Fabric Science II

Assignment -3.1

Report on Factory Visit

(Ruby Mills Ltd.)

By-
Shrishti Agarwal
 The Ruby Mills Ltd., Dhamini Unit

 Manufacture-they manufacture yarn and fabrics of :-

a) Cotton
b) Polyester
c) Viscose fibre
 Sourcing- they source different fibre from different places such as:-
I. Cotton-
a) maharastra
b) Gujrat
c) Karnataka
 Rajasthan
II. Viscose- Birla
III. Polyester-Reliance
 Banking partner-
a) SBI
b) Bank OF Baroda
c) Bank of India
 In cotton they had 100% cotton and blend with polyester and viscose.
 Everyday about 60,000 meter or 10 tone of garment is manufactured.
 There are-
a) 21,000 spindles
b) 744 rotars
c) 144 looms and 96 air jet.
 88% of plain fabric is produced i.e. they use same yarn for warp and
weft.
 They do not sell yarns instead consume it for fabric manufacturing.
 They do not manufacture flax instead they purchase it.
 For cotton they have cotton lines which first remove impurities,
synthetic fibres are directly send for opening while autocoro fibres are
directly send to autocoro machine.
 Process flow chart-Spinning

Raw Material

(Cotton/Synthetic fibres in Bales)

Mixing

(Bale opening)

Blow Room

(Opening and cleaning)

Carding (Sliver)

(Parallelisation of fibre)

Combed Yarn Ring Spun Yarn Open End Yarn

Comber (sliver) Draw Frame 1st Draw Frame 1st

Draw Frame 1st Draw Frame 2nd (uniform Sliver)

Speed Frame (Roving)

Ring Frame (Yarn)

Auto Coner (Cone Yarn)

Auto Coro
(Yarn)

Cheese WDG (Ply Yarn) Warping

TFO
Processing

Raw Materials

 Here raw materials are source from different parts of India.

 They come in compressed form known as bales.

Mixing

 Decompressing of bales take place.

 Fibres are either open by hand or by feeding it in machine(MBO
machine)
 Fibres are preferably open by hand to make better quality yarn.
 On average workers open 160-180 kg fibre per day.

Blow room

 Here opening and mixing of fibre takes place.

 They had two type of machine for this which are-
I. CVT(SP-FPU TRUTZSCHLER) and
II. Uniclean
I. CVT (SP-FPU TRUTZSCHLER)-
a) It is new machine of Germany.
b) It gives 5-6 mm fibre as output.
II. Uniclean
 This is an old machine
 This machine is further bifurcated into
a) Unimix and
b) ERM

Where ERM has pressure of about 200 m3 per Pascal.

 Barometer was put in the blow room to measure pressure.

 In both case fibre goes through pipe for carding.
Carding
 Here parallelisation of fibres occur i.e. sliver is formed.
 They also remove neps from fibre.
  Carding machines are:-
I. DK780
II. DK800
III. LAKSHMI REITER

Where DK780 is newest while LAKSHMI REITER is oldest.

 All three had 3 rollers:-

a) Doffer roller
b) Cylinder roller(combing and lap formation)
c) Lickering (gives flat sheet of fibre as output).
 Web roller- pull fibre and make it into form of web put into trumpet
where sliver is formed and collected in coiler.

Flat

Doffe Lickering
r

Cylinder

Draw Frame

Breaker machine

 After carding fibre goes to breaker machine (RSB/D30).

 This includes binding and drafting.
 Here parallelisation and doubling of fibre takes place.
 This results longer and thinner sliver.
 Speed of machine is 300 m/min but it may vary.
 Length of fibre is fixed by computer.
Sliver lap machine

 In this 18 end sliver is fed to form lap.

 Further 6 same kind of sliver is fed in machine to form one sliver.
 Short fibre comes out at the back side of the machine.

Finisher and combing

 Finisher and combing are additional process.

 It is done to improve quality of fibre.
 After finisher fibre goes for combing.

They opt different process for different types of fibre for example:-

 For cotton they do

a) Carding
b) Sliver lap
c) Ribbon lap
d) Comber
e) Finisher and
f) Speed frame
 For man-made fibre they do
a) Carding
b) Breaker
c) Finisher
d) Speed frame and
e) Auto Coner

Speed Frame

 It is for ring spun yarn and combed yarn.

 Synthetic fibres are made from speed frame.
 Used for making roving from sliver (speed 900-1200 rpm).
 Lower the speed higher the quality of fibre would be there.
 Count of the cotton that goes into the machine is 1.2 to 1 hands.
 it involves 3 process :-
 a) Drafting
b) False twisting
c) Winding
 In drafting they had 3*3 drafting roller which had bet called shore.
 Drafting roller had adhesive tape to remove short fibres.
 Winding was done by dragging the yarn to a rod which rotates the
bobbin.
 Colour of fibre is divided as
 Blue=polyester + viscose
 Pink=polyester + cotton
 Green = slub
 There were 120 cones in each machine.
 Each cone weighs 2.2 kg

Ring Frame

 Speed of machine is 14500 rpm

 For roving it include
a) Drafting
b) Twisting and
c) Winding
 For count 20 Ne TPI of fibre was 19.38 twists per inch 2 hours.
 For 40 it is 33.36 TPI in 5 hours.
 There were 504 bobbins.
 The beam rollers were of 27mm and 27.5mm.
 There was manual fixation whenever there was a yarn breakage.
 They had suction machine to suck fibres.
 Poly viscose count- 45 Ne.

Auto Coner

 Open end yarn, ring spun yarn and combed yarn go for autoconer.
 Small bobbins are converted into cones.
 While winding the yarn break machine will itself detect it through
sensor and spice it.
  Speed is 1200 rpm.
 6 bobbins are placed in which 1 bobbin finishes in 3 min.

Open End Yarn

 Used for making jeans.

 Rotor which was used had speed of 25000-45000rpm.
 There was no draw frame or speed frame process done to make open
end yarn.
 There was 65% humidity (in room).
 Each cone weighs 2.2 to 2.3 kg.
 Carded cotton of 16 count is used.

PLYING

 The machine name is TFO

 There were 120 small machines
 It converts 2 yarns to 1 ply yarn.
 It make single yarn Z twist
 It also make double yarn S twist
 400 gm cone is used.
 2/45 Ne count yarn is produced

WARPING (DIRECT WARPING)

 It had V type creel

 Yarns from the creel were extended to form sheet of yarn which was
wrapped on beam.
 They do direct warping.
 Had 11000 ends
 The fabric produced from it could be single width/double width.

SIZING

 This process had 14 beams which were simultaneously sized.

 In this process first the beams were put into the solution and then
were dried.
 After drying there were lease rods to separate warp beam.
 Then dried out beams are carried out to place in the loom.
 It had many rollers out of which drying cylinders were placed at a very
higher level.

Drawing

In this process, yarns from wrap beam are put individually to single reed
manually.

Then this reed is put in to the loom.

No. of reeds =no. of warp ends.

WEAVING

 This factory has two type of loom

 Air jet looms
 Rapier loom
 In air jet loom the weft is inserted by means of pressurized air.
 Speed of the machine was 750 rpm
 Efficiency of machine was 74%.
 It has 13.3 fillings.
 Machine can insert 1100 picks per min.
 It have maximum insert up to 1250 picks per min.

Personal experience

 It was well organised.

 After that the process of spinning and weaving was cleared.
 Workers of that factory were facing several problem such as :-
a) Suffocation
b) Noise of machines
c) Small fibres causes several lung disease
 They were checking each machine from time to time and were
fixing it if needed.
 Opening of bale were mainly done by women.
 They had colour coding charts which include colour of spindle as
well as of yarns.