Detailed Project Report (DPR) on open end spinning process

OPEN END SPINNING UNIT
[CODE NO.3247]  

Open end spinning is an excellent short-term blending process. The presence of short fibers in the material fed does not seriously affect the efficiency of Open end spinning and it may be that process will have a bright future in the spinning of waste. Whenever the final judgment on open end spinning may be, it is a process that is here to say.

Few innovations in the field of textiles have created such interest as open-end spinning. Despite the tremendous efforts that have been made over the years to further the development of ring spinning, it now seems to be generally accepted that, owing to mechanical, technological and above all economic limitations, the potential of that well established process has been virtually exhausted and that further advancement will only be achieved through an entirely new approach; it may be that Open-end spinning will be the answer.

Spinning may be defined as the process of converting fibres and/or filaments(s) into yarn. In the production of manmade fibres, the extrusion of the fibre forming liquid through the spinners followed by hardening of this liquid jet in to solid filaments is called as the process of spinning.
The meaning of the spinning in this case may be completely different from that used for natural fibres. Generally, we can define spinning as a process that produces a yarn as its final product. The spinning of manmade fibres can be carried out by three different processes:-

    
COST ESTIMATION

Plant  Capacity                                                          :     3.06 MT./day
land & Building (4040 sq.mtr)                                :    Rs. 2.64 Cr
Plant & Machinery                                                     :    Rs. 5.70 Cr
Working Capital for 1 Month                                    :    Rs  1.20 Cr
Total Capital Investment                                           :    Rs. 10.22Cr
Rate of Return                                                            :    24%
Break Even Point                                                        :    59%


INTRODUCTION    
BASIC TEXTILE TERMS OF SPINNING    
PRINCIPLE    
OPEN END ROTOR YARN CHARACTERISTICS    
MANUFACTURING PROCESS    
SEQUENCE OF OPERATIONS:    
ESSENTIAL FEATURES OF THE OPEN END SPINNING PROCESS:    
ELEMENTS OF OPEN END SPINNING SYSTEM:    
ROTOR SPINNING-    
OBJECTIVES OF ROTOR SPINNING:    
OPERATING PRINCIPLES OF ROTOR SPINNING SYSTEMS:    
PROCESS DESCRIPTION    
ROTOR SPEED AND DIAMETER    
THE ROTOR GROOVE :    
SLIVER FEED:-    
PREPARATION OF THE SLIVER    
FIBRE OPENING    
FIBRE TRANSFER :    
DIFFERENCE BETWEEN DIFFERENT ROTOR MACHINES    
ROTOR SPINNING PERFORMANCE    
YARN BREAKAGE    
CONVENTIONAL & OPEN END SPINNING    
CHARACTERISTICS:-    
THE STRUCTURE OF OPEN END-SPUN YARN    
ADVANTAGES:-    
YARN TWIST AND TWIST MULTIPLIER    
RELATION BETWEEN TWIST AND YARN STRENGTH:-    
EXPRESSION OF TWIST    
FACTORS AFFECTING TWIST    
DIRECTION OF S TWIST    
DIRECTION OF Z TWIST    
FUNCTION AND EFFECTS OF TWIST ON YARN & FABRIC PROPERTIES    
FUNCTION OF TWIST IN YARN STRUCTURE    
EFFECTS OF TWIST ON YARN & FABRIC PROPERTIES    
IN THE CASE OF MOISTURE ABSORPTION:    
IN THE CASE OF WEARING PROPERTIES:    
IN THE CASE OF AESTHETIC EFFECTS:    
YARN DIAMETER, SPECIFIC VOLUME & PACKING DENSITY    
SPECIFIC VOLUME FROM TWIST    
PACKING DENSITY    
PRODUCT DESCRIPTION AND APPLICATION    
END USES FOR OPEN END SPUN YARNS    
RAW MATERIALS    
PLANT CAPACITY AND PRODUCTION PROGRAM    
PLANT CAPACITY    
PRODUCTION PROGRAM    
MARKET SURVEY    
COTTON PRODUCTION    
COTTON PRICES    
COTLOOK A INDEX (WORLD COTTON SEASON STARTING AUG 1)    
DOMESTIC COTTON PRICES (DOMESTIC COTTON SEASON STARTING OCTOBER 1)    
COTTON YARN PRODUCTION AND PRICES    
COTTON YARN DEMAND    
COTTON YARN PRICES & PROFITABILITY    
CAPACITIES & INVESTMENT    
SOME SUPPLIER NAME OF SPINNING AND SPINNING MACHINERY    
LIST OF MACHINES    
MACHINERY PHOTOGRAPHS    
BLOW ROOM    
FILTER    
BLOW ROOM FOR VISCOSE/COTTON    
COTTON CARDS    
DRAW FRAME    
TWISTING AND WINDING MACHINERY    
SCHLAFHORST AUTOCONER    
RAW MATERIAL & PODUCT PHOTOGRAPHS    
PROCESS FLOW DIAGRAM    
TECHNICAL SPECIFIACTION    
ROTOR SPINNING ( SAURER SCHLAFHORST):- BD 448    
DRAWING:-    
CARDING:-    
COMPLETE MACHINERY SUPPLIERS    
JOSHI & ASSOCIATES    
YOGESH JOSHI ( CONSULTANT )    
MACHINERY SUPPLIER (QUOTATION RECEIVED)    
BD INNOVATIONS    
RAW MATERIAL SUPPLIER    
CLEANING OF OPEN END SPINNING MACHINE & WASTE DISPOSAL    
INSTRUCTIONS FOR SHIFT CHANGE    
HANDING OVER THE SHIFT:    
PLANT LAYOUT    

            
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET