1

BLOW ROOM -->High Variation In Blow room Lap Weight

Insufficient opening of cotton and wide variation in tuft size.(tuft size should not be more than 2-3 mg) Wrong selection of beaters for the type of cotton processed. Use of excessive soft waste in the mixing.Unequal feeding of the mixing in hopper bale breaker.Improper synchronization in the amount of material fed and delivered from the beaters in the processing sequence. Intermittent failures of feed/delivery mechanism. Ineffective sensitivity of piano feed regulating motion due to worn, sluggish or incorrectly set links. High draft between calender section and lap winder. Irregular airflow on cages and faulty air currents due to incorrect settings of dampers and dust accumulation in air passage. Unnecessary and frequent adjustment of lap feed regulating motion. Uneven mixing of soft waste with cotton. Worn pedal link, knife and cone drum bearings. Malfunctioning of the length measuring motion. Cage choked with dust and dirt. Eccentric cages. Insufficient pressure in the condensers after the beaters. Defective functioning of solenoids and air filters in the modern scutchers. Incorrect fork size in relation to belt width. Slack cone drum belts or other belts. Extreme variation in the ambient condition in the department.

BLOW ROOM -->Nep Formation In Blow Room

Cotton with too high or low moisture. Extremely fine cotton with high trash content. Reprocessing of lap and mixing of soft waste. Damaged and rusty grid bars. Narrow settings between the feed roller or pedal and beater. Long, curved and U-bends in conveyor pipelines. Slow fan speed for transportation of material. Wider setting between stripping rail and beater. Slack or too tight fan belts. Too high beater speeds. Rough or blunt blades and bent pins on beaters. Air leakage and obstruction of cotton flow through pipeline. Use of more number of beaters than the requirement. Low through put speed

BLOW ROOM -->Poor Cleaning Efficiency

Blunt striking edges of beaters. Air leakage at beater chamber and dust receptacle. Improper adjustment of angle of girds, and space between girds Gird bars set too close to beater. High variation of trash content in the different cotton used for the mixing.

2

Insufficient number of beating points. Wider setting between feed roll and beater. Fan speed too high and back draft from gutter. Wider settings between evener roller and inclined lattice. Excessive feed to the beater

BLOW ROOM -->Material Not Opened Properly

Missing or broken spikes. Absence of beater flaps. Worn or rounded striking edges of beaters and spikes. Excessive feed to the beater due to improper synchronization of feed and delivery of the beater in blow room. Incorrect grip of material by one or more pedals due to clogging at pedal support. Excessive suction pressure in the material transport trunk. Lower beater speeds. Fan speed too high.

BLOW ROOM -->Excessive Lint Loss

Grid bars set too widely. Missing grid bars. Lower beater speeds. Higher number of beating points. High short fiber content in cotton. Uneven mixing of soft waste. Weak air current due to inadequate suction pressure in the duct. Improper adjustment of waste control plates in modern beaters

BLOW ROOM -->Conical Lap

Uneven weighting of calendar rollers due to broken spring or worn bearing. Dampers and cages choked with dust and dirt, on one side. Obstruction in the movement of lap rack due to worn out or broken/damaged gear teeth. Worn cage linings.

BLOW ROOM -->Lap Licking

Inadequate calender roller pressure due to worn parts in weighting mechanism. Excessive rack pressure. Too humid condition in blow room. Prolonged stocking of laps in blow room. Rack movement strained due to damaged slots and rack arm. Improper deposition of opened cotton on the cages due to disturbance in suction pressure. Missing or ineffective lap spindle guide bowls. Damaged or eccentric cages.

3

BLOW ROOM -->Holes In The Lap

Cages not cleaned properly. Frequent obstruction in the movement of materials in the material transport truck. Pedal movement not free. Missing/Damaged beater spikes

BLOW ROOM -->Fiber Rupture in Blow Room

Higher beater speeds Less feed speed Closer settings Damaged beaters Moisture content in cotton less than 4% or higher than 9%

CARDS -->High Card Silver Variation

Too high a tension draft and stretching of web. Variation in setting between back plate and cylinder. Variation in flat speed between cards processing the same mixing. Bent/damaged back and front plate. Obstruction in the movement of Aprons during doffing in modern cards. Size of the coiler trumpet not adjusted to the hank. Feed roller weighting not acting properly. Different in draft between cards. Faults in coiler and setting of coiler base. Worn clothing and feed roller bearings. Improper humidity.

CARDS -->Nep Formation In Cards

Closer settings of lap selvedge guides. Wider back plate to cylinder settings. Low licker-in speeds. Licker in set too far from feed plate. Eccentric licker-in or bend feed plate. Blunt licker-in wire or dull flats. Jammed wire in doffer. Uneven flat settings. Cylinder and flats or doffer set too wide. Too much space between licker in covers and feed plate. Ends of front and back plates damaged. Cylinder/doffer not stripped properly after lapping. Dirty/choked under casings. Rough surface in front and back plate. Use of blunt grinding stone.(if used) Insufficient stripping. Higher doffer speeds. Holes or patches in Card Web Cluster of cotton embedded on cylinder wires. Excessive unopened cotton lumps from the licker in, cylinder and flats. Wider setting between licker-in and cylinder.

4

Wider setting between Flat and cylinder Damaged cylinder/doffer/flat wires. Cylinder/doffer wires embedded with excessive seed coats or greasy matters in patches. Faulty air current under the licker in, cylinder & doffer. Heavy feed to card. Damp material. Too fine or immature cotton.

CARDS -->Cloudy Card Web

Improper setting of feed plate to licker-in Missing or damaged teeth in licker-in. Damaged wire on cylinder and/or doffer. Doffer not set parallel to cylinder. Cylinder and doffer not ground accurately.(if done) Excessive fly under doffer. Inadequate grinding frequency.

CARDS -->Sagging Card Web

Blunt doffer wire. Dirty trumpets. Low tension draft. Excess humidity.

CARDS -->Bars In Card Web

Improper setting of back plate. Eccentric licker-in surface. Unsuitable licker-in wire. Damaged back plate across the width. Cylinder wire damaged across the width.

CARDS -->Holes Or Patches In Card Web

Bad condition of doffer wire. Poor condition of cylinder under casing. Damaged cylinder wires. Damaged flat wires. Material embedded on card wires.

CARDS -->Irregular Selvedges In Card Web

Lap guides set too wide. Damaged clothing at the sides. Air escape at the sides of cylinders. Excessive lint accumulation at the sides of under casing

CARDS -->Poor Flat Stripping

Hooked or damaged wires on flats. Excessive fly and seed bits embedded on flat wire.

5

Very close setting of front plate or non-parallel setting. Flat cleaning brush not set properly. Very slow speed of flats.

CARDS -->Poor Cleaning Efficiency

Analyze cleaning efficiency High production rate at card Severe beating at blow room which has caused seed coat fragmentation Slow flat speed (less than 150 cm/min) Wider gauge between flat and cylinder (more than 0.25 mm) Slower cylinder speed (less than 400 rpm) Blunt mote knives Improper cleaning of flat wires Blunt wire points of cylinder or flats Loss of suction (at trash removal)

CARDS -->Fiber Rupture At Card

Improper opening of tufts by blow room (size should be not more than 2-3 mg)

Heavy feed to card Closer setting between feed plate and licker in (narrower than 0.5 mm) Very dry cotton (moisture less than 4%) High cylinder speeds (more than 560 rpm)

COMBER -->Higher Comber Sliver CV

Differences in waste extraction between heads. Variation in the settings between back detaching roller and nipper. Improper cam setting depending upon the staple length of the material. Unicomb choked with seed coats or immature cotton. Wider setting between unicomb and comb clearing brush. Eccentric top and bottom rollers. Misaligned and bent nippers. Improper needle spacing, broken or bent needles. Variation in detaching roller diameter and improper timing of top combs. Fluctuation in pneumatic pressure for top roller weighting. Aspirator choked. Differences in the piecing distance of the combed fleece. Poor condition of saddles and top detaching roller brackets. High variation in average weight of feed laps

COMBER -->Sagging Comber Web

Improper tension Worn top detaching roller brushes

COMBER -->Curly Comber Web

Detaching roller timing incorrect. Bottom detaching roller flutes damaged or dirty Too high or too low humidity.

6

Excessive air currents in the aspirator. Web clogged inside top detaching roller brush.

COMBER -->Thick And Thin Bars In Comber Web

Incorrect timing of the detaching roller cam. Top comb set too deeply. Top comb touching the back-detaching roller. Improper pressure on nippers of damaged nipper jaws. Stretching of web in the sliver condenser

COMBER -->Differences In Noil Between Heads

Variation in top comb penetration between the heads of the same comber. Variation in settings between unicomb and bottom nipper. Improper settings of the cam, which decides the length of overlapping after combing. Uneven and insufficient nipper grip. Variation in diameter and pressure of top detaching rollers. Obstruction in the movement of aspirators. Missing or hooked needles in half lap and top comb. Worn comb holders causing comb depth variation. Improper forward and backward movement of top detaching rollers due to worn quadrant gear.

COMBER -->Differences In Noil Between Heads

Variation in top comb penetration between the heads of the same comber. Variation in settings between unicomb and bottom nipper. Improper settings of the cam, which decides the length of overlapping after combing. Uneven and insufficient nipper grip. Variation in diameter and pressure of top detaching rollers. Obstruction in the movement of aspirators. Missing or hooked needles in half lap and top comb. Worn comb holders causing comb depth variation. Improper forward and backward movement of top detaching rollers due to worn quadrant gear.

COMBER -->Poor Nep Removal Efficiency In Combers.

Back top detaching roller defective. Presence of fiber hooks or disorderly arranged fibers due to non - standard preparatory process. Timing of the combing cycles not adjusted properly. Top comb choked with short fibers/immature fibers. Inadequate penetration of top comb. Half lap cleaning brushes loose on shaft or set too far from the cylinder. Excessive variation in short fibers content in the mixing. Wider settings between unicomb and nipper. Inconsistent mixing of soft waste. Lap Running Slack

7

Improper feed - ratchet movement. Lap loose on the shaft. Insufficient tension draft between lap roller and feed roller. Wider setting between half lap and bottom nipper. Wider setting between comb cleaning brush and stripping rail. Low penetration of brush with half lap. Uneven nipper grip. Top and bottom nipper bites not parallel. Damaged needles in unicomb comb. Damaged/absence of top roller clearer cloth. Incorrect atmospheric conditions.

COMBER -->Comber Lap Licking

Improper rack pressure. Excessive doubling and draft. Inconsistent mixing of waste. Improper selvedge.

COMBER -->Lap Running Slack

Incorrect ratchet-pawl setting. Improper feed ratchet movement. Tension draft between lap and feed roller less than one.

COMBER -->Detaching Roller Lapping

Top roller clearer cloth damaged. Oily or dirty top roller. Worn top roller cots.

COMBER -->Poor Cleaning At Comber

Analyze performance Bad condition of half lap wire points and top comb Higher speed (nips/min) Wider half lap to nipper setting Less top comb depth Narrow step gauge Higher feed per nip Low noil level Trash on web tray or table going along with the material

COMBER -->Long Fibers Going As Waste

Poor condition of wire points (will give head wise variation as well) Grip of nipper improper Wider step gauge setting Thicker bat

8

COMBER -->High Comber Sliver U

Staggered run-in of piecing points. Irregular and poorly aligned feed laps. Unfavorable air conditioning: Badly cleaned machine, whereby the lap tensioning rollers, lips of the nippers, web trays, table, guidance of the sliver at the outlet, air duct and perforated drums are of special importance. (Clean with powdered chalk and not with talc powder.) Lap tensioning roller set wrongly. Damaged circular and top combs. Poor top detaching rollers, i.e. taper not in accordance with instructions, bent or dirty. Weighting of the top detaching rollers insufficient or unsymmetrical. Table trumpet condensers too small. Top table calendar rollers bending. Drafting arrangement and web side guides set poorly

COMBER -->Poor Short Fiber Removal

Analyze performance Wire condition bad Narrow step gauge setting Wider half lap to nipper setting Less top comb depth

DRAW FRAME -->High Drawing Sliver Variation

Improper pressure on top rollers due to defective parts or defect in weighing systems. Wrong settings, improper roller coverings, eccentric top and bottom rollers. Incorrect trumpet size. Improperly meshed or worn gear wheels, gear wheel brackets broken or improperly secured. Excessive creel draft and web tension draft. High draft at back zone. Stop motion ineffective. Incorrect sliver guides setting at feed. Good fibers drawn due to high air suction. Variation in top roller diameter. Worn top roller end bushes/saddles. Improper settings in the sliver condensing plate at the creel. Improper use of break draft in breaker and finisher passages

DRAW FRAME -->Roller Lapping At Draw Frame

Worn/Channeled roller covering. Oil on roller covering. Incorrect setting of top roller cleaners, or worn cleaners. Damaged flutes in bottom rollers. Scratches in calender rollers. Excess humidity.

9

Excessive top roller pressure. Excessive spread of feed sliver. Use of varnishes to the top roller cots. Inadequate suction in the pneumafil. Roller settings too close or too wide for the type of material processed: Excessive trash in the feed material. Softer cots, which lead to more lapping. Draw off funnel too narrow.

DRAW FRAME -->Irregular Selvedge In Drawing

Improper top roller pressure Spread of sliver at feed excessive. Bottom roller flutes damaged. Excessive pneumatic pressure

DRAW FRAME -->Impurities In Sliver

Damaged/absence of top roller cleaners. Incorrect setting of various cleaners. Pneumafil suction ineffective. Periodic removal of waste not done. High trash in feed material.

DRAW FRAME -->Sliver Break At Drawing

Improper piecing at back process. Double sliver in feed. Thin card sliver due to web falling at cards. Incorrect trumpet size. Cottons having excessive honey dew content. Inadequate top roller pressure/break draft. Damaged surface in drafting/calender rollers. Over filling of cans, and poor material handling practices. Very wide setting between drafting rollers. Deeply meshed gears. Improper ambient conditions in the department.

DRAW FRAME -->Un-drafted Silver

Break draft too low. Close setting.

DRAW FRAME -->High Sliver U

Over drafting Improper draft distribution Eccentricity of rollers Wider setting of rollers Less top roller pressure Channeled or worn top rollers Autoleveller malfunctioning For coarser counts, try with a doubling of six

10

SPEED FRAME -->High Variation In Roving Hank

Too high a break draft. Improper selection of condenser guides. Vibration of roving bobbin while running. Stretching of sliver at feed. High variation in bare bobbin diameter. Improper choice of winding-on wheel and ratchet wheel. Inadequate top arm pressure. Incorrect movement of cone-drum belt. Irregular or clogged aprons. Worn, damaged or improperly meshed gears and bearings. Bent flyers or rough spots on flyers. Jerky movement of bobbin rail. Number of coils on the bobbin not optimum.

SPEED FRAME -->Roller Lapping

Excessive spindle speed and higher drafts. Inadequate suction of pneumafil. Damaged surface in the top roller cots. Lengthy buffing interval. Use of varnishes on the top roller cots. Damaged aprons/condenser guides. Improper choice of spacers. Too wide settings at the back zone. Improper ambient conditions in the department

SPEED FRAME -->Retching/Stretching

Improper winding-on or ratchet wheel. Improper starting position of cone drum belt. Improper initial bobbin layer and incorrect build of layers. Variation in bare bobbin diameter. Improper shifting of cone drum belt.

SPEED FRAME -->Ridgy Bobbins

Badly worn or improper meshing of reversing bevels. Incorrect taper formation. Wrong choice of taper wheel. Faulty movement of bobbin rail. Loose lifter shaft pinion. Slack chain on balance weights.

SPEED FRAME -->Slough Off

Improper functioning of builder mechanism during the reversal on bobbin rail. Wrong selection of lifter wheel, which decides the coil density. Incorrect taper formation. Balance weight resting on floor. Excessive bobbin weight than the manufacturers recommendations

11

SPEED FRAME -->Soft Bobbins

Incorrect reduction of bobbin surface speed. Lifter wheel incorrect, which results in fewer layers. Incorrect positioning of bobbin wheel

SPEED FRAME -->Cut roving

Close draft roller setting. Strained bottom roller due to deep meshing of draft gears. Broken gear in draft gear unit. Loose section in bottom rollers

SPEED FRAME -->Slubs

Excessive end breaks. Lower break draft. Waste accumulation at creels, cleaners and flyers. Closer settings at the back zone. Absence of positively driven top roller cleaners. Excessive lashing during end breaks. Damaged or absence of top and bottom roller cloth.

SPEED FRAME -->Roving Breaks

Incorrect choice of creel draft. Sliver entanglement at feed. Improper piecing at back process. Too wide a back zone setting. Loose or broken top/bottom aprons Too high a break draft. Inadequate top roller pressure. Vibration in the flyers. Use of narrow spacer. Damaged top edges of the cam. Feed cam spring inactive, causing high stretch to feed sliver. Loose spindle and bobbin shaft driving wheel. Draft gears set too deeply during meshing. Broken or damaged teeth in draft gears. Loose cone drums. Poor top roller covering.

SPEED FRAME -->Slack ends

Slipping cone drum belt. Binding bobbin rail slides. Long collars clogged with waste and dirt

12

RING FRAMES -->Uneven Yarn (High U)

Inadequate pressure on top rollers.Creel draft variation in roving.Damaged or worn rings, heavy or light travellers. Defective and worn gears, bearings and spindles. Close setting of traveller cleaners and rough surface of separators. Non-alignment of aprons. Improper top roller settings. Lappet and spindle setting not correct. Bottom rollers eccentric and vibrating, and lapping on rollers. Aprons with cracks, seams and grooves. Long roving piecing. Too wide or too close a back zone setting. Improper use of break draft. Broken or damaged roving guide. Obstruction or vibration in the movement of roving traverse.

RING FRAMES -->High Count CV (Between)

Excessive variation in tuft size. Stretch in draw frame sliver fed to roving. Frequent changes of pinion in drawing and ring spinning. Improper roller settings. Improper use of break drafts in breaker and finisher passages. Excessive stretch in roving due to improper function of builder mechanism in speed frame. Unequal shifting of cone drum belt while the formation of roving layers. Wrong selection of winding ratchet wheel. Lower twist in roving. Variation in bare bobbin diameter. Row to row differences in roving hank. Spindle vibration in ring frames. Draft differences between ring frames. Creel draft variation and skewers/bobbin holders clogged with waste. High variation in relative humidity. Variation in top roller pressure.

RING FRAMES -->High Count CV (Within)

High card sliver U% and comber sliver U%. Roller slippage in drawing. Excessive web tension draft in drawing. Ratching in roving. High-tension draft at roving. Excessive pinion changes in ring spinning. Use of long separator plates at high spindle speeds. Low humidity levels.

RING FRAMES -->Crackers in the Yarn

Mixing cottons differing widely in staple length. Too close a setting in ring spinning.

13

Excessive draft in ring spinning. Use of lighter travelers. Worn or unbuffed top roller and eccentric top or bottom rollers. Improper stopping and starting of ring frames. Incorrect apron nip opening. Inadequate top rollers pressure. Loose top/bottom apron. Improper cradle holders.

RING FRAMES -->High Imperfection (Thin and Thick)

High fiber length variation and immature fibers. Poor carding or combing. Uneven roving. Excessive foreign matter in yarn. Eccentric top and bottom rollers in ring spinning. Hard cots. Insufficient pressure on top rollers. Wide setting between aprons; broken, worn and slack aprons. Too high a draft in ring frame. Worn rings. Wobble in arbor. Too close a setting between traveller clearer and traveller. Improper setting of tensor bar. Excessive fly liberation in ring frame. Damaged top/bottom roller cleaners. Jerky movement of ring rail. Improper meshing of gear wheels.

RING FRAMES -->High Long Thin places

Stretch at speed frame creel. Stretch in roving due to improper tension in the roving. Single pin holder at speed frame bobbin holder base. Jammed roving bobbins at ring frame creel. Low roving Twist Multiplier. Condensers at draw frame OR speed frame wider than required. Wider spacers at speed frame. High total draft up to draw frame. Solution is to either make six of a doubling at draw frames AND/OR use single passage after comber. Eccentric draw frame rollers

RING FRAMES -->Slubs

Excessive short fibers in the mixing. Inadequate fiber individualization in cards. Improper piecing in roving. Variation in top roller pressure in ring frames. Poor housekeeping and fluff accumulation on machine parts. Bad piecing with long overlap. Too wide a setting between apron and front roller. Improperly clothed top roller cleaners.

14

RING FRAMES -->End Breaks in Ring Spinning

Damaged skewers and clogged bobbin holder. Jerky motion of ring rail. Vibration or eccentric spindle driving pulleys. Slack spindle tape. Worn gear wheel and deep meshing of gears. Choking and improper alignment of pneumafil. Spindle out - of - center with ring and lappet. Cracked and worn bobbins. Improper fit of bobbins. Bent or worn spindles and bolsters. Lack of oil in spindle. Incorrect bobbin diameter. Worn rings. Improper and worn travelers. Traveller clearer set closer.(less than 0.5 mm) Too high a draft. Break draft not optimum. Loose and worn aprons. Absence of top and bottom clearers. Incorrect shore hardness of top rollers. Insufficient pressure on top rollers. Incorrect apron nip opening and settings.Excessive twist in roving. Excessive soft waste in mixing. Too fine or irregular feed material. Stretch in roving. Lack of control of temperature and humidity.

RING FRAMES -->High Yarn Hairiness

Mixing cottons with wide variation in micronaire and maturity. Excessive short fiber content in the mixing. Addition of waste in mixing. Effect of adding comber waste is more than adding soft waste. Use of excessive draft in spinning preparatory and ring frames. Incorrect choice of traveller. Serrations or cut in lappet hook, ANBC rings, etc. Close roller settings and very high spindle speeds. Maintaining low relative humidity.

RING FRAMES -->Cork Screw Yarn

Aprons with cracked surfaces. Top roller slippage Generation of static charges Feeding of two ends instead of one in ring frame Slashing-in of ends in ring frame

RING FRAMES -->Lower Strength

Improper break draft Improper spacer size

15

Bad condition of top rollers Diameter of top rollers reduced more than 1.8 mm than that of original diameter Eccentric rollers Narrow back zone setting (less than 55 mm for cotton) Wider top front zone setting Fiber rupture at card Fiber rupture at blow room Missing aprons (cause for very weak yarn)

RING FRAMES -->Roller Lapping

Excessive spindle speed and higher drafts. Inadequate suction of pneumafil. (less than 7 cm of water at off end) Damaged surface in the top roller cots. Lengthy buffing interval. Use of varnishes on the top roller cots. Damaged aprons/condenser guides. Improper choice of spacers. Too wide settings at the back zone. Improper ambient conditions in the department.

RING FRAMES -->Higher Long Thick Faults

Wider roller setting at speed frame Eccentric back rollers Undrafted ends at draw frame or speed frame Lower top arm pressure Wider spacer at speed frame

RING FRAMES -->Higher Short Thick Faults

Higher level of seed coat fragments Poor carding Poor house keeping Poor drafting process

RING FRAMES -->Low Elongation

Narrow spacer at ring frame Heavier traveller Low fiber elongation Lower roving TM Higher spindle speed Higher roller pressure Narrow roller setting Higher fiber to fiber friction Higher fiber to metal friction (greater than 0.35 u) Higher winding tension

RING FRAMES -->High Pnumafil Waste

High end breakage rate Higher number of sides per tenter

16

Roller lapping Very high pneumafil suction Slow patrolling by worker

RING FRAMES -->High Twist CV

Spindle tape slippage Improper fit of tube on spindle Worn out spindle buttons Yarn ends/ fiber fly entangled between spindle and brakes Small balloon height

RING FRAMES -->Higher Strength CV

Higher count CV (between) Higher count CV (within) Sliver or roving stretch at any stage Poor drafting at speed frame Improper spacer size Improper draft distribution Improper roller setting Incompatible micronaire of mixings (tolerance is + - 0.2) Elongation variability of blend constituents

WINDING -->Stitches in Cone

Cone holder vibration Cone holder incorrectly set to winding drum Cone holder not secured properly Traverse restrictors fixed at incorrect position Damaged grooves in drums Non-alignment of tension bracket with drum Cut marks in yarn guide Improper fit of cones on cone holder Excessive sloughing off of ring bobbin

WINDING -->Ribbon Wound Cone

Anti-patterning not working properly Cone holder incorrectly set to winding drum Yarn traverse groove choked with impurities Defective setting of cams switch for pilot motor High tension in yarn

WINDING -->Bell Shaped Cone

High yarn tension during winding Cone holder incorrectly set to winding drum Damages in paper cone at the center

WINDING -->Bulging Nose

High pressure on the base of cone causing nose to lift up

17

Loss of tension on yarn Spindle not seated properly at nose Tension variation from start to end of cop during winding

WINDING -->End Breaks in Cone Winding

Higher objectionable faults in yarn. Poor yarn suction pressure in clearer. Magazine failure. Bad cop build. Supply spindle out of line with yarn guide Defective clearer setting Excessive sloughing off of ring bobbin Cuts or Serrations in the thread guide or tension weights Improper ring bobbin holders Supply spindles out of line with yarn guide.

WINDING -->Faulty Splicing

Poor blast pressure in splice. Unequal splicing. Faulty yarn trap. Dampness in the supply air. Faulty function of air blasting & suction system in the splicing prism. Presence of excessive micro dust in the yarn.

WINDING -->Excessive Cuts

Faulty clearers. Failures in electronic yarn clearer sensitivity. Variation in setting. Too close a setting in electronic clearer. Variation of yarn faults in the parent yarn. Improper ambient conditions in the department.

WINDING -->Cone Weight Variation

Faulty function of cone holder. Frequent end breaks. Improper function of length measuring mechanism. Inadequate cone holder pressure.

WINDING -->Clearer Curve Setting Setting of clearing curve

WINDING -->Splicer Setting Setting of splicer

WINDING -->Foreign Matter Clearing Clearing foreign matter

WINDING -->Reducing Imperfection Reducing Imperfection & Hairiness Increase

18

WINDING -->Yarn Slough Off From Cop At Winding

Improper winding to binding coil ratio on cop Improper length per chase Unwinding accelerator set too wide (should be 20-25 mm from the start of yarn on the cop) Loop preventer not working properly Sudden acceleration and deceleration of winding drum Damaged cop tip Non concentric fit of cop in its position on winding machine

Category: WINDING -->High Hard Waste

Higher cuts Long suction time at yarn cut by the upper arm High reverse rotation of drum at yarn cut Upper end failure High number of repeating cycle Putting more yarn in circular magazine suction Unwinding cop or bad cone into winding suction system Slough off of cop Bad cones Double gaiting of cops High number of bottoms High cop rejection

RING DOUBLER -->Cork Screw Yarn

High tension variation between yarns from the supply package. Excessive twist or high variation in twist level in the individual yarns

RING DOUBLER -->Low Yarn Strength

Slack spindle tapes Insufficient grip between top and bottom roller. Variation in twist in the single yarn Excessive breaks in doubling

TWO-FOR-ONE TWISTER -->Low Yarn Strength

Stop motion failure Abraded yarn by thread guides in the yarn passage Improper selection of tensioners

TWO-FOR-ONE TWISTER -->High twist Variation

Incorrect tension of driving belts/belt. Insufficient take up roller pressure. Improper selection of tensioners

TWO-FOR-ONE TWISTER -->Yarn Bunch In Delivery Package

Excessive end breaks

19

Higher yarn reserve Yarn catch not working properly Special attachment for eliminating yarn bunch

OPEN END SPINNING MACHINE -->Uneven yarn

Dirt deposition in the rotor. Higher level of trash content in the feed sliver. Damaged combing roller. Damaged outlet. Lesser combing roller speed. Too low or too high a draft. Draw frame sliver with higher unevenness. Failure of twist flow during piecing.

OPEN END SPINNING MACHINE -->Frequent End Breaks

Damaged condenser. Clogged trash boxes. Higher sliver trash content. Defective operation of sliver feed mechanism. Insufficient pressure in pressure roller. Presence of foreign fibers, neps and thick place. Defective thread guide/sliver clutch. Damaged of bent opening roller clothing. Improper function/setting of trash removal systems. Trash accumulation in suction duct. Obstruction in the feed roller movement. Insufficient twist, inadequate number of fibers in the yarn cross-section

OPEN END SPINNING MACHINE -->Package deformation

Insufficient spring force in the cheese holder. Faulty function of traverse guide. Variation in twist level in the yarn. Excessive end breaks. Improper arms of bobbin holder. Variation in the level of cheese holder brackets.

OPEN END SPINNING MACHINE -->Excessive Kitties

Poor cleaning of cotton in Blow room & cards. Insufficient suction pressure. Lower opening roller speeds. Damaged or bent opening roller clothing.

OPEN END SPINNING MACHINE -->Long Thick Places in Yarn

Presence of immature cottons in the mixing. Inadequate individualization in cards due to lower licker in/cylinder speeds. Lower opening roller speeds in open end spinning machine. Damaged or blunt wire points in opening roller clothing.

20

Improper selection of navel. Dampness in the air supplied to open end spinning machine. Presence of unopened roving in the feed sliver.

OPEN END SPINNING MACHINE -->High Classimat Faults

Lower card production rate on latest cards (below 50 kg per hour) gives high classimat Improper suction at draw frame Narrow back zone setting at draw frame Eccentric draw frame rollers (important for long thin) Wider nozzle at draw frame or rotor

OPEN END SPINNING MACHINE -->High Imperfection

High trash in sliver (more than 0.5%) High total neps in sliver Poor fiber individualization at card Damaged opening roller at rotor Low opening roller speed (less than 6500 rpm)

OPEN END SPINNING MACHINE -->Low Strength

Improper rotor groove selected High micro dust in material Sliver splitting High fiber fragments Fiber length to rotor diameter not near to unity High TM

OPEN END SPINNING MACHINE -->Moiré Effect In Yarn

High micro dust in sliver High trash in sliver High fiber fragments (measured in rotor material)

OPEN END SPINNING MACHINE -->High Count CV

Excessive variation in tuft size.(tuft size should not be more than 2-3 mg at card feed) Stretch in draw frame sliver, fed to roving. Improper use of break drafts in breaker and finisher passages. High variation in relative humidity. Sliver splitting Too narrow sliver trumpet at any stage

B. Mahesan – Technical folder