Innovation and technological advancement in

Spinning
Subject – Fabric Knowledge for Merchandiser

Faculty – Ms. Bhavana Rawat

Submitted by:

Ashish Singh M/FMS/08/08 Kanika Srivastava M/FMS/08/13

Bhavik Gandhi M/FMS/08/10 Ridhima Ranga M/FMS/08/14

Gaurang Gupta M/FMS/08/11 Vijesh Kumar Baraskar M/FMS/08/34

Kanika Jain M/FMS/08/12 Watan Gupta M/FMS/08/35

INTRODUCTION
The Indian textile industry plays
a significant role in the
country’s economy for its
contribution to the Gross
Domestic Product (GDP),
employment generation and
earning foreign exchange. The
textile industry contributes
significantly to the world textile
production capacity and supply
of fibers. The Indian Spinning
machinery manufacturers have
created a milestone in the year
2007-08 with supply of over 3.5
million spindles in the industry.
Constituents of Yarn Spinning
Manufacturing Cost
The raw material accounts for
55 – 60% of the total yarn
manufacturing cost followed by
power cost, labor cost and
interest & other cost. Non-
availability and increased cost
are the major reasons for the raw
material to constitute the larger
share in the yarn manufacturing
cost. The paucity and
intermittent distribution of
power is another major
challenge facing the industry.
The Indian textile industry
Interest is large and diverse,
& other
unique for its coverage of
Labour
the entire gamut of
Power activities ranging from
production of raw material
Raw
to providing the
material
consumers, high value
added products, such as
Interest & Other 10-15%
fabrics and garments.
Labour 8-12%
Challenges Faced by the
Power 12–15% Spinning Sector
Raw Material 55-60% The challenges of the
Hence it is crucial to handle the Spinning Industry which
above factors to achieve profits would impede the Growth
in this competitive scenario. and development of the
Industry are:
 Raw material
availability
 Human resource
 Power cost &
availability
 Investment &
Interest cost, etc.
Raw Material Global and Indian Cotton Scenario

06/07 07/08 08/09 06/07 07/08 08/09

Raw Material vs. Million Tons Million Tons
Yarn Quality Production 26.65 26.28 24.9 122.4 120.7 114
Consumption 26.66 26.67 26.4 122.5 122.5 121
Modern developments Exports 8.13 8.19 8.8 37.3 37.6 40
in Spinning Machinery Ending Stocks 12.41 12.10 10.7 20.7 57.0 49
are mainly
Global focused
and Indian on
Cotton Cotlook A index 59.15 73 83 59.15 73 83
the key properties of a
Scenario Source - ICAC
fiber. Synthetics do not
Raw Material The world 2008/09 projections indicate lower beginning stocks,
pose challenge as the production, consumptions, and ending stocks. World production will
RAW
fibersMATERIAL
could be reduce by 1.5 million bales of 480 lbs. due to mainly reduced
controlled to a great production.
extent. However, the
following are the key
Cotton Balance Sheet (October – September)
properties of cotton
fibers which determine (in lakh bales of 170 kg )
yarn quality. 06/07 07/08(E)
Supply
 The
Micronaire and
world 2008/09 Opening Stock 52.00 47.50
C.V.% of Crop 280 315
Micronaire Imports 5.53 6.5
 Fiber Neps Total Supply 337.53 369.00

The  Contamination
Demand
world 2008/09 Mill Consumption 194.89 203

projections indicate fiber
Short lower Small Scale Unit Consumption 21.26 23
beginningcontent
stocks, production, Non-Mill Consumption 15.88 15
consumptions, and ending Exports 58 85
Micronaire
stocks. and Neps
World production will Total Off-take 290.03 326
contribute
reduce a major
by 1.5 million bales of Carry-over stock 47.5 43
480 lbs. duein the
percentage to mainly
yarn Source – Cotton advisory board E=estimated
reduced
quality production.
determining
The cotton scenario in the country also presents a difficult picture with
factors. decrease in carry forward stock for the upcoming year and decrease in
acreage allotted for cotton production. This would lead to increase in
price of raw material which would subsequently lead to its increase in
yarn manufacturing cost.
Yarn Realization
In the production economics of a
spinning mill, yarn realization
plays a important role. The
machines in every sub system of
the Spinning system are
configured by attaching
importance to raw material
characteristics and yarn
realization.
Human Resource
The Indian textile industry is
facing challenges on the
following in the human resource
front:
 Non availability of labor
 Skilled manpower
To address the above issues to
an extent, automation in the
machines are designed with state
of the art technologies.
Power
The energy efficiency and
power utilization for machinery
has become the need of the hour
to address the power availability
issues. The machines in the
entire spinning system are
designed with less energy
consumption parts.
Short Staple Spinning System
The short staple spinning system
comprises of the following
system:
Cost silver system- blow room
and cards
Combing system- non
autoleveller draw frame, lap
former, comber, autoleveller
draw frame
Ring spinning system- speed
frames, ring frame, and compact
spinning.
Card Sliver System
 Blow Room with Bale
plucker Line
 Production upto 1500
kg/hr
 Bale plucker with
autoscanning increases
machine utility and
efficiency and
elimination of skilled
man power
 Chute feed systems to
cards
 Automatic Can Changers
at card
 Delivery in sizes upto
40” to 48”
 Maintenance free digital
drives
Blow room and card
together form the package in
catering to the deficiencies
of the raw cotton due to
continuous down grading of
the fibre properties, stress is
put more on blow room
machine and cards.
Blow Room
The fibers are subjected to
gentle and soft treatment to
avoid NEP generations /
increase in short fibre content.
The nature
contamination/impurity such as
seed coat fragments, husk, leaf
bits, etc. are difficult to extract.
Due this blow room had to be
readopted with machines
capable of intensifying the
cleaning significantly.
This has resulted in a pre-
cleaning with free movement of
fibers by air handling and fine
cleaning with different beaters
depending on the fibre nature.
The beater in the blow room are
also designed to suit both cotton
and synthetic handling.
The concept of modern blow
room development is based on
the following:
OPTIMAL OPENING
OPTIMAL CLEANING
OPTIMAL DEDUSTING
OPTIMAL BLENDING
But above all, by treating the
fibres softly and gently and
saving the raw material through
less fiber loss. Blow room is
configured with high production
machines thereby decreasing
number of ventilators.
Cards
In the production
Basic principles of carding economics of
remains unaltered even though
spinning mill, yarn
there are other technological
development. The production realization plays a
of rates are determined by raw significant role. The
material properties. The
machine in every
emphasis is on devices which
could control the deterioration sub system of the
of fiber and maintain optimum Spinning system are
production. The neps are
configured by
disentangled and reaches the
minimum level at carding stage. attaching
The wire points in the carding importance to
machines are configured to suit
material
all types of cotton varieties and
synthetics. characteristics and
yarn realization.
Combing System
 Non auto levelor draw
frame.
 High delivery speed upto
1000 mpm.
 Feed and delivery can
with 40” X 48”
Lap former and Comber
 Automatic lap
transportation system
 Automatic / Semi
automatic batt piecing.
\
 Draw frame manpower require to collect and
transfer waste.
 Automatic draft control
 Auto Can Changers with Ring Spinning System
magazines
Speed Frame
 Maintenance free digitals
drive  Suspended flyer
 Bobbin package size –
Combing developments are
16” Height X 6”
By technological being carried under the
Diameter
following criteria :
advancements and  Servo bobbin build
increase in production  Saving the noils
Ring frame
 Higher productivity
the investments cost
 Cost effectiveness  Spindle speed upto
in spinning mill has 25000 rpm
The percentage of noil
drastically reduced.  Servo drive system for
extraction depends on the raw
ring rail
material selection and intended
use of the end product. Combers  Auto doffing for speed
are designed for noils savings frame and ring frame
with optimum parameters.  Link coner attachment
 Automatic bobbin
Comber transportation system
 Maintenance free digital
 High precision combing
drive
dynamics and processes
 Synchronized and Energy saving is achieved with
optimal movement of the following machine
parts configuration:
 Reduced moving parts
 Energy efficient, high
All machine are equipped with performance, noise less
energy efficient drives. high speed spindles
 New light weight
Automatic waste collection in
spindles (lesser DUI)
blow room cards and combers
 4 spindle tape drive
removes wastes from these
 Lower diameter ring
machine either continuously or
intermittently. This system helps  Lower lift
to control incident of fly and  Improved suction tubes
fluff generation and reduces  High efficiency motors
for the same load draw
  less input power than Past and present – Machinery requirements
an ordinary motor and
For a mill producing Ne 30s C, with production 13.7 Tons/day
a considerable
percentage of energy Old line: 28,244 Spdls. & New line: 25,200 Spdls.
is saved. The high
efficiency is achieved 1995 2008
by reducing electrical
No. of Machines
and mechanical losses
in the motor.
29 15
Card Sliver system
Compact Spinning is value
addition in ring spinning. The 37 20
Combing system
principle of compacting or
considering during the
Ring Spinning Sys 38 29
spinning process minimizes
the width and height of the
spinning triangle. The fibre
are aligned in the yarn with Human resource requirements
uniform twist. The following illustration highlights the savings in:
Compact spinning system  Manpower
ensures appreciable reduction  Space
in hairiness and significant
 Recurring cost by way of automation
increase in yarn strength with
enhanced yarn appearance. Spindleage Non Automatic Automatic
plant Plant
Investment Analysis

By technological 30000 320 180

advancements and increase in
production the investment 500 300
50000
cost in spinning mill has
drastically reduced. The chart
A depicts clearly the The savings in manpower is an automated plant is around 40%.
reduction in machine required
for the same spindlege
capacity.
To summarize, the above technological advancements and automation are the key factor in assisting the
capital intensive spinning industry.

 Optimal realization of raw material

 Reduce manpower dependency and
 Lower energy consumption

Spinning machinery produced in india can meet the requirement of the spinning industry with cost
effective solutions.

HISTORICAL DEVELOPMENT OF YARN MANUFACTURING

Hand Spinning

 Earlier staple fibers were twisted together by hand to form yarn.

 Rolling the fiber between the hand and the leg is another primitive method to produce yarn.
 In both the above method excellent yarn is produced by experienced and skilled person.
 Carding process was done to the fiber in which fibers were straightened before Hand Spinning
process.
 Fibers could be made completely parallel by a further step called Combing, this process also
include the removal of very short fibers.
 Hand spinning with Spindle & Distaff. The woman holds the distaff under her left arm, draws
fibers from the bundle tied to the distaff, and spins fibers into yarn by lowering the spindle with a
spinning motion. Spun yarn is wrapped around the spindle as it is formed.
 A major improvement in the spinning of yarn originated in India in the form of Charka or Spinning
Wheel. It seems to have been invented sometime between A.D. 500 and A.D. 1000.
 In the 16th century Flyer and detachable bobbin were invented which allowed the simultaneous
and winding of yarn into bobbin.

MECHANIZED SPINNING

 In 1741 John Wyatt and Lewis Paul built the first series of spinning machines for spinning cotton
yarns. They used a Roller-Drafting principle which helped in producing strand of fibers called
Roving. This roving was stretched to Bobbin-and-Flyer twisting mechanism.
 Arkwright used this same principle in 1769 when he constructed a spinning machine called the
Water Frame which was given this name because it was operated by water power.
 James Hargreaves in 1760’s invented Spinning Jenny which made eight yarns at the same time.
The yarns made by Hargreaves and Arkwright machine were not as strong as hand spun yarn.
 Samuel Crompton combined water frame and spinning jenny into one basic machine known as
Spinning Mule, which was basic machine for producing cotton yarn in England until well into 20th
century.
 John Thorpe invented Automatic Spinning Mule in 1830 which is also called Ring Spinning
Machine and used even today.
 Open End Spinning in which air suction takes the fibers through tube in which twist is imparted to
fiber was invented for staple fiber.