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Industrial attachment of noman weaving mills limited

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Industrial attachment of noman weaving mills limited

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  1. Noman Weaving Mills Ltd Noman Weaving Mills Ltd INDUSTRIAL TRAINING Course Code: Tex -4036 Course Code: Tex -4036 Course Code: Tex -4036 INDUSTRIAL TRAINING INDUSTRIAL TRAINING INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT Noman Weaving Mills Limited Noman Weaving Mills Limited Noman Weaving Mills Limited 1

  2. Noman Weaving Mills Ltd Noman Weaving Mills Ltd 2

  3. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Acknowledgment Acknowledgment Acknowledgment “In the name of Allah, the most merciful and beneficent” “In the name of Allah, the most merciful and beneficent” “In the name of Allah, the most merciful and beneficent” All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and Sunnah, the everlasting source of guidance and knowledge for humanity. Sunnah, the everlasting source of guidance and knowledge for humanity. Sunnah, the everlasting source of guidance and knowledge for humanity. All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable discussion during the training period. It has been a great opportunity to be a trainee under his supervision. supervision. supervision. At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable discussion during the training period. It has been a great opportunity to be a trainee under his discussion during the training period. It has been a great opportunity to be a trainee under his At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Southeast University have made our efforts for training & report writing successful. Southeast University have made our efforts for training & report writing successful. Southeast University have made our efforts for training & report writing successful. Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their valuable time on the very busy schedule. valuable time on the very busy schedule. valuable time on the very busy schedule. During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this training and ultimate success could not come out a good result. training and ultimate success could not come out a good result. training and ultimate success could not come out a good result. Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this 3

  4. Noman Weaving Mills Ltd Noman Weaving Mills Ltd TABLE OF CONTENTS TABLE OF CONTENTS Acknowledgement Acknowledgement Project Description Project Description Introduction Introduction Objectives Objectives Duration of study Duration of study Location of factory Location of factory General information of the factory General information of the factory Units of Noman Group Units of Noman Group Layout plan Layout plan Product mix Product mix Different departments of factory Different departments of factory Manpower Management Manpower Management General organ gram General organ gram Manpower setup Manpower setup Machine Description Machine Description Specifications of the machines Specifications of the machines Layout plan of weaving section Layout plan of weaving section Information’s of raw materials Information’s of raw materials Research & Development Research & Development R & D department R & D department Production Planning, Sequences & Operation Production Planning, Sequences & Operation Sequence of operation Sequence of operation Winding Winding Yarn path diagram of winding Yarn path diagram of winding 4

  5. Noman Weaving Mills Ltd Warping Warping Noman Weaving Mills Ltd Calculations of high speed warping Calculations of high speed warping Calculations of sectional warping Calculations of sectional warping Sizing Sizing Machine specification Machine specification Control system of sizing Control system of sizing Size chemicals & their costing Size chemicals & their costing Calculation of sizing Calculation of sizing Drawing & Denting Drawing & Denting Loom Loom Basic mechanism of power loom Basic mechanism of power loom Weft path diagram of air jet loom Weft path diagram of air jet loom Machine specification of air jet Machine specification of air jet Compressor air quality Compressor air quality Loom piping system Loom piping system General operation of air jet General operation of air jet Rapier loom Rapier loom Specification of picanol Specification of picanol Basic mechanism of rapier Basic mechanism of rapier Setting of rapier Setting of rapier Projectile loom Projectile loom Machine specification Machine specification Operation procedure Operation procedure Quality Assurance System Quality Assurance System Quality assurance system Quality assurance system Inspection system Inspection system Quality standard Quality standard 5

  6. Noman Weaving Mills Ltd Maintenance Maintenance Noman Weaving Mills Ltd Maintenance of machine Maintenance of machine Maintenance procedure Maintenance procedure Utility Services Utility Services Utility services Utility services Available utility facilities Available utility facilities Store & Inventory Store & Inventory Inventory Inventory Cost Analysis & Marketing Activities Cost Analysis & Marketing Activities Cost analysis Cost analysis Marketing activities Marketing activities Conclusion Conclusion Conclusion Conclusion Limitations Limitations Suggestions Suggestions 6

  7. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Chapter -01 Chapter -01 Project description Project description 7

  8. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Introduction: Introduction: Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. future practical work. future practical work. Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our to minimize the gap between theoretical and practical knowledge. We think this idea will help to our Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us Objectives: Objectives: Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product  To know about the quality parameters of the product  To know about the quality parameters of the product  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To gather the maintenance & various utility services  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose Place of study: Place of study: Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. sincere about the quality level so this is a very perfect place for industry. sincere about the quality level so this is a very perfect place for industry. We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Duration of study: Duration of study: Duration of study: The total duration of training period was eight week The total duration of training period was eight week The total duration of training period was eight week Method of study: Method of study: Method of study: We worked here as trainee and our working method was Auto Instruction We worked here as trainee and our working method was Auto Instruction We worked here as trainee and our working method was Auto Instruction 8

  9. Noman Weaving Mills Ltd Noman Weaving Mills Ltd MaymensingN MaymensingN MaymensingN Mawna Bazar Bazar Bazar Mawna Mawna Noman Weaving Mills Noman Weaving Mills Noman Weaving Mills Joydebpur Joydebpur Joydebpur Tangail Tangail Tangail Gazipur Gazipur Gazipur Candana Candana Candana Dhaka Dhaka Dhaka 9

  10. Noman Weaving Mills Ltd Noman Weaving Mills Ltd GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD  Name of the factory  Name of the factory  Name of the factory : Noman Weaving Mills Ltd. : Noman Weaving Mills Ltd. : Noman Weaving Mills Ltd. (An enterprise of Noman Group) (An enterprise of Noman Group) (An enterprise of Noman Group)  Location  Location  Location : (kewa westside), Mawna, Sreepur, Gazipur. : (kewa westside), Mawna, Sreepur, Gazipur. : (kewa westside), Mawna, Sreepur, Gazipur.  Business Type  Business Type  Business Type : 100%Export Woven Factory : 100%Export Woven Factory : 100%Export Woven Factory  Status  Status  Status : Private Ltd. Company. : Private Ltd. Company. : Private Ltd. Company. : Adamjee Court (5th&6thFloor), 115-120, : Adamjee Court (5th&6thFloor), 115-120, : Adamjee Court (5th&6thFloor), 115-120,  Head office (Corporate Office)  Head office (Corporate Office)  Head office (Corporate Office) Motijheel C/A, Dhaka-1000. Motijheel C/A, Dhaka-1000. Motijheel C/A, Dhaka-1000.  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282 History of the project development: History of the project development: History of the project development: Land purchase Land purchase Land purchase : June : June : June 2006 2006 2006 Machine setup Machine setup Machine setup : December : December : December 2006 2006 2006 Year of production Year of production Year of production : January : January : January 2007 2007 2007 Total area of land Total area of land Total area of land : 25 Bigha : 25 Bigha : 25 Bigha Production floor: Production floor: Production floor: (a) Airjet floor (b) Sizing shed (c) Sectional warping (d) Picanol floor (d) Picanol floor (d) Picanol floor (a) Airjet floor (b) Sizing shed (c) Sectional warping (c) Sectional warping (a) Airjet floor (b) Sizing shed : 47581 : 44762 : 18036 :11620 :11620 :11620 : 47581 : 44762 : 18036 : 18036 : 47581 : 44762 sft sft sft sft sft sft sft sft sft sft sft sft No. of machine: No. of machine: No. of machine: (a) Toyota air jet loom (b) Picanol loom (b) Picanol loom (b) Picanol loom (a) Toyota air jet loom (a) Toyota air jet loom : 128 : 40 : 40 : 40 : 128 : 128 pcs pcs pcs pcs pcs pcs Production capacity: Production capacity: Production capacity: (a) Toyota airjet loom (b) Picanol loom Total production Per month production Per month production Per month production (a) Toyota airjet loom (b) Picanol loom Total production Total production (a) Toyota airjet loom (b) Picanol loom : 45000 : 9000 : 54000 : 1404000 : 1404000 : 1404000 : 45000 : 9000 : 54000 : 54000 : 45000 : 9000 Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr 10

  11. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Man power: Man power: Man power: Officer Officer Officer Staff Male Female : 02 Female : 02 Female : 02 Staff Male Male Staff Worker Male Female : 144 Female : 144 Female : 144 Worker Male Male Worker a) Male b) Female : 01 b) Female : 01 b) Female : 01 a) Male a) Male : 41 : 41 : 41 : 93 : 93 : 93 : 418 : 418 : 418 Total manpower of the factory Total manpower of the factory Total manpower of the factory : 699 people : 699 people : 699 people Toilet: Toilet: Toilet: a) Officer/staff b) Male worker c) Female worker c) Female worker c) Female worker a) Officer/staff b) Male worker b) Male worker a) Officer/staff : 13 : 08 : 05 : 05 : 05 : 13 : 08 : 08 : 13 pcs pcs pcs pcs pcs pcs pcs pcs pcs Fire Extinguisher: Fire Extinguisher: Fire Extinguisher: a) DCP b) CO2 c) Water d) Foam d) Foam d) Foam a) DCP b) CO2 c) Water c) Water a) DCP b) CO2 : 99 : 55 : 20 : 06 : 06 : 06 : 99 : 55 : 20 : 20 : 99 : 55 pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs Dormitory: Dormitory: Dormitory: a) Officer/staff & F.Q b) Worker b) Worker b) Worker a) Officer/staff & F.Q a) Officer/staff & F.Q : 01 : 01 : 01 : 01 : 01 : 01 pcs pcs pcs pcs pcs pcs Emergency gate Emergency gate Emergency gate : 01 : 01 : 01 pcs pcs pcs Units of Noman Group: Units of Noman Group: Units of Noman Group:  Sufia fabrics ltd.  Sufia fabrics ltd.  Sufia fabrics ltd.  Talha Tex pro Ltd.  Talha Tex pro Ltd.  Talha Tex pro Ltd.  Artex Fabrics Ltd.  Artex Fabrics Ltd.  Artex Fabrics Ltd.  Noman Fabrics Ltd.  Noman Fabrics Ltd.  Noman Fabrics Ltd.  Nice Denim Mills Ltd.  Nice Denim Mills Ltd.  Nice Denim Mills Ltd.  Marium Textile Mills Ltd.  Marium Textile Mills Ltd.  Marium Textile Mills Ltd.  Zaber Spinning Mills Ltd.  Zaber Spinning Mills Ltd.  Zaber Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Noman Weaving Mills Ltd.  Noman Weaving Mills Ltd.  Noman Weaving Mills Ltd.  Sufia cotton Mills Ltd.  Sufia cotton Mills Ltd.  Sufia cotton Mills Ltd.  Zarba Textile Mills Ltd.  Zarba Textile Mills Ltd.  Zarba Textile Mills Ltd. 11

  12. Noman Weaving Mills Ltd Noman Weaving Mills Ltd  Noman Terry Towel Mills Ltd.  Yasmin Textile Mills Ltd.  Talha Fabrics Limited  Ismail Spinning Mills Ltd.  Zubair spinning mills Ltd.  Noman Textile Mills Ltd.  Zaber Zubair Fabrics Ltd.  Noman Spinning Mills Ltd.  Yasmin Spinning Mills Ltd.  Saad Saan Textile Mills Ltd.  Zaber &Zubair Accessories Ltd.  Noman composite Textile Ltd  Ismail Anzuman –Ara Fabrics ltd.  Saad Saan Apparels Ltd.  Noman Fashion Fabrics Ltd.  Zarba Rotor Spinnimg Mills Ltd. 12

  13. Noman Weaving Mills Ltd Noman Weaving Mills Ltd LAY-OUT PLAN OF THE FACTORY LAY-OUT PLAN OF THE FACTORY LAY-OUT PLAN OF THE FACTORY WASTAGE WASTAGE WASTAGE STORAGE STORAGE STORAGE GENERATOR CHIILLER CHIILLER CHIILLER GENERATOR GENERATOR SECURITY SECURITY SECURITY TOILET TOILET TOILET AIR VESSEL AIR VESSEL AIR VESSEL BOILER BOILER BOILER WARPING WARPING WARPING CANTENE FOR WORKER CANTENE FOR WORKER CANTENE FOR WORKER OFFICE ROOM OFFICE ROOM OFFICE ROOM WEAVING SHED WEAVING SHED WEAVING SHED WORK SHOP WORK SHOP WORK SHOP FOLDING&INSPECTION DEPT FOLDING&INSPECTION DEPT FOLDING&INSPECTION DEPT SECURITY SECURITY SECURITY SIZING SHED SIZING SHED SIZING SHED GATE 01 GATE 01 GATE 01 SECURITY PERSON 20 SECURITY PERSON 20 SECURITY PERSON 20 SECURITY SECURITY SECURITY GATE 01 GATE 01 GATE 01 A/C STATION A/C STATION A/C STATION OFFICE OFFICE OFFICE DIGI DIGI DIGI CLOTH CLOTH CLOTH STORE STORE STORE NOMAN WEAVING NOMAN WEAVING NOMAN WEAVING SECURITY SECURITY SECURITY MILLS LTD MILLS LTD MILLS LTD POST POST POST MAIN GATE MAIN GATE MAIN GATE N N N MAYMENSING DHAKA HIGH WAY MAYMENSING DHAKA HIGH WAY MAYMENSING DHAKA HIGH WAY 13

  14. Noman Weaving Mills Ltd Product mix:  Plain  Plain  Plain Noman Weaving Mills Ltd Product mix: Product mix:  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Twill  Twill  Twill  2/1s twill, 3/2 S twill  2/1s twill, 3/2 S twill  2/1s twill, 3/2 S twill  Satin  Satin  Satin  5 ends satin, stripe satin  5 ends satin, stripe satin  5 ends satin, stripe satin poplin Voile Matt Canvas Oxford stripe fabric stripe fabric 14

  15. Noman Weaving Mills Ltd Check fabric Noman Weaving Mills Ltd 2/1s twill 3/2 S twill 3/2 S twill 5 ends satin Stripe Satin Different Department: Different Department: Different Department:   Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping )  R&D dept.  Production dept.  Production dept.  Production dept.    Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping ) Administration dept. Administration dept.  Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping )  R&D dept.  R&D dept. Administration dept. 15

  16. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Chapter- 02 Chapter- 02 Manpower Management Manpower Management 16

  17. Noman Weaving Mills Ltd Noman Weaving Mills Ltd D 17

  18. Noman Weaving Mills Ltd Manpower setup in different shift: Manpower setup in different shift: Noman Weaving Mills Ltd  Administration dept.  Administration dept. Shift General Shift “A” Shift “B” Shift Short “C” Manpower 26 06 03 01 -04  Accounts dept.  Accounts dept.  Accounts dept. Shift General Shift “A” Shift “B” Shift Short “C” Manpower 03 -02  Store dept.  Store dept.  Store dept. Shift General Shift “A” Shift “B” Shift Short “C” Manpower 37 01 01 01 -04  Security dept.  Security dept.  Security dept. Shift General Shift “A” Shift “B” Shift Short “C” Manpower 02 22 22 22 -17  Mechanical dept.  Mechanical dept.  Mechanical dept. Shift General Shift “A” Shift “B” Shift Short “C” Manpower 18 19 19 19 -34  Electrical dept  Electrical dept  Electrical dept Shift General Shift “A” Shift “B” Shift Short “C” Manpower 09 05 05 05 -15  Quality dept.  Quality dept.  Quality dept. Shift General Shift “A” Shift “B” Shift Short “C” 18

  19. Noman Weaving Mills Ltd Manpower Noman Weaving Mills Ltd 3 2 2 2 -2  Mending &folding dept  Mending &folding dept  Mending &folding dept Shift General Shift “A” Shift “B” Shift Short “C” Manpower 130 16 20 -46  Utility dept.  Utility dept.  Utility dept. Shift General Shift “A” Shift “B” Shift Short “C” Manpower 12 9 14 14 -15  Workshop dept.  Workshop dept.  Workshop dept. Shift General Shift “A” Shift “B” Shift Short “C” Manpower 10 2 2 -3  Preparatory dept.(sizing & warping)  Preparatory dept.(sizing & warping)  Preparatory dept.(sizing & warping) Shift General Shift “A” Shift “B” Shift Short “C” Manpower 6 27 27 27 -55  Production dept.(loom)  Production dept.(loom)  Production dept.(loom) Shift General Shift “A” Shift “B” Shift Short “C” Manpower 11 59 59 59 -35 19

  20. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Chapter -03 Chapter -03 Machine description Machine description Specification of machineries: Specification of machineries: List of the machine: Number of m/c Number of m/c Brand name Origin Origin RPM Winding machine: 3 Tangsi Textile Machinery Co. Chine 1120 Warping machine: 4 Benninger /hacoba Switzerland Switzerland 1200 20

  21. Noman Weaving Mills Ltd Sizing machine Noman Weaving Mills Ltd 2 Benninger sucker muller Switzerland Switzerland 160 Picanol loom 40 Optimax Gamma Belgium Belgium 700/500 Air jet loom 128 Toyota JAT 710 Japan 800 Projectile loom 156 sulzer Switzerland Switzerland 250 Desk loom 1 Bangladesh Bangladesh Knotting m/c 5 Staubli Switzerland Switzerland Lay out plan of weaving section: Lay out plan of weaving section: Lay out plan of weaving section: 21

  22. Noman Weaving Mills Ltd Noman Weaving Mills Ltd 22

  23. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Chapter -04 Raw Materials Information about yarn source and product mix: Information about yarn source and product mix: Important Yarn Receive From Count Count Blend Ratio Ratio 23

  24. Noman Weaving Mills Ltd (Name of spinning mills) Noman Weaving Mills Ltd Nahar (India) 80s/1,60s/1,40s/1 80s/1,60s/1,40s/1 CB/CP 100% 100% Local Yarn Receive From Count Blend Ratio (Name of spinning mills) Zaber 30s/1 BC 100% Zaber 40s/1 CW 100% Zaber 50s/1 Comb 100% Zubair 30s/1,40s/1 30s/1,40s/1 CW 100% Zubair 40s/1,50s/1 40s/1,50s/1 CB/CP 100% Talha 16s/1,20s/1,24s/1 16s/1,20s/1,24s/1 CTN 100% Talha 30s/1 KW 100% Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50% Yasmin 40s/1,45s/1,58s/1,70s/1 40s/1,45s/1,58s/1,70s/1 CW 100% Yasmin 45s/1,46s/1 45s/1,46s/1 TC 65%+35% Yasmin 40s/1,45s/1,50s/1 40s/1,45s/1,50s/1 CVC 60%+40% Yasmin 49s/1 Comb 100% Sufia 19.5s/1,45.5s/1 19.5s/1,45.5s/1 CTN 100% Sufia 30s/1 KC 60%+40% Sufia 45s/1 CVC 100% Ashik Comp. 9s/1 CTN 100% Ashik 16s/1 CTN Double Yarn Double Yarn Double Yarn 24

  25. Noman Weaving Mills Ltd Receive From Noman Weaving Mills Ltd Count Blend Ratio (Name of spinning mills) Z&Z Fab 10s/2,16s/1 10s/2,16s/1 CTN 100% 100% Z&Z Fab 36s/2 CVC 60%+40% 60%+40% Noman Tex 30s/2 CW 100% 100% Noman Tex 40s/2 CB/CP 100% 100% Zaber 32s/2 CW 100% 100% Spuare 20s/2 CTN 100% 100% Mytas 20s/2 CTN 100% 100% R.k. Spg 20s/2 TC 35%+65% 35%+65% R.k. Spg 60s/2 CB/CP 100% 100% R.k. Spg 20s/2 CTN 100% 100% R.k. Spg 39s/2 CW 100% 100% MIMTEX 40s/2 Comb 100% 100% MIMTEX 60s/2 CB/CP 100% 100% TAMIJ 80s/2 CB/CP 100% 100% Dyed Yarn (For sample making) Dyed Yarn (For sample making) Dyed Yarn (For sample making) Receive From Count Blend Ratio Color Color (Name of spinning mills) Paramount 40s/1 CVC 60%+40% Opt.White Opt.White Paramount 20s/1 CVC 60%+40% Beige Beige Paramount 40s/1 PC 50%+50% Opt.white Opt.white Paramount 20s/1 CTN 100% Opt.white Opt.white Paramount 40s/1 CB/CP 100% Navy blue Navy blue 25

  26. Noman Weaving Mills Ltd Paramount Noman Weaving Mills Ltd 40s/1 CVC 60%+40% Sky blue Sky blue Paramount 20s/1 CVC 60%+40% Black Black Paramount 40s/1 PC 50%+50% Blue Blue NOOR 30s/1 Comb 100% Black Black NOOR 30s/1 Comb 100% White White Raw material for Sizing: Raw material for Sizing: Raw material for Sizing: Chemical Name Chemical Name Chemical Name  Kollatex 05  Kollatex 05  Kollatex 05  Penetrose 50  Penetrose 50  Penetrose 50  Glysofill soft  Glysofill soft  Glysofill soft  Elastex  Elastex  Elastex  Tape  Tape  Tape  Pinitex  Pinitex  Pinitex  PVA  PVA  PVA  Quick solan SPR  Quick solan SPR  Quick solan SPR 26

  27. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Chapter -05 Chapter -05 Research & development Research & development 27

  28. Noman Weaving Mills Ltd Noman Weaving Mills Ltd R&D Department: R&D Department: Sample analysis: Sample analysis:  Fabric construction analyses from given sample  Identify the fabric type e.g. yarn dyed or grey fabric  Identify the weave structure of sample  Find out yarn count, EPI, PPI etc.  Measured the yarn consumptions according to the order quantity  Make warp and weft pattern.  During sample making some parameters are considered-  During sample making some parameters are considered-  Fabric construction analyses from given sample  Identify the fabric type e.g. yarn dyed or grey fabric  Identify the weave structure of sample  Find out yarn count, EPI, PPI etc.  Measured the yarn consumptions according to the order quantity  Make warp and weft pattern.  Cover factor  Reed selection  Reed selection  Reed selection  Cover factor  Cover factor Cover Factor: Cover factor is important part during production like as loom running. It indicates the fabric consumption. Is it possible or not to go to production. Expressed as fabric consumption. Is it possible or not to go to production. Expressed as fabric consumption. Is it possible or not to go to production. Expressed as Cover Factor: Cover factor is important part during production like as loom running. It indicates the Cover Factor: Cover factor is important part during production like as loom running. It indicates the British method: British method: British method: EPI EPI PPI PPI C.F C.F count count count count Germany Method: EPI K1 count PPI K2 count EPI EPI PPI PPI K2 K2 K1 K1 C.F C.F count count 28 28 count count 28

  29. Noman Weaving Mills Ltd Reed selection: Reed selection: Reed selection: Noman Weaving Mills Ltd Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric construction & storage of reed. construction & storage of reed. construction & storage of reed. Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric Construction: Construction: Construction: 40 40 40 40 * * * * 58 58 124 124 96 96 Total ends Total ends 124 * 58 124 * 58 7192 7192 Width of cloth Width of cloth Reed count Reed count EPI * EPI * Reed Width Reed Width 100 + % regain 100 + % regain Reed Width Reed Width Fabric With Fabric With * * 100 100 100 + 12 100 + 12 58* * 58* * 100 100 64.96" 64.96" 58 58 64.96 Reed Count Reed Count 124* 124* 64.96 110.7 110.7 Or Or Reed count = Finished EPI × 0 .9 Reed count = Finished EPI × 0 .9 = 124× .9 = 124× .9 = 111.6 = 111.6 29

  30. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Total ends Reed Count 7192 111 = 64.7 Reed Width= = Contraction mesurment: 3 3 Warp contruiction = EPI* Warp contruiction = EPI* Warp count Warp count 3 40 40 3 = 124* = 124* = 9.3 = 9.3 3 3 PPI PPI Weft contruction= Weft contruction= * * Weft count 3 40 40 Weft count 3 = = 96 * 96 * 7.2 7.2 = = Total Contruction = (9.3 +7.2)*.85 Total Contruction = (9.3 +7.2)*.85 = 14.02 = 14.02 Suppose, fabric required = 5000mtr Suppose, fabric required = 5000mtr Tape Length= Required length +(contruction %*.85) + 30mtr wastage Tape Length= Required length +(contruction %*.85) + 30mtr wastage Tape Length= Required length +(contruction %*.85) + 30mtr wastage = = 5000 + (14.02* .85) + (30 5000 + (14.02* .85) + (30 *2) *2) [Here, no of beam = 2] [Here, no of beam = 2] = = 5074 5074 30

  31. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Fabric wt calculation system: Fabric wt calculation system:                 EPI N warp N warp EPI 1.03 1.03 PPI N weft e N weft PPI N weft PPI 1.05 1.05 Oz/Yds² Oz/Yds² = =     0.685 0.685 e e e                 EPI N warp =L w W  EPI N warp 1.03 1.03 PPI N weft 1.05 1.05 GSM =     23.25 23.25 e e e e  N e l width 39.37 width GSM GSM Wt calculation =39.37     length length 1000 1000 Warp wt in lbs (yarn consumption): Warp wt in lbs (yarn consumption): Warp wt in lbs (yarn consumption): EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) +20% waste of the total warp weight +20% waste of the total warp weight +20% waste of the total warp weight EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) Ne warp × 840 Ne warp × 840 Ne warp × 840 Weft wt in lbs Weft wt in lbs Weft wt in lbs EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% waste of the total warp weight waste of the total warp weight waste of the total warp weight EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% Ne weft × 840 Ne weft × 840 Ne weft × 840 31

  32. Noman Weaving Mills Ltd Design identification: Design identification: Design identification: Noman Weaving Mills Ltd Fig: plain weaves (1/1) Fig: plain weaves (1/1) Fig: plain weaves (1/1) Fig: Fig: Fig: 2/1 z twill 2/1 z twill 2/1 z twill Fig: 5 end satin Move-3 Fig: 5 end satin Move-3 Fig: 2/2 Matt Fig: 2/2 Matt Fig: Dobby design Fig: Dobby design 32

  33. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Chapter -06 Chapter -06 Operation procedure Operation procedure 33

  34. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Sequence of operation Sequence of operation Yarn from spinning (Cone) Yarn from spinning (Cone) Winding Winding weft weft warp warp Warping Warping Weft (Cone form) Weft (Cone form) Sizing Sizing Drawing And Denting Denting Drawing And Knotting Knotting Looming Looming Weaving Weaving Unwind the fabric from the cloth roller Unwind the fabric from the cloth roller Inspection Inspection Mending Mending Folding Folding Packing Packing Introduction of winding: 34

  35. Noman Weaving Mills Ltd Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production process, but also other factors such as packing cases, pressure due to winding tension must be considered. considered. considered. Noman Weaving Mills Ltd Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production process, but also other factors such as packing cases, pressure due to winding tension must be process, but also other factors such as packing cases, pressure due to winding tension must be Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production Objectives: Objectives: Objectives:   To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package  To get exact winding rate  To acquire perfect knowledge about winding and apply it in future.  To acquire perfect knowledge about winding and apply it in future.  To acquire perfect knowledge about winding and apply it in future.    To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package To know about the winding process To know about the winding process  To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package  To get exact winding rate  To get exact winding rate To know about the winding process Purpose of winding: Purpose of winding: Purpose of winding:          To remove objectionable faults from the yarns To produce good package containing long continuous length of yarn. The winding package should facilitate smooth operation of the subsequent process To make the suitable package for warping  To control the exact tension of the package  To control the exact tension of the package  To control the exact tension of the package To remove objectionable faults from the yarns To produce good package containing long continuous length of yarn. The winding package should facilitate smooth operation of the subsequent process To make the suitable package for warping To make the suitable package for warping To remove objectionable faults from the yarns To produce good package containing long continuous length of yarn. The winding package should facilitate smooth operation of the subsequent process    Types of winding: Types of winding: Types of winding: Actually winding is divided into three types: Actually winding is divided into three types: Actually winding is divided into three types:          Parallel wound package Near parallel wound package Cross wound package Cross wound package Cross wound package Parallel wound package Near parallel wound package Near parallel wound package Parallel wound package Winding faults: Winding faults: Winding faults: Yarn faults Yarn faults Yarn faults  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter, Adhered loose fiber. Adhered loose fiber. Adhered loose fiber.  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter,  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter, Package faults Package faults Package faults  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls.  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls.  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls. 1 Machine Specification: Machine Specification: Machine Specification: 1 1  High speed cone/ Cheese winding machine machine  High speed cone/ Cheese winding  Cone winding machine  Cone winding machine Model Model : GA014MD- 120 : GA014MD- 120 M/c serial no M/c serial no : 1817 : 1817 Origin Origin : China : China 35 R. P .M R. P .M : 1720 : 1720 Spindle : 120 Spindle : 120 Spindle : 120 Spindle : 120

  36. Noman Weaving Mills Ltd Noman Weaving Mills Ltd  Cone winding machine  Cone winding machine Model : GA014MG Model : GA014MG Origin : China Origin : China Tangsi Textile Machinery Co. Ltd Tangsi Textile Machinery Co. Ltd Yarn path diagram of winding: Yarn path diagram of winding: Winding package Winding package Winding package Yarn package Yarn package Yarn package Yarn clearer Yarn clearer Yarn clearer Tension device Tension device Tension device Traverse Traverse Traverse Guide rod Guide rod Guide rod Bobbin holder Bobbin holder Bobbin holder Fig:Yarn path in winding Fig:Yarn path in winding Fig:Yarn path in winding 2 2 Hardness of cone: Hardness of cone: D D Hardness = wt. of package/ volume of package Hardness = wt. of package/ volume of package 36 H H d d

  37. Noman Weaving Mills Ltd We know, We know, Noman Weaving Mills Ltd Volume of package = πR2H /4 Volume of package = πR2H /4 Where, Where, R2= D2-d2 R2= D2-d2 =142-42 =142-42 = 180cm = 180cm So, So, volume = 3.1416*180*17/4 volume = 3.1416*180*17/4 =2403 cm3 =2403 cm3 Hardness of cone = 1600/2403 gm/cm3 Hardness of cone = 1600/2403 gm/cm3 =0.6658 gm/cm3 =0.6658 gm/cm3 Standard range of hardness: Standard range of hardness: For soft cone …………………..0.350--0.500 gm/cm3 For soft cone …………………..0.350--0.500 gm/cm3 For hard cone ………………….0.550—0.700 gm/cm3 For hard cone ………………….0.550—0.700 gm/cm3 Winding angle and Winding length calculation: Winding angle and Winding length calculation: Winding angle and Winding length calculation: Winding angle, Winding angle, Winding angle, Ѳ =2 tan-1(t / π*d*n) Ѳ =2 tan-1(t / π*d*n) Ѳ =2 tan-1(t / π*d*n) 37

  38. Noman Weaving Mills Ltd Where, Where, Where, Noman Weaving Mills Ltd Travers length, t= 150 mm Travers length, t= 150 mm Travers length, t= 150 mm Scroll number, n= 2 Scroll number, n= 2 Scroll number, n= 2 Bobbin dia, Bobbin dia, Bobbin dia, d = 5cm d = 5cm d = 5cm So winding angle, So winding angle, So winding angle, Ѳ=2 tan-1(150/3.1416*50*2) Ѳ=2 tan-1(150/3.1416*50*2) Ѳ=2 tan-1(150/3.1416*50*2) =51.068 ◦ =51.068 ◦ =51.068 ◦ Winding length = 2t/ sin Ѳ/2 Winding length = 2t/ sinѲ/2 Winding length = 2t/ sinѲ/2 =2*150/sin 51.068/2 =2*150/sin 51.068/2 =2*150/sin 51.068/2 = 695.97mm = 695.97mm = 695.97mm Requirements for winding: Requirements for winding: Requirements for winding:          The fault level in the yarn must be reduced to an acceptable level. The yarn must not be damaged in any way in the winding process. The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed. The package size, shape and build must be most technologically suitable for particular end use. The package size should be controlled to meet the particular economic requirement. The device must be reliable. The device must not introduce difference in count. It must be easily cleaning. The operating surface must be smooth. The operating surface must be smooth. The operating surface must be smooth. The fault level in the yarn must be reduced to an acceptable level. The yarn must not be damaged in any way in the winding process. The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed. The package size, shape and build must be most technologically suitable for particular end use. The package size should be controlled to meet the particular economic requirement. The device must be reliable. The device must not introduce difference in count. It must be easily cleaning. It must be easily cleaning. The fault level in the yarn must be reduced to an acceptable level. The yarn must not be damaged in any way in the winding process. The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed. The package size, shape and build must be most technologically suitable for particular end use. The package size should be controlled to meet the particular economic requirement. The device must be reliable. The device must not introduce difference in count.                   Introduction: Introduction: Introduction: The preparation of warp yarn is more demanding and complicated than that of the weft or filling yarn. So correctly warping (Beaming) is very important for weaving and sizing (slashing). It depends on some aspects as different condition. (slashing). It depends on some aspects as different condition. (slashing). It depends on some aspects as different condition. The preparation of warp yarn is more demanding and complicated than that of the weft or filling yarn. So correctly warping (Beaming) is very important for weaving and sizing filling yarn. So correctly warping (Beaming) is very important for weaving and sizing The preparation of warp yarn is more demanding and complicated than that of the weft or What is warping? What is warping? What is warping? Warping is transferring many yarns from a creel of single end package forming a parallel sheet of yarns wound onto a beam or section beam. sheet of yarns wound onto a beam or section beam. sheet of yarns wound onto a beam or section beam. Warping is transferring many yarns from a creel of single end package forming a parallel Warping is transferring many yarns from a creel of single end package forming a parallel 38

  39. Noman Weaving Mills Ltd Depending on the kind of intermediate carrier used, the industrial warping process can be carried out according to two different technologies: carried out according to two different technologies: carried out according to two different technologies: Noman Weaving Mills Ltd Depending on the kind of intermediate carrier used, the industrial warping process can be Depending on the kind of intermediate carrier used, the industrial warping process can be  Sectional warping ( indirect or conical drum or dresser warping)  Beam warping or direct warping (preparatory beam warping)  Beam warping or direct warping (preparatory beam warping)  Beam warping or direct warping (preparatory beam warping)  Sectional warping ( indirect or conical drum or dresser warping)  Sectional warping ( indirect or conical drum or dresser warping) Objectives: Objectives: Objectives:  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine.  To calculate the different terminology for exact production.  To minimize the machine breakdown time.  To minimize the machine breakdown time.  To minimize the machine breakdown time.  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine.  To calculate the different terminology for exact production.  To calculate the different terminology for exact production.  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine. Purpose of warping Purpose of warping Purpose of warping  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension.  To increase the productivity and decrease the wastage of the yarns  To build a suitable package for the perfect sizing and weaving.  To build a suitable package for the perfect sizing and weaving.  To build a suitable package for the perfect sizing and weaving.  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension.  To increase the productivity and decrease the wastage of the yarns  To increase the productivity and decrease the wastage of the yarns  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension. Direct or high speed warping: Direct or high speed warping: Direct or high speed warping: Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new wound package for an easy package transfer, from the wound packages in the creel. wound package for an easy package transfer, from the wound packages in the creel. wound package for an easy package transfer, from the wound packages in the creel. Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new creel. A magazine creel connects the tail of one wound package to the beginning of a new Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine  Direct warping can be used to directly produce the weavers beam in a single operation. That is use for strong yarn such as mono filament or multifilament yarn this is also called direct beaming. this is also called direct beaming. this is also called direct beaming.  Direct warping can be used to directly produce the weavers beam in a single operation. That is use for strong yarn such as mono filament or multifilament yarn operation. That is use for strong yarn such as mono filament or multifilament yarn  Direct warping can be used to directly produce the weavers beam in a single  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends each. each. each.  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers 39

  40. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Operation procedure of direct warping: Operation procedure of direct warping: Operation procedure of direct warping: The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the machine. The pressure roller supported the warper beam continuously and keeping the yarn parallel. parallel. parallel. The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the machine. The pressure roller supported the warper beam continuously and keeping the yarn machine. The pressure roller supported the warper beam continuously and keeping the yarn The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the M /C specification: M /C specification: M /C specification: Modern- Modern- Modern- Conventional- Conventional- Conventional- Name of the m/c: Name of the m/c: Name of the m/c: Benninger Benninger Benninger Name of the m/c: Name of the m/c: Name of the m/c: hacoba hacoba hacoba Name of origin: Name of origin: Name of origin: Switzerland Switzerland Switzerland Name of origin: Name of origin: Name of origin: China China China Creel capacity : Creel capacity : Creel capacity : 1224 1224 1224 Creel capacity : Creel capacity : Creel capacity : 720 720 720 R P M R P M R P M : : : 1200 1200 1200 R P M R P M R P M : : : 600 600 600 Beam width Beam width Beam width : : : 2400 mm 2400 mm 2400 mm Beam width Beam width Beam width : : : 2400mm 2400mm 2400mm 40

  41. Noman Weaving Mills Ltd Diagram of direct warping: Diagram of direct warping: Noman Weaving Mills Ltd Calculations of high speed warping Calculations of high speed warping 41

  42. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Construction:- Construction:- Construction:- suppose,finish construction suppose,finish construction suppose,finish construction Warp length =1200 Warp length =1200 Warp length =1200 Total ends =7000 Total ends =7000 Total ends =7000 40*40 40*40 40*40 58 inch 58 inch 58 inch 120*70 120*70 120*70 Beam required =8 Beam required =8 Beam required =8 Creel capacity =875 Creel capacity =875 Creel capacity =875 solution: solution: solution: PPI =70 PPI =70 PPI =70 1200 1200 1200 Each beaming time at 100% efficiency = Each beaming time at 100% efficiency = Each beaming time at 100% efficiency = = 15 min = 15 min = 15 min 800 800 800 waste times are --- waste times are --- waste times are --- Creeling =60 min knoting =40 min Beam change =16 min Beam change =16 min Beam change =16 min Creeling =60 min knoting =40 min knoting =40 min Creeling =60 min Breakage time =80 min Breakage time =80 min Breakage time =80 min Total = 196 min Total = 196 min Total = 196 min 196 196 196 wastes time for each beam = wastes time for each beam = wastes time for each beam = = 24.5 min = 24.5 min = 24.5 min 8 8 8 With waste per beaming time = 15 +24.5 With waste per beaming time = 15 +24.5 With waste per beaming time = 15 +24.5 = 39.5 minutes = 39.5 minutes = 39.5 minutes 480 480 480 For one shift,/8 hours production = For one shift,/8 hours production = For one shift,/8 hours production = = 12 beam = 12 beam = 12 beam 39.5 39.5 39.5 12 39.5 39.5 39.5 12 12 So efficiency, = So efficiency, = So efficiency, = *100 *100 *100 =37.9746 % =37.9746 % =37.9746 % Indirect or Sectional warping system: Indirect or Sectional warping system: Indirect or Sectional warping system: 42

  43. Noman Weaving Mills Ltd Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these reason it’s called sectional warping. By sectional warping we can produce cheek and stripe fabric. fabric. fabric. Noman Weaving Mills Ltd Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these reason it’s called sectional warping. By sectional warping we can produce cheek and stripe reason it’s called sectional warping. By sectional warping we can produce cheek and stripe Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these The sectional warping depends on some parameters such as: The sectional warping depends on some parameters such as: The sectional warping depends on some parameters such as:  Head stock  Control device.  Creel arrangement.  Creel arrangement.  Creel arrangement.  Head stock  Control device.  Control device.  Head stock Operation procedure of sectional warping: Operation procedure of sectional warping: Operation procedure of sectional warping: In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that value is input into the device with respect to the repeat width. After finished the total length is transferred to the sized beam. transferred to the sized beam. transferred to the sized beam. In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that value is input into the device with respect to the repeat width. After finished the total length is value is input into the device with respect to the repeat width. After finished the total length is In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that M/C Specification: M/C Specification: M/C Specification: Name of the m/c: Name of the m/c: Name of the m/c: Benninger supertronic Benninger supertronic Benninger supertronic Name of origin: Name of origin: Name of origin: Switzerland Switzerland Switzerland V-reed capacity: V-reed capacity: V-reed capacity: 650 650 650 Eye reed capacity: Eye reed capacity: Eye reed capacity: 650 650 650 Creel capacity: Creel capacity: Creel capacity: 576 576 576 R. p. m R. p. m R. p. m : : : 800 800 800 Components of sectional warping: Components of sectional warping: Components of sectional warping: 43

  44. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Indirect Warping process: 44

  45. Noman Weaving Mills Ltd Pattern chart of warp & weft Pattern chart of warp & weft Pattern chart of warp & weft Noman Weaving Mills Ltd Warp length =1300(1300+118) Warp length =1300(1300+118) Warp length =1300(1300+118) Construction:- Construction:- Construction:- Total ends =5900 Total ends =5900 Total ends =5900 40*40 40*40 40*40 Reed density/inch = 46 Reed density/inch = 46 Reed density/inch = 46 102*70 102*70 102*70 Reed cound =92 Reed cound =92 Reed cound =92 Reed width =64.1 Reed width =64.1 Reed width =64.1 Order quanty =1100 Order quanty =1100 Order quanty =1100 PPI =70 PPI =70 PPI =70 Weft pattern Weft pattern Weft pattern Warp pattern Warp pattern Warp pattern 6 6 6 Navy Navy Navy All optical white All optical white All optical white Optical white Optical white Optical white 7 7 7 Total Total Total 13 13 13 In warp In warp In warp Required warp in kg in kg in kg Required warp Required warp per color req. in kgremarks per color req. in kgremarks per color req. in kgremarks Ends Ends Ends % of color % of color % of color Color Color Color 6 6 6 46.15 46.15 46.15 Navy Navy Navy 116 116 116 54 54 54 62 62 62 Optical white Optical white Optical white 53.85 53.85 53.85 7 7 7 116 116 116 Total Total Total 116 116 116 In weft In weft In weft per color req. in kg req. in kg req. in kg per color per color Required warp in kg warp in kg warp in kg Required Required picks picks picks Color Color Color % of color % of color % of color remarks remarks remarks White White White 84 84 84 1 1 1 100 100 100 84 84 84 45

  46. Noman Weaving Mills Ltd Why sectional warping is different? Why sectional warping is different? Why sectional warping is different? Noman Weaving Mills Ltd In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly than solid dyed fabric. than solid dyed fabric. than solid dyed fabric. In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for The computerized sectional warping can automatically calculates the following: The computerized sectional warping can automatically calculates the following: The computerized sectional warping can automatically calculates the following: 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing 5. Constant warp tension over the full warp width 6. Memory of yarn breakage during warping for beaming 6. Memory of yarn breakage during warping for beaming 6. Memory of yarn breakage during warping for beaming 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing 5. Constant warp tension over the full warp width 5. Constant warp tension over the full warp width 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing Faults in warping Faults in warping Faults in warping 1. 2. 3. 4. 5. 5. 5. 1. 2. 3. 4. 4. 1. 2. 3. Practically for winding Machine fault Operator misconception Low quality yarn others others others Practically for winding Machine fault Operator misconception Low quality yarn Low quality yarn Practically for winding Machine fault Operator misconception Problems in warping Problems in warping Problems in warping a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) e. Incorrect warp length f. Big knot f. Big knot f. Big knot a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) e. Incorrect warp length e. Incorrect warp length a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) Checking have to done during warping: Checking have to done during warping: Checking have to done during warping: 1. Lot mixing 2. Count mixing 3. Color variation 3. Color variation 3. Color variation 1. Lot mixing 2. Count mixing 2. Count mixing 1. Lot mixing 46

  47. Noman Weaving Mills Ltd Calculation of sectional warping: Calculation of sectional warping: Noman Weaving Mills Ltd Construction: Construction: 40*40 57 102*70 Total ends =5900 Total ends =5900 Reed dents per inch =46 Reed count =92 Reed count =92 Reed dents per inch =46 Reed width =64.1 PPI =70 winding angle = .8 winding angle = .8 Reed width =64.1 PPI =70 Solutions: 5905 5905 5905 = 147.625 = 147.625 = 147.625 d tex = d tex = d tex = Ne Ne Ne Total ends *10 Total ends *10 Total ends *10 5900 *10 5900 *10 5900 *10 = 31.052 cm = 31.052 cm = 31.052 cm Mesured phase or e/cm = Mesured phase or e/cm = Mesured phase or e/cm = = = = warp width warp width warp width 1900 1900 1900 Number of ends = Fabric width *EPI Number of ends = Fabric width *EPI Number of ends = Fabric width *EPI = 57*102 = 5814 = 57*102 = 5814 = 57*102 = 5814 5900 5900 5900 Total ends Total ends Total ends = = = = 453.846 = 453.846 = 453.846 Number of section = Number of section = Number of section = 13 13 13 Repeat size Total ends Total ends Total ends Repeat size Repeat size 5900 5900 5900 = 57.843 = 57.843 = 57.843 Fabric width = Fabric width = Fabric width = = = = 102 102 102 EPI EPI EPI 147.625*5900*0.8 147.625*5900*0.8 147.625*5900*0.8 d tex * total ends * 0.8 d tex * total ends * 0.8 d tex * total ends * 0.8 = 0.91mm = 0.91mm = 0.91mm Warp density= Warp density= Warp density= = = = 400 * warp width(mm) 400 * warp width(mm) 400 * warp width(mm) 400*1900 400*1900 400*1900 47

  48. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Suppose Cone weight =2000gm Cone weight =2000gm Cone weight =2000gm Suppose Suppose Length of one cone = 1.6933*30*2000 Length of one cone = 1.6933*30*2000 Length of one cone = 1.6933*30*2000 Creel capacity =512 Creel capacity =512 Creel capacity =512 * 200 * 200 * 200 = 101598 mts = 101598 mts = 101598 mts Number of cone =200 Number of cone =200 Number of cone =200 =20319600 mts =20319600 mts =20319600 mts Count = 30 Count = 30 Count = 30 =22221514.56 yds =22221514.56 yds =22221514.56 yds length per creel stand =22221514.56/512 length per creel stand =22221514.56/512 length per creel stand =22221514.56/512 = 43401.3956 yds = 43401.3956 yds = 43401.3956 yds Required weight of yarn per cone in creel, Required weight of yarn per cone in creel, Required weight of yarn per cone in creel, 43401.3956 43401.3956 43401.3956 = = = 840*30 840*30 840*30 =1.72227 lbs =1.72227 lbs =1.72227 lbs Following terms should be considered Following terms should be considered Following terms should be considered 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet 3. Warping efficiency 60% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet 3. Warping efficiency 60% 3. Warping efficiency 60% 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet What is sizing: What is sizing: What is sizing: The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the tensions and the rubbing caused by weaving. tensions and the rubbing caused by weaving. tensions and the rubbing caused by weaving. The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent Purpose of sizing: Purpose of sizing: Purpose of sizing:       To improve the weave ability of the warp yarn To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness, strength of yarn. To increase the tensile or breaking strength for cellulose yarn. To increase the tensile or breaking strength for cellulose yarn. To increase the tensile or breaking strength for cellulose yarn. To improve the weave ability of the warp yarn To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness, strength of yarn. smoothness, strength of yarn. To improve the weave ability of the warp yarn To maintain good fabric quality by reducing hairiness, weakness and by increasing    48

  49. Noman Weaving Mills Ltd To increase the elasticity To remove the protruding/floating fibers To reduce electrostatic formation for synthetic or blended yarn To reduce electrostatic formation for synthetic or blended yarn To reduce electrostatic formation for synthetic or blended yarn Noman Weaving Mills Ltd To increase the elasticity To remove the protruding/floating fibers To remove the protruding/floating fibers          To increase the elasticity Sizing Technique: Sizing Technique: Sizing Technique: All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the beams under process minus one and have the function of keeping the threads separate and of preventing that they get entangled and are not wound up with the correct sequence. preventing that they get entangled and are not wound up with the correct sequence. preventing that they get entangled and are not wound up with the correct sequence. All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the beams under process minus one and have the function of keeping the threads separate and of beams under process minus one and have the function of keeping the threads separate and of All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s beam. beam. beam. A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp Reason for different sizing recipe: Reason for different sizing recipe: Reason for different sizing recipe: Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon as warping is completed, to the sizing machine where they are assembled. as warping is completed, to the sizing machine where they are assembled. as warping is completed, to the sizing machine where they are assembled. Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when a particularly thick size is required. a particularly thick size is required. a particularly thick size is required. There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The Machine specification: Machine specification: Machine specification: 49

  50. Noman Weaving Mills Ltd Noman Weaving Mills Ltd Shade-02 Shade-02 Shade-01 Shade-01 Machine Name Brand Origin R.P.M Cylinder V-reed Lease Beam capacity Winding pressure Press tension Lease tension Cylinder temperature Production capacity/day: 30000 meters Production capacity/day: 30000 meters Machine Name Brand Origin R.P.M Cylinder V-reed Lease Beam capacity Winding pressure Press tension Lease tension Cylinder temperature : Sucker Muller :Hacoba : Switzerland :60 each roller : 12 : 1450 : 14 : 16 : 4500 bar : 3500 bar : 2000 bar (Maximum) : 145 degrees : 145 degrees : Sucker Muller :Hacoba : Switzerland :60 each roller : 12 : 1450 : 14 : 16 : 4500 bar : 3500 bar : 2000 bar (Maximum) Machine Name Origin R.P.M Cylinder Lease Beam capacity V-reed Cylinder Temperature Winding pressure Creel tension Production capacity/day: 40000-45000 Max Production capacity/day: 40000-45000 Max Machine Name Origin R.P.M Cylinder Lease Beam capacity V-reed Cylinder Temperature Winding pressure Creel tension :Benninger : Switzerland :160 Max : 14 : 29 : 32 : 1372 : 145 degree : 1800 N : 700 N : 700 N :Benninger : Switzerland :160 Max : 14 : 29 : 32 : 1372 : 145 degree : 1800 N Scematric diagram and control system of sizing m/c: Scematric diagram and control system of sizing m/c: 50

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