TO STUDY THE FIBRE DYEING PROCESS FOR MELANGE YARNInternship report

1
Project Report On
“TO STUDY THE FIBRE DYEING PROCESS FOR MELANGE YARN”
Submitted in partial fulfillment of the
Requirements for the award of the degree of
BACHELOR OF TECHNOLOGY
In
TEXTILE CHEMISTRY
Submitted By
NAVI ALAM (1704460032)
ANKIT CHAURASIYA(1704460009)
RITESH VISHWAKARMA(1704460044)
RAJEEV TIWARI(1704460041)
Under the Guidance of
Mr. YD Tiwari
Prof Alka Ali
Prof A.I. Amjad
Submitted to
Uttar Pradesh Textile Technology Institute, Kanpur
And
Rajasthan Textile Mills, Ltd

2
Table of Content
For
Sr. No. Content Page No.
1 Introduction 07
2 FLOW CHART 08
3 HIERARCHY OF THE ORGANIZATION 09
4 WORKING OF DIFFERENT DEPARTMENT 10
4.1 Production of department
4.2 Maintenance department
4.3 Engineering department
4.4 HR department
4.5 Accounts department
4.6 Quality controle,R&D
5 CONCLUSION

Introduction
As textile industries growing day by day in terms of developing the textile sectors various
researches and developments are taking place to improve the quality of final products as well as
different innovative products to cater specific markets. Quality improvement is not only single
stage process at every stage it should be monitored.
Melange yarn is produced in combination with two or more fibres either of same &/or different
generic nature and colour. These fancy yarns are widely produced in the textile industry & find
their application primarily in the hosiery apparel sector. It also finds application in denim,
upholstery and even in sophisticated fashion fabrics in the garment industry. Though, melange yarn
offers a great variety of shades, but its strength is inferior to normal grey yarn and the loss in
strength increases with increase in the amount of coloured fibre. Much attention is generally paid
to the aesthetics than to the strength of the yarn. However, attainment of minimum strength to
sustain stress during post spinning operation and during use in given importance. The present study
primarily deals with a quantitative analysis of melange yarn produced with varying depth of
coloured fibres, and different blends of fibres using ring and compact spinning systems. The
structural difference of two types of yarns necessitates the study of yarn properties. Effect of
percentage of dyed fibre, spacer size & spinning system on yarn evenness, imperfection, tenacity,
elongation, hairiness and frictional behaviour was studied. The compact yarn exhibited better mass
uniformity, strength & elongation while the hairiness, coefficient of friction are low as compared
to normal ring yarn.

Non-compact Vs Compact Yarn Comparative Report
COUNT 1/30s 1/30S 1/30S
BLEND Cotton-100% Cotton-100% C/P 60/40
SHADE NO. SCO3BK03 SC1BK48 SP1BK64
QUALITY
Non-
Compact
Compact
Non-
Compact
Compact
Non-
Compact
Compact
ACT.
COUNT
30±0.2 30±0.2 30±0.2 30±0.2 30±0.2 30±0.2
COUNT C.V. 1.50 ± 0.25
1.50 ±
0.25
1.50 ± 0.25
1.50 ±
0.25
1.50 ± 0.25 1.50 ± 0.25
CSP 2300±50 2550±50 2150±50 2400±50 2450±50 2600±50
U% 12.5± 0.25
12.25±
0.25
12.5± 0.25 12.0±0.25 12.5± 0.25 11.75±0.25
THIN 20 –25 12 –18 15 –20 7- 10 15 -20 8 - 12
THICK 325 - 350 275-300 250-275 150 - 175 275 - 300 175 - 225
NEPS 550– 600 425-450 350- 400 250 -300 300 - 350 225 - 250
TOTAL IMP. 895 – 975
712 –
768
615 – 695 407 -485 595 - 675 408 - 487
Hairiness 7.6±0.2 6.0±0.2 7.5±0.2 5.8±0.2 5.0±0.2 4.3±0.2
RKM 15.5 ± 0.50
16.5 ±
0.50
14.5 ± 0.50 15.5±0.5 16.0±0.5 16.75±0.5
Improvement in quality
Increase CSP 10 -12% 10 -12% 6 -8%
Reduce IPI 20 - 25% 25 - 30% 20 - 25%
Reduce
Hairiness
20-22% 20-22% 15 - 17%
Among the types of fancy yarns, melange yarn is known for its attractive colour and appearance..
Mixing of fibres with different colours could be done either in the blow room at the start of spinning
preparation or by feeding different Sliver to the draw frame(Snow Hether) or by feeding of different
roving on the R/F (Like- Jaspe yarn, Injection slub yarn). The wavy like effect and a wide range of
colour tones due to different colour fibres blending makes it much popular and rich in look.
Melange yarn has unique dyeing process, with different technological know-how as compare to

yarn dyeing or fabric dyeing in terms of fibre dyes, colour matching and mixing of multiple
coloured fibres. Dyeing the fibres before spinning can keep energy saving, emission reduction
and environmental protection. Melange yarn can present multiple colours on one single yarn, which
gives it rich colours, slenderness and tenderness. Textile made of melange yarn has a certain
ambiguous cyclical effect. Studies show that scouring and dyeing process of cotton fibres lead to a
greater entanglement and cohesion among them, decreasing of fibres strength and removal of a
part of the wax present on the surface of cotton fibres. Further mechanical processes on the
fibres lead to fibre damage and decreasing of their length parameter. These variations on fibres
not only affect the efficiency of the spinning process, but also the mechanical and physical
properties of the final yarn and fabric [4-6].
In conventional ring spinning, there is always a triangular bundle of fibres without twist, the so
called spinning triangle, at the exit from the rollers, which represents the most critical part of ring
spinning system. In this zone, the fibres assembly contains no twist. The edge fibres play out from
this zone and make little or no contribution to the yarn properties like tenacity and hairiness [7]. In
compact spinning, the spinning triangle is almost eliminated and almost all fibres are incorporated
into the yarn structure under the same tension. This leads to significant advantage such as
increasing yarn tenacity and reducing yarn hairiness [8, 9].
Fig 1:- The Compacting System [9]
The distance between the top and bottom aprons is determines the intensity of pressure applied to the
fibres to be under control. This distance, which is introduced by means of the special device, is called
spinning spacer. With widened apron spacing, a progressive deterioration in regularity and strength of
yarn was noticed.

MANUFACTURING PROCESS:
Indians were the pioneers in making the mélange yarn for the first time in 1980’s. It may be defined
as “the yarn produced by the combination of at least two or more than two fibers”. Conventionally,
the term mélange is used for such yarns which are produced by the combination of two fibers
(whether of same type but different in color or type of fiber used is different). Furthermore, Mélange
yarn can be classified into two of its very basic types:
I. Blended mélange yarn
II. Non blended mélange yarn
I. Blended Mélange Yarn:
Such type of yarn in which different fibers are mixed/blended together in a certain fixed ratio for
instance PC (Polyester Cotton blend) 50:50, PC 70:30, PV 80:20, CVC 40:60 etc.
II. Non Blended Mélange Yarn:
Yarn in which there are no different fibers blended together, but different colored fibers of same
type are used to make the yarn e.g. 100% cotton dyed yarn, 100% bamboo yarn etc.

PROCESS FLOW CHART OF SPINNING DEPARTMENT
(FOR MELANGE)

CARD
BREAKER DRAWING FRAME
FOR CARDED
QUALITY
FORCOMBED
QAUALITY
LAP FORMER
COMBER
MATERIAL GO TO DYE
HOUSE FOR DYEING
BLOW ROOM
CARD
BREAKER DRAWING FRAME
FINISHEER
DRAWING FRAME
ROVING FRAME (SIMPLEX)
RING FRAME
AUTO CONNER
PACKING
MATERIAL READY FOR
DISPATCH
BLOW ROOM
GREY COTTON
YARN CONDITIONING
CHEESE WINDING
T.F.O.

I. Preliminaries of the Process:
The production of mélange yarn is similar to the simple (Un‐dyed) yarn, but there are some
additional things that need to be discussed here. Initially, the raw cotton is stored in form of bales
in godowns. These bales after certain time of conditioning are sent to different location of mills
for dyeing. There the bales are opened to flock form and conventionally, disperse dyes, reactive
dyes and VAT dyes are used for fiber dyeing. After this is done, the bales are returned to the at
manufacturing area that is Mixing zone; these bales are again opened, well mixed, conditioned with
a (LOT NUMBER). This number may vary from mill to mill for identification purpose, but this
is important to discuss because we are not sure that we get the same type of dyed fibers ( in terms
of dye ability, dye affinity, rubbing & washing fastness ) of the fibers every time. This may depend
upon the dyeing conditions, dye quality, recipe, process conditions, fiber used (mature/ immature/
dead fiber content). These factors are important to consider because these are some unrevealed
factors that causes very common problems in mélange yarn i.e. rejection of the shade. There comes
the importance of making the LOTS, so that we can easily track from where the error occurs.
However, another technique may be used which is termed as “SAMPLING”. For every new LOT
or new mixing of the running order, a sample should be made and get it cross checked with the
Customer’s sample. In this way we can reduce the chances of error and shade variation can be
limited and predicted in advance, so necessary remedies can be taken.
II. Types Of Blends:
Normally, we speak of types of blends depending upon the percentage of shade (colored fibers) in
the mixing recipe or yarn. So, this classification mainly depends upon the Shade percentage, but it
can also be done deliberately to ease and balance the process.
a) Blow room Blend
b) Drawing Blend

a) Blow Room Blend Shade:
Such shades which are blended through blow room are called “Blow Room blends”. Normally,
darker shades and shades constituents variety of colored fibers are run as blow room blend shades.
Conventionally, shades having percentage more than 15% are run as blow room blends. This is
done to achieve the maximum blending and uniformity in the shade.
It should be clear that by the term “shade” here we only mean the total percentage of colored fibers
in the yarn. For example let us consider a shade SC1BK30 (this code may vary from mill to mill),
it has fiber coding as:
So, in above recipe shade SC1BK30, total percentage regarded as shade is 30.% Means in 100% Cotton
there is 30 % Black fibre.
b) Drawing Blend Shade:
Such shades which are blended on draw frame in form of alteration in doublings are termed as
“Drawing Blends”. Mostly, lighter shades are blended on draw frame, as they are easy to blend
and provide ease in balancing the process. In drawing blends, we can blend having 15% shades.
III. Calculating the Drawing Blend Shades:
Usually, drawing blends are set in accordance with the need to make the process easy and some
how on shade percentage. This can be made clearer by considering the example below. Let us
consider the shade SGL915 (these codes not holds for all mills) having following recipe:
This is the required percentage of shade in the yarn, but this recipe will vary if we make it drawing
blend. Now, this depends upon us, whether in what percentage we need to blend that and adjust the
doublings on the draw frame in accordance with that. This can be easily under stood by following
calculations. Let us say, we want to run it as 2 carded sliver cans of this Blow room blend shade, and
6 carded sliver cans of the cotton. So the actual recipe will shift in this way, and that recipe is to be
made and mixed in blow room.
Mixing cans of carded sliver = 02
White cotton cans of carded sliver = 06
Total doublings = 08 (on one side of draw frame)
Olive – 01 = 2%
White Cotton = 98%

This gives us the blow room recipe as follows:
Olive – 01 = 8%
White cotton = 92%
But the question is how was it done?? There is a simple logic behind that, so let us calculate it. Say,
we are running 65 grams / yard of the sliver on draw frame.
We have, 02 slivers of mixing = 65 * 2 = 130 grams / yard
White cotton 06 slivers = 65 * 6 = 390 grams / yard
Total (grams/yard) = 520 grams / yard
By determining the simple percentage, we have:
Shade % = 130/520 * 8% = 2%
White cotton = 390/520 * 92% = 98%
This 8% was blow room recipe, and 6% additional of olive – 01 fiber was added, which is
reduced here on draw frame and ultimately brought to the 2% which was the required shade in
the yarn. This may be done depending upon the requirement and easing the process, as drawing
blend shades are easy to run as compared to blow room blends. There is only one set back, that
they require an extra passage of drawing for proper blending of shade and attaining uniformity ,
which some how effects the sliver quality and adds cost to extra machinery.
IV. Common Problems In Making Mélange Yarn:
There may be lot of problems occurring in the production process, but we will only highlight such
problems which are in particular related to the mélange yarn. Any of these problem may cause the
rejection of production made, ultimately suffering a major loss. So, in order to get rid of this, we
need to consider some of very basic flaws & focus upon its remedies. These problems are:
a) Shade variation
b) Variation in ratio (esp. in PC/PV/CVC) yarns

c) Spots in the fabric
a) Shade variation:
When ever there is the difference between the colors of two “LOTS” of the same running order,
this is termed as “Shade Variation”. There will be difference in the color of the yarn / knitted
fabric on the whole, which should be removed in order to avoid rejection of LOT.
There is variety of reasons of this variation as far as my knowledge is concerned. Some of them are
listed below:
 Twist variation in the yarn over ring frame (T.M / T.P.I variation)
 Wrong fiber blended / proportion of fiber is not exactly the same
 Moisture content of the yarn
 Count variation
 Dyed fiber variarion against the std.
 Weighment variation of the components
 No Proper blending and toppling done
 Randomisation not followed strictly
 Twist Variation:
There is difference observed in the shade while the same shades are being run on two frames but
with different T.P.I. it reflects like greater the T.P.I will give the darker shade as compared to the
lower T.P.I. T.P.I checking tests should be followed strictly to avoid this sort of problem. A clear
example is stated below for clarification.
SGD – 1616 (30/1 Knitting, Non‐ Compact) SGD – 1616 (30/1 knitting, Non‐ compact)

T.M = 3.75 T.M = 4.1
Fig. Difference in shade due to T.P.I
 Wrong Fiber Blended (Improper Mixing)
The other and very major flaw that is observed is use of improper fiber/ improper ratio of any fiber
leads to change in “TONE” and “DEPTH” of the knitted fabric. The following graph shows the
percentage contributions to shade variations. So, the proper selection and exact ratio is very basic
requirement in order to avoid this major flaw. In order to make this concept clearer, we should be
well defined about the two above cited words.
Sh.Amjad: Please include the points added in Yellow highlights in picture.
Fig. showing percentage of different causes of shade variation of a mill
We find variety of fiber which is used conventionally in the industry. For example, we consider the
series of fibers.

HIERARCHY OF ORGANISATION
Rajasthan Textile Mill located at Bhawanimandi, Rajasthan. Produces cotton yarns and man-made fibre
yarns with a capacity of 35,280 spindles for production of cotton melange and 91,584 spindles for man-
made fibres.
Rajasthan Textile Mill comes under Sutlej Textiles.
They follow a policy of continuous modernisation and upgrade there machines regularly; this has led
them to having latest state-of-the-art plant and machinery. In the last decade / 5 years they have
increased there spinning capacity from 253,000 Spindles in 2011-12 to 420,840 Spindles in 2018-19
spindles. There best-in-class technology at manufacturing plants has resulted in the reduction of
conversion costs, batch changeover time and defects. This has enhanced there production flexibility,
quality, efficiency and asset utilisation. There technology partners are the most important spinning
equipment to be listed – big brands.
There production facilities are well-equipped with cutting-edge quality testing and development
equipment, managed by a team of qualified and experienced professionals. They have up-to-date
technological equipment like USTER – 5 Evenness Tester,HVI Spectrum, Tenso Jet-4, Advance Fibre
Information System AFIS PRO –LMNT,Classimat-5 Yarn Fault Classifying System, Lab Expert
System all from Uster, Lab Dyeing and Sample Development system including Auto Dispenser, Beaker
Dyeing machines.
WORKING OF DEPARTMENT

Spinning industry consists of following departments-
1. Production Department.
2. Maintenance Department.
3. Engineering Department.
4. HR.
5. Accounts Department.
6. Quality control, R&D.
1- PRODUCTION DEPARTMENT:
The main work of production department is to make yarn. It works 24*7 to maximum production &
reduce material loss. It also effectively handle man power so to get maximum production.
Production of melange consists of following machines. They are-
On General Bale Weight
Avg. wt of H-4/MCU-5 & S-6 : 165 Kg
Size of bale: 127cm*56*45cm Lot size :
55, 45, 90, 100
Type of contamination removed in sorting
1) Plastic dori 7) thread (color)
2) Paper 8) Yellow cotton
3) Cloth 9) wood
4) Polythene 10) leather
5) Wires 11) hair
6) Feather 12) sutli
Cotton Bale: Bale
weight = 165 Kg
Contamination per Bale: S-6/H-4: 3-4 per gm
BALE PLUCKER

1- The basic objective of bale plucker is to open the bales into smaller & lighter tufts.
2- To transfer this material to various other machines of blow room line for further processing.
The setting of BALE PLUCKER system depends upon two factors:
1. Overall production of unit.
2. Length of belt.
Machine details
1) Make LMW
2) Model LA23
3) No. of m/c 1
4) No. of bales per lay down 52
5) Production rate 1200 Kg/hr
6) Efficiency 50%
7) motor speed 1430rpm
8) beater speed 1430 rpm
9) traverse speed 3 -12 m/min 10) Chanel length
40m
VARIO CLEAN (LB-9/2)

Objective:
1- It opens and clean all types of cotton.
2- It gives an efficient cleaning action.
3- It opens the cotton lumps with the help of pin type beater.
Machine details:
1) Make Laksmi
2) Model LB9/2
3) No. of m/c 2
4) Motor speed 1430 rpm
5) Beater speed 500rpm
6) Beating type ½
7) Beater type Pin type
8) Drive system Inverter type
9) Production rate 900kg/hr
10) Waste 2%
11) Efficiency 25-30%
UNIMIX(LB-7/4)

Objective:
1- To achieve extremely good homogenous and consistent blend of material.
2- Large amount of tufts volume is to be achieved with space required.
3- Intensive blending through simultaneous feeding of the entire vertical fibre deposing
in chutes by turbulent airflow.
Machine detail:
1) Make LAXMI
2) Model LB7/4 R
3) No. of m/c 4
4) No. of beaters 1
5) Beating point 1
6) Beater type Pin type
7) Dia. of motor pulley (line 1) 108mm
8) Dia. of m/c pulley (line 1) 365mm
9) Motor speed 1430rpm
11) Dia. of motor pulley 130mm
12) Dia. OF m/c pulley 240mm
14) Beater speed 775mrpm
15) Production rate Up to 600kg/hr with cleaning or opening device up to 400 kg
16) Capacity Active blending capacity up to
300kg With additional storage section 1m up
to 350kg,1.5m up to 375kg

17) Waste 0.7-1%
FLEXI CLEANER (LB5/6)
Objective:
1-To clean the efficiently.
2-To transfer the material for further processing.
A fan draws the flocks by suction from the preceding machine and ejects them into a filling chute.
The rear wall of the chute consists of individual aluminum lamellae with slot openings through
which the air can escape. The raw material remains in chute, is condensed and is fed to the
opening roller by means of filter drum/blind drum and the feed roller pair. The opening roller is
exchangeable and can be fitted with bladed discs or a sawtooth clothing.
Machine Details:
1) Make LAXMI
2) Model LB5/6 3) No. of m/c 1
4) Capacity of m/c 550kg
5) No. of beaters 1 6) Beating point 1
7) Beater type beater length Saw tooth type
8) Beater dia. 450mm
9) Beater length 1050mm
10) Feed roll dia. 60mm, 80mm
11) Dia. Of motor pulley (line 110mm 4&5)
12) Dia. Of m/c pulley (line 240mm
4&5)

15) Dia. Of motor pulley ( line 130mm
1)
16) Dia. Of m/c pulley ( line 1) 300mm
19) Production rate Up to 400kg/hr
20) Waste <0.5%
21) Efficiency 15-20% CARDING
Objective:
1) Individualization of fibers.
2) Parallelization of fibers.
3) Cleaning the fiber by removing foreign matter as waste.
4) Removal of waste ,seed coat, dust.
5) To obtain continuous uniform sliver hank.Carding is also known as heart of spinning
Carding action:
Two basic actions performed inside carding machine are:-
1) carding proper
2) striping action

Machine Details:
1) Make LMW
2) Model LC300A-V3
3) No. of machine 28
4) Cylinder dia. 1290mm
5) Licker-in dia. 253mm 6) Doffer dia. 680mm
7) No. of flats 94
8) No. of working flats 33
9) Feed system Chute feed system
10) Gauge b/w cylinder 0.20mm and licker-in
11) Gauge b/w cylinder 0.25,0.25,0.20,0.20,0.20mm and flats
12) Gauge b/w doffer and 0.125mm cylinder
13) Dia. Of doff roll 80mm 14) Dia. Of feed roll 80mm 15)
Dia. Of sensor roll 80mm
16) Flats travelling Opposite of cylinder direction
17) Speed of cylinder 430rpm
18) Speed of licker-in 1097rpm
19) cleaner gauge (front) 0.25mm
20) cleaner gauge (back) 0.25,0.30,0.35 mm
21) Under casing gauge 0.65-1.33, 1.5 mm, 1.3mm,2.6mm 22) Feed (gm/m)
450 gm/m.
23) Delivery rate 135m/min
24) Delivered sliver count 0.140 hank

BREAKER DRAW FRAME-LDO/6
Objective:
The SB-2 machines unite the fed sliver; draft them into drafting
arrangement& delivers them into form of sliver coiled in a can.
Machine Details:
1) Make LMW
2) No of m/c 2
3) No. of doubling 8
4) No. of delivery 2
5) Count of fed sliver 0.130
6) Delivered hank O.130
7) Can dia. 18”
8) Can height 42”
9) Drafting system 3/3
10) Draft 5.5
11) Break draft 1.7
12) Main draft 3.5
13) Tension draft 1.01
14) Loading pneumatic loading
15) Load on roller 33Kg
16) Bottom roll dia. Front 52, middle &back28,28 mm
17) Hardness 78 deg.
18) Buffing 1month
19) Length of material 5000mt
20) Delivery speed 500-550mt/min
21) Production 2167.8 Kg/shift
23) Waste 1%
24) Type of waste Fan waste
LAP FORMER

Objective:
Work of this machine is to form a uniform lap from the sliver which can be feed to
comber machine.
Machine details:
1) Make LMW
2) Model LH-10
3) No. of m/c 2
4) No. doubling 22
6) Fiber length Up to 60mm
7) Sliver weight 4.5-5 K tex
8) Count of sliver fed 0.108
9) Delivery hank 0.008
10) Can dia. 24”
11) Can height 42”
13) Draft 1.435
14) Break draft 1.046
15) Main draft 1.305
16) Intermediate draft 1.051
17) Loading Pneumatic
18) Load on roller 4-5 bar
19) Bottom roll dia. Front 32, middle& back
32,32 mm

20) Top roll dia. 36 -39 mm
21) Hardness of roller 83 deg.
22) Buffing time 30 days
23) Length of material 5000mt
24) Delivery speed 120 m/min
25) Spool length 300mm
26) Spool dia. 210mm
27) No. of hole in spool 90
28) Full lap dia. 510mm
29) Lap width 300mm
30) Full lap weight 60-80 ktex
31) Production 3240 Kg/shift
33) Waste 0.5-1 %
34) Type of waste Fan waste
COMBER(LK-54)

In unit 3 there are 10 comberautomatic doffing and empty spoolremoving
system. Comber is central waste collection system.
Objective:
• Elimination of predetermined short fiber.
• Elimination of remaining impurities.
• Removal of large proportion of nep in the fiber material.
• Formation of sliver having maximum possible evenness.

Machine Details:
1) Make LMW
2) Model LK-54
3) No. of m/c 10
4) No. of head 8
5) Lap weight 77gm/m
6) Sliver hank 0.115
7) Feed per nips 4.7
8) Nips per min 350-450
9) Noil % 15%
10) Circular comb 80/4 90 degree
11) Drafting System 3/3
12) Loading penumatic
13) Can diameter 600mm
14) Can height 1200mm
15) Lap weight 62gm/m
16) Draft 9.12-25.12
17) Breaking Draft 1.13-3.2
18) Feed forward

19) Efficiency 95%
20) Production 421.4 kg/shift
FINISHER DRAWFRAME (RSB-851)
Objective:
1- To parallelize criss-cross fiber in the sliver.
2- To improve the regularity in length/weight of the sliver.
3- Remove the hooks present in the sliver and hence to straighten the fiber.
4- Thoroughly mix different type of fiber so as to give homogenous blending.
5- More than 80% of incoming dust is extracted.

Machine details:
1) Material S-6/MCU-5
2) Staple length 32 mm max
3) Feed sliver hank 0.120 4) Delivery sliver hank 0.120
6) Draft 3.6-11
7) Doubling Up to 8
9) Loading Spring loaded
10) Load on roller 33kg
11) Roller dia. 52, 28,28mm
12) Can dia. 500mm
13) Can length 1200mm
14) Roller hardness 82 deg.
15) Buffing 1 month
SPEEDFRAME
Objective:

• To reduce the thickness of D/f sliver to from arelatively fine fibrous
strand of the material know as ROVING.
• To insert amount of twist ino the drawn out thinned material in order to
avoid breakage.
• To wound the delivered roving into a bobbinsuitable for the next m/c.
Machine details:
1) Make LMW
2) Model LF 1400A
3) No. of m/c 8
5) Draft 3-16
6) Draft b/w 2nd & 3rd roller 1.086
7) Roller dia. 27,30mm 8) Bottom roll gauge 44-56mm 9) Top roller hardness 83 deg.
10) Top apron thickness 0.86-1.04mm
11) Bottom apron thickness 0.86-.04mm
12) Weighting 3 roller pneumatic weighting top arm
13) Arm pressure 22.5 kg
14) Spindle gauge 121.83
15) Creadle length 36
16) No. of spindles 120
17) Maximum flyer rpm 1400rpm
18) Maximum delivery speed 30m/min
19) Bobbin size 12”*6 ½”
20) Bobbin dia 48mm
21) Bobbin length 360mm
22) Pressure gauge 1.2kg/cm
23) Type Bobbin leading
RING FRAME

Objective:
The spinning process basically consists of three stages:
1. Reduction of thickness of the supplied roving of the required yarn count.
This is usually done by drafting roller with some means of fiber control such
as double apron.
2. The prevention of further fibre slippage by twisting the fibre strand and
hence increasing the intercohesion.
3. Winding onto a package which is convenient for handling and which
protects the yarn.
Machine details:
1) Make LAKSHMI 2) Model LR-6/S 3) No. of m/c
24
4) No. of spindles 13248 5) Spindle speed 18000 max.
6) Spindle gauge 70mm 7) Creadle length 36mm 8)
Drafting system 3/3 apron
9) Draft Up to 60
10) Roller dia. Roller Bottom Top
Front 27mm 30mm

Middle 27mm 27mm
Back 27mm 30mm
11) Spacer 2.5-6.00 mm 12) Tube length 180mm
13) Ring dia. 40mm
14) Spindle drive By four tape 15) Pressure (bar)
2.0-2.3 16) Breaking pressure 1.8 bar 17)
Display 4 digit LED 18) Air usage 2.0 Nm3/hr 19)
Without doffer 1.0 Nm3/hr 20) Front cot hardness
65deg. 21) Middle cothardness 80 deg 22)
Back cot hardness 83 deg 23) Creadle roll dia.
30mm, 25mm
24) Ring type CR ring
AUTOCONER
Objective:
1- To producea package with long continuous length of yarn.
2- To producecone or cheese of specific length.
3- To remove weak places, slubs, etc i.e. the yarn should be free from all
types of imperfections.
Precautions to be taken during winding:
1- Quality of splicing should be such that it does not spoil the appearance
and at the same time the strength loss in spliced yarn should be
minimized.

2- Important yarn properties like yarn strength, elongation at break,
appearance should not be deteriorated.
3- Package should not contain winding faults i.e. hairiness and the no. of
naps shold not increase during winding.
Machine details:
1) Make SCHLAFHORST
2) Model Auto coner 338
3) No. of machine 5
4) No. of head/machine 60
5) Winding speed 900-1500m/min
6) Time for splicing 8-9 sec.
7) Time for doffing 50-60 sec.
8) Time to replace the bobbin 8sec.
9) Cone weight 1.89 kg.
YARN CONDITIONER
Objective:
• To improve yarn quality i.e. hairiness is reduced.
• Strength of yarn is increased.
• Weight of package is increased.
Check point: Cones are checked by using ULTRA VOILET RAY. If in a
trolley a different count yarn cone is remained it will be determined.
Because in UV ray different count yarn give different brightness. Temp.-60
Time-1hr
Number of packages-372

PACKAGING
Cones obtained from the conditioning are sent to the packaging section. There are two types of
packaging-
Neutral packaging: LOGO is not there on the cartoon.
Regular packaging: LOGO is there on the cartoon. Cardboard used for making
cartoons is of 5 ply.
Dimensions of cartoon=750 mm*370 mm*510 mm
Proper care is taken for packing the material export purpose. The packed material
obtained is kept in the go down and transport to its destination afterwards.
Following particulars are put on the packing cartoon-
• 100% combed cotton yarn on cones
• Count
• Excise number
• Lot number
• Cartoon number
• Gross weight
• Net weight
• Cartoon size
• In one cartoon box=24 cones
2- MAINTENANCE DEPARTMENT:
Maintenance schedule

TO STUDY THE FIBRE DYEING PROCESS FOR MELANGE YARNInternship report

1.General Cleaning Per Day
2. M/C setting 3 Months
3. Grid bar cleaning 3 Months
CARDING
1. M/C Full Setting 15 Days
2.Cylinder Wire Grinding IGS
3. Doffer Wire Grinding 6 Months
4. Flat Top Emery/ Stone Grinding 6 Months
5. L-in Wire Change 9 Months
6. Stationary Flats
SFL-14 9 Month
SFL-24 9 Months
SFL-34 9 Months
SFL-62 18Months
7. Wires change
Cylinder Wire 4yr

8. Flat Drive Gear Box Greasing 1 yr

1. General Cleaning & Lubrication 20 Days

3. Gearing Box Oil Change 12Months

3.Saddle Gauge & Top Arm Height 180 Days

4. Gear Box Oil Change 6 Months
5.spindle true 16 Months
6. Bottom Apron Change 2 Year
7. Top Apron Change 2 Year
8. False Twister Change 24 Months
RING FRAME
2. Cots Buffing 60 Days
3. Ring Traveller Clearer Setting 90 Days
4.Drum Pulley Bearing Greasing 6 Months
5. Jokey pulley greasing 1 Year
6. Top apron change 2 year
7. Bottom Apron Change 18 month
8. Spindle Oil Change 12 Months
9. Spindle Centering 18 Months
10. Ring gauge 2 Year

3- ENGINEERING DEPARTMENT
The Engineering Department provides technical, engineering surveying and hands on support
on capital improvement projects. Engineering department understands the importance of
production and delivery output, use queuing theory to design on-time package delivery
systems, and devise simulations or supply chain tools for their system integration tasks.
• To manage the breakdown of the machine.
• To install new machine.
• To suggest new ideas for reducing break down & increase efficiency of the machine.
4- HR DEPARTMENT:-
The man is ultimate resources of the organization because they think, speak,so that utilization
of this resource is very critical. Every success of origination is depending on efficient and
effective man power. HR starts when a man enters in the organization and its end, when he
leaves the organization. HR deals with the human
dimension. It is an active participant in charting the strategic course an organization must take
place to remain competitive, productive and efficient. Its focal point is people, people are the
life blood of the organization. The HR department function is much more integrated and
strategically involved. HR department and every other function must work together to achieve
the level of organization. Effectiveness required competing locally and internationally.
• To recruitment of various employers.
• To decides salary & wages.
• Placements.
•
• Industrial relation.
• Activity of employer.
• Personal Record
• Training & Development
5- ACCOUNT DEPARTMENT:-
Accounts Departments is directly under the supervision of the top management. However,
they closely work with purchase,commercial and personnel department. Information related
to this department is highly sensitive and therefore all the information regarding this
department is not disclosed with others.
● To collect information regarding the employees salary and wages like hours of work from the
Personnel Department and prepare the salary sheet, pay slip etc.

● Ensure payment of the workers wages by the stipulated time period as applicable by the law with
the instructions and approval from the top management.
● Keep Accounts Departments of all the financial transactions of the company in a clearly eligible
and legal format as prescribed by the law.
● Prepare and maintain all the financial statements of the company.
6- QUALITY CONTROL, R&D DEPARTMENT:-
Research & development department is an important department for any textile and garments
industry. This plays a direct role on developing a product. Every order firstly comes into R&D
department via marketing peoples by mail or swatch. In the textile quality control is practiced right
from the initial stage of sourcing raw materials to the stage of final finished garment. For textile
industry product quality is calculated in terms of quality and standard of fibres, yarns, fabric
construction, colour fastness,surface designs and the final finished garment products. However
quality expectations for export are related to the type of customer segments and the retail outlets.
● To finding best production process with quality.
● Try to fulfill any buyer requirement according to buyer comment. ● To minimize time and
cost with productivity ● Increase productivity.
● Increase profitability.
The quality control department consists of followings machines.
They are-
NAME OF
INSTRUMENT
OBJECTIVE PARAMETER
TESTED
Wrap reel To determine yarn count Lea wt.and

USTER eveness tester To check the delivery material of simplex, card,
draw frame,R/F.
U% & CV%,
foreign matter, neps,
thick and thin places,
trash particales ,
diameter, shape of
yarn
USTER
classimate
quantum
To check imperfections Slubs, thick and thin
places
Twist tester To determine twist and twist multiplier in yarn
Tpi and Tpm
USTER HVI
Spectrum
To test
strength,elongation,fineness,colou

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