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Introduction: Warping is a department, where single warp ends are combined into parallel sheets of ends. Objective of warping: 1) Removal of yarn-faults and foreign matter, which are the main causes of warp breakage. 2) Making warpers beam, which are used in sizing. WARPING
SECTIONAl WARPING
Direct warping is a warping process, where warps are prepared from V-creel simultaneously. M/c name: BENINGER BEN-DIRECT M/c DETAILS: CREEL CAPACITY SPEED RANGE PRESSURE(WARPING) PRESSURE(CREEL) TEMP, RH 784 500-1200 rpm 35 bar 5 bar 34C, 64.9%
COUNT 20 O.E 2/40 C, 2/40 ELI 2/50 C, 2/60 C 2/80 PC, 2/80 C 20 30 40, 40 PC 45 PC, 50 PC,60 C 80
SPEED(mpm) 1000 1000 1000 1000 1000 900 800 700 600
PRE-TENSIONER SETTING 12 mm 10 mm 10 mm 6 mm 8 mm 4 mm 2 mm 0 mm 0 mm
WARPING CHECK REPORT SORT NO: 12360 NO OF CREEL: 1 COUNT: 20 O.E BLEND: 100% COTTON DATE: 14/06/11 LOT NO:52080012 SUPPLIER: GIMATEX TENSION: 12mm
LENGTH
FOREIGN MATTER
WEAK PLACE
CUT CONE
SLUGG OFF
ENTANGLEMENT
8470
12
24
700
752
10
700
752
15
900
752
900
752
. TIME TAKEN FOR M/C STOP & CREEL CHANGE EVENTS OLD CREEL END CUTTING CLEANING REVERSING CREEL DRAWING THROUGH SENSOR DENTING TIME 20 sec 15 min 2 min 10 sec 11 min 10 min TOTAL TIME TAKEN FOR WARPING BEAM COMPLETE TIME(min) 1 2 3 4 5 60 30 33 23 25 RUN TIME (min) 12 12 10 10 10 FAULT REPAIR 18 21 13 15 14
SECTIONAL WARPING
INTRODUCTION; Sectional warping is a warping m/c, where warp yarns of different quality are used for stripe or other warp variation in weavers beam. Direct weavers beam is created for loom-shed.( Sectional warping is preferred for strong yarns). M/C name: BENINGER KARL-MAYER M/C DETAILS: DETAILS SORT NO: DATA 14223 DETAILS WORK ORDER DATA S22
1 P405
54.28 40 SLUB
DATE
13-06-11
TOTAL END
5796
35 YES
200mm YES
CENTRE LEASE
YES
DENTING ORDER
4.4.4.3
CREEL END
166
REED SPACE
1900mm
SIZING
Objective: Sizing is specially applied to the woven fabric for the following purposes: 1) Increase its weavability 2) Increase the yarn strength 3) Reduce the yarn hairiness 4) Minimize the abrasion between warp threads and various loom parts, and between threads that are adjacent to each other. M/C NAME: BENINGER BEN-SIZETEC No. of machines: There is basically one sizing machine. There is a Separate part beside the machine known as Kitchen. It consists of: Mixer: Here basically the size ingredients are mixed with water. An optimum amount of pressure and temperature is maintained here. Total capacity= 56 inch (first 6 inch = 100 L, 1inch=25 L) Cooker: Here the mixture is whirled around so that the size ingredients are properly mixed with each other. Temperature maintained is 1200C and the material is processed here for 30min.(same capacity) Storage unit: The mixture is stored here and sent to the main unit when necessary. The material is kept here at 90c.(approximately same capacity Optimum size percentage The percentage size to be applied to a warp in order to achieve a minimum number of end-breaks during weaving is dependent mainly on: The end density, as this will affect the amount of end-to-end abrasion that will take place; The linear density of the warp, which greatly influences the strength of the yarn and will also affect the amount of abrasion; and The pick density, which will affect the amount of abrasion between the warp ends and the reed as it reciprocates. There are other factors which may also need to be taken into consideration, such as the fibre type, the yarn type, the yarn structure, the type of size and the type of loom.
90C
TEMP OF DRYER
120
4+4+4=12
STEAM
STORAGE CHAMBER
SIZE BOX
WATER
SIZE BOX
LEASE ROD
COMB
TENSION ZONES: Tension imparted on warp yarns are implemented on different zones in sizing m/c. There are 5 zones in sizing m/c. Each zones have unique multiple factor, which are used to calculate the warp yarn tension. WARP TENSION:= g/m*TENSION FACTOR G/M = Total ends/ (1.693*count) DETAILS OF TENSION ZONES IN SIZING M/C ZONES CREEL ZONE SHOW BOX ZONE CYLINDER ZONE LEASING TENSION ZONE WINDING ZONE PRESSURE ROLLER ZONE NO: Z-1a, Z-1b Z-2a, Z-2b Z-3a, Z-3b Z-4 Z-5 Z-6 MULTIPLE FACTOR 5-6 STRETCH 12 12-13 16 14 G/M*12 G/M*12-13 G/M*16 G/M*14 TENSION(N) G/M*(5-6)
SIZING RECIEPE: Sizing recipe is the amount of chemicals used for sizing in sizing box.
COTTON 40 S CHEMICALS ALPENAL JV KETANAL NIPPA SOFT WATER TOTAL VOL TEMP FINAL VOL ANTI STATIC SOLID PERCENTAGE VISCOSITY TIME TOTAL WEIGHT( kg) 100 15 4.5 25 28 135C 31 1 12% 15 sec 10+35
COTTON 20 O.E CHEMICALS MAIZE STARCH NIPPASOFT WATER TOTAL VOL TIME TEMP FINAL VOL SOLID PERCENTAGE VISCOSITY TOTAL WEIGHT 75 4.5 28 31 10+35 135C 31 71% 6 sec
60 VISCOSE ALPENAL JV KETANOL NIPPA SOFT WATER TOTAL VOL TIME TEMP FINAL VOL SOLID % VISCOSITY 75 12 6 33 36 10+30 min 130C 38 78% 6 sec SIZANIL LV-100 KETANOL NIPPBOND NIPPASOFT WATER TIME TEMP FINAL VOL SOLID% VISCOSITY
SIZING M/C TENSION CALCULATION Sizing tension is calculated by multiplying factors of zone with gm/m. Calculated tension can be adjusted by 50N from fixed value. Gm/m = Total ends/1.693/count = 42.15 WINDING ZONE TENSION: gm/m*16 = 575N (fixed = 680N) CREEl ZONE = gm/m*6 = 252.9N (fixed = 300N)
DRAWING-IN
Introduction: Drawing-in is a dept. where warp ends are inserted through heald wires and reed dent with different denting orders from weavers beam according to the required quality. No of Drawing-in stand: 10 No of worker required/stand: 2 Different reed count used: 72/4, 67/5, 70/5, 80/3, 72/5, 66/5, 68/5 etc
DRAWING IN CHART FOR DIFFERENT QUALITY SORT NO. ENDS REED COUNT REED SPACE TIME FOR DRAWING (hr) DENTING ORDER ENDS/HEALD WIRE 14278 6350 96/2 66.1 5 hr 30 min (approx) 1,2,3,4 1 end/heald wire 27206 5852 88/2 66.5 5 hr (approx) 1,2,3,4 2 end/heald wire 110203 5796 86/2 66.5 5 hr (approx) 1,2,3,4 1 end/heald wire
LOOMSHED
Introduction: Loom shed is the department where fabric is weaved in loom. Warp yarns are taken from weavers beam and weft yarns are inserted from another package. FABRIC PRODUCTION PROCESS
DESIGNING DEPT. Fabric pattern, denting order and pegging plans are made.
SAMPLING DEPT. A sample fabric is produced with given preference, for testing
PREPARATORY DEPT. Warping, Sizing and leasing process are done to assist weaving
LOOM-SHED Fabric produced by interlocking warp and weft yarns. Drawing & knotting will be required before fabric produced sometimes for different quality
INSPECTION & DISPATCH. After production inspection for fabric faults are done and mended. After that fabric is dispatched
DETAILS OF LOOM-SHED There are two loom-sheds. Four types of air-jet looms are there: 1) 2) 3) 4) PICANOL OMNI PLUS (sumo motor function) - 56 looms TOYATA JAT710 64 loom SULZER TEXTIL L5400 - 20 looms SULZER TEXTIL L5500 1 loom Three types of shedding mechanisms are used: 1) STAUBLI CAM SHEDDING 2) STAUBLI DOBBY SHEDDING 3) FILTEXTILES DOBBY Two types of knotting m/c are used: 1) TODO - 2 m/c 2) STAUBLI -1 m/c Working patterns: 1) 2) 3) 4) PLAIN -1/1 TWILL- 2/1 OXFORD- 3/1 SATIN- 4/1 Compressor used for pressure supply in looms 1) SAMSUNG 2) L&T
LOOM DETAILS
LOOM NO. 1,2,3,4,5,6,7,8,9,10,11,12,13, 14,15,16,17,18,19,20,21,25, 26,27,28,29,30,31,32,33,34, 35,36,37,38,39,40,41,42,43, 44,45,46,47,48 22,23,24 49,51,52,53,54,56 50,55 57,58,59,60,61,62,64,71,73, 74,75,76,78 63 FILMTEXTILES 65,66,67,68,69,70,72,113, 114,115,116,117,118,119, 120 77, 79,80,81, 82,83,84,85,87,88 86 89,97,100,110 90,91,92,104,111 93,107,108,112 94,96,98,101,102,103,105 95,106 99 109, STAUBLI TYPE 1661 NO.OF LEVERS 7 PREWINDER LOOM TYPE 2 TOYOTA 710 R.S. (CM) 190
16 16 16 8 6 6
4 TOYOTA 710 4 TOYOTA 710 6 TOYOTA 710 4 SULZER 5400 4 SULZER 5400 2 PICANOL
2871 2871 2871 2871 1761 1661 1661 1661 1661 2861 1761
10 12 16 13 6 7 7 6 4 14 6
2 PICANOL 2 PICANOL 2 PICANOL 2 PICANOL 2 PICANOL 2 PICANOL 4 PICANOL 2 PICANOL 2 PICANOL 2 PICANOL 4 PICANOL
190 190 190 190 190 190 190 190 190 190 190
STAUBLI TYPE starting with 1 (eg: 1661) indicates Cam shedding, and starting with 2 (eg: 2871) indicates DOBBY shedding. NO OF LEVERS indicates no of heald frames. PREWINDER indicates no of weft accumulator. R.S means reed space.
QUALITY NO.
18202 12359 16233 14223 14520 14292 A 16239/A 15522 24338 16226 14528 16236 14278 14308 13348 14277 14273 14525 14273-A 14272 14527 14532 14533 12360 18202 14526 15924 14285 25317 110203 27206 12361
WARP COUNT
80 COMP. 20 OE 60 COMP. 40 CW. 40 COMP. 45 P/C 60 VISCOSE 50 COMP. 2/4O 60 COMP. 40 COMP. 60 COMP. 40 P/C 40 CW. 30 COMP. 45 P/C 40 P/C 40 COMP. 40 P/C 40 P/C 40 COMP. 40 COMP. 40 COMP. 20 0E 60 40 COMP. 50 DYED 40 P/C 2/50 ELI 100 COMP. 2/76 POLT. 20 OE.
WEFT COUNT
80 CW 300 DENIER 80 DENIER 40 CW +150 DENIER 30 CW. 45 P/C 60 VISCOSE 20 SPANDEX 300 DENIER 80 DENIER + 60 CW 30 CW. 60 CW +80 DENIER 40 P/C 30 CW. 20 SPANDEX 45 P/C 40 P/C 30 SPANDEX 40 P/C 40 P/C 300 DENIER MILLENGE 30 CW.+30 SLUB 30 MILLANGE 300 DENIER 80 300 MILLENGE 50 BLEACH 40 P/C 150 DENIER 100 COMP. 2/30 TFO. 300 DENIER
LOOM MECHANISMS
Primary motions: 1) SHEDDING 2) PICKING 3) BEAT UP Auxiliary motions: 1) TAKE-UP PRIMARY MOTIONS
SHEDDING: Shedding is done either CAM or DOBBY mechanism. Shedding shaft gets movement from SUMO 2) LET-OFF 3) WARP STOP 4) WEFT STOP
MOTOR(Picanol) or Main motor(Toyata, Sulzer). Heald frames are set as some difference for staggering.
PICKING: Picking is done by air-jet. Weft yarns are inserted by air pressure. There are two main valves and relay
nozzles for continuity of jet integration. Main and relay valves are connected with main nozzles and relay nozzles.
BEAT UP: Beat-up mechanism get motion from crank drive connected by gear with main motor.
AUXILIARY MOTION
TAKE UP: Take-up motion is controlled by individual motor. Fabric is rolled on a cloth roll which is surface driven LET OFF: Let off motion get control by individual motor. Let-off motion is assisted with easing motion where feeler rollers are vibrated to adjust warp tension. WARP STOP: If warp ends get broken loom is automatically stopped by hydraulic brake. Warp stop motion is controlled by drop pins, when a warp breaks drop pin fall on a electrode, completing the circuit and making loom stop. WEFT STOP: Weft stop motion is controlled by two filling detector (FD1 and FD2).
15 MM 30 MM 20-25 MM
37 MM 35 MM 35-40 MM
VALVE PRESSURE: Pressure in main valve should be 6 bars. SELVEDGE : In air-jet loom dummy selvedge are used with leno selvedge. There is a leno box for every loom. REED: For air-jet looms profile reeds are used for jet integrity.
LOOM PRODUCTION
Loom production determines the total production of weaving. Loom production data is stored and updated on spreadsheet and informed to MIS. Main hurdles of loom production are beam gating, knotting and warp stop and weft stop motion. TOTAL PRODUCTION OF LOOM-SHED: 37,000 meters/day AVERAGE PRODUCTION LOOM TYPE TOYATA PICANOL
AVG. PICKS/INCH
84 PPI
83 PPI
AVG. RPM
830
785
NO. OF M/C
64
56
PRODUCTION/ DAY
EFFICIENCY
88%
85%
(Production in meters/shift/ m/c * FABRIC WIDTH * GSM) gm Fabric width in meter, GSM= gram weight of one square meter fabric
1- 1hr 30 min
LOOM SETTINGS
LOOM TIMING DIAGRAM: Loom timing diagram is the timing settings of all motions of a loom. As for better production and m/c stability and less wear and tear perfect loom timing diagram is essential. MOTION BEAT UP CUTTER SHED OPENING DWELL PERIOD SHED CLOSING PICKING FILLING DETECTOR 1 STARTING (DEGREE) 0 5 10 61 320 80 210 60 319 360 300 290 STOPING (DEGREE)
WEFT YARN
PRE-WINDER
PFT
TENDOM NOZZLE
MAIN NOZZLE
RHS
CUTTER
RELAY NOZZLE
CUTTER
Make of the m/c: Indiana Euro, Shreetex (Silvasa) Motor rpm: 1415 Motor hp: 1.0 Power consumption: 0.75 KW Length of the beam: almost 70
WARP DEFECTS
UP TO 3 INCH 3 INCH TO 6 INCH 6 INCH 9 INCH 9 INCH TO UP 1 POINT 2 POINT 3 POINT 4 POINT
WEFT DEFECTS
UP TO 3 INCH 3 INCH TO 6 INCH 6 INCH TO HALF WIDTH HALF WIDTH TO FULL WIDTH HJHKJ 1) 2) 3) 4) No one meter should be penalized more than 4 points. Fabric shall be inspected on one side. Total no of points allowed in 100 linear meter are 24 points. Deviation of 10 points per linear meter allowed. 1 POINT 2 POINT 3 POINT 4 POINT
DIFFERENT FABRIC FAULTS QUALITY NO 14292 16239A 12361 110203 14534 FABRIC FAULTS STARTING MARK, BREAKING END, BROKEN PICK, DOUBLE PICK, THICK PLACE, SELVEDGE DEFECT, LOOPS WEFT DISTORTION, SIZE PATCH, BROKEN PATERN, COARSE PICK BUMP MARK, OIL STAIN, THIN PLACE, MISSING END, WEFT SLUB, CONTAMINATION, HOLE/CUT/TEAR LOOSE WEFT, WARP SLUB, STICHES, MISSING PATTERN, WRONG DENTING WRONG DRAWING, DOUBLE END, THICK PLACE, STARTING MARK, LOOSE WEFT
SOMETHING ABOUT THE SECTION Each fault is given a marking. This marking technique varies from mill to mill. Here the marking technique is shown below. Maximum points given to a fault = 4.There are corresponding marking of 1, 2& 3. Maximum allowable points to consider a fabric as A grade is 24 within 100metres of fabric, for B grade this range varies for 24 - 90 within 100 meters of fabric. Above this it is considered as C grade fabric.
MAINTAINANCE SHEDULE
MAINTAINANCE SCHEDULE FOR DIRECT WARPING M/C( 500 operating hr service) SIZING M/C WEEKLY MAINTAINANCE SCHEDULE
CLEAN MACHINE CLEAN WINDSHIELD CLEAN GUIDE ROLL CLEAN PRESSURE ROLL CLEAN TRAPEZOIDAL THREADED SPINDLE AND LIMIT SWITCH ASSEMBLIES CHECK OIL LEVEL CHECK SCREWED LEVEL CHECK DRIVE LEVEL RESET MAINTAINANCE INTERVAL LUBRICATING QUILS CLEAN / BEAM POSITION CLEAN / LUBRICATE TRAPEZOIDAL THREADED SPINDLE CHECK WARP BEAM CLEAN / LUBRICATE COMB TRAVERSE CHAIN GREASE CYLINDER PRESSING DEVICE RESET MAINTAINANCE INTERVAL OIL CHANGE: REPLACING OIL FILTER INSPECT/ REPLACE BRAKE PADS REPLACE DRIVE BELTS CHECK BEAM CLAMPING AXIAL PLAY CHECK COMPENSATING SPRING REPLACE PRESSURE ROLL BEARING REPLACE GUIDE ROLL BEARING REPLACE QUILL ROLL BEARING REPLACE BRAKE CALIPER SEALS
CLEAN THE COMPRESSOR FILTER CLEAN THE OIL LEVEL CLEAN THE BEAM SHAFT CLEAN THE AIR FILTER AND AIR SILENCER CLEAN THE ALL VALVE POSITION CLEAN THE ALL SAFETY GUIDE POSITION CHECK THE ALL MANDI PUMP POSITION CHECK THE ALL BEARING POSITION ALL M/C GEAR BOX POSITION CHECK ALL THE NUT BOLT CHECK CREEL BELT POSITION ALL M/C GREASING STEAM LEAKAGE PROBLEM
10. BEAM LOCKING AREA 11. BACK REST BEARING AND BACK REST PLAY 12. LENO DEVICES, LENO SHAFT, WHEEL 13. EASING RAD, BEARING 14. HEALD FRAMES, SIDE SUPPORTS AND BOLT TIGHTNESS 15. WARP STOP MOTION SENSOR, SERRECTED BAR 16. TEMPLE RING CONDITION 17. TAKE UP ROLL,GEAR, PRESS ROLL 18. CATCH CORD SET 19. TAKE UP, DRIVE MOTOR, GEARS, CHAINS 20. TAPPET CAM BOX AREA & BELT TENSION 21. UNDER MOTION, JACK LEVERS 22. MAIN MOTOR AREA AND BELT TENSION 23. CONTROL PANEL 24. AIR PRESSURE AND REGULATOR AREA 25. AIR FILTER, OIL FILTER AND GREASE FILTER 26. CLUTCH GAP UP TO 0.6mm 27. OTHERS
The days we passed at Gimatex taught us a wonderful lesson in our lives. Gimatex taught us to survive even in the most competitive situations against the most powerful competitors. The lesson we learnt is an experience of a lifetime. None of us has enough of oblivion to forget it.