentor Ms Parul (HRD) and Project Guide Mr. Punit Singhal (R&D) for giving me chance to work on such a nice project. I pay my thanks to Mr. Vipin Sachan, Mr. Sunil Mishra and Mr Harpeet Rana (Shift Officer, Unit 5) who gave his valuable time and attention during my training and completion of project report.. Instructions of each person I meet in Auro were very beneficial for the successful completion of my project report. I pay my special thanks to all the other HODs also for their valuable time, co- operation,, guidance and providing useful data, namely Mr Ravindra Yadav (R&D), Mr Devendra Vasist(R&D) and Un-doubly Mr Ravi Ranjan (TPM) for his all source of inspiration all along.

Spin

Weave

Process

VARDHMAN GROUP 2|TWO Vardhman is a leading conglomerate with interests in textiles and steel having a turnover of Rs.2100 crores. The Vardhman group comprises six companies and twenty production units located in Punjab, Himachal Pradesh and Madhya Pradesh. A growth rate of almost 15% per year in turn over the last five years has been reflected in the financial results of the group. MANUFACTURING 2.2|TWO Vardhman group consists of integrated facilities of spinning, weaving and finishing. By and large it has a strong focus on textiles, which remains the largest industry in our country. Over 8, 00,000 spindles 65 tons per day yarn and fiber dyeing 900 shuttle-less looms 90 million meters per annum processed fabric 33 tons per day sewing thread 18000 metric tons per annum acrylic fiber 100,000 tons per annum special and alloy steel Vardhman started its operation in 1965 from Ludhiana with a modest capacity of 14000 spindles. Today 5, 00,000 spindles which is largest any single group has in India. Besides it has weaving capacity of 264 looms and fabric finishing capacity of 95,000 meter per day. In addition it has mercerizing and dyeing of yarn and fiber and an acrylic production unit at Gujarat.

MANUFACTURING UNITS 2.2.2|TWO Vardhman group consists of integrated facilities of spinning, weaving and finishing. By and large it has a strong focus on textiles, which remains the largest industry in our country.
Vardhman Spinning and General Mills Ltd. Vardhman Spinning and General Mills Ltd. Ludhiana Auro Spinning Mills Baddi, H.P. Auro Dyeing Baddi, H.P. Auro Weaving Mills Baddi, H.P. Auro Textiles Baddi, H.P. V.S.G.M. 100% E.O.U. Baddi, H.P. V.S.G.M. Unit 2 Ludhiana V.S.G.M. Unit 3 Ludhiana Mahavir Spinning Mills Ltd. Mahavir Spinning Mills Ltd. Hoshiarpur Arihant Spinning Mills Malarkotla Anant Spinning Mills Vardhman Special Steel Lidhiana, Punjab M.S.M.L. Sewing Threads Unit 2 Ludhiana, Punjab Arist spinning Mills Baddi, H.P. Arist Spinning Mills 100% E.O.U. Baddi, H.P. Vardhman Polytex ltd. Vardhman Ploytex ltd. Bhatinda, Punjab Anshupati Textiles Ludhiana, Punjab V.M.T. Spinning Co. Ltd. Baddi, H.P. Vardhman Acrylic Ltd. Bharuch, Gujrat Vardhman Threads Ltd. Baddi, H.P.

PORTFOLIO 2.3|TWO

Actual 2008-09

Group Total USD Million ( crores) 329 150 73 71 47% 22% 11% 10% % Share

Business Wise TurnOver for Financial Year 2008-2009

Yarn 47%
Yarn Fabric Sewing Thread

1513 689 337 327

Fabric 22% ST 11% Steel 10%

Fiber 8%

Steel

Power plant

66

14

2%

Power Plant 2% Steel Yarn

Fibre

254

55

8%

Fiber ST

PowerPlant Fabric

Total

3186

693

100%

ADMINISTRATTION 2.4|TWO Corporate office located in Chandigarh road in Ludhiana adjacent to Vardhman Spinning and General Mills Ltd.(Ludhiana). It came into being in 1995. Vardhman Group has administrative and marketing branches all over India and in more than 20 countries for its various businesses. The group is well diversified in making sewing threads, fabrics, hand knitting yarns, cotton yarns, acrylic yarns etc. with a capacity of over 5,00,000 spindles and 264 looms producing yarns and fabrics. Shree S.P. Oswal, a gold medalist in M.Com. heads the group who is the chairman and managing director of all group companies.

QUALITY POLICY 2.5|TWO Quality should be built into companys products to not only meet customer requirements continuously but also exceed them. The company shall achieve this through an interface with the market place, access to state of the art technology, R&D process development and adoption of innovative manufacturing and marketing strategies. The quality policy shall be implemented through a network of systems and procedures understood and followed throughout the company. The quality policy shall be integrated with the companys main objectives: 1. To remain market leader in the quality. 2. Increase market share with focus on niche segments. 3. Improved productivity. 4. Cost reduction. 5. Reduction in percentage of seconds. 6. The management shall be committed to provide capital and human resources to achieve the above objectives. A companywide quality culture shall be created through training and motivation of people at all levels of organization.

PHILOSOPHY 2.6|TWO

AURO SPINNING MILLS (77904 SPINDLES)

Auro Spinning Mills Baddi (Himachal Pradesh)

3|THREE
77904

Auro weaving mills, a weaving subsidiary of Vardhman Spinning and General Mills Limited, has now emerged as one of the premium companies in India.

PRODUCTION DETAILS 3.1|THREE

Production Halls Production Units 5

UNIT 1 (HALL1) 3.1.1|THREE

Manufacturing Activity Greige Cotton ( both cared & combed) and core spun with lycra. Unit Capacity Product Range 24,422 spindles Production of yarn per day: 16,000 kg

10s-60s

UNIT 2 (HALL 2) 3.1.2|THREE

Manufacturing Activity Sliver preparatory and sample line Unit Capacity Product Range 1382 spindles Production of sliver per day: 9,000 kg

Lycra, compact, compact+lycra, slub+lycra, slub, Blends

UNIT 3 (HALL 3) 3.1.3|THREE

Manufacturing Activity Unit Capacity Product Range

Cotton and lycra (bulk orders) 38592 spindles Lycra, slub, fancy yarns

UNIT 4 (HALL 4) 3.1.4|THREE

Manufacturing Activity Open- end yarn Unit Capacity Product Range 6s-20s 1248 rotors Production of yarn per day: 12,000 kg

UNIT 5 (HALL 5) 3.1.5|THREE

Manufacturing Activity Unit Capacity Product Range

Compact ( Elite) spun yarn 14256 spindles Production of yarn per day: 4000 kg 40s-200s

AURO LAYOUT 3.2|THREE

RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3|THREE BALE SPECIFICATION 3.3.1|THREE Fiber Net Weight Origin/Supplier Length Width Staple length BALE INSERTION PARAMETER 3.3.2|THREE Origin: Thickness or Fineness (micronaire) Bale weight: 165 or 220 kgs (approximately). Staple length: 30-35mm Degree of Reflection (RD): 60-80Degrees Strength : 24-29 gram/tex Moisture regain Evenness Maturity MACHINE USED FOR TESTING OF FIBER 3.3.3|THREE HVI: High Volume Instrument AFIS: Advance Fiber Information System

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PROCESS FLOW 3.4|THREE

Godown

Mixing (MBO)

Sorting (Manualy)

Carding

Blow Room

Bale Formation

Pre-Combing

Combing

Drawing (F D/F)

Winding

Ring Frame

Speed Frame

Conditioning

Packing

Dispatch

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BLOW ROOM 3.5|THREE INTRODUCTION 3.3.1|THREE Blow-room consists of a number of machines used in succession to open and clean the cotton fiber. About 40% - 70% trash is removed in blow-room section. PROCESS FLOW IN BLOWROOM 3.3.2|THREE pre opening with Blendomat BDT metal or fire detection by SPMF pre cleaning by Maxi-flow mixing or blending by MPM fine opening by CVT PROCESS PARAMETER IN BLOWROOM 3.3.3|THREE The basic purpose of Blow-room is to supply small fiber tufts clean fiber tufts Homogeneously blended tufts if more than one variety of fiber is used, without increasing the fiber rupture, fiber neps, and broken seed particles and without removing more good fibers. PRE-OPENING 3.3.4|THREE Effective preopening results in smaller tuft sizes, thus creating a large surface area for easy and efficient removal of trash particles by the fine openers. Vardhman Textiles uses Trutzschler Blendomat BDT (019) as the preopening machine.

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PRE-OPENING FEATURES 3.3.5|THREE It helps maintaining the homogeneity of the long term blending cotton is opened gently without recycling as it is done in manual bale openers the tuft size can be as small as 50 to 100 grams without rupturing the fibers the opening roller speed is around 1500 to 1800 rpm. the depth of penetration of the opening should be as minimum as possible for better quality If the production per feeding machine is less than 150 kg, then four mixings can be done METEL / FIRE DETECTION 3.3.6|THREE Cotton fiber may catch some metal components while its fiber extraction process which needs to be removed before it goes into any further processing. Cotton fiber also may generate sparks due to friction while passing through connecting ducts. Thus it needs to be blown out. This is done just after the blendomat takes up the fiber from the manually opened bales. Vardhman Textiles uses Trutzschler SPMF for this process. PRECLEANING AND BEATING 3.3.7|THREE Vardhman Textiles uses Trutzschler Maxi flow for this work.

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VARIOUS MACHINE PARAMETERS 3.3.8|THREE The fiber treatment in this machine is very gentle because the fibers are not gripped by the feed roller during beating. Fiber tufts treated by the pin beater when it is carried by air medium all heavy trash particles fall down before it is broken cleaning efficiency of this machine is very high in the blow room line Mostly all heavy seeds( full seeds) fall in this machine without any problem around 50 pascal suction pressure should be maintained in the waste chamber for better cleaning efficiency beater speed, air velocity through the machine, grid bar setting and gap between grid bars will affect the cleaning efficiency higher the cleaning efficiency, higher the good fiber loss, higher the nep generaion and higher the fiber rupture the optimum cleaning means maximum cleaning performance, minimum loss of good fibers, a high degree of fibre preservation and minimum nep generation in general the beater speed is around 750 and minimum 50 pascal suction pressure to be maintained in the suction chamber MIXING OR BLENDING 3.3.9|THREE If different grade of same fibers are kept together, then it is called mixing, whereas, when different fibers of same or different grades are kept together, then it is called blending. Physical properties (fibre length, fineness, strength) of the resultant blend can be predicted, and are reproducible.

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MIXING OR BLENDING: OBJECTIVES 3.3.10|THREE To achieve uniform quality. To improve performance. To reduce and control the production cost. To meet the functional and user requirements. To enhance aesthetic properties i.e. appearance, color, lusters etc. To enhance physical properties i.e. tensile strength, abrasion resistance, stretch etc. Vardhman Textiles uses Trutzschler MPM machine for uniform mixing and blending of fibers. FINE CLEANING 3.3.10|THREE

Vardhman employs Trutzschler CVT1. The cleaning points in CVT1 consist of opening roller, deflector blades, mote knives and suction hood. Trash particles released due to centrifugal forces are separated at the mote knives and continuously taken away by the suction. This gives better cleaning.

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CARDING 3.6|THREE INTRODUCTION 3.6.1|THREE Carding process is considered as heart of spinning. Any defects occurring in this process continue throughout the remaining process of spinning resulting in defective yarn. In this process the cotton fibres pass through in between two sets of wire points moving in opposite direction resulting in the parallelization of fibers. High production in carding to economize the process leads to reduction in yarn quality. Latest machines achieve the production rate of 60 - 200 kgs / hr, which used to be 5 - 10 kgs / hr, up to 1970. MACHINES AVAILABLE 3.6.2|THREE Machine: Trutzschler DK-800 No. of Machines: 10 Delivery Speed: 76 mt/min

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PURPOSE OF CARDING 3.6.3|THREE cleaning or elimination of impurities to open the flocks into individual fibers reduction of neps elimination of dust elimination of short fibers fiber blending fiber orientation or alignment sliver formation TYPES OF FEEDING 3.6.4|THREE Feeding material in the form of scutcher lap Flock feed system (flocks are transported pneumatically) PROPERTIES OF FLOCK FEEDING (TRUTZSCHLER USES) 3.6.5|THREE high performance in carding due to high degree of openness of feed web labor requirement is less due to no lap transportation and lap change in cards flock feeding is the only solution for high production cards linear density of the web fed to the card is not as good as lap installation is not flexible auto leveler is a must, hence investment cost and maintenance cost is more

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DRAWING 3.7|THREE INTRODUCTION 3.7.1|THREE The sliver from the carding section is combined together to form one dense sliver. The process is called as Doubling One for Six (DO/6). It means 6 slivers are taken together to form one sliver which is the input for the formation of laps. MACHINES AVAILABLE 3.7.2|THREE Machine: Lakshmi Reiter No. of Machines: 2 Drafting arrangement: 3 over 3 Type of weighing: Pnuematic Loaded High delivery speed: upto 500 mts/min Production: upto 360 kg MAIN OBJECTIVES 3.7.3|THREE To straighten the fibers and make them parallel To improve uniformity To improve evenness PROCESS PARAMETER 3.7.4|THREE 1. Flexibility: The pneumatically loaded 3-cylinder pressure bar drafting arrangement makes the processing of noils as well as fibres of a staple length upto 75 mm possible Controlled positive sliver feed table for can size of 600 x 1100 mm (24''x42'') 2. Sliver Compression: Sliver compression before coiling increases can content 3. Automatic can change: Increases the efficiency of the machine 4. Cleanliness: Dust extraction improves working condition Doubling 6 for 1.

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LAP FORMER 3.8|THREE

INTRODUCTION 3.8.1|THREE Lap former machines form the lap from the sliver of desired fineness and weight. The D/F slivers are drafted and wound into a lap. 8-12 slivers are fed into drafting arrangement from both sides and these are drafted in drafting system to produce fleeces. These are then drawn into the lap head by the calendar rolls which compresses its strongly to form a lap sheet (batt). This is then wound onto a tube by the lap rolls and lap roller flanges. When tube is full it is automatically changed for an empty one. MACHINES AVAILABLE 3.8.2|THREE Machine: Lakshmi UNIlap (LH-10 & LE4/1a) No. of Machines: 2 Delivery speed: up to 120 mts/min Batt weight: up to 80 gms/mt Time to complete one lap: 2.5 min

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COMBING 3.9|THREE INTRODUCTION 3.9.1|THREE

Combing is the operation in which the short fibers in the cotton are removed so that the final yarn appearance and strength of the yarn is improved. It is optional as per the end-use of the yarn. MACHINES AVAILABLE 3.9.2|THREE

Machine: - Lakshmi REITER E-65 and LK 54 Number of machines: - 6 Capacity: - 3000-5000mtr MACHINES SPECIFICATION 3.9.3|THREE No. of heads No. of Deliveries Drafting arrangement Weighing arrangement Lap Diameter Hank Delivered Delivery speed Production (in kg) ( per shift per machine) Comber E-65 8 1 3 over 3 Pneumatic 250 to 300 N 550 mm (500-650 mm) 0.16 Ne 250 mpm 689.93 Comber LK-54 8 1 3 over 5 Pneumatic 250 to 300 N 540 mm ( 500-650 mm) 0.16 Ne 300 mpm 965.9

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PROCESS & OBJECTIVES 3.9.4|THREE Combing is a process which is meant for upgrading the cotton raw material so that the following yarn properties will improve compared to the normal carded yarn. Tenacity gms/tex Trash in the yarn Lustre Visual appearance Slivers from carding section can go either directly to Finisher Drawing through Breaker Drawing or through Uni Lap/Comber to Finisher Drawing.

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FINISHER DRAW FRAME 3.10|THREE INTRODUCTION 3.10.1|THREE

MACHINES AVAILABLE 3.10.2|THREE Machine: Trutzschler D-40 & TD-03 No. of machines: 3 MACHINES SPECIFICATION 3.10.3|THREE Doubling Drafting arrangement Type of weighing Material Delivery speed Auto can changer Auto-leveller Waste quantity Suction air rate Operation pressure PROCESS & OBJECTIVES 3.10.4|THREE Upto 8 ply 4 over 3 ( with adjustable pressure bar) Pneumatic loaded Combed 300-1000 mt/min Yes Yes Max 0.15 kg/hr 800 m3 per hr 450 Pa

1. Used for weight control to form products of fine quality. 2. To contribute towards doubling and draft of the combed material and to change hooks disposition. 3. To straighten the fibres and to make them parallel. 4. To improve uniformity and eveness(homogenous sliver structure).

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SPEED FRAME 3.11|THREE INTRODUCTION 3.11.1|THREE

MACHINES AVAILABLE 3.11.2|THREE Machine: Lakshmi LFS 1660 Simplex No. of spindles: 120 spindles No. of machines: 4 machines Delivery rate: up to 50 m/min MACHINES SPECIFICATION 3.11.3|THREE Count: 0.7 Ne ( running) Twist per Inch: 1.21 tpi ( running) Production Rate: 21.3 mt/min ( roving) Machine Efficiency: 75.1% Drafting Array Type of weighing Total Draft Hank Fedytg6 Efficiency Production ( in kg) per shift per spindle) Ultima/ MCU5 4 over 4 Pneumatic 10.31 1.8 85% 2.13 J34/ S6 4 over 4 Pneumatic 8.1 1.38 85% 2.75 PROCESS & OBJECTIVES 3.11.4|THREE 1. to draft the draw-frame sliver to make roving 2. to impart necessary twist to the roving 3. to wind the roving on the bobbin for ring frame machine

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RING FRAME 3.12|THREE INTRODUCTION 3.12.1|THREE The roving bobbins of the speed frame are brought to and crewed on ring frame. These machines convert the roving into yarn. These machines further attenuate and draft the roving to the desired thickness of yarn, which is then wound on bobbins. MACHINES AVAILABLE 3.12.2|THREE Machine: LR6 R/frs with ELITE Attachments No. of Machine: 16 ring frame MACHINES SPECIFICATION 3.11.3|THREE Drafting arrangement Type of weighing Spindle speed Max. Speed Tpi (nominal) ELITE Compact 3 over 4 Spring 16300 rpm 17500 rom 13.89 z Elitwist 3 over4 Spring 18362 rpm 21000rpm 33.07 z 590.22 1.38 68.04

Delivery Rate (spindle speed/Tpi) 326.60 Hank Fed Production (in gm ) ( per shift per spindle) 1.8 40.82

PROCESS & OBJECTIVES 3.12.4|THREE 1. To attenuate the roving to get the desired fineness. 2. To insert the required twist to provide sufficient strength. 3. To form a suitable package of required dimension for subsequent processing.

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WINDING 3.13|THREE MACHINES AVAILABLE 3.13.1|THREE Machine: Autoconer- 338 with Uster Quantum clearer 2 No. of Machines : 5 PROCESS & OBJECTIVES 3.13.2|THREE

1. To form a suitable bigger package with continuous length 2. To clear objectionable faults 3. To clear excessively weak spots in the yarn by tensioning 4. High degree of tension is not given as it can lead to loss of elongation of yarn. MACHINES SPECIFICATION 3.13.3|THREE Material Package Wt. Pkg. Length Speed Tension (cN) No. of Drums Pkg. Density Splicing Splice strength 58s 2.01 kg 195200 m 1200 mpm 14 60 0.5 gm/cc Pneumatic 80-85% 60s 1.89 kg 195200 m 1200 mpm 14 60 0.5 gm/cc Pneumatic 80-85% 70-75% 80s 1 kg 135000 m 1000 mpm 9 60 0.5 gm/cc Pneumatic 80-85% 70-75%

Actual Production 70-75%

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CONDITIONING 3.14|THREE OBJECTIVES 3.14.1|THREE 1. Twist setting of the final yarn. 2. To let the material reach required moisture regains value so that the company does not suffer commercial losses. MACHINES SPECIFICATION 3.14.2|THREE

Machine: CONTEXX or Xorella AG Heating medium: Saturated steam Power Consumption: 150kW Working pressure: -1 to 3 bar Starting temperature: 400 C Maximum conditioning time: 12 hrs. Efficiency: 70-75% Hoseiry Time 5 min 25 min Warp 5 min 10 min Perforated Cheese Improved Elongation 5 min 10 min Temp. 55 C 60 C 760 C 800 C 760 C 800 C
0 0

Pressure 88% 88% 80% 80% 80% 80%

Improved Strength

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PACKING 3.15|THREE TYPES 3.15.1|THREE After conditioning, the material is packed according to the customers demand. There are two ways of packing: 1. Carton packing 2. Pallet packing SIZE 3.15.2|THREE Carton Packing 1. Normal Size

Dimension: 655 mm x 460 mm x 515 mm Capacity: 18 cones Headed to other countries

2. Maha-Bali Lot Pallet Packing 1. Normal Size

Dimension: 640 mmx 480 mmx 350 mm Capacity: 24 cones Headed to Japan

Dimension: 1150 mm x 790 mm For 1.89 kg cones: 24 layers x 13 cones

2. Maha-Bali Lot Dimension: 1150 mm x 1150 mm For 2.5 kg cones: 25 layers x 13 cones For 1.89 kg cones: 36 layer x 13 cones

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