PABNA TEXTILE

ENGINEERING COLLEGE

DEPARTMENT
OF YARN
MANUFACTURIN
G
PRESENTATION ON

Effect of waste reduction on

production cost and waste extraction
system of different m/c on different
section
Textile engineering is the oldest branch of Science.
Many Scientist played a vital role for its
development. But today textile engineering is the
most modern, sophisticated and a prestigious
INTRODUCTION
degree in the world. It is a practical oriented
subject. That is why the textile engineers must
have sound practical knowledge. Besides this , a
textile engineer must have knowledge on
Electrical, power , mechanical & maintenance also.
An engineer must look after the quality production
and he has know man handling. It is beyond saying
that textile industry is the backbone of Bangladesh
 DISCUSSION

If a given mixing is not handled properly, some of the fibers may be damaged during its passage through various machines. As
a result the waste percentage would increase and the quality of yarn would deteriorate. Moreover, the yarn manufactured
under such conditions would result in reduced profit margin due to increased costs.

Conversion of lap into yarn is a question of reducing weight per unit length of the input material, and, at the same time,
maintaining product uniformity. The uniformity is achieved by appropriate rate of draft; higher drafts above certain optimum
limits produce irregularity with the advent of high drafting, much more attention has to be paid to accurate setting for
maintaining quality. In practice, the reduction in weight per unit length is carried out in stages; each drafting operation
introduces fresh irregularity; the irregularity of final yarn being the summation of irregularities produced at each operation.

Fiber breakage is a very important factor, because any increase in breakage can lead to additional fly waste and greater
number of ends down. Fiber breakage is a function of two main factors; the ratch setting (the distance between consecutive
roll pairs in a roller drawing system) and the roving twist. To avoid breakages, it is necessary to set the ratch longer than the
longest fiber, because a shorter ratch will break all fibers greater in length.

For a given ratch the extent of machine control over the fiber depend on the length distribution; a wider distribution and a
longer ratch lead to lesser fiber control. The strain and distortion imposed on fiber ends during drafting due to the initial pull,
continually repeated at each operation also lead to an increase in breakages. It is to be expected, therefore, that fiber will be
beheaded as a result of this stress and fatigue, the effect being more pronounced in case of longer fibers.

Blending of different varieties of cotton is usually the responsibility of the spinner. With natural fibers, like cotton
maintenance of a completely uniform blend can be very difficult.

A spinner’s first concern is to control staple length and fiber fineness so as to maintain consistent conditions and standard
yarn properties. His second concern is with yarn’s appearance. Generally speaking a spinner has to sure, that if yarns
out of different dispatches (lots) from the factory are
compared, the weaver/ user should not be able to see
any difference between different lots).
For achieving uniform blend, good quality, higher
production, sandwich/ Stack mixing, block creeling
and cross creeling / color coding at each operation is
must.
Yarn breakages and their gradual increases with higher
spindle speed poses another bit problem. Frequent
yarn breakages result in higher waste percentage and
the quality of yarn is also impaired due to thick places
emerging from piecing of yarn; moreover, extra labor
 TERMS , DEFINATION & OBJECT

Wastage:
When any industry starts its production from
raw material then some kinds of unusable things have
been produced. These unusable things are produced
from different m/c. The unusable things are called
wastage. The quality of the product is depended on the
waste percentage. If quality is high then the wastage
percentage is high. But production cost is also be high
and production rate would be low. So wastage should
be controlled as perfectly in different m/c. In a
spinning mill the raw material is cotton. So unusable
things in cotton are short fibre , seed coat, foreign
material, neps, color material, metal etc. We should
 Relative Waste rate
Setting «1» (Low): Setting «10» (High):
Grid closed, lowest waste rate Grid open, highest waste rate
dark waste composition light-colored waste composition
NRE:
NRE means neps removal efficiency. NRE is
depended on the relative waste rate on Blowroom.
When the removal of neps is expressed as percentage
with respect to feed neps then it is called NRE. If
relative wastage is increase NRE is increase. So NRE
is one of the wastage extraction system in carding m/c.

NGP:
NGP means neps generation percentage. NGP is
depended on the relative waste rate on Blowroom.
 PROCESSING VARIABLES

Yarn waste

The yarn waste in a spinning mill should not normally exceed 0.1% with conventional cone winding. In the
case of automatic cone winding, the yarn waste generally varies from 05% in winders fitted with round
magazine feed to 0.8% in winders with auto bobbin feed system. However, if the yarn under goes additional
processes such as reeling, doubler winding and TFO twisting/ring twisting, the waste would be somewhat
higher. A high incidence of yarn waste, apart from leading to a loss of Rs.6 to Rs.15 per spindle per year for
every 0.1% waste (savings increase with decrease in count), is an indication of poor machinery condition and
maintenance, and inappropriate work practices of operatives. A number of factors such as vibrating spindles,
spindle out of center, soft cops, oil stain on yarn, improperly built cop bottom, yarn left over in cops during
winding and operatives using excess length while piecing, leads to high yarn waste. For further information
on yarn waste control reference may be made to SITRA publication “Measures to Control Hard Waste in
Spinning” Vol. 41, No.11 March 1996.

Sweep waste

The sweep waste in all departments of a spinning mill together should be within 1%. A high sweep waste
arises invariably due to operatives throwing away the wastes like bonda waste, lap bits, sliver bits, roving
ends etc. on the floor and generation of fly and fluff. The fly frame and ring frame tenters should be provided
with hip bags and it should be ensured that the bonda waste and roving ends are deposited in the bags during
piecing. Good waste, if any, should be picked before sweeping instead of sorting out the waste later. A high
price fetched for sweep waste would give an indication of the presence of good fibers in the waste.
Invisible loss
Invisible loss in a spinning mill occurs due to a
number of factors such as short fibers (fluff) escaping
from the departments, improper accounting of wastes
produced, weighment errors in cotton purchased and
wastes sold, excess give away of yarn and inaccuracies
in the estimates of stock held in process. Since it would
be difficult to accurately assess the process stock, it is
suggested that the invisible loss be assessed only once
in 4 months for control purposes. This will help in
minimizing the variation in invisible loss due to errors
in process stock estimate. From the data compiled
every month, a cumulative average could also be taken
 WASTE PRODUCE IN DIFFERENT
SECTION

Waste produced in different production

processes:

Blow Room (4-5%) : Dropping 1,

Dropping 2
Fine dust
Carding (5-6%) : Flat strip, Taker in

Drawing (0.5%) : Filter waste, Sliver waste

 BLOWROOM AND CARD WASTE
MEASUREMENT
From the all report we get the various setting points of
B/R and Carding m/c:
B/R setting of Ring line:
Uniclean→ 1.Cleaning Intensity
2.Relative Waste rate
Uniflex → 1.Cleaning Intensity
2.Relative Waste rate
B/R setting of Rotor line:
Uniclean→ 1.Cleaning Intensity
2.Relative Waste rate
Click to edit Master text styles
Second level
● Third level

● Fourth level

● Fifth level
We get following setting statistics from the
report no.1

For keeping the setting point of Uniclean and Uniflex

at
Cleaning Intensity= 0.2
Relative Waste rate= 8
Mainly two types of waste found in B/R
1.Dropping
2.Flat strip
We get following setting statistics from the
report no.2

For keeping the setting point of Uniclean and Uniflex

at
Cleaning Intensity= 0.2
Relative Waste rate= 9

Dropping found from Ring and Rotor.

From the report one, we can get total neat production
We get following setting statistics from the
report no.3

For keeping the setting point of Uniclean and Uniflex

at
Cleaning Intensity= 0.2
Relative Waste rate= 10

Dropping found from Ring and Rotor.

From the report one, we can get total neat production
 ANALYSE THE USTER TESTER REPORT

For the report no.1 we get the following Uster

statistics:
Mean of U% = 12.04
Mean of CVm = 15.39
Mean of Thin(-50%) =5.8
Mean of Thick(+50%)=262.8
Mean of Neps(+200%)=390.3
So Imperfection Index(I.P.I)=(Thin+Thick+Neps)
=5.8+262.8+390.3
= 659
For the report no.3 we get the following Uster
statistics:
Mean of U% = 11.54
Mean of CVm = 14.72
Mean of Thin(-50%) =3.5
Mean of Thick(+50%)=181.8
Mean of Neps(+200%)=257.3
So Imperfection Index(I.P.I)=(Thin+Thick+Neps)
=3.5+181.8+257.3
= 443
 conclusion

In this research we investigate the waste extraction system and effect of waste
reduction on production cost. The production of the high quality yarn free
from faults and its production in bulk quantities are the major considerations
in spinning. Yarn breakages and their gradual increase with spindle speed
causes a problem.
A spinner’s first concern is to control staple length and fiber fineness so as to
maintain consistent conditions and standard yarn properties. His second
concern is with yarn’s appearance. Generally speaking a spinner has to sure,
that if yarns out of different dispatches (lots) from the factory are compared,
the weaver/ user should not be able to see any difference between different
lots).