What is Bale management?
Receiving Bales: Raw cotton is harvested and then ginned to remove seeds and impurities. After ginning, the cotton fibers are pressed and packaged into bales for transportation and storage. These bales are often labeled with information about the cotton variety, grade, and origin.
Quality Inspection: When bales arrive at a spinning mill, they undergo a thorough quality inspection. This involves checking for foreign matter, moisture content, fiber length, color, and other characteristics that can impact the quality of the yarn produced. Any substandard bales may be rejected or segregated.
Storage and Inventory: Bale management includes storing the bales in a controlled environment to maintain their quality. Temperature and humidity levels are monitored to prevent damage to the cotton fibers. Spinning mills maintain an inventory of bales, carefully tracking each bale’s details.
Blending: In many cases, cotton from different bales is blended together to create a uniform and consistent feedstock for the spinning process. Bale management involves selecting and combining bales with similar properties to achieve the desired yarn characteristics.
Feeding the Opening Line: Once bales are selected and blended as needed, they are opened to loosen the fibers and make them suitable for further processing. This is typically done using machinery like bale pluckers or opening machines.
Carding and Spinning: After opening, the cotton fibers go through carding and spinning processes to transform them into yarn. These processes align and twist the fibers to create the desired yarn characteristics, including count, strength, and quality.
Record-Keeping: Bale management also involves maintaining records of each bale’s journey through the spinning mill. This includes tracking the bale’s source, quality, blending details, and processing parameters. These records are important for quality control and traceability.
The object of Bale management?
- To ensure evening out of the quality characteristics of a yarn.
- To avoid quality jumps.
- To reduce costs.
What is mixing and blending?
Mixing -If different grade of same fibres are kept together, then it is called mixing. e.g. 50% of 1.25” staple length of cotton + 50% of 1.125” staple length of cotton.
Objects of blending:
- To achieve uniform quality.
- To improve processing performance.
- To reduce and control of production cost.
- To give the required characteristics to the end product.
Process parameters in the blow room?
- Number of opening machines,
- Type of beater,
- Type of beating,
- Beater speed,
- Setting between feed roller and beater,
- The production rate of the individual machine,
- The production rate of the entire line,
- The thickness of the feed web,
- The density of the feed web,
- Fibre micronaire,
- Size of the flocks in the feed,
- Type of clothing of the beater,
- Point density of clothing,
- Type of grid and grid settings,
- Airflow through the grid,
- Position of the machine in the sequence,
- Amount of trash in the material,
- Type of trash in the material,
- Temp and relative humidity in the blow room department.
Ring data is an additional attachment for data collection. It is one kind of software which collects data about the ring frame. It is also called production controlling system of the ring frame.
The data collected on:
👉Production data (OPS, GMS total data of previous 3 shift)
👉End breakage rate
👉No. of Doff
👉No. of working spindle
Yarn spinning methods?
|Order of importance||Ring||Rotor||Air-jet||Friction|
|1||Length and length uniformity||Strength||Fineness||Strength|
|3||Fineness||Length and length Uniformity||Strength||Length and length uniformity|
|4||–||–||Length and length uniformity||Cleanliness|