BLOW ROOM CALCULATIONS

OBJECTIVE OF BLOW ROOM: 

                       The main objectives of blow room are opening , cleaning  and  blending.


Calculation involves in this process:


i  - Lap length (yards): lap weight (k.g) x 16 x 2.2046
                                                  oz/yards

ii - Oz / yards : lap weight ( k.g ) x 1000  
                          lap length ( yrds ) x 28.35

iii- Lap Hanks :                16         
                                840 x oz/yards
 
iv - Yards / min :   shall roll dia ( m.m ) x r.p.m x 3.141
                                                  25.4  x  36

v  - Lap Completion Time ( min ) : Total lap length (yrds)   
                                                                   yards / min

vi - Production in lbs/shift :
                                      shall roll r.p.m  x dia(inches) x 3.141
                                                        lap hanks  x  63



          

SHORT INTRODUCTION ON SPINNING TECHNOLOGY

SPINNING IS THE PROCESS WHICH STARTS FROM FIBRE AS A RAW MATERIAL  AND ENDED WITH THE PREPARATION OF YARN AS A PRODUCT.SPINNING CONSIST OF TWO TYPES,WHICH ARE NAMED AS BELOW:

- RING SPINNING .
- OPEN END SPINNING.

SPINNING MILLS  CONSIST OF FOLLOWING PROCESS:
RING SPINNING:                                     OPEN END SPINNING:
- BLOW ROOM                                           - BLOW ROOM
- CARDING                                                  - CARDING

- DRAWING                                                 - DRAWING
- COMBERS                                              - AUTOCORO
- SIMPLEX
- RING
- AUTO CONE

SOME PICTURES OF SPINNING PROCESS:


                                                                  BLOW ROOM DEPARTMENT
TRUTZSCHLER

        CARD MACHINES
              RIETER C - 60

            



                              DRAWING PROCESS
                                   RIETER RSB D-35

                        COMBER PROCESS
                         HOWA MACHINES

                       SIMPLEX DEPARTMENT
                             HOWA MACHINES 

                  RING SPINNING MACHINES
                           F - 1520 COMPACT

                  AUTO CONE MACHINES
                    SCHLAFHORST - 338

        SPECIAL THANKS TO:
                             QUETTA TEXTILE MILLS.

WOOL FIBRE

Wool production and use dates back approximately 10,000 years in Asia Minor. People living in the Mesopotamian Plain at that time used sheep for three basic human needs: food, clothing and shelter. As spinning and weaving skills developed woollens became a greater part of people's lives. The warmth of wool clothing and the mobility of sheep allowed people to spread civilisation beyond the warm climate of the Mesopotamia. Between 3000-1000 BC the Persians, Greeks and Romans distributed sheep and wool throughout Europe. The Romans took sheep everywhere they built their Empire including the British Isles. From here the British took sheep to all their colonies.

Fibre Structure

Wool is different to other fibres because of its chemical structure. This chemical structure influences its texture, elasticity, staple and crimp formation. Wool is a protein fibre, composed of more than 20 amino acids. These amino acids form protein polymers. Wool also contains small amounts of fat, calcium and sodium.

Types of Wool Yarn

There are two types of wool yarn – woollens and worsteds.
Woolens: Woolens is a general term describing various fabrics woven from woollen yarn that is spun from the shorter wool fibres. These shorter fibres are not combed to lie flat as in the worsted yarn. This results in soft surface textures and finishes and the weave of individual yarns does not show as clearly as in worsted fabrics.
Worsteds: Worsted is a general term for fabrics woven from worsted yarns that contain longer fibres spun from combed wool. Worsted wool refers to tightly woven, smooth, clear finished goods in a variety of twill and other stronger weaves.
Worsteds undergo several processes:

• Scouring – Washed to remove dust, suint (sweat) and wool wax.
• Carding – Rolled with a roller that is covered with teeth tease apart the staples of wool, laying the fibres nearly parallel to form a soft rope called a 'sliver'.
• Combing – Combed to separate short from long fibres, ensuring that the long fibres are laid parallel to produce a combed sliver called a 'top'.
• Drawing – Drawing out of tops into the thickness of one, to thoroughly blend the wool and ensure evenness or regularity of the resulting 'roving'.
• Finisher drawing – Drawing to reduce the roving thickness to suit the spinning operation and further improve evenness.
• Spinning – Inserting twist into the yarn to give strength to the finished yarn.

HEMP FIBRE

Hemp production is easy to achieve organically. Therefore many of the ecological problems in chemical farming of other fibres are obviated. Hemp quickly grows up to 5 metres in height with dense foliage which blocks weed growth. This means herbicides are not needed and the field is weed free for the next crop. Unlike cotton hemp does not have a high water requirement. The hemp plant has a deep tap root system which enables the plant ot take advantage of deep subsoil moisture, thus requiring little or no irrigation.

Hemp has been produced for thousands of years as a source of fibre for paper, cloth, sails/canvas and building materials. Natural fibre from the hemp stalk is extremely durable and can be used in the production of textiles, clothing, canvas, rope, cordage, archival grade paper, paper, and construction materials.

There are two principal types of fibres in hemp – bast or long fibres and hurds or inner short fibre. Traditionally hemp has been grown for its valuable and versatile high quality bast fibres. Bast fibres account for 20-30 percent of the stalk (depending on the seed variety, and planting density). There are two types of bast fibres:

·     primary bast fibres. Primary bast fibres make up approximately 70 percent of the fibres and are long, high in cellulose and low in lignin. Primary bast fibres are the most valuable part of the stalk, and are generally considered to be among the strongest plant fibres known.

·     secondary bast fibres. Secondary bast fibres make up the remaining 30 percent of the bast fibres and are medium in length and higher in lignin. They are less valuable and become more prevalent when the hemp plants are grown less densely, making shorter fatter stalks since they do not have to compete for light.

The production or extraction of the primary bast fibres has traditionally been a very labour intensive process, but recently an alternative fibre separation process has been developed using technologies such as ultrasound and steam explosion, which are much less labour intensive. Once separated the bast fibres are ready for spinning and weaving into textiles, or for pulping into high quality pulp. Bast fibres are ideal for specialised paper products such as industrial filters, currency paper, tea bags or cigarette paper.

Hurds are the short fibred inner woody core of the hemp plant. They comprise 70-80 percent of the stalk and are composed of libriform fibres which are high in lignin. Traditionally hurds have been considered waste as they are the by-product from bast extraction. The hurds are 50-77 pecent cellulose making them ideal for paper making. One acre of hemp can replace 4.1 acres of trees for pulp production. Although the fibres are shorter than bast fibres they are suitable for a range of products such as rayon, biomass fuel, cellophane, food additives, industrial fabrication materials and newsprint pulp.

SISAL FIBRE

Sisal is a plant of the agave family Agave sisalina. The stalk grows to about one metre in height. The fibre is contained in the lance-shaped leaves that grow out from the stalk in a dense rosette. The sisal plant produces approximately three hundred leaves throughout its productive period.
To extract the fibre the leaves are crushed and the pulp scraped from the fibre. This is then washed and dried. The sisal fibre strands are usually creamy white in colour.
When harvested, the sisal fibre is coarse and relatively inflexible. The process of turning these fibres into silky fabric involves a high degree of beating and pulping. The result is a fabric that is light enough to be worn in the hottest weather. It is able to be woven into nearly invisible sheers and is used as a replacement for silk. Because of the amount of work to process the sisal into this sheer fabric its value is very high. Despite these excellent qualities, sisal is most commonly used for more practical products eg for cordage because of its strength, durability, ability to stretch and its resistance to deterioration in salt water. Other common products are sisal twine, mattings, rugs, and brushes.
In recent years, China has maintained approximately 12,000 hectares of sisal production. This area produces around 40,000 tonnes of fibres. This level of production means that China accounts for approximately 11-13 percent of total world production. Sisal products of Chinese origin first entered the world market in the late 1970s.

FLAX

Flax is also known as linen. The flax plant yields the fibres for linen cloth; the short fibres not needed for cloth production can be used to make paper. Linen has been used for thousands of years. The earliest traces of its use have been dated as far back as 8,000 BC. Flax is thought to have originated in the Mediterranean region of Europe, the Swiss Lake Dweller People of the Stone Age apparently produced flax for fibre and seed. Mummies in Egyptian graves dating back 6,000 years have been found wrapped in linen wraps. In the USA the early colonists grew flax for home use. Commercial production of flax fibre began there in 1753.
Currently the major flax fibre producing countries are France (64,000 tons annually), China (31,000 tons), Belgium (15,300 tons), Holland (4,600 tons).
The fibre is obtained from the stalk of the flax plant - Linum Usitatissimum. This plant grows 80 - 120 cms high with few branches and small flowers. The stems are composed of 70 percent cellulose. Prior to fibre harvesting, the flax plants are first de-seeded then retting or separating the straw or bark for the fibre occurs. The flax is then rolled and stored for use. Flax plants are pulled from the ground rather than cut, in order to retain the full length of the fibres, and to prevent fibre discoloration.
Some of the benefits of linen are that it is allergy-free, absorbs humidity and allows the skin to breathe, antistatic, antibacterial and low elasticity (fabrics don't deform). Linen can be washed many times without alteration. It is able to absorb up to 20 times its weight in moisture before it feels damp.
Common uses for linen include:

• Table wear
• Suiting
• Clothing apparel
• Surgical thread
• Sewing thread
• Decorative fabrics
• Bed linen
• Kitchen towels
• High quality papers
• Handkerchiefs
• Draperies
• Upholstery
• Wall coverings
• Artists canvases
• Luggage fabrics
• Panelling
• Insulation, filtration
• Light aviation use (fabrics)
• Reinforced plastics and composites

ABACA FIBRE.

Also known as 'Manila hemp,' the abaca plant is actually a small, inedible species of banana, Musa textilis. This plant is grown mostly on small, multi-crop farms in the Philippines where there are som 200 varieties in cultivation. The strong fibers of the stalk are stripped off primarily to make rope, but many Filipinos also make cloth of it; the beautiful clothing of the Bagobo (considered some of the most colourful people in the Philippines), for instance, is woven of abaca. Abaca is also grown in Ecuador where, in contrast to the Philippines, is grown on large estates. It makes an extremely durable fabric, although it is not nearly as soft as cotton.