Introduction

These programs "TEXTILE TECHNOLOGY AND SPECTROGRAM ANALYSES BY ITRU GROUP LTD have been developed by ITRU GROUP LTD -International Textile Consulting & Management through extensive research work carried out in many spinning mills and mill experience in carding,combing and rotor spinning. These PC-PROGRAMS could be used on all IBM compatible PCs to improve mill performance level to the international standards.

The number of mills which utilize these PC-PROGRAMS are growing each year since they bring tremendous advantages to the spinning mills. It is clear that all the spinning mills will eventually have to install these PC-PROGRAMS in their mills if they wish to be competitive in the market.

Objectives of the PC-programs

The PC-PROGRAMS include following main points:

Technical Data/Machine Settings

All the technical calculations related to quality/ production process/quality control procedures.

Optimum machine settings

Machine Card Index based upon the date and lot #

Process Summary based upon the date and lot#

DATA BANK for analyzing different lots and further reuse.

All technical know how related to machine data/machine setting and mill control systems

Mechanical fault analyses of each item in the machinery

Wavelength and r.p.m. of each item of the machinery according to technical data/machine settings

Gearing and machine setting diagrams for each machine and their importance in quality and production levels

All technical calculations in tables form.

These programs have been designed from blowroom to spinning machinery. With the help of these programs it is possible to improve your quality and increase your production as well as improving your mill performance level each passing day.

The Importance of Technical Data/Machine Settings

It is very well known that mills having the same machinery lay-out and producing identical yarn counts could have very different profit values. As the technology improves the differences in the production costs between developed and developing countries get less and less each day. Now,CIM systems have been widely used in United States,Europe and Japan. However,CIM systems are only effective if they are supported by. The future of spinning mills would be dependent upon the CIM AND THE KNOWLEDGE BASED PC-PROGRAMS which analyze the data produced by CIM.

In order to achieve higher profit ratio per operating hour following points should be considered.

Raw material price per kg >>TYPE OF RAW MATERIAL

Percentage of total waste >>TYPE OF RAW MATERIAL/MACHINE SETTINGS

Efficiency >>TYPE OF RAW MATERIAL/MACHINE SETTINGS

Production levels >>TYPE OF RAW MATERIAL/MACHINE SETTINGS

Direct labor >>EFFICIENCYTRAINING

Indirect labor >>MILL ORGANIZATIONTRAINING

MAXIMUM PROFIT >>Optimum yarn quality with minimum costs

THEREFORE THE SOLUTION IS NOT THE BEST QUALITY OF YARN BUT OPTIMUM QUALITY WITH MINIMUM COSTS WITH ZERO DEFECTS. In order to achieve these aims

• Proper selection of raw material [FIBRE MIX-SELECTION-BALE MANAGEMENT ]

• OPTIMUM TECHNICAL DATA/MACHINE SETTINGS [T-TECHNOLOGY-SPECTROGRAM]

• ZERO DEFECTS [ELIMINATION OF MECHANICAL FAULTS] >>spectrogram analyses

• MINIMUM DRAFTING WAVES >>DRAFT ZONE SETTING

• [MINIMUM FIBRE DAMAGE AT PROCESSING]>>DRAFT ZONE SETTING

• [MAINTENENCE+CHECK LISTS]

One could clearly see that how important the PC-PROGRAMS in spinning mills and how the technical data/machine settings influence the manufacturing costs.

The effect of Spectrogram curve on yarn quality

The spectrogram curve at each stage of processing is closely related to the

Number of fibres in x-section

Fibre length distribution and its coefficient of variation

Type of yarn manufacturing process(carded,combed and open-end)

The CV% irregularity of sliver or yarn is related to above factors and mechanical faults in the machinery. Mechanical faults in all processing stages would cause thick and thin places. And it is not always possible to eliminate them by doubling. One could check this by taking four subsequent tests of spectrogram and would get different shapes if there were faults in the previous stages. Therefore,mechanical defects should be eliminated.

Mechanical defects in the machinery could cause

• Higher irregularity

• More faults in the yarn as seldom occurring and frequently occurring

• Higher strength variation and higher end-break rate in weaving and spinning therefore more waste in spinning and more operative work load.

Since these programs identify the mechanical defects these problems are eliminated.

Savings As a Result of Installation of These PC-Programs

The savings could be summarized as follows:

a)Standardization of technical data machine settings for each type of lot

b)Establishing of a standard process organization according to each lot

c)Elimination of mechanical defects and achieving better quality and less down time .

d)Identifying of standard running machines and styles with respect to quality,production and waste.

e)Determination of the important parameters which influence the quality and production and taking more accurate measures.

For Further information

ITRU GROUP LTD -International Textile Research Unit

Serving to textile industry ,science and technology since 1992