MODIFICATIONS IN JUTE FLYER SPINNING MACHINE BY SITRA A.SIVARAMAKRISHNAN V.KUMARAVEL G.ILANGO & T.MAHESHKUMAR The South India Textile Research Association Coimbatore - 641 014
JUTE INDUSTRY SCENARIO Obsolete Jute Machinery More Labour Intensive Less Technological Advancement Lack of Modernisation
IMMEDIATE NEEDS FOR MILLS Increased Productivity (Machine and Labour) Reduction in Energy Consumption Improvement in Quality
YARN PRODUCTION PROCESS BATCHING & OILING CARDING (BREAKER / INTER / FINISHER) GILL DRAWING (1 st, 2 nd and 3 rd ) FLYER SPINNING WINDING / FLYER DOUBLING PREPARATION TO WEAVING
FABRIC PRODUCTION PROCESS CONE YARN WARP BEAMING WEFT COP WINDING WEAVING MEASURING & INSPECTION CALENDERING CUTTING / HEMMING / SEWING / BUNDLING / PACKING 5
JUTE PROCESSING MACHINES Softener - 10 Cards - 60 Gill Drawing - 66 Flyer Spg - 103 Macrol Winding - 15 Cop Winding - 20 (TYPICAL MILL) Ring Twisting - 8 Spool Winding - 15 Looms - 314 Finishing - 4 ETP, Boiler & Compressors *HESSIAN & SACKING CLOTH PRODUCTION (80-90Tonnes per day) ENERGY CONSUMPTION (50000 UNITS PER DAY)
FLYER SPINNING MACHINE INPUT - SILVER OUTPUT - YARN DRAFTING - SLIP SPINDLE - BOXTER COUNT SPUN - 8,10,12,16,22 lb (Ne Jute)
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 FRAME Count Twist Speed Prod. Doff Yarn Energy lb tpi rpm kg/ Duration Content UPT day min g 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 CONSUMPTION SECTION PERCENT PRE SPINNING 20 FLYER SPINNING 25 WINDING 5 PREPARATION TO WVG 5 WEAVING 35 FINISHING 5 OTHERS 5
PATTERN OF ENERGY CONSUMPTION 35 5 PRE SPG 5 20 FLYER SPG 5 5 25 WINDING PREP.WVG WEAVING FINISHING OTHERS
SITRA MODIFICATIONS IN FLYER SPINNING MACHINE IMPROVED MOTOR DRIVE SYSTEM ENERGY EFFICIENT MOTOR MODIFIED DRAFTING SYSTME IMPROVED SPINDLE ASSEMBLY PULLEY DRIVE SYSTEM WITH ENERGY EFFICIENT TAPE
SITRA MODIFICATIONS IN FLYER SPINNING MACHINE TRANSMISSION OF MOTIION BY HELICAL GEARS BALL BEARINGS FOR SMOOTH TRNASMISSION TIMING BELT DRIVE INSTEAD OF CHAIN DRIVE MODIFIED BOBBIN DESIGN SIMPLIFIED BOBBIN DRIVE SYSTEM
SITRA JUTE FLYSPIN MOTOR DRIVE SYSTEM SPINDLE DRIVE SYSTEM SPINDLE TAPE TENSION BUILDING MECHANISM GEAR DRIVES (HELICAL) BELT DRIVES (TIMING)
MOTOR DRIVE SYSTEM Description Conventional SITRA Motor Ordinary Energy Efficient Weight of Drive 41.3 20.5 Pulleys (kg) 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 BELT (BUTTERFLY BED SYSTEM)
CONVENTIONAL MODIFIED
SPINDLE DRIVE SYSTEM Description Conventional SITRA Jockey Pulley Type Bush Bearing High Speed Ball Bearing Jockey Pulley Dia (mm) Jockey Pulley Weight (g) Spindle Tape Type & Size (mm) 114 90 / 70 SR9 / SR7 375 280 Cotton 2275 x 25 x 1.5 Synthetic 2360 x 20 x 0.8 Belt Tension Dead Weight Spring Loaded
SPINDLE DRIVE SYSTEM Description Conventional SITRA Main Drive Shaft Solid Solid Main Drive Shaft OD (mm) Wt of Drive Pulley & Shaft (kg) 44.5 38.1 248.0 110.0 Drive Pulley Type Group Individual MS ABS/AL Drive Pulley Dia. (mm) 149.0 228.0
COTTON TAPE SYNTHETIC TAPE
SPINDLE DRIVE SYSTEM (EXISTING)
SPINDLE DRIVE SYSTEM (MODIFIED)
BOBBIN DIMENSIONS Description 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 BOBBINS
MODIFIED BOBBINS WITH YARN
YARN CONTENT (MODIFIED) (EXISTING)
GEAR DRIVE SYSTEM (EXISTING) (MODIFIED)
45 15 BUILDING CAM EXISTING CAM MODIFIED CAM 1:1 2:1
POWER CONSUMPTION ANALYSIS (EXISTING MACHINE) Description Power kw % on Total Motor No-load 0.60 8 Tin-roller + Flyer 2.31 30 Drafting 1.23 16 Twisting 3.60 46 Total Power 7.74 100
ENERGY SAVING IN MODIFIED MACHINE Description % saving Motor No-load 2-3 Tin-roller + Flyer 8-10 Drafting 1-2 Twisting & Winding 4-5 Total 15-20
PERFORMANCE IMPROVEMENT (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 IN CONSUMPTION
Cost Benefit Analysis for SITRA Jute Flyspin Description Existing M/c SITRA Modified M/c Make/Mc No (4 ¼ ) SP 58 SP 55 SP 61 Total Running Hrs 5.18 2.298 4.91 Total Prod.,(kg) 260.5 124.0 247 Energy Consum (kwh) 46.83 20.86 36.02 Production / hr (kg) 50.289 53.959 50.28 Units / hr 9.0425 9.077 7.3328 Units / kg 0.1798 0.1681 0.1458 % Saving in Units/hr -- -- 18.9 & 19.2 % Saving in Units/kg -- -- 18.9 & 13.3 Investment required -- -- 2.0 lakhs Saving in Rs/Yr/fr -- -- 56000 ROI / Pay Back Period -- -- 28% / 3.5 Yrs
SALIENT FEATURES Improved motor drive assembly with energy efficient motor Flyer speed can be increased from 4000 to 5000 rpm Energy efficient spindle drive system Improved gear drive system for reduction in noise and energy consumption. Improved Bobbin design accommodates 20% more yarn content
CONCLUSIONS 20-30% increase in machine & labour productivity 15 % - 20 % reduction in specific energy consumption Improvement in yarn quality in terms of twist variation & hairiness 20 % increase in yarn content
SITRA LICENSEE-JUTE FLYSPIN M/s. Servo Polytech Coimbatore (P) Ltd., S.F.189, Mahatma Gandhi Road, Neelikonampalayam, Coimbatore 641 033.
ACKNOWLEDGEMENT Mr.H.V.Kanoria, Chairman Mr. Nawal Kejriwal, WholeTime Director Mr. D.Majumdar, President (Works) M/s. CHEVIOT COMPANY Ltd. BUDGE BUDGE, KOLKATA.
ACKNOWLEDGEMENT Ms. Indra Doraiswamy Research Advisor Dr.Arimdam Basu Director, SITRA