Spinning Calculation

CHAPTER #01
BASIC CONVERSIONS
&
YARN COUNT
Kashif,Nadeem,Atif 1
DERIVATION
CHAPTER#02
RAW MATERIAL CALCULATIONS
mportance Of RawMaterial In Yarn Manufacturing:
Raw material represents about 50 to 70% of the production cost of a short-staple yarn.
This fact is sufficient to indicate the significance of the rawmaterial for the yarn
producer. It is not possible to use a problem-free raw material always, because cotton is a
natural fiber and there are many properties which will affect the performance. If all the
properties have to be good for the cotton, the rawmaterial would be too expensive. To
produce a good yarn with this difficulty, an intimate knowledge of the raw material and
its behavior in processing is a must.
Basic Fibre Characteristics:
A textile fibre is a peculiar object. It has not truly fixed length, width, thickness, shape
and cross-section. Growth of natural fibres or production factors of manmade fibers are
responsible for this situation. An individual fiber, if examined carefully, will be seen to
vary in cross-sectional area along it length. This may be the result of variations in growth
rate, caused by dietary, metabolic, nutrient-supply, seasonal, weather, or other factors
influencing the rate of cell development in natural fibers. Surface characteristics also play
some part in increasing the variablity of fibre shape.
Following are the basic characteristics of cotton fibre which are given below:
Fiber Length
Moisture
Fiber Strength
Micronair Value
Fiber Elongation
Trash
Maturity
Short Fiber Content (SFC)
Spinning Consistency Index (SCI)
Short Fiber Index (SFI)
Elongation
Fineness
1. Fiber Length:
The "length" of cotton fibers is a property of commercial value as the price is generally
based on this character. To some extent it is true, as other factors being equal, longer
cottons give better spinning performance than shorter ones. But the length of cotton is an
indefinite quantity, as the fibers, even in a small random bunch of cotton, vary
enormously in length. Following are the various measures of length in use in different
countries:
i. Mean length
ii. Upper quartile Length
iii. Effective length
iv. Modal length
v. 2.5% span length
vi. 50% span length
Mean length:
It is the estimated quantity which theoretically signifies the arithmetic mean of the
length of all the fibers present in a small but representative sample of the cotton. This
quantity can be an average according to either number or weight.
Upper quartile length:
It is that value of length for which 75% of all the observed values are lower, and 25%
higher.
Effective length:
It is difficult to give a clear scientific definition. It may be defined as the upper quartile of
a numerical length distribution
eliminated by an arbitrary construction. The fibers eliminated are shorter than half the
effective length.
Modal length:
It is the most frequently occurring length of the fibers in the sample and it is related to
mean and median for skew distributions, as exhibited by fiber length, in the following
way.
(Mode-Mean) = 3(Median-Mean)
Where,
Median is the particular value of length above and below which exactly 50% of the
fibbers lie.
2.5% Span length:
It is defined as the distance spanned by 2.5% of fibers in the specimen being tested when
the fibers are parallelized and randomly distributed and where the initial starting point of
the scanning in the test is considered 100%. This length is measured using "DIGITAL
FIBROGRAPH".
50% Span length:
It is defined as the distance spanned by 50% of fibers in the specimen being tested when
the fibers are parallelized and randomly distributed and where the initial starting point of
the scanning in the test is considered 100%. This length is measured using "DIGITAL
FIBROGRAPH".
Fibre Length Variation:
Even though, the long and short fibers both contribute towards the length irregularity of
cotton, the short fibers are particularly responsible for increasing the waste losses, and
cause unevenness and reduction in strength in the yarn spun. The relative proportions of
short fibers are usually different in cottons having different mean lengths; they may even
differ in two cottons having nearly the same mean fiber length, rendering one cotton
more irregular than the other. It is therefore important that in addition to the fiber length
of cotton, the degree of irregularity of its length should also be known. Variability is
denoted by any one of the following attributes
Co-efficient of variation of length (by weight or number)

Irregularity percentage
Dispersion percentage and percentage of short fibers
Uniformity ratio
Uniformity ratio:
Uniformity ratio is defined as the ratio of 50% span length to 2.5% span length
expressed as a percentage. Several instruments and methods are available for
determination of length.
Following are some
Shirley comb sorter

Baer sorter
A.N. Stapling apparatus
Fibrograph
Uniformity Ratio (U.R) = (50% Span Length) x 100

2.5% Span Length
Uniformity Index (U.I) = (_____Mean Length __) x 100

Upper Half Mean Length
Short Fibres:
The negative effects of the presence of a high proportion of short fibers are well known.
A high percentage of short fibers is usually associated with,
- Increased yarn irregularity and ends down which reduce quality and increase processing
costs.
- Increased number of neps and slubs which is detrimental to the yarn appearance.
- Higher fly liberation and machine contamination in spinning, weaving and knitting
operations.
- Higher wastage in combing and other operations.
While the detrimental effects of short fibers have been well established, there is still
considerable debate on what constitutes a 'short fiber'. In the simplest way, short fibers
are defined as those fibers which are less than 12 mm long. Initially, an estimate of the
short fibers was made from the staple diagram obtained in the Baer Sorter method
Fibrograph:
Fibrograph measurements provide a relatively fast method for determining the length
uniformity of the fibers in a sample of cotton in a reproducible manner.
Results of fibrograph length test do not necessarily agree with those obtained by other
methods for measuring lengths of cotton fibers because of the effect of fiber crimp and
other factors.
Fibrograph tests are more objective than commercial staple length classifications and also
provide additional information on fiber length uniformity of cotton fibers. The cotton
quality information provided by these results is used in research studies and quality
surveys, in checking commercial staple length classifications, in assembling bales of
cotton into uniform lots, and for other purposes.
Fibrograph measurements are based on the assumptions that a fiber is caught on the comb
in proportion to its length as compared to total length of all fibers in the sample and that
the point of catch for a fiber is at random along its length
Staple Length mm Spinning Count
classification
Short Less than 24 Coarse Below 20
Medium 24- 28 Medium Count 20s-34s
Long 28 -34 Fine Count 34s - 60s
Extra Long 34- 40 Superfine Count 80s - 140s
Notes:
Spinning Count does not depend on staple length only. It also depends on fineness
and processing machinery.
Length is measured by hand stapling or Fibrograph for 2.5% Span Length
2.5%SL (Spun Length) means at least 2.5% of total fibers have length exceeding this
value.
50% SL means at least 50% of total fibers have length exceeding this value.
2. Moisture:
Cotton and yarn having moisture absorption property. Under average humidity
condition cotton takes up about 6-8% of moisture. Cotton has moisture regain 7-8.5%
under 65%R.H and 21C Temperature.
The Formula for moisture Regain is given below
Moisture Regain= (Total Weight-dry weight) x100

Dry Weight
The Formula for Moisture Content is given below
Moisture Content= (Total weight-Dry weight) x100

Total Weight
Relation Between Moisture Regain (R) and Moisture Content(C):
R= ___C ___
1- C_ (I)
100
And
C= ___R ___
1- R_
100 . (II)
Example:
Find the Moisture Regain of Cotton which has Moisture Content is 10%.
Required:
Moisture Regain =???
Given Data:
Moisture Content=10%
Solution:
We know that
R= ___C ___ . (I)

1- C_
100
By putting the values in equation (I),then we have
R= ___10 ___
1- 10_
100
R= ___10 ___
1- 1
10
R= ___100___
10- 1
R= ___100___
9
R= 11.11% Ans.
Example 02:
Find the Moisture Content of Cotton which has Moisture Regain is 9%.
Required:
Moisture Content =???
Given Data:
Moisture Regain=9%
Solution:
We know that
C= ___R ___ . (II)

1- R_
100
By putting the values in equation (II), then we have
C= ___9 ___
1- 9_
100
C= ___9 ___
1- 9_
100
C= ___900___
100- 9
C= ___900___
91
C= 9.89% Ans.
MEASUREMENT OF MOISTURE
Absolute Humidity:
Weight of water in a unit volume of moist air. It is usually denoted by gm/m3 or grain/ft3 .
Relative Humidity:
It is the ratio of actual vapor pressure divided by the saturated vapour pressure multiply
by 100.
R.H = 98.6 (dry temp. wet temp.)*100
Dry temp.
Original weight:
This is the wt. Of material in its original condition containing any level of moisture. It is
usually denoted by O.W.
Dry weight:
The weight of material without any moisture. It is denoted by D.
Oven dry weight:
The weight of material dried at oven state. The temperature in the oven is 1050C.
Correct invoice weight:
it is the weight of the material at standard moisture regain. It is given as:
C.C.W = Dry wt. * 8.5%
C.C.W = D * (100+R %) /100
Moisture Regain:
Weight of moisture in a material expressed as %age of oven dry weight.
R = W*100/D
Moisture content:
Weight of moisture based on original weight of sample expressed in % age.
M = W*100/ (D+W)
Relation between Regain & moisture Content:

M = 100 R/ (100+R)
R = 100 M/ (100 M)
RELATION BETWEEN MOISTURE REGAIN &CONTENT

M TO R
M = R
1+R/100
NOW
M =M*R/R
= W *R*100
D+W W *100
D
R*100
1+W*100
D
M = R
1+R/100
R TO M
R = M
1-M/100
NOW
R =R*M/M
= W *M*100
D W *100
D+W
M
D
D+W
M
D
D+W+1-1
M
1-W
D+W
R = M
1-M/100
Q. Oven dry wt. Of 500 grains of lint was found to be 400grains, calculate:
1. Wt. Of moisture
2. CCW of lint
3. R
4. M
Sol.
1. Weight of moisture = 500 400 = 100 grains
2. CCW = D * 1.085
400 *1.085 = 434 grains
3. R = W * 100 /D
100 * 100/ 400 = 25%

4. M = W * 100 /(D+W)
100 * 100/ (500) = 20%
Q. Moisture regain, if cotton was found to be 10.5. what will be the value of content
% age?
Sol.
R = 10.5 %
M = 100 R / (100+R)
100 * 10.5/ (100 + 10.5) = 9.5%
Q. A spinning unit has purchased lint of 20,000kg at 8.5% moisture regain.

Calculate the reduction in wt. If the moisture regain is found to be 10.2%.
Sol.
Dry wt. = 20,000 * 10.2/100
= 17960kg
CCW = D * 1.085
= 17960 * 1.085
= 19486.60kg
Reduction in wt. = 20,000-19486.60
= 513.40kg
Q. A consignment of 400kg of lint cotton was dispatched to a station where oven dry
wt. Of 1000gm sample was found to be 850gm. Calculate CCW for which the
supplier is to be paid by the consigny. Also calculate the value of R and M and
excessive moisture regain %age.
Sol.
1000gm = 1kg
850gm = .85kg
Dry wt. Of consignment = dry wt of sample * total wt of consignment/original wt of
sample
= .85 * 400 /1 = 340kg
CCW. = D * 1.085
= 340 * 1.085 = 368.9kg
Wt of moisture = W = 400 340 = 60kg
R = W*100/D
= 60*100/340 = 17.65%
M = W*100/ (W+D)
= 60 * 100/ (400) = 15%
E.M = moisture regain std. regain
= 17.65 8.5 = 9.15%
Q. A representative sample of 9.5 oz. Drawn from a consignment of 1200 lbs of lint
cotton gave the oven dry wt of 8.5 oz. Determine the CCW of consignment and the
amount of money to be paid by the purchaser if the price per lbs is 45Rs.
Sol.
9.5oz = 0.59375 lbs
8.5oz = 0.53125 lbs
sample
= 0.53125 * 1200 /0.59375 = 1073.69 lbs
CCW. = D * 1.085
= 1073.69 * 1.085 = 1164.95 lbs
Price per lbs = 45Rs
Total price = 1164.95 * 45
= 52422.63 Rs
Q. A representative sample is taken from the consignment of 2 lots with bale wt of
170 kg. Sample wt was 13oz and dry wt was 11oz find out the conditioned wt of
consignment and conditioned price if price per lbs is 60 Rs. Also calculate M.R and
M.C.
Sol.
Total wt of consignment = 2 * 100 *170
= 34000kg
sample
= 11 * 34000 /13 = 28769.2kg
CCW. = D * 1.085
= 28769.2 * 1.085 = 31214.6 kg
Price for original wt = 34000 * 60 2.2046 = 4497384 Rs
Price for conditioned wt. = 31214.6 * 60 * 2.2046 = 4128942 Rs
Saving = 4497384 4128942 = 368442 kg
R = W*100/D
= 2*100/11 = 18%
M = W*100/ (W+D)
= 2 * 100/ (13) = 15%
Q .A sample of cotton yarn is wrapped and the count is 40s. A certain amount of
moisture has been added & count becomes 38s. What %age of moisture has been
added?
Sol:-
Count= No of hanks
lbs
Hence,
40s weight = 1/40 = 0.02slbs

38s weight = 1/38 = 0.263lbs
Moisture wt. = 0.0263-0.025

= 0.00131517lbs
%age of moisture added = 0.00131517

0.025
= 5.26%
Q .A spindle point yarn of 40s contains 5% moisture, hat will be count of yarn when
moisture added becomes 8.5% which is standard moisture?
Sol:-
Weight of yarn= 1/40 = 0.025slbs.

Excess moisture= 8.5-5 = 3.5%
C.CW = 0.025+0.025*8.5/100
= 0.025875lbs
Hence,
Count = 1/0.025875 = 38.65s
3. Fiber Strength:
The different measures available for reporting fibre strength are
Breaking strength
Tensile strength and
Tenacity or intrinsic strength
Its Units are
gram/tex
gram/denier
Newton/tex
Centi Newton/tex
Coarse cottons generally give higher values for fiber strength than finer ones. In order, to
compare strength of two cottons differing in fineness, it is necessary to eliminate the
effect of the difference in cross-sectional area by dividing the observed fiber strength by
the fiber weight per unit length. The value so obtained is known as "INTRINSIC
STRENGTH or TENACITY". Tenacity is found to be better related to spinning than the
breaking strength.
The strength characteristics can be determined either on individual fibers or on bundle of
fibers.
Or
Single fiber strength is called tenacity
Single Fibre Strength:
The tenacity of fiber is dependent upon the following factors

Chain length of molecules in the fiber orientation of molecules size of the crystallites
distribution of the crystallites gauge length used the rate of loading type of instrument
used and atmospheric conditions
The mean single fiber strength determined is expressed in units of "grams/tex". As it is
seen the unit for tenacity has the dimension of length only, and hence this property is also
expressed as the "BREAKING LENGTH", which can be considered as the length of the
specimen equivalent in weight to the breaking load. Since tex is the mass in grams of one
kilometer of the specimen, the tenacity values expressed in grams/tex will correspond to
the breaking length in kilometers.
Bundle Fibre Strength:
In practice, fibers are not used individually but in groups, such as in yarns or fabrics.
Thus, bundles or groups of fibers come into play during the tensile break of yarns or
fabrics. Further, the correlation between spinning performance and bundle strength is at
least as high as that between spinning performance and intrinsic strength determined by
testing individual fibers. The testing of bundles of fibers takes less time and involves less
strain than testing individual fibers. In view of these considerations, determination of
breaking strength of fiber bundles has assumed greater importance than single fiber
strength tests.
Liner density:
Strength = F.V = Lbs inch = inch

A.M inch Lbs
Gram/denier = g/w 9000 = gL

L g 9000
= L____ or inch
9000 9000
Denier:
Density = Mass
Volume
M= DV
D = g/cm A L
= A 9000 10^6 g/cm
Denier = A 9000 10^6 (density)
Prove 1st:
MPa= 88.2 g/denier .. (a)
P.S.I= 12800 g/denier (b)
K.S.I= 12.8 g/denier . (c)
If
g = F1000
9.8
g/denier = F1000 1
9.8 A 9000 10^6
g/denier= F 1000
A 9.8 9000 10^6
g/denier= Stress 1000

9.8 9000 10^6
By cross multiplication we have
Stress= 88.2 10^6 g/denier
Hence proved;
MPa= 88.2 g/denier (a)
From equation (a)
Pa =88.2 10^6 g/d
Kgg = 88.210^6g/d
(1/39.37)
Kgg = 88.210^6g/d
(39.37)
P.S.I = 88.2 10^6 g/d 2.20461
(39.37) 9.8
P.S.I = 194.44 10^6 g/d

1550 9.8
Hence proved;
P.S.I = 12800 g/d

(b)
If we divide the equation (b) by 1000 then we have K.S.I
P.S.I = 12800 g/d

1000 1000
K.S.I = 12.8 g/d
Hence proved;
K.S.I = 12.8 g/d (c)
Prove 2nd:
MPa = 9.8 g/tex (d)
P.S.I=1422.32 g/tex ..... (e)
K.S.I=1.422 g/tex . (f)
Solution:
Hence proved; M = D V
Tex = g/cm A L
Tex = A 1000 g/cm
Tex = A 1000 10^6 (density)
g = F 1000
9.8
g/tex = F 1000 1________
9.8 A 1000 10^6
=F 1000_______ because stress = F

A 9.8 10^9 A
g/tex= stress 1_______

9.8 10^6
Stress = 9.8 10^6 g/tex
Pa = 9.8 10^6 g/tex
MPa = 9.8 g/tex
MPa = 9.8 g/tex .. (d)
From prove 2nd equation (a) then we have
Pa =9.8 10^6 g/tex
Kgg = 9.8 10^6 g/tex because 1meter = 39.37

(1/39.37) 1__ m = 1
39.37
Kgg = 9.8 10^6g/tex
(39.37)
P.S.I = 9.8 2.20461 10^6 g/tex 1Kg = 2.20461 Lbs

(39.37) 9.8 1___ Kg = 1 Lbs
2.20461
P.S.I = 1422.32 g/tex
Hence proved;
P.S.I = 1422.32 (e)g/tex

P.S.I = 1422.32 g/tex
1000 1000
K.S.I = 12.8 g/tex
Hence proved;
K.S.I = 12.8 g/tex (f)
NOTE:
Strength is measured in HVI (High Value Instrument) and result is given in terms of
grams/tex.
Interpretation of Strength value is given below
G/tex Classification
Below 23 Weak
24-25 Medium
26-28 Average
29-30 Strong
Above 31 Very Strong
Prove 3rd:
MPa = 98 g/d.tex ... (g)
P.S.I=14223.29 g/d.tex ..... (h)
K.S.I=14.22 g/d.tex . (i)
Solution:
M= DV
d.tex = g/cm A L
d.tex = A 10000 g/cm
d.tex = A 10000 10^6 (density)
g = F 1000
9.8
g/d.tex = F 1000 1________

9.8 A 10000 10^6
=F 1000____________ because stress = F

A 9.8 10000 10^6 A
g/d.tex= stress 1_________

9.8 10 10^6
Stress = 98 10^6 g/d.tex
Pa = 98 10^6 g/d.tex
MPa = 98 g/d.tex
Hence proved;
MPa = 98 g/d.tex
b .. (g)
From prove 3rd equation (a) then we have
Pa =98 10^6 g/d.tex
Kgg = 98 10^6 g/d.tex

(1/39.37)
Kgg = 98 10^6g/d.tex
(39.37)
P.S.I = 98 2.20461 10^6 g/d.tex

(39.37) 9.8
P.S.I = 14223.2 g/d.tex
Hence proved;
P.S.I
d = g/d.tex
14223.2 (h)
P.S.I = 14223.2 g/d.tex
1000 1000
K.S.I = 14.22 g/d.tex
Hence proved;
K.S.I = 14.22 g/d.tex (i)
Prove 4th:
g/denier = 9 g/tex (j)
g/tex = 10 g/d.tex (k)
g/denier = 1.11 g/d.tex ... (L)
Solution of equation (j)
For gram/denier
Density = Mass
Volume
M= DV
D = g/cm A L
= A 9000 10^6 g/cm
If
g = F1000
9.8
g/denier = F1000 1
9.8 A 9000 10^6
g/denier= F 1000
A 9.8 9000 10^6

9.8 9000 10^6
MPa= 88.2 g/denier . (I)
For gram/tex
M= DV
Tex = g/cm A L
Tex = A 1000 g/cm

g = F 1000
9.8
g/tex = F 1000 1________

9.9 A 1000 10^6

A 9.8 10^9 A
g/tex = stress 1_______

9.8 10^6
Pa = 9.8 10^6 g/tex
MPa = 9.8 g/tex . (II)
By comparing equation (I) & (II)
88.2 g/denier = 9.8 g/tex
g/denier = 9 g/tex
Hence proved;
g/denier = 9 g/tex (j)
Solution of equation (k)
For gram/tex
M= DV
Tex = g/cm A L
Tex = A 1000 g/cm
g = F 1000
9.8
g/tex = F 1000 1________

9.10 A 1000 10^6

A 9.8 10^9 A
g/tex= stress 1_______

9.8 10^6
Pa = 9.8 10^6 g/tex
MPa = 9.8 g/tex . (I)
For gram/d.tex;
M= DV
d.tex = g/cm A L
g = F 1000
9.8
g/d.tex = F 1000 1________

9.9 A 10000 10^6

A 9.8 10000 10^6 A

9.8 10 10^6
Pa = 98 10^6 g/d.tex
MPa = 98 g/d.tex (II)
9.8 g/tex = 98 g/d.tex
Dividing both sides by 9.8
gram/tex = 98 g/d.tex
9.8
gram/tex = 10 g/d.tex
Hence proved;
gram/tex = 10 g/d.tex (k)
Solution of equation (L):
For gram/d.tex;
M= DV
d.tex = g/cm A L
g = F 1000
9.8
g/d.tex = F 1000 1________

9.10 A 10000 10^6

A 9.8 10000 10^6 A

9.8 10 10^6
Pa = 98 10^6 g/d.tex
MPa = 98 g/d.tex (I)
For gram/denier
Density = Mass
Volume
M= DV
D = g/cm A L
= A 9000 10^6 g/cm
If
g = F1000
9.8
g/denier = F1000 1
9.9 A 9000 10^6
g/denier= F 1000
A 9.8 9000 10^6

9.8 9000 10^6
MPa= 88.2 g/denier . (II)
98 g/d.tex = 88.2 g/denier
gram/denier = 98 g/d.tex
88.2
gram/denier = 1.11 g/d.tex
Hence proved;
gram/denier = 1.11 g/d.tex

(III)
4. Micronair Value:
The Weight of micron gram per inch is called Micronair value

.
We know that
Mic is inversely proportional to fineness.
We know that
Denier= [ Weight (gram) ] x 9000

Length (meter)
Denier= Weight (g) x 9000 x 39.37

Length (inch) x 10^6
Denier= Mic x 0.354 . (I)
Similarly for d.tex system
D.tex= [ Weight (gram) ] x 10000

Length (meter)
D.tex= Weight (g) x 10000 x 39.37

d.tex=mic x 0.393 ................. (II)
And also same as for tex system
Tex= [ Weight (gram) ] x 1000

Length (meter)
Tex= Weight (g) x 1000 x 39.37

Tex= Mic x 0.0394 .. (III)
Number of fiber in cross-section:
O = Denier of yarn
Denier
Example No.01
Find the number of fibers in cross-section area for the count of PC (Polyester Cotton
Blend) 30Nec from the given data???
60% polyester 1.2 denier
40% cotton 4.5 mic
Data Given:
Count = 30Nec
Cotton mic = 4.5
Polyester denier =1.2
Required:
Number of fibers in cross-section (O) =???
Solution:
We know that;
Denier= Mic x 0.354 ............ (I)
By putting the values in equation (I) then we have
1.2 = Mic x 0.354

1.2__ = Mic
0.354
Mic = 3.38
Mic of polyester = 3.38mic . (II)
Now we find average mic
Average mic = mic x %age (polyester) + mic x %age (Count)
By putting the values in formula then we have
Average mic = 3.38 x 60 + 4.5 x 40

100 100
Average mic = 2.028 + 1.8
Average mic = 3.82
Now find denier for average mic so we put the values in equation (I)
Then we have;
Denier = 3.82 x 0.354
Denier = 1.352
Now we convert Nec to denier
We also know that
Denier = 5315
Nec
Denier = 5315
30
Denier = 177.16
O = Denier of yarn
Denier
O = 177.16
1.352
O = 131
Number of Fibers in cross-section area are (O) = 131
Answer;
O = 131
Example No.02
Find the number of fibers in cross-section area for the count of PC (Polyester (Black &
White) Cotton Blend) 20Nec from the given data???
60% Polyester
i. 60% White =1.2 denier
ii. 40% Black = 1.4 denier
40% Cotton =4.5 mic
Data Given:
Count = 20Nec
Cotton mic = 4.5
Polyester denier
White =1.2 denier
Black = 1.4 denier
Required:
Number of fibers in cross-section (O) =???
Solution:
First of all we find the Denier of Polyester (Black & white)
We know that;
Average Denier = Denier x %age (Black) + Denier x %age (White)
So we putt the values in Formula then we have
Average Denier = 1.2 x 0.60 (Black) + 1.4 x 0.40 (White)
Average Denier = 1.28
We know that;
Denier= Mic x 0.354 ............ (I)
By putting the values in equation (I) then we have
1.28 = Mic x 0.354

1.28__ = Mic
0.354
Mic = 3.61
Mic of polyester = 3.61mic . (II)
Now we find average mic
Average mic = mic x %age (polyester) + mic x %age (Count)
By putting the values in formula then we have
Average mic = 3.61 x 60 + 4.1 x 40
100 100
Average mic = 2.166 + 1.64
Average mic = 3.80
Now find denier for average mic so we put the values in equation (I)
Then we have;
Denier = 3.80 x 0.354
Denier = 1.345
Now we convert Nec to denier
We also know that
Denier = 5315
Nec
Denier = 5315
20
Denier = 265.75
O = Denier of yarn
Denier
O = 265.75
1.345
O = 197.58
Number of Fibers in cross-section area are (O) = 197.58
Answer;
O = 197.58
5. Fiber Elongation:
There are three types of elongation
Permanent elongation:
The length which extended during loading did not recover during relaxation
Elastic elongation:
The extensions through which the fibers does return.
Breaking elongation:
The maximum extension at which the yarn breaks i.e. permanent and elastic elongation
together Elongation is specified as a percentage of the starting length. The elastic
elongation is of decisive importance, since textile products without elasticity would
hardly be usable. They must be able to deform, In order to withstand high loading, but
they must also return to shape. The greater resistance to crease
for wool compared to cotton arises, from the difference in their elongation. For cotton it
is 6 -10% and for wool it is around 25 - 45%. For normal textile goods, higher
elongations are neither necessary nor desirable. They make processing in the spinning
mill more difficult, especially in drawing operations.
Elongation %age = Length

Original length
6. Trash:
In addition to useful fibers, cotton stock contains foreign matter of various kinds. This
foreign material can lead to extreme disturbances during processing. Trash affects yarn
and fabric quality. Cottons with two different trash contents should not be mixed
together, as it will lead to processing difficulties. Optimizing process parameters will be
of great difficulty under this situation, therefore it is a must to know the amount of trash
and the type of trash before deciding the mixing.
The formulae of Trash are given below:
Trash= (Trash extracted) x100

Total weight
And Formula Of percentage invisibility is
%age Invisibility= [Total weight-(delivery weight +Trash) ]

Total weight
Shirley Trash Analyzer:
A popular trash measuring device is the Shirley Analyzer, which separates trash and
foreign matter from lint by mechanical methods. The result is an expression of trash as a
percentage of the combined weight of trash and lint of a sample. This instrument is used
To give the exact value of waste figures and also the proportion of clean cotton
and trash in the material
To select the proper processing sequence based upon the trash content
To assess the cleaning efficiency of each machine
To determine the loss of good fiber in the sequence of opening and cleaning.
Stricter sliver quality requirements led to the gradual evolution of opening and
cleaning machinery leading to a situation where blow room and carding
machinery were designed to remove exclusively certain specific types of trash
particles. This necessitated the segregation of the trash in the cotton sample to
different grades determined by their size. This was achieved in the instruments
like the Trash Separator and the Micro Dust Trash Analyzer which could be
considered as modified versions of the Shirley Analyzer.
The high volume instruments introduced the concept of optical methods of trash
measurement which utilized video scanning trash-meters to identify areas darker
than normal on a cotton sample surface. Here, the trash content was expressed as
the percentage area covered by the trash particles. However in such methods,
comparability with the conventional method could not be established in view of
the non-uniform distribution of trash in a given cotton sample and the relatively
smaller sample size to determine such a parameter. Consequently, it is yet to
establish any significant name in the industry.
7. Maturity:
Fiber maturity is another important characteristic of cotton and is an index of the extent
of development of the fibers. As is the case with other fiber properties, the maturity of
cotton fibers varies not only between fibers of different samples but also between fibers
of the same seed. The causes for the differences observed in maturity, is due to variations
in the degree of the secondary thickening or deposition of cellulose in a fiber.
A cotton fiber consists of a cuticle, a primary layer and secondary layers of
cellulose surrounding the lumen or central canal. In the case of mature fibers, the
secondary thickening is very high, and in some cases, the lumen is not visible. In the case
of immature fibers, due to some physiological causes, the secondary deposition of
cellulose has not taken sufficiently and in extreme cases the secondary thickening is
practically absent, leaving a wide lumen throughout the fiber. Hence to a cotton breeder,
the presence of excessive immature
fibers in a sample would indicate some defect in the plant growth. To a technologist, the
presence of excessive percentage of immature fibers in a sample is undesirable as this
causes excessive waste losses in processing lowering of the yarn appearance grade due to
formation of neps, uneven dyeing, etc.
An immature fiber will show a lower weight per unit length than a mature fiber of the
same cotton, as the former will have less deposition of cellulose inside the fiber. This
analogy can be extended in some cases to fibres belonging to different samples of cotton
also. Hence it is essential to measure the maturity of a cotton sample in addition to
determining its fineness, to check whether the observed fineness is an inherent
characteristic or is a result of the maturity.
Different Methods of Testing Maturity:
Maturity Ratio:
The fibres after being swollen with 18% caustic soda are examined under the microscope
with suitable magnification. The fibers are classified into different maturity groups
depending upon the relative dimensions of wall-thickness and lumen. However the
procedures followed in different countries for sampling and classification differ in certain
respects. The swollen fibers are classed into three groups as follows
Normal:
Rod like fibers with no convolution and no continuous lumen are classed as Normal"
Dead:
Convoluted fibers with wall thickness one-fifth or less of the maximum ribbon width
are classed as Dead"
Thin-walled:
The intermediate ones are classed as thin-walled"
A combined index known as maturity ratio is used to express the results.
Maturity ratio = ((Normal - Dead)/200) + 0.70
Where,
N = %age of Normal fibers

D = %age of Dead fibers
Maturity Co-Efficient:
Around 100 fibers from Baer sorter combs are spread across the glass slide (maturity
slide) and the overlapping fibers are again separated with the help of a teasing needle.
The free ends of the fibers are then held in the clamp on the second strip of the maturity
slide which is adjustable to keep the fibers stretched to the desired extent. The fibers are
then irrigated with 18% caustic soda solution and covered with a suitable slip. The slide
is then placed on the microscope and examined. Fibers are classed into the following
three categories
Mature:
(Lumen width "L") is less than 1

(Wall thickness"W")
Half mature = (Lumen width "L") is less than 2 and more

(Wall thickness "W") than 1
Immature:
(Lumen width "L")/ (wall thickness "W") is more than 2
About four to eight slides are prepared from each sample and examined. The results are
presented as percentage of mature, half-mature and immature fibers in a sample. The
results are also expressed in terms of "Maturity Coefficient"
Maturity Coefficient = (M + 0.6H + 0.4 I)

100
Where,
M = Percentage of Mature fibers

H = Percentage of Half mature fibers
I = Percentage of Immature fibers
If maturity coefficient is
Less than 0.7, it is called as immature cotton

Between 0.7 to 0.9, it is called as medium mature cotton
Above 0.9, it is called as mature cotton
AIR FLOW METHOD FOR MEASURING MATURITY:
There are other techniques for measuring maturity using Micronaire instrument. As the
fineness value determined by the Micronaire is dependent both on the intrinsic fineness
(perimeter of the fiber) and the maturity, it may be assumed that if the intrinsic fineness is
constant then the Micronaire value is a measure of the maturity.
Dyeing Methods:
Mature and immature fibers differ in their behaviour towards various dyes. Certain dyes
are preferentially taken up by the mature fibers while some dyes are preferentially
absorbed by the immature fibers. Based on this observation, a differential dyeing
technique was developed in the United States of America for estimating the maturity of
cotton. In this technique, the sample is dyed in a bath containing a mixture of two dyes,
namely Diphenyl Fast Red 5 BL and Chlorantine Fast Green BLL. The mature fibers take
up the red dye preferentially, while the thin walled immature fibers take up the green dye.
An estimate of the average of the sample can be visually assessed by the amount of red
and green fibers.
8. Short Fiber Content (SFC):
The measure of short-fiber content (SFC) in Motion Control's HVI systems is based on
the fiber length distribution throughout the test specimen.
It is not the staple length that is so important but the short fiber content which is
important. It is better to prefer a lower commercial staple, but with much lower short-
fiber content.
The following data were taken on yarns produced under identical conditions and whose
cotton fibers were identical in all properties except for short-fiber content. The effects on
ends down and several aspects of yarn quality are shown below.
LOT -A, (8.6% SFC) LOT-B (11.6% SFC)

Ends down / 1000 hrs 7.9 12.8
Skein strength (lb) 108.1 97.4
Single end strength g/tex 15 14.5
apperance index 106 89
Evenness (CV %) 16 17.3
Thin places 15 36
Thick places 229 364
Minor Defects 312 389
These results show that an increase of short-fiber content in cotton is detrimental to

process efficiency and product quality.
HVI systems measure length parameters of cotton samples by the fibrogram technique.
The following assumptions describe the fibrogram sampling process:
The fibrogram sample is taken from some population of fibers
The probability of sampling a particular fiber is proportional to its length
A sampled fiber will be held at a random point along its length
A sampled fiber will project two ends away from the holding point, such that all of the
ends will be parallel and aligned at the holding point.
All fibers have the same uniform density
The High Volume Instruments also provide empirical equations of short fibre content
based on the results of cotton produced in the United States in a particular year.
Short Fiber Index (SFI) = 122.56 - (12.87 x UHM) - (1.22 x U.I)
Where
UHM = Upper Half Mean Length (inches)

UI = Uniformity Index
Short Fiber Index (SFI) = 90.34 - (37.47 x S.L2) - (0.90 x U.R)
Where
SL2 =2.5% Span length (inches)
UR = Uniformity Ratio
9. Spinning Consistency Index (SCI):
The spinning consistency index (SCI) is a calculation for predicting the overall quality
and spinnability of the cotton fiber.
The SCI could be used to solve the complexity of cotton bale selection . Within the SCI
there are various fiber properties which allow us to take the advantage of inherent
correlation prevailing among the fiber properties. Thus, the use of the SCI will drastically
reduce the real number of cotton varieties available for selection. Practically, the SCI
could be used as the first priority for the selection of bales, followed by micronaire as the
second priority, in order to exert additional control in the fiber selection. As the SCI
contains six interrelated properties, good distribution control of all the cotton properties
could be achieved by controlling the SCI and micronaire. The regression equation used to
calculate the SCI is as follows:
SCI = - 414.67 + 2.9 x Strength - 9.32 x micronaire + 49.17 x UHML + 4.74 x UI +

0.65 x Rd + 0.36 x (+b)
Where:
UHML= Upper half mean length (inch)

UI = Uniformity index
Rd = Reflectance degree
+b = yellowness of cotton fiber.
10. Fineness:
Fiber fineness is another important quality characteristic which plays a prominent part
in determining the spinning value of cottons. If the same count of yarn is spun from two
varieties of cotton, the yarn spun from the variety having finer fibers will have a larger
number of fibers in its cross-section and hence it will be more even and strong than that
spun from the sample with coarser fibers.
Fineness denotes the size of the cross-section dimensions of the fiber. AS the cross-
sectional features of cotton fibers are irregular, direct determination of the area of cross-
section is difficult and laborious. The Index of fineness which is more commonly used is
the linear density or weight per unit length of the fiber. The unit in which this quantity is
expressed varies in different parts of the world. The common unit used by many countries
for cotton is microgrammes per inch and the various air-flow instruments developed for
measuring fiber fineness are calibrated in this unit.
Following are some methods of determining fiber fineness.
Gravimetric or dimensional measurements

Air-flow method
Vibrating String Method:
Some of the above methods are applicable to single fibers while the majority of them deal
with a mass of fibers. As there is considerable variation in the linear density from fiber to
fiber, even amongst fibers of the same seed, single fiber methods are time-consuming and
laborious as a large number of fibers have to be tested to get a fairly reliable average
value.
It should be pointed out here that most of the fineness determinations are likely to be
affected by fiber maturity, which is another important characteristic of cotton fibers.
Air-flow method (micronaire instrument):
The resistance offered to the flow of air through a plug of fibers is dependent upon the
specific surface area of the fibers. Fineness tester has been evolved on this principle for
determining fineness of cotton. The specific surface area which determines the flow of air
through a cotton plug is dependent not only upon the linear density of the fibers in the
sample but also upon their maturity. Hence the micronaire readings have to be treated
with caution particularly when testing samples varying widely in maturity.
In the micronaire instrument, a weighed quantity of 3.24 gms of well opened cotton
sample is compressed into a cylindrical container of fixed dimensions. Compressed air is
forced through the sample, at a definite pressure and the volume-rate of flow of air is
measured by a rotometer type flowmeter. The sample for Micronaire test should be well
opened cleaned and thoroughly mixed (by hand fluffing and opening method). Out of the
various air-flow instruments, the Micronaire is robust in construction, easy to operate and
presents little difficulty as regards its maintenance.
Neps count/gram:
Neps Cnt/g= [ logN log(N x)] 100

0.434
Where
N= number of holes in template
X= number of holes containing neps
CHAPTER #03
BLOW ROOM CALCULATIONS
Question:
If there are 3 blades of a beater and rpm of the beater is. The dia of the
feed roller is 4 and speed is 8rpm. Then according to the given date find
out beats/min and beats per inches?
No. of Blades = 3
Rpm of beater = 200
Dia of feed roller = 8 rpm
Beats / min = ?
Beats / in = ?
Beats min = No. of blades x rpm of beater
` = 3 x 200
= 600
Beats / in = beats / min/Delivery speed
Here
Delivery speed= ?
Delivery speed= rpm x 3.14 x d
= 8 x3.14 x 4
= 100 inches/min
Putting the values in
Beats / = beats/min/Delivery speed
= 600/100
Beats/in = 06
Questions:
No. of blades = 3
Rpm = 400
Dia = 3
Speed = 6 rpm
Beats/in = ?
Beats/min = No. of blades x rpm
= 3 x 400
= 1200
Delivery speed= rpm x 3.14 x d
= 6 x 3.14 x 3
= 56.52 in/min
Beats/in = beats/min/Deliver speed
= 1200/56.52 = 21.23
Question:
No. of blades = 4
Rpm of the beater = 437
Feed roller dia = 3.5
Speed = 6 rpm
Beats/in = ?
Beats / min = no. of blades x rpm
= 4 x 437
= 1748
Delivery speed = rpm x3.14 x d
Beats / in = 6 x 3.14 x 3.5
= 65.94 in/min
Beats/in = beats/min/Delivery speed
= 1748/65.94
= 26.5
Finding Waste %age
Question: if 50 kg cotton is feeded to the machine and 4kg is the amount of waste.
Find out the %age waste of the material.
Cotton feed = 50kg
Waste = 4kg
Waste % = ?
Waste %age = weight of waste x 100/total weight
= 4 x 100 / 50
Waste %age = 8%
The waste which can be used again is known as soft waste.
The waste which is un-useable is called the hard waste.
Trash %age:
1 Bale weight= 365 Lbs
2 Bale weight= 360 Lbs
Total weight = 10 Lbs
Weight = 725 10
= 715 Lbs
Lap. Weight = 680 Lbs
Waste = 715 680
= 35 Lbs
Waste % = waste weight x 100 / total weight
= 35 x 100 / 715
= 4.89 %
More waste %age more will be the efficiency % more the material to be cleaned.
Fiber stressing index:

Fiber stressing index is expressed by increase of short fiber content and is calculated as ;
Example:
Short fiber content input = 21.6%
Short fiber content out put = 28.6%
Fiber stressing index =????
St =
= 32.4%
It means that short fiber content has been increased by 32.4%
General factors which affect the degree of opening , cleaning

and fiber loss are,
fiber alignment
size of the flocks in the feed (flock size may be same but density
is different)
the type of opening device
speed of the opening device
degree of penetration
type of feed (loose or clamped)
type of opening device
point density of clothing
arrangement of pins, needles, teeth
speeds of the opening devices
throughput speed of material
type of grid bars
area of the grid surface
grid settings
Example 01
Calculate rmp of beater, if
Rpm of motor = 1450
Motor pulley diameter = 70mm
Beater pulley diameter =100mm
Putting values in above equation
Beater RPM =
= 1015RPM
Example 02
Diameter of card cylinder motor = 150mm
RPM of card motor = 1500
Diameter of card cylinder pulley = 30mm
Card cylinder rpm =???????
RPM of card cylinder =
= 7500rpm
Surface speed of revolving parts:
Surface speed of any revolving part is calculated as :
Surface speed =ND
Where: N = no of revolutions
D = diameter of revolving part
Example: 01
Diameter of feed roller of breaker = 4.5
RPM of feed roller = 15
Surface speed of feed roller =?????
S.S = 3.14154.5
S.S = 211.95inch/min
Example02
Surface speed of calendar roller = ??
Diameter of calendar roller = 51mm
RPM of calendar roller = 2071rpm
Surface speed = 3.14207151

= 331.64m/min
Beats per minutes:
Beats per minutes depends upon following things
Speed of beater
Number of blades of beater
General formula for computing the bears per minutes is as follows:
Beats per minute = RPM of beater no of blades of beater
Example 01
RPM of beater = 300
No of blades = 3
Beats/min =??????
Beats /min = 3003 =900beats/min
Example 02
RPM of beater = 1015
No of blades of beater = 3
Beats / min =?????
Beats /min = 10153= 3045beats /min
Example03If speed of beater is 600rpm and no of blades are 2 find beats / min
Beats /min = RPM of beater no of blades
=600 2
= 1200
Beats per inch
Beats per inch depends upon following two factors
Beats / min
Surface speed of feed roller
Example
If diameter of beater pulley is 100mm and diameter of motor pulley is70mm and motor is
running at a speed of 1450rpm.The diameter of feed roller is 4and is revolving with a
speed of 6 rpm find beats /inch?
Solution:
RPM of beater =- = 1015rp
Beats/min = rpm of beater no of blades =10153 =3045 beats/min
Surface speed of feed roller = ND =3.1464 = 75.36 inch/min
= =40.401beats/min
DERIVATION OF SCUTCHER PRODUCTION FORMULA
Blow room Production = 9 * 3.14 *13 * 12 *60 *3 * 8* 3* 0.85
36 * 16
Blow room Production = 9 *3.14 * 13 * 12 * 60* 3 * 8* 3 *0.85
36 * 16
= 16188232.3
576
Blow Room Production = 28100 lb/day
Q.If Blow Room Production is 30000 and number of scutchers are 3, shell roll dia is
9, lap weight is 13oz/yd ,efficiency is 85% then calculate shell roll speed
Sol:
Blow room Production = shell roll dia* shell roll rpm*3.14* oz/yd* 60*3*8* number of
scutchers* efficiency
36 * 16
Now putting values in the formula
Blow room Production = 9 * 3.14 * rpm * 13 *60 *3 * 8* 3* 0.85

36 * 16
30000 = 9 *3.14 * rpm * 13 * 60* 3 * 8* 3 *0.85

36 * 16
rpm = 30000 * 36 * 16
9 *3.14 *13 *60 *3 * 8 * 3 * 0.85
rpm = 17280000
1349019.36
Shell roll speed = 13rpm
Q.If Blow Room Production is 30000 and number of scutchers are 3, shell roll speed
is 13rpm, shell roll dia is 9, efficiency is 85% then calculate lap weight.
Sol:
Blow room Production = shell roll dia* shell roll rpm*3.14* oz/yd* 60*3*8* number of
scutchers* efficiency
36 * 16
Now putting values in the formula
Blow room Production = 9 * 3.14 * 13 * oz/yd *60 *3 * 8* 3* 0.85

36 * 16
30000 = 9 *3.14 * 13 * oz/yd * 60* 3 * 8* 3 *0.85
36 * 16
oz/yd = 30000 * 36 * 16
9 *3.14 *13 *60 *3 * 8 * 3 * 0.85
oz/yd = 17280000
1349019.36
lap weight = 13 oz/yd

Balancing in Blow room
Q .In a spinning mill there are 30 ring frames each have 480 spindles and producing
20s count with TM 4.1. Spindle speed is 1600rpm and efficiency is 90%. The yield
age of mill is 83%. In blow room there are 3 scutchers with shell roll speed is 12rpm
wt of bale is 170kg. Vary the ozs/yard calculate:
a) Total no. of bales required?
b) No. of lap/scutcher (Lap length is 50 yards)?
c) Total no of laps?
d) Balance the production of blow room with reference to ring department?
Ans:
Ring production (ops) = (Spindle speed x 0.254)/TPI x count

= 16000 x 0.254/18.33 x 20
= 11.1 x 0.90 x 3
= 29.92ozs
Production = 1.8lbs
= 1.8 x 480 x 30 = 25920lbs
= 260bags
Total wt required = 25920/0.83 = 31228.90

= 31228.90/2.24 = 13194/170
= 82bales
Total no of Lbs = 31228.90

Deducting 6% waste = 31228.90 x 0.94
= 29355.10lbs
Scutcher calculation:
Production = (shell roll Dia x rpm x x ozs/yard x 60 x 8 x 3) x 3

36 x 16
= (9 x 12 x 3.14 x 11.5 x 60 x 8 x 3) x 3
36 x 16
= 29349.5lbs
1 lap = 50yards
1 lap = 11.50ozs/yard
1 lap = 50 x 11.5 = 36lbs
16
Total no. of laps = 29349.5
36
= 816 laps
No. of laps/ scutcher = 816/3
80 bales of cotton, each of 167kg are being feed daily in a 2- line scutcher .Actual
production per 2 scutcher is 12000kg per day.
Calculate
a) total quantity of waste throughout whole blow room line
b) waste %age
Soln:
Input = 80*167=13360kg
Output=12000kg
Waste = input-output
=13360-12000
1360kg
Waste% age=1360*100
13360
=10.18%
Q:70 bales of cotton, each of 165kg are being feed daily in a 3- line scutcher
The total waste removed from blow room machines is 1000kg per day .Calculate
.a) Actual production per scutcher per hour
b) waste %age.
Soln:
Input=70*165=11550kg
Waste+ 1000kg
Output=11550-1000=10550kg/day
Waste% =1000*100
11550
=8.65%
Production per scutcher per hour=10550
3*24
=146.58kg
Q.Trash %age in given cotton in bale is 8%.the C.E of blow room is 60%.calculate
1) %age of impurities remained in the material delivered by blow room.
Soln:
Trash removed= 60*8
` 100
=4.8%
Impurities=8-4.8= 3.2%
Blending &Mixing Calculations
Q .The price of a cotton A is 60 RS/Kg with a weight of 1000Kg.while price of
cotton B is 55 Rs/Kg with a weight of 2000 Kg. Calculate the average price of
mixing of two cottons.
Solution:
Pa = 60 Rs Wa =1000
Pb = 55Rs Wb =2000
Pm = 60*1000+55*2000
1000=2000
= 56.67 Rs/Kg
Q .The average price of mixing is Rs 40/Kg.The average price of component A with
a weight of 2500 Kg is Rs 45/Kg.What should be wt of component of B with a price
of 35 Rs/Kg.
Solution:
Pm = Pa *Wa+Pb*Wb
Wa=Wb
40 = 45*2500+35*Wb
2500+Wb
(2500+Wb)*40 = 112500 +35 Wb

100000 +40 Wb = 112500 =35 Wb
(40 -35) Web = 112500 - 100000
Wb = 12500/5 = 2500 Kg
Q .The Price of cotton A is 64/Kg While Price of Cotton B is 70Rs/Kg .If total
quantity of two cottons is same, what will be average price of mixing.
Solution:
Let wt of samples = w
Pm = w*paw*pb
W+w
= Pa+Pb
2
Pm = 64=70
2
= 67 Rs/Kg
Ratio of Mixing
Q .The average mixing price per kg in a mill is Rs 45.The price of components A is

38Rs/Kg while price of 2nd component 38Rs/Kg.
Calculate the followings.
o Percentage of individual component for getting required price
o Total no of bales of individual components, if total bales available are 50000.
Slon:
Given data:
Pm = 45
Pa = 38
Pb = 48
% Age of components
A= 3/10*100=30%
B= 7/10*100=70%
Bales of component A= 3/10*50000

=15000bales
Bales of component B= 7/10*50000=35000bales
Q .The average mixing price for making PC yarn is Rs 52/Kg.The price of 1Kg
cotton is 42Rs while price of 1Kg polyester is 64Rs calculate
Percentage of two components
Total no of bales of individual components, if total quantity is 100000.
Cotton = 170Kg
Polyester = 200Kg
Soln:
Given data
Pm = 52
Pc = 42
Pp = 64
Cotton bales =12/228*100=54.55

Polyester bales =10/22*100=45.45
Cotton bales =12/22*100000=54545Kg

=321bales
Polyester bales =10/22*100000=45454.5Kg
=228bales
Q .Total quantity is 25000kg.Calculate quantity for each component while

Pm = 42
Pa = 48
Pb = 43
Pc = 38
Soln:
Given Data
Pm = 42
Pa = 48
Pb = 43
Pc = 38
Qa=4/15*25000=6666.67kg
Q= 4/15*25000=6666.67Kg
Qc=7/15*25000=11666.67Kg
Piping calculations
Q .The main pipe in a Blow room has to feed 3-branch pipes, their respective dais
are 2.5, 1.5 and 1.25. Calculate the dia of main pipe?
Sol:-
2 2 2
Dm = (2.5) + (1.5) + (1.25)
= 6.25+2.25+2.56 = 3.325inch
.The main pipe is to feed 4 branch pipes with following dia 2, 2.5, 3 and 3.5
respectively. If capacity of main pipe is only 90% to that of branches then what
should be the dia of main stream pipe?
Sol:-
2 2 2 2
Dm = (2) + (2.5) + (3) + (3.5)
= 4 + 6.25 + 9 +12.25
= 31.5
= 5.61
Main pipe capacity is 90% hence die of main pipe required
= 5.61*90/100
= 5.05
2
Area of circular pipe = r
Area of rectangular pipe = L x W
Q .A vertical system and rectangular duct of 10 x 10is to be replaced a circular

duct 25% greater in capacity. What will be the dia of circular duct?
Sol:
Area of rectangular duct = 10 x 12 = 120

25% greater capacity area A = 120(1+25/100) = 150
2
A = /4 d
2
D = 4 x 150/= 13.83
Q .A tower of blow room is 8 ft in section discharging into base by pipes with

particulars.
1) One pipe of 15 dia having linear air speed of 3000 ft/min.
2) One pipe of 9 dia having linear air speed 1500 ft/min.
Calculate the velocity of air flow in ft/min?
Sol:-
2
Area of tower = 8x8 = 64ft
Volume = Area x Velocity
2 3
V1 = /4(15/12) x 3000 = 3681.6 ft
2 3
V2 = /4(9/12) x 2000 = 883.57 ft
2 3
V3 = 6[/4(12/12) x 1500 = 7068 ft
Air volume in tower = Sum of air volume in branches
V = V1+V2+V3
= 3681.6 + 883.57 +7068
3
V = 11638.17 ft
Velocity = V/A
= 11638.17/50.24
= 231.55ft/min
For square pipe = 11638.17/64

= 181.77 ft/min
CHAPTER#04
Cardingcalculations
Power transmission to different parts of card machine is shown in fig.
Card Calculations
4.3.2.5.1 Draft Calculations

Feed Roller:
Rpm of Feed roll = 4
S.S. of Feed roll = 4 x 4 x 3.1416
= 50.26 / min
Doffer:
Rpm of doffer = 1430 x (10 / 14.9) x (9.9 / 14.9) x (9.9 / 13) x (19 / 19) x (5.5 /
16.91) x (8.7 / 26.67)
= 52 rpm
S.S. of doffer = 52*3.1416*20
= 3268/min
Stripper Roller:
Rpm of stripper Roll = 1430*10/14.9*9.9/14.9*9.9/13*19/19*5.5/16.91
= 159.4 rpm
Surface speed of stripper roll = 159.4*3.1416*6.5
= 3285/min
Crush Roller:
Rpm of crush roll =1430*10/14.19*9.914.19*9.9/13
= 445.6 rpm
Surface speed = 445.6*3.1416*3
= 4576.8/min
Tung & Groove Roller:
Tung and groove roller = 1430*10/14.9*9.9/14.9*7.2/7.6
= 604.6 rpm
Surface speed = 604.6*3.1416*3
=5693.6/min
CCR:
Rpm of CCR roller = 1430*10/14.9*9.9/14.9*9.9/9.9*14.9/15
= 630 rpm
Surface speed = 630*3.1416*3
= 5937.6/min
Draft between feed roller and doffer

D1= surface speed of doffer / surface speed of feed roller
= 3268 / 50.26
= 65
Draft between doffer and stripping roll
D2 = surface sped of stripping roll / surface speed of doffer
= 3286 / 3268
= 1.005
Draft between crush roll and stripping roll
D3 = surface speed of crush roll / surface speed of stripping roll
= 4576.6 / 3285
= 1.2
Draft between Tung and groove roller and crush roller
D4 = surface speed of groove roller / surface speed of crush roller
= 5693.6 / 4576.6
=1.05
Draft between coiler calander roller and Tung groove roller
D5 = surface speed of CCR roller / surface speed of Tung roller
= 5937.6 / 5693.6
= 1.03
Total draft = D1*D2*D3*D4*D5
= 65*1.005*1.2*1.05*1.03
= 84
RPM and surface speed calculations of the carding machine
(Gearing diagram is shown on the next page)
RPM of cylinder
= 14504/20 =290rpm
Surface speed of cylinder
= ND = 3.1429040 = 925m/min
RPM of taker-in
= 14504/2016/5 = 928 rpm
Surface speed of taker-in
= ND = 3.149259 = 666.13m/min
Rpm of the doffer
= 14503/1120/5023/80=45.47
Surface speed of the doffer
= ND = 3.1445.4720 =72.54m/min
Rpm of the feed roller
= 14503/1120/5023/8018/120=3.6rpm
Surface speed of the feed roller
= ND = 3.143.62 =0.58m/min
Rpm of the lap roller
= 14503/1120/5023/8018/12033/48=2.47rpm
Surface speed of lap roller
= ND = 3.142.46 =1.18m/min
Rpm of the stripping roller
=14503/1120/5023/43=84.60
Surface speed of the stripping roller
= ND = 3.1484.606 =40m/min
Rpm of crush roller
=14503/1120/5023/4352/28=157rpm
Surface speed of the crush roller = 3.141574 =50m/min
Rpm of short calendar roller
= 14503/1120/5023/20 =182rpm
Surface speed of short calendar roller
= ND = 3.141824 =58m/min
Rpm of coiler calendar roller
= 14503/1120/5023/2031/1520/2016/16=375rpm
Surface speed of coiler calendar roller
= ND = 3.143752 =65m/min
Draft Calculations
Draft between lap roller and feed roller
D1= surface speed of feed roller/surface speed of lap roller
D1= 0.58m/min1.18m/min=0.5 tension draft
Draft between doffer and feed roller
D2= surface speed of doffer/surface speed of feed roller
D2= 72.500.58 = 125
Draft between doffer and stripping roller
D3= surface speed of stripping roller/surface speed of doffer
D3= 4072.50 = 0.55
Draft between stripping roller and SCR
D4= surface speed of SCR/ surface speed of stripping roller
D4= 58 /40=1.45
Draft between SCR and CCR
D5= surface speed of CCR/surface speed of SCR
D5= 65/58=1.12
Total draft
= D1D2D3D4D5= 0.51250.551.451.12 =56
Or
= surface speed of the CCR/surface speed of lap roller
= 651.18= 55.08
Draft:-Attenuating the textile material without breaking is called as draft it is of two
types
1. dispersion draft( with one roller and one metallic plated e.g. at comber)
2. roller draft( with at least two pair of roller e.g. at ring drawing etc)
Roller draft is further of two types
i. actual draft
ii. mechanical draft
Actual Draft:
A.D = weight/yd fed weight /delivered
Or
A.D = count delivered count fed
Example 01: 600gram/yd is fed and 100G/yd sliver is obtained calculate the actual draft?
Feed = [(6001000) 2.2046] 7000 =9259.32grains/yd
Delivered = 100 grains/yd
A.D = 9259.32100 =92.59
Mechanical Draft
M.D = linear speed out put/ linear speed input
M.D = A.D [(100-W %) 100]
MD = A.D (1 0.01W %)
Mechanical Draft for above example if waste extraction is 6%
M.D = 92.59(1-0.016)
M.D = 87.03
Example 02:
Card sliver weight = 75G/yd
Lap weight feed = 14 ozs/yd =14/16700= 6125 G/yd
Waste %age = 6.5
A.D = lap weight sliver weight = 612575 =87.5
M.D = A.D (1 0.01W %) = 87.5(1-0.016.5) =81.81
Hence those machines at which waste is removed
Actual draft mechanical draft
Example 03:
Lap count = 0.00124
Sliver count = 0.111
Waste %age = 7%
A.D = count delivered count fed = 0.111 0.00124 = 89.51
M.D = A.D (1 0.01W %) = 89.51(1-0.017) =81.81=83.24
Example 04: if the surface speed of the delivery roller is 250m/min, the mechanical draft
is 85.52 and diameter of the feed roller is 6(0.1524) calculate the rpm of the feed roller
M.D = S.S of delivery roller/ S.S of feed roller = NDd / NDf
85.52 = 250/3.14N1.0524
N = 250 /3.1485.521.0524 = 6.10rpm
Transfer Ratios:-
Transfer ratio between taker in to cylinder
TR =
Condensing Ratio:-
Cylinder diameter= 1286mm

Cylinder rpm= 507
Doffer diameter= 700mm
Doffer rpm = 58
Condensing ratio =?
Neps/gram (AFIS Method)
Neps per gram = 104n/N1/S1/W

Where:
n= number of holes containing neps
N= number of holes on the template =20
S = surface area of the holes6.16cm2
W = web weigh in gram/m 2
Neps per gram = 81.17n/W .01

Let
Card Web weight in gram/m2 =W = 12.5g/m2
No of holes containing neps =n =08
Nepd per gram = 81.178/12.5 = 52
Nep Removal Efficiency:-The parameter characterizing the carding machine
effectiveness in the aspect of nep reduction is the Nep Removing Efficiency (NRE %),
which is expressed by equation
:
Example
Nep cnt/g feed =350
Nep cnt/g del =52
NRE = [(350-52) 350]100 = 85.14%
Example Lap neps= 300
Sliver neps = 50
N.R.E = 300-50 x 100

300
= 250/300 x 100
= 83.33 %
Waste % age removed:-
W%age = 100-[(M.D/A.D)100
Suppose
M.D = 85.52 and A.D = 89.56 then W%age =?
W% age = 100-[(85.52/89.56) 100] = 100-95.48 =4.52%
Can dimensions and capacity:-
Delivery speed 285m/min
Height of can = 45
Diameter of the can = 42
Can capacity in meters = 8000m
Can capacity in yds = 8000 1.0936 = 8756.8yds
Can capacity in grains = 8756.8 grain /yd of sliver= 8756.8 70 = 612976gr
Can capacity in lbs = 612976gr 100 87.568
Can capacity in kgs =87.568 2.2046
Time required to fill one can:-
Time =can capacity in meters/delivery speed m/min =
Production calculations of card Derivations

We know that count is defined as
Count = length in yards/ (weight in lbs840)
Weight in lbs = Lyd(count840) 01
Length delivered in specified time can be determined from the doffer ignoring tension
draft between doffer and ciler calendar roller.
If ; diameter of the doffer is D inch and N is the rpm of the doffer then surface speed of
the doffer is calculated as
Length delivered S = ND inch/min36= delivery speed in yds/min.02
If we consider the coiler calendar roller as the last delivery roller then we have to
include tension draft as follows:
Yds/min = ( ND yds/min) tension draft
Since the efficiency of the machine cannot be greater than 1(100%), so.
Yds/min = ( ND yard/min) tension drafteffi %age
Count of the delivered sliver is defined as
Hank of sliver = 8.33/ grains per yard ..03
From Equation 1,2 &3 we have
Lbs/mint = [ ( ND yards/min) tension draft effi %ageG/yd](8.33840)
Lbs /hour = [( ND yards/min) tension draft effi %ageG/yd60](8.33840)
Lbs/shift = [( ND yards/min) tension draft effi %ageG/yd608](8.33840)
Lbs/day = [( ND yards/min) tension draft effi %ageG/yd6083](8.33840)
Lbs/day = 0.205delivery speed yds/minG/yd%age
Bags per day = [0.205delivery speed yds/minG/yd%age] 100
Example01
Calculate the bags per day if the diameter of the card is 20 revolving with 52rpm giving
sliver of 70g/yd with efficiency of 93% tension draft given is 1.30
Delivery speed yds/min
= (3.14522036) 1.30 = 117.92yds/min
Bags per day= [0.205delivery speed yds/minG/yd%age] 100
Bags /day = [0.205117.92 yds/min700.93] 100 = 15.73bag/day

Example 02
Calculate the bags per day if the diameter of the card is 40 revolving with 65rpm giving
sliver of 70G/yd with efficiency of 93% tension draft given is 1.62
Delivery speed yds/min
= (3.14654036) 1.62 = 367.38yds/min
Bags per day= [0.205delivery speed yds/minG/yd%age] 100
Bags /day = [0.205367.38 yds/min700.93] 100 = 49.19bag/day

Example03Calculate the bags per day if the delivery speed of the card is 285m/min
giving sliver of 60G/yd with efficiency of 90% no. of machines is 24
Delivery speed yds/min = delivery speed m/min1.0936 = 2851.0936 =311.67yds/min
Bags per day= [{0.205delivery speed yds/minG/yd%age} 100] no. of m/cs
Bags /day = [{0.205311.6 yds/min600.90} 100 ] 24= 828bag/day
CHAPTER#05
Drawingcalculations
Gearing Diagram of DX-500
77 E.R 51mm
F.C. 44
116
DC
P B.R 35mm
52 37
54
3rd 35mm 30
75 75 47 59
nd
2 35mm
37
58
F.R 35mm
30 71 77
49 48
C.R 51
23
44
Motor
Draft Calculations
Draft b/w Front & Calendar Roller:
= 30/4849/4451/35
= 1.014
Draft b/w Front & Back Roller:
= 54/44F.C/D.C.P52/7575/4948/30
= 54/44116/3752/7575/4948/30
= 6.533
Draft b/w Front & 2nd Roller (Main Draft):
= 48/3044/4977/358/71
= 5.081
Draft b/w 2nd & 3rd Roller:
= 30/4759/37
= 1.018
Draft b/w 3rd & Back Roller (Break Draft):
= 54/44116/3752/7575/4423/7771/5837/5947/30
= 1.63
Draft b/w Back & Electric Roller:
= 77/5435/51
= 0.97
PRODUCTION OF DRAWING FRAME

Q no: 1Calculate the production of drawing frame per day if the delivery speed is
275m/min. with effy of 85% and delivered weight is 60gr/yd?
Sol:
Production = delivery speed6024output gr/ydeffy
7000100
= 2751.0936602460852
7000100
= 6310.338lb/day
Q no: 2 lculate the production of drawing frame per day if the delivery speed is 250m/min.
with effy of 85% and delivered weight is 65gr/yd?
Sol:
Production = delivery speed6024output gr/ydeffy
7000100
= 2501.093660246582
7000100
= 6214.77lb/day
= 62bags/day
CHAPTER#06
LapFormer calculations
LAP FORMER
Qno: 1
A 70 gr/yd drawing sliver is fed in lap former to form a suitable package for comber, with
draft and doubling of 2.5and 8 respectively. Calculate the weight of lap?
Sol:
Draft = Input put grains/yd *Doubling
Output grains /yd
Out put grains/yd = in put grains/yd* doubling

Draft
= 70*24
2.5
= 672gr/yd
Q no: 2 65 grains per yd drawing sliver is fed to lap former to produce a comber
sheet of 650gr/yd. calculate a draft when doubling of 24 is given?
Sol:
Draft = Input put grains/yd *Doubling
Output grains /yd
= 65*24
650
Draft = 2.4
PRODUCTION OF LAP FORMER

Q no:1 calculate the production of lap former if delivery speed is 80m/min and 650 gr/yd
lap is produced with efficiency of 80%?
Sol:
Production = delivery speed*60*24*output gr/yd*effy
7000*100
= 80*1.0936**24*60*650*80
7000*100
= 9358.71lb/day
= 94bags/day
Q no: 2 Calculate the delivery speed of lap former if production of lap former is 8000lb per
day with 650gr/yd lap and efficiency is 82%?
Sol:
Production = delivery speed*60*24*output gr/yd*effy
7000*100
Delivery speed = Production* 7000*100

60*24*output gr/yd*effy
= 8000*7000*100
60*24*650*82
= 73m/min
CHAPTER#07
Comber calculations
Production of comber
Q NO: 1 Calculate a production of 6 combers per shift if there nips per minute is 300 and
waste% is 15 with effy of 85%. Feed per min is .25 inches and lap sheet of 650 gr/yd?
Solution:
P = nips per minute*feed per min*waste%*grains/yd*60*no .of heads*effy

36 7000 100
= 300*.25*.85*650*60*8*85
36*7000*100
= 67lb/hr
= 67*8*6
= 3216 lb/shift
Q NO: 2 Calculate a production of 6 combers per day if there nips per minute is 250 and
waste% is 18 with effy of 84%. Feed per min is .25 inches and lap sheet of 660 gr/yd?
Solution:
P = nips per minute*feed per min*waste%*grains/yd*60*no .of heads*effy

36 1000 100
= 250*.25*.82*660*8*.84*60
36*7000
= 54.12lb/hr
= 54.12*8*3*6
= 7793.28lb/day
= 78bags /day
Balancing comber with respect to lap former

There are 2 lap formers in a spinning unit which are running at 85m/min each sliver hank
s
at back of lap former is .125 , draft on lap former is 3.5 with a doubling of 32 and
production effy, about 86%. These m/c are to feed certain combers with following data
Nips per min=250
No. of heads=8
Waste %age=16
Effy of comber=85%
Feeding rate=.25in/min
How many combers are required to balance the production?
Sol: sliver weight = 8.33

.125
=66.64gr/yd
Production of lap former = delivery speed*60*24*output gr/yd*effy

7000*100
= 85*1.0936*60*66.64*86*32
7000*100*3.5
= 417.5lbs/hr
Production of lap formers= 417.5*2
= 835lbs/hr
P of comber = nips per minute*feed per min*waste%*grains/yd*60*no .of heads*effy
36 1000 100
(
Production = 609.3*250*60*.25*8 * 100-16 )
7000*36*100 100
= 51.79lbs/hr
No. of combers = output of lap former
input of comber
= 835
51.79*100/84
= 14 comber
CHAPTER#08
Simplex calculations
To find Draft & Draft Constant of Simplex Machine.
33
Back 28.5 83
50 60
50
TDCP 50
3rd 28.5 26 104
2nd 28.5 21
60
26
Front 28.5
20
DRAFT CONSTANT
Total Draft constant == 83/ T.D.C * 104/ 26 * 28.5/ 28.5
== 332/ T.D.C
== 332
BREAK DRAFT CALCULATION
Break Draft Constant == 33/ B.D.C * 60/ 26 * 30.74/ 28.5
== 82.14/ B.D.C
== 82.14
DRAFT CALCULATION
NOW Draft == 82.14/ 50

== 1.64
To find Twist constant
28.5 91
63
94
91
54 T.C
47
72 91
32
82
47
TWIST CONSTANT CALCULATION
Twist Constant == 91/ T.C * 91/ 72 * 91/ 82 * 47/ 54 * 47/ 32 * 25.4/ 3.14* 28.5
== 91/ 1 * 91/ 72 * 91/ 82 * 47/ 54 * 47/ 32 * 25.4/ 3.14* 28.5
== 46.3
To find production of simplex
EXAMPLE: spindle speed = 1050rpm
TPI = 1.05
Count of hank roving = 0.8
Efficiency = 85 %
Total no of spindles = 120
Bags /day =?
= 60.71bags per day
Example: Spindle speed = 1210
Twist multiplier = 1.18
Count = 1
Efficiency = 90%
Spindles /frame = 120
Bags /day =?
= 1.18
= 74.70bags /day
14-05-2010 Total production
m/c Flyer Roving T,P.T Efficiency Bags

# speed count % /day
01 1050 0.8 1.05 85 60.71
02 1050 0.8 1.05 85 60.71
03 1210 01 1.18 85 74.70
04 1108 0.7 0.92 85 83.50
05 1108 0.7 0.92 85 83.50
06 850 0.7 0.96 85 61.39
07 850 0.7 0.96 85 61.39
08 850 0.5 0.70 85 117.87
09 850 0.5 0.70 85 117.87
10 850 0.5 0.70 85 117.81
Total bags per day = 839.5
15-06 -2010
Machine Material H.R T.P.I Speed Efficiency Bags
# /day
01 Comber 1.00 1.18 1150 88 48.97
02 Comber 0.80 1.05 1100 85 63.56
03 Comber 0.80 1.05 1100 85 63.56
04 Comber 0.70 0.96 1025 85 74.03
pak
05 Comber 0.70 0.96 1025 85 74.03
pak
06 Carded 0.70 0.92 1000 85 75.36
07 Carded 0.70 0.92 1000 85 75.36
08 Carded 0.50 0.76 920 78 107.83
09 Carded 0.50 0.76 920 78 107.83
10 Carded 0.50 0.76 920 78 107.83
Total bags per day = 798.36
Example
T.P.I = 1.1
Hank roving = 1
Draft constant = 332 Sliver weight fed = 64.70 grains /yd
Draft wheel =???
= 0.128
DRAFT = = = 7.81
Draft Wheel = = 42T
Delivery speed of the front roller =
= 28.48yds/min
Take up speed of the back roller =
Time taken to exhaust one can
Balancing of Simplex frame
Calculate number of simplex frames to feed to a ring department producing

25000lbs/day.Hanks roving required is 0.96 & 1.15T.M. Flyer speed is 1000rpm and
number of flyers per m/c are 120. Waste percentage in ring is 1.2% & efficiency of
roving department is 85%.
Soln:
Production of simplex frame per end
Flyer speed*60*eff.
=
T.M*C*36*840*H.R*100
1000*60*85
= =1.56lbs/hr
1.15*0.96*36*840*0.96*100
Production of simplex frame in lbs/day =1.56*120*24=4490.3lbs/hr
Input for ring=25000*100/98.8

= 25303.6lbs/day
No.of m/c=25303.6/4490.3 =5.64 frames

= 6 frames
CHAPTER#09
RingFrame calculations
Ring Department (RY-4)
Break Draft
Break draft constant = 27/32*82/36*1/29
= 0.0663
break draft = constant / gear
=0.0063 / 18
= 1.2
Total Draft
Total Daft Constant
Total daft Canstant = 27/32*82/33*70/1*74/51*87/36
= 514.62
draft = constant / gear
= 514.62 / 24
= 21.44
Main Draft
Main Draft = total draft / break draft
= 21.44 / 1.2
= 17.86
Twist Constant
Twist Constant = 36*84*97*67*200*25.4 / 36*35*TW*39*20.2*25*3.14
= 1274.88
TPI = 1274.88 / 58
= 22
Gearing diagram of Ring frame G-5/1
47 Back Roller 27mm
112
21
26
F
W
93 20
Middle Roller 25mm
D 42
84 C 26
Front Roller 27mm
97 44 29
81
T
W 67
35 250mm
200mm
39
Motor 22KW
250mm
960
rpm
21mm
Calculations
Draft Calculations
Draft b/w Back & Middle Roller (Break draft)

Break draft = 47/21*26/42**25/27
= 1.28
Draft b/w Middle & Front Roller (Main draft)
Main draft = 42/26*112/20*93/44*26/29*27/25
= 18.5
Total Draft
Total draft = 47/21*112/20*93/44*26/29*27/27
= 23.7
OR
Total draft = Break draft * Main draft
= 1.28*18.5
= 23.7
Total Draft Constant
D.C = Total draft * draft wheel
= 23.7 * 44
= 1042.8
Break draft constant
B.D.C = Break draft * Break draft wheel
= 1.28 * 42
= 53.8
4.3.5.4.1.2 Twist Calculations
Twist per inch

T.P.I = 29/26*84/81*97/35*67/39*205.5/21.5*25.4/27*1/3.14
= 19.2
Twist constant
T.C = T.P.I * Twist wheel
= 19.2 * 35
= 672
Twist Multiplier
T.M = T.P.I / Ct
= 19.2 / 1.18
= 3.6
Twisting And Winding
The essence of staple spinning is about twist insertion. In ring spinning, twist is inserted
into the thin strand of fibres emerging from the front roller nip to form the yarn. During
ring spinning, the spindle is positively driven by a belt or tape at a constant speed. The
traveller is dragged around the ring by the yarn being wound onto the bobbin. The
rotation of the traveller allows the yarn between the traveller and the pigtail guide to
rotate at the same speed. The persistence of vision will give us the impression of a yarn
balloon as the yarn rotates at a high speed. It is the rotating balloon that inserts the actual
twist into the yarn.
As twist is generated in the yarn balloon, it travels past the yarn guide towards the front
roller nip. But the twist can not quite reach the nip line of the front rollers, because the
fibres emerging from the nip have to be diverted inwards to be twisted around each other.
So a small triangle of fibres, without any twist, is formed between the front roller nip and
the fibre convergence point as shown in figure 1.3. This triangle is called the spinning
triangle or twist triangle. It is also known as the yarn formation zone. Because there is
no twist in this zone, it is a weak point and ends-down most often occurs in this region.
For this reason, a large triangle is not desirable. The height of the spinning triangle is
affected by the spinning geometry and the twist level in the yarn. Overhang of front top
roller and high twist will reduce the height, hence the level of ends-down in spinning.
Because of air drag on the yarn balloon and friction between the traveller and ring, the
yarn balloon and the traveller rotate at a slower speed than the spindle. As we will see
shortly, the balloon speed keeps changing as spinning continues. Theoretically, we should
use the balloon speed to work out the twist level in the yarn. But this is obviously
difficult because of the changing speed of the balloon.
In practice, the nominal twist level in the yarn is calculated using the constant spindle
rotational speed rather than the balloon speed. The discrepancy arising from this
approximation is quite small.
Spindle rpm ( revs per min .)

Twist (turns per metre )
Yarn delivery speed ( metres per min .)
The yarn delivery speed is surface speed of the front rollers. It is also referred to as the
yarn production speed (rate).
Winding-on:-
As mentioned earlier, the yarn balloon rotates at a slower speed than the spindle due to
air drag (resistance) on yarn and the friction between traveller and ring. It is this
difference in rotational speeds of the balloon and the spindle (bobbin) that allows the yarn
to be wound up onto the bobbin. Without this difference in rotational speed or if the
traveller and spindle rotate in sync, there will be no winding of yarn onto the bobbin. In
addition, the linear winding-on speed needs to match the delivery (surface) speed of the
front rollers, otherwise the yarn will be too taut or too slack during spinning.
Figure shows a cross-sectional view of the bobbin/ring/traveller assembly, with a yarn

being wound onto the bobbin via the traveller.
If the diameter of the bobbin at the yarn wind-on point is dwind-on, the linear winding-on
speed (Vwind-on) should equal the circumference of yarn package (dwind-on)
multiplied by the difference in traveller and bobbin rotational speeds (nbobbin -
ntraveller), i.e.
Vwind on d wind on (nbobbin ntraveller )

This wind-on speed should match the speed at which the fibre strand is delivered by the
front rollers. But as the yarn package builds up, its circumference changes. With a
constant bobbin rotation speed (nbobbin), the traveller needs to change its rotation speed
(ntraveller) so that the winding speed (Vwind-on) remains constant and matches the front
roller delivery speed. The beauty of ring spinning is that the traveller can self-adjust its
rotational speed during spinning. It's all done automatically by the traveller itself.
Twist variation within yarn package

As the yarn package builds up, the traveller adjusts its rotational speed automatically.
This would suggest that within a yarn package, the twist level would be different. This is
true. But the difference is only marginal as the following example demonstrates.
Assume:
Cop dimensions as in the diagram below
(1) Front roll delivery speed is 15 m/min
( 2) Spindle speed is 10,000 rpm
Since the linear wind-on speed = winding rpm x circumference of the wind-on point =
front roll delivery speed, we have:
15
Winding rpm at A = = 191 revs
2.5 10 - 2
15
Winding rpm at B = = 80 revs
6 10 - 2
Ignoring the effect of up and down movement of ring rail, we have:

Traveller speed at A = 10,000 - 191 = 9,809 rpm
Traveller speed at B = 10,000 - 80 = 9,920 rpm
Therefore,
A(2.5 cmin dia.)
B(6cmindia.)
9809
twist at A = = 654 twists/m,
15
9920
twist at B = 662 twists/m
15
The difference in twist is about 1% only. If the effect of added potential twist due to
unwinding the yarn axially (at the next process) is taken into account, then at the
minimum diameter A, more twists will be added and at the maximum diameter B less
twists will be added thus bringing the twist levels more or less equal at both points.
Therefore, the effect of traveller speed change (and cop build-up) on yarn twist is very
small.
Results Related To wind-on- Tension

1. Wind-on tension increases with the square of the spindle speed (). Since wind-
on tension is directly related to spinning tension in the yarn above the pigtail
guide, increasing the spindle rotational speed will drastically increase the yarn
tension, which may lead to increased ends-down. This limits the maximum
spindle speed in ring spinning. If spindle speed is reduced to reduce yarn tension,
the production rates will drop.
2. Winding tension increases as package diameter decreases. This puts a limit on the
minimum diameter of the empty bobbin.
3. Since larger balloon means higher yarn tension, the winding tension increases as
the balloon gets longer. This limits the length of the bobbin.
4. Winding tension increases as ring radius (R) increases. This limits the size of the
full package that must fit inside the ring.
5. The package capacity is approximately proportional to (ring diameter)2, so a
large ring diameter is desirable for increased package capacity. But in practice,
the ring diameter is restricted by considerations of the yarn tension, the minimum
angle of lead previously discussed, as well as other factors such as power
consumption, spindle rpm, and traveller speed limitations (see relationships
below
1
Max . spindle speed
Ring diameter
Max. linear traveller speed Ring diameter
This is why we do not see ring spinning machines with very large rings and very
small bobbins (tubes). For coarser and stronger yarns, large ring radius and yarn
packages are used to allow for more yarns on the package. For finer yarns, both
ring radius and the package size are smaller
6. Winding tension increases with traveller mass. Heavier yarns require a greater
centripetal force to keep them rotating. Traveller mass is used as a variable to
increase the tension and generate the higher centripetal force for heavier yarns.
The traveller mass is usually chosen according to the linear density of the yarn
being spun.
7. Winding tension increases with an increase in the frictional coefficient between
the ring and the traveller (RT).
While we talk about the winding tension here, we should note that the spinning tension in
the yarn is directly related to winding tension, so any factor that contributes to an increase
in winding tension will also increase the tension in the yarn during ring spinning. In fact
all the implications for winding tension apply to tension in the yarn or spinning tension.
Ring Production
OPS/shift=
Bags/day =
Example 01
M/c#01
Count = 40/s comb compact
TPI = 24.70 , spindle speed=21700rpm
No of spindles /machine = 1152
Efficiency = 97%
OPS=
Bags per day per machine = = 11.32 bags/day/machine

Example 02
Yarn count =6/ carded hosiery
TPI =8.70
Spindle speed = 9500rpm
Efficiency =97%
OPS =
Bags per day= =84.74bags/day

Delivery speed of front roller =?
Spindle speed = 9500
Traveler speed = 9300
Difference = 200 rpm
Delivery speed = 3.142 41/25.4 200
= 1013.7 inches/min.
Delivery speed of back roller =?
= 1013.7 /total draft
= 1013.7 /45
= 22.52 inches/min.
Filling time of 1 bobbin =?
Bobbin length = 1848 yds./draft
= 1848/47.53
= 38.88 min.
Exhausting time of roving =?
= Length of roving/back roller speed
= 1500/22.52
= 66.60mint
Bobbins change by 1 roving = ?.
By wt
Roving wt = 1450 g
Bobbin wt = 50 g
= 1450/50
= 29
Setting the twist gearing on RX-240

Calculation formulae
= 625.05
Abbreviation Name Teeth

TCA Twist constant change wheel A 36,47,53,65T
TCB Twist constant change wheel B 88,77,71,59T
TC Twist change wheel 3070T
DP Driving pulley diameter 200mm
BT Thickness of the driving belt 0.5mm
DW Spindle wharves diameter 18.5mm/20.5mm
DF Front roller diameter 27mm
Let
Twist wheel = 47T
Twist set = 77/47T (TCA= 47.TCB =77)
Tape thickness = 0.5mm, front roller dia.= 27mm, tin pulley dia.= 200mm
Spindle wharves dia. =19mm
TPI=
The number of twists is calculated by using above formula. Since the twist table differs
depending upon the users, refers to the table separately provided.
The relationship between the TPI and TM is explained here
The actual number of twists is slightly smaller than that set by the twist gearing. The
twist change gearing recommended by the table separately provided is designed taking
loss of 1% into consideration
Setting the Total Draft Gearing:-

Calculation formula
Draft constant
Where
DCA: draft constant change wheel A(82,67,53,43,35T) actual used =43T
DCB: draft constant change wheel B (88,103,117,127,135) actual used =127T
DFC: draft fine change wheel (132135T) actual used = 133T
DC; draft change wheel (3070T) actual used = 34T
Total draft =
The total draft is calculated using the formula above. As the reference, total drafts
calculated from the roving weight and the yarn count are actual drafts and is always
smaller than calculated draft mainly due to twist shrinkage (i.e. yarn delivered is slightly
heavier than calculated value ). Twist shrinkage factor varies by the twist multiplier.
Consequently the total draft change gearing should be determined according to the actual
yarn weight.
Draft given in the gearing table
Twist shrinkage =
Desired draft =
Roving count /number =

Calculate the total draft under thee following spinning conditions:
Roving weight = 220grains / 30yds
Yarn count = 40/s
T.M = 3.7
Roving count
Twist shrinkage =
Desired draft =
Draft given in the gearing table =
Twist loss lies in the following range 0.03---0.05
Weighting arms and their loads:-

Front roller Middle roller Back roller
6da N
10daN 10----14daN 12----16daN
14dan
18dan
Setting the Break Draft:-
Calculation formula
BC: break draft change wheel (4068T) actual used= 54T

DM: middle roller dia. 27mm
DB; back roller dia. 27mm
AT: thickness of the bottom apron =1.2mm
= =1.33
Break draft constant = 72.04
Break draft =
Count change process in Ring frame (RX-240 non compact)

When a count is changed at the ring frame the following things are changed
depending upon the conditions:
Spacer
Ring traveler
Spindle speed
Draft wheel
Package time
Twist wheel
Break draft wheel
Twist set(if required)
Draft set ( if required)
Ring bobbin
Roving count ( if required )
Top roller( rubber cots it batch change )
Roller gauge (if required )
Usually when we change count on the ring frame, first of all we calculate total draft and
TPI required.
Draft calculations:
We calculate the total draft in the following way, e.g.
Count spun 36/s compact
Roving count = 0.8
We use the following formula
Where, X= (2.64 01
If T.M= 3.85
Then X = (2.64 5.34
Putting this value of X in equation #01
Twist contraction =
Total draft =
Total draft =
=30.50
Twist calculations:-
Twist per inch is calculated in the following way
T.M= 3.85
TPI = 3.85
Twist constant =625.02
Twist wheel =
Break draft constant =72.04
Break draft wheel =
R.H in the Ring department:-

Relative humidity in the ring department lies in the following order 55% to 70%
R.H depends upon the type of the raw material and mills outside atmosphere. Because
to spun the natural fibers less dry temperature and less R.H is required as compared to
synthetic fiber. Also, if the outside of the mill, temperature and R.H is too high
(especially in month of June, July and August) then the internal temperature and R.H is
very difficult to control. R.H is calculated as
In ring department:
Dry temperature = 90F0
Wet temperature = 80F0
R.H =
Relation between actual and mechanical draft:-
Actual draft
A. D. = COUNT/HR
= 36/0.8
= 45
Mechanical draft
Twist contraction =
X= (2.64 5.34
Twist contraction =
M. D. = A. D. Twist contraction
= 45 1.056
= 47.53 Note Only in ring department, mechanical draft is greater than actual
draft .Reason is that in ring, twist contraction is given to yarn that increases the
mechanical draft.
Number of fibers in the yarn cross-section

Example 01
Yarn count =36/s
Mic. Value =5.05
Since,
Fiber denier = mic. Similarly yarn denier
Yarn denier =
Number of fibers in cross section = =82.61 fibers
Example 02:-
Mic. = 5.05
Yarn count =50/s compact
Fiber denier = 05.05 0.354 = 1.787
Yarn denier =
No of fibers =
Count change at Ring Frame:-15-06-2010
Machine # 12
Old New
Cotton Pak .cotton Pak cotton
Nominal count 20/s CM 26/s CM hosiery
Actual count 20.40 25.70
Hanks roving 0.7 0.7
Draft wheel 42 45
Fine wheel 132 132
Draft set 117/53 127/43
Total draft 29.49 36.82
Twist wheel 32 56
Twist set 59/65 77/47
TPM 741 764
TPI 18.82 19.41
TM 4.21 3.81
Break draft wheel 56 56
Break draft 1.24 1.24
Spacer color violet Violet
Spindle speed 18500rpm 17500rpm
Ring traveler # 1/o RECIUM 2/no Recium
Ring bobbin color Black Black
Simplex bobbin color Green Green
CHAPTER#10
Periodicity calculations
PERIODICITY CALCULATIONS OF A SPINNING MILL
The irregularity U%:
It is the percentage mass deviation of unit length of material and is caused by
uneven fiber distribution along the length of the strand.
The coefficient of variation C.V%:
C.V% is commonly used to define variability and is thus well suited to the
problem the most widely accepted way of quantifying irregularity. It is given by:
C.V% = (S.D / mean) 100
Imperfections:-
In addition to measuring the overall variability of fibrous strand thickness the Uster tester
also counts the larger short-term deviations from the mean thickness. These are known as
imperfections and they comprise thin places, thick places and neps. The sensitivity of the
eye to thick and thin places in a yarn is such that around a 30% change from the mean
thickness is needed for a thick or thin place to be visible. In the instrument, therefore,
only thick and thin places above these levels are counted. Neps are considered to be those
thick places that are shorter than 4mm whereas areas counted as thick places are the ones
that are longer than 4mm. The total volume of the nep is considered in the assessment but
for the purposes of counting they are all assumed to have the same length of 1 mm so that
any variation in size is registered as a variation in thickness. Neps are counted at
sensitivities of +140%,+200%, +280% and +400% above the mean thickness. For the
purpose of the instrument thick and thin places generally have a length equal to the mean
fibre length; any places longer than this are considered to be part of the general yarn
diameter variation. In general it has been found that the number of imperfections at any
one level is related to the imperfections at all other levels so that for comparison purposes
it is not important which particular levels are chosen to be recorded.
Factors responsible for Irregularity:-
The factors determining the single zone drafting wave irregularity are:
Strictly Random Occurring Faults
1. The size of draft
2. The count of the input material
3. Multiple inputs or doubling
4. Roller or drafting zone setting
5. The degree of parallelism, length, and fineness of fibers in the input material
Strictly periodic occurring faults
6. Eccentricity of roller shaft
7. Belt life comes to end
8. Bearings out dated
9. Apron faults
10. Rubber cots faults
11. Waste between gear meshing
12. Damaged Gear teeth
Faults can be detected by the USTER-5 the latest version of evenness tester. You just
have to feed the machine model its particulars and it will show the mass variation in the
test length in the form of vertical histogram.
Mass Spectrogram:-
An important type of thickness variation is the regular appearance of a thick or thin place
at equal intervals along the yarn length. This type of unevenness can give rise to visual
effects such as stripiness or moir patterns in the finished knitted or woven fabric
depending on how the repeat length of the fault compares with the fabric width or course
length. A level of unevenness which would not be apparent if it was random is much
more Objectionable if it comes from a regular fault as the eye is very sensitive to pattern.
The spectrogram measures the periodic mass variations in a yarn by analyzing the
frequencies at which faults occur electronically. From the speed at which the yarn is
running the frequencies are converted to wavelengths and slotted into a finite number of
discrete wavelength steps. The result is a histogram as shown in Fig where the amplitude
is a measure of the number of times a fault of that repeat length occurs owing to the fiber
length having an effect on the distribution of repeats around that Length the background
level of the spectrogram is not flat but a periodically repeating fault will show a level
much greater than the background as is shown in the figure. As a general rule the height
of a peak in the spectrogram should not be more than 50% of the basic spectrogram
height at that wave length.[4]
The wavelength of the fault gives an indication of its cause and therefore allows it to be
traced to such mechanical problems as drafting waves, eccentric or oval rollers in the
spinning plant or in earlier preparation stages. The wavelength can also correspond to the
diameter of the yarn package, in which case it will vary between the full and empty
package. The wavelength of a fault that occurs before the drafting in the spinning process
will be multiplied by the drafting ratio.
"DIAGRAM" is a representation of the mass variations in the time domain. Where as

SPECTROGRAM is a representation of the mass variation in the frequency domain.
Spectrogram helps to recognize and analyze the periodic fault in the sliver, roving and
yarn. For textile application, the frequency spectrum is not practical. A representation
which makes reference to the wavelength is preferred. Wavelength indicates directly at
which distance the periodic faults repeat. The more correct indication of the curve
produced by the spectrograph is the wave-length spectrum. Frequency and wavelength
are related as follows
Frequency = (wavelength)/ (material speed)
In the SPECTROGRAM, the X-axis represents the wavelength. In order to cover a

maximum range of wavelengths, a logarithmic scale is used for the wavelength
representation. The y-axis is without scale but represents the amplitude of the faults in
yarn. The spectrogram consists of shaded and non-shaded areas. If a periodic fault passes
through the measuring head for a minimum of 25 times, then it is considered as
significant and it is shown in the shaded area. Wavelength ranges which are not
statistically significant are not shaded. In this range the faults are displayed but not
hatched. This happens when a fault repeats for about 6 to 25 times within the tests length
of the material. As far as those faults in the un-shaded area is concerned, it is
recommended to first confirm the seriousness of the fault before proceeding with the
corrective action. This can be done by testing a longer length of yarn. Faults which occur
less than 6 times will not appear in the spectrogram. A spectrogram starts at 1.1 cm if the
testing speed is 25 to 200 m/min. It starts at 2.0cm if the testing speed is 400 m/min and it
starts at 4 cm if the speed is 800 m/min. For spun material the maximum wavelength
range is 1.28 km. Maximum number of channels is 80
Depending upon the wavelength of the periodic fault, the mass variations are classified
as:
Short-term variation (wavelength ranges from 1 cm to 50cm)
Medium-term variation (wavelengths ranges from 50cm to 5 m)
Long-term variation (wavelength longer than 5 m)
Periodic variations in the range of 1 cm to 50 cm are normally repeated a number of

times within the woven or knitted fabric width, which results in the fact periodic thick
places or thin places, will lie near to each other. This produces, in most cases, a "MOIRE
EFFECT". This effect is particularly intensive for the naked eyes if the finished product
is observed at a distance of approx. 50 cm to 1m. Periodic mass variations in the range of
50cm to 5m are not recognizable in every case. Faults in this range are particularly
effective if the single or double weave width or the length of the stretched out yarn one
circumference of the knitted fabric, is an integral number of wave-lengths of the periodic
fault, or is near to an integral number of wavelengths. In such cases, it is to be expected
that weft stripes will appear in the woven fabric or rings in the knitted fabric. Periodic
mass variations with wavelengths longer than 5m can result in quite distinct cross-stripes
in woven and knitted fabrics, because the wave-length of the periodic fault will be longer
than the width of the woven fabric or the circumference of the knitted fabric. The longer
the wavelength, the wider will be the width of the crossstripes.Such faults is quite easily
recognizable in the finished product, particularly when this is observed from distances
further away than 1 m. A periodic mass variation in a fibre assembly does not always
result in a statistically significant difference in the U/V value. Nevertheless, such a fault
will result in a woven or knitted fabric and deteriorate the quality of the fabric. Such
patterning in the finished product can become intensified after dyeing. This is particularly
the case with uni-colored products and products consisting of synthetic fibre filament
yarns. The degree to which a period fault can affect the finished product is not only
dependent on its intensity but also on the width and type of the woven or knitted fabric,
on the fibre material, on the yarn count, on the dye up-take of the fibre, etc. A
considerable number of trials have shown that the height of the peak above the basic
spectrum should not overstep 50% of the basic spectrum height at the wavelength
position where the peak is available.
Chimney type faults:
The eccentricity roller results in a sinusoidal mass variation whereby the periodicity
corresponds to full circumference of the roller. With one complete revolution of an
OVAL roller, a sinusoidal mass variation also results, but 2 periodic faults are available.
Chimney types of faults are mainly due to -mechanical faults -eccentric rollers, gears etc
-improper meshing of gears -missing gear teeth -missing teeth in the timing belts -
damaged bearings etc
Periodic fault
Hill type faults:
These faults are due to drafting waves caused by -improper draft zone settings -improper
top roller pressure -too many short fibres in the material, etc numerous measurements of
staple-fibre materials have shown that there are rules for the correlation between the
appearance of drafting waves in the spectrogram and the mean staple length. It is given
below
yarn: 2.75 x fibre length

roving: 3.5 x fibre length
combed sliver: 4.0 x fibre length
draw frame sliver: 4.0 x fibre length
A periodic fault which occurs at some stage or another in the spinning process is
lengthened by subsequent drafting. If the front roller of the second draw frame is
eccentric, then by knowing the various drafts in the further processes, the position of the
peak in the spectrogram of the yarn measurement can be calculated. The wavelength of a
defective part is calculated by multiplying the circumference of the part and the draft up
to that part. The wavelength of a defective part can be calculated if the rotational speed of
the defective part and the production speed are known. Doubling is no suitable means of
eliminating periodic faults. Elimination is only possible in exceptional cases. In most
cases, doubling can, under the best conditions, only reduce the periodic faults. The
influence of periodic mass variation is proportional to the draft. Due to the quadratic
addition of the partial irregularities, the overall irregularity of staple-fiber yarns increases
due to the periodic faults only to an unimportant amount.
Periodicity determination system from gearing diagram
The pre-requisite to successfully localize the periodic occurring fault is the sufficient
knowledge about the gearing diagram/ drive transmission network. Calculation has to be
performed to point out the faulty component of the machine. Lets start this work by
considering simple example of the drafting zone drive of ring frame. Simple gearing
sketch is shown here in fig. ork
Fault length of front roller = circumference or the front roller = D = 3.14 25.4/10 =
= 7.979 cm
Fault length of the Z1 gear will be same as that of front roller because these are
connected on the same shat mean;
Number of revolutions of front roller = No of revolutions of the gear Z1 = 7.979 cm
If the gear Z2 is supposed to be defective then the number of teeth of Z1 and Z2 must be
taken into consideration:
Fault length of Z2= fault length of Z1 Z2 teeth/ Z1 teeth
= 7.979 121T/11T= 87.76 cm
It means the front roller will turn (87.7697.979) 11 times until the fault is repeated.
If the gear Z3 is supposed to be faulty then its fault length will be similar to that of Z2
because these two are situated on the same shaft.
Fault length for Z4 will be calculated from the relation of their number of teeth and
relative fault length as follows:
Fault length of Z4 = F.L Z3 Z4/Z3 = 87.769 90T/30T = 263.30cm = 2.63m
It means that the front roller will turn 33 times until the same fault is repeated.
Fault length of Z5 will be same as that of Z 4 because these two are lying on the same shaft
so, having same delivery speed. Fault length of back roller will also be affected as the
roller is on the same shaft
Fault length of Z6 will be calculated from the relation of number of teeth of the two
meshing gears as follows
Fault length Z6 = F.L Z5 Z6/Z5 = 263.30 26T/32T = 228.193cm = 2.28m
Fault length of Z7= F.L Z 6 Z7 /Z6 = 228.193 26/26 = 228.193 cm = 2.28m
Fault length = circumference of middleZ6/Z7 Z5/Z6

= 2.3 3.14 26/26 32/26 = 8.89 cm roller
Periodicity of Rieter Ring Frame G 5/1

Break draft = 1.28
Main draft = 18.5
Total draft = 23.7
Draft constant= 1042.8
Main draft = 18.51
Top apron length = 12cm
Bottom apron length = 28cm
Length of top apron=12cm
Length of bottom apron=28cm
Twist constant =672
Fault length of front roller 27mm = 273.1416/10 = 8.482cm
Fault length of 29Tgear =8.482cm
Fault length of 26T gear = 8.48226T/29T =7.604cm
Fault length of draft wheel 44T=7.604cm
Fault length of fine wheel FW 93T=7.60493T/44T =16.072cm
Fault length of 20T wheel = 16.072cm
Fault length of 112T wheel=16.072112T/20T =90.00cm
Fault length of break draft wheel 26T=90.00cm
Fault length of 26T carrier wheel = 90.00cm
Fault length of middle roller 25mm = 9042T/26T =145.39cm
Fault length of back roller27mm =9047T/21T= 201.428cm
Fault length of 84T gear = 7.604cm
Fault length of twist constant set wheel 97T gear =7.33cm
Fault length of twist wheel35T =7.33TW/97T=7.3335T/97T=2.645cm
Fault length of 39T wheel =2.645 39T/67T =1.540cm
Fault length of spindle pulley=1.540cm
Fault length of spindle wharve =0.129cm
Fault length of top apron = top apron length main draft= 12cm 18.15 =217.8cm
Fault length of bottom apron = bottom apron length main draft= 28 18.15 = 508.2cm
Fault length of spindle (empty cop) = dia. of spindle 3.14 = 6.5 3.14 = 20.41cm
Fault length of ring traveler = D of ring 3.14 = 38mm3.14/10 = 11.93cm
47 Back Roller 27mm
112
21
26
FW
93
20
Middle Roller 25mm
42
DC
84 44 26
Front Roller 27mm
97 81 29
TW
67
35 250mm
200mm
39
Motor 22KW
250mm
960 rpm
21mm
Gearing diagram of Reiter Ring frame G-5/1
RX-240 TOYOTA Ring Frame Periodicity calculations
Specifications:-
Front roller diameter = 28.5 mm
Middle roller diameter = 27 mm
Back roller diameter = 28.5 mm
Twist constant wheel set = 36/88
Twist change wheel= 65T
Draft constant wheel set = 43/127
Draft wheel = 65T
Break draft wheel = 52T
T.P.I =23.50
Draft constant = 1449.48
Draft = 22.299
Break draft = 2.047
Main draft = 10.893 cm
Bottom apron thickness = 1.2mm
Top apron thickness = 1.1mm
Top apron length = 12mm
Bottom apron length =28mm
At G.E Gearing
Gearing diagram of RX-240 is shown on the next page
Fault length of front roller = 28.5 3.1416/10 = 8.953 cm
Fault length of 40T gear = 8.953 cm
Fault length of 82T gear = 8.953 82T /40T =18.354 cm
Fault length of 64T gear =18.354 64T/40T= 14.325 cm
Fault length of 43T gear = 14.32543T/70T =8.800 cm
Fault length of twist constant wheel TCB (88T) = 8.800 cm
Fault length of twist constant wheel TCA (36T)=8.80036T/88T=3.600 cm
Fault length of 75T wheel = 36.600 cm
Fault length of twist change wheel TC (65T) = 3.60065T/75 = 3.120 cm
Fault length of 38T gear = 3.120 38T/62T = 1.912 cm
Fault length of 26T wheel = 1.912 26T/45T =1.104 cm
Fault length of tin pulley = 1.104 cm
Fault length of spindle wharves = 1.104 18.5/200 = 0.102 cm
Fault length of 125T gear driving the 40T gear on the other side of the machine for the
front roller = 14.325 125T/64T = 27.978 cm
Fault length of 40T gear driving the front roller = 27.978 40T/125T = 8.953 cm
Fault length of front roller from other side of frame = 8.953 cm
Fault length of draft constant wheel DCA (43T) = 27.978 cm
Fault length of draft constant wheel DCB (127T) =27.978 127T/43T = 82.632 cm
Fault length of draft change wheel DC 65T = 82.632 cm
Fault length of draft change fine wheel DFC (133T) = 82.632 133T/65T =169.077 cm
Fault length of 94T carrier wheel = 169.077 94T/38T =418.245 cm
Fault length of break draft change wheel BC(52T) = 418.245 52T /94T = 231.369 cm
Fault length of 55T carrier wheel = 231.369 55T/ 39T = 326.290 cm
Fault length of middle drafting roller = 326.290 31T/ 55T = 183.80 cm
Fault length of 93T carrier wheel = 169.077 93T/ 50T =314.48 cm
Fault length of back drafting roller = 314.48 68T/ 93T = 229.94 cm
Fault length of top apron = 28 3.1416/ main draft = 28 3.1416/10.89 = 8.077 cm
At O.E Gearing
Fault length of front roller in G.E Gearing = 8.953 cm
Fault length of draft constant wheel DCA (43T) = 27.978 cm
Fault length of draft constant wheel DCB (127T) = 27.978 127T/43T = 82.632 cm
Fault length of draft wheel DC 65T = 82.632 cm
Fault length of draft change fine wheel DFC 133T = 82.632 133T/65T = 169.07 cm
Fault length of 38 T wheel = 169.07 cm
Fault length of 94T carrier wheel = 169.07 94T/38T = 418.24 cm
Fault length of break draft change wheel 52T = 418.24 52T/94T =231.37 cm
Fault length of middle drafting roller = 326.291 31T/55T = 183.90 cm
Fault length of 39T wheel = 27.978 Fault length of 125T gear = 8.953 125T/40T
= 27.978 39T/125T = 8.729 cm
Fault length of 78T wheel = 8.729 78T/39T = 17.458 cm
Fault length of front roller = 8.729 40T/39T = 8.9528 cm
Fault length of top apron = 12cm main draft = 12 10.893 = 130.72
Fault length of bottom apron = 28cm main draft = 28 10.893 = 305.004
Finding the defective component through spectrogram wavelength:-[3]
The chimneys may exceed the basic height of the spectrogram by 50%at most. If the
value is higher a defective end product must be expected. If two chimneys occur close
together the excessive length of the chimneys must be added. If the spectrogram shows a
periodic fault; we can process as follows to find out the route cause of that fault.
Step -1:-
Wave length from spectrogram/
= diameter of the defective component

Let wavelength = 9.4cm
= 9.4/3.14 = 3cm =30mm (diameter of the front roller)
Step -2:-
Check if the result matches with an existing technological component
Result: the fault is due to front top roller it has a diameter of 30mm.
Step -3:-
If this is not the case divide the term in addition by the main draft
i.e. Wavelength from the spectrogram/ main draft = dia. Of defective component
Let
Chimney at = 5.74cm
Main draft =42
Dia. Of defective component = 5.74cm423.14 = 43.5mm
Step -4:-
Check if the result matches with an existing technological component
Result: the fault is due to top apron which has a diameter of 43.5mm
Step -5:-
If this is not the case divide the tem in addition to the break draft
Wavelength from spectrogrammain draft breaks draft
Periodic faults may also be due to spinning preparatory machines.
Drafting disturbance:-
Floating fibers, short fibers, or such fibers which are neither clamped by delivery roller
nor by take off roller of the drafting plan can cause drafting waves or chimneys. The
height of such chimneys depends upon the number of uncontrolled fibers and the drafting
values. Such a fault can be due to an unsuitably set drafting system. The average
wavelength of the drafting chimney always corresponds to 2.5 times the medium staple
length.
Wavelength Range of Ring Spinning Machine in Cotton spinning Mill
Yarn Spectrogram
Machine Source Formula Calculation Faults

of wavelength Range (M/cm)
Front Top Roller (Dia 3.14) 85.408 8.54cm
Middle Top Roller ( Dia 3.14 1297.605 12.98m

Main Draft)
Back Top Roller ( Dia 3.14 1965.55836 19.66m
Total Draft)
Front Bottom Roller (Dia 3.14) 84.78 8.48cm
Middle Bottom ( Dia 3.14 1401.4134 14.01m

Roller Main Draft)
Back Bottom Roller ( Dia 3.14 1836.3348 18.36m
Total Draft)
RING SPINNING MACHINE
Top Apron (I Main Draft) 611.61 6.12m
Bottom Apron (I Main Draft) 1371.99 13.72m
Ring Traveller (Dia of Cup 131.88 1.32m

3.14)
Spindle Full Cop (Dia full 0.00
cop3.14)
Spindle Empty Cop ( Dia empty cop 0.00
3.14)
Periodicity calculations of EJM-168
Fault length of front bottom roller = 273.1416/10 = 8.482cm

Fault length 40T A gear = 8.482cm
Fault length of 45T gear = 8.48245/40 = 9.54 cm
Fault length of 64T gear = 9.54 64/45 =13.57cm
Fault length of 72T gear = 9.54 64/45 =13.57cm
Fault length 40T B gear = 13.57 40 / 72 = 7.54 cm
Fault length of Twist-Set wheel B (64T) = 7.54 cm
Fault length of Twist-Set wheel A (62T) = 7.30 cm
Fault length of D 64T gear = 13.57 64/64 = 13.57 cm
Fault length of 123T gear = 13.57 123/64 = 26.07 cm
Fault length of Fine Draft wheel FW (134 T) = 26.07 cm
Fault length of Draft wheel DW (47 T) = 26.07 47 / 134 = 9.147 cm
Fault length of 101 T gear = 9.147 cm
Fault length of 59 T gear = 9.147 59 / 101 = 5.35 cm
Fault length of 36 T gear = 5.35 cm
Fault length of 40T C gear = 5.35 cm
Fault length of 0T gear = 5.35 70 /36 = 10.40 cm
Fault length 42T gear = 10.40 42 / 28 = 15.60 cm
Fault length of 50T gear = 15.60 50/31 = 25.16
Fault length of 20T gear = 25.16 20/50 = 10.06 cm
Fault length of middle bottom drafting roller = 10.06 cm
Fault length of 80T gear = Fault length of 40T C gear 80/ 40
= 5.35 84 /40 = 10.70 cm
Fault length of 52T gear = 10.70 52 /80 = 6.95 cm
Fault length of back bottom drafting roller = 6.95 cm
EJM-168 Ring Frame
Periodic faults Detection System for Simplex FL-100 TOYOTA
Hank roving = 0.80
Top apron length = 28cm
Bottom apron length = 28 cm
Thickness of bottom apron = 1.4mm
Thickness of top apron = 1.1mm
Draft constant = 332
Draft change Wheel =53T
Back draft wheel= 69.025=69T
Total daft = 6.2
Break draft = 1.19
Main draft = 3.674
Twist constant= 46.38
Twist wheel = 44T
TPI= 1.05
Lifter set=24T/36T
Spacer = green
Gauge = 6.5-19.5-23mm
Fault length of front roller = 28.53.1416/10 =8.95cm
Fault length of 60T gear = 8.9560T/20T = 26.85cm
Fault length of 21T gear driving the bottom apron shaft = 26.8521T/60T=9.39cm
Fault length of twist change wheel of 44T = 6.17244T/91T=2.984cm
Fault length of 87T gear = 2.98487T/76T = 3.416 cm
Fault length of twist constant wheel C with 91T= 3.416cm
Fault length of twist constant wheel B with 82T =3.41682T/91T =3.078cm
Fault length of main motor driven gear with 66T =3.078cm
Fault length of 54T gear driving the flyer driving shaft= 3.078 54T/47T =3.536cm
Fault length of 47T gear driving the flyer = 3.536cm
Fault length of flyer wheel of 32T =3.536 32T/47T =2.407cm
Front roller to backward periodic fault locations
Fault length of draft constant set wheel104T = 8.95 104T/26T =35.8cm
Fault length of draft wheel TDC 53T = 35.8cm
Fault length of draft constant set wheel83T=35.8 83T/64T =46.648cm
Fault length of back roller 28.5mm = 46.468 cm
Fault length of break draft change wheel 60T =46.648 60T/33T = 84.815cm
Fault length of 60T gear =84.815cm
Fault length of 3rd roller = 84.81526T/60T =36.53cm
Periodic faults in feeding region

Fault length of 61T gear =46.468 61T/33T =85.89 cm
Fault length of oscillating shaft and 62T gear =85.895 62T/61T =87.3030cm
Fault length of oscillating drive wheel a( 28T)= 87.303cm
Fault length of oscillating drive wheel b (41T)=87.30341T/28T=127.837cm
Fault length of oscillating drive wheel c (33T)=127.837cm
Fault length of oscillating drive wheel d (36T) = 127.83736T/33T= 139.45cm
Fault length of feed roller (50mm) = 87.303 17T/18T=82.452cm
Fault length of 2nd feed roller (50mm) =82.452 cm
Fault length of 3rd feed roller (50mm) =82.452cm
Fault length of top apron= apron length main draft= 28cm 3.674 = 102.87cm
Fault length of bottom apron= length main draft= 28cm 3.674 = 102.87cm
Wavelength Range of Simplex Frame in Cotton Spinning Mill [2]
Gearing Diagram of DX-500
77 E.R 51mm
F.C. 44
116
DC
P B.R 35mm
52
54
37
3rd 35mm 30
75 75 47 59
2nd 35mm
37
58
F.R 35mm
30 71 77
49 48
C.R 51
23
44
Motor
Periodicity of DX-500
Fault length of calendar roller 51mm diameter=51mm3.1416/10 =16.022 cm
Fault length of 30T gear= 17.29244T/49T=11.151cm
Fault length of front roller = 11.151cm
Fault length of 77T gear = 16.02277T/23T = 53.638 cm
Fault length of 2nd roller =53.63858T/71T = 43.817 cm
Fault length of 3rd roller = 69.87130T/47T =44.598 cm
Fault length of back roller =59.36454T/44T =72.855 cm
Fault length of 75T wheel = 16.02275T/44T =27.310cm
Fault length of 52T gear =27.31052T/75T=18.935cm
Fault length of DCP gear 37T =18.935 cm
Fault length of fine draft wheel 116T = 18.935116T/37T=59.364cm
Fault length of electric roller =59.36477T/44T = 103.88cm
Periodicity of SB-2 Draw frame RIETER
Fault length of calendar roller = 55mm3.1416/10 = 17.278cm

Fault length of 50mm pulley = 17.278cm
Fault length of 57.8mm pulley = 17.27857.8/50 =19.974cm
Fault length of W3 140.2mm = 19.974cm
Fault length of 89.1mm pulley = 19.97489.1/140.2 = 12.694cm
Fault length of 1st drafting cylinder = 12.694cm
Fault length of 114.6mm pulley = 12.694114.6/89.1 = 16.327cm
Fault length of draft wheel NW1 (31T) =16.327cm
Fault length of break draft wheel Nw2 (70T) / fine wheel
= 16.32770/31 = 36.867 cm
Fault length of 35 mm middle roller driving pulley =36.867 cm
Fault length of W4 (57.9mm) = 36.86757.9/35 =60.988cm
Fault length of middle drafting cylinder = 60.988 cm
Fault length of back drafting cylinder = 36.86781.5/35 = 85.847cm
Fault length of W8 (31T) = 36.687W8/26 = 36.687 31/26 =43.742 cm
Fault length of 28mm diameter creel roller = 43.742 27/39 = 30.283 cm
Fault length of table creel roller 50mm dia. = 43.74260/48.2 = 54.45 cm
Fault length of W1 (146.mm) =54.45 146.7/60 = 133.131 cm
Fault length of 60mm power creel driver wheel = 133.131 cm
Fault length of power creel cylinder of 80mm = 133.131 40/60 =88.75 cm
Periodicity Calculations for DYH-500c TOYODA
Fault length of calendar roller 51mm = 51/10 3.1416 = 16.022 cm

Fault length of 30T wheel driving the front roller = 17.842 30T/49T =10.924 cm
Fault length of front roller = 10.924 cm
Fault length of draft constant set wheel A = 17.842 cm
Fault length of draft constant set wheel B = 17.842 59T/68T = 15.480 cm
Fault length of draft wheel TDC = 15.480 cm
Fault length of fine wheel F, C 116T = 15.480 116T/38T= 47.254 cm
Fault length of back drafting roller 35mm = 55.846 54T/52T = 57.994 cm
Periodicity of second side gears of machine
Fault length of 2nd drafting roller 35mm = 44.751 cm
Periodicity of creel
Fault length of 51mm feed roller = 82.693 cm
DYH500 -C DRAWFRAME
Fault length of 28T bevel gear = 89.054 cm
Fault length of 27T bevel gear = 89.054 27T/28T = 85.874 cm
Fault length of creel roller 50mm diameter= 85.874 14T/27T = 44.52
Periodicity or RSB D35 finisher Draw frame
Fault length of calendar roller = 55 3.1416/10 =17.278 cm

Fault length of 28 wheel = 17.278 cm
Fault length of W3 82.5 = 17.728 cm
Fault length of 60mm wheel = 17.728 60/82.5 = 12.893 cm
Fault length of front drafting cylinder = 12.893 cm
Fault length of 77.2 wheel = 12.893 77.2/60 = 16.589 cm
Fault length of 38 wheel = 16.589 cm
Fault length of DA = 16.589
Fault length of DW3 54.1mm = 16.589
Fault length of 100 wheel = 16.589 100/38 = 43.655 cm
Fault length of NW1= 43.655 (36/54+36/54) = 58.206 cm
Fault length of Nw2 = 58.206 60/56 = 62.364 cm
Fault length of back drafting cylinder = 62.36452/52= 62.364 cm
Fault length of w4 (60.3) = 62.364 cm
Fault length of middle drafting cylinder = 62.364 52/60.3 = 53.780 cm
Fault length of W8 (204) = 62.364 204/150 = 84.815 cm
Fault length of W2 (48.9) = 84.815cm
Fault length of table feed rollers of 45mm = 84.815 55/48.9 = 95.395cm
Fault length of W1(101.1) = 95.395101.1/55 = 175.353 cm
Fault length of creel roller 80mm = 175.353cm
Fault length of top rollers = Running circumference of the rollers
Causes of spectrogram faults in range 40 - 50 cm
Fault through coiling / procedures

Material feed-related faults
Faults due technological settings
Faults for mechanical reasons
Faults for electrical reasons
Figure shows the drive and coiling process of can
Z1=16, Z3 = 32, Z2 = 33, and Z4Z11 = 25
The guide roller of the coiler turns quicker than calendar roller the tension
draft produced by the gears reaches
Tension Draft = Z3/Z2 = 33/32 = 1.03
The coiler plate produces a coil having a mean radius of 15cm the mean coil
length will be therefore
C.L = D = 3.14 152 = 94.2 cm
For each revolution of the can 18 coils are laid so material length will be
referred as:
Total length delivered in one revolution of can= 94.2 18
= 1695.6cm=16.96m
It means the feed roller must feed 94.2 cm of sliver per complete revolution of
the coiler having diameter of 5.08cm and processing rotational speed
Rpm of guide roller = 94.2cm/5.083.14 = 5.9 rpm
The gears Z4..Z11 also turn with the same rotational speed and delivering
length
= 5.9 18 =106.2cm
Summary: - [1]
1. Irregularity in distribution of mass of the stream of fibers may be caused by a lot
of factors, often very difficult to identify. Periodicity of linear density distribution
occurring in the stream of fibers may be caused both by the elements having
direct contact with the fibers and by the elements transferring power to the
working rollers.
2. Preparing a spectral analysis of machines with complex driving systems requires
time - and work-consuming calculations, which make it considerably more
difficult to quickly find the cause of the detected periodicity in the stream of
fibers and to take steps to eliminate the element generating the fault.
References:-
1-AUTEX Research Journal, Vol. 9, No4, December 2009 AUTEX p: 103-105
2-USTER TESTER application hand book 4-32
3- Application hand book of Suessen Elite compact system
4- B.P Saville Physical Testing of Textile Fibersp-
CHAPTER#11
Auto-cone&Doubling
calculations
Doubling Auto cone Production (lbs/day)
=Drum speed (m/min)1.0936efficiency6024no. of drums/840count
Q.If drum speed is 1200 m/min and count is 20 s what will be the production per day of
12 frame if efficiency is 88 %.( no. of heads are 60)
Auto cone Production (lbs/day)
=Drum speed (m/min) 1.0936efficiency6024no. of drums/840count
= (12001.09360.88602460/84020) 12
= 71270 lbs/day
=712 bags/day
Q.If the spindle speed of doubling m/c is 1100m/min. calculate the production of
doubling m/c at 90% efficiency at 10TPI of 16 count.
=Spindle speed (m/min) 1.0936efficiency6024no. of spindles2/840TPIcount
=11001.093660240.91202/8401610
=262 3=786lbs/day
If 3% contraction
=7860.97=762lbs/day
Q#1: what will be the production of a 280 spindle of FO (twisting) frame is 8hrs at
84% efficiency, if it is working 66s/3 yarn and speed of 2 Dia delivery roller is 126
rpm????
SOLUTION:
The resultant count of 66s/3 ply is as:
1/R=1/C1+1/C2+1/C3
1/R=1/66+1/66+1/66
1/R=1+1+1/66
R=3/66
R=66/3
=22s Count
Production/shift in lbs=del. Speed/min860/840countefficiencyno of spindles
=N3.14D/36860/840countefficiencyno of spindles
=12623.14/36860/840220.84280
=134.27 lbs Ans
Q#2: A double frame is twisting 21/1, 28/s 42/s counts together. Calculate the count
of resultant yarn, if 1000 lbs of resultant yarn is required. Find the weight of each
single yarn required????
SOLUTION:
1) Resultant count of21/s,28/s,42/s in,
1/R=1/C1+1/C2+1/C3
1/R=1/21+1/28+1/42
=1176+882+588/24696
=2646/24696
1/R=24696/2646
=9.33/3 PLY
2) Hanks in resultant count
=pounds R count
=1000*9.33
=9330 hanks
3) (a) Weight of 21/s will be:
Hanks/count
=9330/21
=444.44 lbs
(b) Weight of 28/s will be:
Hanks/count
=9330/28
=333.33 lbs
(c) Weight of 42/s will be:
Hanks/pounds
=9330/42
=222.23 lbs
TOTAL WEIGHT of 9.33/3 ply yarn =W1+W2+W3
=444.44+333.33+222.23
=1000 lbs
Ans
Q#3: A doubling frame is running 28/2 on one side and 36/2 on other side.TPI is
17.0 on both sides, if the spindle speed is 8500 rpm, what will be the production
in oz/spindle in 8 hrs at efficiency of 84% of both the counts???
GIVEN DATA:
C1=28/2, C2=36/2
TPI (C1) (C2) =17.0
Spindle speed=8500 rpm
Efficiency=84%
Time=8 hrs
REQUIRED:
1) Production of 28/2 in OPS
2) Production of 36/2 in OPS
SOLUTION:
1) =5.92 ANS Production of 28/2 will be;
Production (OPS) = spindle speed/TPICount16/63efficiency
=8500/17.0count16/6384/100
=85002/17.02816/6384/100
=7.619
2) Production of 36/2 will be;
Production (OPS) =spindle speed/TPICount16/63efficiency
=8500/17.0count16/6384/100
=85002/17.03616/6384/100
Q#4: A Three ply yarn of 9.52s resultant count is composed of three different
counts..if two of them are 40/s and 25/s, what will be the count of third yarn???
GIVEN DATA:
Resultant count of three ply yarn=R=9.52
Count C1=40/s
Count C2=25/s
Required=count (3) =???
SOLUTION:
Let C3 will be the count of doubled together with 40/s and 25/s,
So,
1/R=1/C1+1/C2+1/C3
1/9.52=1/40+1/25+1/C3
1/9.52=250C3+400C3+10000/10000C3
650C3+10000/10000C3
10000C31/9.52= (650C3+10000)
10000C3=9.52(650C3+10000)
10000C3=6188C3+95200
10000C3-6188C3=95200
C3=95200/3812
=24.97 ANS
Setting the number of twist for a set
The number of twist is obtained from the following formula:
Number of twists (T/m) = spindle rpm*2/circumference speed of the winding drum

friction ring m/min
1. Determination of the number of twists for a set:
2. Obtain the reference number of twist for a set with the following formula:
Reference no. of twist for a set=req. twists + req. twist (1/cos -1)*1/2
1/cos =winding angle ( ) compensation factor
1/2 = experimental compensation factor obtained from the measured
value..
EXAMPLE: If the no of required twist is 590T/m, and the winding angle is 18*
08, what will be the no of twists for a set???
GIVEN DATA:
0
Winding angle( ) (1/cos ) 1/cos -1*1/2
12 degree 14(12.23) 1.023 0.012

14 degree 32(14.533) 1.032 0.016
18 degree 08 1.051 0.026
21 degree 24 1.074 0.037
Required twists=590T/m
Winding angle=180 08==18 0+08/60
=18+0.133
=18.1330
REQUIRED: no of twists for a set?????
SOLUTION: We know that;
No of twists for a set= req. twists + req. twist (1/cos -1)01/2 (1)
Putting the given value in the formula (1)
No of twists for a set=590+590([1/cos (18.133)] -1)*1/2
=590+590 (1/0.9503-1) 1/2
=590+590 (1.052-1) 1/2
=590+590 (0.05) 1/2
=590+5900.026
=590+15.41
=605.416 T/m ANS
EXAMPLE: what will be the number if twist/m if MURATA m/c spindle diameter is
140, 160 and twist constant is 1182.7? Gear A is 55 T,B is 21,and C is 56 and D is 20
T..
GIVEN DATA:
I. Constant=1182.7
II. Gears A=55T
III. GEARS B=21T
IV. C=56
V. D=20T
REQUIRED: no of twist/meter=?????
SOLUTION:
WE KNOW THAT;
No of twists/m=twist constantB/AD/C
Putting the values in the above formula, so
=1182.721/5520/56
=161.27 T/m ANS
EXAMPLE::What will be t/m if twist constant is 446.80 and other gears as follows;
A=36 B=40 C=49 D27
SOLUTION:
T/m=Twist constantB/AD/C (1)
Putting the values in EQ (1) then;
T/m=446.8040/3627/49
=273.55 or
=274 T/m ANS
EXAMPLE #1: A winding speed of 60 spindles is working (winding the yarn of) 28s
count from ring bobbins to one cone. The surface speed of 10 diameter drum is 1000
yards/min. calculate the lbs, of ring yarn required by the machine in 8 hrs, if the machine
efficiency is 84%...
GIVEN DATA:
Count=28s
No. of spindle/drum=60
Drum Dia=10
Drum speed=1000 yd/min
Time=8hrs
Efficiency=84%
REQUIRED: Production in lbs=????
Production in lbs/60 drum/8 hrs= yards /min/840count860no of drumsefficiency
=1000/840288606084/100
=1028.57 lbs ANS
EXAMPLE#2: The production of winding frame, working 40s count, 616lbs in 8 hrs. T
he drum shaft speed is 1960 rpm and the diameter of drum is 3. If there are 120 drums
in the machine, calculate the efficiency???
GIVEN DATA:
Count=40S
Production=616 lbs
Time=860=480 minutes
Drum speed=1960 rpm
Drum diameter=3
No of drum=120
Required: Efficiency=????
SOLUTION:
We know that
Production in lbs=N3.14D/36860/840countno of drumsefficiency
(1)
Putting the given value in formula (1)
616=19603.143/36860/84040120eff/100
6163684040/19603.143860120=eff/100
0.7001=eff /100
0.7001100=efficiency
Efficiency =70.01 ANS
Compressor Calculation:
Q. 1 The gages on the suction gas and discharge gas lines of a compressor read 5 psiv
2
(lb/in ) and 60 psig, respectively. How much is the pressure increased by a compressor?
Solution:
The pressure increase is;
Pressure increase = 60 + 5 = 65 psi. Ans
Q. 2: We want to measure the pressure of air in a duct. So, connect one leg of a water
manometer to the duct and other leg is exposed to atmosphere. The difference in height of
the water columns in 8in, w.g. (inches of water gage) what is the air pressure in the duct
in psig?????
Solution:
The difference is related to pressure by equation p = d x H, Changing the unit of H first,
H = 8 in. w.g. x 1 ft/12in = 0.667 ft w.g.
P=dxH
= 62.4 lb/ft3 x 0.667 ft
= 41.6 lb/ft2 x 1 ft 2/144 in2 = 0.29 psig. Ans
The air pressure in the duct is 0.29 psig above atmospheric pressure.
Q.No1. Determine the cost to operate the compressors
This was doing by using following equation.
EU= NHPLFUFH/Efficiency
Where:
N=Number of compressors
LF= Load Factor .ratio of actual load to maximum load
H.P= H.P of compressors, converted to kilo watt at rate of 0.746 kw/hp
UF= Utilization factor, maximum demand of system over its capacity
H= Operating hours of compressors
Efficiency= Efficiency of compressors motors
Cost of consumption of energy is finding by using this equation
EC= EU*ER
Where
EC= Energy cost
EU= Energy usage
ER= Rate of efficiency (kw/hr)
P=250HP0.746kw/hp80%
=150kw
To calculate the time a compressors is running, we multiply the number of hours in a year
by utilization factor, in the percentage of time.
The compressor is running:
T= 8766hours/years 91%=8000hour/year
Work out put=150kw*8000hr/year
=1,200,000kw-hours
Efficiency= 85%
EU= 1,200,000kw-h/85%=1411764kw-hours
Current cost of electricity is 5 rupees per k w h
Cost of compressor= 51411764=7058823PKR
EU= 120kw8000h/year /95%
=1010500kw-hour/year
Cost= 10105005=5052631PKR or $57416
Pressure conversion
I psi 2.3 ft w: 2.04 in Hg

1atm: 101,300N/m3
1mm Hg: 133.3Pa
14.7psi: 1atm
Capacity Measures
1 cu. inch: 16.387cu. Centimeters
1 cu. ft: 0.02832 cu. meter = 28.32litres
1 cu. yard: 0.7646 cu. Meter= 764.6litres
1 gallon: 4.546litres
1 cu. centimeter: 0.061 cu. inches
1cu. decimeter: 61.024 cu. Inches
1cu. meter: 35.3cu.ft.
CHAPTER#12
SlubYarn calculations
NEW CSTU - CAIPO SLUB AND TWIST UNIT
CAIPO presents a new innovating and technologically updated system,

which is the result of decades of experience in the spinning sector for
the production of SLUB YARN (coarse and fine yarn) - MULTICOUNT -
MULTITWIST with performances at production level and of very high
quality.
The CAIPO research and development centre worked for many years on
this new project and took advantage of the many inputs received from
a close collaboration with his customers and from the market demand,
by using the well known
CSM-90 system.
The CSTU can be applied to any type of ring frame and Open end, both
to new machinery and to the existing one.
The high simplicity of programming, th e high quality of the hardware
and the high performances of the product mak e it as a very important
instrument to develop new yarns with customized characteristics.
TECHNICAL FEATURES:
Yarn types that can be obtained:

- Normal
- Slub yarn (coarse and fine).
- Multicount wit h twist variation.
- Multitwist
Direct control of feed shafts (top and middle), bes ide s the
production of slub yarn, the draft con be set too.
The delivery shaft (front roller) can be controlled, by adding a motor to

set the twist and to change it according to the count processed.
Motors digital-control (through CAN-BUS), allowing a very high
Precision on draft and twist control.
Draft and twist electronic control, by eliminating the different pulley
ranges.
CSTU internal mem ory containing 10 programs of 500 lines each.
CAIPO-MEM solid-state cartridge, containing 30 programs of
500 line each.
Programs length of 500 lines; each line holds the following information:
Pause len gth (mm, cm or dm). Slub length (mm, cm
or dm).
Slub thickness (in time as to the pause). Twist % as to the
base twist.
Slub thickness: from 0,1 to 9,00 with steps of 0,01.
Twist: from 30% to 300% of nominal twist. Checking of

spinning par ame ter s set.
Draft - Count corresponding to the program - Twist.
Offset functions either for slub yarn or for multicount and multitwist.
Setting of the acceleration and feed rollers braking ramps to adjust at your
liking the starting and terminal angle of the slub.
Setting of nominal twist: from 5, 00 to 300, 00 (according to
the spinning fra me ).
SLUB YARN CALCULATION
1. Slub yarn pattern out calculation
Slub length reading
Pause length reading
2. Maximum and minimum reading
Pause Count = Pause length in cm x 0.0059/Weight in Milligram
Slub Count = Slub Length in cm x 0.0059/ weight in Milligram
Thickness = Pause count / Slub Count
(Count = length in yd / Wt in Lbs x 840
Count = 64.8 / wt in grams of one lea 120yds {453.6/840 x 120 = 64.8}
Count = 0.54 / wt in grams of 1 yd {64.8/120 = 0.54}
Count = Length in CM x 0.54 x 10 / 914.4 / Wt in Milligrams.
Count = Length in CM x 0.0059 / Wt in Milligrams)
Average Count of pause is called base count.
MULTI COUNT CALCULATION

Giving Pattern
6.5 90 CM
10 290 CM
6.5 90 CM
10 390 CM
Avg. Count Formula
Count = Length in Yds Weight in Lbs x 840
Weight in Lbs = Length in Yds count x 840
Avg. count = Total length Total Wt x 840
Example:
First of all we convert the cm in to yards as;
90cm / 2.54 = 35.433 inches 36 = 0.98 Yds.
290cm /2.54 = 114.17 inches 36 = 3.17 Yds
390 cm / 2.54 = 153.543 inches 36 = 4.26 Yds
By using the Count formula find out the weight as;
0.98/6.5*840 = 0.000180 lbs
3.17/10*840 = 0.000377 lbs
0.98/6.5*840 = 0.000180 lbs
4.26/10*840 = 0.000780 lbs
Total Weight in lbs = 0.000180+0.000377+0.000180+0.000780 = 0.001517
Total Length in Yds = 0.98 + 3.17+ 0.98 + 4.26 = 9.39
Avg. count = 9.39 0.001517*840 = 7.37
Thickness;
7.37/6.5 = 1.13
7.37/10 = 0.73
7.37/6.5 = 1.13
7.37/10 = 0.73
TWIST %AGE
TPI = T.M base count

Avg. T.M = 4.20 and Avg. T.P.I = 11.40 and therefore
1. Avg. T.M 4.20 x 6.5 = 10.70 TPI
10.70 / Avg. T.P.I (11.40) = 0.93 * 100 = 93.92 %
2. Avg. T.M 4.20 x 10 = 13.28 TPI
13.28 / Avg. T.P.I (11.40) = 1.16 * 100 = 116.5 %
3. Avg. T.M 4.20 x 6.5 = 10.70 TPI
10.70 / Avg. T.P.I (11.40) = 0.93 * 100 = 93.92 %
4. Avg. T.M 4.20 x 10 = 13.28 TPI
13.28 / Avg. T.P.I (11.40) = 1.16 * 100 = 116.5 %
(Usually In Slub Yarn T.M is greater than plain yarn)
Draft = Count Delivered Count Feed (Hank Roving) 1.25 %

1.25 % is Draft construction Factor, whose range is = 15 ~ 40 in Slub Yarn .
ZA = 43 Twist Wheel
Zb = 64 Twist set Encoder
Zc = 62
Zd = 59
Ze = 101 Draft set 40 Front Roller (L)
Zf = Draft Wheel 28
Zg = Fine Wheel 59 Middle Roller (L)
Zh = B.D Wheel Zd 123
52 Back Roller (L)
50
Zf 101 75
35 Ze 31
40
ZG Encoder
36 39 Encoder
132 40
64 39
72 70 Encoder
75
Zc 31
ZH
62 40 64 44
50
72 52 Back Roller (R)
64
Zb 28
58 Middle Roller (R)
ZA 43 45
40 Front Roller (R)
Encoder
24 176 Dia
D3
d 20.2
D3 = 250mm
1465 rpm 200 Dia

25 KW
Ring EJM 168 Gearing Layout D1

LDiagram 400 V
DRAFT CALCULATION
SURFACE SPEED OF FRONT ROLL
DRAFT
SURFACE SPEED OF FEED ROLL
1*52*F.W*DRAFT*SET*123*64*27*3.14
DRAFT
40*64*40*27*3.14
DRAF SET*F.W
DRAFT=3.9975
D.W
BREAK DRAFT CALCULATION

SURFACE SPEED OF MIDDLE ROLL
BREAK DRAFT=
SUEFACE SPEED OF BACK ROLL
1*52*36*31*27*3.14
BREAK DRAFT=
40*B.D.W*28*27*3.14
51.82
BREAK DRAFT=
B.D.W
TWIST CALCULATION
SPINDLE SPEED
T.P.I. =
SURFACE SPEED OF FRONT ROLL
1*40*72*TWIST SET*72*58.5*(250+1.2)
T.P.I. =
64*TWIST WHEEL*40*26.5*(19.2+1.2)
TWIST SET
T.P.I=665.75*
TWIST WHEEL
Draft Constant = 3.9975 x Fine Wheel x Draft Set /Draft Wheel = Total Draft
Twist Constant = 723.61 x Twist Set/Twist Wheel = TPI
B.D.C = 55.19 / B.D.wheel
LYCRA YARN CALCULATION

LYCRA DRAFT CONSTANT CALCULATION
1. 38 X Front Roller Diameter / attachment roll wheel / 19
38 x 27 50 19
=1.08
2. lycra Draft Calculation
Count x Denier x 100 / Lycra % age = Draft
3. Lycra %age Calculation
Count x Denier x 100/5315/Lycra Draft = %age
4. Lycra Used In Bags
Total Bags x 45.36 x %age / Yield = KG.
5. Lycra Traveler Speed Calculation
Traveler Speed m/sec x 1000 x 60 /3.1416 / Ring Cup Diameter.
Sp.speed
6. Lycra draft Calculation by Count
Count /Hank Roving +15 % = Draft
CHAPTER#13
Costingof aSpinning Mill
INTTRODUCTION:
It is better to review the basics concepts, costing methods and techniques and elements of
costing before we work out a costing for a spinning mill.
Cost accounting is a system of determining the costs of products or services. It has
primarily developed to meet the needs of management. It provides detailed cost
information to various levels of management for efficient performance of their functions.
Financial accounting provides information about profit, loss, cost etc., of the collective
activities of the business as a whole. It does not give the data regarding costs by
departments, products, processes and sales territories etc. Financial accounting does not
fully analyze the losses due to idle time, idle plant capacity, inefficient labor, sub-
standard materials, etc. Cost accounting is not restricted to past. It is concerned with the
ascertainment of past, present and expected future costs of products manufactured or
services supplied. Cost accounting provides detailed cost information to various levels of
management for efficient performance of their functions.
"A cost is the value of economic resources used as a result of producing or doing the
things costed "Cost is ascertained by cost centers or cost units or by both.
For the purpose of ascertaining cost, the whole organization is divided into small parts of
sections. Each small section is treated as a cost centre of which cost is ascertained. A cost
centre is defined as " a location, person, or item of equipment (or group of these) for
which costs may be ascertained and used for the purpose of control. A cost accountant
sets up cost centers to enable him to ascertain the costs he needs to know. A cost centre is
charged with all the costs that relate to it. The purpose of ascertaining the cost of cost
centre is cost control. The person in charge of a cost centre is held responsible for the
control of cost of that centre. Cost unit breaks up the cost into smaller sub-divisions and
helps in ascertaining the cost of saleable products or services. A cost unit is defined as a
unit of product, service or time in relation to which cost may be ascertained or
expressed." For example in a spinning mill the cost per kg of yarn may be ascertained.
Kg of yarn is cost unit. In short Cost unit is unit of measurement of cost.
METHODS OF COSTING:
Method of costing refers to the techniques and processes employed in the ascertainment
of costs. The method of costing to be applied in a particular concern depends upon the
type and nature of manufacturing activity. Basically there are two methods of costing
1. Job costing: Cost unit in job order costing is taken to be a job or work order for which
costs are separately collected and computed.
2. Process costing: This is used in mass production industries manufacturing
standardized products in continuous processes of manufacturing. Cost is accumulated for
each process or department. For spinning mills, process costing is employed
TECHNIQUES OF COSTING:
These techniques may be used for special purpose of control and policy in any business
irrespective of the method of costing being used there.
Standard costing: This is the valuable technique to control the cost. In this technique,
standard cost is predetermined as target of performance and actual performance is
measured against the standard. The difference between standards and actual costs are
analyzed to know the reasons for the difference so that corrective actions may be taken.
Marginal costing: In this technique, cost is divided into fixed and variable and the
variable is of special interest and importance. This is because; marginal costing regards
only variable costs as the costs of products. Fixed cost is treated as period cost and no
attempt is made to allocate or apportion this cost to individual cost centers or cost units.
Cost Ascertainment is concerned with computation of actual costs. Ascertainment of
actual costs reveals unprofitable activities losses and inefficiencies.
Cost Estimation is the process of predetermining costs of goods or services. The costs
are determined in advance of production and precede the operations. Estimated costs are
definitely the future costs and are based on the average of the past actual costs adjusted
for future anticipated changes in future. Cost estimates are used in the preparation of the
budgets. It helps in evaluating performance. It is used in preparing projected financial
statements. Cost estimates may serve as targets in controlling the costs
CLASSIFICATION OF COSTS:
Costs are classified into direct costs and indirect costs on the basis of their identifiably
with cost units or possesses or cost centers.
DIRECT COST: These are the costs which are incurred for and conveniently identified
with a particular cost unit, process or equipment. For a spinning mill, costs of raw
material used, packing material, freight etc are direct costs
INDIRECT COST: These are general costs and are incurred for the benefit of a number
of cost units, processes or departments
These costs cannot be conveniently identified with a particular cost unit or cost centre. In
a spinning mill, power cost, administrative wages, managerial salaries, materials used in
repairs etc are indirect costs.
The terms direct and indirect should be used in relation to the object of costing. An item
of cost may be direct cost in one case and the same may be indirect in the other case. It is
the nature of business and the cost unit chosen that will determine whether a particular
cost is direct or indirect.
FIXED AND VARIABLE COSTS; Costs behave differently when level of production
rises or falls. Certain costs change in sympathy with production level while other costs
remain unchanged. As such on the basis of behavior or variability, costs are classified
into fixed, variable and semi-variable.
FIXEDCOSTS; These costs remain constant in "total" amount over a wide range of
activity for a specified period of time. They do not increase or decrease when the volume
of production changes.
VARIABLE COSTS: These costs tend to vary in direct proportion to the volume of
output.
ELEMENTS OF COST: A cost is composed of three elements i.e. material, labor and
expense. Each of these elements may be direct or indirect.
DIRECT COST INDIRECT COST
Direct material Indirect material
Direct labor Indirect labor
Direct expenses Indirect expenses
MATERIAL COST:
DIRECT MATERIAL is that which can be conveniently identified with and allocated to
cost units. Direct materials generally become a part of the finished product. For example,
cotton used in a spinning mill is a direct material.
INDIRECT MATERIAL is that which can not be conveniently identified with individual
cost units. In a spinning mill, engineering department spares, maintenance spares,
lubricating oils, greases, ring travelers etc
LABOUR COST:
DIRECT LABOUR cost consists of wages paid to workers directly engaged in converting
raw materials into finished products. These wages can be conveniently identified with a
particular product, job or process.
INDIRECT LABOUR is of general character and cannot be conveniently identified with
a particular cost unit. In other words, indirect labor is not directly engaged in the
production operations but only to assist or help in production operations. For example in
a spinning mill, the number of maintenance workers, no of workers in utility department
etc
EXPENSES; All costs other than material and labor are termed as expenses.
DIRECT EXPENSES are those expenses which are specifically incurred in connection
with a particular job or cost unit. Direct expenses are also known as chargeable expenses.
INDIRECT EXPENSES can not be directly identified with a particular job, process and
are common to cost units and cost centers
PRIME COST = Direct material +Direct labor + Direct expenses
OVERHEAD = Indirect material + Indirect labor + Indirect expenses

TOTAL COST = PRIME COST + OVERHEAD
ADVANTAGES OF COST ACCOUNTING:
It reveals profitable and unprofitable activities.
It helps in controlling costs with special techniques like standard costing and
budgetary control
It supplies suitable cost data and other related information for managerial decision
making such as introduction of a new product, replacement of machinery with an
automatic plant etc
It helps in deciding the selling prices, particularly during depression period when
prices may have to be fixed below cost
It helps in inventory control
It helps in the introduction of a cost reduction programmed and finding out new
and improved ways to reduce costs
Cost audit system which is a part of cost accountancy helps in preventing
manipulation and frauds and thus reliable cost can be furnished to management
ESSENTIALS OF A GOOD COST ACCOUNTING SYSTEM:
The method of costing adopted. It should be suitable to the industry

It should be tailor made according to the requirements of a business. A ready
made system can not be suitable.
It must be fully supported by executives of various departments and every one
should participate in it
In order to derive maximum benefits from a costing system, well defined cost
centers and responsibility centers should be built within the organization.
Controllable and uncontrollable costs of each responsibility centre should be
separately shown.
Cost and financial accounts may be integrated in order to avoid duplication of
accounts.
well trained and educated staff should be employed to operate the system
It should prepare accurate reports and promptly submit the same to appropriate
level of management so that action may be taken without delay.
Resources should not be wasted on collecting and compiling cost data not
required. Only useful cost information should be compiled and used whenever
required.
MILL COSTING
Following information is required to work out a costing for a new plant:
The average count of the plant

Capacity of the plant - No of spindles to be installed and the number of back
process and winding machines required
Investment on machineries
Investment on land
Investment on building
working capital required
product lay out, the count pattern
Selling price of individual counts
raw material cost including freight, duty etc)
packing cost per kg of yarn
freight per kg of yarn
direct labor cost
indirect labor cost
fixed power cost
variable power cost
spares consumption
administration costs
selling overheads
STEP NO.1: Contribution to be calculated. In general for a spinning mill, contribution

per kg of a particular count is calculated to work out the economics for a new project as
well as for a running mill.
Contribution = selling price - direct cost

Direct cost for a spinning mill includes raw material price, packing cost, freight. All other
costs are either fixed costs or semi variable costs. The other costs can not be conveniently
allocated to per kg of a particular count.
The basic idea of a new project or a running plant is to maximize this contribution.
Because once the plant is designed, spares cost, power cost, and administration cost,
labor cost etc almost remains constant. There will not be significant changes in these
costs for different count patterns if the plant is utilization is same.
The following table gives the details of count pattern, selling price, raw material price,
packing cost and contribution per kg of different counts for a particular period (year).
This is just an example; one should understand that the selling price, raw material price
and all other costs keep changing. This is the reason why costing is important for a
running mill. All the costs are changing. Some costs change every month, some once in a
year. Therefore costing plays a major role to run the plant efficiently
count no. no prdn/mc prdn raw packing freight commn selling contribn
of of kgs/day material cost /kg per kg 2% on price / per kg
spls mcs cost/kg selling kg
price
20s 4480 4 1109 4436 1.456 0.046 0.051 0.04 2.2 2674
CVC
24s 4480 4 881 3525 1.456 0.046 0.051 0.05 2.3 2470
CVC
30s 5600 5 679 3394 1.456 0.046 0.051 0.05 2.4 2712
CVC
30s 4480 4 679 2716 1.240 0.046 0.051 0.04 2.15 2091
TC
36s 6720 6 552 3315 1.240 0.046 0.051 0.05 2.4 3365
TC
23 17385 contrbn/ day 13312
In the above table, all the costs are in US$. The ring frames are with 1120 spindles per
machine with automatic doffing and link to auto-cone
The ultimate aim of the project is to maximize the contribution. Looking into the
contribution per kg of yarn, the project should produce only 36s TC. But in this project
they have considered 5 different counts. Because
Yarn market is not stable. It needs a lot flexibility

customers are not same, the price depends on the customers
the end uses are not same, the price depends on the end-use
This unit exports 80% of the yarn; it can not depend on one country, eg. 36sTc is
only for Philippines market, it can not be sold in Malaysia, even though the
quality is good
the count pattern depends upon the market requirement and the major counts in
the market, not only on the contribution
A linear programming technique can be used to maximize the contribution,
considering all market constraints, and production constraints.
flexibility needs more investment and more day to day expenses, if a project has
to be more flexible, it has to invest more money on infrastructure
the major factor which will make the project feasible with less flexibility is
YARN QUALITY in a spinning mill
Since this is a critical step for a new project, management should be clear about
their Yarn quality; Flexibility required for marketing and should make use of
Linear Programming Techniques to find out the best product mix to maximize the
contribution.
STEP NO. 2
To work out the Total Investment cost (machineries, accessories, land and building,
humidification and electrical instruments)
The following table gives the requirement of production machines. To calculate the
number of back process and winding drums required, a detailed spin plan should be
worked out with speeds and efficiencies to be achieved in each machine.
While calculating the no of machines required, m/c utilization, m/c efficiency, waste
percentage, twist multipliers, delivery speeds etc should be considered properly. These
factors should be decided based on yarn quality required, end breakage rates and the
capacity of machine.
INVESTMENT ON MACHINERY
MACHINERY NO. OF RATE / MC TOTAL
MCS COST
Trutzschler Blowrrom line for cotton 1 line 416,640 416,640
Trutschler Blowrrom line for Polyester 1 Line 321,365 321,365
Trutshcler DK-903 cards 22 92,500 2,035,000
Rieter RSB-D30 draw frames (with 6 1,648,000
autoleveller)
Rieter double delivery drawframe 10
Rieter unilap 2
Rieter E62 combers 10
Howa speed frames with overhead 7 144530 1,011,710
blower
Ring frames with auto doffer 23 148,960 3,426,080
winding machines ( 26 drums per mc) 23 93,200 2,143,600
Roving transport ( manual) 1 150,000 150,000
Argus fire system 1 50,000 50,000
Some of the following points can be considered while deciding the machines.
From the above table it is clear that, 23 ring frames with 1120 spindles are working with
auto doffing and with link to auto corner. The major advantage of this automation is to
reduce labor and to reduce the problems related to material handling. One has to really
work out the benefits achieved because of this and the pay back for the extra investment.
Draw frame contributes a lot to the yarn quality and the ring frame and winding machine
working. It is always better to go in for the best draw frames like RSB-D30 draw frames
with auto-leveler. It is not wise to buy a cheaper draw frame and save money.
It is always better to keep excess carding and auto-leveler draw frames, so that flexibility
of the project is also maintained. If the coarser counts contribute more and the market is
good, overall production can be increased. If the market is for finer count, both the
machines (carding and draw frames) can be run at slower speeds, which will surely
contribute to yarn quality.
Speeds of speed frame, combers and ring frames do not affect the yarn quality as it is
affected by card and draw frame speeds.
Blow room capacity should be utilized to the maximum, as it consumes a lot of power,
space and money.
Ring frame specification should be perfect, because the working performance and power
consumption of the ring frame depends on the specifications like, lift, ring die, no of
spindles etc. Ring frame specification should be decided to get the maximum production
per spindle and to reduce the power consumed per kg of yarn produced by that spindle.
INVESTMENT ON ACCESSORIES: The following table gives the details of the

accessories like cans for carding, draw frame, bobbins, trolleys etc
ACCESSORIES NO. OF RATE / MC TOTAL

MCS COST
Carding cans 36" x 48" 120 160 19,200
comber cans 24" x 48" 350 85 29750
Draw frame cans 20" x 48" 1100 53 58,300
Identification bands 20" 400 1.2 480
Identification bands 24" 50 1.8 90
Roving and spinning bobbins 36,000
Plastic crates 400 6 2,400
trolleys 10,000
Cone trolley 80 200 16,000
Fork lift 1 27,000 27,000
hand truck 3 1000 3,000
TOTAL 202,220
SERVICE AND MAINTENANCE EQUIPMENTS:

The following table gives the details about the investments required on service and
maintenance equipments
SERVICE AND MAINTENANCE NO OF MCS RATE/MC TOTAL

EQUIPEMENTS PRICE
Cots buffing machine and accessories 1 20000 20000
Card room accessories 1 set 60,000 60,000
Spindle oil lubricator 1 4000 4000
Clearer roller cleaning machine 1 3000 3000
Vacuum cleaner 5 3000 15000
pneumatic cleaners 6 500 3000
Weighing balance 3 2000 6000
Strapping machine 2 2000 4000
Premier auto sorter 1 2500 2500
Premier uster tester 1 45000 45000
Premier strength tester 1 45000 45000
premier fiber testing 1 45000 45000
Premier Classidata 1 25000 25000
Erection charges 150000
TOTAL 427500
Card service machines like Flat tops clipping machine and flats grinding machine are
very important for yarn quality. One should not look for cheaper machine. It is always
better to go for reputed manufacturers like GRAF, HOLLINGSWORTH etc.
Rubber cots contribute a lot to yarn quality. Bad buffing in ring frame can increase the
imperfections by 15%. Poor quality of buffing in draw frame and speed frames can affect
both production and quality. It is better to go for the best cots mounting machine and cots
buffing machine.
HUMIDIFICATION AND ELECTRICAL EQUIPMENTS
The following table gives the details about the investments required on humidification
and electrical instruments
Electrical installation including transformer, incoming and 350,000

outgoing panels, bus duct, capacitor, etc for 3800 KVA
Cables 125,000
Compressor, Dryer and pipe lines 180,000
humidification system 767,000
chillers 176,000
Ducting and installation for humidification system 125,000
workshops, hydrant and other equipments 100,000
TOTAL 1,823,000
The following table gives the details about land and building investments
Land cost 200,000

Land development 40,000
Factory building Including Service ally 192 x 62 meters 1,405,440
11,712 Square meter @ 120 used/sq meter
Road and others 40,000
TOTAL 1,445,440
STEP NO.3: To calculate the expenses (labor, power, stores, working capital, insurance
etc)
Working capital = 3,000,000
LABOUR: The following table gives the details about labor requirement
DEPARTMENT No of people required

Production 140
packing 15
maintenance 30
utility 17
administration and personal dept 20
Total no of people required per day 222
wages at 50 usd/month including bonus and 111,00

insurance
other facilities at 35 % 3,885
salaries for managerial staff 10000
Other facilities at 35 % 3500
Total labour cost / month 28485
POWER: The following table gives the details about the power
Total units(KWH) produced 69559

(consumed)per day
Unit cost (cost / KWH) 0.03
Total production in Kgs 17,390
KWH/ Kg of yarn 4.0
TOTAL POWER COST /DAY 2087
SPARES: The following table shows the spares cost, repair, and insurance
spares cost at usd 8/1000 spindle shift 222,566
repairs and other overheads 200,000

Insurance at 0.175% on investment and 31320
working capital
TOTAL cost per year 453886
STEP NO.4: PAY BACK CALCULATION
DETAILS IN USD
INVESTMENT:
Land and building 1,444,440
Machinery, accessories & service equipments 11,832,115
Electrical and Humidification ducts 1,823,000
TOTAL INVESTMENT 15,099,555
WORKING CAPITAL 3,000,000

GRAND TOTAL 18,099,555
RECURRING EXPENDITURES PER DAY
Salaries and Wages 949.5

Power cost 2087
Stores , repairs and insurance 1260.8
TOTAL 4297.3
INTEREST CALCULATION (per day)

On capital 8% 3355.5
on working capital 9% 750
TOTAL EXPENSES INCLUDING INTEREST 8402.8
TOTAL CONTRIBUTION PER DAY 13312

NET PROFIT( before depreciation & taxation) 4909.2
PAY BACK PERIOD 8.54 years
Mills Costing
Profit= Setting Price/Pound Minimum Yarn/Pound
Rupees per Spindle = Total Expenses

No. Spindles/ M/c * NO. of M/c * No. Shifts * 30 Days
Total Expenses = Salary + Wages +Electric Bill/months + Generator Consumption/Month + General Maintenance
Expenses
= 1500000 + 100000 + 2600000 + 1600000 + 1000000 = 6800000

Rupees per Spindle = 6800000
480 * 34 * 3 * 30
Rupees per Spindle = 4.629 * 16
Rupees/Pound (Factor) = 74.074
Count No. of Production OPS Setting Price Price/ Day

Frames in lbs
30/1 PC 14 9200 7.34 49 450800
Warp
30/1 PC 15 10500 7.80 49 514500
Hos.
24/1 PC 4 3800 10.60 47 178600
Hos.
16/1 Warp 1 1500 16.66 43 64500
25000
1208400
Setting Price/Pound = Total Price/ Day
Total Production in Pound/Day
= 1208400 = 48.336
25000
Minimum Yarn Sale Price = Average PC price/pound + Rupees/pound
Count 30/1 PC HOSIERY

Rupees/Pound = Factor (rupees/pound)
OPS
= 74.074 = 9.496 Rupees/pound
7.80
Average PC Price/Pound = Cotton Price/Pound + Polyester Price/Pound
Cotton Price/Pound = Rate/Maund = 2400 = 35.57 Rupees/Pound
82.28 * 0.82 82.28 * .82
Polyester Price/Pound = Rate/Kg = 53rupees/kg = 25.695 Rupees/Pound
2.20469 * 0.97 2.20469 * 0.97
Average Price/Pound (PC) = 30.632
Minimum Yarn Sale Price = Average PC Price/Pound + Rupees/Pound
= 30.632 + 9.496
= 40.128
Profit in Rupees/Pound = Setting Price/Pound Minimum Yarn Sale Price
= 48.336 40.128 = 8.208 Rupees
Total Profit/Day = Total Pounds/day * Profit/Pound
At 30/1 PC Hosiery 10500* 8.208 = 86184 Rupees
Count 30/1 PC WEAVING

OPS
= 74.074 = 10.091 Rupees/Pound
7.34
82.28 * 0.82 82.28 * .82
2.20469 * 0.97 2.20469 * 0.97
= 30.632 + 10.091
= 40.723
= 48.336 40.723 = 7.613 Rupees
Total Profit/Day = Total Pounds/Day * Profit/Pound
At 30/1 PC Weaving 9200 * 8.208 = 70039.6 Rupees
Count 24/1 PC HOSIERY

OPS
= 74.074 = 6.988 Rupees/Pound
10.60
Cotton price/pound = Rate/Maund = 2400 = 35.57 Rupees/Pound
82.28 * 0.82 82.28 * .82
2.20469 * 0.97 2.20469 * 0.97
= 30.632 + 6.988
= 37.6201
= 48.336 37.6201 = 10.74 Rupees
Total Profit/Day = Total Pounds/Day * Profit/Pound
At 24/1 PC Hosiery 3800 10.74 = 40811.62 Rupees
Count 16/1 PC WEAVING

OPS
= 74.074/16.66
= 4.446 Rupees/Pound
Average PC Price/Pound = Cotton Price/Pound + Polyester
Price/Pound
82.28 0.82 82.28 .82

2.20469 0.97 2.20469 0.97
= 30.632 + 4.446
= 35.0782
= 48.336 35.0782 = 12.74 Rupees
Total Profit/Day = Total Pounds/day Profit/Pound
At 16/1 PC Weaving 1500 12.74 = 19109.85 Rupees
Total Profit/Day = 216145.07 Rupees
Total Profit/Month = 216145.07 30
Grand Total = 6484352.1 Rupees

Spinning Calculation

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Spinning Calculation

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CHAPTER #01

RAW MATERIAL CALCULATIONS

Basic Fibre Characteristics:

Upper quartile length:

2.5% Span length:

50% Span length:

Fibre Length Variation:

Co-efficient of variation of length (by weight or number)

Shirley comb sorter

Uniformity Ratio (U.R) = (50% Span Length) x 100

Uniformity Index (U.I) = (_____Mean Length __) x 100

- Higher wastage in combing and other operations.

The Formula for moisture Regain is given below

Moisture Regain= (Total Weight-dry weight) x100

The Formula for Moisture Content is given below

Moisture Content= (Total weight-Dry weight) x100

Relation Between Moisture Regain (R) and Moisture Content(C):

Moisture Regain =???

R= ___C ___ . (I)

By putting the values in equation (I),then we have

Moisture Content =???

C= ___R ___ . (II)

By putting the values in equation (II), then we have

Relation between Regain & moisture Content:

RELATION BETWEEN MOISTURE REGAIN &CONTENT

400 *1.085 = 434 grains

100 * 100/ 400 = 25%

Q. A spinning unit has purchased lint of 20,000kg at 8.5% moisture regain.

40s weight = 1/40 = 0.02slbs

Moisture wt. = 0.0263-0.025

%age of moisture added = 0.00131517

Weight of yarn= 1/40 = 0.025slbs.

Count = 1/0.025875 = 38.65s

The different measures available for reporting fibre strength are

Its Units are

Single Fibre Strength:

The tenacity of fiber is dependent upon the following factors

Bundle Fibre Strength:

Strength = F.V = Lbs inch = inch

Gram/denier = g/w 9000 = gL

= A 9000 10^6 g/cm

MPa= 88.2 g/denier .. (a)

P.S.I= 12800 g/denier (b)

K.S.I= 12.8 g/denier . (c)

g/denier= Stress 1000

By cross multiplication we have

Stress= 88.2 10^6 g/denier

MPa= 88.2 g/denier (a)

From equation (a)

Pa =88.2 10^6 g/d

P.S.I = 194.44 10^6 g/d

P.S.I = 12800 g/d

If we divide the equation (b) by 1000 then we have K.S.I

P.S.I = 12800 g/d

K.S.I = 12.8 g/d

K.S.I = 12.8 g/d (c)

MPa = 9.8 g/tex (d)

P.S.I=1422.32 g/tex ..... (e)

K.S.I=1.422 g/tex . (f)

Tex = A 1000 g/cm

Tex = A 1000 10^6 (density)

=F 1000_______ because stress = F

g/tex= stress 1_______

By cross multiplication we have

Uniformity Index (U.I) = (___Mean Length ) x 100

R= _C _ . (I)

C= _R _ . (II)