HOW TO CONTROL RINGFRAME END BREAKAGES AND STARTUP BREAKAGES

How to control the ringframe breakage

Mr.R,Chidambaram, Senior Manager, Kandagiri Spinning Mills Ltd, Unit-1, Salem, Tamilnadu Raw material vs. Speed in spinning:- Selection of raw material in relation to spinning speed plays a vital role in control of breaks in spinning. For cotton, the fiber length, strength, Micronaire and uniformity, based on count and speed at spinning had very high correlation with End breaks at spinning. Preparation:- The strand of fiber to be twisted should be uniform without thick, thin and with low count CV%. At thin place the twisting force will break the Yarn, and at thick places the twist will not flow resulting in weakening of the Yarn. If the count CV% is high, then, the breaks will be high. In preparation up to Simplex the material handling plays a vital role as the slivers disturbed, up to bobbin stage will create a slub followed by a weak place. Contamination as Jute, polypropylene, and big size husk will not allow easy twist follow, resulting in weak spot. Twisting zone:- At twisting zone there are various force acts on the yarn as centrifugal force, and traveler’s gravitational force and dragging force. The strength of the yarn is to be in such a way that it can with stand the above force. Care should be taken, that other external disturbance like traveler clearers, ABC rings, separators should not disturb either the yarn or traveler to avoid unnecessary strain to the Yarn. The selection of correct traveler number and profile will optimize the load on yarn Environment:- The environment as RH%, housekeeping and cleanliness are major factors creating breaks at spinning. Low RH% will brittle the yarn as there will not be inter fiber coherence, leading to breakage of the yarn. While running the machine after a long time stoppage a traveler running in should be scheduled to reduce breaks. Machine condition & Workers work methods:- The condition of the machine without vibration, and Ring rail leveling with exact Ring centering and Spindle/ lappet gauge are necessary to reduce the breaks. There should not be burs in yarn path (Lappet hook and ABC rings are to be highly polished material). The Life of Ring and traveler to be scheduled as if that there should not be any wear out. The poor work practice resulting in poor material handling and poor house keeping with more fiber flies will result in higher breaks. Mr.Rohit Arora, Production Manager, Arihant Spinning Mills limited, Malerkotla, Punjab Steps to be taken care to reduce the end breakage rate in spinning End breakage rate is a phenomenon in ring spinning system where the dynamic yarn tension increases the localized strength of yarn body. There are several factors which contribute in end breakage which range from raw material specifications, process parameters, ambient conditions, machine & accessories condition, settings & maintenance, skill & cleaning level at the shop floor etc. Fibre properties like length, micronnaire, strength, & elastic behavior have direct impact on EBR. Low conditioning of fibers results in higher EBR in further stages. Higher soft waste addition at mixing stage decreases fibre to fibre friction & EBR increases due to increase in slippage In process parameters tighter gauges, higher relative speeds between cylinder & flats, higher beater speeds, higher drafts, higher speeds increases fibre fatigue. This in turn decreases fibre elasticity modulus & chances of fibre rupture increases. Higher parallelization due to excessive draft, decreases fibre cohesion & thus thin places /weak places gets generated which cannot withstand the spinning tension. In ring spinning section EBR is actually either due breakage by slippage of fibres or breakage by rupture of fibers or combination of both. Studies reveal that EBR at ring spinning is dominated by slippage mechanism. Optimum R/frame TM levels, break draft level, spindle speeds, damping cylinder setting, proper running in of ring, are some factors to control EBR in concern of process parameters.  Spindle gauge setting, Lappet hook gauge, ABC ring gauge, oil level in bolster, bolster bearing condition, spindle eccentricity, bobbin gripping buttons, tape condition, jockey pulley centering, machine frame vibrations, ring rail synchronization, condition of separators, fly catcher gauges, ring / adaptor fitting, lower cot offset, tighter spacers etc. are some factors which are directly related to EBR in ring spinning. Some other reasons for EBR are poor Bobbin fitting, missing bobbin surface serrations , lower angle of pull, improper  LH eye diameter, LH to bobbin gauge, ABC ring to ring rail gauge, ring dia in conjunction to bobbin height, chase length adjustment, heart cam running direction, choice of correct flange width,  matching ring & traveler profiles, ring life, traveler life, too much changes in count on machines, spinning angle less than 20 deg, poor cleaning of machines, damaged fluted rollers  or top cots, Improper ambient conditions, high difference between fibre parameters in case of blended yarns. Usually end breakage rate is higher at 25-30% position of cop & at 90-100% position of cop. Higher EBR reduces total production rate of ring frame section & is a direct loss to the spinning mill. Although EBR is generally related to choice of machine & accessories but here are some steps which are tailor made solutions of a running plant to reduce EBR in ring spinning. 1.Reducing fibre slippage at spinning triangle: As studies reveal that most of the breakage are due to fibre slippage in spinning triangle, better gripping with softer cots (65 degree), higher top arm load or reducing cot width for higher localized load are highly helpful. Making front cot offset also puts positive impact of controlling EBR. 2.Reducing fatigue in fibers:If yarn quality permits reduce beater speeds, widen up beater / drafting gauges. 2.5% SL front gauge at draw frames a favorable gauge for strength & IPI level. 3.Balloon geometry & yarn friction:Put recommended traveler only for balloon stability. Allow short running in schedules if EBR is abnormally high with one step higher traveler to reduce yarn friction.  Traveler running in at each change need to be done. Wiping ring with coconut oil also reduced yarn friction. 4.Ambient Conditions:Maintain 32 – 35 deg Celsius temp, 50-55% RH with 26-28 air changes at ring frame. Lower fly levels & better cleaning of machines reduces EBR 5.Parameterization:Appropriate draft range in preparatory machines, lower speeds at bottom & top of cop, ring rail speed optimization as per count, & parabolic speed patterns in ring frame reduced EBR. 6.Fibre packing:Improving fibre parameters like lower SFC (n), higher yarn strength & length, lower micronnaire improves fibre packing in yarn & hence reduced fibre slippage. 7.Machine maintenance:Perhaps one of the most vast & important point. Any vibration, rusting, lack of lubrication, wear/tear increases significantly the EBR. Although the EBR is a local phenomenon & the solution lies itself in the plant, a detailed step by step study is required to curb EBR in ring spinning. Collaborative approach of production & maintenance department for identification & rectification of individual spindle points helps in maintaining the end breaks in spinning. Mr. K.Balaji Natarajan, Factory Manager, Chowdary spinners Limited, Tanuku, Andhra Pradesh Steps to be taken care to reduce the End Breakage rate in Spinning 1. Raw Material selection to be done carefully, not only Length and Strength of Fiber also uniformity ratio, Maturity ratio and Micronaire value will contribute for End Breakages in Ring Frame. It has to be noted that around 70 – 80% of yarn characteristics are depend on Raw material including End breakages and optimum selection will help to maintain consistency in all aspects. 2. Process parameters in machineries such as speeds, draft zone settings, spacers etc., should be selected such that it should not rupture the Fiber from Blow Room to ring frame. Fiber rupture will convert the good Fiber into short Fibers’ during processing. The amount of short Fiber content in cotton majorly contributes in R/F Breakages. The amount of waste removed in blow room, cards and combers plays one of the major roles for end breakages. Here not only the quantity of waste removal also the quality and how effectively it was removed without much removal of lint and that will also help in commercial side. The feed and delivery hank in every stage from carding to speed frame should be set as per the recommendations of “total draft” in each department. Especially in speed frame the total draft should be 10 & in ring frame it should be 30 to 35. Excessive draft will lead to fiber movement away from centre axis of feed material during drafting thus leads to fiber fly and rupture. 3. Machine cleaning is also plays one of major cause for end breakage .The proper cleaning to be carried  out from blow room to ring frame &especially additional care to be taken for Speed frame & ring frame due to more chance of fluff and loose fiber to go along with roving material. The ring frame cleaning to be carried out in 2 ways viz Draft zone cleaning (semi cleaning) and general cleaning (full cleaning).The schedule for Half/Full cleaning varies mill to mill based count and material (combed or carded) .The speed curve plays one of the major role and it has to be set based on study i.e. the decrease /increase of spindle speed to be modified in curve based on end breaks on that particular step without affecting average spindle speed . 4. Proper RH to be maintained in all departments. The number of air changes per hour for Ring frame should be 35-40 and it should be little higher for carded counts. The Fiber flies either should be removed by exhaust (or) to be sweep manually by Operator to ensure it will not disturb the spinning process in from creel to cop to avoid end breakages. 5. Machine cleaning is also plays one of major cause for end breakage .The proper cleaning to be carried  out from blow room to ring frame &especially additional care to be taken for Speed frame & ring frame due to more chance of fluff and loose fiber to go along with roving material. The ring frame cleaning to be carried out in 2 ways viz Draft zone cleaning (semi cleaning) and general cleaning (full cleaning).The schedule for Half/Full cleaning varies mill to mill based count and material (combed or carded) .The speed curve plays one of the major role and it has to be set based on study i.e. the decrease /increase of spindle speed to be modified in curve based on end breaks on that particular step without affecting average spindle speed . 6. Proper RH to be maintained in all departments. The number of air changes per hour for Ring frame should be 35-40 and it should be little higher for carded counts. The Fiber flies either should be removed by exhaust (or) to be sweep manually by Operator to ensure it will not disturb the spinning process in from creel to cop to avoid end breakages. 7. The rogue spindle in ring frame is one of cause and it will “Keep on” break the yarn due to so many reasons such as poor feed bobbin quality, eccentric in spindle rotation, poor ring centering, damaged separator and lappet hooks, defective aprons etc, The defective bobbing holder will create thin place and repeated creel breaks .All the above to be rectified continuously to avoid repeated/ continuous yarn breakage in particular spindles. For quick identification of rogue spindles, “on line spindle monitoring equipments” available in market which will reduce the time and manpower for rectification. Finally there are so many factors influencing end breakage in spinning such as Proper raw material selection Optimum waste removal, appropriate opening and cleaning in blow room &cards Appropriate machinery settings, speeds, total draft Appropriate mechanical schedule for replacement of travelers/rings and aprons. Identification and rectification of rogue spindles Proper buffing schedule In time Machinery cleaning and good up keeping of machines Maintaining appropriate Humidification Mr.Malkappa M Biradar   HOD – Spinning PV, Raymond Limited, Chhindwara Madhya Pradesh               One basic way to increase the profit and quality in ring spinning process is to keep the end breakage rate to a minimum level. The end breakage is a critical spinning parameter that not only affects the maximum spindle speed but may also indicate the quality of yarn, the mechanical condition of the machines and the quality of raw material. Therefore it is an important parameter which determines the overall working of a spinning mill. Any attempt to explain the end breakage mechanism in terms of qualitative approach will provide an aid to understanding the problem and to tackling it to any possible degree.To reduce end breaks, the following few aspects should be taken into consideration 1.The width of the drafted ribbon at the front roller nip should be reduced. 2.Measures to be taken to reduce mass irregularity of yarn straight after carding. 3.A reduction in friction between ring and traveler could reduce the peak tension during the rotation of the traveler. 4.Since the end breakage in ring spinning is related to slippage of fibers at the spinning triangle as a result of peaks occurring in the spinning tension fiber, the grip at the front drafting rollers should be increased by having a higher top roller pressure. The use of softer cots also enhances the grip at the front roller. If the total pressure on the rollers cannot be increased, the grip at the front rollers nip can be improved by reducing the width of cots. 5.The permutation and combination of speeds at different stages of cop build in ring frames can help a lot in reduction of breaks. 6.In case of spring loading top arms in ring frames, when you restart the ring frame after a mill holiday, the breakages are very high. The practice of inching at interval of 8 to 10 hrs on holiday without releasing the top arm pressure, reduce the end breaks to a great extent. 7. In case of pneumatic loading top arms ring frames, when you restart the ring frame after a mill holiday, the breakages are very high. The practice of tightening the material in drafting zone by reversing the back & middle rollers with the help of back roller wheel before starting the machine helps in reduction of end breaks during starting of the ring frames. 8.The lowering of spindle speed by 5 to 6% just after putting new travelers for 2 hours for running-in of travelers helps in reduction of end breaks to large extent. 9.The use higher twist multipliers will reduce breaks even at higher spindle speeds than at lower spindle speeds with low twist multipliers. 10.The lower twist than required in roving reduces the creel breaks in ring frames. 11.The delay in change of travelers will increase end breaks in spinning. Hence timely change of travelers is a must. There are many such points, but uncommon points are mentioned to share with fellow technicians. Mr.Atul Pareek, General Manager, BSL Limited, Bhilwara, Rajasthan End breakage rate playing a vital role in Ring spinning and having direct relationship with productivity and quality. Following steps are to be taken care to control the end breaks rate in spinning – Yarn passage: Regular monitoring and checking of yarn passage is very essential in order to reduce the end breaks rate, therefore inspect the followings – a).Condition of bobbin holders - if clogged with fly b).Condition of roving guides – there should be any cut mark c).Aprons - Channeling or worn d).Top rollers - Cut mark / defective e).Suction tubes - Choking, misalignment or serration inside f).Centering of spindle with lappet hook, ring and balloon control rings g).Condition of surface of yarn eyelet h).Spindles should run vibration free i).Ensure proper fitting of bobbins on spindles j).Condition of rings k).Use of Right  Traveller profile - Shape, wire and number l).Ring rail - Speed or check if any Jerky movement m).Spindle tapes - Slack / loose Cleanliness – Maintain perfect housekeeping inside the department and cleanliness of machines especially at drafting zone to avoid accumulation of fly, fluff. Use of optimum process parameters at all stages Preparatory – --Use right kind of fiber suitable to count processed, optimize the fiber fineness and length. --Maintain regularities in sliver, roving and control variations --Optimize roving twist multiplier Spindle speed – At higher spindle speed, the spinning tension increases. As a result of higher spinning tensions, the difference between the yarn breaking force and the tension places on the yarn becomes much less and therefore the probability of end breaks increases. Setting of Traveller clearer – If the setting is wider, chances of fluff accumulation will be more on the Traveller, leads to higher weight of Traveller and balance will be lost, therefore optimize the setting of Traveller clearer according to count. Spinning geometry – Spinning geometry is directly related with spinning tension and spinning triangle. Perfect geometry with respect the count, speed, material processing will help to achieve the lesser breakage rate. Ratio of Ring to Bobbin diameter should be 2 : 1 and Ratio of Bobbin length to Ring diameter should be 5 : 1 Ring path --Ring race way should be clean, smooth and free from rust, any cut mark or damages. Traveller lag (Difference between spindle and Traveller speed) will be more when the ring path is damage, thus more the Traveller lag more the yarn breakage rate. --Avoid formation of rust / corrosion at rings --Use rings with good surface protection Traveller type: Too heavy traveler also causes the higher end breaks rate – Special care should be taken to choose favorable Traveller type like Shape, wire cross-section, weight and surface treatment. Travellers are to be kept clean Use Travellers with well-protecting surface treatment -Test wear and tear of ring traveler timely Avoid Roller Lapping --Monitor closely the breaks rate just after doffing, during speed change and at maximum speed --Standardize the pressure applied to top rollers --Set setting of suction tube to the bottom roller closer, because closer the setting higher the suction efficiency and lower the lapping propensity Avoid Multiple Breaks To avoid multiple breaks, ensure --Proper Traveller number --Good house keeping --Perfect condition of pneumafil suction tubes --Condition of separators should be good --Perfect condition of lappet hooks, bobbins and Anti balloon rings Humidification Management System There should be appropriate atmospheric conditions like temperature, relative humidity, number of air exchanges etc.  Maintain the Air humidity and temperature inside the department as per standard requirement because too low RH & temperature may result to static charge that is responsible for lapping and hence increase the breakage rate. Engineering dept. should also monitor the Air changing intervals and adjust blower and exhaust installations as per RH requirement. Mr.B.Thangappan, Kader Compact Spinning Limited, Bangladesh STEPS FOR REDUCE THE BREAKAGE IN SPINNING --The bobbin holders alignment should be perfect --The over head nozzle position is in right place and the blowing of air should be properly positioned --The bottom roll setting and top roll setting (saddle gauge) should be uniform. --The proper selection of break draft, spacer, ring Travellers. --All gears engagement and teeth conditions should be perfect condition. --All lifting tapes and guide pulleys alignment ensure the ring rail movement(without  jerk) --The inverter spindle speed setting one step to another step not much difference (better 1000 to 1500 rpm). --In case of the drafting pneumatic the pressure hose & letch condition should be good --Timely servicing of Jockey pulley and replacement of spindle tapes. --In case of tangential belt drive take extra care during spindle oil change chances of   low TPI which leads end breakages. --Spindle button and proper seating of bobbins. --Increase the frequency of Spindle centering incase of manual doffing. --Close monitoring of Rings and ring travelers. --Overall taking care of apron  maintenance (Washing and replacement) --Proper alignment of pneumafil pipes and frequent checking suction pressure --Control and close monitoring of temperature and humidity --In speed frame breakage and very control & implement good piecing method control on twist. --Yarn tension and control ballooning --The ABC Ring surface finish is very important (free from rust and scratches) --There should not be any cross roving during running. --Proper tilting of lappet if not the start up breakage more in Auto doffing machines Mr.K.Gururaja, Factory Manager, Hi Tech Spinning Mills, Sulur, Tamilnadu Every end breakages apart from being potential cause of breaks, in subsequent department results in the yarn defect, lower machine efficiency, higher waste and more work load for the siders. End breakages in drawing, fly frame are in variability from poor material handling, improper piecing of back material from carding on wards. In adequate of top and bottom clearer, more breaks in fly frame. Following precautions/measures should be taken to avoid more end breakage in spinning. End breaks more than 3 breaks/spindle hour or more than per hour individual spindle shift is unacceptable. 1).Creel breaks due to low TM in fly frame 2).Excess friction in bobbin holders 3).Improper spacer size 4).Un uniform pressure in top rollers 5).Improper ring & Traveller combination 6).Poor condition of cots & on some spindle position 7).Poor condition of rings and lappet hooks 8).Too early change over speed from slow to fast 9).Damaged bobbin holders 10).Jerky motion of ring rail 11).Vibration or eccentric spindle driving puppy 12).Slack spindles 13).Worn out gear wheel and deep meshing of gears 14).Chocking and improper alignment of pnemafil 15).Cracked and worn-out bobbins 16).Closer Traveller clearer setting 17).Too high a draft 18).Not optimized break draft 19).Incorrect shore hardness of top rollers 20).Incorrect apron nip opening and setting 21).Lack of control of temperature and humidity Mr.P.Sankar, Senior Technical officer, Precot Meridian Limited, M- Unit, Pollachi, Tamilnadu End Breakage rate in spinning will be under control if we ensure the following 3 conditions. --Optimized machine parameter like machine lift, Ring dia., Ring, Traveller, other    basic settings and pneumafil suction to the level of 150 mm of water at fan end --Optimized process parameter like drafting settings, spacers, winding length    and with parabolic speed control with 16 steps. Peak speed running time should    be 60% of doff time & speed difference between peak speed & average speed    to the level of less than 7%. --Maintaining the dept conditions like RH %, Temperature, Lux & free from flies etc. b) Detailed Answer as follows Mainly End breaks in spinning depend on the 3 conditions and are Machine, Process & Atmosphere a) Machine condition 1.M/C lift as 160 mm & Ring dia as 36 mm 2.Ensuring the ring, lappet condition & ring centering 3.Pneumafil suction as 150 mm of water in Fan end & 80 mm off water in gear end. 4.. Ensuring of basic m/c settings like initial lappet setting 40 mm &    Lappet movement after 80 mm of cop etc 5.Choosing correct Traveller profile & number based on count type & material b) Process condition 1.Selection of optimized TPI, Drafting settings & spacer size 2.Incorporation of parabolic speed control system and best suited speed table    with minimum 16 no of steps by conducting trials for checking the stage wise breaks. Ensure the speed difference between peak speed & average speed is    less than 7% and peak speed running time should be 60 % of total doff time. 3.Infeed roving Unevenness %, CV % within STD & Bobbin weight to STD. 4.Maintaining of clearance between ring & Traveller as 3 mm at least &   Optimum winding length. 5.Optimized Chase length, Cop content, Cop top & bottom clearance c) Atmosphere condition. 1.Maintaining the department free from flies, with Optimum temperature & RH % 2.Lux level 100 with reduced noise level. Mr.G. Sundar, Factory Manger, Aruppukottai Sri Jayavilas Ltd, A – Unit, Aruppukottai, Tamilnadu. The steps to be taken care to reduce the end breakage rate in spinning can be classified into 3 categories 1.Process control in Preparatory 2.Mechanical maintenance process in spinning 3.Housekeeping and R.H. in Spinning 1.Process control in Preparatory     a).Proper selection of cotton varieties with less variation of physical cotton properties like Fibre Length,     Strength, Micronaire value, less trash content and short fibre content. b.)To control of waste level at Blow Room, Carding waste% and Comber Noil % c).Modern Blow Room lines the cleaning efficiency is up to 60% and to achieve the higher degree of opening     which result in better cleaning at cards. d).To avoid the fibre rupture in Blow Room and carding stage if the 2.5% Span Length drops by more than     4% and the Uniformity Ratio drops by more than 5% then it is considered that there is fibre rupture. e).Draw frame is one of the important stage in the spinning process Sliver CV% and setting.                          1 meter CV%                 -            Below 0.75 %                          5 meter CV%                 -            Below 0.50 % f).Simplex is also another important stage in the spinning process.                          Roving Hank CV%          -           Below 2 %                          Roving Stretch %           -           Below 1 % g).Spinning blending influence the process performance through                          Yarn count CV%             -           Below 2 %                          Yarn strength CV%        -            Below 5 %                          Twist variation                -            Below 2 % h).To proper mechanical condition of machinery and top roller pressure to be maintained in Draw frame and     Simplex helps to reduce the end breakage rate. 2.Mechanical maintenance in spinning a).To avoid Jerky motion of bobbin holder and subsequent creel stretches. b).To maintain creel guide rods without peeled off coated portion. c).To avoid Roving guide clogged with waste. d).To avoid channeled bottom and top aprons which causes fibre plucking and   breaks. e).To proper selection of spacer and break draft. f).To proper maintain top roller pressure. g).To avoid groove formation on lappet hook. h).Peeled off coated portion in ABC ring. i).To avoid spindle vibration and spindle out of centre. j).To avoid loose tapes and proper Jokey pulley tensioning. k) To proper gauging of Ring, Lappet and ABC centering help to reduce the yarn tension. l).To proper selection of Ring traveler profile (Traveller wt., height and cross section) m).To proper setting of lappet height and ABC ring height. n)To proper setting of cop build at bottom. o).To proper selecting the ratio of tube length and ring diameter to 5:1 p).To proper setting the lappet hook distance from the top of the tube to be two times of top portion diameters of ring tube q).To proper setting to traveler clearer to be 0.25 mm to traveler. r).Proper setting of speed pattern pre twist – under winding – etc. s)Workers training related for removing cops properly and replacing empties in time will reduce end breaks during doffing t).To proper maintenance to be done delay drafting setting and avoid Jerky motion of ring rail motion. u).The overhead traveler clearer is to be run with correctly positioned blowing nozzles. v).To proper mechanical condition of machinery and top roller pressure to be maintained in spinning department. 3. House Keeping and R.H.%           Good Housekeeping to be maintained inside department and maintain proper humidity (48 – 53%) is to be maintained and there should not be any wide variations further flies in the spinning department and to be controlled by running the necessary fresh air fans, water pumps and exhaust fans. Mr.G.Balachandar, Textile consultant, Coimbatore, Tamilnadu Steps to be taken to reduce end breakage rate in ring spinning In ring spinning the end breakage rate is associated with so many factors. Among this the following are the some major reasons for end breakage. a)   Raw material since raw material contributes  to a major level , for the count we are going to spun  the cotton parameters has to be maintained as per std. Especially uniformity ratio of cotton is to be 48%+and while mixing more than 2 varieties of cotton  we should ensure that micronaire range is maintained at+/-5%. b)  Preparation of mixing When 2 or more varieties of cotton is blended, more attention is to be paid for the homogeneity of mixing in all areas. Secondly while mixing soft waste it should not exceed the level of 3%. c)  Process parameters While starting a process, from BR to spinning all the process parameters has to be optimized based on the std as well as actual trial. The following are some of the important process aspects/parameters which have a direct link with spg end breakage rate. 1)  In blow room no. of beating points is to be optimized so that the fibre rupture is maintained below 3%. 2)  In carding also we should ensure that there is no fibre rupture by optimizing the licker in speed and feed plate to licker in setting. 3)  In draw frames(especially in finisher),creel tension draft, web tension draft, break draft is to be optimized since these parameters have a direct impact on yarn long thin faults(H1,I1)which in turn will influence the spg end breakage rate. Normal range of these parameters is as under, Break Draft                -   1.17 Creel tension   Draft   -   0.97 to 0.99 Web tension    Draft    - 0.98 to 0.99 4)  Normally every roving breaks in simplex will cause an end breaks in spinning. Hence the roving breakage rate is to be maintained at below 1 in simplex. Mainly in simplex roving stretch is to be maintained below 0.5 because this has a direct impact on yarn long thin faults which in turn influence spg breakage rate. 5)  In ring frame while selecting ring Travellers, like Traveller number, equal importance is to be given for the profile of Traveller and finish of Traveller (Sapphire, Hi-tech, Maxima and Express like wise) also. 6)  In ring frame apron spacer is to be chosen as per std otherwise too narrow spacer (than std) will increase the end breakage rate. d)  Machine setting and maintenance activities ( for LR make ring frames) 1)  In ring frame spindle and lappet gauge setting is to be done once in 6 months 2)  Ring rail, lappet, ABC setting is to be done once in a year. 3)  Variator C1, C2 setting is to be checked once in 3 months. 4)  Machine full cleaning is to be done once in 15 days and draft zone cleaning using pickers is to be done daily. 5)  Ring Travellers are to be replaced at specified intervals. Sapphire finish -    5 to 6 days Hi-tech    finish -    8 to 10 days Maxima   finish -   15 to 18 days Express finish -   25 to 28 days 6)  Condition of rings is to be examined and if necessary replacement of rings is to be done as per manufacturer recommendation e)  Maintaining proper relative humidity in ring frame shed ( 50 to 55%) will help to minimize the end breakage rate. f)  Yarn twist multiplier is to be as per std for the count going to spin and spindle speed also to be selected based on condition of machinery, quality of raw material, piecing efficiency of spg siders and availability of sufficient no of workers for that shift Along with the above maintenance activities, in general the machine is to be maintained as it was on the first day of commissioning. Mr.Pandia Rajan.P, Spinning Master, Premier Mills Pvt Limited. Pulankinar, Tamilnadu The following steps to be taken care to reduce end breaks in spinning. Preparatory: 1.Simplex Hank and TPI influence Spg breaks. Correct TM and hank to be select in simplex. Higher TM roving creates more undrafted ends in spinning and lower TM roving creates higher creel breaks.  So, optimum TM shall be select. 2.Bobbin content - Higher bobbin weight gives more breaks in spinning. Correct bobbin weight with free from roving faults to reduce Spg breaks. 3.Quality of roving (like CV%, Stretch % & U %) influencing RF breaks. Optimum is Stretch % - 0.5 % & U % - 3.5%, EBH - 0. 4.Auto leveler Drg sliver with CV %( 1m) - 0.6% gives lesser breaks in spg. Spinning 5.Right Traveller selection gives lesser breaks in spinning. 6.Optimum Traveller clearer setting (1.6mm) helps to have lesser breaks. 7.Traveller changing frequency to be followed as per manufacturer recommendation and RF performance. 8.Timely ring changing is mandatory. 9.Spinning spindle life influence spinning breaks. 10.Optimum Break draft and right spacer will give lesser breaks. 11.In spg, Correct RH %: 42 - 44 & 32 degree Dry temp, gives better performance in spinning. 12.Optimum drafting pressure to be ensured always to avoid undraft end breakage & overdraft end breakage 13.Considering various Step speed stage wise breakage rate optimum speed pattern to be derived. 14.Cots dia - Minimum cots dia 28.5 mm to be maintained to avoid lapping tendency on cots. 15.Damage free of Aprons and timely replacement of apron is required to have less breaks. 16.Cleanliness of Ring frames and dept. housekeeping gives less breaks in Spg. Individual Top arm loading to be ensured periodically. 17.Short snarl settings to ensure in periodic maintenance to have lesser start up breaks. 18.Smooth movement of Ring rail to be ensured. 19.Correct lappet centering to be set. 20.In spinning, bobbin holder frees rotation to be ensured. 21.Damaged and worn out ring tubes to be avoided. 22.Optimum OHC blowing pressure gives lesser breaks in spg. Mr. S. Chidambaram, Factory Manager, KKP Textiles Limited, Viralimalai, Tamilnadu Selection of proper Traveller profile, Lappet height setting according to the lift with correct RH % will help to reduce the end breakage rate in spinning. To reduce the end breakage the following points to be noted & corrective actions to be taken, if necessary. 1) Lappet height should be maintained from 40 to 45 mm from the top of the cop. If it is low, Balloon size will large and breaks will occur and if it is high tension increase, the yarn may touch the tip of the cop and also breaks increase. 2) Optimum break draft with suitable spacer to be selected for better performance. Both of these factors should be considered according to the Roving hank and its TPI. 3) Simplex Empties condition should be good so as it hold in the spinning creel properly. If there is any damage inside the bobbin, then the bobbin becomes tilting, while running in the creel caused stretch, breaks will occur due to thin place. Simplex Empties to be good. 4) Roving guide rod in the creel should be just below the half size of the bobbin to avoid roving stretch. 5) Roving guide on the guide rod should be proper and it should not go outside the cots area. Traverse distance to be maintained within 4 – 5 mm. 6) Damaged top and bottom aprons can also end breaks and it should be changed if necessary. 7) Improper bobbin holder & worn out bobbin holder also creates stretch in roving caused end breaks. 8) Improper buffing of top rollers, (i.e., Taper formed in cots) also creates end breaks, cots taper to be checked while after buffing. 9)  Proper RH (55 to 58%) to be maintained for better performance. 10) Machine up keeping should be good to minimize the end breaks especially in coarser counts. 11) Speed fluctuation should be minimum of 100 to 150 rpm in variator belt drive machines. More speed fluctuation can also cause more end breaks. 12) Suitable Traveller to be selected according to count and Ring for better performance. If the Traveller is too light, lashing will occur, if it is too coarser, tension raised and fly out may occur. 13.Ring Rail movement should be smooth, jerky movement to be avoided, and also all draw bar bearing should be freely rotate. 14) Traveller clearer setting should be done so as not it touch the Traveller. 15) Over head clearer blowing positions should be in proper as per the recommendation. Excess blowing should  be avoided. 16) Running of loose spindle tapes to be avoided 17) Bobbin gaiting should be proper. Cross gaiting should be avoided. 18) RT changing schedules to be followed without fail for better performance. Mr.Radhakrishnan.R, Technical Officer, Precot Meridian Limited, A-Unit, Kanjikode, Kerala How to reduce end breakages in spinning? 1.Centering of rings:  Ring and spindle centering should be perfect 2.Centering of ABC rings:  ABC and spindle centering should be perfect 3.Centering of lappet - Lappet and spindle centering should be perfect 4.Lappet height optimum setting- 38 mm: Lappet height from the tube top should be optimized according to the ring dia, count, speed etc, so that the ballooning neither touches the tube nor over size. 5.ABC ring height optimum setting -50 mm: ABC ring height to be optimized, so that the position of the balloon should not be either top or bottom of the ABC ring. 6.Traveller clearer optimum setting: Traveller clearer should not affect the free flow of Traveller but should clear the Traveller fluff. 7.Size of Traveller- optimum: The size (number) of Traveller should be perfectly matched with the count spun and spindle speed 8.Profile of Traveller –optimum: The profile of the Traveller should match with the profile of the ring and material being processed. 9. Mechanical condition of ring, ABC ring, Lappet hook: Mechanical condition of the parts like ring ,abc ring lappet hook etc should be perfect. 10.Optimum TM/TPI: TM/TPI has to be optimized. 11.Optimum chase length: Ring dia + 3 mm 12.Optimum cop dia: Ring dia - 2.5 mm 13.Optimum ring rail speed: Optimize as per the count spun 14.Cots buffing schedule: Optimize as per the count and material 15.Spacer used: Optimize as per the roving hank, count spun 16.Speed pattern: Optimize the speed pattern by trial and error method. 17.Meshing of gear wheels: Meshing of gear wheels to be perfect. Over and under meshing to be avoided 18.Performance of additional drive: Additional drive function, breaking condition oil level have to be perfect. 19.Mechanical condition of gear wheels: All the gear wheels should be free from damage 20.Condition of bearings: All the bearings especially at gearing area and fluted rolls should be in good condition Delay drafting function performance: Performance of delay drafting and its function should be perfect. Any uneven air supply also to be avoided. 22.Bobbin holder condition: Condition of bobbin holder and its performance has to be good. 23.Selection of bobbin holder -gm force: Bobbin holder spring tension to be optimized as per the roving hank and count 24.TM/TPI of feed bobbin: Optimum TM/TPI of the feed bobbin required to avoid creel cuts as well as undrafting. 25.OHTC nozzle allocation: OHTC air blowing nozzles to be allocated (12 no preferred) perfectly and the suction nozzle must be able to catch the loose fluffs 26.OHTC performance: Maintenance of OHTC  is very important 27.Roving alignment at drafting zone: Roving should pass through the center area of cots and aprons. 28.Humidity: Most important factor in a spinning mill. Dry 34-35 and RH 55-56% preferred. It can be optimized according to the cotton, outside climatic condition, count spun etc. 29.Humidification Plant suction performance: Plant suction performance should be perfect to avoid any loose flies and air rebounding. 30.Drafting pressure: Both total drafting pressure and individual top arm pressure has to be maintained. 31.Air leakages at drafting: Any air leakages at drafting zone (air hose, pressure hose etc) will create problem. 32.Top arm setting: Individual top arm setting should be perfect 33.Cleanliness: Last but not least, the machine cleaning and department housekeeping have very important role in ring frame working performance Mr.  B.K.Swami, Production Manager, Mahatma Phule MSSG Ltd., Kolhapur, Maharashtra Following are the steps to be taken to reduce End Breakage Rate in Spinning, --To maintain proper RH% & Temperature in Ring frame dept. --O.H.T.C. is to be run with correct position of blowing nozzles to maintain ring frame fluff free. --Better housekeeping to reduce fluff generation in ring frame dept --Maintaining the spindle speed in parabolic form for avoiding jerky movement of ring rail. --Use of count wise suitable Ring traveler. --Strict follow-up of Ring traveler change schedule. --As per feed hank & count produce use optimum spacer, break draft & T.M. --Strict follow-up of maintenance activity like Spinning Ring Centering, Lappet & ABC Centering, Saddle Gauge. Cots Buffing, Rogue Spindles etc. Mr.N.Raghunathan, Senior Manager, Sambandam Spinning Mills Ltd, Unit-3, Salem, Tamilnadu To maintain the uniform RH with auto control system for avoid the Traveller loading. Selection of Traveller profile according to the type of ring (36mmф) with adopting proper tension. Speed pattern should be set with smooth curve. Clearer rolls, Draft zone cleaning should be done in 24 hours once. Process to be with appropriate Spacer, Roller setting, Break draft, Pressure and Top roll shore hardness. Periodic checkup like spindle gauge, ABC gauge (ABC ringф= Ringф+3mm), Lappet gauge (Lappet hookф-1mm) and bobbin holder conditions. Critical components like as Apron, Cots, Tape, Bobbin holder etc., should be changed at specified period. Identify the repeated spindles and correcting then and there. To maintain the adequate pressure of pneumatic suction for avoiding lashing of ends. OHTC blowing should be adequate and at specified machine parts. After doffing, to reduce the more ends down, best work practices to be implemented. To maintain the quality level with appropriate CSP and Elongation of yarn. Traveller to be changed at desired life of Travellers. Mr. Palaniappan.C, Factory Manager, Shri T P Textiles, Rajapalayam, Tamilnadu 1) Temperature and humidity to be controlled. 2)  Suitable ring Traveller (no &flange) to be used according to the count by trial and error.Ring Traveller changes to be done correctly. 3) Spindle out of centrewith ring and lappet to be corrected. 4) Apron nip opening & settings, top roller pressure, break draft, total draft, pnemafil suction pressure, Traveller clearer settings, lappet height setting, traverse motion setting, and top roller buffing schedules, bobbin dia. to be set optimum. 5)  Optimum shore hardness of top roller cots should be selected 6)  Loose and worn-out aprons, worn-out rings, jerking ring rails, worn-out bobbin holder, worn-out bobbins, worn-out gears, deep meshing gears, eccentric spindle driving pulleys to be corrected. 7)  During rings change, ring Traveller running in period must be followed 8)  For variator drive, correct speed stages to be selected according to the count cops sizes. Mr.Pradeep Kumar Roul, General Manager, Sathyam Spinners Ltd, Sedhwa, Madya Pradesh --Controlling Roving Linear Density --Proper Draft & Roller setting --Optimum Spindle Speed based on material & its spinnable properties with eccentricity free spindles --Proper selection of Travellers i.e. type & weight --Monitoring Life of Rings & Travellers --Maintaining uniform Relative Humidity & Good housekeeping in spinning --Following proper & standard process parameters --Changing Travellers strictly at ¾ th cop stage --Proper positioning of OHTC nozzles --Proper settings of  top arm pressure, ABC rings, separators, Traveller clearers and height & centering of       lappet hooks Mr.V.Ravikannan, DSM-QAD, Cottonblossom India Pvt Limited, Sathyamangalam, Tamilnadu Steps to be taken care to reduce the end breakage rate in spinning 1.Department RH% maintain from 50-60%. 2.Spinning traverse not exceed to 10mm. 3.Avoid using damaged separators. 4.Using modified anti-ballooning rings 5.Maintain the cleaning schedule of the m/c once in 15 days. 6.Maintain the ring traveler changing schedule once in 6 days. (No more days exceeded.) 7.Do the daily half-cleaning and clearer roller cleaning.(top& bottom) 8.Select the ratio 1:5 between rings and ring tubes. 9.Select the ratio 2:1 between rings and ring tube diameter. 10.Do the ring, ABC and lappet centering once in 6 months. 11.Using poly carbonate ring tubes. 12.Using proper ring traveler profile based on raw material quality. 13.Avoid too narrow traveler clearer setting.(not below to 1.8mm) 14.Avoid too more cop diameter.(Distance between cop and ring minimum 1.5 mm) 15.Select the proper winding length according to the count. 16.Select the chase length from 40 to 42mm. 17.Maintain the distance between spindles to lappet. (start-60mm, running-40mm) 18.Select the correct speed step according to the count.(using speed curve chart) 19.Select the optimum TM according to the count 20.Maintain the distance between front bottom roller to suction tube.(not below to1 mm) 21.Select the optimum top roller pressure.(front-18kgs,middle-14kgs,back-16kgs) 22.Select the shore hardness of the rubber cots 60 to 70 degrees. 23.Select the optimum break draft. Mr.S.Selvam, Asst. Manager –Technical, Sree Narasimha Textiles P Limited, Sulur Tamilnadu Here with given below the steps taken to reduce end breakages rate in spinning. 1. In Mixing soft waste % not be extended more than 2.5%.Homogenious mixing & percentages   of mixing ration to be ensured & followed 2. Carding breaks/shift maintains 1 / shift. 3. Comber to maintain breaks / shift blow 2/shift. 4. Drawing breaks /shift below 10/shift. 5. Simplex breaks /100spl hr below 1/100spls/hr. 6. Lap former to simplex machines draft zone based on 2.5% span length to be set and also optimum speed at beaters & delivery rollers can be set, otherwise fiber ruptures will create breaks at Ring frames 7. RH% up to prep dept 45 – 55% to be maintained. 8. At spinning department RH% to be maintain 46 – 52% and to ensure the below based on counts run Traveller clear setting, Rings & ABC rings center ,spacer/bobbin holder conditions ,spindles lubrication as per. frequency    Traveller changes with optimum frequency maintained and m/c draft zone daily cleaning and schedule cleaning with frequency Lappet eye diameter mm suitable used, lappet setting, winding & binding coils based on counts and ring tubes used based    on lift and parabolic speed pattern curve to be set from starting to end speed increasing .start up breaks below 3% maintained  and day to day ensure the Ring frame performance with individual spindle monitor to reduce rouge & repeated spindles breaks. 9.Operator should be trained well in proper work method training We can follow the above steps at spinning we can able to maintain breakage rate at Ring frames below 4-5/100spl./Hrs. Mr.Veeraswamy Sivarathri, Manager-QAD, Mandava Cotton Mills (P) Limited, Gannavaram, Andra Pradesh 1. Use suitable Traveller for suitable count 2. Suitable setting of Travellers clearance setting (below40s-1.8mm, and 60s and above counts should be maintain 1.6mm respectively) 3.Travellers changing procedure maintain correctly in running in procedure 4.Should be maintain perfect humidification 5.Good clg. of draft zones in spinning and minimize the top, bottom aprons cuts and also avoid rogue spindles. 6.To maintain good suction in water coloum level should be gear end-5 to 7, off end-10 to 12 and middle end-8 to 9. 7.To minimize higher speeds in spinning. 8.maintain suitable spacer in suitable count(if spacer is wider, cause imperfections level come high and closer spacer used, cause un drafting due breakage. So, pl. choose correct spacer maintained 9.Should be maintain time to time maintain schedules and Travellers changing procedure 10.Mainly should maintain short fibre content may minimize Mr.T.A.Shanmga Sundaram, Factory Manager, Saravana Polythreads (P) Ltd, Gobichettipalayam. Tamilnadu Control and reduce the end breakage in spinning classified as follows 1. Process control by the technical team 2. Maintenance works executed by the maintenance department 3. Snap survey adoption by QC department. The average breakage rate to be control by the process control such as Homogenous mixing, carding web quality, drawing and simplex U% and stretch in roving (should be below 0.5%). Selection of break draft, back zone setting and spacer by taking trial and error method in terms of breaks per 100 spindle hour. By the way of maintenance 1. Aprons and cots condition 2. Buffing schedule followed 3. Condition of rings 4. Selection of Traveller according to ring profile 5. Periodical changes of rings and lappet hook 6. Bobbin holder condition 7. Rings and lappet centering Initial breakage should to be control by operating lower speed at the starting stages and selection of Traveller size i.e. not heavy to touch the tip of the bobbin and not too light to lashes on to the separator. Traveller cross section flat type for cotton and half oval for synthetic, setting the lappet height to 25mm from the bobbin top. Later stage breakages controlled by setting the lappet to bobbin top height is not less than 100mm Repeated breakages to be controlled by follow-up of snap survey 1. Vibrating spindle 2. Defective rings 3. Aprons damage 4. Apron Missing 5. Spacer missing 6. Weak tapes Maintain the RH 55% at the spinning department. Mr.K.S.Gowri Shankar, Director, Saravana Polythreads (P) Ltd., Gobichettypalayam, Tamilnadu The following steps are reduce the end breaks in spinning, yarns breaks occur generally at places that are too weak to with stand the tension imposed, during spinning increase in yarn strength should reduce end breakage rate. 1.  End breaks are usually more at the cop bottom stage. So dual motors help in reduce the breakage. 2.  Change the shore hardness top roller and correct the top arm pressure. 3.  Replace the worn out aprons, damage or defective top rollers and eccentric top rollers 4.Correct the roving guide and traverse movement. 5.Type of Traveller used and correct Traveller clearer setting. 6.Traveller change in correct duration (7 to 10 days). 7.Spindle, Lappet hook and ABC ring are in correct centre. 8.Smooth ring rail movement. 9.Reduce 20 to 50 % end breaks by improve the machinery maintenance and material handling. 10.Relative humidity of 55 % and temperature at 80*F, high humilities increase roller lapping and end breaks. 11.Regular cleaning of top clearer rollers and always in free rotations. 12.Proper piecing in the back feeding materials drawing, simplex. 13.Maintain free rotation of bobbin holders to avoid the stretches in the rowing and control the end breaks. The above points are reducing the end breakage rate in spinning. Mr.V.Chandrasekaran, Senior Manager, Adwaith Textiles Limited,   Coimbatore,Tamilnadu The steps to be taken care to reduce the endbreaks rate in spinning mill 1. Setting of average speed and maximum speed based on the previous   history of machine and accordingly speed curve is to be set 2 Selection of Traveller number, profile, and renewal and changing    of Traveller after ¾ th stage and follow 80% speed after Traveller changing and restarting   the machine. 3. Steps taken to control ballooning at 1/4 th stage by optimizing    speed and using higher wall thickness empties (say 3 mm for 70s and above count) and maintain 10 mm initial height to be set to start   initial winding. 4. Cop bottom optimum setting, based on ring dia. 5. Daily cop content to be checked and cop dia should be minimum   less than 2.5 mm than ring dia., also start up breaks to be taken in specified format machine wise. 6. In ring frame, winding length, chase length also to be set based on ring dia and count. 7. Life of rings, apron, top arm setting creel height, bobbin holder,   life/service, machine, cleaningness, buffing f cots, overhead    setting also helps to reduce breaks 8. Dept RH% must be 50 to 55% but the dry should be good as 98f to 100f and wet should be 82 f to 85 f will help to reduce ends down% 9. Traveller speed to be checked with handbook given by manufacturer for example -30s count ring dia 38 mm speed maximum    19000 rpm means 38 mtrs/sec& for 60s it should be 40 mtr/sec & 80s it will   be 37 mtr/sec 10. Machine setting like abc, Traveller clearer, lappet height, proper    scientific checking and setting, lesser lappet dia will helps to   minimize breakage rate. Mr.B.N.Malleswara Rao, Engineer, Kakatiya Textiles Limited, Kodad, Andra Pradesh 1. Maintain good RH% in spinning and preparatory process (48%-55%), because RH% is plays vital role in spinning production and quality. 2. Fine tune the process according to the raw material from mixing to ring frame (waste % adding in mixing, count, TM, draft, waste removing, blow room, carding settings...etc). 3. Based on SFC n in raw material and back process set the further process because it is the main roll to control the breakage and quality 4. Use the raw material, length CV%, Mick CV% within the range or otherwise week spots will be increase and caused more breakage in spinning 5. Implement, and Practice the correct work methods (group feeding, doffing practice, patrolling, bobbin creeling, piecing at back process, cleaning) in all depts. Like production, maintenance, cleaning. 6. Follow the schedules as per manufacturer recommendations like ring Traveller change, ring centering, ring traveler clearer setting, cots buffing. 7. Use suitable profile Traveller, (based on in high speed yarn tension Traveller burning rate). Mr.V. Balasundaram, Mill Manager, Madura Coats Pvt Ltd, Madurai, Tamilknadu Breakages occur when higher tension and weak spots coincide during spinning. Hence, controlling both these aspects gains significance. For reducing the yarn tension selection of proper ring dia, tube length and tube dia & selection of ring and Traveller profile depending upon the material and count to be processed is most critical. Maintaining uniform tension throughout the cop build by varying the spindle speed is another critical aspect. Maintaining minimum thin faults by optimization of process parameters is essential to avoid unwanted breaks. Apart from the above aspects ensuring appropriate RH% depending on the material and maintaining proper maintenance schedules will help in reducing the end breakages in spinning. Mr.S.Murugaraj, Maintenance Manager, Moon Spinners Pvt Limited, Surankudi, Tamilnadu Optimum drafting force according to count spun, Optimum TPI, proper centering of ring, ABC & lappet centering , Correct timing& better selection of renewal parts like bobbin holder, cots, apron, ring, spindle, spindle  tape & ring Travellers , Optimum spacer setting of top & bottom rollers according to count spun, Proper selection of winding length(winding coil/chase length=chase length/yarn dia*8) , Better ring geometry (chase length=ring dia+4mm, ABC ring dia=Ring dia+3mm, Initial lappet hook distance from cop tip=2*top dia of empties+5mm, cop content=ring dia-3mm, empties length=ring dia*5) Air circulation inside the dept should be free from flies & dust, Overhead nozzle position proper, use of parabolic speed curve, good housekeeping and correct timing of maintenance schedules. The above will be reducing the end breakage rate in ring spinning. Mr.Ramasubramanian.S, Spinning Master, Mani Spinning Mills (P) Ltd, Unit - II, Vedasandur,  Tamilnadu Points to reduce the end breakage in spinning. --Selection of Traveller according to the count spun and Speed is very important factor. --The yarn pulling angle must be maintained below 30 degree and it may be achieved by the selection of ring dia & spindle DUI. The Traveller speed must not be exceed above 40 m/s. Adopting Proper Spacer and Break draft should helps to reduce the Breakage. Over spinning of cotton must be avoided. The spinning department R.H% should be maintained between 50% to 55%. Smooth curvature of speed pattern helps to reduce the breakage. Mr.S.K.Jindal, Senior General Manager, Ginni International Limited, Neemrana, Rajasthan The various steps to reduce the spinning breaks are: 1. Proper combination of ring and Traveller. Weight, height, cross section of the ring Traveller should be proper. 2. Proper atmospheric conditions (relative humidity and temperature) 3.  No undrafted spindles, right size of spacer, no jerky movement of ring rail, roving traverse should not be out. 4. Ring traveler loading should not be there. Setting of fly catcher should be ok 5. Eccentric spindles, vibration in spindles, worn out rings should be eliminated 6. Fly and fluff should be minimum side in department 7. Spindle speed pattern should be set properly 8. No worn out parts like lappet hook, separators, damaged cots, damaged ABC rings, worn out ring tubes etc 9. Setting of lappet hook w r t ring tube should be correct 10. Improper ring centering Mr.R.Annadurai, Manager, Victory Spinning Mills Limited, Erode, Tamilnadu Following are the steps to be taken to reduce End Breakage Rate in Spinning, 1.  Correct relative humidity should be maintained in spinning department. 2.  Machine cleaning should to be done proper i.e. drafting, ring rail, and correct fixing of suction tube. 3.  Traveller clearer setting should be properly maintained and also changing the Traveller in proper schedule. 4.  Ring centering ABC ring centering to be maintain at the correct interval. 5.  Drafting accessories like Aprons, Cots, and Saddles to be changed with in the schedule. 6.  Spindle tape and spindle oil to be changed in correct schedule. 7.  Ring condition to be checked periodically and should be changed if it necessary. 8.  Sliver and roving quality should be controlled properly Mr.K.V.Shanmugasundaram, Dy.General Manager, Jayavarma Textiles Pvt. Ltd Unit-1, Chokumaripalayam, Tamilnadu Proper Traveller number to be selected depends on counts and speeds, one number lighter can be tried for higher speeds so that friction & hairiness can be avoided. Department supply air & exhaust air required CFM to be maintained and rotary filter will help to catch micro flies so that Traveller flies can be arrested. General maintenance schedules to be followed like ring centering, spindle oil changing, lappet centering, lappet height setting and drafting unit service and ring life & ring condition to checked. Mainly, Good raw material selection needs to spin suitable length & strength of fibres based on counts. Mr.A.Vallinayakam, General Manager, Pavizham Spinners (P) Ltd, Veppadi, Tamilnadu To reduce the end breakage rate in Spinning:- Spindle and lappet to be fixed concentric to the ring with constant room climate condition ( R.H% 50 to 55%) and 2:1 ring & tube diameter, Vibration free spindle/tube, Selecting correct type & number of Traveller with respect to count, material, spindle speed, yarn strength etc. Distance between lappet eye to Ring tube top while ring rail bottom most position, Proper Traveller clearer setting, minimum break draft to unwind the bobbin, Minimum TPI in the roving, correct size roving condensers in simplex and spinning. Mr.L.Shenbagamuthu, ASM – QA, Santha Spinning Mills Ltd, Kangeyam, Tamilnadu Traveller clearer setting should to be done properly. The over head cleaners are to be run with correctly positioned blowing nozzles Department RH should be maintained properly. The air circulation inside the department should to be done free from fly Speed pattern proper step follow up Mr. Suba. Chokkalingam, Asst.Managerr, Premier Mills Ltd, Udumalaipettai, Tamilnadu To chose the correct traveler profile and traveler number To maintain the proper RH 48 to 50%, To maintain the lappet setting and Traveller clearer setting. Maximum speed can set after 20% of set length Use of smooth speed curve can reduce the end breaks. Mr.A.Balasubramanaim, Factory Manager, V R Textiles Pvt Limited, Punjai Puliampatti, Tamilnadu Suggestions for reducing the breakage rate in spinning 1.After replacement of Traveller, the machine speed should be reduced by 20% for 30 minutes 2.Traveller clearer setting should be maintained 1.6 to 1.8 MM for 40s and Traveller loading to be avoided 3.Type of Traveller to be selected according to the profile of the Rings 4.RH to be maintained properly 5.Air circulation inside the department should be free from fly and dust as the dust will affect the Ring Traveller