PROCESS CONTROL IN

SPINNING

Prof. R. Chattopadhyay

IIT, Delhi

QUALITY ASSURANCE IN SPINNING

STEPS

� Setting of Norms

� Quality of incoming raw material to the Khadi

Institution

� Process Monitoring and Control

� Inspection of final product

MATERIAL FLOW

Transportation of Sliver / roving

Internal transportation

CENTRAL SLIVER

PLANT

Raw cotton

Khadi Institution 1

Khadi Institution2

Khadi Institution3

Distributed spinning in villages

Institutional spinning

Transportation of sliver or roving

Village 1 Village 2 Village 3 Village n

Charkha

1 2 3 4 10

PROCESS Input Output

Monitor

Compare

against norm

Corrective

action Monitor

Process parameters

/Intermediate product

characteristics/Machine

conditions/Work practice /

process waste

Compare

against norm

Corrective

action

Monitor

Compare against

norm

PROCESS CONTROL

QUALITY OF INCOMING RAW

MATERIAL TO CENTRAL SLIVER PLANT

� Test of raw cotton in terms of physical parameters

and accept if comparable with norms

� Careful transportation & storage of cotton bales

� Check sliver or roving parameters i. e

Count and count CV%

Trash % & Neps

�Checks on material handling during packaging and

loading on trucks

- Transfer sliver into polythene bags

- Put roving bobbins into polythene bags

- Transport sliver cans, polythene bags

containing sliver or roving on to the trucks.

- Properly cover sliver cans, polythene bags

containing sliver or roving on trucks

QUALITY OF RAW MATERIAL RECEIVED BY

KHADI INSTITUTION

�Checks on material handling during Unloading from

trucks

- Careful unloading of packages

- Careful internal transportation to avoid damage

- Proper storage and segregation of sliver/ roving

to avoid accidental mixing

�Checks on delivered sliver / roving

- Weighing of packages

- Cross checking of average count

DISTRIBUTUON OF ROVING OR

SLIVER TO THE SPINNERS

- Ensure that the sliver or roving corresponds to

the count to be spun.

– - The package is covered in polyethylene sheet.

In - Instruction about careful handling of package

during way back to village.

CHARKHA SPINNING GUIDELINES

a) Work practice related I. Running of Charkha

- Run at a slow speed in the beginning and then

raise speed and maintain speed at a convenient

level.

- Cover the charkha once spinning is over.

- The broken end should be pieced (joined)

properly. A knot is to be avoided as it becomes

too large with respect to the yarn diameter,

which deteriorates fabric appearance

II. Lea Making

-All the sections of the lea should be made from

same yarn count.

-The end of the yarn should be inserted in to the

inner portion of the lea.

-Leas should be properly stored in plastic bags or

fabric bags with count wise segregation by colour

mark.

-If possible, lea bundles should be segregated

while storing according to the type of fibres used

or count to avoid accidental mixing.

b) Maintenance related

-Follow a specified maintenance schedule in terms

of cleaning and oiling.

-Top roller pressure should be checked at regular

intervals.

-Check the condition of the aprons and driving

belts (mall) and adjust if necessary.

b) Parameters selection

- Select parameters based on past experience that

suits the raw material.

QUALITY ATTRIBUTES TO BE

CONTROLLED IN KHADI YARN

�Average Count and It’s CV%

�Lea CSP

�Yarn Unevenness

�Imperfections

�Soft and hard twisted portion

�Faults

�Pote

�Kachara

�Moore

�Daghi

�Bakar

�Slubs

�Possible reasons for deterioration in quality

�Characteristics and occurrence of faults

PROCESS CONTROL OF CHARKHA

SPUN YARN

�Detection of significant shift in quality level

�Investigation on the causes of departure

�Taking remedial action immediately to set the process

back to normal

Monitoring stages and Characteristics to be monitored

YARN STAGE

-Average count and count variability

-Uniformity

-Imperfections

-Count Strength Product (CSP)

INTERMEDIATE STAGES

Sliver

-Sliver count and its variability

-Sliver uniformity

-Sliver cleanliness

Roving

-Roving count and its variability

-Roving uniformity

-Roving cleanliness

Process Performance

-Waste level

-End breaks in charkha

- Productivity

Detection of shift in yarn count:

Example:

Nominal Count = 20 Nm

Average weight of lea = 50 gm

Count CV % = 10

S.D. of count = 5gm

Warning limit = Mean ±±±± 2 ×××× S.D. = 50 ±±±± 10

= 60 gm and 40 gm

Action limit = Mean ±±±± 32 ×××× S.D. = 50 ±±±± 15

= 65gm and 35gm

Lea weight

( gm)

Operator ID

Lower Warning Limit (LWL)

Upper Action Limit (UAL)

Upper Warning Limit (UWL)

Lower Action Limit (LAL)

50 g

40 g

35 g

60 g

65 g

Shift

Lea weight

( gm)

Operator ID

Lower Warning Limit (LWL)

Upper Action Limit (UAL)

Upper Warning Limit (UWL)

Lower Action Limit (LAL)

50 g

40 g

35 g

60 g

65 g

Lea weight

( gm)

Operator ID

Lower Warning Limit (LWL)

Upper Action Limit (UAL)

Upper Warning Limit (UWL)

Lower Action Limit (LAL)

50 g

40 g

35 g

60 g

65 g

WHAT ACTION IS TO BE TAKEN

�For case I

-Wrong Draft Change Pinion ( DCP)

-Inadvertent change in draft constant

-Wrong count of sliver or roving

�For case II

-Count of sliver / roving supplied is to be verified

-Too coarse and too fine sliver / roving are to be

withdrawn

-Draft on charkhas are to be adjusted

Control of Count Variability

Opera

tor

No.

Count Values of Lea No.

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

Calculation of within and between count CV

REASONS FOR HIGH BETWEEN OPERATOR COUNT

VARIABILITY (CVBO)

�Difference in average hank of sliver/ roving used.

�Difference in the total drafts in the charkhas

�Difference in effective drafts between spindles of charkhas

due to cot slippage.

�Roving stretch

REASONS FOR DIFFERENCE IN AVERAGE SLIVER HANK

Difference in waste level and mechanical draft in card breaker

or finisher draw frame.

DIFFERENCE IN AVERAGE ROVING HANK

�Difference in sliver hank.

�Draft difference in speed frames.

�Differences in waste level in card.

DIFFERENCE IN AVERAGE DRAFT IN CHARKHAS

� Wrong draft constant in charkha or wrong change

pinions

� Difference in effective draft within a charkha

-Slippage of top rollers, inadequate roller pressure.

ROVING STRETCHING

� Inadequate roving twist, low inter fibre cohesion

(specially when fibres are short),defective bobbin

holder

YARN UNIFORMITY / UNEVENNESS

1. A routine check on all the samples received may not

be practicable.

2. Only when yarn samples for any new lot arrives , the

test can be carried out by randomly selecting 30 leas

from as many operators as possible.

REASONS FOR UNEVEN YARN

�Incorrect setting of break draft on D/F, S/F or charkha.

� Inadequate top roller pressure.

� Wear/damaged apron or cots.

� Eccentric top roller y in charkha.

� High short fiber percentage in sliver or roving.

� Too wide setting in the front zone of charkha.

� Slipping apron.

YARN APPEARANCE

� Subjective assessment based on visual check of yarn

boards on yarns received from operators when fresh

yarn lots are received from them for a new mixing .

� Maintain a record according to operator ID

REASON FOR POOR APPEARANCE

� High yarn unevenness

� Many excessively severe thick, thin places and neps

in the yarn

� Presence of too many impurities like seed coat,

leaves, stalks etc in the yarn

CORRECTIVE ACTIONS TO BE TAKEN

�Check the overall condition of the charkha and roller

setting

�Replacement of defective drafting rollers or aprons

�Cleaning of accumulation of stray fibres on drafting

elements, ring, travelers, gears etc should be avoided.

�Roller slippage because of low pressure or presence of

oil on roller surface is to be avoided.

� Neps in sliver to be maintained as per the norms

� Cleanliness of the sliver

Yarn Count Strength Product (CSP)

Operator ID

LWL

UAL

UWL

LAL

1000

640

760 gm

1240

1360

Lea weight (g)

Average CSP = 1000 for count 24 – 36 Nm CSP CV% = 12, CSP S.D. = 120 UAL = 1000 + 3××××120 = 1360 UWL= 1000 + 2 ××××120 = 1240 LAL = 1000 - 3×××× 120 = 640 LWL= 1000- 2 ××××120 = 760

Action to be taken

Case I: Points fall below the lower Action Limit or

continues to fall in between Warning and Action Limit

for many operators.

Case II: Points are distributed with a wide scatter.

Case I: A repeat check on the yarn supplied by the

operator whose estimated CSP value fall below the

action limit is to be performed. At least 6 leas are to be

tested and the average is to be found out. If the average

is found to be still lower, then remedial measures should

be taken.

POSSIBLE REASONS FOR LOW AVERAGE CSP -Inadequate twist in the yarn.

-Finer yarn count.

-Weak fibres in mixing.

Twist and count testing of the same are to be

performed to find out whether the twist is really low

or the count is fine. The lower twist could be

attributed to:

Lower spindle speed due to slippage, which can

be due to

Loose driving cord of spindles.

Accumulation of oil/grease on cord

driving the spindles (mall).

Reasons for finer yarn

-Higher total draft.

-The finer sliver/roving supplied.

If count and twist are as per nominal value but

CSP is still found to be less, inadvertently a sliver/ roving

may have been supplied from a mixing in which the

fibres are intrinsically weak.

Reasons for high strength variation

– Intermittent slippage of top roller in the charkhas.

– Variability in between yarn count produced on

different charkhas.