handbook of textile calculations and stastical formulaes

	1					2
							1)  Double yarn imperfections = S.Y.Imperfections x 0.2.
							Single yarn imp  x 0.17
THE HANK BOOK OF STATASTICAL
AND PRODUCTIVITY FOURMULAS							2 ) Single yarn strength in grams =
	PART - 1						Strength inlbs/ 0.276
Contents :-							3 ) RKM  =  C.S.P / 176 or C.S.P X 0.6/100
>  The machine related faults & remidies
> Statastical & prodectivity fourmulas							4) 1 Deg C = 32 X F X 9/2
>  Process problems & remidies
>  The compleat source of yarn faults classifications							5)  Traveller speed =   ( Meters/Sec )
> The orgin of yarn faults and remedies							3.14 x Ring dia X spdl speed
							-------------------------------------
							60  x 1000
Prepared By :							6)  No. of winders =
D.NAGESWARARAO.							Production/ Frame
Quality control officer							------------------------
M/s I.C.M. LIMITED							Production/ Winder
GUNTUR ( Dt)
3						4
7) No. of drums allotment =							11) Double yarn C.S.P = S.y C.S.P X 1.25
	4.8 x length of yarn per bobbin mts +1						12) Double yarn U%  = Single yarn u% x 0.7
	-----------------------------------------------------						13) Cop content   =
	winding speed mpm						3.8 x ( Ring dia2)x lift in Inches
							14)  Denier =  Mic x 0.354
8 ) Machine effciancy  =							15) Mic = Denier x 2.82
4500 x length of yarn in mts
	-------------------------------------------						16) STD. FRS =   Caliculated speed
	Winding speed x no. of drums						STD.Speed/ Act. Tpi x Fr. Dia x 3.142
9 )  Ring traveller cut in groving =
							17)  ACT. FRS = Act. SPEED
	494 x lea strength in lbs x 10						-------------------
	--------------------------------------------						Act. TPI X Fr. Dia X 3.142
	Ring dia in mm x Spdl speed						18) No. of coils/ inch ( For course count )
							T.M  X 10 SQR H.K
10 )  Tension weight in Grams =							19) No. of coils/inch ( Fine HK )
Lea strength in lbs x 0.118							T.M X 13 SQR H.K
5						6
20) Sides allotment in ring frame =						23) Fiber mturity ratio :
						Normal fibers - Dead fibers
b = 125/n - 30/sqr c - 1							-----------------------------------------   x 0.7
b = end breaks/ 100 spdl/ hr							200
c = count ne
n = no. of sides assinged for a tinter							24) Maturity co - effciant =
21 ) Relative humidity =							N +0.75+0.45D/ 100
Actual Vapaur pressure							N = Normal fibers
	---------------------------------		x 100				T = Thin walled or half mature
	Standard vapour pressure						D = Dead fibers
22)  Correction of yarn count for Humidity							24) Fiber diameter in microns
changes  ( Corrected count Ne)							Sqr of  3.14 x Denier/specific gravity
= n (100 +b Ra )
	---------------------					25) Drawing delevery speed mts/min
	100 + Rs					=  3.14 x D X N/1000
N =  Actual count
Ra  = Actual regain
Rs  = Standard Regain
7						8
26) Maturity co - effciant						28) R/F Production/ spindle/ 8 hrs =
						SPDL speed x 60 x 8
N + 0.75 +b 0.45D						--------------------------------  x eff
	----------------------					840 x 36 x tpi x ct x 2.204
	100
						28) Expected hanks/ shift/ 8 hrs =
	N = Normal fiber
	T = Thin walled or half walled mature					Spdl speed/ tpi / 63 x eff
	D = Dead fiber
						29) Fourmula to find out bobbin building
27)  Fiber diameter in microns						Total turns on bobbin/ spdl speed
sqr of 3.14 x Denier/ Specific gravity
						Total turns on bobbin =
Delevery speed in mts/ Min  ( Drawing )						Length in inches of yarn in bobbin x TPI
=  3.14 x D X N / 1000						Length in inches in bobbin =
						Wt of the material in lbs x 840 x 36
9						10
32)  Twist contraction %  =						36 Total mechanical draft =  MD X BD
( 2.64 x T.M ) - 4.82						24.22 X 1.46
33)  Avg, Count						37) Winding length /cam revaluations
(  C1W1 +C2W2 +C3W3 )						1 x 121 x 73 x 69 x 26 x 3.14 x 27
--------------------------------						-------------------------------------------------
W1 +Bw2	W1 + Bw2 +W3					2 x 40 x 102 x 29 x 1000
							= 5.67 mts
C1, C2, C3 are the counts						38) Count delevered at front roller nip
W1 ,W2,W3 Production/shift						Total draft x Roving hank
						39) Yarn cv% =
34) IFTPI Changed then grams/ Spindle						CV% +/- 2CV%/SQR OF N
Given production x curent TPI/EXPT. TPI						40) Yarn diameter = 0.95/ sqr of count
35) If spindle RPM Changed  then grams/spdl						41) Coils/ inch = 0.50x sqr of ct x 25.4
= Given production x expected RPM						42) Yarn relisation =
---------------------------------------------						( 95 -T) ( 1 - C/100)3
Running spindle RPM
11						12
43) To find out the average Denier in a mixing						46) Energy cost  =
Denier %						Total units /Production in kgs
Ex : 1.5D    - 50%						47) U.K.G = total units lost consumed/
8.0D     20 %						Production in kgs
3.0D     30 %						48) Linear density  of yarn in count systeam
=  50/1.5 +20/8 +30/3   =  45.8						Ne = 453.6/ 7 x M
100/45.8 = 2.18						m =  120 yds
44)  Caliculation of siders% achived siders%						49) Count in yarn tex =  M/100 X 100
Act. Hanks ( 100 - cal.w% +ach idles
	------------------------------------------------------					50) Dia correction facture =
	STD Hanks x (100 - Stdw% +STD					Old correction facture x Normal dia
	IDLES					--------------------------------------------
						Actual dia
45)   Twist variation %  =						51) Centinutons to grams
Twist variation/Intial tpi x 100						CN X 2.5 = GRAMS
13						14
51) T.F.O Producton/ spindle/ 8 hrs  =						55) Take up roller speed =
						0.204 x Spindle speed/TPI
Spdl speed x 60 x 8 x 2
-----------------------------------------------						56) Cam speed = Take up roller speed x 27
TPI X 36 X 840 X Ct x 2.204						-------------------------------------------
						100 x cam wheel  x 50
52) No. of Twists = Spdl speed rpm x 2/
Yarn speed in mpm						57) Pre take up roller speed =
						Take up roller speed x 72/28 x Drive wheel
=  15168.6 x d/D						--------------------------------------------------------
						Driven wheel
53) Delevery speed = Spdl speed/
TPI X 39.37 X 2						58) Over feed ration = 72/28 x Driver / Driven x 51
						/77- 1 x 100
54) Lease Angle ( Tan )
2 x Traverse length x takeup roll Speed						59) Density of take up package =
-------------------------------------------------------
3.14 x Take up roller dia x Cam speed
15						16
60)  Density of take up package =						65) Total imperfections  = 0.170 x S.Y Imperfections
Package in grams x 3.14
-------------------------------------						66)  Double yarn uster =  Single yarn uster
12 x H X ( D2 X D X d2)							--------------------------
							Sqr fo No. of plyes
H = Length in traverse
D = Bigger dia of delevery package						LF 1400A 4/4 DRAFTING CALICULATIONS
d = Smaller dia of delevery package						Dia 27 mm
61) Power consumption wats/ Hr						67) Creel tension draft = 0.022 x We
3 x cos tita
62) 1 unit = 100 Wattts/ Hr						68) Twist constant =  0.0091426 x G/H X T.W
1 Unit = 1 kw/ hr
1 Unit = 745 Watts						69) Draft constant = 29967.95/ BDCP X CP
63) Doubling yarn strength =
2.5 x ring yarn strength						70) Cone drum end wheel  =
64) Doubling TPI =  S.Y TPI X 0.7						K X D1 X 1.83/ds
						71) Lifter whel =  10.5 x E/F X B1 / sqr of H.K
						B1 = 2.8
17						18
71) Tensen wheel =						77) Draft constant = 29967.95 / BDCP
4742 x B2 / D.S. X SQR H.K						78 ) Break drat  =  66.818/ BDCP
B2 =  0.58						79)  Tension wheel = 4742 x B2 X D.S X sqr of H.K
D.S = Bare bobbin dia
						80) Coils per inch  for course roving =-
72) Coils/ inch  = For course roving =
TM X 10 ( Hank) 1/2						TM X 10 ( H.K) 1/2
For fine  =   TM X 13 ( HANK) 1/2
						81) For fine roving  =
LF 1400A DRAFTING 4/4 30 MM
						TM X 13 ( Hank) 1/2
73 ) Creel tension draft =
0.024 x We ( creel tension wheel)
74) Twist constant  0.008270 x g/h x Tw						RSB 851 CALICULATIONS
75) Draft constant = 29967.95						82) Creel tension draft =
-------------------						0.00694 x w1 ( creel tension wheel)
BDCP X CP
19						20
83) Draw of tension  = 0.0175 x W3						83) Intake tension draft  = 0.7398 x w8/w9
( Draw of tension pully)						( W8 +b W9 = 132 Teeth)
84) Draft = 6.017 x   ( Nw2/nw )						84) Break draft =  draw ot tension =
85) NW1 = Required hank						0.0175 X W3 ( Draw of tension pully)
--------------------						85)  Draft = 6.017 x NW2/NW1
Present hank x present draft
86) NW2 = Required hank							LR 6/S CALICULATIONS
	---------------------					Spindle wharve = 19 mm             18.5 MM
	Present hk x present  NW2					Twist constant = 27.44 x d/c x b/a    28.15
						Draft constant = 10.519x H/G
87)  B90 = Act. Hk - Std hk						Winding leangth =  3.11 x E/F
------------------------	---------------------------  x 1600					Break draft constant = 67.09/BDCP  67.09
Act. Hk
						A +B = 165  C+D = 137  E+F = 113
88)  A %    n - 1  =  (n - 1) - n /n x 100						G+H = 130 TO 175
n +1 = (n+1) - n / n x 100
21						22
WINDING CALICULATIONS						96) Production % =    Act. Prod
						----------------- x 100
Production/Drum / 8hrs						Std. Production
						97) Overall %   =   P% X U%/100
MPM X 1.0936 X 60 X8
-----------------------------------------------						98)   Tension weight in grams =
840 XX COUNT X 2.204						1.8 +b(0.571x elongation lea str/kg)
0.2835 X MPM/ COUNT						Yarn quality facture =
						Cleaning effciancy/ Knot facture
94) Length correction factor  =
						99) Knot facture =  Total number of slub catchers
STD Length / Act. Length x present						related yarn breaks in
LCF						given length
						-----------------------------------------------------
95) Utilisation %   =						Total number of objct. Yarn faults
						removed by S.C from same length
Worked hrs/Alloted hrs x Worked dr						Bobbin running time  =
--------------------------------------------------						Avg length in meters/ Speed in mpm
Alloted drums x 100
23						24
AUTOCONER CALICULATIONS						103)  RTI =  Ratio of retair ( the average number
						of breaks/ bobbin
100) S.E.F %  =  ( Spindle effciancy )						No. of sucsess ful splicer - no. of bobbin
						change
Winding time ( WDTM) / Shift
-------------------------------------  x 100			x 100			104) MIS = Miss splicing% =
Run time ( RTM) - CBF alaram down time
						No. of doffs (NDOP)
						----------------------------  x 100
101)  A.E.F.%  ( Actual effciancy)						No. of bobbin change
						105) LW% = Ratio fo yellow buttion%
Winding time / Shift						= No. of times yellow buttion activated
------------------------------  x 100						-----------------------------------------------------x 100
SFTM ( shift time )						No. of splicings
102) JOIY% = Avg. no. of splicings/ 1000						106) RTM = Runtime minutes
miles of yarn
No. of splicings
----------------------- x 100
Yarn winding length/ Shift
25						26
106) SBC % = Ratio of bobbin change %						111)  SDTM = Splice down time for caser
						= Run time - Winding time
=  No. of bobbins changes						112) AC/Y = Avg. no. of NEPcutts/100000 mts
--------------------------------
No. of bobbin changes +bNo.of yarn ct						No. of yarn clearers defective cutts
						------------------------------------------------- x 100000
107) SCC% =  ( Ratio of yarn clearer cutts)						Winding length
						113) SC/Y = Avg. no. of slub cutts /100000 mts
Additional cutts ratio
---------------------------       x 100						= No. of yarn clearence
No. of bobbin changes +no. of yarn clg cuts						Diffective cutts - Wdg length
						------------------------------------ x 100000
108) SPCY = SPDL CUTS/LAC MTS						Shift ( all yarn)
CCLY = CLEARER CUTS/LAC METERS
NYCA  = No. of yarn ct alaram						114) LC/Y  = Avg. no. of long thick placess cutts/
						100000 mts
109) NADM = No. of miss auto doffing						115) No. of T defective clearer  =
						Yarn alaram cutts
110)  AC/Y Avg . No of nep cutts/10000mts						-------------------------  x 100000
						Winding  length/ shift
27						28
117) Drawing production/Del =						120)  D/F Production/ Del/ 8 hrs =
						0.625 x MPM X EFF/100
0.069 x sliver hk  ( 35 mm frd )
0.053 x Sliver hk ( 27 mm frd)						121) NO. Of fibers in sliver cross section =
0.050 x Sliver hk  ( 25.44 mm frd)						15000/ hank x mic
118)  Riquired draft in ring spinning						122) Simplex & Spinning productin/spdl/ 8 hrs
						=  7.2 x Spdl speed x Mc eff
Count 18s to 44     4.5 sqr count						------------------------------------
Count 50s to 70     4.0 sqr count						TPI X Roving hk x 100000
Count 80s to 100  3.3 sqr count						123) Doubling prod =  7.2 x spdl speed
						-----------------------   x eff
119)  Actual hank =						tpi x resultan count
8.33 x no. of yards
--------------------------						124) Blow room production =
15.432 x Avg.wt in grams
						8.9 x S x d     S = lap roller speed
( i.e lenear density in high production cards)						-------------------   D = Dia of lap roller
						1000 x H        H = Hank of lap
29						30
CONVERSION FACTURES						126) Cone winding production =
125)						0.2835 x S/C = KGS
1 YARD     =       36 INCHES						S = WINDING SPEED  C = COUNT
1 Hank      =        840 yards
	1 Meter      =       1.094 yards					127) Conversions for hanks to kilograms  =
	1 Kg           =       2.204 lbs					Hanks x 0.4536
	1 Inch         =      2.54 cms					-------------------------------------------------
	1 inch         =     25.4 mm					Sliver / roving/ count
	1 Lb           =   453.4 grams					128)  Carding production = 0.855 X S/H
	1 Gram      =   15.4 grains					S = Doffer speed
	1 Yard       =  3 feets					H = Hank of sliver
	1 Foot       =  12 inches					Tension draft = 1.4
	1 Lb          -   16 ouncess
	1 Ounce    =  28.34 grains					129) Linear density in high production card sliver
	1 Yard     =   0.91 meters					=
	1 Meter    =  39.37 inchess					Actual hank =
						8.33 x no. of yards
						-------------------------------
						15.432 x Avg weight in grams
31						32
127) Time to build a full bobbin =						132)  Standard nep count =
						(Nep/ board x H.K X Card width cms)
( Length of yarn on bobbin )
----------------------------------						133) Can content in drawing =
(Length delevery per hour)						1.5  x Hight x Dia 2/ 1000
128) Yarn breaking strength =						134) Trumpet bore size =
For karded yarn =  2000/ count						0.22 x sqr of grain per yard of sliver
For combed yarn = 2250/ count
						135) Twist contraction% =
129) Density of yarn package =						(2.64 x T.M ) - 4.82
Net weight on yarn package
--------------------------------------						136) Spinning limit =
Valume of yarn package							5315
							----------------------------------------------------------------
130 )  Tape width  =							Diameter of fiber  x Actual fiber/ fross section
Face width of spindle wharve - 4 mm
						137) Uniformity ration =
131) A/C Production = 0.283 x mts/ min/Ct						Mean fiber length/ upper hald mean lengt
						x 100
33						34
135)   expected  U% =							STATASTICAL FOURMULAS
100/ sqr of N
N =  No. of fibers in cross section							140)  Q95%  =
							K = T X S.D./ sqr of N
N =  Yarn denier/ Fiber denier							T  = T value
Yarn denier = 5315/ count							SD = Standard deviation
							N = No. of samples
136) Break draft =  ss back roller/ ss of mid
							141)  T  Value =
137) Main draft = ss of first roll./ss of mid roll							X1 - X2 sqr of N
							-----------------------
138) Total draft = ss of delevery roll /							sqr of SD1 +SD2
ss of feed roller							T value more than 2.67 it is statastically
139)  Comber production/day/ machine							siginificant
0.0384 / 1000 x LSF( 100 - W)							X1  X2  =  Mean values
							N =  Number tests
L = Lap weight							SD1  AND SD2  =  Standard deviations
S =  Nip/Minits
F  = Feed/ Nip
35						36
STATASTICAL FOURMULAS						144) Che sequare test  =
						( A +B )/ (A - B) 2 = > 4.0
142)   F  Test :-
Two cv values are to be compared						145) Power consumption =
is to be conduct						HP X 0.746 X 3 SHIFTS X 8
						--------------------------------------- x eff
F  = S1 squar						Consumption of production/ mc
---------------						146) T.F.O Production/ day / machine =
S2  squar
F  is always greater than  1						14.4 x Spdl rpm x eff x No. of drums x 3
						-------------------------------------------------------
143) Degree of freedom Caliculation per						TPI X COUNT X 1000
T  test   =
						The diffrence between variator drive and
No. of samples  = 2						inverter drive  =
No. of readings per each test  = 20						Variator type machine mainly in spg. Motor
Degree of freedom = 2(20-2) = 38						rpm is fixed
You can see that  T value chart at 38						Inverter drive in this principle inverter varie the
degree of freedom						freequancy if frequancy is increased
						N = 120 X f/p
37						38
STATASTICAL FOURMULAS							146)  Ex   A mill having 150 breaks/ 1000spdl
							per hr in 60s count
145)    The hank of the drawing sliver for the							After change of mixing  the level of
department as whole would be							breakage 220 per 1000spdl/ hr
							Has the change of mixing increased the
=  0.145 +/- 3SD/sqr of N							breakege rate  ?
+/- 3 X 0.00145/sqr of 8							At present  O = 220   E = 150
=  0.145 +/- 0.0016
Range = 01434 and 0.1466							X2  = ( 220 - 150)2/150 = 4900/150
The hank 0.145 is statastically different for							=  32.7
the nominal hank 0.140							I degree of freedom = 3.87 it is statasti
							cally significant
APPLICATION OF X2( Che Squar ) Method
146)    X2  Defined as ( O - E)2 /E
O & E are the observed and expected
values
39						40
STATASTICAL FOURMULAS							STATASTICAL FOURMULAS
148)  Application of   F test							149)  SNAP STUDY :
Card hank cv%  = 4.0							A round inside the department to list
Taking some precations cv% reduced							the number of machines stopped due to
3.5%  Card hk 0.200 No. of readings							various causes is known as snap study
= 40  is it statastically significant
or Not ?							S = 1/100 X sqr of P(100-P)/sqr of N X rounds
SD1 = CV1 X Mean /100 = 4 x 0.2/100
=  0.008							S = SD of the estimate
SD2 =   CV2 X Mean/100 = 3.5x0.2/100							P  =  Efficancy of the department
=  0.007							N = No. of machines observed
SD1 sqr/SD2 sqr = 1.31							S = 1/100 X sqr of 91 x 9/sqr of 30+60
							=  0.67
The value should be grater than = 1.53
41						42
STATASTICAL FOURMULAS						151)  Fiber to yarn relation ship =
150)						Lea C.S.P =
Department      Nature of problem   Test to						165 sqr of FQI +590 - 13C  For karded count
Blow room       Fiber repture            C.D						152) Lea C.S.P
Cleaning eff%           C.D						165 sqr of FQI +590 -13C (1+W/100)
Neps generation         X2						for combed counts
Carding           Fiber repture            C.D
Cleaning eff             C.D.							Here
Nep generation           X2
Cv% Hank               F test							FQI = LSM/F
M/c Stoppage          Snap test							L = Mean length
Drawing           S.L Hank                CV test							S = Fiber bundle strength
S.L. Breaks             F test							f = Micronaire value
Cv of SL Hk               F test							C= Yarn count
M/c Stoppage              Snap test							W = % of comber noil
Simplex    Str in roving      Analysis of roving
Mean hk of roving  CV  test
End Breaks           X2 TEST
43						44
153)  Time of build a full bobbin						SNAPSTUDY TEST
Length of yarn on bobbin
-----------------------------------						A  Round inside the department  to list the
Length delevered per hr.						no. of machines stopped due to various
154)  Diameter of fiber in microns =						causes is known as snap study
2000 x (sqr X /Y X 9000)
X  = Fiber diameter						>  Expected effciancy of snap study = 95
y = Fiber specific gravity						> Observed efficancy = 91
						> No. of rounds =         31
155) Uniformity ration =						> No. of ring frames = 60
Mean fiber length
------------------------  x 100						S = 1/100 X sqr of P(100-P)/sqr of N X Rounds
Upper half mean length
156)  Opend end spinnign TPM =
Delevery speed mpm / Rotor rpm						S  = 1/100 X sqr of 91 x 9
						------------------   =  0.67
157) OE  Production in kgs/ hr/ Rotor						sqr of 30 x 60
= Delevery speed mpm x tex x 60xeff
-----------------------------------------------
1000 x TPM
45						46
163)							MONETARING DATA DETAILS
N =  Diameter limit/ Neps
DS = Diameter limit for short faults
LS = Limit for short fault length						Total yarn cutts =  Total yarn faults
DL = Diameter limit for long faults						Short off cnt cutts =  yarn count deviation
and double yarn						Short count range
LL = Limit for long fault length
-D = Limit of the diameter decreases						Off count cutts =  Yarn count deviation cutts
for the faults
-L = Limt for thin placess length						SFI/D Cutts  = Surface index
						F cutts  = Forgin matter cutts
VCV    = Varable CV channel						P cutts  = Synthatic forgin matter
Ex :						Short cluster cutts =  Short faults cluster cutts
Laboratory prcticess where check						Long cluster cutts = Long fault cluster cutts
length of 400 or  1000 meters for CV						F cluster cutts = Forgin matter cluster cutts
determination						VCV Cutts = Cuts resulting from a deviation of the
In vcv the check length of cv can be varied						VCV Value from the mean value
contionously between 1 and 50 meters
Specific detection fo diameter variance						D Bunch cutts = Delayed cutts caused by a
						Bunch of similar running faults
47						48
	mixing						NEP AND FIBER DAMAGES
Longer the finer cotton with high trash content							Carding
are more prone to neppiness than shorter							1. Damaged and worn wire points and depositi
and courser ones very fine and long cottns							on of waxy material on the wire surface
are found to break during processing and							are potencial cause of nesp
thus create the nep formation
							2. Higher Lickren speeds remove the more
Micronaire value greater than 3.5 and							motes and fly waste thus reduce the seed
maturity co effciant about 0.8 are							cot neps
likely to reduce nep formation							3. Higher cylinder speed of the order of 460 rpm
							combined with high flats speed 15 to 20 cms
							per minute result a
The addition of excissive shoft waste in
Mixing will create yarn that are more neppy							4) Modren high production cards  the direction
improper mixinf of long and short cottons							of rotation of flats is made opposite to rotation
widley different level will produce neps							of the cylinder this helps to reduce the neps
							Fres flats are presented to the fibers that is
Cottn with widly different trash levels will							coming out of the cylinder at the tranceper point
produce more nep
49						50
NEP AND FIBER DAMAGES							NEP FORMATION IN BLOW ROOM
Fiber dmages refer to reduction in fiber length							1. Cotton with too high or low moisture
due to repture of repture of fibers during process							2. Extreamly fine cotton with high trash
The diffrence must be lower than 4.0 %							3. Reprocessing of laps and soft waste mix
							4. Rough blend blades blent point beater pins
Length between the length of feed and delevery							5.Damaged grid bars
is an indication fo fiber repture							6.Narrow setting between the feed rollers or
							pedal and beater
The chancess of fiber repture in the department							7.Long curvecd aand U bends in conveyaer pipe
							line
1. Blow room							8.Inproperate ratio of fan to beater speed
							9.Excissve application of tint improper dreying
The number of beating points  used are							of tint before processing
Not more than  3 to 5 depending upon the							10.Wider setting between stripping rail and beater
level of trash in the mixing							11.Slak or too high fan belts
							12. Too high or low beater speeds
2.  Fiber damage main area lickren and feed							13.Air leakege and obstruction of cotton through
plate to lickren setting  it is suggested tnat							pipe line
20 to 25 thous							14. More number of beater than the requirement
51						52
CARDING							CARDING
High card sliver variation :							Nep formation in cards :
1. Too hihg a tension draft and stretch of web							6.  Jammed wire in doffer
2. Variation in setting between back plate							7.  Uneven flat setting
and cylinder							8. Cylinder and flats or Doffer set too wide
3. Variation in flats speed between cards							9. Too much space between lickren cover and
peocessing the same material							feed plate
4. Damaged front and back plate							10.Undercasing chocked with fly
5. Size of the coiler trumpet not adjested							11.Cylinder doffer not stripped properly after
to hank							lapping
6. Feed roller weighing not acting properly							12. Dirty or chocked undercasing
7. Diffrence in draft between cards							13. Rough surface in front and back plate
							14.Insuffciant stripping
Nep formation in carding :-							15.Higher doffer speed
							16. Too fine immeture or damp cotton
1. Lap too heavy coler settings of selvedges
2.Wider back plate to cylinder settings
3. High lickren speed
4. Lickren set too far form feed plate
5. Blunt lickren wire or dull flats
53						54
COMBER
High combeer sliver variation :_
1. Diffrence in waste extraction between
heads
2. Variation in the settings between back
detaching roller and nipper
3. Improper cam setting depending upon the
staple length of the material
4. Unicomb chocked with sead cots or
immeture cotton
5. Variation in detaching roller diameter
6. Improper timing of tomp comb
7. Poor condition of sadles and top detaching
roller breakets
8. Top comb touching the back detaching
roller
9. Improper pressure on nippers jaws
55						56
DRAW FRAME							DRAW FRAME
High drawing sliver variation:_							ROLLER LAPPINGS IN DF
1. Improper pressure on top rollers
2. Improper roller coverings ecentric top							1. Incorect setting of top roller clearers or
and bottom rollers							worn clearers
3. Incorrect trumpet size
4. Improperly meshed or wrong gear wheels
5. Excessive creel draft and web tension draft
6. Stopmotion ineffctive function
7. Incorrect sliver guide setting at feed
8. Good fibers drawn due to high air pressure
9. Variation in top roller diameter
10. Warn out top rollers end bushess							End breaks in drawing :-
11. Improper settings at sliver conditioning							1. Double sliver in feed
plate at creel							2. Improper peicing at back feed
12. Imnproper settings in sliver tension							3. Incorrect trumpet size
							4. Cotton having excissive honey diew
							5. Damaged surface in drafting rollers
							6. Deeply meshed gears
57						58
	SIMPLEX PROBLEMS						SIMPLEX PROBLEMS
Hank variation in roving :							Stretch at simplex :-
1. Too high a break draft or total draft
2. Improper selection fo condencer guide							1. Improper winding on ratchet wheel
3. Vibration fo roving bobbinon the slat							2. Improper starting position of cone drum belt
4. Streching of sliver at feed							3. Improper intial bobbin layer and incorect
5. High variation in bare bobbin diameter							build of layer
6. Indaquate top arm pressure							4. Variation in bare bobbin diameter
7. Incorrect movement of cone drum belt							5. Improper shifting of cone drum belt
8. Irregular are closed aprons
9. Warn damaged or improperly meshed
gears and bearings
10. Jurkey motion of bobbin rail
Roller lappings :_
1. Damaged surface in the top roller cots
2. Use of varnished in the top roller cots
3. Damaged aprons are condenser guides
4. Too wide settings at the back zone
59						60
	SIMPLEX PROBLEMS						END BREAKS IN SIMPLEX
SLUBS :-							6. Indaquate top roller pressure
1.Excissive end breaks							7. Vibration in flyers
2. Wate accumalation at creels clearer							8. Use of narrow spacers
and flyers							9. Damaged top edge of the cam
3. Improper choice of spacer							10. Loose spindle and bobbin shaft drive wheels
4. Use of lower break draft							11. Broken or damaged teeth in draft gears
5. Closer setting at back zone
6. Absence of positively driven top clearers							12. Improper cleaning of draft zone
7. Damaged or obsence of top and bottom
roller cloth							13. Damaged can springs and D shape cans
END BREAAKS IN SPX							14. Lashing of ends
1. Incorrect choice of creel draft
2. Sliver entanglement at feed							15.  Undrafting  ends
3. Improper peicing at back feed
4. Too wide a back zone setting							16.  Warn out false twisters
5. Looser or broken top and bottom
apron
61						62
RING SPINNING							BETWEEN BOBBIN COUNT VARIATION
Uneven yarn :_							1. Excive variation in tuft size
							2. Use of three passage in post comber
1. Indaquate pressure on top rollers							3. Frequent changes in penion df and comb
2. Damaged or worn rings							4. Improper roller space setting or finisher passage
3. Heavy or lighter travellers							settings colser than the breaker passage in
4. Defective and worn gears							drawing
5. Colse setting of traveller clearer							5. Excive stretch in roving
6. Non alignement of aprons							6. Lower twist in roving
7. Improper top roller settings							7. Variation in bare bobbin diameter
8. Lappet and spindle setting not correct							8.  Row to row diffrence in roving hank
9. Bottom roller ecentric							Spindle vibrations and ring frame vibrations
10. Too wide or too close back zone setting							9 .High variation in relative humidity
11. Improper use of break draft							10. Variation in top roller pressure
12. Broken or damaged roving guide
13. Obstruction or vibration in the
movement of roving travers
63						64
WITHIN BOBBIN COUNT VARIATION							THICK AND THIN PLACESS IN YARN
1. High card sliver and comber sliver u%						1. High fiber length variation
2. Roller slippage in drawing						2. Poor carding or combing
3. Excive web tension draft in drawing						3. Uneven roving excive forgin matter in yarn
4. Ratching in roving						4. Ecentric top and bottom rollers
5. High tension draft or improper coils in roving						5. Insufficant pressure on top rollers
6. Use of long seperater plates at high						6. Wider settings between aprons broken aprons
spindle speeds						7. Too high a draft in ring frame
7. Low humidity levels						8. Improper setting of of tnesor bar
Cracks in the yarn :_						9  Worn rings
1. Mixing cotton diffreing widely  in staple						10. Too close setting between traveller clearer
length						and traveller
2. Too close  setting in ring spinning						11. Damaged top and bottom rollers
3. Worn or unbuffed top rollers						12. Jurkey motion of ring rail
4. Improper stopping and starting of ring frames						13. Worn out travellers
5. Loese top and bottom aprons						14. Excive fly lebaration in ring frames
6. Inadequate top roller pressure						15
7. Incorrect apron nip opening
65						66
SLUBS IN THE YARN						7. Spindle out of center with ring and lappet
						8. Cracked and worn bobbins
1. Excive short fibers in the mixing						9. Improper fit of bobbins
2. Inadaquate indivedualisation in cards						10. Incorrect bobbin diameter
3. Improper peicing in roving						11. Worn rings
4. Variation in top roller pressure in ring fr						12. Traveller clearer set close
5. Improper pecing of roving						13. Improper fit of bobbins
6.Bad peicing with too long over lapping						14. Worn rings
7. Too wide setting between apron and						15. Traveller clearer too close setting
front roller						16. Too high a draft
						17. Break draft not optimum
END BREAKS IN RING SPINNIG						18. Loose and worn aprons
						19. Incorrect shore hardness of top rollers
1. Dmaged skeewers and clogged bobbin						20. Insufficant pressure on top rollers
holder						21. Incorrect apron nip opening and setting
2. Jerkey motion of ring rail						22. Excessive twist in roving
3. Vibration or ecentric spindle drive						23. Lack of control of temparature nad humidity
4. Slak spindle tapes
5. Worn gear wheel and deep messhing gears
6. Choking and improper alignment of pnumafil
67						68
HIGH YARN HARINESS						CLASSIMATE FAULTS
						Factures influancing the classimate faults
1. Mixing cotton with vide variation
2. Excive short fiber content in mixing
3. Use of excive draft in spinning & prep						1.   25% of the classimate faults are influanced
4. High spindle speed						by card process ( A1 B1 A2 B2 )
5. Incorrect choice of travellers
6. Cutt in lappet hook
7. Spindle lift						2. 20% of faults inflyanced by Comber process
8. Ballon formation						( E F G  faults )
10. Worn rings
11. Ring rail jurkey motion						3.  30% of faults are influanced by the ring
12. Worn out travellers						frame process
13. Improper bowe hight in traveeller						( DRAFTING FAULTS )
14. Traveller pulling angle
15. Too close traveller clearer setting
16. Low tpi at ring spinning
						4. 30% of faults influanced by simplex and
						material handling ( Thin faults)
69						70
CLASSIMATE FAULTS						CLASSIMATE FAULTS
						Long thick faults :-
Short thick faults :-						1. Presence of un opened roving in the blow room
						lap or card sliver
1. Presence of large ammount of trash high						2. Folding or over lapping the blowroom layers
praportion of seed cot prigments						while feeding  to the lickren of the cards
2. Use of low micronaire cotton with high						3. Use of improper settings in drawing
level of humidity						4. Too low a web or creel draft in drawing
3. Use of cotton containing high proportion						resulting improper drafting
of shart fibers						5. Improper seating of floting and fixed condencers
4. Excessive fiber entanglements						6. Improper peicing in speed frame and ring frame
5. Damaged wire points cylinder doffer						7. Presence of lashing of excessive end breaks
6. Absence of top roller clearers in simplex						in speed frame
7. Use of broken and damaged surface of						8. Too close a setting between traveller clearer
the floting condencers						and traveller in ring frame
8 Use of too wide or narrow settings in roving						9. Use of narrow spacers in ring frames resulting
and spinning machines						in undrafted ends
9 use of improper spacers in speed frame						10. Use of fibers having excessive variation in
and ring frames						fibers length resulting in formation of crakers
						in the yarn.
71						72
CLASSIMATE FAULTS						Method of reducing classimate faults
Long thin faults :-
1.Excissive incedence of web falling						While preparing the mixing  wide variation
2. Too high a break/ creel / web draft in						in length should be avoid
draw frames
3. Excessive variation in top roller pressure						2. Treatment and selection of beaters in blow
4. Looses top roller end bushes in draw frame						room could be decided depending upon the
5. Distrubence for the free rotation of creel						type of cotton to used avoid entanglements
callender rollers in draframe
6. Sliver stretch  of creel in speed frames						3. Sytsamatic mentinence schedules should be
due to high a creel draft						followed
7. Excisive roving stretch due to improper
function of builder mechanisiom						4. Keep vire points condition should be followed
8. Use fo empty roving bobbin In speed frame
with a wide variation in bare bobbin dia						5. Higher cylinder and flats speed may be emplyed
9. Sliver spliting in speed frame while drafting
10. Use of ring tubes with improper fit on the						6. Higher noil extraction during combing helps for
spindles						better removal of fiber cluster and immeture
						fibers in lumps
73						74
CONTROLLING OF CLASSIMATE							SPECTOGRAMM ANALYSIS
FAULTS
1. Break draft, creel draft in dra frame							IDENTIFICATION OF DEFECTIVE PART
speed frame should be maintedas per							FROM A GIVEN GEAR PLAN
standards
						GEAR DIAGRAM
2. The Condition and seating aprons , Floting
condencers Roving guidesShould be
maintained satisfactorily
3. The setting between drafting rollers in
preparatory and spinning machine
should be kept as per the standard
4. Over head clearers bottom roller clearers
should be used when ever necessery
5. Better maintinence of machenery house
keeping Draft zone cleaning AND to avoid						WEAVE LENGTH OF THE PEAK IS = 3.0 CMS
fiber accumalation in lappet and traveler
clearer
75						76
SPECTO GRAM ANALYSIS						SPECTO GRAM ANALYSIS
Weave length of the faults form the						Defective component identification from
different parts :						ROTATING SPEEDS
85T gear front roller = 22/7 x 2.54 cm = 8 cm						Whavelength in cms =
160t Gear =  22/7 x 160/85  = 15 cms						Delevery speed in cms/ min (v)
						---------------------------------------------
32T Gear 140T Gear  = 15 x 32/16 = 3 cms						Frequancy in rpm ( f)
100T Gear 35T Gear =  3 x 100/140						Therefore   f  = v/lamida
=  2 cms
						euating the rotating part ( wheel or roller)
Conclusion :						whose rpm matches with this  "f" value
32T Gear or 140T Gear or the						the defective part can be identified
connecting shaft is the defective part
77						78
SPECTOGRAMM ANALYSIS - D40						LR SB - 851 PEAKS ANALYSIS
1 Meter      =   Back top roller or can						10  CMS =  Top roller out of round
90 Cms     =   Coiler
80 Cms     = Back bottom roller						12 CMS  = Top roller with cutts
50 Cms   = CP value or middle top roller						6 Cms  = Ovell shaped top rollers
12 Cms   = Front top roller						68 Cms = Top roller with one spot
10 Cms  = Front bottom roller						Caused by pressure on stopped
40 Cms  =  Middle bottom roller						toproller over an extend period of time
17 Cms   = Delevery roller						11.3 Cms  = 1st bottom roller
						3 Meters = Problem with scanning roller drive
LRSB - 851 PEAKS ANALYSIS						50 Cms = Sliver funnel
						17 Cms = Callender roller or callender roller disk
38  Cms  = Breaak draft roller setting too wide						85 Cms = Dort accumalation on the belt
50 Cms = Main draft roller setting too narrow						98 Cms = Distrubued sliver deposition
8  Cms = Main draft roller setting too wide or
fiber to fiber friction is too high
Zig zag peaks = Top roller pressure not suffciant
12 Cms =  1st bottom roller drive problem
79						80
LF 1400A  PEAKS CALICULATIONS							COMBER PEAKS CALICULATIONS
						1. COLER CALLNDER ROLLER	1. Coiler callender roller or 28t pully  = 18.6 mm
7 Cms =   50T Wheel							2.79.5 pully or 40t     =   26.6 mm
10 Cms = Front roller							3. 50 Pully  =  16.8 mm
12.5 Cms = 80 T Wheel							4. 37T or 20T   = 24.66 mm
8.0 Cms = Draft change gear							5. Vertical shaft Wobbling = 29.6 mm
9.0 Cms = Front bottom roller							6. 40t or 25 t =  26.65 mm
							7. B wheel or 45t or 72T = 47.99 mm
14.0 cms = Spindle wharve shaft							8. Front bottom roller = 12 mm
15.0 Cms = bobbin gear							9. A Wheel 20T Wheel 35T Wheel X A/B
16.0 Cms = Bobbin faults							10. Front top roller = 15.423 mm
17.0 Cms = carrier wheel							11. Middle bottom roller = 28t or
18.0 Cms = carrier wheel							Drafting whave = 3358.74 A(BX C)
19.0 Cms = carrier wheel							12.Back bottom roller  /Drafting wharve = 120x a/b
28.0 Cms Apron Top							13. 44T/22T/ = 30.16 X A/B
60.0 Second bottom roller							14. Machine Pully /29T/40T = 1206.48 X A(BXT)
65.0 Cms = Second top roller							15. 143T / PEICING PEAK = 5849.2 X A(BXT)
70. Second top roller							16.Main motor pully = 4.605 x A X G (BX T)
95.0 to 1.0 meters = 3rd bottom roller							17. 138T/35T = 4162.35 X (A/BX T)
110 = third top roller  130 = 3rd drive wheel							20. Take of roller = 16696.96 x A (B XT)
81						82
PREACATIONS AT T.F.O						PREACATIONS AT T.F.O
1. Clean the seperators and capsules						11   Every time hard waste should be put in the
whenever put feed package into pot						pecer bag
2. Feed the feed package into one unwinding						12. Lock the drop wire at the time of knotting
direction						13. When ever the machine stopped lift the drop wire
3. Do not feed the rejected cheeses						assembly through handle rod
4. Particular condition should be followed
5. At the time of thread cut  knot under the pig tail						14.  Clean the flyer brush for every knot
rod release the break and arrange the
delevery package to the drum						15. Do not keep any article inbetween the free
6.  Every yarn cutt clean the capsule and						takeup roller and take uproller
set it right
7. All the pots should be infront of the red dots						16. Feed the feed packages according to
8. T.V Number should equal to all spindles						instructions
9.Observe the ballon for all spindles if
ballon is not formed stop the package and
remove the untwisted yarn
10. Every end cut delevery package should be
lifted automatically
83						84
ANALYSIS OF QUALITY PROBLEMS						Nep Generation Mechanical process
IN COTTON SPINNING
						1. Damaged blent beaters and spikes
Thick and thin generation :-						2. Damaged bent clothings
1. More short fiber in raw mateerrrial						3. Poor condition of bushes in combers
2. High length variation in raw meterial						4. Rough damaged of grid bars and cover factures
						5. Toomaney pipe lines with bending in B/R
At Drafting stage :-						6. Rough and damaged surface of fan blades
1. Roller setting of finisher drawing						CLASSIMATE FAULTS
2. Draft applied beyond the capacity
						RAW MATERIAL FAULTS  ( A & B ) Type
In process stage :-
						1. Large ammount of trash in cotton
1. Quality of carding						2. More sead fragmentation in cotton
2. Quality of combing						3. Low micronire
Nep generation :-						4. Immaturity of cotton
1. Low mic cotton						5. More short fiber content of cotton
2. Variation in moisture content in cotton
85						86
CLASSIMATE FAULTS ANALYSIS						CLASSIMATE FAULTS ANALYSIS
						LONG THICK FAULTS :-
In process :-						1. More soft waste in mixing
1. Insuffciant nep removal at carding						2. Excissive short fiber in mixing
and combing						3. Poor control of humidity
2. Higher total draft in spinning						4. Improper peicing of drawing
3. Fly and hariness in spinning						5. Low top roller pressure at drawing
4. Improper spacers in spinning						6. Roller lapping at speed frame
						7. Lashes of ends at speed frame
SLUBS :-							Low top arm pressure in speed frame
1. Accumalation of fluff						8. Low break draft in speed frame
2. Improper cleaning of clearer rollers						9. Too wide spacer in speed frame
3. Broken tooth of gear wheels improper						10. Poor house keeping in spinning
messing of wheels						11. Hard rovong peicing
4. Damaged roller covering						12. Low spinning peicing
5. Poor carding due to worn out wire						13. Low break draft at spinning
6. Too wide front zone setting						14. Low top arm pressure in spinning
7. Improper spacer						15. High hariness in yarn
8. Indaquate top arm pressure
87						88
CLASSIMATE FAULTS ANALYSIS						CLASSIMATE FAULTS ANALYSIS
LONG THIN FAULTS :-						LONG THIN FAULTS :-
1. More soft waste in spinning
2. Mic value range more than 10% in mix						17. Low Tm at speed frame
3. Web falling in carding						18. Speed frame bobbin variation/Play
4. Too low and too high tension draft						19. More break draft in spinning and  simplex
5. Chowking of under casing						20. Wide back zone setting in spinning and spx
6. Static charge generation in PV and PC
7. Too narrow trumpet carding/drawing						21. Creel strtetch criss cross in ring frame
8. Wraong peicing practices at all stages
9. Missing of sliver infective stopmotions						22. Wide back zone in speed frame and
10.Sliver rubbibg at each and inside cans						carding frame
11. Distrubunce in creel						23. Excessive tension weight in winding
12. Sliver splittings
13. Speed frame stretch
14. Flyer leg chouking
15. Inlet condnecer chouking
16. Improper selection of sliver condencer
89						90
POSSIBLE CAUSES FOR CLASSIMATE						CLASSIFICATION OF CLASSIMATE
FAULTS						FAULTS
1. SPACERS   -            A4 ,B2, C2						OBJCT. FAULTS
2. SPUN IN FLY  - B4,C4,C3,D3,D4							A4         B4        C4           D4
3. CAGE SETTING - B4,C4,C3,D3,D4							A3         B3        C3           D3
4. FLY & HARINESS -  A, B, C.							A2         B2        C2           D2
5. FORGIN MATTER  - A3 +A4							A1         B1        C1           D1
6. FLY AT TRAVELLER - A3,A4							RAW MWTERIAL FAULTS
7. RING FRAME PEICING - C3 ,C4							A4         B4        C4           D4
8. FLY IN DRAWING - B4,C4,C3,D3,D4							A3         B3        C3           D3
9. RING FRAME APRONS - B2, C2							A2         B2        C2           D2
10. SPEED FRAME STRETCH - H1							A1         B1        C1           D1
11. SPEED FRAME APRONS     E							DRAFTING FAULTS
12. SPEED FRAME DRAFTING - C3,C4,D2.D3							A4         B4        C4           D4
D4							A3         B3        C3           D3
13. MORE TRASH IN MIX - B & C							A2         B2        C2           D2
14. FUSED FIBERS - B3,C2,C3							A1         B1        C1           D1
						REASON WISE ANALYSIS
						FOR CLASSIMATE FAULTS
91						92
FOR CLASSIMATE FAULTS						A4 +400%  0.10 TO 1.0 cms
						1. High ring frame speed
A1  +100%  0.10 to 1.0 cms length						2. Loose fly
1. Raw material						3. High forgion matter
2. Low mic						4. Type of spacers
3. Immature fiber						B1  +b100% 1.0 TO 2.0 CMS  Length
4. Insuffciant nep removal							1. Raw meterial
5. High ring frame speed						2. High ring frame speed	2. High ring frame speed
A2     + 150%  0.10 to 1.0 cms length							B2  +150%  1.0 to 2.0 cms Length
	1. Raw meterial						1. High ring frame speed
	2. Low mic						2. Loese spun in fly
	3. Immature fiber						3. Setting of spacer
	4. Insuffciant nep removal						4. Piecing of faults
	5. High ring frame speed						5. Cracks in spinning aprons
	6. Spun in fly						6. Excissive trash
A3     + 250%  0.10 TO 1.0 CMS Length
1. Raw material
2. High ring frame speed
3. Fly at travel
4. Spun in fly & Forgion matter
REASON WISE ANALYSIS						REASON WISE ANALYSIS
FOR CLASSIMATE FAULTS						FOR CLASSIMATE FAULTS
B3 +250% 1.0 TO 2.0 CMS Length
1. High ring frame speed							C3 +250%  2.0 TO 4.0 Cms
2. Loose fly							1. High ring frame speed
3. Spun in fly							2. Drafting faults
4. Piecing faults							3. Piecing faults
B4 +400 % 1.0 TO 2.0 cms   Length							4. Spun in fly
1. High ring frame speed							C4 +400% 2.0 TO 4.0 CMS Length
2. Loose fly							1. High ring frame speed
3. Spun in fly							2. Drafting faults
4. Long fibers and narrow guage setting							3. Long fibers & narrow guage setting
5. Tight guage setting							4. loose fly
C1 +100%  2.0 TO 4.0 CMS Length							D1 +100% 4.0 to 8.0 cms length
	1. Excessive trash						1. Drafting faults
	2. Drafting faults						D2  +150% 4.0 to 8.0 cms length
C2   + 250% 2.0 to 4.0 Cms length							1. Drafting faults & long piecings
1. High ring frame speed							D3  +250% 4.0 TO 8.0 CMS
2. Drafting faults							1. Drafting faults
3. Piecing & spun in fly							2. Long fibers
							3. Narrow guage length
94						95
D4 +400%  4.0 TO 8.0 cms length						G  +100% 8.0 TO 32.0 cms length
1. Drafting faults						1. Worn out rings in ring frame
2. Long fibers						2. Incorrect setting and more breakeges
3. Narrow guage length						in draframe
4. Tight guage settings						3. Very high hariness
						4. Improper mentinence of spinning machines
E   +100% 4.0 TO 8.0 CMS Length						5. Poor air conditioning control humidity
1. Incorrect setting at draw frame						and air return
2. More piecings at drawings						H1 -30% 8.0 TO 32.0 cms  length
F +45% 4.0 to 8.0 cms						1. Stretch of roving at speed frame
1. Worn out rings in ring spinning						2. Draframe settings and mentinence
2. Inncorrect setting and more						3. High brekege at drawing and speed
sliver breaks in speed frame						H2 - 45%  8.0 TO 32.0 cms
3. Very high hariness						1. Sliver splittings at speed frame
4. Improper mentinence of spinning						2. Creel stretch at ring frame
5. Poor house keeping						3. Settings and speed in R/F and speed
6. Poor conditioning humidity						I1 & I2   ( - 45% 32 cms   - 70% 32 cms above )
and return air						High drafting whaves
						Seperation of meterial
CV% CONTROL IN PREPARATORY
PROCESS						CONTROLLING OF COUNT CV% IN PREP
Comber :-
Use 26 mm detaching rollers						6	Avoid back bottom roller lappings
Drawing :  When ever lapping occures						7. Check correct size of condencers no. of
remove sliver from the can						foldings
CAN :-  1. Can content must be optimum						8. Use lesser break draft/ less cv% correct nose
2. Coiling must be proper						bar setting
3. Gap between sliver and can						9.  Trail with close bottom roller setting in
ptimum to avoid damage sliver						cotton optimum spacer
Speed frame :-						10. Stretch at speed frame  should be less
1. Variation in top ar load should be						check stretch at intial 1/4th 1/2 and full
minimum						11. Adjest shifting of belt / ratchet movement
2. Check round as both sides of
top rollers adjest evenly by tilting						12. Leave spindle idle in case of more breaks
the saddel
3. Check traverse for sliver  run through						13. Avoid sliver splittings at creel and delevery
center cots and aprons
4. Use low tension cradel springs to						14. Maintian same creel draft in all draw frames
avoid lesser load on front top
rolleer						15. Crsiis crossing of sliver movement to be avoid
CV% CONTROL IN RING SPINNING						ADOPTION MESURES TO CONTROL
1. Bobbin holder rotation should be						COUNT CV% IN PROCESS
proper						Mixing :-
2. Criss crossing of roving should be						1. Adopt bale management tequnic
avoid						2. Bale openeing  done properly in such a way
3.Creel high must be optimum -3 to bobbin						then tuft shouls be as less as possible 25 to 50
from top arm						3. Limit no. of bales to 10/ Mixing
4. Group cv% must be checked						4. Lay sandwitch mixing by drawing correspon
5. Check for the balloning at ring frame to						ding ammount from each bale
avoid clashing with seperator						5. Allow the mixing from 24 hrs conditioning
6. Check proper filment of ring frame tube						for regain moisture
7. Roving path should not touch bobbin						6. 2.5% span length variation between lots should
8. Winding length should be max possible							be  below 0.5 mm the av3erage
						7. Weighted average of mic value should not be
9. Trail with different top roller setting and						more than 8%
spacer						8.  Uneven mixing of soft waste and more soft
10. Required same draft wheels for all ring						waste adding
frames for one count						9. Maintain right RH% in all departments
						ensure that humidifications  correction factore
						is taken care while correcting hank in machine
ADOPTION MESURES TO CONTROL						ADOPTION MESURES TO CONTROL COUNT
COUNT CV% IN PROCESS						CV% IN PROCESS
Blow room :-						Drawing :-
1. Variation in tufft size is an important						1. Maintain suffciant gap between the coils in
facture influence between bobbin						delevery can to avoid pealing
variation.						2. Maintain the can contant as per recomanda
2. Irregualr air flow in blow room condencer						tions  18" can dia should 14 to 16 kgs only
area						to avoid over filling
3. Improper openeing and improper beater						3. Avoid sliver distrubunce due to improper
speeds						handling
4. Improper shyncranisation						5. Life of the spring and ensure that the sliver
5. Faulty air currents						coils has to come up due to spring pressure
6.Dirty condencer screen with rough						while unwinding at next process
serface						6. Use minimum web tension draft
Carding :-						7. Ensure that the loading variations on top
1. Ensure card sliver hank variation are not						roller to minimum possible extent
more than  +/- 3.0%						8. Ensure that all the top rollers are the same
2. Ensure that meter to meter variation in						diameter
card sliver should be < 3.5%						9. Ensure that A% and 1 meter cv% are under
						control
102						103
Drawing :						ADOPTION MESURES TO CONTROL COUNT CV%
Ensure that correct size of feed and						IN PROCESS  -  SIMPLEX
and delevery condencers are running
in the machine for the same count						1. Ensure that the correct size of delevery and
11. Draframe sliver U%  a direct influance						feed condencers and also same process
on the count cv% as well as fabric						2. Worn out chouwking condencers to be
appearance						replaced
12	Hank to be confirmed in the autolevelers					3. Sliver in creel should not be criss/ cross
	off positiojn once in a week for					4. Can spring condition  can top edge damage
	all draframes					coiling in cans  should not touch cans inner
13. Normally hank correction to be carried						edge to avoid peeling off
out +/-  1.0 %						5. Damage false twister
14.  With short staple cotton 2 passages						6.  Ensure minimum diffrence  in between front
of post combing drawing will reduce						and back row
the count cv% significaantly						7. Check 5 meters  30 samples for roving cv%
15. Ensure group feeding at all placess						once in a week  cv for corser hank 0.7 and
for better control on  aaand better						finer haank 1.0
quick tracability of deviations						8.  Ensure that same number of turns on
						all spindles ensure that there is no choking in
						the flyers inside portion  use horn for cleaning
104						105
Simplex :-							ADOPTION MESURES TO CONTROL CV%
corrct wi nding on wheel ( L.W)						1. Variation in RF Draft in between frames
incorrect winding on wheel  is more						2. Slippage of top rollers and aprons indauate
determental to  count cv% in correct						weighting improper grip groved formation
ratching wheel						3. Stretch of meterial in creel  lesser roving TM
( No. of coils/ cm = 5.0/ Hank)						Bobbin holder struck up and more creel hight
						4. Higher frequancy of cots buffing and high
Preferbly wind the bobbin rail up or down						starting dia will helpful to reduce count cv%
to start with a full layer to avoid ratching						5. Toparm loading variation  Due to worn out
in the intial layer						springs air leakege improper seating of cradel
Ensure that creel drive is smooth						6. Mis alignment of creel roving bobbin criss - cross
						roving
Attention should be given to clearer waste						7. Creel guide rod position inrelation to the bobbin
problem  process wise mc wise spdl wise						and count ( if located too high or too low stretch
delevery wise						taken when roving un winds from top most bottom
						most portion of roving bobbin
Attention should be given to groved aprons						8. Ensure that roving does not touch other bobbin
groved cots which causes slippage						in ring frame creel
106						107
GENERAL CONSEPT OF COUNT CV%						REDUCING RING FRAME BREAKEGES
Higher cv especially of medium to long						If brekege rate is more from 0 to 1/4 th stage
length range results in moire like appearance						the following precotions to be taken
in fabric and increase warp way steaks and						1. Reduce the speed pattren at intial stage
weft bars						2. Check the ballon formation when the ballon
More clearance between ring dia and full						touch the seperator create a breakage
package						at lappet eye ank make multiple breakes
cv% of half lea will be 1.2 to 1.3 times more						3. Bottom cop built  change cercular shape
than cv% of full lea						to  "V" Shape
Wraping of cv of wraping may be on 5 yards						4.  Use heavy traveller to control baloon formation
instead of 15 yards at simplex						5. Change the traveller profile
at drawing cv of wrapping based on 0.5 yard						6. Observe the traveller loading means fluff
length will be more useful						at travellers
Total yarn coung variation is contributes by						7. Change the traveller clearer setting 1.8 mm
65% between bobbin variation and 35%						8. Lappet hole dia should be 1.5 mm to 1.8 mm
within bobbin variation						9. Select suitable flange and traveller profile
						10. Use ring lope oil in ring spinning
under good working condition blow room						11. Slect propler hase length  D to d = 2:1
and carding accounts for 14% draw frame
108						109
REDUCING RING FRAME BREAKEGE						REDUCING RING FRAME BREAKEGE
1. The ring traveller together with the
yarn as a pull element is set into						1. The tube length  determains (with the yarn
motion on the ring by the rotation of the						guide  the maximum ballon length  this is an
spindle						important facture for the performance of  ring
2. If the direction of pull deviates too much						spinning machine.
from the running direction of the						2. Shorter the ballon higher traveller speed
traveller (alpha less than 30 deg) the						can achive
tension load will be too high						3. spindle rotation without vibrations and
3. The pulling tension can be reduced						correct consist of bobbin tube
by adopting the ring or tube dia
4. During winding upon the tube after						4. Ring with exact roundness and firm seating
doffing resp. at the top of the conical						in horizental position
part of the bobbin						5. Correct seating of the traveller clearer  space
5. Ratio of tube length to ring diameter						should be 0.2 to 0.3 mm
ideal ratio  5 :1						6. Rtecomanded flange width
6. Lappet hight  2d +5 of tube dia for lappet						1/2 flange  2.6 mm
setting						Singel flange 3.2 mm
						Double flange 4.0 mm
110						111
REDUCING RING FRAME BREAKEGES							BLEND TEST PROCEDURE
							Binarey mixtures of regenerated cellulosic
							and cotton mix
1. When the ring diameter is less ballon						1. Ammonia ( Dilute solutions )
diameter will be small  this leds to more						20 ml concentrated Ammonium hydroxide
yarn tension hence use lighter traveller						specific gravity % 0.88 made up to 1 leter
						of water
2. When the ring diameter is high ballon						2. Concentrated solfuric acid  = 60% +b wa	2. Concentrated solfiric acid
diameter will be more this leads to less yarn							60% H2SO4  +40 % WATER
tension and ballon touches the seperator
hence uyse heavier traveller						3. Tools  two glas flasks and one mechanical
						rod.
3. When the tube length is long the yarn						Procedure :-
tension will be less hence use hevier
traveller						1. Take test specimen about one or two  grams	1. Take test specimen one or two grams or lea
							2. Then dry the specimen at 105 Deg c in oven
4. When the yarn contact area and ring contact							3. Trancefor the specimen to a glass flask at
area in traveller is closer fiber lubrication is							room temparature
better especially in cotton  hence use
hevar traveller
112
BLEND TEST PROCEDURE						113
BLEND TEST PROCEDURE						BLEND TEST PROCEDURE
4. Apply the saluation 60% sulfuric						PERCENTAGE OF COTTN =
40% water at 27 De c
5. Shake thoughly preferby with a						100 X Mr x d / MS
mechanical rod for 30 min
6. And then trancefor the specimen						Mr = Specimen weight after dessolve
to another glass						d  = Correction factore  ( 1.05)
7. Then use again apply the saluation						MS = Weight of the specimen bofore
with few minutes wash the specimen						dessolve
with the salfuric acid saluation
8. Then wash the specimen with						Then you an know the percentage of
dilute ammonia saluation						cellulosic re- generated fiber
( Ammonium hydroxide )
9. Then wash the specimen with water						Report :-  The report shell include the following
twice						information
10. Dry the specimen with 105 De c							A = Type of meterial  B = % of re generated fiber
Temparature							C =  Cotton
114						115
SOME BLEND TEST SOLVI NG							P.V. BLEND TEST PROCEDURE
AGENTS
							1. Water 30 ml  +H2SO4 40 ML
100 % Polyester dissolved in final
							Reduce the sulution temparature 45 Deg C
100% vsf Dissolved in H2SO4
							Kept the specimen in the sulution
Wool  95% water +5% costic soda
Heat the soulation							Kept 30 Min idle condition
PV  =  H2SO4 + WATER
							Wash the specimen with hot water
Acrylic : Dyemethal formide							Dry the specimen
							Weight the specimen
							After weight/ Before weight x 100
							100 - Value = Blend %  ( Viscose dessolved)
116						117
YARN FAULTS GENERATED IN							TYPES OF FAULTS GENERATED IN SPINNING
RING SPINNING							Spun - in - fly :-   S1
DIAGRAM							This referse to free fibers which fall into the
							drafting elements or into the roving beaing fed into
							the drafting unit and are then twisted into the yarn
							along their entire unit
							Loosese fly :- S2
							This refers to fibers which are collected by the
							yarn at a position after the front roller and in most
							cases are only spun in out one end
							Longe collection of fly :- S3
							These are matted fibers which collect together on
							apron or rollrs and form time to time are collected
							and carried along by the yarn
118						119
YARN FAULTS AT SPINNING						YARN FAULTS AT SPINNING
						Crakers :_  ( S7)
Fishes ( Corkscrew ) :- S4						These results due to extra long fibers
These faults results to due to static charging						which distrubute the drafting process and
or a result of un suitable drafting or drafting						for short instant of time stop the passage of
aprons which have craked surface						yarn.
Pushed together of fibers :-  ( S5)						PIECINGS ( P1 )
These are faults resulting from held back						As with the short staple materiales  these
fibers and occure primery at the ring						faults are normally produced  in the process
traveller						prior to spinning
Chains of faults :- ( S6)						LONG SLUBS (P2) :-
These are combination of the faults  S1 S2
Possibely also S3  which occure in short						This referse to premearly short fibers or haires
sucession one after the other along the						which hold together as a single unit and appear
length of the yarn						IN	the yarn as  untwisted placess
120						121
TIPS FOR RING TO TUBE RELATIONS						HOW TO REDUCE BREAKEGE RATE IN RING
						SPINNING AT THE STAGE OF 0 - 1/4 Th
						1. Reduce the speed patterning at initial stage
Lappet setting   =  2d + 5 mm						2. Check the ballon formation when the ballon touch
						the seperator  break at lappet eye and make
2d =  Tube top dia ( Bobbin)						multyple breaks
Ring dia to tube dia  =						3. Bottom cop built change cercular shape to
2 : 1 mm  =						"V" shape
Ex ring dia = 36 mm Tube top = 18						4. Use heavy traveller to control ballon formation
Ratio = 2 : 1 mm						5. Change the traveller profile
Ring dia to  tube length = 1 : 5 mm						6. Observe the traveller loading mean fluff at
						traveller
Ex ring dia 36 mm Tube length = 180						7. Change the traveller clearer setting 1.8 mm
						8. Select suitable flange and traveller profile
Chase length =						9.  Use ring lope oil in ring spinning
						10.Select the proper chase length
Ring dia + 5 mm or 10% of ring dia						11. The ring traveller together with the yarn
						as a pull element is set into motion on the ring
122						123
REDUCING BREAKEGE RATE IN SPINNING						HOW TO REDUCE BREAKEGE RATE
By the rotation of the spindle						IN RING SPINNING @ 1/4 Th stage
If the directin of pull deviates too much
from the running direction of the traveller						The tube length determains ( With the yarn guide)
( Alpha less than 30 Deg ) the tension load						The maximum ballon length this is an important
will be too high.						factore for the performance of ring spinning
						machine
The pulling tension can be reduced by
Adopting the ring or tube diameter						14. Shorter the ballon higher traveller speed can
						achive
( Alpha greater than 30 Deg during the winding						15. Spindle rotation without vibration and correct
upon the table after doffing resp. At the top						connectivity of bobbin tube
of the conical port of the bobbin						16. Ring with exact roundness and firm seating
						in horizental position
Ratio of the tube length to ring diameter						17. Correct seating of the traveller clearer space
						should be 0.20 t0 0.3 mm
124						125
HOW TO REDUCE BREAKEGE RATE						18.0 1/2 Flange = 2.6 mm
IN RING SPINNING @ 1/4 Th stage						Single flange = 3.2 mm
ring by the rotation of the spindle if the direction						Double flange = 4.0 mm
of pull deviates too much from the running
direction of the traveller ( alpha less than 30						When the ring diameter is less ballon diameter
degree) the tension load will be too high						will be small . This leads to more yarn tenson
						Hence use lighter traveller
The pulling tension can be reduced by
adopting the ring or the diameter						When the tube length is long  the yarn tenson
During winding upon the tube after doffing						will be less  hence use  havier travellers
resp at the top of the conical part of the
bobbin.						When the yarn contact area and the ring
12. Ratio between tube length to ring diameter						contact area in traveller  is close  fiber lubrication
Ideal ratio = 5 :1						is better especially in cotton  hence use heavear
13. Lappet hight 2d +5 mm of tube dia for lappet						Traveller
setting
						Traveller speed should be  35 to 40 mts/Sec
GENERAL FOURMULAS
126						127
1. Builder motion :						6. Cotton yarn content in cop   =
New ratchet = present ratchet wheel						3.25x L X D2  = L = SPDL LIFT D = RING DIA
x sqr of present HK/ New hk						7. Roving contnent in kgs  = ( 3 x L X D2)/1000
						8. Sliver content in kgs ( for different can size)
2. Twist change wheel :						= 1.5 x Height x Diameter 2
New change wheel = Present wheel x						9.  HOK  =
( sqr of present Nec /New Nec ) x Present						( Operative hours/ Total of the standardized
TM/ New TM						ring spinning production in indivedual counts x 100)
3. Yarn tension weight = 0.571 x lea strength						OHS =
in kgs +1.8						( HOK adjested to 40s x Production/ spindle
4. Open end spinning  TPM =						adjested to 40s )/800
Delevery speed in mts/ min x tex x 60						10. Relation between twist Multiplier for maximum
x eff% / 1000						strength
= (Rotor rpm x tex x eff x 60) / 1000 x tpm						T  max   =  ( 50 - L + f )/9
						T max = Tm for maxximum strength
						L = 50% SPAN LENGTH f = Mic value
GENERAL FOURMULAS						2
128						129
11. Fiber bundle strength =
( Breaking load in kgs x 15)/ sample
weight in milligrams
Breaking elongation% =
( Length at breaking load - Nominal guage
length )/Nominal guage length x 80
The pressely index ( P.I)
( Breaking load in pounds/ Bundle weight
in milligrams )
12. Effictive length bear sorter =
1.013 x 2.5% span length
13.Mean length = 1.242 x 50% SL + 9.78