Spin Plan of 60S count cotton Yarn 1

Spin plan for a cotton mill (For 60 count):

s

Number of spindles = 25000

Parameter B/R Carding D/R Super lap Combing Simplex Ring
former frame
Hank or count 0.0016 0.16 0.16 0.0098 0.16 3.5 60
(52 grains/yds)
Doubling 8 32
Draft 100 8 1.96 16.32 21.87 17.14
Delivery speed or 12 45 400 90 1500 18000
spindle speed yd/min m/min
Delivery roller dia 9.5 27 inch
inch
TPI 1.87 27
Efficiency % 85 90 85 90 90 85 90
Ideal Time % 12 10 10 7 7 7 5
Waste % 5 5 0.75 2.5 18 0.5 2.5
Delivery per frame or 2 2 8 120 480
Spindles per frame
Average count = 60S

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 Spin Plan of 60S count cotton Yarn 2
Ring frame:

Total no. of spindles = 25000

Spindle speed = 18000 rpm
Spindle per frame = 480
Yarn count = 60S
TPI = 27
Efficiency = 90%
Waste = 2.5%
Average stoppage = 5%

25000
Required ring frame = =52.08 ≈52for 24960 spindles.
480

100−5 95
No. of running spindles = 24960 × = 24960 × = 23712
100 100

Production per hour =

Spindle speed × 60
× Efficiency × No . of running spindles
TPI ×36 ×840 ×Count

18000 ×60 90
= × ×23712=470.48 lbs
27 ×36 ×840 × 60 100

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 Spin Plan of 60S count cotton Yarn 3

Simplex section:

Spindle speed = 1500 rpm

Spindle per frame = 120
Roving hank = 3.5
TM = 1
TPI = 1.87
Efficiency = 85%
Waste = 0.5%
Average stoppage = 7%

100+ Ring waste

Production of simplex = Production of ring frame ×
100

100+2.5
= 470.48 ×
100

= 482.24 lbs

spindle speed ×60

Production / hour/ spindle = × Efficiency
TPI ×36 ×840 × Roving h ank

1500 ×60 85
= ×
1.87× 36 ×840 ×3.5 100

= 0.39 lbs

482.24
No. of running spindles = =1247.65 ≈ 1248
0.39

100+stoppage time
No. of established spindles = 1248×
100

100+7
= 1248 ×
100

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 Spin Plan of 60S count cotton Yarn 4
= 1335.36 ≈ 1335

1335
No. of simplex machines = = 11.13 ≈ 11
120

Combing

Feed/Nip = 7 mm
Nips/ min= 250
Feed lap weight = 850 grains/yds
Feed Lap hank = 0.01
Delivery sliver weight =52 grains/yds
Delivery sliver hank = 0.16
Noil = 18%
No. of head/frame = 7
Efficiency = 90%.
Average stoppage time= 7%

100+simplex waste
Production of combing = Production of simplex ×
100

100+0.5 %
= 482.24×
100

= 484.65 lbs.

Production/hour =

feed /nip(mm) Nips

× × 60 ×lap wt .∈grain× no . of h ead × Efficiency
1000 min

7 ×250 ×1.09 ×60 850 90

= × ×7×
1000 7000 100

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 Spin Plan of 60S count cotton Yarn 5
=87.55 lbs

484.65
Number of comber = = 5.53
87.55

100+7
Installed no. of comber = 5.53 × = 5.91≈ 6
100

Super Lap former:

Delivery speed = 90m/min

Lap hank in grain/yds =850
Lap hank =0.0098
Efficiency =90%
Waste = 2.5%
Stoppage time = 7%

100+waste
Production of lap former = production of comber ×
100

100+18
= 484.65 × = 571.89 lbs
100

grain
Delivery speed × laphank ∈ × 60
Production per hour = yds
× efficiency
7000

90 ×1.09 ×60 ×850 90

= × = 643.26 lbs
7000 100

571.89
Number of super Lap former = = 0.89
643.26

100+stoppage time
Number of Installed super lap former = 0.89 ×
100

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 Spin Plan of 60S count cotton Yarn 6
100+7
= 0.89× =0.95 ≈ 1
100

Draw frame:

Delivery roller speed = 400 yds/min

Sliver hank = 0.16
Delivery head per frame = 2
Efficiency = 85%
Waste = 0.75%
Stoppage time = 10%

100+S . L . F waste
Production of draw frame = Super lap former production ×
100

100+2.5
= 571.89 ×
100

= 586.19 lbs

Delivery roller speed ×60

Production /hour/frame = × Efficiency × delivery h ead /frame
840× Sliver h ank

400 ×60 85
= × ×2
840 ×0.16 100

= 303.57

586.19
Running Draw frame = =1.93
303.57

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 Spin Plan of 60S count cotton Yarn 7
100+stoppage time
Install draw frame = 1.93 ×
100

100+10
= 1.93 ×
100

= 2.12 ≈ 2

Carding section:

Doffer diameter = 27 inch

Doffer speed = 45 rpm
Sliver hank = 0.16
Efficiency = 90%
Wastage = 5%
Average ideal time = 10%

100+ Draw frame wastage

Carding production = Draw frame production ×
100

100+0.75
= 586.19 ×
100

= 590.59 lbs

π × Doffer dia × Doffer speed ×60

Production/hour/machine = × Efficiency
36 × 840 × sliver h ank

3.14 ×27 × 45 ×60 90

= ×
36 ×840 × 0.16 100

= 42.58 lbs

Total Carding production

Running Carding machines =
Production /hour /machine

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 Spin Plan of 60S count cotton Yarn 8
590.59
= = 13.87
42.58

Installed Carding Machines =

100+ Avg . stoppaagetime

Running Carding machines×
100

100+10
= 11.04 ×
100

= 15.26 ≈ 15

Blow Room Section:

Calendar roller Diameter (C.R.D) = 9.5 inch

Calendar roller speed (C.R.S) = 12 rpm
Lap hank = 0.0016
Waste = 5%
Efficiency = 85%
Scutcher / blow room line = 2
Average ideal time = 12%

100+Carding wastage
Blow Room production = Carding production×
100
100+5
= 590.59 ×
100

= 620.12 lbs
π ×C . R . D× C . R . S ×60
Pro./hr./Scutcher of Blow room = × Efficiency
36 ×840 × Lap h ank
3.14 ×9.5 ×12 ×60 85
= × lbs
36 ×840 ×0.0016 100

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 Spin Plan of 60S count cotton Yarn 9
= 377.31 lbs
Blow Room production
Running Scutcher =
Pro ./hr ./Scutcher of Blow room
620.12
=
377.31

= 1.64
100+ Average ideal time
Installed Scutcher = 1.64 ×
100
100+12
= 1.64×
100

= 1.84 ≈ 2
No. of Blow room line = 2/2 = 1

Summary:

Number of required machines for 25000 spindles & 60 S Count Cotton yarn:

 Blow room line = 1 (2 Scutcher)

 Carding machines = 15

 Draw frame = 02

 Super lap former =01

 Comber = 06

 Simplex = 11

 Ring frame = 52

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 Spin Plan of 60S count cotton Yarn 10

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