Detailed Project Report on open end spinning unit
Detailed Project Report on open end spinning unit
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OPEN END SPINNING UNIT
[CODE NO.4058]
Open end spinning is an excellent short-term blending process. The presence of short fibers in the material fed does not seriously affect the efficiency of Open end spinning and it may be that process will have a bright future in the spinning of waste. Whenever the final judgment on open end spinning may be, it is a process that is here to say.
Few innovations in the field of textiles have created such interest as open-end spinning. Despite the tremendous efforts that have been made over the years to further the development of ring spinning, it now seems to be generally accepted that, owing to mechanical, technological and above all economic limitations, the potential of that well established process has been virtually exhausted and that further advancement will only be achieved through an entirely new approach; it may be that Open-end spinning will be the answer.
Spinning may be defined as the process of converting fibres and/or filaments(s) into yarn. In the production of manmade fibres, the extrusion of the fibre forming liquid through the spinners followed by hardening of this liquid jet in to solid filaments is called as the process of spinning.
The meaning of the spinning in this case may be completely different from that used for natural fibres. Generally, we can define spinning as a process that produces a yarn as its final product. The spinning of manmade fibres can be carried out by three different processes:-
• Wet Spinning
• Dry Spinning
• Melt Spinning
These different types of spinning methods are used based on the properties of the fibre forming substance can be spun by using more than one type of the above mentioned spinning techniques.
In today’s technology, many spinning systems are used commercially to produce spun yarns with a wide range of values of characteristics. Among these systems, ring spinning enjoys the greatest diversity and the highest quality levels. Ring spinning has been able to supplant almost all other conventional spinning methods and has proved very resistant to inroads by the newcomers. This can be attributed mainly to its flexibility, universal applicability, and yarn quality.
In ring spinning drafting, twisting and winding of the yarn is carried out simultaneously. By the end of 19th century process of ring spinning was fairly well perfected. Its output rate was much than that of self-acting mule which was an intermittent process. Consequently, the world textile industry made a major shift from mule to ring spinning in the first quarter of the 20th century. The developments of ring frame were accelerated after its adoption as a major system of yarn manufacturing. However, during mid of the twentieth century it was realized that output rate of ring spinning frame cannot be increased because of inherent limitations. It was concluded that it has reached a pinnacle of achievement! The textile institutes, universities and machinery manufacturers accelerated research work for development of new technologies, which did not suffer from the limitations of ring spinning frame. The research work led to the development of some new technologies based on the concept of performance of the processes of drafting, twisting and winding separately and independently of each other so that following objects can be achieved:
• Full speed of twisting mechanism is utilized for twist insertion.
• Full speed of the winding mechanism is utilized for winding of the yarn for substantial enhancement of output rates.
The open-end rotor spinning system is one of the new technologies and has penetrated world-wide the spinning industry.
Open end spinning is not a new concept, although it has only recently become a commercial proposition; Samuel Williams mentioned the basic idea as long ago as 1807! Several patents was filled about the turn of the century and the others between 1925 & 1950. Since then, over 100 patents relating to free-fibre-spinning devices and associated mechanisms have been filled. Although the first full-sized machine, the KS200, was only demonstrated publically at Brno in 1965 & the first really commercial machine, the BD200, appeared in 1967, by 1971 no fewer than thirteen free-fibre spinning machines, made by various manufacturers, were on show at the Paris exhibition, and further models hav been introduced since then.
Several attempts have been made to catalogue and classify the many embodiments of the open-end principle that have materialized over the years. This is from simple, since there are so many variables involved and certain features are common to several of the various systems, whereas others are not. The variables involved include the state of the material as fed; the method of the feed; the means of opening, separating, and conveying the fibres; and the techniques of reassembling the fibres and of imparting twist of them.
Perhaps the best classification is that devised by the Shirley Institute which is based on the methods of fibre assembly, namely;-
• Vortex assembly
• Axial assembly
• Discontinuous assembly
• Rotor assembly
Open End Spinning is a technology for creating yarn without using a spindle. It is also known as break spinning or rotor spinning. It was invented and developed in Czechoslovakia. Open End spinning is also known as breaks spinning or free fibre spinning. In this process the fibrous material is highly drafted to separate out the individual fibres. The individual fibres are subsequently collected onto the open end of the yarn.
In this process the fibre silver is separated in to single fibres and in which the separated fibre material is brought by an air stream to a collecting surface from which it is drawn off while being twisted. This I s wound on to a bobbin to form the yarn package.
A typical OE-rotor spinning system as shown in this figure essentially consists of a feed roller which feeds the sliver to an opening roller to open the sliver. Fibres are pneumatically delivered to the rotor groove through a conically shaped feed duct. During pneumatic transport, the fibres lose their orientation which is partially corrected by the conical cross-section of the feed duct For yarn formation a seed yarn is sucked in by the rotor.
Transition of the untwisted fibres into twisted yarn takes place in the rotor groove. As the fibres are deposited in the rotor groove continuously, the yarn is formed and wound by a separate winding mechanism continuously. The processes of drafting fibres, twisting into yarn and winding of yarn take place independently of each other. Due to the utilization of the entire rotational speed of the rotor for twist insertion, output is about 7 times higher than that of ring spinning frame. However, the twist generated by the rotor and transmitted by the open yarn end entails a considerable twist loss at the yarn formation point and is reported to be about 20%, as the Torque developed is very small.
This places a critical limit to the number of fibres at the yarn formation point below which spinning cannot take place. Consequently, OE rotor spinning is limited to the production of coarse and medium categories of yarn counts. Furthermore, the flow of fibre feed intersects the yarn withdrawal vector once per rotor revolution. Wrapper fibres which receive alternating directions of twist form an integral part of the OE-Yarn Structure. Twist in OE-Yarn is therefore indeterminable. The wrappers fibres either do not or only partially share in load bearing, when stress is applied to the yarn.
COST ESTIMATION
Plant Capacity 8 Ton/Day
Land & Building (14,000 sq.mt.) Rs. 6.67 Cr
Plant & Machinery Rs. 10 Cr
Working Capital for 2 Months Rs. 3.27 Cr
Total Capital Investment Rs. 20.64 Cr
Rate of Return 29%
Break Even Point 55%
INTRODUCTION
CHARACTERISTICS OF OPEN END SPINNING
A GOOD OPEN-END MACHINE SHOULD HAVE:
HIGHER PRODUCTIVITY
HIGH-CONTENT SLIVER CANS (UP TO 18”)
LARGER PACKAGES OF YARN (4 TO 5 KG.)
LESS POWER CONSUMPTION
AUTOMATION
FLEXIBILITY OF SPINNING COMPONENTS
HANDLING COUNT RANGE.
ADVANTAGES
PRODUCTS
BASIC TEXTILE TERMS OF SPINNING
YARN COUNT/SLIVER HANK:
YARN COUNT SYSTEM:
PRINCIPLE
FIGURE: FORMATION OF AN OPEN-END SPUN YARN
OPEN END ROTOR YARN CHARACTERISTICS
ROTOR SPINNING PROCESS
ROTOR SPINNING SYSTEM:
OUTER STRUCTURE OF OPEN END (ROTOR SPINNING YARN)
STRUCTURE AND WORKING OF ROTOR SPINNING MACHINE:
SCHEMATIC DIAGRAM OF ROTOR SPINNING MACHINE
SLIVER FEEDING ASSEMBLY:
FIBRES OPENING ASSEMBLY:
FIBRES DRAFTING ZONE:
CLEANING ASSEMBLY:
FIBRE CONDENSATING SYSTEM:
TWISTING (TWIST INSERTION)
MANUFACTURING PROCESS
SEQUENCE OF OPERATIONS:
FIGURE: BLOCK DIAGRAM OF PROCESS FLOW IN OPEN END SPINNING
ESSENTIAL FEATURES OF THE OPEN END SPINNING PROCESS:
ELEMENTS OF OPEN END SPINNING SYSTEM:
ROTOR SPINNING:
OBJECTIVES OF ROTOR SPINNING:
ROTOR SPINNING WAS INITIALLY DEVELOPED WITH TWO MAIN OBJECTIVES
OPERATING PRINCIPLES OF ROTOR SPINNING SYSTEMS:
FIGURE: MAIN FEATURES OF ROTOR SPINNING SYSTEM
PROCESS DESCRIPTION
ROTOR SPINNING: -
ROTOR USED IN ROTOR SPINNING:-
ROTOR SPEED AND DIAMETER
THE ROTOR GROOVE:
THERE ARE THREE DIFFERENT TYPES OF ROTOR GROOVES AVAILABLE:
FIGURE BELOW SHOWS THE SHAPES OF DIFFERENT TYPES
OF ROTOR GROOVE.
FIGURE: DIFFERENT TYPES OF ROTOR GROOVES.
THE ROTOR WALL
THE TAKE-OFF NOZZLE
SMOOTH TAKE-OFF NOZZLE:
FLUTED TAKE-OFF NOZZLE:
SPIRAL TAKE-OFF NOZZLE:
SWIRL TAKE-OFF NOZZLE:
SLIVER FEED:-
PREPARATION OF THE SLIVER
FIBRE OPENING
FIGURE: OPENING ROLLER
FIBRE TRANSFER:
FIGURE: FEED GUIDE CHANNEL
DIFFERENCE BETWEEN DIFFERENT ROTOR MACHINES
THE MAIN DIFFERENCES BETWEEN DIFFERENT ROTOR MACHINE
DESIGNS ARE:
OTHER FEATURES INCLUDE THE FOLLOWING:
ROTOR SPINNING PERFORMANCE
YARN BREAKAGE
CONVENTIONAL & OPEN END SPINNING
CHARACTERISTICS:-
THE STRUCTURE OF OPEN END-SPUN YARN
STRUCTURE AND PROPERTIES OF ROTOR-SPUN YARNS
FIGURE: - STRUCTURE OF ROTOR SPUN YARN
(A) SCHEMATIC DRAWING (B) OPTICAL MICROGRAPH
ADVANTAGES:-
DISADVANTAGES:-
YARN TWIST AND TWIST MULTIPLIER
DIFFERENT DEFINITIONS OF TWIST OF THE YARN
TYPES OF TWIST
HIGHER TWIST MULTIPLIERS ARE USED,
LOWER TWIST MULTIPLIERS ARE SELECTED, PRESUPPOSING
ADEQUATE YARN TENACITY,
TWIST LEVEL:-
RELATION BETWEEN TWIST AND YARN STRENGTH:-
EXPRESSION OF TWIST
AMOUNT OF TWIST EXPRESSED IN –
FACTORS AFFECTING TWIST
IN PRACTICE, YARN TWIST IS DESCRIBED USING THREE MAIN PARAMETERS:
DIRECTION OF S TWIST
DIRECTION OF Z TWIST
FUNCTION AND EFFECTS OF TWIST ON YARN & FABRIC PROPERTIES
FUNCTION OF TWIST IN YARN STRUCTURE
EFFECTS OF TWIST ON YARN & FABRIC PROPERTIES
IN THE CASE OF HANDLE:
IN THE CASE OF MOISTURE ABSORPTION:
IN THE CASE OF WEARING PROPERTIES:
IN THE CASE OF AESTHETIC EFFECTS:
YARN DIAMETER, SPECIFIC VOLUME & PACKING DENSITY
SPECIFIC VOLUME FROM TWIST
PACKING DENSITY
PRODUCT DESCRIPTION AND APPLICATION
END USES FOR OPEN END SPUN YARNS
PLANT CAPACITY AND PRODUCTION PROGRAM
PLANT CAPACITY
PRODUCT RANGE:
PRODUCTION PROGRAM
INDIAN SPINNING INDUSTRY
GLOBAL AND DOMESTIC COTTON SCENARIO
GLOBAL POSITION:
INDIA’S POSITION:
CHINA’S POSITION:
COTTON PRICES – TRENDS & OUTLOOK
INTERNATIONAL PRICES:
INDIAN PRICES:
INDIAN YARN PRODUCTION AND EXPORTS
EXPORTS:
PRODUCTION:
DOMESTIC YARN PRICES AND CONTRIBUTION
YARN PRICES:
CONTRIBUTION:
FINANCIAL PERFORMANCE OF COTTON SPUN-YARN MANUFACTURERS
QUARTERLY PERFORMANCE:
INDIAN TEXTILE AND APPREAL INDUSTRY
ADVANTAGE INDIA
PRODUCTION OF YARN IN INDIA
PRODUCTION OF YARN IN INDIA FROM FINANCIAL YEAR 2011
TO 2020 (IN MILLION KILOGRAMS)
SOME SUPPLIER NAME OF SPINNING AND SPINNING MACHINERY
LIST OF MACHINES
MACHINERY PHOTOGRAPHS
BLOW ROOM
FILTER
BLOW ROOM FOR VISCOSE/COTTON
COTTON CARDS
DRAW FRAME
TWISTING AND WINDING MACHINERY
SCHLAFHORST AUTOCONER
RAW MATERIAL & PODUCT PHOTOGRAPHS
PROCESS FLOW DIAGRAM OF OPEN END SPINNING FROM WASTE COTTTON
PROCESS FLOW DIAGRAM
TECHNICAL SPECIFICATION
ROTOR SPINNING (SAURER SCHLAFHORST):- BD 448
DRAWING:-
CARDING:-
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
COMPLETE MACHINERY SUPPLIERS
DETAILS OF MACHINERY
SCHLAFHORST:-
BD INNOVATIONS
DELIVERED FROM CHINA
SHANDONG LINQING SANHE TEXTILE GROUP
RAW MATERIAL SUPPLIER
CLEANING OF OPEN END SPINNING MACHINE & WASTE DISPOSAL
INSTRUCTIONS FOR SHIFT CHANGE
HANDING OVER THE SHIFT:
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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