The success of a spinning mill that wishes to speed up its ring frames not only depends heavily on the quality of the fibers but also on the capability of the mill's technical and managerial cadre staff for undertaking the task of high-speed spinning and making it a success.

  1. 1)Spares from the original machine suppliers: Another important point is that mills going for high speeds have to buy all spares from respective original machine manufacturers. This practice not only enhances the life of machines but also helps in delivering consistently good quality of the product. The budget is a little bit higher, but you will enjoy the quality of the product. The timely replacement of spares is also important, apart from procuring from original machine manufacturers.

  2. 2)Best Available Accessories: The use of the best accessories like a combination of Brackers Titan Solid Rings and Travellers contributes a lot to high-speed spinning. Only a few quality-conscious mills are using such a ring and traveler combination. The other important accessories which play a vital role in the overall working of the material are flyers, cots, aprons, card clothing, lappet hooks, guides, drums, false twisters, bobbin holders need attention and these should also be from reputed manufacturers.

  3. 3)Annual Maintenance Service Contracts: There are online monitoring & controlling electronic systems that continuously monitor/correct the entire quantity of production of machines of a few sections like autolevellers of Cards and Draw Frames, Yarn clearers of auto-winding machines. Going for an annual maintenance service contract with the principal manufacturers of these online quality monitoring systems turns out to be a very wise decision. Its impact is seen in very low values of CV% of 6mts wrapping which are around 0.146 to 0.152, and U% of finisher sliver is also around 1.6 to 1.7 so that finisher sliver is as even and as uniform as can be made, thereby laying a good foundation for high-speed spinning.

  4. 4)Installation of C-Factors on Cards: The mills that have old cards have to go for the installation of C-Factors for better quality of sliver. It lowers imperfections of yarn and improves card sliver physical appearance.

  5. 5)Use of Higher Twist Multipliers: The mills that are not selling yarns but consume yarn in their own plant for weaving premium-quality fabric are very quality-conscious. It is better for them to go for higher twist multipliers. It helps not only in controlling breakages at high speed but also in the reduction of yarn hairiness, imperfections as well as a reduction in winding cuts. It has been found that with higher than normal twist, the fabric appearance, feel, and texture are improved significantly. The high roving twist multipliers OF 0.8 and high yarn twist multipliers of 3.53 will yield good yarn quality at high speeds.

6) Pre Carding of Viscose Component of Yarns : In some mills , spinning small lots of fiber dyed yarns with 3 - 4 differently coloured polyester fibers and also 3-4 differently coloured dope dyed viscose fibres is a very typical practice. Many shades have either one dark coloured viscose shade blended with other light coloured shades or vice versa. The dark or light coloured viscose component forms neps, which become objectionable at finished fabric inspection. Cloth menders remove the neps that look bad. The pre-carding of these specific shades of viscose fibres gives good results in terms of eliminating such neps. The pre-carding of viscose before using in blend will reduce neps in yarns almost by even less than 50%.

7) Use of larger diameter cots on ring frames: The recommendations of cot diameters are different for different ring frame suppliers. The supplied by KTTM on their ring frames are larger in diameter than cots supplied with LMW ring frames, working is far better on KTTM ring frames with larger cots and same is true on LMW ring frames if we use larger diameter cots. The small shop floor trial is good enough to see the difference in working of material.


8) GO-NO GO system in Draw Frame: At draw frame, practicing testing of every lot for its U% is preferable & not allowing the lot to run without getting desired U% values is turns to be a wise decision.


9) Involvement of Production Staff in QC activities: If QC and production team work together results in good working atmosphere among the people and healthy product quality. The yarn at high speed is to be treated like a new born baby in a family. Every body has to take care to ensure that everything is done right in day to day working. The quality and productivity are like a two sides of the same coin; both are equally important to make the product not only quality competitive, but also cost effective at high speeds.


10) Well Equipped Testing Laboratory : The mills going for high speed spinning must be provided at least with following instruments

Latest Model Uster Tester, Uster Classimat System, Uster Tensorapid or tensojet Single Thread Tester, Roller Eccentricity Tester, Hardness Tester for Cots, Manometer for measuring vaccum pressure in suction clearer tubes at fly & ring frames, Meter to measure top arm pressure, Stroboscope, Single thread Twist Tester, Yarn Appearance Board Winder etc.

 

11) Creating Conducive Atmosphere in the work area: The head of the department must provide the leadership to weld all staff into a fighting team, both by appreciating good work and pulling up people gently but firmly if they make mistakes or have overlooked details. He must himself be fired to run his ring frames at good high speeds and must lead discussion on this assignment frequently.


12) Taking unions into confidence by making them aware: The last, but important point is that the management must take the labour unions into confidence before starting any trials for going over to high spindle speeds. The unions must be assured that a revision of salary could be done if high speed spinning trials are a success; so that unions do not regist or stop high speed trials.


13) Capability of Technology set-up: Before going for high speeds, one has to look into preparatory and post spinning balancing with proposed production at high speed. Also it is equally important to ensure machine specifications which include electric motors, inverters, high speed spindles etc in the existing mills in consultation with suppliers of machines. If you are planning for new set-up with high speeds, better involve machine manufacturers while selecting machines itself and need not worry after the completion of project.

 

14) Creating learning atmosphere rather than working atmosphere: while implementing high speed spinning, must take initiative in willingness to support the efforts of technical staff, willing to pick-up good ideas from all sources, willing to try out different approaches till success gets achieved, different sections like production, quality control & maintenance work together for the set goal, management appreciates sustained improvement etc. People think some times that only those who get higher pay, should provide new ideas, but salary and position has nothing to do with generation of ideas.


15) Technical Audits: The mills producing premium quality yarns must go for various technical audits which include productivity audit by renowned technologists, quality audit by reputed research organizations and machinery audit by machine manufacturers as and when required or on a fixed interval as mutually agreed upon. Such type of audits not only helps in improving overall working of mills, but also helps in enriching technical competency of staff working in the organizations.


The author is a Senior Manager & HOD Spinning PV Raymond Limited, Textile Unit, Chhindwara Division, Madhya Pradesh (India).