Waste Management in Spinning

Spinning Waste managment


Waste Management in Spinning
Pranay Latkar
Department of Textile Manufactures
Government Polytechnic, Nagpur, Maharashtra State, India
Introduction:
Every textile mill and manufacturing unit should be pay almost attention for the management of the waste if the waste percent is high it can be affect the quality of the material, if the more percent waste remove from the material it can be affect the production of the mill. In the mill the  different type of the waste is remove from the different department that is product waste, process waste and invisible losses hence it is important that to manage the waste properly in the mill to increase the production and improving the quality of the material the waste which is reusable can be again fed in the blowroom mixing in order to form the yarn whilc hard waste like yarns are sold in the market at lower price as they cannot be use again. Spinning mill should pay attention on waste management in order to get improve the productivity and profit of the mill. Following article provides information of waste control at different departments of spinning mill from blowroom to ring frame.

Background:
Main objective of any spinning mill is to produce a quality yarn at low cost. That can be achieved by the better quality and the quantity of the raw material to the finished product it is possible by the proper waste management system. Many mills are facing losses due to improper waste management the percentage of waste will affect the productivity of the mill. 1% waste can be make loss of lakh of rupees for the mill. So it is important to improve the waste management system in the spinning mill. In the  economic of the spinning mill the waste  management plays a significant role. To illustrate in the prevailing cotton cost and the yarn selling price even an 1℅ improvement in the waste management  would lead to saving of 20 lakhs rupees per year for a about 30000 spindle of 20s - 40s count.

Definition and Concept of the waste:
 Waste is type of material which has not in use, discarded some waste are useful some are not useful.Waste which is usable are use for the courser count yarn, open end spinning etc,. Those waste are not reusable are sold out to the market at low prices these waste are seeds, coats, leafy matter etc, are use as fertilizers in a farm.

TYPES OF WASTE:
In Textile mill there are two major type of wastes generated
  • Soft type of waste
  • Hard type of waste

Soft waste:- The waste which is in fibers form are called as the soft waste. The soft waste is generated  from carding to the speed frame (Including all types of slivers) . These soft waste are reusable for producing a low quality of yarn. Examples ; coarser count yarn or open-end spinning yarn .
Hard waste:- The waste which is not reusable is called as hard waste.
These waste are produced in ringframe  and the winding department.
                                                                                                                     
Blowroom
Types of waste in blowroom
  • Dropping
  • Seeds, cotes
  • Dust, Dirt
  • Floor sweep

Improving the cleaning efficiency and reducing waste at Blowroom
To improving cleaning efficiency of beater first examine the mechanical condition of the machine spikes on the krishner beater blades and fingers on the blades and porcupine openers and rapiers  or replace as required, the inter grid bars space should be checks for any chock up the waste is affected by change such as..
  •  Distance between the grid bars and angles between of inclination of bars (2-3mm)
  •  Speed of the beaters (680 rpm)
  •  Fan speed is related to the beater speed (1000)mm
  •  Setting between the beaters and feed rollers  (8-10mm)
  •  Setting between the beaters and gridbar(10mm)

                                                                                                                  
CARDING
Types of waste at carding
  • Flat strips
  • Licker-in waste
  • Sliver cut
  • Filter waste
  • Floor sweep
  • Dropping

Controlling the waste at the card
  • Higher licker-in speed or greater wire points density on licker-in gives higher cleaning efficiency accompanied the lint lost under the licker-in
  • Use of the perforated undercasing  helps in reducing waste
  • With other speed and setting held constant the flat strip waste various almost proportionately with the flat speed
  • Flatstrip waste increses due to wider front and back plate setting.
  • For controlling the cleaning of the card, almost the only place is the licker-in region
  • Card is an excellent  cleaning machine for seed coats especially the cylinder flat region which removes 805 of the seed coats .
  •  Higher flat with high cylinder speed can be use for better removal of seed coats and also  reducing neps  thick places . Seed coats content of 0.1%in  the card sliver can be considered as satisfactory
  • 5 to 7% more good cleaning efficiency can be achieved by using tandem carding.


                                                                                                                        
Comber
Types of the waste in comber
  • Noils
  • Lap wastages
  • Sliver wastage
  • Swipper wastages.


For an effective removal of short fibers retention of long fiber, removal of neps the following  considerations are of almost importance during combing:
In carding trailing hooks are more in number when compared to leading hooks they are removed when fed as leading hooks by keeping an even number of reversals between the cards and the comber
By increasing the pre combing draft waste can be reduced to significant level at comber without affecting the resultant yarn quality however a high comber draft also result in extremely low inter fiber cohesion causing excessive lap liking frequent sliver breaks at comber at comber , drawframe and the can feeder imer creel there for a pre comber draft of30-40 for counts up to 40s is adequate pre comber draft of above 20s is suitable only for very long staple cottons.
Neps can be controlled during the carding process most of the neps should be removed during card process not combing. It is often  more economical to run cards a some what low production rate than to take out extra comber waste .

CONTROL OF WASTE IN THE RING FRAME
  • Analysis and segregation of the waste of different types.
  • Weight that waste and recording that section wise person wise and shift wise.
  • Comparison with the stranded .
  • Feed backs and action to improve waste generation.
  • Waste percentages in ring frame

Other types of waste in the spinning department
  • Fly and dust
  • Directly reusable waste
  • Dirty waste

Waste material falling in to the first group can be collected without difficulty and can be fed back into  the blowroom line. In Modern mill waste management system pneumatic suctions are mostly used for collection of waste.

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