Inspection of wastes extracted by various machines of spinning departments and mounting samples on lab report

 

Inspection of wastes extracted by various machines of spinning departments and mounting samples on lab report.

  Abstract:

 To inspect the various wastes extract from different machines in the spinning process. The machines of spinning department were started and different type of waste extract from cotton were observed and were different from each other. We came to know about different wastes in different sections of machines. The waste of every machine is different than previous. 

Background:

 Blow Room:

Blow room is the initial stage of spinning process. The name blow room is given because of the “air flow” and all process is done in blow room because of air flow. Blow room is consisting of different machines to carry out the objectives of blow room. In blow room the tuff size of cotton becomes smaller and smaller. 

Carding:

 Carding is a mechanical process that disentangles, cleans and intermixes fibers to produce a continuous web or sliver suitable for subsequent processing. This is achieved by passing the fibers between differentially moving surface covered with card clothing.  

Objectives:

Ø Inspection of waste extracted by various machines of spinning department.

Ø The collection of wastes.  

Theory:

Spinning:

is the twisting together of a drawn out strands of fibers to form yarn, and is major part of textile industry. The yarn is then used to create textiles which are then used to make clothing and many other products.  

Objective of Blow room: 

1. To open compress bales of fibers.

 2. Remove dirt and dust, broken leaf, seed particles of any other foreign impurities from the fibers.

3. To transfer the opened and cleaned fibers into a sheet form of definite width uniform weight per unit length, which is called lap.

 4. To roll the lap of predetermined length into a cylindrical shape around a lap pin.

5. To transfer the lap from the lap pin into a lap rod to a suitable and feed it to the subsequent machine (Carding). 

Equipments,Tools  and materials

• BlOW ROOM MACHINES:

 Porcupine opener. Exit flow machine. Step cleaner machine. Krischner bitter waste.             Scutcher machine.

 • CARD MACHINE: Taker in waste. Cylinder under casing waste. Flate strip waste. Goffer waste. • DRAWING FRAME MACHINE.

 • ROVING FRAME MACHINE.

• RING FRAME MACHINE.

 • WINDING MACHINE. 

Procedure:

The blow room machine was run and the waste from porcupine beater, step cleaner, fine opener (2), krischner beater, carding machine and from Ring Frame were taken. All types of wastes samples were collected.

    

Observations:

 1. Bale breaker:

  The bale breakers are useful at start of the process for the opening of bales of textile fibers. The bale breaker loaders are used to automatically open the bales of textile fibers and then send it to the fiber to fiber blending bins or the carding machine. To make the bales smaller to smaller the bales are break with the help of machines to make small tuffs. 

Porcupine opener:

The waste of porcupine opener is sometimes called fine opener. The cotton fed by the previous opener is carried forward by the feed lattice. The cylinder of porcupine opener is wrapped with a saw tooth wire. Pedal roller feed the cotton in between pair of feed roller which is weighted to give necessary grip on the cotton. Each striker is bent to a slightly different angle. Because of this beating action, the cotton is effectively opened and extracted trash particles are passed through the spacing of grid bar. 

Step Cleaner machine:

It is an important machine in ring spinning for cleaning and opening impurities from cotton. This machine is set normally after porcupine opener machine. The main purpose is to open and clear the cotton by the combinations of opposite spike action and beating action. The main impurities such as leaves, stalk, motes and sand were removed without damage the fiber. 

Fine opener 2:

Krischner breaker is used in fine opener 2. In beating operation flocks are subjected to a sudden strong blow the inertia of impurities accelerated to higher. The waste contains leaf particles, dust and dead fibers are also find out but in limited extend.

Krischner beater: 

These machines are similar to the multiple bladed beaters, but instead of beater bars, pinned bars are secured to the end of cost-iron arms. They comb through the web at 800-900 rpm. The relatively high degree of penetration results in good opening. Therefore, krischner beaters often used at last opening position in blow room line. 

2. Carding machine:

Taker in waste:

 A roller on a carding machine, especially the roller that opens the stock as it fed into the card and transfers the fibers to the main cylinder. It opens the cotton into very small tufts. It extracts the sand bits, sand and other vegetable trash particles from the cotton. It transfers the cotton into the cylinder surface and distributes the fibers as evenly as possible both transversely and longitudinally on the cylinder surface. The rollers that receives fiber from the feed roll is called taker in.                        

 Fly waste: 

           The fly waste contains a large amount of unparalleled fibers and those fibers which              are entangle with each other. Avery little number of wooden particles are also                              present. 

Auto Cone Waste:           

Also called hard waste. Hard waste in spinning industry is generated only in department such that in ring frame and in winding department, so the focus on these departments is necessary. The causes of hard waste is improper ring alignment, count much coarser than normal, vibrating spindle, wrong spindle, gauging and less clearance between ring and ring cop. Generally, the un-parallel and extra threads are remove out. The hard waste can be used into sewing thread.                                                                                                           

 

Result: 

The initial waste was collected from Step Cleaner machine, fine opener 2 and Krischner beater. Taker in waste and Fly waste was collected from Carding machine. Hard waste was collected from Auto Cone machine. 

Discussions:

 After breaking the bale with bale breaker, the Tuff passed through different machines to remove the waste and trash. Different type of waste is observed from different machines i-e. Porcupine opener, Step cleaner, krischner Beater and Hard waste from Auto cone. The most of dirt drop through the space between grid bars in porcupine beater. The amount of waste is more in number in porcupine beater. The Step cleaner machine open and clean the tuffs with opposing spikes and beating action. It effectively removes heavy impurities such as leaf, stalk, motes and sand without damaging the fibers. The waste removed in krischner beater is done with help of cage. The cage revolves at very slow speed, during rotation of cage dust particle and shorts fibers are also removed from the fibers. The auto coner waster is usually harder and they are removed to align the yarn. 

Safety measure: • Run the machine carefully. • Keep yourself away from the machine at running. • Handle the machine parts carefully. • Do not collect the waste from the machine at running. 

Questionnaire:

➢ What are the opening and cleaning principles of machine? The opening is the result of holding and pulling bunches of cotton by fingers or strikers of beater. Cleaning is result when cotton is thrown against grid bars, and most of dirt is dropped through the space between grid bars. 

➢ What are different types of impurities? The impurities cotton exist are sand, trash, dirt, leaf stalk and hard impurity like thread.

➢ What is the name of machine based on opposing spikes? Maxi flow.  

Conclusion:

The waste has different forms removed from different machine in Blow room, carding and in auto cone machine. Pakistani cotton contains greater amount of trash, so to fulfill the customers demand, we should take some extra weightage of cotton i.e. taken mostly +5% extra. The hard trash removed in autoconer machine is used in sewing threads.