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BAGADI NIKHIL L. BUCHADE SACHIN G. CHAVAN HRISHIKESH V. DAMLE RAVIRAJ V. PATNAWAR SHREYAS M. 08 TEXT 02 08 TEXT 05 08 TEXT 07 08 TEXT 12 08 TEXT 36
UNDER THE GUIDANCE OF Prof.A.U.Awasare Prof.S.D.Mahajan D.K.T.E SOCIETYS TEXTILE AND ENGINEERING INSTITUTE, ICHALKARANJI 2011 - 2012
INTRODUCTION
Yarn realization Types of waste Economics
= ( PW ) / T . P = Production in Each Process. W= expected waste as per norms. T = total production in Kg.
2) Hard Waste Index (HWI) = (actual hard waste %) / (expected hard waste %) * 100
Reassessment
Soft built
Improper Built
Contaminated bobbins
Wild Yarn
Rubbed yarn
53 52
30 23
39
38
50
54
22
29
53 50
20 20
41
44
50
54
18
19
33.86
0.625
Double gaiting
Slough off
46.56
26.52
0.86
0.49
1 KTTM 34 103 114 111 102 105 111 115 107 105 103 106 100 112 128 92 107.6
2 KTTM 34 97 106 99 94 107 104 102 92 112 108 102 92 107 99 102 101.53
3 KTTM 32 125 117 109 114 99 104 108 110 97 112 119 103 98 106 109 108.67
4 KTTM 34 101 102 108 103 101 104 98 116 101 100 95 107 102 104 110 103.47
5 KTTM 32 108 112 120 108 119 118 112 116 101 118 105 107 106 119 102 111.4
7 KTTM 40 107 91 103 84 102 100 98 104 96 103 84 102 100 98 99 98.07 103
8 KTTM 32 104 108 110 97 112 119 103 101 118 105 107 106 118 112 116 109.07
Grand average ( cm )
1
2 3 4 5 6 7 8 9 10
81
80 84 84 89 95 91 87 77 81
102
93 113 90 96 84 96 84 70 77
95
97 84 89 95 91 87 77 81 78
99
77 79 92 87 87 81 101 84 95
101
101 104 95 98 95 99 80 81 88
75
90 72 77 77 78 84 89 87 107
96
84 96 84 84 96 84 113 90 96
99
98 101 102 93 113 90 96 84 70
90
102 84 95 88 81 88 76 82 94
87
95 91 90 89 85 106 89 94 99
11
12 13 14 15 avg (cm)
78
79 82 72 77 82.47
78
100 101 93 113 92.67
79
97 99 101 92 89.47
78
95 99 81 98 88.87
81
76 83 79 89 82.2
101
101 104 95 79 87.73
84
96 84 79 75 89.4
77
78 100 101 84 88.5 87
90
64 80 77 78 84.6
92
77 87 91 79 90.07
Grand average ( cm )
Breaks At Start 58 49 53 44 85 68
End Pieced
Breaks At End
Total Breaks
145 97 90 88 113 92
37 52 63 34 53 49
Effect Of Type Of Yarn Clearer On Hard Waste COUNT - 32S Ne On LOEPFE clearer
Content Fan waste Bottom waste Total waste ( fan + bottom ) Total ring yarn weight ( doff wt.- 500 bobbins ) Hard waste % Weight ( kg ) 0.251 0.024 0.275 27 ( 0.275 / 27 ) * 100 = 1.01 %
Contd.
49 50 3 2 0 0 0 2 1 3 0 13 12 30 18 12 11 19 22 23
1 2 32 33 1 2
4
5 6
0
1 0
35
17 19
EFFECT OF MACHINE CLEANING ON RING FRAME Idle spindle = 3 % total bobbins tested = 1070
R/F MAKE KTTM LR 6/S End breaks / 100 spl hr On 10th day 9.15 5.98 ON 12TH DAY 10.65 7.28 Defective Bobbin On 10th day 52 36 ON 12TH DAY 68 46
Other
20
25
17
EFFECT OF TRAVELER LIFE ON RING FRAME Idle spindle = 3 % total bobbins tested = 1070
R/F MAKE END BREAKS / 100 spl hr On 10th day KTTM LR 6/S 7.94 6.10 On 12th day 9.34 7.25 DEFECTIVE BOBBIN On 10th day 48 36 On 12th day 70 46
Total cuts
Neps Short thick Long thick Thin Other
88
5 44 13 5 20
104
8 51 15 5 25
44
9 20 2 4 9
58
12 25 4 4 17
MIXING OF WASTE WITH GOOD BOBBINS WHICH LEADS TO CONTAMINATED OR SOILED BOBBIN
BAD WORK PRACTICE - DOING DOUBLE GAITING AT WINDING OF RING BOTTOM WHICH LEADS IN COP REJECTION IN WINDING
ENTANGLEMENT
Loepfe clearer produces more hard waste than UQ2. Mill has proper control on winding process.
built and defective empty bobbins are to be controlled to reduce hard waste. In case of backwind length, NF speed of ring rail & the time at which ring rail comes down at the time of doff should be controlled. Optimized machine cleaning schedule and traveler change schedule should be followed to reduce end breaks at ring frame and winding cuts. Another major reason of hard waste generation i.e. bad work practices, improper material handling, poor house keeping etc. should be avoided.
Process control in weaving By Kimothi & Paliwal (ATIRA) Studies on ring frame to reduce Winding Cuts, Spinning Textiles, June 2010 Yarn waste control in textile mills, by BTRA Impacts of hard waste on profitability of spinning mills By G. Kathirvel Pandian, D. Shanmuganandam (T.I.T.J.,MAY1996) Measures to control hard waste in spinning mill By G.Kathirvel Pandian, D.Shannmuganandam (A.T.J.,1996) Quality requirements of ring cop in modern cone winding (I.T.J.,MAY2008) Process control in weaving By Paliwal How to improve Yarn realization and control wastes? By D.Shanmuganandam Lappage James,End breaks in spinning and weaving of weavable single yarns, textile research journal, June 2005 www.fiber2fashion.com