Factors affecting

Production in Spinning
Mill

Raw material
Labour
Machinery


Raw material

FIBER LENGTH

STAPLE LENGTH,
SPAN LENGTH AND
EFFECTIVE LENGTH
1.If fibers have good staple length it results in
the form of high production, because less TPI
is required to give enough strength.

2.Higher percentage of short fibers will result in
the form of production losses due to more
end breakage and higher twist per inch.


3.Fiber maturity, in case of immature fibers it
results in the form of production loss.

Because the yarn made from these types of
fibers have poor strength and also it produces
breakage in spinning department.
4.Fiber strength is the dominating feature of
fiber.

When fiber strength is higher it outcomes in
the form of high production due to less twist
multiplier.



Labour

Labour plays a very crucial role because
without their participation nothing could be
done.
The proper way to improve productivity in
textile mills is first to take those workers

Machinery

Machinery is the back bone of every industry.
In the textile industry machine are working 24
hours so it is important that its efficiency
would be excellent.



While analyzing in Ring Department, during working
stoppages may occur due to the following reasons.

Ends down
Doffs
Creeling
Bobbin size
These factors affect the productivity to a great extent.

If we control these stoppages then production can be
increased and it also has an impact on yarn quality
which is improved under the same conditions of cost
and labour charges.


Ends Down

The end down is due to the less strength of yarn and
greater spindle speed.

Adding to stops, no. of spindles per frame, lift of bobbin rail
and cleanliness of the department also affects the
production.

More number of spindles on a frame increases its
efficiency.

Cleanliness means no fibrous mass is floating in
atmosphere of ring otherwise ends down rate will be
increased.


Doffs

Doffing means removal of full size package and replacing it
with the empty one.

During doffing, the machine is stopped and it is carried out
by skilled workers.

For coarse count like 7s, 10s etc, doff time is less and for
finer count like 30s, 40s etc, time is more. For 20S it takes
90-110 min for complete doff.

During doffing, it should be kept in mind that it should be
carried out in the shortest possible time.


Creeling

The changing of the roving bobbin when it is
empty and to replace it by a new full roving
bobbin is called creeling.
Creeling time should be as small as possible.


Bobbin Size

The production can be increased by increasing the bobbin
size because with a bigger bobbin less doff is required per
shift.

The Bobbin size depends on ring dia, but as we increase the
ring dia, ends down rate also increases so it also has a limit.

Usually 42 mm ring dia is available on which 40 mm dia
bobbin can be prepared.


Maintenance

Proper maintenance of machine is necessary otherwise
it results in the form of many problems like sudden
shut downs and big production loss.

Proper maintenance results in the form of efficient
working of machine and good outputs.

For example by proper maintenance and by proper
preparation of roving it results in the form of
minimizing the end breakage rate.


Improving productivity of ring
frames
Functions of ring frame:
1.To draft the roving until the required fineness
is achieved,
2.To impart strength to the fibre, by inserting
twist
3.To wind up the twisted strand (yarn) in a form
suitable for storage, transportation and
further processing
Drafting zone

Drafting type
Design of drafting system
Drafting settings
Selection of drafting elements like cots,
aprons, travelers, etc
Choice of appropriate draft
Service and maintenance

Drafting arrangement influences the economics of the
machine -- directly by affecting the end-break rate and
indirectly by the maximum draft possible.

If higher drafts can be used with a drafting
arrangement, then coarser roving can be used as a
feeding material.

This results in higher production rate at the roving
frame and thus reducing the number of roving
machines required, space, personnel and so on.

In fact increase in draft affects the yarn quality
beyond certain limit.

Within the limit some studies show that
increase in draft improves yarn quality
Twisting zone

Traveler imparts twist to the yarn. Traveler and
spindle together help to wind the yarn on the bobbin

Length wound up on the bobbin corresponds to the
difference in peripheral speeds of the spindle and
traveler.

The difference in speed should correspond to length
delivered at the front rollers. Since traveler does not
have a drive on its own, it is dragged along behind by
the spindle.

High contact pressure (up to 35 N/square mm)
is generated between the ring and the traveler
during winding, mainly due to centrifugal
force.
This pressure leads to generation of heat. Low
mass of the traveler does not permit
dissipation of the generated heat in the short
time available.
As a result the operating speed of the traveler
is limited.

When the spindle speed is increased, the friction
work between ring and traveler (hence the build-
up) increases as the 3rd power of the spindle rpm

Consequently if the spindle speed is too high, the
traveler sustains thermal damage and fails.

This speed restriction is felt particularly when
spinning cotton yarns of relatively high strength.

If the traveler speed is raised beyond normal
levels, the thermal stress limit of the traveler
is exceeded; a drastic change in the wear
behaviour of the ring and traveler ensures.

Winding zone

The bobbin is formed in three parts:

1.The curved base
2.The cylindrical body and
3.The conical top
The winding procedure is:

The ring rail is raised slowly to wind the yarn
and is then moved downward at a higher
speed to lay coils at an increased helix angle
to lock-in the previous layer.

The combination of the two layers having
different winding angles is beneficial in the
stability of the build in the re-winding process.

Occasionally the spinning ends down will be
higher during the faster downward movement
and should be considered in setting up the
speeds and conditions of the machine.

The stroke is short at the beginning of the build
and is increased throughout the formation of the
curved base. After the base formation the stroke
length remains constant.
The upward and downward movement is referred to as
the stroke.

The height of the stroke is normally about 15 to 20%
greater than the diameter of the ring.

The downward movement of the ring rail is 2 to 3 times
faster than the upward movement.

The combination of the two layers having different
winding angles is beneficial in the stability of the build in
the re-winding process.



Occasionally the spinning ends down will be
higher during the faster downward movement
and should be considered in setting up the
speeds and conditions of the machine.

The stroke is short at the beginning of the
build and is increased throughout the
formation of the curved base. After the base
formation the stroke length remains constant.
End Breakage in Spinning
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.
End breaks 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 can not 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.

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.


1. 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.
2. The use higher twist multipliers will
reduce breaks even at higher spindle speeds
than at lower spindle speeds with low twist
multipliers.


3.The higher twist than required in roving reduces the
creel breaks in ring frames.

4. The delay in change of travelers will increase end
breaks in spinning. Hence timely change of travelers is
a must.

5. The use of common tube suction system improves
suction of pneumafil system further without increasing
power consumption compared to individual suction
tube system in ring frame and reduces end breakages
to a large extent.

6. Any compromise in right selection of fibre
properties may lead to higher end breakages
in spinning ring frames.

7. The frequent stoppage of Over Head
Travelling Cleaners accumulates fly and results
into higher breaks due to loading of traveler
with fly.


The end breakage in spinning not only
increases physical exercise of workmen, but
also increases waste.
Hence ultimate effect is on productivity of
spinning mill.