The South India Textile Research AssociationCoimbatore - 641 014

MODIFICATIONS IN JUTE FLYER MODIFICATIONS IN JUTE FLYER SPINNINGSPINNING MACHINE BY SITRAMACHINE BY SITRA

A.SIVARAMAKRISHNANA.SIVARAMAKRISHNANV.KUMARAVELV.KUMARAVELG.ILANGO &G.ILANGO &T.MAHESHKUMART.MAHESHKUMAR

JUTE INDUSTRY SCENARIOJUTE INDUSTRY SCENARIO

Obsolete Jute MachineryMore Labour IntensiveLess Technological AdvancementLack of Modernisation

IMMEDIATE NEEDS FOR MILLSIMMEDIATE NEEDS FOR MILLS

Increased Productivity (Machine and Labour)Reduction in Energy ConsumptionImprovement in Quality

YARN PRODUCTION PROCESSYARN PRODUCTION PROCESSBATCHING & OILING

GILL DRAWING (1st, 2nd and 3rd)

FLYER SPINNING

WINDING / FLYER DOUBLING

CARDING (BREAKER / INTER / FINISHER)

PREPARATION TO WEAVING

5

FABRIC PRODUCTION PROCESSFABRIC PRODUCTION PROCESSCONE YARN

WEAVING

MEASURING & INSPECTION

CALENDERING

WARP BEAMING – WEFT COP WINDING

CUTTING / HEMMING / SEWING / BUNDLING / PACKING

JUTE PROCESSING MACHINES JUTE PROCESSING MACHINES (TYPICAL MILL)(TYPICAL MILL)

Softener - 10Cards - 60Gill Drawing - 66Flyer Spg - 103Macrol Winding - 15Cop Winding - 20

Ring Twisting - 8Spool Winding - 15Looms - 314Finishing - 4ETP, Boiler & Compressors

*HESSIAN & SACKING CLOTH PRODUCTION (80 -90Tonnes per day)

ENERGY CONSUMPTION (50000 UNITS PER DAY)

FLYER SPINNING MACHINEFLYER SPINNING MACHINE

INPUT - SILVEROUTPUT - YARNDRAFTING - SLIPSPINDLE - BOXTERCOUNT SPUN - 8,10,12,16,22 lb(Ne Jute)

MACHINE SPECIFICATIONS MACHINE SPECIFICATIONS Machine : Flyer Spinning Frame

Drafting Type : Slip Draft - Mechanical

No. of Spindles : 100

Spindle Type : Boxter

Spindle Gauge : 4 ¼”

Lift : 6 ½”

Motor Capacity :15 hp;1440 rpm; 3phase

JUTE FLYER SPINNING FRAMEJUTE FLYER SPINNING FRAME

Countlb

Twisttpi

Speedrpm

Prod.kg/day

DoffDuration

min

Yarn Content

g

EnergyUPT

8 4.4 4000 780 55 340 174

10 4.0 4000 1030 44 345 172

12 3.7 4000 1380 32 360 126

16 3.3 3750 1860 22 358 105

PATTERN OF ENERGY CONSUMPTIONPATTERN OF ENERGY CONSUMPTION

SECTION PERCENTPRE SPINNING 20FLYER SPINNING 25WINDING 5PREPARATION TO WVG 5WEAVING 35FINISHING 5OTHERS 5

PATTERN OF ENERGY CONSUMPTIONPATTERN OF ENERGY CONSUMPTION

20

25

5 5

35

5 5 PRE SPG

FLYER SPGWINDINGPREP.WVGWEAVINGFINISHINGOTHERS

SITRA MODIFICATIONS IN FLYER SITRA MODIFICATIONS IN FLYER SPINNING MACHINESPINNING MACHINE

IMPROVED MOTOR DRIVE SYSTEMIMPROVED MOTOR DRIVE SYSTEMENERGY EFFICIENT MOTORENERGY EFFICIENT MOTORMODIFIED DRAFTING SYSTMEMODIFIED DRAFTING SYSTMEIMPROVED SPINDLE ASSEMBLYIMPROVED SPINDLE ASSEMBLYPULLEY DRIVE SYSTEM WITH ENERGY PULLEY DRIVE SYSTEM WITH ENERGY EFFICIENT TAPEEFFICIENT TAPE

SITRA MODIFICATIONS IN FLYER SITRA MODIFICATIONS IN FLYER SPINNING MACHINESPINNING MACHINE

TRANSMISSION OF MOTIION BY HELICAL GEARS BALL BEARINGS FOR SMOOTH TRNASMISSIONTIMING BELT DRIVE INSTEAD OF CHAIN DRIVEMODIFIED BOBBIN DESIGNSIMPLIFIED BOBBIN DRIVE SYSTEM

SITRA JUTE FLYSPINSITRA JUTE FLYSPINMOTOR DRIVE SYSTEMSPINDLE DRIVE SYSTEMSPINDLE TAPE TENSIONBUILDING MECHANISM GEAR DRIVES (HELICAL)BELT DRIVES (TIMING)

MOTOR DRIVE SYSTEMMOTOR DRIVE SYSTEMDescription Conventional SITRA

Motor Ordinary Energy Efficient

Weight of Drive Pulleys (kg)

41.3 20.5

Belt Material Cotton Synthetic

Belt Tension Method

Dead Weight Butterfly Type

Belt Size (mm) 2080 x 138 x 6 1800 x 70 x 3

ENERGY EFFICIENT MOTOR AND BELTENERGY EFFICIENT MOTOR AND BELT((BUTTERFLY BED SYSTEM)BUTTERFLY BED SYSTEM)

CONVENTIONALCONVENTIONAL MODIFIEDMODIFIED

SPINDLE DRIVE SYSTEMSPINDLE DRIVE SYSTEMDescription Conventional SITRAJockey Pulley Type Bush Bearing High Speed

Ball BearingJockey Pulley Dia (mm)

114 90 / 70SR9 / SR7

Jockey Pulley Weight (g)

375 280

Spindle Tape Type & Size (mm)

Cotton2275 x 25 x 1.5

Synthetic 2360 x 20 x 0.8

Belt Tension Dead Weight Spring Loaded

SPINDLE DRIVE SYSTEMSPINDLE DRIVE SYSTEMDescription Conventional SITRAMain Drive Shaft Solid SolidMain Drive Shaft OD (mm)

44.5 38.1

Wt of Drive Pulley & Shaft (kg)

248.0 110.0

Drive Pulley Type Group –MS

Individual –ABS/AL

Drive Pulley Dia. (mm) 149.0 228.0

COTTON TAPECOTTON TAPE SYNTHETIC TAPESYNTHETIC TAPE

SPINDLE DRIVE SYSTEM SPINDLE DRIVE SYSTEM (EXISTING)(EXISTING)

SPINDLE DRIVE SYSTEM SPINDLE DRIVE SYSTEM (MODIFIED)(MODIFIED)

BOBBINBOBBIN DIMENSIONSDIMENSIONSDescription Conventional SITRA

Stem OD (mm) 29.5 25.8

Winding Ht. (mm) 166 173

Yarn Volume (cc) 656 784

Yarn Weight (kg) 339 405

Increase in Yarn Content - 19.4 %

REDESIGNED BOBBINSREDESIGNED BOBBINS

MODIFIED BOBBINS WITH YARNMODIFIED BOBBINS WITH YARN

YARN CONTENT YARN CONTENT (MODIFIED) (MODIFIED) (EXISTING)(EXISTING)

GEAR DRIVE SYSTEMGEAR DRIVE SYSTEM(EXISTING) (MODIFIED)(EXISTING) (MODIFIED)

BUILDING CAMBUILDING CAM

EXISTING CAM MODIFIED CAM1:1 2:1

45

15

POWER CONSUMPTION ANALYSIS POWER CONSUMPTION ANALYSIS (EXISTING MACHINE)(EXISTING MACHINE)

Description Power kW

% on Total

Motor No-load 0.602.311.233.60 46

Total Power 7.74 100

Tin-roller + Flyer 30Drafting 16Twisting

8

ENERGY SAVING IN MODIFIED ENERGY SAVING IN MODIFIED MACHINEMACHINE

Description % saving

Motor No-load 2-3

4-5Total 15-20

Tin-roller + Flyer 8-10Drafting 1-2Twisting & Winding

PERFORMANCE IMPROVEMENTPERFORMANCE IMPROVEMENT(SITRA JUTE FLYSPIN)(SITRA JUTE FLYSPIN)

PRODUCTIVITY - FLYER SPEED CAN BE INCREASED UPTO 5000 RPM

QUALITY - REDUCTION IN TWIST VARIATION (5%)HAIRINESS UPTO 10%

ENERGY - 15-20% REDUCTION INCONSUMPTION

Description Existing M/c SITRA Modified M/c

Make/Mc No (4 ¼”) SP – 58 SP – 55 SP – 61Total Running Hrs 5.18 2.298 4.91Total Prod.,(kg) 260.5 124.0 247Energy Consum (kWh) 46.83 20.86 36.02Production / hr (kg) 50.289 53.959 50.28Units / hr 9.0425 9.077 7.3328Units / kg 0.1798 0.1681 0.1458% Saving in Units/hr -- -- 18.9 & 19.2% Saving in Units/kg -- -- 18.9 & 13.3Investment required -- -- 2.0 lakhsSaving in Rs/Yr/fr -- -- 56000ROI / Pay Back Period -- -- 28% / 3.5 Yrs

Cost Cost –– Benefit Analysis for SITRA Jute FlyspinBenefit Analysis for SITRA Jute Flyspin

SALIENT FEATURESSALIENT FEATURESImproved motor drive assembly with energy efficient motorFlyer speed can be increased from 4000 to 5000 rpmEnergy efficient spindle drive system Improved gear drive system for reduction in noise and energy consumption.Improved Bobbin design accommodates 20% more yarn content

CONCLUSIONSCONCLUSIONS20-30% increase in machine & labour productivity 15 % - 20 % reduction in specific energy consumptionImprovement in yarn quality in terms of twist variation & hairiness20 % increase in yarn content

SITRA LICENSEESITRA LICENSEE--JUTE FLYSPINJUTE FLYSPIN

M/s. Servo Polytech Coimbatore (P) Ltd., S.F.189, Mahatma Gandhi Road, Neelikonampalayam, Coimbatore – 641 033.

ACKNOWLEDGEMENTACKNOWLEDGEMENTMr.H.V.Kanoria, Chairman

Mr. Nawal Kejriwal, WholeTime Director Mr. D.Majumdar, President (Works)M/s. CHEVIOT COMPANY Ltd.

BUDGE BUDGE,KOLKATA.

Ms. Indra DoraiswamyResearch AdvisorDr.Arimdam BasuDirector, SITRA

ACKNOWLEDGEMENTACKNOWLEDGEMENT