general presentation on RSWM.pptx

RSWM spinning some overview, production capacity, product variants, technologies used, and how to calculate the basic terms in textiles.

1. L.E.A.P.  Enhance, Advance & Perform Leverage,

2. Presented By Mahesh Ladha Manish Gupta Suraj Gupta Prashant Srivastav Guddu Prasad Project Production Yarn Business Greige (grey) / Dyed)

3. Pramod Mahipal Satyakam Srivastava Sunil Rai Rajendra Sankhkla Project Production Yarn Business Greige (grey) / Dyed)

4. RSWM JOURNEY 1960 – Company incorporated and in 1961 established a spinning unit at Bhilwara . 1973 - Second plant commissioned at Gulabpura . Later, Bhilwara plant was spun off as independent Company ( Bhilwara Spinners Ltd.) 1989 - Established grey yarn spinning unit at Banswara . 1994 - Established Melange Yarn manufacturing unit at Mandpam , Bhilwara 2003 - Acquired Rishabhdev plant from HEG Ltd. 2005 - Acquired Jaipur Polyspin Ltd, Reengus and Mordi Textiles & Processors Ltd. Banswara 2011 – 2012 Executed another expansion plan with capital outlay of Rs . 400 Crore. Expanded capacity at Kharigram (SJ-11), Banswara (Rotors), Denim (Spinning), Mordi (50 Looms). 2014 - Established a Green Fibre manufacturing unit at Reengus with capacity of 18000 MTs p.a. 2015 – Added another Melange Yarn unit at Kanyakheri , Bhilwara . 2017 – Installation of Sheet Dyeing facility at Denim 2017 - Commissioned 3.3 MW Rooftop Solar Power Plant at Mandpam and Kanyakheri . 2018-19 – 18.7 MW Solar Power Plant and 25000 MTs p.a. Green Fibre 2019-20 – 3.3 MW Solar Power Plant

5. RSWM REENGUS Synthetic yarn Effect yarn Polyester Viscose Blended Slub Effect Viscose 100% Injection Slub Polyester 100% Roving Grindle Polyester Acrylic Blended Melange Polyester Cotton Blended Spindles : Synthetic 32736 Production Capacity 33 MT/Day Count range 8 s to 40 s

6. RSWM RISHABDEV Spindles Production Capacity 50.7 MT/Day 52704 Count range 8 s to 40 s Synthetic yarn Viscose yarn Specia l fibre Effect yarn Viscose 100% Viscose Blended Viscose with Modal, Tencel , Bamboo, Excel Viscose Linen Slub Polyester 100% Polyester Blended Cationic Injection Slub Neppy Slub Lycra

7. RSWM KHARIGRAM Spindles : Synthetic Production Capacity 136 MT/Day 167136 Count range 6 s to 60 s Synthetic yarn Dyed yarn Effect yarn Acrylic 100% Acrylic blended Poly Viscose Slub Viscose 100% Viscose Blended Poly Cotton Core spun Polyester 100% Polyester Blended 100% Polyester Neppy yarn 100% Acrylic Roving Grindle D/F Grindle

8. RSWM BANSWARA Spindles : Synthetic Cotton Production Capacity 99 MT/Day 63600 31104 Count range 6 s to 60 s Synthetic yarn Cotton yarn Specia l fibre Effect yarn Acrylic 100% Acrylic blended Cotton 100% Coolmax Slub Viscose 100% Viscose Blended Cotton with Modal, Tencel , Bamboo Thermolite Injection Slub Polyester 100% Polyester Blended Siro Lycra Rotors 3140

9. A SHORT INTRODUCTION OF TEXTILE FIBRE

10. TEXTILE FIBRE NATURAL FIBRE MAN MADE FIBRE

11. VEGITABLE FIBRE NATURAL FIBRE Cotton Jute Linen

12. ANIMAL FIBRE NATURAL FIBRE Wool Silk

13. SYNTHETIC FIBRE MAN MADE FIBRE Acrylic Polyester Nylon Spandex

14. SEMI SYNTHETIC FIBRE MAN MADE FIBRE Viscose

15. SYNTHETIC RECYCLE FIBRE MAN MADE FIBRE PET bottles PET flakes PET fibre

16. YARN COUNT ( FINENESS OF YARN ) AND VARIOUS SYSTEMS OF YARN COUNT

17. YARN COUNT ( FINENESS OF YARN ) AND VARIOUS SYSTEMS OF YARN COUNT THE FINENESS OF YARN IS KNOWN AS COUNT OF YARN , ALSO KNOWN AS LINEAR DENSITY OF YARN. THE COUNT OF THE YARN IS EXPRESSED IN THE FORM OF NUMERICAL NUMBER, DIFFERENT SYSTEM ARE USED AT VARIOUS REGIONS OF THE WORLD TO EXPRESS YARN COUNT. ALL SYSTEM FOLLOW THE PRINCIPLES GIVEN AS BELOW . DIRECT SYSTEM : HERE THE LENGTH OF YARN REMAINS CONSTANT AND THE WEIGHT OF YARN VARIES ACCORDING TO THE FINENESS OF YARN . AS THE NUMBER ( COUNT ) OF YARN INCREASES , THE YARN BECOME COARSER.

18. INDIRECT SYSTEM : IN THIS SYSTEM OF YARN COUNT , THE WEIGHT OF YARN REMAINS CONSTANT AND THE LENGTH OF YARN VARIES ACCORDING TO THE FINENESS OF THE YARN. AS THE NUMBER ( COUNT) OF THE YARN INCREASES THE YARN BECOMES FINER. TEX : THE WEIGHT IN GRAMS OF 1000 METER OF YARN IS CALLED THE TEX OF A YARN , WHEN THE TEX OF YARN INCREASES, THE YARN BECOME COARSER. DENIER : THE WEIGHT OF YARN IN GRAMS OF 9000 METER OF YARN IS CALLED DENIER OF A YARN FOLLOWING YARN SYSTEM ARE BEING USED TODAY

19. THE NUMBER OF HANKS OF 840 YARDS IN A POUND IS THE NEW ENGLISH COUNT NEW ENGLISH COUNT ( Ne)

20. THE LENGTH OF YARN IN METER OF ONE GRAM OF YARN OR LENGTH OF YARN IN KILOMETER OF ONE KILOGRAM OF YARN IS CALLED NEW METRIC COUNT ( Nm). NEW METRIC COUNT ( Nm ) THE YARN BECOME FINER WHEN Nm INCREASES.

21. Spinning At A Glance

22. PREPARATORY SECTION BLOW ROOM Section: Production starts at Blowroom , Fibres are Opened, Cleaned and Mixed.

23. PREPARATORY SECTION CARDING Heart of spinning , Individualization of fibres ; i.e . separation of fibres from each others To produce thick rope form of fibres called slivers which is suitable for subsequent processing.

24. PREPARATORY SECTION DRAWFRAME This ensures a high level of sliver quality due to precise sliver scanning process and the dynamic auto leveling function .

25. ROVING FRAME It is an intermediate process in which fibers are converted into low twist lea called roving . It’s purpose is to prepare input package for next process. PREPARATORY SECTION

26. SPINNING SECTION RINGFRAME Ring spinning is a method of producing yarn from fibers like cotton, wool, flax etc. It is mostly used in yarn manufacturing.

27. POST - SPINNING SECTION WINDING It is process of creating large yarn packages called “cone” from a number of small yarn packages (ring cops ). The Winding process not only make bigger yarn packages , it also corrects spinning faults like neps , hairiness, and waxes.

28. POST - SPINNING SECTION Two for one Twister Assembly Winder Cotton & all synthetics Yarn Parallel Assembly Winding Machine for 2 ply, 3 ply & 4 Ply yarns & all kinds of Threads for prepare feed package for TFO & Doubling. Two-For-One (TFO) is a two-stage process where the yarns are doubled and then twisted. In TFO process two or more single yarns are twisted in order to enhance the properties of the end-products such as strengthening the yarns.

29. POST - SPINNING SECTION SSM WINDER The key features are: SSM XENO - the new modular winding machine platform, available with all three leading winding technologies . Precision winding Digi Winding & Soft package winding This is only one m/c , we have to produce 25 mm to 270 mm traverse wound in one segment.

30. POST - SPINNING SECTION SSM WINDER The key features are:

31. POST - SPINNING SECTION Carton strip machine Type of packing Mainly 3 type of packing used in textile Industries Packing Bag Packing :- Use for Domestic packing. Carton Packing :- Used in Domestic & Export packing & Pallet Packing :-Mainly used for Export packing BAG PACKING CARTON PACKING

32. POST - SPINNING SECTION Pallet Warp machine Specifications

33. Technology Comparison Old Technology Latest Technology Less power & Air consumption Production increased by 6% & HARD Waste reduce by 0.3%

34. YARN SPINNING CONVENTIONAL AND NEW TECHNOLOGY

35. TYPES OF SPINNING CONVENTIONAL NON CONVENTIONAL

36. TYPES OF SPINNING Ring spinning Conventional spinning

37. TYPES OF SPINNING Compact spinning Fancy conventional spinning

38. Siro spinning TYPES OF SPINNING Fancy conventional spinning

39. TYPES OF SPINNING Core spun yarn spinning Fancy conventional spinning

40. TYPES OF SPINNING Rotor spinning Non conventional spinning

41. TYPES OF SPINNING Airjet spinning Non conventional spinning

42. TYPES OF SPINNING Non conventional spinning Friction spinning

43. RING SPINNING YARN PROCESS FLOW RAW MATERIAL (Fibre form) BLOWROOM (Fibre opening) CARDING (Rope formation) DRAWING ( Homogenising fibre ) LAP FORMER COMBER RING FRAME ( Yarn creation ) ROVING FRAME DRAWING (II Passage) AUTOCONER (Final Package )

44. ROTOR and NON CONVENTIONAL SPINNING YARN PROCESS FLOW RAW MATERIAL (Fibre form) BLOWROOM (Fibre opening) CARDING (Rope formation) ROTOR MACHINE (Final package) RAW MATERIAL (Fibre form) BLOWROOM (Fibre opening) CARDING (Rope formation) DRAWING ( Homogenising fibre)

45. COMPARATIVE YARN STRUCTURE OF DIFFERENT SPIINNING SYSTEM

46. YARN PROPERTIES CLOSED LOOP (RING SPINNING) OPEN LOOP (ROTOR SPINNING) STRENGTH UNIFORMITY (EVENNESS) PRODUCTION PRODUCTION COST DYEABILITY FABRIC TYPE GOOD FOR FINER FABRIC, WIDE RANGE OF APPLICATION ONLY FOR COARSE FABRIC LIKE DENIM, FURNISHING ETC. FIBRE LENGTH REQUIRED FOR PRODUCTION LONGER SHORTER FABRIC FEEL SOFT HARSH

47. PRODUCTION CALCULATION

48. PRODUCTION CALCULATION PRODUCTION IN KG / DAY / (SPINDLE or ROTOR or Machine head) Delivery speed (840 yards x 0.914) (453.6 gms ) 1000 x count of yarn min meters x number of shift x hours shift x minutes hour x 1 x OR Delivery speed min meters x count of yarn 1 x 0.85

49. PRODUCTION CALCULATION for Ring spinning frame We require Spindle speed Twist multiplier 16000 rpm 3.8 Count 20 We calculate FRS( front roller speed) = Spindle speed Turns per inch Turns per inch = Twist multiplier X   = 16.99 = 941 inch/min (or Delivery speed)

50. PRODUCTION CALCULATION for Ring spinning frame Spindle Speed x No of Spindle x Efficiency x 60 x 8 Production per Shift =——————————————————————————————— — TPI x Yarn Count x 36 x 840 In lbs (pounds) 1 Pound(lb) = 453.6 Gram Conversion: 1 Meter = 39.37 Inch Yarn Count means the number of 840 yards length that weight exactly 1 pound (lb)

51. PRODUCTION CALCULATION for Rotor spinning frame We require Rotor speed Twist multiplier 100000 rpm 4.8 Count 20 We calculate Delivery speed (in m/min) = Rotor speed Turns per meter Turns per meter = Twist multiplier X X 39.37   = 845 = 118 m/min

52. PRODUCTION CALCULATION for Rotor spinning frame Del Speed x no. of rotors x Efficiency x 0.28 Production per Shift = ———————————————————————————— Yarn Count In Kgs per 8 hours of shift

53. WAY FORWARD DIFFERENT BLENDING PROCESS/TECHNIQUES FOR DIFFERENT FIBRE CHART FOR COUNT CONVERSION FROM DIRECT TO INDIRECT SYSTEM GENERAL THUMB RULE FOR SELECTING FIBRE DENIER TO COUNT OF YARN 1 2 3

54. DIFFERENT BLENDING PROCESS/TECHNIQUES FOR DIFFERENT FIBRE Blowroom Blending Drawframe Blending

55. Blowroom Blending Laydown Method (fibre in bale form is laid in pattern to achieve blend%) Manual Weighing Method (balance is used to weigh various component) Automatic Weighing Method (machine equipped with auto weighing system)

56. Drawframe Blending Alternative sliver of polyester 100% and Cotton 100% component is used to blend material on drawframe .

57. Thumb rule selection for fibre denier with respect to count Fibre Count Range Blend Denier Length               100% polyester 1.0 34   24 and finer         1.2 38   from 10 to 24 only         1.4 40   coarser than 10           100% viscose 1.2 38   20 and finer         1.5 44   coarer than 20           Poly viscose blend 1.5 44 poly from 24 to 34 1.5 44 vis  

58. Basic Count conversion calculator with formula for conversion To work the calculator kindly double tap to activate on attached Excel

59. T H A N K Y O U