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Efficient Production Planning in Cotton Spinning Mills

Learn about the spinning process flow, from bale to ring spinning, for optimal efficiency in cotton spinning mills. Detailed consultancy on machinery installation and production calculations provided by industry expert Aftab Global Textile and Nannu Spinning Mills.

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Efficient Production Planning in Cotton Spinning Mills

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  1. Production planning in cotton Spinning Mills Lecture: spinning mills Cotton Ginning & Spinning Technology Consultant: Aftab Global Textile and Nannu Spinning Mills

  2. Spinning Process Flow Bale Carded Sliver Drawing Mixing Blow Room Carding By pass for Karded Yarn By Pass Combed Sliver Lap Lap Forming Drawing Combing Roving bobbin Cops Cone Roving Winding Ring Spinning Consultant: Aftab Global Textile and Nannu Spinning Mills

  3. Blow Room L-1 Blendmat >LVSA > Axi-Flow > Multimixer >Asta >CVT-03>Loptex>Sp-Fp>Lvsa> Card 1 - 10 Blow Room L-2 Blendmat >SP-MF> Multimixer >Clc3 >Loptex>Sp-Fp>Lvsa> Card 1 - 12 Draw Frame Breaker Draw Frame Finisher Breaker Draw >1 to 4 Finisher Draw> 5 to 8 Lap Former >1 to 1 Comber 1 to 4 Simplex Line -1 > 1 to 5 Simplex Line -2 > 5 to 10 Ring Frame Line -1 > 1 to 19 Line -2> 20 to 38 Finishing Line -1 > 1 to 10 Consultant: Aftab Global Textile and Nannu Spinning Mills

  4. Picture: Diagram for Spinning Mills Consultant: Aftab Global Textile and Nannu Spinning Mills

  5. Consultant: Aftab Global Textile and Nannu Spinning Mills

  6. By M.H.Rana PgD in CIT(JU) and MBA in Textile (PAU)

  7. By M.H.Rana PgD in CIT(JU) and MBA in Textile (PAU)

  8. Consultant: Aftab Global Textile and Nannu Spinning Mills

  9. Consultant: Aftab Global Textile and Nannu Spinning Mills

  10. Consultant: Aftab Global Textile and Nannu Spinning Mills

  11. Consultant: Aftab Global Textile and Nannu Spinning Mills

  12. Consultant: Aftab Global Textile and Nannu Spinning Mills

  13. Consultant: Aftab Global Textile and Nannu Spinning Mills

  14. Consultant: Aftab Global Textile and Nannu Spinning Mills

  15. Consultant: Aftab Global Textile and Nannu Spinning Mills

  16. Delivery speed = 100m/min Lap hank in grain/yds =750 Lap hank =0.0098 Efficiency =85% Waste = 2.0% Stoppage time = 5% Production of lap former = production of comber ×(100+waste)/100 =809.0827×1.15=930.45 lbs Production per hour = deli speed*lap hank (grain/yd)*60*Eff% / 7000 = 100*1.09*60*750*85/7000/100 =595.6071 lbs Number of Lap former = 930.45/595.6071 =1.57 No. of installed lap winder =1.57 *(100+stoppage time)/100 =1.57*1.05 =1.65 that it required 40% So Lap winder required 1.65*40/100=0.66 = 1 Consultant: Aftab Global Textile and Nannu Spinning Mills

  17. Draw frame Delivery roller speed = 450 m/min Sliver hank = 0.14 Delivery head per frame = 2 Efficiency = 90% Waste = 2% Stoppage time = 6% Production of draw frame = Super lap former production *(100+waste)/100 = 595.6071 *1.02 =607.51 lbs Production /hour/frame = deli speed*60*eff%*No. of head/840/sliver hank =450*60*85*2/840/.14/100 = 390.3061 lbs Running Draw frame = 607.51/390.3061 =1.55 Install draw frame = 1.55 ×(100+stoppage time)/100 =1.55*1.06=1.65 = 2 Consultant: Aftab Global Textile and Nannu Spinning Mills

  18. Carding section: Doffer diameter = 27 inch Doffer speed = 40 rpm Sliver hank = 0.12 Efficiency = 90% Wastage = 4% Average ideal time = 10% Carding production = Draw frame production ×(100+Waste)/100 = 607.6071*(100+0.5)/100=607.6071*1.005= 610.65 lbs Production/hour/machine =pie *doff dia*doof speed*60*eff%/36/840/sliver hank =3.14*27*52*60*90/36/840/.12/100 = 65.65lbs Running Carding m/cs= 610.65/65.65 =9.31 Installed Carding Machines =Running Carding machines *(100+avg stoppage time)/100 =9.31*1.10=10.23 = 10 set Consultant: Aftab Global Textile and Nannu Spinning Mills

  19. 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 = 4% Efficiency = 85% Scutcher / blow room line = 2 Average ideal time = 12% Blow Room production = Carding production×(100+carding waste)/100 610.65*(1.04)=635.07 lbs Pro./hr./Scutcher of Blow room = pie*C.R.D*C.R.S*60*Eff% / 36/840/.0016 = 3.14*9.5*12*60*85/36/840/.0016/100= 377.314 lbs Running Scutcher = blow room prod/prod/hr/scutacher of blowroom = 635.07/377.31 =1.68 Installed scutcher = 1.68 *(100+avg ideal time)/100 =1.68*1.12=1.88 =2 No. of Blow room line = 2/2 = 1 Consultant: Aftab Global Textile and Nannu Spinning Mills

  20. Autoconer section: No of Drum per autoconer =60 Speed per drum =1350 m/min Yarn Count=52 Ne waste = 1% Efficiency = 75% Average ideal time = 5% Winding production = ring prod×(100-ring waste)/100 791.25*0.98= 775.425 lbs Pro./hr./drum =drum speed*eff%* time/840/count =1350*75*60/840/52/100 =1.49 lbs Running drum =775.425/1.39 =557.54 Running aotoconer machine = 557.54/60 =9.29 Installed autoconer = 9.29*(100+avg ideal time)/100 =9.29*1.05=9.75 No. of autoconer = 10 Consultant: Aftab Global Textile and Nannu Spinning Mills

  21. Summary: Number of required machines for 42528 spindles & 52S Count Cotton yarn: " Blow room line = 1 (2 Scutcher) " Carding machines = 10 " Draw frame = 02+02 " Super lap former =01 " Comber = 04 " Simplex = 10 " Ring frame = 22(1200)+16(1008)=38 “ Autoconer = 10 Consultant: Aftab Global Textile and Nannu Spinning Mills

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