srsl2014 150428214953 Conversion Gate02

Bangladesh University of Textiles
Report on
Industrial Attachment
at
SINHA ROTOR SPINNING LIMITED
SUPERVISING TEACHER
Mr. Reajul Islam

Lecturer, department of yarn manufacturing
Bangladesh University of Textiles
Submitted by
Shahadat Hossain, ID: 20101043
K. M. Mamunur Rashid, ID: 20101059
Sadikur Rahman Shawpon, ID: 20101060
Ashfaqur Rahman, ID: 20101063
Session: 2012-13
Department of Yarn Manufacturing
1
Acknowledgement
We are very fortunate that we were well supported and co-operated at all points in our industrial
attachment training in Sinha Rotor Spinning Ltd. it is high time we expressed our gratitude to all who
are related to our training session. First of all, we express our heartiest gratitude to our revered Head
of the Department, Professor Dr. Hosne Ara Begum, Department of Yarn
Manufacturing for arranging the mill training with convenience. We also express our heartfelt
thanks to our supervising teacher, Lecturer, Mr. Reajul Islam, Department of Yarn
Manufacturing. We also are very fortunate to have completed our attachment under training
supervisors engineer Mr. Mainul and Mr. Saif. Their thoughtful advices, guidance and untiring efforts
made it possible for us to execute the training activities effectively.
Dr. Aftabuddin Hossain Chowdhury, executive director of the Sinha rotor spinning ltd who
allowed us the opportunity to do the training is remembered with honour. Special thanks goes to Mr.
Imrul Kayes, (DGM of production) and supervising officer of our training session for arranging the
training session with a systematic schedule and provide us all sorts of help.
Finally we place our sincere acknowledgement to all the officers, staffs and technicians for their cordial
behavior and helpful support to gather the necessary information during the training period.
2
Introduction
Practical knowledge is very much essential for the education of textile engineering and technology. It
makes us capable and perfect to apply theoretical knowledge to the practical life.
That is why the B.Sc. in textile engineering course is extruded over four years followed by two months
long industrial attachment in textile mills. This training provides sufficient practical knowledge on
production, maintenance, mill management, working atmosphere, worker management, quality and
production planning, utility services and machine operations.
Industrial attachment is an important part of study in technical education. This training system is
attached to our study curriculum to achieve adequate practical knowledge and develop the adaptation
power with the industrial environment.
We preferred our attachment in Sinha Rotor Spinning Ltd. a concer4n of Sinha Textile Group which
is one of the best and modern cotton spinning mills in Bangladesh.
We have taken training for two months from 04-10-2009 to 05-11-2009. During this period, we
acquired knowledge on production, quality control, operation and maintenance of various machines,
A/C plants, chiller, boiler and compressor etc. we also gather some knowledge on purchase of raw
materials and marketing of finished products. We tried the best to learn more about this mill which
will be very helpful in future.
3
TABLE OF CONTENTS
CHAPTER TOPICS PAGE NO

NO
1 Project description 05-09
2 Manpower management 10-18
3 Machine description 19-57
4 Raw materials 58-61
5 Production planning, 62-67
sequences & operations
6 Quality assurance system 68-74
7 Maintenance 75-89
8 Utility services 90-102
9 Store & inventory control 103-105
10 Cost analysis 106-108
11 Marketing activities 109-111
12 Conclusions 112-113
4
CHAPTER I
PROJECT DESCRIPTION
5
PROJECT PROFILE
At a glance
01. Name of the Mill : SINHA ROTOR SPINNING LIMITED

(A Concern of Sinha Textile Group)
02. Project owner : Md. Anisur Rahman Sinha
03. Contact address : House # 368, Road # 28, New DOHS,
Mohakhali, Dhaka, Bangladesh
04. Project location : Sinha Textile Group Complex, Post: Kanchpur,
P S: Sonargaon, Dist: Narayanganj, Bangladesh
05. Final product : Cotton Yarn
06. Spinning system : Ring Spinning & Rotor (OE) Spinning
07. Installed machine capacity : 28,224 Ring Spindles & 960 Rotor Heads
08. Factory floor area : 134,140 sq ft
09. Production start : On February 01, 2001
10. Plan production capacity : 6,228 Metric Ton/ Year
11. Raw Material : 7,474 Metric Ton/ Year
12. Nos. of employment : 820
13. Project cost : BDT 1300.6 million
14. Annual Turnover : BDT 1200 million
15. Average Earning per Year : BDT 150 million
16. Returned on Investment : 11.53%
17. Water Requirement : 30m3/hr
18. Electrical Connected load : 5450 KW
19. Generator : 06 Nos. (Capacity: 1006 KW each)
20. Generator Sub station : 01 set (Capacity: 8000 KVA)
21. Boiler : 01 No. (Capacity: 3.5 Ton/hr)
22. Humidification plant : 05 Nos.
23. Chiller : 03 sets (Capacity: 580 TR, 300 TR, 130 TR)
6
Location of Sinha Textile & Opex Group
7
SINHA SPINNING LIMITED
01. Name of the Mill : SINHA SPINNING LIMITED
(A Concern of Sinha Textile Group)
02. Project Location : Sinha Textile Group Complex, Post: Kanchpur,
P S: Sonargaon, Dist: Narayanganj, Bangladesh
03. Type of Mill : Cotton Spinning Mill
04. Production Start : September 03, 2006
05. Spinning System : Rotor Spinning
06. Capacity : 1688 rotor heads
07. Total Space Area : 31475 sq ft
08. Production per Day : 20 metric ton
09. Production Capacity achievement : 90%
10. Contact Address : House # 368, Road # 28, New DOHS,
Mohakhali, Dhaka, Bangladesh
Aim of the Project:
Production of export quality yarn

Providing employment to the local people
Earning foreign exchange for our country
Providing the local people with the second basic need of quality commodity (yarn), locally
produced at a lower cost.
Production Mix:
Ring Yarn: Combed yarn, Carded yarn, Special yarn. I.e. Compact, Slub and Core.
Rotor Yarn: Normal yarn and Special yarn i.e. Slub and Core.
Production Capacity (SRSL)
Section Total Spindle Count Range Production Capacity

(Tons/day)
Ring yarn 28224 Ne 10 to 50 12.5
Rotor yarn 960 Ne 06 to 20 08
Production Capacity (SSL)
Section Total spindle Count range Production capacity

(Tons/day)
Rotor yarn 1688 Ne 06 to 25 13
8
Different Departments:
1. Production Department
2. Administration and Labor
3. Store
4. Quality Assurance Department
5. Security
6. Utility Department
7. Maintenance Department
8. Accounts
9. Procurement
10. Marketing
Physical Infrastructure:
Sinha Rotor Spinning Limited and Sinha Spinning Limited are organized into three major parts: Factory,
sales & procurement (S&P) department, Finance department and Account department. Among these
three, the Factory consists of five departments namely production, Maintenance, Quality Assurance,
Administration and Information Technology.
9
CHAPTER II
MANPOWER MANAGEMENT
10
Organogram
Man power setup (SRSL)
Name of department Setup

Total worker for production 555
Total worker for utility 47
Total worker for maintenance 61
Grand total 663
11
Officers and stuff:
Name of department Setup

Total officer (with ed +aso) 77
Total staff (with 22 security personnel) 80
Grand total 157
GRAND TOTAL STAFF AND OFFICERS: 820
Workers rights and privileges:
1. Wages statement for workers:

Grade Salaries House rents Treatment Travel fares Total
01 4200 1470 200 100 5970
02 3500 1215 200 100 5025
03 2800 980 200 100 4080
04 2400 840 200 100 3540
05 2100 735 200 100 3135
06 1800 630 200 100 2730
07 1600 560 200 100 2460
08 1400 490 200 100 2190
09 1300 455 200 100 2055
10 1150 402 200 100 1852
2. Total salaries:
Basic salaries + house rent + treatment allowance + travel allowance = total salary
3. Over time per hour = ( Basic salary * 2 ) / ( 26 days * 08 hours )
4. Salaries and wages should be paid within the first seven days of the next month.
5. Working schedule:
a. General shift : 09 am to 06 pm
b. A shift : 07 am to 03 pm
c. B shift : 03 pm to 11 pm
d. C shift : 11 pm to 07 am
e. Working hour : 08 hours per day, 48 hours per week
f. Over time : 02 hours per day, 12 hours per week
g. Weekly holiday : Friday or any other day in a week
6. Specified leaves:
a. Occasional leave : 11 days
b. Normal holiday : 10 days
c. Leave for illness : 14 days
d. Weekly holiday : 01 day
e. Pregnancy leave : 12 weeks
12
POINTS OF IKEA (IWAY) COMPLIANCE:
01. Training of workers (Syllabus and training program)

a. IWAY
b. Fire aid
c. Machine aid
d. Electrical safety
e. PPE
f. Labor law rights and privileges
g. Dangerous operations
02. Firefighting evacuation:

a. Extinguisher
b. Team
c. Evaluation plan
d. Fire drill
e. Alarm
f. Records keeping
03. First aid:

a. Box
b. Medicine
c. Team
04. Sanitation
05. Pure drinking water
06. Noise level
07. Safety instruction on machine safety device
08. Marking isles and dangerous areas
09. Use of PPE
10. Compensation and benefit
11. Working hour and weekly holiday
12. Harassment, abuse and disciplinary practices
13. Child labor
14. Issue of appointment letter
15. Grievance policy and welfare
16. Personal file and list of workers with date of birth
17. Attendance register and card (shift wise)
Major duties and responsibilities of a production officer:

1) Collection of necessary information and instruction from the previous shift for the smooth
running of the section.
2) Make the junior officers understand how to operate the whole production process.
3) All the junior officers and workers of his shift keep themselves busy in their duties under
his supervision.
4) Always ask his officers what steps they have to take for the betterment of the factory.
13
5) Check the worker setting to the machine in case of worker shortage in a particular
machine and fill up the gap deputing worker from other sections.
6) To control the production process and parameters of the machine.
7) To ensure target production of each machine with appropriate quality.
8) To control the workers so that they can operate the machine as per instruction.
9) In case of machine breakdown, he has to try his best to start it as early as possible.
10) Secure conventional rules and regulations inside the factory.
11) Ensure cleanliness of all machines and floor.
12) Ensure use of proper dress, wastage bag, cleaning stick of the workers.
13) To keep eyes on worker to minimize machine down time.
14) Ensure sorting of contamination and heavy particles from lay down.
15) Ensure sue of wastage sliver and pneumafil in the blowroom.
16) Prevent lot, count mixing in different production stages.
17) Checking of machine setting, drafting zone cleaning.
18) To train up the learners.
19) To take necessary steps to reduce oft wastage.
20) In case of any problem regarding production, maintenance etc. take decision when the
high officials are not present in the section.
21) To keep workers busy all the time so that they dont get scope of gossiping.
22) Checking of stickers, defected cone, package weight in finishing etc. to avoid mixing.
23) Sometimes he works in different machines if needed.
24) To check the production report produced by assistant officer at the end of the shift, if
production is not achieved as per target create, pressure on worker.
25) Finally, hand over the shift with all information to the coming shift and leave the section.
Purpose:
To control shift according to the pan made by the production manager.
Territory:
Production section (major)
Quality assurance department maintenance department (minor)
Nature and scope:
Role within the organization:
Responsibility of own shift production with good quality and minimum time.
Environmental:
Production officer has to work under huge stress. He has to work in acute heat under physical and
mental pressure.
Task:
Areas of development: responsible for training the production pupils to get the maximum and quality
output from them.
14
Control: he has to control the production and people according to the plan to get optimum efficiency.
Organizing: he watches all the processes of spinning and introduces required system if needed for
quality product during spinning.
Reviewing: production officer reviews the activities of the shift in charge and supervisor every month
according to the production managers order.
Planning: production officer has to plan in all the section for the smooth flow of production. He has to
distribute the work of the worker for balancing their work.
Administration: he checks daily and monthly production report including reprocess of dyeing section
and the daily production process.
Leadership: he makes the worker to give their best by inspiring and motivating. He commits himself
to the company and fosters the same in his followers. He knows their strength, weakness, hope and
goals. He demonstrates strength of character by their words and actions.
Management contact: the job holder contacts with the production manager in matters of production
planning and distribution of work of the workers. He also consults with the quality assurance manager
in case of quality falls and production quality of individual buyer.
MANAGEMENT INFORMATION SYSTEM:
Management information system (MIS) is very important for any production process which helps the
management to get correct information about production of different machine, machine efficiency,
idle spindle, end breakage, product quality, process parameters like hank, count, TPI, wastage %,
doffing time, creeling time, CV%, imperfection etc. it is necessary to make these correct by decision
and take the correct course of action. It is clearly essential that they do not get confused by vague
information or mislead by confusing information.
15
Manpower Administration
Chairman
Executive director
1. Production department
2. Administration & labour
3. Store
4. Quality assurance department
5. Security
6. Utility department
7. Maintenance department
8. Accounts
9. Procurement
10. Marketing
1. Production department
DGM/PM (1)
A.M. (Back process)- 1 A.M. (Ring+ Finishing+ Rotor)- 1
A Shift B Shift C Shift A Shift B Shift C Shift SPO-

SPO- 1 SPO- 1 SPO- 1 SPO- 1 SPO- 1 1
Mix. & Mix. & Mix. & Ring Ring Ring

B/R B/R B/R
Winding Winding Winding
Card Card Card
Rotor Rotor Rotor MIS Packing
Simplex Simplex Simplex
PO/APO: PO/APO: PO/APO: PO/APO: PO/APO:
PO/APO PO/APO PO/APO:
2+1+1=4 2+1+1=4 2+1+1=4 -1 -1
: 1+2=3 : 1+2=3 1+2=3
2. Administration & Labour: AM/A & LWO- 1
3. Store Department
AM/ Store Officer- 1
ASO- 2
Jr. Executive (C)- 1
16
4. Quality Assurance Department:
Manager (QA)- 1
Test & Bale Management Process Control, R&D
Sr. QAO- 1 Sr. QAO- 1
QAO- 2 QAO- 3
5. Security: ASO- 1
6. Utility Department (8)
Manager/ DM- 1
AM/ Sr. Engr. /Engr. (EL)- 1 AM/ Sr. Engr. /Engr. (G & B)- 1 AM/ Sr. Engr. /Engr. (AC &
Chiller)- 1
SAE- 1 SAE- 9 SAE- 4
7. Maintenance Department:
AM- 1
Engr./ Asst. Engr.- 2
8. Accounts:
DGM- 1
AM/ Sr. Accounts Officer- 1

Cost. Acct.- 1
Assistant Account Officer- 1
9. Procurement: Manager/ DM/ AM- 1
10. Marketing:
AM- 1
AMO- 1
17
Manpower of different section:
18
CHAPTER III
MACHINE DESCRIPTION
19
Layout of SRSL
Machinery list of
20
21
SINHA ROTOR SPINNING LIMITED
Serial Name of machine Quantity Model Mfg. year Country of

no. origin
01. BLOW ROOM
Unifloc 02 RIETER A11 2000 Switzerland
Uniclean 02 RIETER B11 2000 Switzerland
Unimix 03 RIETER B7/3 2000 Switzerland
Uniflex 03 RIETER B60 2000 Switzerland
Mixing Bale Opener 01 RIETER 3/4 2000 Switzerland
Waste Opener 01 RIETER B2/5 2000 Switzerland
Mono-cylinder 01 RIETER B4/1 2000 Switzerland
JOSSI Vision Shield 02 JOSSI 2006 Switzerland
Bailing Press 02 2006 India
02. CARDING 21 RIETER C51 2000 Switzerland
03. DRAW FRAME
Breaker RIETER SB2 2000 Germany
Finisher RIETER RSB-D35 2000 Germany
04. LAP FORMER 02 RIETER E32 2000 Switzerland
05. COMBER 10 RIETER E62 2000 Switzerland
06. SIMPLEX 03 ZINSER RO- WE- 2001 Germany
MAT-670
05 TOYOTA FL-100 2000 Japan
07. O.E. ROTOR FRAME RIETER R20 2000 Germany
08. RING 28 RIETER G33 2000/2001 Switzerland
09. AUTOCONE 07 MURATECH 7V 2000 Japan
01 SCHLAFHORST- 2001 Germany
338
01 PROCESS 2006 Japan
CONER-21C
10. XORELLA yarn 01 XORELLA 2000 Switzerland
conditioning
11. A/C PLANT 05 BEST AIR 2000 Taiwan
12. GAS GENERATOR 06 GE JENBACHER 2000 Austria
13. CHILLER 03 THERMAX 2000 India
22
Machinery list of
SINHA SPINNING LIMITED
Serial Name of Machine Quantity Model Mfg. year Country of

no. origin
01. BLOWROOM
Uniflock 01 RIETER A11 2005 Switzerland
Uniclean 01 RIETER B11 2005 Switzerland
Unimix 02 RIETER B7/3 2005 Switzerland
Uniflex 02 RIETER B60 2005 Switzerland
Condenser 02 RIETER 2005
02. CARDING 08 RIETER C60 2005 Switzerland
03. DRAW FRAME
Finisher 05 RIETER RSB- 2005 Germany
D35
BLOWROOM
Blowroom is the first processing stage in yarn manufacturing process. It performs the actions of
opening, cleaning, dust removal, sometimes blending and accelerates even feed of the material to the
card. The blowroom section of SINHA ROTOR SPINNING LTD. is a sophisticated one, equipped with
modern machines which are suitable for quality production. In order to produce carded, combed and
rotor yarn- the blowroom section is divided into two parts or lines reffered to as combined line and
rotor & card line.
23
Machines available in blowroom section (SRSL):
Unifloc machine:
Number of machine :2
Model : A11
Manufacturer : RIETER
Year of manufacturing : 1999 & 2000 (Comb Line)
Country of origin : Switzerland
Traverse drive speed: : .8 m/min (min.) to 12.0 m/min. (max)
Take off depth : .8 to 20 mm
Additional layer : 0.0 (min.) to 1 mm (max)
Frequency : 50 Hz
Voltage : 400 V
production : 1400 kg/hr.
Uniclean machine:
24
Model : B11
Pin roller speed : Normal: 640 rpm, Actual: 570 rpm
Cleaning intensity : .3 (0.0 - 1.0)
Relative amount of waste : 6 (1-10)
Frequency : 50Hz
Voltage : 400 V
Grid angle : 15.00
Production : up to 1200 kg/hr.
Working width : 1600 mm
Cleaning cylinder diameter : 750 mm
Unimix machine:
Model : B 7/3
Frequency : 50 Hz
Voltage : 400 V
production : up to 800 kg/hr.
No. of blending chamber :6
25
Uniflex machine:
Model : B11
Frequency : 50 Hz
Voltage : 400 V
Cleaning intensity : .8 (0.0-1.0)
Relative amount of waste : >6 (1-10)
Cleaning cylinder diameter : 750 mm
Pined roller speed : 960-1300 rpm
Monocylinder:
Model : B 4/1
Year of manufacturing : 1999
Frequency : 50 Hz
Voltage : 400 V
production : 1400 kg/hr.
Material used : 100% cotton
26
Waste opener:
Model : B 2/5
Frequency : 50 Hz
Voltage : 415V
production : 3-6 kg/hr.
Material used : Cotton bale part, slivers, laps, roving
Mixing bale opener:
Model : B 3/4
Frequency : 50 Hz
Voltage : 415 V
Working pressure : 6 bar
Bale press:
Model : CI 20SA-01
Manufacturer : Laxmi
Country of origin : India
production : 640 kg/shift
Machines available in blow room section (SSL):
Unifloc:
Number of machine :1 Take off depth : .8-20 mm

Model : A11 Additional layer : 0.0-1.0mm
Manufacturer : RIETER Frequency : 50 Hz
Year of manufacture : 2005 Voltage : 400 V
Country of origin : Switzerland production : 1400 kg/hr.
Traverse drive speed : (0.8 15) mm/min
27
Uniclean:
Number of machine :1 Voltage : 400 V

Model : B11 Grid angle : 15.00
Manufacturer : RIETER Production : up to 1200
Year of manufacture : 2005 Working width : 1600 mm
Country of origin : Switzerland Cleaning cyl. Dia : 750 mm
Pin roller speed : 960 Length : 2205 mm
Cleaning intensity : 1 (0.0 - 1.0) Width : 1040 mm
Relative amnt of wst. : 6 (1-10) Height : 2000 mm
Frequency : 50Hz
Unimix:
Model : B 70
Frequency : 50 Hz
Voltage : 400 V
No. of blending chamber :8
Length : 7700 mm
Width : 1510 mm
Height : 4000 mm
Uniflex:
Number of machine :2 Voltage : 400 V

Model : B60 Production : up to 600 kg/hr.
Manufacturer : RIETER Working width : 1200 mm
Year of manufacture : 2002/2005 Cleaning cyl. Dia : 400 mm
Country of origin : Switzerland Pined roller sp. : 960-1300 rpm
Cleaning intensity : (0.0-1.0) Length : 1428 mm
Relative amnt of wst. : (1-10) Width : 1800 mm
frequency : 50 Hz Height : 3985 mm
Condenser:
No. of machine Country of origin : Switzerland

Manufacturer :RIETER
28
Blowroom line for comb line:
Unifloc
Uniclean
Unimix
Uniflex
Chute feed
For combed yarn
Blowroom line for Rotor line (SSL):
Unifloc
Uniclean
Unimix
Uniflex
Condenser
Chute feed
For Rotor yarn
29
Blowroom line for Card and Rotor line:
Waste opener
Unifloc Mixing bale opener
Uniclean
Unimix Unimix
Uniflex Uniflex
Vision shield Vision shield
Chute feed Chute feed
For Rotor yarn For Carded yarn
Beating points:
i. Major beating points:
Uniclean B11
Uniflex B60
ii. Minor beating points:
Waste opener
iii. Dust collection system:
Air suction system
Mixing system in blowroom line:

Completely auto mixing system
Delivery system towards the card line:
Chute feed system
Beater rpm setting:

Beater is set according to cleaning intensity and relative amount of waste.
Cleaning intensity:
Range: 0.0 - 1.0
30
Relative amount of waste:
Range: 1.0 10
Grid bar settings wider: 10 (max)
Grid bar settings closer: 1 (min)
Comments on blowroom:
The blowroom section of Sinha rotor spinning ltd is well equipped with modern machinery. Production
is also higher. But it should be noted here that this spinning deals with 100% cotton only. As a result
it contains only blowroom line that does not present any variation and complexity in machine
sequence and operational procedures as it would be seen in a mill producing blended yarn. For
different counts of yarn, weight should be varied. But in SRSL, it is not carried put and wastage
extraction percentage is not measured regularly. In blowroom section, maintaining a standard RH% is
a must. As auto mixing is available, a proper mixing and opening of material is obtained. The overall
performance of the blowroom line is good.
Carding section
Carding is the process in which fibers are opened, parallelized and removal of dust, impurities, neps,
short fibers are done to produce a continuous strand of fibers called sliver of uniform weight per unit
length.
31
Carding is the heart of entire spinning process and as such requires utmost care. To card well is to
spin well is a very widely used saying by all of those who are concerned with spinning technology.
Well carded is half spun demonstrates the immense significance of carding for the final result of
spinning operation.
The carding machines available at Sinha rotor spinning ltd are well equipped with high performance
machinery suitable for constant production at a high rate. In order to produce both carded and
combed yarn simultaneously, the card line is divided into two lines.
Objectives:
a) Individualization of fibers from tuft

b) Elimination of impurities
c) Disentanglement of neps
d) Elimination of dust
e) Producing uniform sliver
Specification (SRSL):
Model : C51
Total number of machine : 21
Production capacity : Up to 90kg/hr.
Feed system : Aero feed system (A70)
Diameter of aero feed roller : 120 mm
Feed roller diameter : 120 mm
Taker in diameter : 253 mm
Taker in speed : 1800 rpm
Cylinder diameter : 1290 mm
Cylinder speed : 450-550 rpm
Number of stationary flat (back side) :3
Number of stationary flat (front side) :2
Number of revolving flat : 104 (total), 45(in action), 59(out of action)
Doffer diameter : 500 mm
Doffer speed : 51-55 rpm
Total draft range : 85-250
Specification (SSL):
Model : C60
Total number of machine :8
Production capacity : 110-115kg/hr.
Delivery speed : 250-300 m/min
32
Feed system : Aero feed system
Diameter of aero feed roller : 156 mm
Feed roller diameter : 100 mm
No. of taker in :3
Taker in diameter : 180 mm, 180 mm, 253 mm
Taker in speed : 1904 rpm
Cylinder diameter : 814 mm
Cylinder speed : 855 rpm
Number of stationary flat (back side) :3
Number of stationary flat (front side) :2
Number of revolving flat : 79(total), 24(in action), 55(out of action)
Flat speed : .33 m/min
Doffer speed : 51-55 rpm
Doffer diameter : 680 mm
Total draft range : 85-250
Different gauge (settings) of the carding machine:
Setting points Distance (mm) Distance (thou)

Taker in to cylinder .3 12
Taker in to mote knife 1 40
Cylinder to doffer 0.175 7
Cylinder to flat .3, .275, .25, .225, .225 12, 11, 10, 9, 9
Cylinder to stationary flat (back) .6, .55, .5 24, 22, 20
Cylinder to stationary flat (front) .45, .4 18, 16
Doffer to detaching roller .15 6
Detaching to cross roller .125 5
Top delivery to bottom delivery .25-.3 10-12
roller
Calendar roller 1.6 64
Cylinder to cylinder under casing .9-1.2 36-48
Taker in to taker in under casing .5 20
Specification of card clothing:
Card clothing PPSI Height Angle (0)

Taker in 90-120 5 mm 10
Cylinder >900 for card/ comb 2 mm for card/ comb 40 for card/ comb
>750 for rotor 1.8 mm for rotor 30-40 for rotor
Doffer >250 5 mm 30-36
Top flat >500 for card/ comb 75
>400 for rotor
Stationary flat 140-160
240-300 (back)
640-660 (front)
33
Drawing section
The draw frame is an essential section in any spinning mill. The process by which a number of carded
sliver are combined to produce a regular and uniform drawn sliver by drafting and doubling is known
as drawing.
Objectives:
Strengthening and parallelization of fibers

To facilitate blending of the fibers
To remove hook fibers
To reduce irregularities of fibers by doubling
Types of draw frame: There are mainly two types of draw frames used in Sinha textile mills. They are
mentioned below:
a) Breaker draw frame b) Finisher draw frame
Breaker draw frame: Five breaker draw frames are used in Sinha rotor spinning ltd.
Number of machine : 05
Machines 01 and 02 : are used for rotor process
Machine 03 : is used for woven process
Machine 04 : is used for
Machine 05 : is used for woven and Sudan process
34
Specification:
Model : SB-2
Drafting system : 3 over 3
Doubling : 6 (max- 8)
Sliver length per can : 5000 m
Delivery speed : 650 m/min
Drafting zone pressure control : hard pressure
Cot roller diameter : 38 mm
Bottom roller diameter : 30 mm(back), 30 mm(middle), 30 mm(front)
Feed sliver weight : 75 grains/yard
Delivery sliver weight : 75 grains/yard
Can size : 1200*600 mm
Cot roller shore hardness : Comb- 76-800, Card- 830
Voltage : 3*415 V
Frequency : 50 Hz
Amp : 28
pressure : 10 bar
Pressure on drafting system:
Front roller Middle roller Back roller

200N 320N 320N
Roller setting:
Back to middle Middle to front

36-60 mm (existing- 44 mm) 40-88 mm (existing- 40)
Finisher drawframe:
8 finisher draw frames are used in Sinha rotor spinning ltd.
Machine 01 to 03 : are used for rotor process
Machine 04 : is used for comb woven process
Machine 05&06 : are used for card woven process
Machine 07 : is used for Sudan process
Machine 08 : is used for comb hosiery
Specification:
Model : RSB-D30
35
Doubling : 6 (max 8)
Sliver length per can : 3000m
Drafting zone pressure control : compressor
Feed sliver weight : 75 grain/yard
Delivery sliver weight : 75 grain/yard
Cot roller shore hardness : Comb- 76-800, Card- 830
Sliver creel : Power creel
Can size : 1000*500 mm
Auto leveler system : Present
Pressure on drafting system:
Front roller Middle roller Back roller

200N 320N 320N
Roller setting:
Back to middle Middle to front

36-60 mm (existing- 44 mm) 40-88 mm (existing- 40)
Finisher draw frame (SSL):
Used for : Rotor process
Specification:
Model : RSB-D35
Doubling : 6 (max 8)
Sliver length per can : 3000m
Drafting zone pressure control : compressor
Feed sliver weight : 75.68 grain/yard
Delivery sliver weight : 75.68 grain/yard
Auto leveler system : Present
36
Lap former
It should be realized that the super lap former is used primarily in production of combed yarn. Lap
former is mainly used for processing of pre-comb sliver. Doubling and drawing them is essential
to produce uniform lap which is fed in comber machine.
If pre-comb sliver is fed directly to comber machine, noil extraction percentage rate would be
high, a greater quantity of long fibers would be wasted with short fibers and possibility of needle
breakage in comber machine would be higher. For these reasons, lap former is essential for the
processing of combed yarn. As Sinha spinning mills deals with combed yarn, they use lap formers
conveniently.
Purpose of lap former:
Fibers in the pre-comb sliver are blended and mixed. Thus blending provides a degree of
compensation of raw materials variation.
It helps in arranging the fibers with better orientation.
It helps in better parallelization of the fibers
The tailing hooks in pre-comb sliver is reversed to leading ones here, which ensures less
fiber damages during combing.
Particulars obtained (SRSL):
Number of lap former : 2

Machine 01 : is used for comb woven or Sudan
Machine 02 : is used for hosiery
Specification:
Model : E32
Number of doubling : 26
Draft : 1.746 (front), 1.062 (back)
Top roller diameter : 42 mm
Lap weight : 20 kg (1 meter= 80 grams)
Lap length : 270 m
Significance of signal light:
Color of light Meaning

Blue Full bobbin, doffing is to be done
Red Electrical fault, door open or close
White Plate open or close
37
Comber
The process of removing short fibers by comber so as to increase the spin ability of the yarn and
remove trash, impurities to produce a higher quality of yarn is called combing.
Objectives of combing:
Elimination of precisely pre-determined quantity of short fibers

Elimination of remaining impurities
Elimination of large proportion of the neps in the fiber material
Formation of sliver having maximum possible evenness.
Particulars obtained:
Number of combing machine: 10
Specification:
Model : E62
Number of doubling :8
Draft : 23.1 (existing total)
Nips / min : 300/min
Can feeling : 6000 m
Feed per nip : 4.7 (when ratchet wheel S=20)
Diameter of full lap : 520 mm
Maximum noil extraction : 24%
38
Diameter of the drafting roller:
Roller Diameter Type

Top roller 45 mm Rubber coated
Bottom roller 27, 27, 27, 27, 35 mm (front) Helical steel fluted
Detaching roller diameter:
Roller Diameter
Top roller 25 mm
Bottom roller 25.5 mm
SIMPLEX SECTION
Objectives:
1. To draft the sliver i.e. reduce the weight per unit length of sliver
2. To insert small amount of twist to strengthen this roving in order to prevent breakage
during processing
3. To wind the twisted strand (roving) on to a bobbin
4. To make conical or taper shape of bobbin
39
Number of simplex machine: 8
Specification:
Model: FL-100
Number of machine: 5
Manufacturer: Toyota
Year of manufacturing: 2000
Drafting system: 4 over 4
Number of flyer: 108
Maximum flyer speed: 1205rpm
Shoulder angle: 34
Bobbin length: 452mm & 445mm
Lift length: 390mm & 384mm
Stop position: 150mm
Main pulley (A): 35
Winding pulley (E): 30
Specification:
Model: RO-WE-MAT 670
Manufacturer: Zinser
Year of manufacture: 2001
Number of flyer: 96
Maximum flyer speed: 1350 rpm
Shoulder angle: 34
Bobbin edge: 56mm
Bobbin bottom: 320mm
Doffing system: Automatic
Pressure arm loading: Spring loaded
Maximum roving length: 1400m
40
Pressure arm weight:
Machine name Front Middle (Front) Middle Back
Fl-100 15kg 25kg 20kg 20kg
Zinser 25kg - 20kg 20kg
Diameter of the drafting roller:
Machine name Front Middle (Front) Middle Back
FL-100 28mm 28mm 28mm 28mm
28.5mm 28.5mm 25mm 28.5mm
Zinser 30mm - 25.5mm 30mm
30mm - 30.5mm 30mm
Relation between spacer size and roving count:
Space color Roving count
Green .8-.7 (<1)
brown 1.25 (>1)
Significance of light:
Light color Meaning
Red Roving breakage
Green For doffing
Yellow Sliver breakage
White Auto stop indication by light
41
RING SECTION
Ring spinning was invented in 1838. It is a universal spinning system. Higher count, quality yarn can
be achieved by this machine. The processes involved in the ring are creeling, drafting, twisting,
winding & doffing.
Objectives:
To draft the roving feed to the ring frame from the simplex roving.
To insert the necessary amount of twist in the yarn.
To wind the twisted yarn on a cylindrical bobbin.
Machine specification:
Manufacturer: Rieter
Model: G33
Number of spindle per machine: 1008
Country of origin: Switzerland
Voltage: 400v
Frequency: 50Hz
Working pressure: 7 bar
42
Spindle speed: maximum 18000 rpm
Pressure at pneumatic pressure arm: 2.5-3 bar
Ring cup diameter: 38mm, 40mm, 42mm & 45mm
Bobbin length: 190mm, 200mm, 210mm, 230mm
Whirl diameter: 21mm
Diameter of balloon control ring: 41mm, 43mm, 45mm & 48mm
No. of overhead travelling cleaner
(OHTC) per machine: 1
Top apron origin: Germany
Top apron size: 39.2mm*30mm*1.1mm (L*W*T)
Bottom apron origin: Germany
Bottom apron size: 72.5mm*30mm*1.1mm (L*W*T)
Manufacturer of apron: ACOTEX
Cot roller size: 30mm*28mm*19mm (L*W*T)
Spindle wharve diameter: 21mm
Flange width: 3.2mm for 38mm diameter of ring cup
4mm for 45mm diameter of ring cup
Particulars obtained:
Process name Machine no.
Compact yarn 15-20
Lycra yarn 1,2,5,13,14 & 15
Slub yarn 2,3,4,6 & 22
Normal yarn Rest of the machines
Drafting roller diameter:
Roller Front Middle Back
Top 28mm 28mm 28mm
Bottom 27mm 27mm 27mm
43
Cot roller shore hardness:
Roller Shore hardness
Front 65
Middle 80
back 75
Spacer size and their color:
Spacer size (mm) Color
2.50 Chocolate
2.75 Ash
3.00 White
3.25 Yellow
3.50 Black
4.0 Orange
4.5
5.0 Blue
Diameter of Balloon control ring:
According to lift there may be:
48mm
45mm
43mm
41mm
Different gauge in ring frame:
Front to middle roller dia :42.5

Middle to back roller dia :70mm
Spindle gauge :70mm
Ring plate gauge :70mm
Lappet gauge :70mm
Try rail gauge :70mm
Tin pulley gauge :140mm
44
Traveler:
Manufacturer:
KANAI JUYO CO. LTD
OSAKA, JAPAN
KANAI Improved
Hi ni, TM, Pk/hf No. 1-6
Manufacturer: Breaker, Saphir
Parameter which are used in Ring Frame:
Sinha rotor spinning ltd

Kanchpur, Narayangonj
Quality assurance department
Special yarn
Count Type Avg. Avg. TPI TM Spacer R/T

count speed
Comb woven (core)
9 CW(core) 9.00 10000 13.80 4.60 4.50 NO-08
10 CW(core) 10.00 10000 14.60 4.67 4.50 NO-08
20 CW(core) 20.00 11000 21.00 4.70 3.50 1/0
30 CW(core) 30.00 10500 26.00 4.75 3.25 2/0
40 CW(core) 40.00 12000 31.50 5.00 2.50 3/0
50 CW(core) 50.00 12000 33.00 4.65 2.50 4/0
60 CW(core) 60.00 10000 36.35 4.70 2.50 5/0
Kard woven (core)
9 KW(core) 9.00 9000 13.85 4.60 5.00 NO-08
10 KW(core) 10.00 10000 14.60 4.61 5.00 NO-08
12 KW(core) 12.00 10000 17.00 4.90 4.00 NO-08
14 KW(core) 14.00 10300 17.95 4.80 3.50 NO-04
16 KW(core) 16.00 10500 19.00 4.75 3.50 NO-4
20 KW(core) 20.00 11000 21.50 4.80 3.50 1/0
45
Kard woven (slub)
6 KW(slub) 6.00 6500 11.75 4.80 5.00 NO-11
7 KW(slub) 7.00 6500 13.23 5.00 5.00 NO-11
8 KW(slub) 8.00 8000 13.85 4.90 5.00 NO-11
9 KW(slub) 9.00 8500 14.70 4.90 5.00 NO-09
10 KW(slub) 10.00 9500 15.49 4.90 5.00 NO-09
11 KW(slub) 11.00 9800 16.25 4.90 5.00 NO-08
12 KW(slub) 12.00 9800 16.97 4.90 4.50 NO-06
14 KW(slub) 14.00 10000 18.33 4.90 4.00 NO-04
16 KW(slub) 16.00 10500 19.60 4.90 4.00 NO-04
20 KW(slub) 20.00 12000 21.90 4.90 4.00 NO-01
30 KW(slub) 30.00 13000 26.83 4.90 3.25 2/0
Comb woven (slub)
30 CW(slub) 30.00 13000 24.64 4.50 3.25 2/0
40 CW(slub) 40.00 14000 29.60 4.60 2.75 4/0
Comb hosiery (slub)
20 CH(slub) 19.70 11000 19.47 4.39 3.50 NO-01
24 CH(slub) 23.70 11500 19.35 3.98 3.50 2/0
26 CH(slub) 25.70 12000 20.50 4.05 3.25 2/0
30 CH(slub) 29.70 12500 21.80 4.00 3.25 2/0
Comb woven
10 CW 10.00 10500 13.59 4.30 4.50 NO-08
16 CW 16.00 12500 16.00 4.00 3.50 NO-04
18 CW 18.00 13000 18.24 4.30 3.50 NO-01
20 CW 20.00 13000 18.78 4.20 3.25 NO-01
21 CW 21.00 13500 19.01 4.15 3.25 NO-01
30 CW 30.00 15000 23.50 4.30 2.75 3/0
46
32 CW 32.00 15000 24.00 4.25 2.75 3/0
40 CW 40.00 16000 27.50 4.35 2.50 4/0
50 CW 50.00 16500 31.50 4.45 2.50 6/0
60 CW 60.00 16500 33.00 4.26 2.50 6/0
80 CW 80.00 16500 39.00 4.36 2.50 12/0
Comb woven (compact)
20 CW(com) 20 13000 18.50 4.15 3.25 NO-01
21 CW(com) 21 13000 19.01 4.15 3.25 NO-01
28 CW(com) 28 13500 22.00 4.15 3.00 3/0
30 CW(com) 30 15000 22.50 4.11 2.75 3/0
32 CW(com) 32 15000 24.00 4.24 2.75 3/0
38 CW(com) 38 16000 25.83 4.19 2.50 4/0
40 CW(com) 40 16500 26.50 4.19 2.50 4/0
50 CW(com) 50 16500 30.80 4.35 2.50 6/0
60 CW(com) 60 16500 33.00 4.26 2.50 7/0
Comb hosiery (compact)
20 CH(com) 19.70 12000 15.75 3.55 3.25 NO-01
24 CH(com) 23.70 14000 17.30 3.55 3.25 1/0
26 CH(com) 25.70 14500 17.85 3.53 3.00 2/0
28 CH(com) 27.70 14500 18.70 3.55 3.00 2/0
30 CH(com) 29.70 14500 19.35 3.55 2.75 3/0
34 CH(com) 33.70 15000 20.40 3.52 2.75 3/0
40 CH(com) 39.70 15000 22.75 3.60 2.50 4/0
47
Kard woven
7 KW 7 8600 11.00 4.15 5.00 NO-11
8 KW 8 9000 11.85 4.20 5.00 NO-11
9 KW 9 9000 13.20 4.40 5.00 NO-09
10 KW 10 10500 13.75 4.35 5.00 NO-09
12 KW 12 11500 14.55 4.20 5.00 NO-08
14 KW 14 12500 16.08 4.30 4.00 NO-04
16 KW 16 12500 17.20 4.30 3.50 NO-04
17 KW 17 13500 17.73 4.30 3.50 NO-04
20 KW 20 13000 20.00 4.47 3.25 NO-01
21 KW 21 1500 20.00 4.36 3.25 NO-01
24 KW 24 14000 21.50 4.39 3.25 1/0
26 KW 26 15000 22.40 4.39 3.00 2/0
30 KW 30 15500 24.50 4.47 2.75 3/0
32 KW 32 16000 24.89 4.40 2.75 3/0
40 KW 40 16000 29.00 4.58 2.50 4/0
Comb hosiery
12 CH 11.70 10500 12.50 3.65 4.25 NO-09
16 CH 15.70 12000 14.40 3.63 3.50 NO-04
18 CH 17.70 12500 15.00 3.56 3.50 NO-01
20 CH 19.70 13000 16.00 3.60 3.25 NO-01
22 CH 21.70 13000 17.00 3.64 3.25 1/0
24 CH 23.70 14000 17.50 3.60 3.25 1/0
26 CH 25.70 14000 18.25 3.60 3.00 1/0
28 CH 27.70 14500 19.00 3.61 2.75 2/0
30 CH 29.70 14500 19.62 3.60 2.75 2/0
32 CH 31.70 14500 20.26 3.60 2.75 2/0
34 CH 33.70 15000 20.89 3.60 2.75 3/0
36 CH 35.70 15000 21.50 3.60 2.50 3/0
48
40 CH 39.70 15500 23.75 3.76 2.50 4/0
45 CH 44.70 15500 25.05 3.74 2.50 4/0
Kard hosiery
20 KH 19.70 13000 16.50 3.71 3.25 NO-01
24 KH 23.70 13500 18.01 3.70 3.25 1/0
26 KH 25.70 13700 18.75 3.70 3.00 2/0
28 KH 27.70 13500 19.47 3.71 2.75 2/0
30 KH 29.70 14500 20.45 3.70 2.75 2/0
32 KH 31.70 14800 20.83 3.70 2.75 2/0
34 KH 33.70 15000 21.47 3.70 2.75 3/0
36 KH 35.70 15000 22.10 3.70 2.50 4/0
40 KH 39.70 15200 23.75 3.76 2.50 4/0
49
WINDING SECTION
Winding is considered as an integral part of the spinning process. Winding not only improve the
quality of the yarn but also step up production at the later process, i.e. weaving, knitting & Yarn
dyeing.
Winding machine commonly used for all types pf fibers (100% cotton, MMF, blended yarn).
Function of winding machine: The following functions are performed in winding machine:-
To make a suitable yarn package from ring bobbin.

Yarn clearing and splicing
Waxing
Machine details:
Number of drums per machine: 60
Speed range: 800-1300 m/min
Groups per machine: 6
Length of yarn per package: 74000 m (avg.)
Package mass: 2-3 kg
Bobbin mass: 54 g
Air pressure of the spicing unit: 6.5 bar
Untwisting and cleaning pressure: 6.5 bar
Twisting pressure: 6.0 bar
50
Winding machine:
Name or model of m/c Number of m/c
Muratec Machconer No. 7-V 7
Process Coner Muratec No. 21C 1
Schalfhorst Autoconer 338 1
Total: 9
EYC: EYC stands for Electronic Yarn Clearer. It is used in winding machine in order to avoid
disturbance and consequently cost can result during subsequent processing in the finished product.
All electronic yarn clearer observes the length of a yarn based on the duration of an electric signal.
This time is multiplied with speed of the winder which is given from the winder. Then the diameter is
obtained with yarn sensors operating on two different principles i.e. capacitive and optical principle.
Different EYC & their model are given below:
Name & model Machine name (m/c no.)
Uster quantum Schalfhrost Autoconer 338 (09)
Uster quantum 2 Process Coner Muratec No. 21C (08)
Loepfe TK830 Muratec Machconer No. 7-V (4)
Loepfe TK840 Muratec Machconer No. 7-V (1,2,3)
Loepfe TK930F Muratec Machconer No. 7-V (7)
Loepfe TK940F Muratec Machconer No. 7-V (5&6)
Example of EYC setting in winding machine:
Cou Proces Neps/m Ds(sho Ls(short DL(lon LL(long - - SPD SPL +/ N

nt s m rt thin thinlengt g thin thin D L L L -D
dia) h) dia)m length)m % %
m m
40 CH 4.5 2.0 1.6 1.22 20 18 1 1.2 14 7. 1

6 5 9
20 CW 5.0 2.1 1.7 1.22 25 20 2 1.2 14 7. 1

0 5 9
51
16 KW 5.0 2.1 1.7 1.22 25 20 2 1.2 14 7. 1
5 5 9
50 CWCO 4.5 2.0 1.6 1.20 20 20 2 1.2 14 7. 1

M 0 5 9
30 CH 4.5 2.1 1.7 1.22 20 18 1 1.2 14 7. 1

6 5 9
Winding speed:
Yarn count Process Winding speed (m/min)
14 KW slub 900
14 KW slub 950
16 KW 1200
20 CW 1250
20 KW 1250
20 KW slub 950
20 CW 1200
23.7 CH 950-1250
32 CW 1300
32 CW 1250
32 KW 1250
40 CW compact 1300
50 KW compact 1200
Muratc Macconer:
Maintenance schedule:
Once in a shift:
a) Cleaning with compressed air ( splicing area, tensor box, bottom of magazine, belcon area
and peg area)
b) Blower waste remaining
c) Drum brush cleaning by removing brush
d) Cleaning the yarn waste around the cone holder
52
Once a day:
a) Bobbin conveyor brush, pulley area yarn waste remove

b) Drain water at air mist separator.
c) Check visually-tensor motor rotation.
d) Check air pressure (P1, P2, P3)
Once a month:
a) Splicer untwisting nozzle cleaning by brush

b) Check splice quality
c) Cam, shaft chain oiling After cleaning apply oil ( spindle oil or molykote spray or chain oil)
Terrus oil 10
d) Tensor box cleaning (gate feeder, tensor cutter, tensor disk, yarn trap cleaning)
e) Check bal-cone centering and sensor surface cleaning by clean cloth.
f) S10 cam -after cleaning apply grease (albenia2) or molykote spray.
g) Cassette gear cover and can shaft bearing unit greasing (Albania 2 )
h) Checking yarn clearer cutter function by double yarn insertion.
i) Blower impeller suction port and blower motor fan cleaning, belt tension checking.
j) Check belt centering (empty bobbin, package conveyor)
k) Magnetic cleaning ( clean burrs at edges if necessary)
Once every 3 month:
a) Shutter cutter cleaning

b) Blower shaft bearing greasing
Pulley side 25 grams
Impeller side 12 grams
Once in six month:
a) Cassette gear cleaning cleaning then apply molykote spray

b) Cam shaft reduction gear oil change (ISO grade 150) Shell Omara 150
c) Winding unit inside cleaning & lubrication all cams and levers and followes cleaning (all
foller bearing should rotate freely)
d) Slicer cam area clearing and lubricating all cam and levers and follers cleaning
e) Check memory function
f) Check blower static pressure and take necessary actions
g) Mist separator cleaning
53
ROTOR SECTION
SRSL ROTOR SECTION

Model: R20
Manufacturer: RIETER
Country of origin: SWITZERLAND
Number of rotor frame: 04
Number of rotor head per frame: 240
Rotor RPM: 60000-1400000
Rotor diameter: 31mm, 32mm, 35 mm, 40 mm
Feed roller RPM:
Feed roller diameter: 35 mm

Opening roller diameter: 80 mm
Opening roller RPM: 6500-8500
Draft range: 50-120
54
Winding angle: 34.5
Tension draft: 1.006
Delivery speed: 145m/min
Count range: 6-20 Ne
TPM: 450-800
Package weight: .5-4 kg
Shape of yarn package: cylindrical
Machine efficiency: 75-100%
Voltage: 3phase 415 V
Frequency: 50 Hz
Amp: 6
SSL ROTOR SECTION:
Model: R40 (M/C no. 1-5), BT-904 (M/C no. 6)
Manufacturer: RIETER
Country of origin: SWITZERLAND
Number of rotor frame: 06
Number of rotor head per frame: 280 (R40) & 288 (BT-904)
Rotor RPM: 70000-1600000
Rotor diameter: 31mm, 32mm, 35 mm, 41 mm & 50mm
Feed roller RPM:
Feed roller diameter: 35 mm
Opening roller diameter: 80 mm
Opening roller RPM: 7000-8500
Draft range: 95-120
Winding angle: 36
Tension draft: 1.006
Delivery speed: up to 350m/min
55
Count range: 6-20 Ne
TPM: 450-800
Package weight: .5-4 kg
Shape of yarn package: cylindrical
Machine efficiency: 75-100%
Voltage: 3phase 415 V
Frequency: 50 Hz
Amp: 6
Finishing section
Yarn bobbins which are to be supplied to market should undergo the following operation
Yarn bobbin
Cone winding
Heat setting
Packing (carton)
Storing
Heat setting:
Heat setting is an important finishing of yarn. For heat setting, one room is provided and
required temperature and humidity are supplied to the room. The package of yam is placed
on the creel for the specified time. After the pre-selected time the yarn are taken out from
the machine.
The advantages of heat setting:
Increased strength of yarn
Increased elasticity of yarn
Set the twist
Increased the weight of yarn (1-2%)
56
Machine specification:
Brand: Xorella AG
Model: CH-5430 WETTINGEN
Type: CONTEXXO
Manufacturer: peterhans AG 5605 Dottikan
Country of origin: Switzerland
Production no./ year: 2010630/2000
Medium: saturated steam el. 100KW
Perm working pressure: -1bar-.5bar
Perm working temperature: 111.4C
Volume: 14250L
Heat setting time: 60-70 minutes
Number of input yarn package: 480-498
Weight of input yarn: 998-1035 kg
57
CHAPTER IV
RAW MATERIALS
58
Raw materials
Productivity, quality and profit all are dependent on raw material. Raw material is the main
factor in every spinning mill. Sinha rotor spinning mill produces only cotton yarn. As cotton
is not grown in our country, so they are imported from other countries. Sinha rotor spinning
mills has used several types of cotton, which are imported from different countries of the
cotton growing area.
The following cottons are used by mills in the last months:
Brand name Country of origin Staple length (inch)
CIS Uzbekistan 1 1/8
CIS Kazakhstan 1 3/32
USA USA 1 1/16
PAKISTAN PAKISTAN
ZIMBABWE ZIMBABWE 1 1/8
MCU India 1 1/32
SUDAN Sudan 1 1/16
SANKAR India 1 1/16
For the rotor unit, there are various types mixing are available
They are:
50% virgin cotton + 50% wastage

For example, a mixing ration is shown:
Lay down for rotor line:
Type of cotton No. of bale Weight /bale (Kg) Percentage
USA-1117 8 222 45%
Jossi cotton 2 80 4%
Loose cotton 5 50 6%
Pneumafil 2 80 9%
59
Dropping-2 2 80 4%
Noil bale 2 80 4%
Flat strip (FS) 4 80 4%
FS & dropping-1 11 80 23%
Total: 3866 100%
Price of raw cotton:

Name of cotton Staple length (inch) Price (USC per lb)
Sankar 1 1/8 75.00
India 1 1/18 68.00
India, J-34 1 1/16 69.00
CIS 1 1/16 90.00
Zimerex 1 1/8 57.50
Sankar-6 1 1/8 61.00
Statement of raw cotton consumption March-08 (sample):
SR Description Consignment L/C no. Bales Issued kg Price per

of cotton lb
No.
2417 Sankar 1 1/8 Consign- 1094 66 10527.00 .75

1051(159.59)
2421 ,, ,, ,, 50 7975.00 ,,
2422 ,, ,, ,, 10 1595.00 ,,
2423 ,, ,, ,, 76 12122.00 ,,
2424 ,, ,, ,, 89 14195.00 ,,
2425 ,, ,, ,, 20 3190.00 ,,
2426 ,, ,, ,, 45 7177.00 ,,
60
Raw cotton suppliers:
Cotton name Staple length Supplier
Sanker-6 29mm DM lakhani overseas pvt. Ltd
Sanker-6 28.5mm Hazi almohamed mosa & Co.
India J-34 26mm LGW ltd.
Sanker-6 29mm Welt cot int.
CIS 29mm Fibertex ltd
61
CHAPTER V
PRODUCTION PLANNING & SEQUENCES

&
PROCESS CONTROL
62
Production Planning & Process Control
Concept of bale management:
Bale management is a process of inventory control and selection of bales of fibers according to their
properties and also to mix the fibers homogenously to get consistent production as well as quality of
yarn. For bale management, all bale samples are tested and bale with almost similar category are
arranged for homogeneous mixing.
In Sinha Rotor Spinning Mills bale management is bone by bale information advance system (BIAS).
Bale category i.e. Mic, color grade, staple length

Bale identification I.e. bale no.
Bale management procedure:
1. At first 100% bales of a lot are tested. Normally micronaire value and color grade are taken
as parameter to be tested.
SL no. Bale no. Mic. Color grade
1 1 4.0 GM
2 2 4.2 SM
3 3 4.1 GSM
- -
1200 1200 4.0 SM
2. After that closely similar MI. (.03) and color grades bales are selected.
Mic Color grade Total
GM SM(S) SM
3.9 75 25 4 100
4.0 90 8 2 104
4.9 110 20 3 135
63
3. Then the mi. which have the major proportion in the lot are taken
4. Finally a number of bales are selected according to the capacity of the industry
Let,
Total no. of bale: 800
Dailey consumption: 40 bales
No. of days to process the lot: 800/40 = 20
Information found on a bale:
Gin no.
Lot no.
Bale weight
Suppliers bale no.
Binding materials for bales:
Steel wire, copper wire

Polyester strap
No. of binders. 6 to 8
Manpower available in mixing section:
Mixing man: 6
Cleaning man: 2
APO: 1
Total: 9
64
65
66
67
CHAPTER VI
QUALITY ASSURANCE SYSTEM
68
Quality assurance department
In SINHA ROTOR SPINNING LIMITED, quality assurance department is well equipped with various
types of yarn testing instrument. Actually it is a quality based mill. They are careful about the quality
of the product with production. All information related to yarn process are controlled from this
department.
List of the machines which are used in QAD laboratory: Sinha Rotor Spinning Ltd. Is enriched with the
following instrument:
I. Premier ART
II. USTER AFIS PRO
III. Premier tester 7000
IV. Premier TENSOMAXX 7000
V. WIRA yarn reel
VI. Digital twist tested DE-5 (WIRA)
VII. Premier rapidcon 2B
VIII. Optical yarn reader
IX. Premier ART-N
Premier ART
Manufacturer: premier, India
Function: Premier ART is used to test the following physical properties of the fiber. It tests according
to the HVI calibration.
Test Result Abbreviation
Spinning Consistency Index SCI
Micronaire Mic
Maturity Index Mat
Upper Half Mean Length UHML
Uniformity Index Unf
Short Fiber Index SFI
Strength Str
Elongation Elg
Moisture Moist
Reflectance Rd
69
Yellowness +b
Color Grade CG
Trash Count Tr cnt
Trash Area Tr area
Trash Grade Tr grade
Fluorescence UV
Neps Nep
Uster AFIS PRO
Manufacturer: Zelleweger Uster, Switzerland
Model: AFIS PRO
AFIS modules:
NC modules:
The USTER AFIS PRO comes with different modules enabling a customized configuration for eaxch
plant.
The NC module is included in the base configuration of the USTER AFIS PRO. It stands for nep
classification and measures the amount and the size of neps and seed coat neps in raw cotton, card
mat and sliver.
Test result Abbreviation
Nep count per gram Nep Cnt/g
Nep size (micron) Nep size [m]
Seed coat nep count per gram SCN Cnt/g
Seed coat nep size (micron) SCN size [m]
The L&M module measures fiber length and maturity in raw cotton, card mat and sliver. The length
is measured on single fibers in order to get a true fiber length distribution within a cotton sample.
The USTER AFIS PRO is the only instrument that measures the maturity of single fibers, resulting in
a true distribution of maturity within a cotton sample.
Test result Format Abbreviation
Mean length by weight X.XX
XX.X L (w)
Length variation by weight XX.X L (w) CV%
70
Upper quartile length by X.XX
weight
XX.X UQL (W)
Short fiber content by weight XX.X SFC(W)
Mean length by number X.XX
XX.X L (n)
Length variation XX.X L (n) CV%
5% length by number X.XX
XX.X L (n) CV%
Short fiber content by number XX.X SFC (n)
Fineness (millitex) XXX FINE (mtex)
Maturity ratio X.XX MAT
Immature fiber content (%) XX.X IFC %
Test setting: different setting points are to be set before starting the test. These are shown below.
Identifier
Location
Test module
Weight: weight of the sample must be in between 0.4-0.6gm
Main parts of the machine: the main parts of the machine are given below.
a) Monitor
b) Printer
c) Computer system
d) Electronic balance
e) Sample feed unit
f) Different sensor for test the sample
Premier tester 7000
Basic installation: module to test evenness properties
Additional properties:
To measure the hairiness index

12-40 ktex for coarser sliver
Application range:
Yarn, roving and sliver

4 to 12 ktex
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Measuring principle:
Evenness capacitance sensor
Hairiness optical sensor
Test condition:
Test time up to 20 min

Test speed up to 400m/min
Test speed:
Speed (m/min) Generally used for
400 Yarn
125 Sliver and roving
100 Sliver and roving
50 Roving
Main parts of the machine: the main parts of the machine are given below:
a) Hairiness sensor (optical sensor)

b) Tensor type D
c) Sensor type B (capacitance sensor)
d) Conveyor
e) Absorber type B
f) Computer system (CPU)
g) Creel (it can holds 24 bobbin max)
Other parts:
a) UPS
b) Monitor
c) printer
Sensor type B (capacitance sensor) has four slots for evenness testing. These are shown below:
Slot no. Used for
1 Sliver
2 Roving
3 Yarn (less than 30Ne)
4 Yarn (more than 30Ne)
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Output parameters: premier tester 7000 tests the following parameters of the materials.
a) Unevenness (U%) & Co-efficient of variation (CV%)

b) Imperfection
c) Cut length CV%
d) Index of irregularity
e) Relative count
f) Maximum and minimum mass value of different length
TENSOMAXX 7000
Manufacturer: Premier polytronics ltd. India
Serial no: P64
Description: Premier TENSOMAXX 7000 is a single yarn strength tester; it works on constant rate of
elongation (CRE). It determines the tensile characteristics of yarn. This tester tests the following
properties of yarn.
Breaking tenacity
Breaking force
Force elongation
Graphical results
Output parameters: after testing yarn premier TENSOMAXX 7000 gives some results. These are
given below:
Breaking time
Breaking force
Breaking tenacity (RKM)
Breaking elongation
Breaking work
It also gives the mean value, CV% minimum & maximum value of them.
Test setting: before starting ab=ny test it needs to set the following setting:
Test ID
Sample (yarn)
Material (cotton)
Speed: 5000.00 mm/min
Length: 500.0 mm
Pre-tension: .50 CN/tex
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Twist tester:
Digital twist tester DE 5
Serial number: 350110007
Manufacturer: WIRA
Country of origin: UK
Function: determination of yarn TPI
Wrap reel:
Manufacturer: WIRA
WIRA yarn reel: 5-SKRM-36
Serial no. 100110024
Country of origin: UK
Function: to make lea (120 yards) of yarn.
Optical yarn reader:
Manufacturer: caipo
Model: OYR 1513
Country of origin: Italy
Function: to measure slub dia, length & distance between two slubs.
74
CHAPTER VII
MAINTENANCE
75
Maintenance
Maintenance points in Blow Room:
MACHINE NAME MAINTENANCE POINTS WORK TO BE DONE

Chasis Clean properly by compressed air.
Take off Unit Clean properly by compressed air.
Take off roller Check & clean properly by compressed air.
Unifloc A11 Retainer roller Check & clean properly by compressed air.
Conveyor belt Check & clean properly by compressed air.
Sensor Lenses to be cleaned by soft cloth.
Control cabinet Clean by skilled person..
Cleaning cylinder Properly clean & check any damage.
Cleaning grid Check any damage & position.
Uniclean B11 Airlock cylinder Check & clean properly.
Gear and drive motor Clean properly.
Chamber Clean properly by compressed air.
Upright lattice Properly clean & check any damage.
Blending roller Properly clean & check any damage.
Unimix B 7/3 Take off roller Properly clean & check any damage.
V-belt pulley Clean, check belt & chain tension.
Lamellar chute Cleaned by soft cloth & compressed air.
Perforated roller Check & clean properly by compressed air.
Uniflex B 60 Opening &cleaning Properly clean & check any damage.
cylinder
Cleaning grid Check any damage & position.
Gear and drive motor Clean properly.
Tube light Clean by soft cloth.
Jossi CCD camera Lenses to be cleaned by soft cloth.
Waste opener Upright lattice Properly clean & check any damage.
B 2/5 V-belt and pulley Clean, check belt & chain tension.
Mono cylinder Beater Properly clean & check any damage.
B 4/1
Mix bale opener Upright lattice Properly clean & check any damage.
B V-belt and pulley Clean, check belt & chain tension.
Maintenance carried in Blow Room:

Periodic maintenance : After 7 to 10 days
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Maintenance Period : From 8a.m. to 5p.m.
No of men in maintenance of Blow room to carding machine are ten

Maintenance Assistance :3
Maintenance Helper :7
Schedule maintenance : After two weeks
Preventive maintenance : 1 month or 3 months.
Maintenance Tools for blow room to carding machine:

Adjustable range
Screw driver
Hammer
Spancer etc.
Lubrication schedule:
1 month, 3 month, 6 month, 1 year, 1 and a half year.
Duration of maintenance for carding machine : 2.5 to 3 hrs.
Duration of maintenance for blow room : 3.5 to 4 hrs.
Maintenance procedure:
At the beginning of the maintenance operation, all the covers of the machines are opened
and the machine is cleaned with a cloth internally. This is called as general cleaning. Inside the
machine the conveyor belt tension (if present) is checked and wooden lattice is also cleaned and
conveyor belt is cleaned if needed. Jam in the two sides of spiked lattice is opened and under cover
of spiked lattice is opened and cleaned. Jam in the sides of bearing house of evener roller with oils or
lubricants as instructed by the manufacturer. China box is checked and jam is cleaned if necessary.
M/C parts are checked conveniently and or changed if necessary.
Examples of maintenance procedure instructed by the manufacturer:

Name of the machine : Unifloc
Maintenance and Lubricating schedule : Every month
Item Action
Plucker roller Inspect for sign of damage
Head slewing Ensure clean
Traverse Inspect and clean cowl plate grille
Flexible pipe check condition
Internal structure comb Ensure clean
77
Maintenance and Lubricating schedule: Six month
Item Action
Plucked roller Check condition of the teeth
Plucked roller drivers V-belt drive check
Head lifting drive Duplex drive chain-chain tension
Head slew drive Duplex drive chain-chain tension
Transport fan drive Drive belt check tension
Maintenance and Lubricating schedule: One year

Item Action
Bearing for plucker roller Replenish lubricant using shell
Cutting head Alvania-3 or equivalent
Tower support head Do
Lubrication of head drive unit:

Mobil synthetic oil ED62/230 viscosity class VG680 or equivalent.
Lubrication of head slewing drive unit:
Shell BP mineral oil viscosity class VG220 or equivalent.
Lubrication of traverse drive unit:
Shell BP mineral oil viscosity class VG220 or equivalent.
Name of the machine: Unimix

Maintenance and lubricating schedule: Every three month.
Item Action
Variable speed for feed rollers Duplex drive chain-chain tension
Variable speed for beater rollers Duplex drive chain lubricant using, gear box
check oil levels and replenish if necessary.
Conveyor belts Duplex drive chain to roller lubricating used.
Maintenance check list of carding m/c:

MAINTENANCE AREA MAINTENANCE POINTS WORK TO BE DONE
Aero feed Check and clean.
Opening roller Check and clean.
Lap roller Check and clean.
Feed roller Check and clean.
Licker in Check and clean.
Flat Clean properly & check sharpness
of the wire.
78
All Flat belts Clean, check tension & adjust if
required.
Card C 51 Doffer Clean properly & check sharpness
of the wire.
Detaching roller Check and clean.
Cross roller Check and clean.
Delivery roller Check and clean.
Calendar roller Check and clean.
Pneumatic system Clean & check condition.
All suction points Clean & check condition.
Cylinder Clean properly & check sharpness
of the wire
Control cabinet Clean properly
Feed roller to licker-in Check gauge & adjust if required
Licker-in to cylinder Check gauge & adjust if required
Gauge Cylinder to doffer Check gauge & adjust if required
Cylinder to flat Check gauge & adjust if required
Doffer to stripping roller Check gauge & adjust if required
Coiler calendar roller Clean & check condition.
Coiler Rotary plate for can Clean & check condition.
Drive for rotary can plate Clean & check condition.
Can changer Clean & check condition.
Maintenance points Frequency

Suction points and hoses 2 weeks
Interior of the coiler 2 weeks
Detaching unit 2 weeks
Check the doffer 2 weeks
Clean flats reversing points & the space
Inside the flats 2 weeks
Empty condenser 3 months
Check the tension & condition of the belts 2 weeks
Check the condition of the flat bar 6 months
Clean & check carding profiler 3 months
Check the tension of the flat belt 2 weeks
Cylinder inside & Cylinder gasket 6 months
Check the stripping knives 3 months
Check the bottom of the coiler & coiler tube 3 months
Check setting 6 months
Maintenance of draw frame, comber & simplex:

Nine person are involved in D, C, S maintenance.
Number of maintenance assistant 4
Number of maintenance helper 5
Schedule maintenance After 2 weeks
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Preventive maintenance 1 month, 2 month, 3 month
Maintenance check list of Breaker drawing:

Outer surface Outer surface of the whole Clean properly by compressed air.
machine
Pressure bar, dead weight, Clean properly check its condition.
Drafting zone condenser, trumpet.
Top roller Cleaning by washing powder &
grinding after 5000 hour.
Bottom roller Clean & check its gauge, reset if
required.
Gear box Planetary gear box Check oil level & put oil if required.
Electrical parts Motor, fan, creel light barrier Clean & check by electrical person.
Nut-bolts Top roller lock, pulley nut-bolt, Check tightness & make perfect
creel nut-bolt, drafting zone nut- tightness if required.
bolt
Belt tension and Flat belt, V-belt, timing belt Clean all the belt, check tension
condition adjust if required.
Suction system Filter box, filter screen, fan blade Clean properly filter & blade
condition.
Can Changer Can plate Check & clean properly.
Power cylinder Check & clean properly.
Maintenance procedure of lap former:

At first, the great box is opened and grease is applied to all gears. Top and
bottom rollers are opened and cleaned with spirit. Top roller, feed roller, calendar roller, sliver table,
sliver guide, counter shaft, conveyor belt, guide roller, lap plate, lap drum, bobbin box, bobbin
feeder, creel parts are cleaned. In all the bearings and gearings of the above parts lubrication is
carried out. All the nuts and bolts are checked. If any parts of the m/c is damaged, it is either
changed or repaired. Then the whole m/c is set sincerely and the m/c is started experimentally to
watch if the m/c is running smoothly.
Maintenance checklist of Lap former:

Maintenance Area Maintenance Points Work to be done
Suction Unit Waste suction pipes, motor knives. Clean & check suction properly.
Filters Clean & check condition.
Drive motor All belts and chains Clean, check tension, greasing &
apply grease if required.
Sliver feed frame Guide rolls, sliver guide Clean properly & check setting.
Table calendar Top cleaning device & bottom Clean & check its physical condition.
cleaning device
Drafting system Top and bottom roller Clean & check gauge reset if
required.
80
Gear units Setting gear Clean & check gear, vibration,
abnormal sound etc.
Sensors All sensors unit Clean all sensor unit by soft cloth.
Safety Device Safety switch, pneumatic switch Check safety device.
Nut and bolt Main gear box, drafting gear box, lap Tightness check & make correct if
plate etc. required.
Electrical function Main motor, electronic board, To be cleaned & checked by
connection board etc. electrical function.
Lubrication Main gear box, drafting gear box Check oil level & put oil if required,
and all greasing point also check greasing.
Maintenance procedure of comber:

According to the schedule maintenance of particular m/c is done.
First gear box is opened, then all the gears are cleaned and grease is applied to gears and cover is set
again. Top detaching roller, bottom detaching roller, top drafting roller, bottom drafting roller are
opened and spirits is served to clean these rollers are set to the machine. Sliver table, sliver guide,
top comb nipper, cushion plate, feed roller, lap roller, cylinder, cylinder brush, wastage suction pipe,
coiler box and can wheel cover are opened and cleaned and grease is applied to every bearing and
gearing. Then all the nuts and bolts are checked. In bottom detaching roller corium 157 is used. If
any part of the m/c is damaged, it is changed or repaired. After this, machine is started.
Maintenance checklist of Comber:

Maintenance Area Maintenance points Work to be done
Drafting system Top bottom and stripping roller Clean Properly & check physical
condition if required.
Top comb and circular comb setting Gauge check & adjust if required.
and condition.
Gauge points Nipper feed plate, nipper gauge, Gauge check & adjust if required.
bottom detaching roller
Belt tension and V-belt, timing belt and flat belt. Clean all the belt, check tension &
physical condition adjust if required.
Feed table, table funnel, calendar Clean & check condition if
roller and trumpet required.
Nipper, nipper level on in feed side, Clean & check condition if
Delivery unit circular comb brush required.
Feed roller, nipper lips, top Clean & check condition gauge,
detaching roller, guide plate, top adjust if required.
delivery roller and lap plate.
Gear box All gear Check gear condition & correct if
required.
Oil level in gear box Check oil level and apply oil if
necessary
Electrical parts Motor, switch, connection board, Clean & check by electronic
electronic board, motor fan person.
Can changer Chain tension on turn table Clean & check condition, adjust if
required.
Belt tension roll axles and other Clean & check grease if required.
greasing points.
81
Beating bush of the top detaching Clean & check grease if required.
Greasing points roller
Drafting roller, stripe nipper frame, Clean & check grease if required.
lower delivery and table calendar
Top roller pressure, main gearbox,
top comber nipper, all pulley, index Check tightness and make correct
Nut Bolts wheel, coiler wheel, lap feed plate, if required.
lap roller nut-bolt, circular comb,
can wheel.
Maintenance parts of comber E-62 by Rieter:

Cylinder comb
Nipper
Top comb
Detaching roller
Bottom feed roller
Bottom top roller
Brush
Drafting rollers
Noil % control system:

Top comb setting change
Ecartment setting change
Lubrication points:
Drafting system
Bottom detaching rollers
Top detaching rollers
Rush
Nipper
Gear box
Circular comb
Table calendar roller drive shaft
Spare parts life:

Parts Life time
Top comb 1-1.5 years
Cots 2-3years
Bearing 6 years
82
Maintenance procedure of draw frame:
First gear box is opened and cleaned finally with cloth. Then grease is applied to
gears. Roller part is opened and cleaned with spirit. In all the bearing of cover is opened and cleaned.
In the bearing gears, grease is applied. All the settings, nuts and bolts are checked. If necessary any
parts of the machine can be changed.
Maintenance check list of Breaker drawing:

Outer surface Outer surface of the whole Clean properly by compressed
machine. air.
Drafting zone Pressure bar, dead weight, Clean properly check its
condenser, trumpet. condition.
Top roller Cleaning by washing powder &
Bottom roller Clean & check its gauge, reset
if required.
Gear box Planetary gear box Check oil level & put oil if
required.
Electrical parts Motor, fan, creel light barrier Clean & check by electrical
person.
Nut-bolt Top roller lock, pulley nut-bolt, Check tightness & make
creel nut-bolt, drafting zone perfect tightness if required.
nut-bolt.
Belt tension and condition Flat belt, V-belt, timing belt Clean all the belt, check
tension adjust if required.
Suction system Filter box, filter screen, fan Clean properly filters & blade
blade condition.
Can plate Check & clean properly.
Can changer Check & clean meshing
Gear condition, vibration, abnormal
noise etc.
Maintenance check list of Finisher drawing:

Outer surface Outer surface of the whole Clean properly by compressed
machine air.
Auto leveler Funnel, scanning roller, Clean & check their condition
contact roller adjust if required.
Pressure bar, dead weight, Clean & check their condition
condenser, trumpet. adjust if required.
Drafting zone Top roller Cleaning by washing powder &
Bottom roller Clean & check its gauge, reset
if required.
Gear box Planetary gear box Check oil level & put oil if
required.
83
Electrical parts Motor, fan, creel light barrier Clean & check by electrical
person.
Nut-bolt Top roller lock, pulley nut-bolt, Check tightness & make
creel nut-bolt, drafting zone perfect tightness if required.
nut-bolt.
Belt tension and condition Flat belt, V-belt, timing belt Clean all the belt, check
tension adjust if required.
Suction system Filter box, filter screen, fan Clean properly filters & blade
blade condition.
Can changer Can plate Check & clean properly.
Gear Check & clean meshing
condition, vibration, abnormal
noise etc.
Spare parts life:

Parts Life time
Cots 6-8 years
Belts 3-4years
Timing belts 10 years
Cans 6 years
Bearing 6 years
Maintenance procedure of simplex:

At first the machine is opened and a general cleaning is done. Greasing done to all
outer bearings. Gear box is opened according to the authorized booklet of the machine. Top and
bottom rollers are opened and cleaned with spirit and then acid treatment is done. Cotton aprons
are opened with jet powder and then acid treatment is done. Collector, condenser, sliver guide, top
and bottom cleaner, roller stand, roller beam, top arm, lifter rack, building part, creel part and each
flyer and bobbin rail cover are cleaned. At the last every nuts and bolts are checked. Thus routine
maintenance in the simplex machine is carried out.
Maintenance checklist of Simplex:

Creel Clean & check bearing
condition.
Sensor Clean by soft cloth.
Balancing spring and chain Clean & check greasing.
Back side Creel chain Clean & check greasing.
Rack groove Clean & check greasing.
Grease level in the grease Check grease level & apply
pump grease if required.
Top and bottom roller Clean & gauge check & adjust
if required.
Condenser assembly Clean & check assembly &
adjust if required.
84
Drafting zone Traverse bar and sliver guide Clean & check setting.
Neck bearing of bottom roller Clean & check & replace if
required.
Cradle unit Clean & check & replace if
required.
Pressure arm Check height gauge & readjust
if required.
Top and bottom apron Clean properly by detergent &
replace if required.
Yarn cleaner Clean by brush replace if
required.
Flyer cap Clean set properly.
Flyer rail Flyer and its gear Clean & check gear-meshing
condition.
Shaft Clean & check condition.
Bobbin rail Bobbin rail and seal Clean & check the gear
condition.
Outer surface Outer surface of the machine Clean the outer surface
properly.
Auto doffing Auto doffing in machine Auto doffing system is clean by
compressed air.
Maintenance procedure for Ring frame:

First machine cover is opened. All the top aprons and bottom aprons are opened with Surf
ultra. Here acid treatment is done. It is also with ammonia. In all the middle bearing, necessary
amount of grease is applied. Ring plate is taken down and the ring caps are cleaned with corium 97.
After cleaning all the gears, sufficient amount with corium 97.
If any part of machine is damaged or rough, it is changed or repaired. In this way, all the works of
maintenance is done successfully.
Maintenance checklist of Ring frame:

MAINTENANCE AREA MAINTENANCE PONTS WORK TO BE DONE
Cog belt tension Cleaning & checking condition if 30 days
required.
Bottom apron tension bracket Cleaning & checking condition if 30 days
required.
Type tension roller condition Cleaning & checking condition if 30 days
required.
All type of timing belt condition Cleaning & checking condition if 30 days
for head stock & tail stock required.
ROBO doff, lifting rod, drive Cleaning & checking condition if 30 days
required.
Brushes of servo discs Cleaning & checking condition if 30 days
required.
Cot roller Cleaning & checking condition if 30 days
required.
Cradle Cleaning & checking condition if 30 days
required.
85
Top & bottom apron Cleaning & checking condition if 30 days
required.
Spindle & spindle break Cleaning & checking condition if 30 days
required.
Pneumatic line, mono meter & Cleaning & checking condition if 240 days
pressure regulator required.
Pressure hose condition Cleaning & checking condition if 30 days
required.
Gripper membranes condition Cleaning & checking condition if 30 days
required.
Filter box, filter cloth, seal of Cleaning & checking condition if 240 days
filter drum required.
Suction tube gauge 1mm Cleaning & checking condition if 30 days
required.
Sensors Cleaning & checking condition if 30 days
required.
Ring cup, balloon control ring & Cleaning & checking condition if 120 days
lappet guide required.
Ring rail, lappet bar setting Cleaning & checking condition if 120 days
gauge required.
Spinning traveler cleaner gauge Cleaning & checking condition if 120 days
required.
Auto doffer, beam & conveyor Cleaning & checking condition if 90 days
belt centre required.
Roller eccentricity & bearing Cleaning & checking condition if 730 days
condition check (back & middle required.
roller
Front roller eccentricity, bearing Cleaning & checking condition if 365 days
condition required.
Driving shaft eccentricity & Cleaning & checking condition if 730 days
bearing condition check required.
Machine leveling Cleaning & checking condition if 730 days
required.
Maintenance of ring frame:

Twenty three persons are involved in ring frame maintenance
No of maintenance assistance 6
Grade 1=2
Grade 2=4
No of maintenance helper 17
Schedule maintenance : after one month
Cleaning, checking and lubrication are included in ring frame maintenance
Lubrication schedule : 6 months (spindle oil), grease(driving shaft), 1 year (gear oil),
1 month (bottom roller)
86
Maintenance of ring frame:
Waxing shaft Cleaning & checking any damaged
(cwf)
Pressure fork Cleaning & checking any damaged
Waxing device (cwf)
Yarn trap Remove the yarn accumulation
Guide plate Cleaning the wax properly
Splice cutter Cleaning and apply RS-400
Prism and its cover Cleaning the prism by compressed
Splice unit air
Untwist nozzle Clean/wash by petrol & brush,
checking the position.
Clamping guide Cleaning by cloth.
Feeder guide Checking the position.
Rubber sleeve Cleaning & checking.
Tension device Sensor Cleaning carefully & adjust if
required.
Cuter Cleaning and apply RS-400
Lower end sensor Cleaning the sensing area.
Package adapter Check for unobstructed rotation.
Cradle holder Sliding part (cradle) Cleaning and apply silicon oil.
Cradle sensor Check its cover and screw.
Circular magazine Check, clean and refixing.
Magazine Chute door Cleaning and centering check.
Elector Cleaning and movement check.
Bobbin peg Cleaning.
Conveyor belt Tensioning device Remove cover from the belt
tensioning device of the conveyor
belt & remove yarn jam if
required.
Deflection roller Remove loose yarn ends from the
deflection rollers.
Maintenance procedure for Autoconer:

Ten persons are involved for winding m/c maintenance
No of maintenance assistance 3
Grade 1=1
Grade 2=2
No of maintenance helper 7
Schedule maintenance is done for winding m/c
87
60 drums consist in a winding m/c
Every day except Friday 12 drums maintenance
Maintenance schedule for a winding m/c : 45 days
Frequency of each drum maintenance : 45 days
Cleaning, checking, lubricating are done in winding m/c maintenance.
Lubrication schedule:
Sliding part of gamo, cradle - 6 months
Driving part inside winding unit - 3 months
Winding unit outside cam drives and cassette type gear 1 month
Line shaft driving chain - 2 months
Bearing center for (right side) : 6 months
Bearing center for (left side) : 6 months
Line shaft gear motor : 6 months
Cam shaft bearing : 3 months
Blower shaft : 1 month
Cassette type joint gear cover : 1 month
Maintenance checklist of Rotor:

MAINTENANCE POINTS WORK TO BE DONE INTERVAL
Rotor Cleaning by dishwasher. 15 days
Nozzle Cleaning by detergent. 15 days
Opening roller Cleaning by compressed air. 15 days
Rotor chamber Cleaning by compressed air. 15 days
Belt, pulley Clean all the belt, check tension & adjust if 15 days
required.
Electrical function To be cleaned & checked by electrical function. 15 days
Gear units Clean & check gear, vibration, abnormal sound etc. 15 days
Sensor Clean all sensors unit by soft cloth. 15 days
Robot Check & cleaning by compressed air. 15 days
Magazine Check & cleaning by compressed air. 15 days
List of Maintenance equipments for general purpose:

1. Dial Gauge : used measure roller eccentricity.
2. Tightening tools : used to tight bottom roller.
3. Thickness gauge : to measure thickness.
4. Straightening gauge : used to measure straightness of bottom roller after joining.
5. Grease pump : use to apply grease.
6. Stropping pliers : to open or close the ring.
7. Spring piece for level plate : for leveling parts of m/cs.
8. Bobbin rail jack : use to level the bobbing rail.
9. Weight gauge : use to alignment of the arm pressure.
88
10. Carding gauge
11. Outside calipers : use to measure the dia.
12. Roller setting gauge : use to set roller to roller distance.
13. L-key
14. Ring spanner
15. Spindle gauge : use to set spindle at the center of the ring.
16. Double end spanner : use to open the nut bolts.
17. Soft hammer
18. Puller
19. Oil can
20. Grease gun
21. Nose pliers.
89
CHAPTER VIII
UTILITY SERVICES
90
Utility service
The utility department undertakes the following units:
1. Power supply 6. Workshop services

2. A/C Plant 7. Water treatment & water supply
3. Water collection plant 8. Civil works
4. Chiller 9. Fire-fighting system
5. Boiler
Power Supply (Generator)
Sinha spinning mill generate its own power. It has six generator in SRSL and three generator in SSL.
The generator specifications are given below:
Generator of SRSL:
Name: JENBACHER Engine
Model: JGS 320
Country of origin: Austria
Necessary information:
Number of Generator: 6 (5 generator runs for power supply and 1 stand by)
Capacity: 1006 Kw
Production requirement: 60-70% of capacity
Type of Generator: Gas Generator
Synchronizing system: Auto synchronizing system
Controlling system: PLC (Programming Logic Control) Controlling system
Number of cylinder per generator: 20
Gas source: TITAS Gas
Gas line pressure: 14.5 PSI
RPM: 1500
Voltage: 415
Frequency: 50Hz
91
Gas consumption per day: 18000-20000m3
Price of gas: 4.18taka/m3
Island parallel operation:

Cylinder Exhaust Gas temperature:
Average : 542oC
Maximum : 552oC
Minimum : 534oC
Return water temperature: 63.6oC
Jacket water temperature: 81.6oC
Jacket water pressure: 1.11 bar
Engine oil temperature: 79.0oC
Engine oil pressure: 4.2 bar
Generator of SSL:
Name: JENBACHER Engine
Model: JGS 320
Country of origin: Austria
Necessary information:
Number of Generator: 3
Capacity: 1064 Kw
Production requirement: 60-70% of capacity
Type of Generator: Gas Generator
Synchronizing system: Auto synchronizing system
Controlling system: PLC (Programming Logic Control) Controlling system
Number of cylinder per generator: 20
Gas source: TITAS Gas
Gas line pressure: 10 PSI
RPM: 1500
Voltage: 415
Frequency: 50Hz
92
Price of gas: 4.18 taka/m3
Boiler:
Number of boiler: 1
Capacity: 10 Kg/hour
Production: 5.6 Kg/hour
Source of heat: Exhaust of generator
Temperature raised: 550oC (Maximum)
Steam pressure: 405 Kg/cm3
Manufacturer: Hurst Boiler, India
Serial no: BA.BO. 2332
Compressor
Compressor 1
Manufacturer: Comp Air Drucklufttechnik GmbH, Germany
Type: L160-9A (Delcos 3000)
Voltage: 400V
Year of Manufacture: 2002
Serial no: 349020/0206
More information:
Capacity: 26.10m3/min
Motor: 160KW
Suction pressure: 1bar
Speed: 1500rpm
Stage pressure: 9bar
Compression medium: Luft/Air
Receiver:
Manufacturer: Lohenner GmbH & CO, Germany
Serial no: 81857
Date of Manufacture: 26.08.2002
93
More information:
Capacity: 2000 L
Working pressure: 11 bar (maximum)
Working pressure: 0 bar (minimum)
Test pressure: 15.8 bar
Compressor 2
Manufacturer: Comp Air, England
Model: 6220N8A
Serial no: F146/0827
Year of manufacture: 1997
More information:
Capacity: 29.10m3/min
Maximum pressure: 8 bar
Motor (KW input): 199.1 KW
Motor RPM: 1480
Voltage: 415V
Phase: 3Ph
Frequency: 50Hz
Compressor 3
Manufacturer: Atlas Copco
Model: GA 75
Serial no: 473279
Year: 2001
Country of origin: Belgium
More information:
Maximum working pressure: 7.5 bar
Free air delivery: 1/s=236
Nominal shaft power: 75Kw
94
Rotational shaft speed: 300.0
Gross weight: 1600 Kg
Compressed Air Dryer:

Model: Js-100Ac
Date of manufacture: 29.08.2001
Capacity: 14.4 Nm3/min
Maximum inlet temperature: 70oC
Maximum inlet pressure: 10 Kg/cm2
Amp: 7
Voltage: 415V
Phase: 3
Frequency: 50Hz
Compressor 4
Manufacturer: Atlas Copco
Model: GA 75
Serial no: 472583
Year: 2001
Country of origin: Belgium
A/C plant:
The factory consists of five A/C plants in SRSL and the two A/C plant in SSL.
The A/C plant in SRSL for
Blow room
Carding
Simplex
Rotor
Ring
AC Number Use for the Area

1 Blow Room
2 Carding& drawing (Rotor side)
3 Carding, drawing, comber & simplex
4 Ring (East & West side)
5 Rotor & Auto cone
95
The A/C plant in SSL is for
Rotor
The manufacturer of A/C plant for SRSL & SSL is BEST AIR.
The main task of A/C plant is to maintain specific humidity in the factory in the shed, for this
it circulates the cooling air. A/C plant without chilling helps to maintain only the RH% without much
difficulty. They can be classified generally as either unitary or central station. Central system is the
most widely used in the textile industry.
The systems principal components are:
1. Air moving devices-fans.
2. Mixing devices for air and washer i.e. Air washers.
Air moving devices are always two types:

1. Return Air fans
2. Supply Air fans
The return air fans return the air to the plant room from where it may circulate or exhausted in the
mill.
The supply of air to the mill from plant room.
Air washer is a device for intimately mixing water and air. The mixing water and air supply by nozzle.
Number of fans in different AC:

Name of fans/pump AC 1 AC 2 AC 3 AC 4 AC 5
Return Fan 1 1 3 6 3
Supply Fan 1 1 3 6 2
Waste water pump 1 1 2 3 1
Main suction fan 2 2 2
Disk-pre separator 2 1 2
Material transfer fan 5 1 2 2 3
Fiber compactor 2 - 2 1 1
Duct Evacuations fan 1 1 2 4 2
Rotary air fan 1 1 2 4 2
96
The following components are a must in an A/C plants:
Return Air and Supply Air fans.

Air washer
Return Air floor grills.
Exhaust damper
Fresh air damper
Supply air ducts and grills
Face and bypass dampers on the air washer
Control panel for Automatic control the RH and Temperature.
The fresh air come from outside, air is sucked by fan. Then the air humidified in the washer
room. In the washer room air and water is mixing then it supply by nozzle through the supply air
fan. Supply air fan supply the cooling air through the air floor grills. The invisible waste is
separated by filter and fresh air sucked by return air. Then the air is circulating again in the
washer room. It is continuous process.
The humidity and temperature controlling depend on the machine performance, machine life
and on personnel.
A/C plant is must needed for textile industries mainly spinning shed- if A/C plant will run
smoothly then the operators will feel comfortable and performance will be optimum.
Otherwise all these will suffer.
Supply and Return Air Fan capacity:

Suction Supply air capacity Return air capacity
Carding 74000 CMH 17180 CMH
Drawing 70000 CMH 237820 CMH
Lap former 70000 CMH 237820 CMH
Comber 70000 CMH 237820 CMH
Simplex 70000 CMH 46700 CMH
Ring 452000 CMH 436640 CMH
Auto cone 70000 CMH 67900 CMH
Rotor 106000 CMH 100020 CMH
Number of Air Change Cycle per hour:

Suction Air Change Rate (per hour)
Carding 29.7
Drawing 11.9
Lap former 11.9
Comber 11.9
Simplex 11.8
Ring 40.4
Auto cone 20.8
Rotor 27.3
97
Importance of RH% and Temperature:
The atmospheric conditions with respect to temperature and humidity play very important part
in the manufacturing process of textile yarns. The properties like dimensions, weight, tensile
strength, elastic recovery, electrical resistance, rigidity etc of all textile fiber whether natural or
synthetic are influenced by moisture regain.
Moisture regain is the ratio of the moisture oven-dry weight of the material expressed as
percentage. Many properties of textile materials very considerably with moisture regain, which
in turn is affected by the ambient Relative Humidity (RH) and Temperature. If a dry textile
material is placed in a room with a particular set of ambient conditions, it absorbs moisture and
in course of lime, attains equilibrium.
Some physical properties of textile materials which are affected by RH is given below:
Strength of COTTON goes up when R.H.% goes up
Strength of VISCOSE goes down when R.H.% goes up
Elongation% goes up with increased R.H.% for most textile fibers
The tendency for generation of static electricity due to friction decreases us RH goes up
At higher levels of RH, there is also a tendency of the fibers to slick together
Temperature alone does not have a great effect on the fibers- However the temperature dictates
the amount of moisture the air will hold in suspension and therefore, temperature and humidity
must be considered together.
ISO Standard # 139 defines Standard Atmospheric Conditions:
Temperature of 68
Relative humidity 75%
RELATIVE HUMIDITY & TEMPERAURE FOR DIFFERENT DEPARTMENT:

Section R.H.% Temperature
o o
C F
Blow Room 49.6 38.5 101.3
Carding 54.5 37.9 100.22
Comber 55.0 37.5 99.5
Simplex 60.2 37.7 99.86
Ring 58.3 38.0 100.4
Auto coner 63.0 39.0 102.2
Rotor 59.8 39.1 102.38
Chiller:
The main purpose of chiller is to supply chilled water to the A/C plant. Here three chiller in SRSL and
one chiller in SSL.
98
Chiller 1
Manufacturer: Thermax Ltd, India
Type: DE
Model: EW 770V
Serial no: 18
Manufacturing date: August, 2000
Other information:
Capacity: 770 TR
Cooling system: Steam heated vapor absorption cooling system
No. of cooling tower: 2
Steam pressure: 8.0 Kg/cm2
Temperature of the cooling water: 23oC (it should be> 10oC)
Voltage: 415V
Phase: 9Ph
Frequency: 50Hz
Chiller 2
Type: Hot water
Model: THW-LT/16
Serial no: 2
Manufacturing date: October, 2000
Other Information:
Capacity: 160 Nom. RT (Nominal Refrigeration of tons)
Cooling system: Hot water
Temperature of hot water: 67oC
Voltage: 415V
99
Phase: 3 Ph
Frequency: 50Hz
Chiller 3(it does not work)

Type: Hot water
Model: THW-LT/42
Serial no: 3
Manufacturing date: March, 2000
Other information:
Capacity: 425 Nom. RT (Nominal Refrigeration of tons)
Cooling system: Hot water
Temperature of hot water: 87oC
Voltage: 415V
Phase: 3 Ph
Frequency: 50Hz
Fire Fighting System:

Cotton fiber catches and spreads fire very rapidly. So any kind of accidents related to fire generation
can turn into a devastating calamity in cotton spinning mill. That is why the factory has a well-equipped
firefighting system. Water lines are spread throughout the factory. External and internal firefighting
groups are always ready to action. Some workers practice to go out quickly from the factory during
fire alarm is start. It helps to make any action against fire and reduce any kind of injury.
Number of fire fighters:
Shift SRSL SSL
P/A 20 16
P/B 20 16
P/C 20 16
100
Fire extinguisher:
Name of fire extinguisher SRSL SSL
ABC Power Box 59 24
CO2 25 10
Foam 2 6
Exit Box 10 5
House Cabinet box 6 5
Smoke Detector 6 3
Fire Alarm 7 4
Safety against fire hazard:

Automatic fire door-
One pair between Blow room and pre-spinning
One pair between pre-spinning and spinning
One pair between spinning and finishing
Firefighting equipment:
Section No. of fire exit No. of water drum Water in each bucket
Blow Room 6 5 10
Pre-spinning 13 9 10
Spinning 20 4 8
Yarn finishing 5 - -
Power sub station 3 - -
Store & godown 3 4 8
Generator house 2 - -
Total 52 22 36
Hose pipe points:

Location of points No. of point
North-west of Blow room 2
South-west of Blow room 1
Simplex gate Generator 2
East of yarn finishing section 1
Power supply & Power consumption:

Main power source: Generator
Substitute: DESA
DESA Line:
Supply: 1415 Volts
No. of step down transformer: 3
Transformer capacity: 1500KVA
No. of low tension distribution board: 14
Fluctuation: 2-5%
101
Humidification Plant
Country of origin: Singapore
Total no. of machine: 5
Machine Presentation:
For Back section: 1
For Ring section: 2
For finishing section: 1
Comber and Simplex: 1
No. of air change (Filtration): 30 times per hour
Air spreading system: by different duel line
Relative Humidity in Different Section:

Back Process: 45%
Ring Section: 52%
Finishing Section: 65%
Comments:
Sinha Rotor Spinning Mills Ltd. try to maintain proper humidity required for different
section. So less problem is occurred in processing materials from back to finishing section. There is no
system for temperature controlling system by slightly controlling the humidity.
102
CHAPTER IX
STORE & INVENTORY CONTROL
103
Raw materials:
Import processing by head office

Physical received by stock spare LC or invoice as bale or Kg.
The raw materials are provided for lay down according to lay down plane given from Q.C
Department.
The inventory systems are divided into four groups:
1. Raw cotton inventory

2. Finisher yarn inventory
3. Wastage yarn inventory
4. Spare parts & materials inventory
The inventory is maintained in first in first out system. When store keeper receive some goods, they
write a note in the receive book. They also inform inventory related department. Then the department
made MRR (Material Receiving Report). They made BIN card which contain its name, amount and
other necessary information. Then the materials are stored in the store.
If any department requires any item, they prepare a SR (Requisition Slip) for the particular item and
send it to store. The store then checks its availability and delivers as required.
1. Raw cotton inventory:
In case of raw cotton inventory, QAD department sampling every bale and numbering the bale
according to micronaire value.
2. Finished yarn inventory:
Different lots of finished yarn are given to the production department by Transfer Memo. The store
produces its daily, monthly production report based on the yarns are delivered to order of the
marketing department, the yarns are delivered to the buyers.
3. Wastage yarn inventory:
Different wastage produces from different department. Such as hard waste, pneumafil, FS, dropping
etc. They are measured even day and transferred to store same procedure.
4. Spare parts and materials inventory:
Different type machine parts are stored in the store. When any kind of machine parts broken, damage
etc then this machine parts collect from store.
Finished Yarn: 1) Received from production department
2) Delivered to customer
3) Count, Lot or LC
104
Engineering stock or spare:
All kind of spare parts are received and stocks are maintained.
At first received by reporting system
Stock purchase required
Material receiving report (MMR)
Posting to bin card
Issue
Balance position
N.B: Gate pass is required for receiving or delivery.
Quality certify by the following items:

SPR no.
MRP no.
Chalan no.
User name.
Reference
Remarks: Sinha Spinning mill tries to maintain proper stock report required for different section. So
less problem is occurred in processing materials from back to finishing section. The store
department & inventory control system of this mill is well organized.
105
CHAPTER X
COST ANALYSIS
106
Study of yarn costing
Type of cost: There are three types of cost mainly related to the yarn costing. These are given below:
Manufacturing cost
Selling cost
Marketing cost
Product Cost:
Product cost consists of the following costs:
Cost of raw materials:
L/C price
C & F Value
Landing cost
Transport cost
Carrying, Loading & Unloading cost
Conversion cost:
Bale management cost

Wastage cost
Machine cost
Machine depreciation
Fuel cost
Lubrication cost
Power cost
Spare cost
Manpower cost
Salary & Wages
Bank interest
Establishment cost
Packing cost:
Paper cone
H.D.P.E bag
P.P bag/ Hosiery bag / Cartoon
Label
Jute twine
Wrapping
107
Formula of various cost:
Marketing cost= Manufacturing cost + Selling Cost + Distribution Cost
Selling Cost= Manufacturing cost + certain amount of profit
Gross profit= Selling cost Manufacturing cost
Net profit= Gross profit (Bank charge + All sorts Taxes)
Yarn Prizes:
Yarn prize depends on the following factors.
Raw material cost --------60-70%

Spare cost ------------------2-2.5%
Financial charge ----------12-17%
Wages & Salary -----------3-10%
Power cost -----------------3-4%
Others ----------------------1.3-2%
108
CHAPTER XI
MARKETING ACTIVITIES
109
Brand name:
1. Sinha Rotor Spinning Ltd.
2. Sinha Spinning Ltd.
Buyer of Product:
1. Denim:
Hamim Denim Ltd.
Pacific Denim Ltd.
Chittagong Denim Ltd.
Royal Denim Ltd.
Sinha Denim Ltd.
2. Textiles:
Sinha yarn dyeing Ltd.
Sinha knitting Ltd.
Adnan textile Ltd.
Asian dyeing Ltd.
Dacca Dyeing Ltd.
Radiance group.
Mascot group.
Shirazgonj Check
Reja Fabrics
Padma textiles
All tex
Bengal textile
Competitors:
a. Square textile
b. Shamim textile
c. Ages cotton
d. Akij textile
e. Thermax textile
f. Sayham textile
g. Nasa textile
h. RK textile
i. Al-Haj Karim Textile
110
Foreign buyers:
H&M
Mark Kough
Synergies
Lee & Fung
AMC
VF Asia
TCP
Hanes
GAP
Responsibilities of a Marketing Officer:

The Marketing Officer oversees the companys marketing campaigns both internally and externally
and plays a key part in communicating the organizations marketing message.
Duties include:
Preparing, planning and project managing the publication of all publicity material to
maximize brand promotion.
Creating marketing campaigns and working with the company's external PR agency
to see them executed.
Creating and developing new innovative ways to communicate the company
message to their existing customers.
Contributing to the annual sales and marketing plan.
Planning and project managing marketing events and evaluating their success.
Evaluating the effectiveness of all marketing activity.
Developing and implementing an internal marketing programme.
Supporting the marketing manager in day to day marketing activities.
Plan, develop and deliver campaigns as agreed within timescales.
111
CHAPTER XII
CONCLUSIONS
112
Technical education and its adoption in practical field we involved inextricably. Without the
implementation of the knowledge gathered in technical education its success bound to suffer.
Therefore, this two months long industrial as a partial fulfillment of our B.Sc. in textile engineering
course helped us accomplish the gap between the theoretical and practical knowledge by providing
an elementary idea about industrial environment processing machines, tools, equipment production
system and maintenance, administration and management system.
Our selected SINHA ROTOR SPINNING LIMITED may be regarded as the pioneer of modern
spinning mill in our country. It was established a few years ago with latest model of efficient
machinery. Within a very short time it earned name and fame at home and abroad for its quality in
production and administrative facilities. It is now not only providing knitted yarn to the local market,
but also exporting them to foreign countries at a stationary level. It mainly uses online process control
and its qualify control department helped us to achieve a profound knowledge about spinning mills
production sequence maintenance, quality control & assurance as well as its organization structure.
We tried our best to gather all necessary information but it is true that within this short period
it is quiet impossible to achieve 100% success as a whole this industry training was a satisfactory. Once
again we should like to thank the authority of SINHA ROTOR SPINNING LIMITED as well as honorable
teachers for their altruistic help and advice.
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Bangladesh University of Textiles

SINHA ROTOR SPINNING LIMITED

Mr. Reajul Islam

Bangladesh University of Textiles

K. M. Mamunur Rashid, ID: 20101059

Sadikur Rahman Shawpon, ID: 20101060

Ashfaqur Rahman, ID: 20101063

Department of Yarn Manufacturing

CHAPTER TOPICS PAGE NO

01. Name of the Mill : SINHA ROTOR SPINNING LIMITED

Aim of the Project:

Production of export quality yarn

Production Capacity (SRSL)

Section Total Spindle Count Range Production Capacity

Production Capacity (SSL)

Section Total spindle Count range Production capacity

Man power setup (SRSL)

Name of department Setup

Name of department Setup

GRAND TOTAL STAFF AND OFFICERS: 820

Workers rights and privileges:

1. Wages statement for workers:

01. Training of workers (Syllabus and training program)

02. Firefighting evacuation:

03. First aid:

Major duties and responsibilities of a production officer:

To control shift according to the pan made by the production manager.

Production section (major)

Quality assurance department maintenance department (minor)

Nature and scope:

Role within the organization:

MANAGEMENT INFORMATION SYSTEM:

A.M. (Back process)- 1 A.M. (Ring+ Finishing+ Rotor)- 1

A Shift B Shift C Shift A Shift B Shift C Shift SPO-

Mix. & Mix. & Mix. & Ring Ring Ring

2. Administration & Labour: AM/A & LWO- 1

SAE- 1 SAE- 9 SAE- 4

AM/ Sr. Accounts Officer- 1

9. Procurement: Manager/ DM/ AM- 1

Serial Name of machine Quantity Model Mfg. year Country of

SINHA SPINNING LIMITED

Serial Name of Machine Quantity Model Mfg. year Country of

Mixing bale opener:

Machines available in blow room section (SSL):

Number of machine :1 Take off depth : .8-20 mm

Number of machine :1 Voltage : 400 V

Number of machine :2 Voltage : 400 V

No. of machine Country of origin : Switzerland

For combed yarn

Blowroom line for Rotor line (SSL):

For Rotor yarn

Unifloc Mixing bale opener

Vision shield Vision shield

Chute feed Chute feed

For Rotor yarn For Carded yarn

Mixing system in blowroom line:

Beater rpm setting:

a) Individualization of fibers from tuft

Different gauge (settings) of the carding machine:

Setting points Distance (mm) Distance (thou)

Specification of card clothing:

Card clothing PPSI Height Angle (0)

Strengthening and parallelization of fibers

Top apron size: 39.2mm30mm1.1mm (LWT)

Bottom apron size: 72.5mm30mm1.1mm (LWT)