Application of Computer in Spinning

Software and Machineries used in Spinning Laboratory

What is Bale Management?

Bale management refers to the process of inventory control and selection of fiber according
to its properties and also to mix fiber homogeneously to get acceptable spinning performance,
consistent production and quality of yarn. The function of bale management is very much
unique to the spinning industry. The module should have a function in such a way that the
system should automatically generate the issues for mix or a count, where all the lay down or
issues should have a consistent quality parameter both in terms of average and SD.

So, we can define bale management in

the following way: Testing, sorting and
mixing bales according to the properties
of fibers for producing specific good
quality of yarn at minimum cost is called
Bale management. Bale management is
the important step of cotton fiber
engineering and in dealing with storage
and retrieval of cotton bales.

Various definitions are given for bale management. Among them popularly used are as
follows:

Engr. Nurunnabi_Lecturer_NITER
 Application of Computer in Spinning

Bale management is a sophisticated attempt to acquire the raw-material with desired

characteristics to parameters categorized and store bales according to predetermined patterns
and to select and blend bales in order to attain a consistent and uniform product.

Bale management is a process to mix fiber homogeneously to get consistent production,

quality of yarn, inventory control and selection of fibers according to its properties.

Objects of Bale Management:

The key purposes of bale management have presented in the below:

1. It also used to meet the functions and end use requirements.

2. It has done to compensate for the variation in properties of the raw materials.
3. Used to control or reduce fabric barre.
4. It has done to provide the desired properties of the end product.
5. It’s done to reduce raw material cost.
6. It has done to achieve uniform yarn quality.
7. To achieve required quality of yarn.
8. Used to decrease shade variation of the finished fabric.
Importance of Bale Management in Textile:

1. Fabric barre effect is produced if bale management is missed out.

2. Shade variation is occurred in weaving if bale management is absent.
3. Color variation has done in knitted yarn if bale management is not used.
4. Count Variation.

Specification of a Cotton Bale/ Information sheet

Origin: CIS (Uzbekistan) raw cotton

Crop year: 2008-2009

Bale weight: 215-220 kgs (approximately).

Staple length: 1 inches

Micronaire: 4.0 – 4.8

Strength: 24-29 gram/tex

Grade: SMW (Strict middling white)

Price: 65.5 $/lb

Engr. Nurunnabi_Lecturer_NITER
 Application of Computer in Spinning

Managing Bales:
To manage the bales we need four modules of fibers and the relation exist between fibers and
yarn. They are:

 Fiber Strength
 Fiber Length Factors effecting yarn quality.
 Fiber Color grade and Relation between fiber quality and
 Fiber Micronaire value/Fineness yarn quality

Procedure of Bale Management in Spinning Mill/Flowchart of Bale management

Raw material selection (fiber lot number)

Total bales

Sample collection

HVI (High Volume Instrument) testing

Number of mixing

Category defines (micronaire value and color grade) for different mixing

Discard the lower micronaire value and color grade bales

Define daily requirements

Receiving and ware house punning

Evaluation by QA personnel

Engr. Nurunnabi_Lecturer_NITER
 Application of Computer in Spinning

Preparation of bale layout as per mixing

Delete the consumed bale from the current bale

Procedure of Bale Management Summery/ Flowchart of bale management

Bale management process has done by following the below steps:

1. Raw cotton,
2. Moisture percentage testing of bale,
3. Collecting sample from each bale,
4. Testing of sample,
5. Bale classification,
6. Bale law down,
7. Mixing.
***Some key properties of bale has to follow before bale management. Those
are-
1. Strength,
2. Trash content,
3. Fineness,
4. Maturity,
5. Length,
6. Brightness or whiteness and yellowness.
7. Uniformity.

Factors for Effective Bale Management:

1. If the cotton received is from different ginners, it is better to maintain the percentage of
cotton from different ginners throughout the lot, even though the type of cotton is same.

2. It is not advisable to mix the yarn made of out of two different shipments of same cotton.
For example, the first shipment of Sudan cotton is in January and the second shipment is in
March, it is not advisable to mix the yarn made out of these two different shipments. If there
is no shade variation after dyeing, then it can be mixed.

3. Stack mixing is the best way of doing the mixing compared to using automatic bale
openers that picks up the material from 40 to 70 bales depending on the length of the machine
and bale size, provided stack mixing is done perfectly.

4. Improper stack mixing will lead to barre problem. Stack mixing with bale opener takes
care of short-term blending and two mixers in series takes care of long-term blending.

5. Tuft sizes can be as low as 10 g and it is the best way of opening the material (nep creation
will be less, care has to be taken to reduce recycling in the inclined lattice).

Engr. Nurunnabi_Lecturer_NITER
 Application of Computer in Spinning

6. The raw material gets acclimatized to the required temperature (20 degree) and R.H%
65%) since it is allowed to stay in the room for more than 24 h, and if the fiber is opened, the
fiber gets conditioned well.

Types of Bale Management System:

There has four types of bale management. They are-

1. On-line bale management

2. Off-line bale management
3. Traditional bale management
4. Modern bale management

Off-line Bale Management System/ Flowchart in Spinning Mill:

1. Identification:

a. To identify bales according to test parameter, identification is needed.

b. The same identification number is inserted onto bale and sample packet.

2. Sample collection:
The sample collect from the bales to carry out fiber quality test. Sample weight
approximately 25-30gm.

3. Sample condition:
Samples are conditioned for obtaining reproducible test result.20+65% @24hr

4. Sample testing:

a. Samples are tested in HVI, MVI, LVI.

b. Before testing machine is checked by standard. Sample and calibrated if needed.

5. Preparation of fiber database:

a. Tested parameter of fiber is stored in the HD of HVI.

b. Preparation of fiber database over long period is performed either in HVI or separate
database storage device.

6. Export or Import of data:

The stored data is export or import to suitable from hard disc for working procedure.

7. Analyzation and categorization:

a. The fiber parameter data is then analyzed and border line of parameter is selected.
b. Quality data distribution i.e. categorization of bales is carried out for right quality.

Engr. Nurunnabi_Lecturer_NITER
 Application of Computer in Spinning

8. Preparation of lay down plan:

a. After categorization of total bales, for each lay down, bales are selected.
b. After selection of lay down bales, lay down plan is prepared for optimal quality.

Application of Different Software in Spinning

ERP:
ERP (Enterprise resource planning) is one of those software which helps to make correct
planning and implementing decision of an enterprise. ERP software is now used in many
spinning mill.
Advantages of ERP Software:

1. Can make report in a very short period of time.

2. Saves valuable time.
3. Facilitate easy monitoring of the industry.
4. There is no chance of data manipulation.

USTER Bale Manager:

It is a software that is widely used in yarn manufacturing all over the world. In cotton lines
employ automatic bale manager system to certify correct mixing percentages for consistent
fiber properties to avoid shade variation during dyeing.

Advantages of USTER bale manager

Bale Identification and Tracking: The USTER Bale Manager provides a robust system for identifying
and tracking bales throughout the production process. Each bale is assigned a unique identification
code, allowing for easy traceability and quality control.
Quality Assurance: With the USTER Bale Manager, textile manufacturers can ensure consistent and
high-quality bales. The system monitors key quality parameters such as moisture content, trash
content, and fiber properties, enabling manufacturers to take corrective actions and optimize their
processes.
Process Optimization: By providing real-time data on bale quality, the USTER Bale Manager allows
manufacturers to identify process inefficiencies and make data-driven decisions for process
optimization. This leads to improved productivity, reduced waste, and better resource utilization.
Data Integration and Analytics: The USTER Bale Manager integrates with other systems in the textile
production chain, such as spinning and weaving machines, as well as enterprise resource planning
(ERP) systems. This seamless integration enables comprehensive data analysis and reporting,
facilitating better decision-making and performance monitoring.
Traceability and Compliance: In the modern textile industry, traceability and compliance with quality
standards are crucial. The USTER Bale Manager helps manufacturers meet these requirements by
providing complete traceability records and ensuring adherence to industry standards and regulations.
Customer Satisfaction: By consistently delivering high-quality bales, manufacturers using the USTER
Bale Manager can enhance customer satisfaction. Customers can have confidence in the quality and
consistency of the textile products they receive, leading to stronger relationships and repeat business.

Engr. Nurunnabi_Lecturer_NITER
 Application of Computer in Spinning

Cost Savings: Through process optimization, waste reduction, and improved quality control, the
USTER Bale Manager can help textile manufacturers achieve cost savings. By minimizing defects
and waste, manufacturers can reduce rework and material losses, leading to increased profitability.

USTER AFIS:

It is a method which is based on aeromechanical fiber processing, similar to opening and

carding followed by electro-optical sensing and then by high speed microprocessor based
computing and data reporting. A fiber sample is introduced into the system and is processed
through a fiber individualizer, which aero mechanically separates the sample into three
components consisting of cleaned fiber, micro dust and trash. Each of these components is
transported into separate pneumatic path and may analyzed electro optically or by other
means.

DATA LOG:

Data log is logger online monitoring software for spinning mill that facilitates continuous
monitoring of each machine separately and all together. The data is processed and useful
reports generated help in the unified running of all the operations.
Features:

1. Automation.
2. Reduction of labor cost.
3. Doffing time is less than 3 minutes.
4. Gentle removal of cops increases the life of spindles.
5. Crash proof auto doffing.
6. Linking with the upstream machine.

Ring Data System and Its Application on Ring Frame

RING DATA is online monitoring system which assess the performance of ring frame on
machine itself with the help of sensor and embedded electronics. This system enables to
locate the faulty yarn package and material. It is a powerful analysis tools allow instant
identification of poor performing machine and spindles, resulting in faster reaction to
problems and an increased efficiency and quality level with minimum efforts.

Machine display provides information about production, end breakages, stop time, overall
performance and power consumption of machine. USTER ring data is the most popular
among other ring data system.

Drawbacks of offline control:

1. Required extra laboratory with equipped with modern testing instrument which increase
cost.
2. Sampling and testing is time consuming and may add human error.
3. Corrective action is taken by observing result which may wrong.
4. Saving of testing result which may difficult due to paper work.

Engr. Nurunnabi_Lecturer_NITER
 Application of Computer in Spinning

5. Calibration of testing instrument in specific time should done which increase cost.
modern system approaches online monitoring on ring frame which will
overcome drawbacks of offline monitoring.

RING DATA SYSTEM/Functions

1. Detaching and signaling ends down.

2. Detaching and reciprocating ends down.
3. Detaching and recording ends down.
4. Detaching and analyzing ends down.
5. Recording stoppages
6. Recording output
7. Calculating efficiency
8. Roving stop motion in the events of end down.

TYPES OF RING DATA:

A) Machine Monitoring System:

B) Individual spindle monitoring system:

*****Following data are given in ring data reports

1.MACHINE NUMBER,

2. DATE, TIME,

3. PRODUCTION PERIOD,

4. SPINDLE SPEED,

5.YARN TWIST,

6.OUTPUT IN KG OR KG/SPINDLE,

7.EFFICIENCY

, 8.DOWNTIME, DOFFING TIME, ENDS DOWN/ 1000 SPINDLE HOURS .

Questions:

1. What do you mean by bale management in spinning?

2. What are the key purposes of bale management in textile?
3. Writ down the significance of bale management in spinning.
4. Mention the total process of bale management followed in spinning.
5. Mention the process flow chart of bale managemen

Engr. Nurunnabi_Lecturer_NITER