"Vastram ready to use cotton manufacturing process".
FILED OF INVENTION
This invention relates to vastram ready to use cotton manufacturing process.
BACKGROUND OF INVENTION
With all harvesting methods, however, the cotton seed, together with the fibers, always gets into the ginning plant where it is broken up into trash and seed-coat fragments. This means that ginned cotton is always contaminated with trash and dust particles and that an intensive cleaning is only possible in the spinning mill.
In the cotton spinning industry, the mill receives cotton bales with a typical waste percentage of 4% to 5.5%. To clean this cotton in order to make it spinnable, there is a neecl for large capital investment of machines mainly in Blow Room line.
If the spinning mill receives clean cotton with a trash percentage of 2.0% to 2.5%, it can shorten the blow room line.
Case Study (Analysis for a spinning mill)
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♦ Power Saving per day = 1320 units.
♦ Reduction of machines in Blow Room Line - Two beater & two material transport fans.
Process Flow Chart
Normal Cotton
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Process Flow Chart Clean Cotton
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The invention 'A novel sliver making machine for cotton processing from central institute for research on cotton technology published in 2008 shows a novel silver making machine comprising an assembly of plurality of an intake hopper feed lattice for feeding cotton which is connected to the Inclined spike lattice for picking up the cotton tufts it further leads to a lump preventor for passing tufts in forward direction, it is further connected with a leather flap roller for further opening of tufts and it further connects to the feed place for moving the cotton tufts towards feed lattice for collecting the tufts, the cotton moving over the feed lattice gets caught between the nip of the closely moving feed roller pair and is further opened out by the lickerin and the opened tufts cleared, by clearer rollers are passed on to cylinder, individualization of fibers takes place between the wire clothing mounted flats surface and cylinder surface by clearer and an opener the individualized fibers are stripped by stripping rollers from the doffer by a closely oscillating doffer comb the web of fibers emerging from the doffer surface is condensed by passing through a condensing trumpet and condenser roller via a web plate further the sliver guide collect the silver through a trumpet followed by an appropriate condensing mechanism which further taken to the silver winding drum wherein plurality of pressure rollers strengthen the silvers received from the silver winding drum which is the transferred to silver package.
OBJECTS OF INVENTION
The main object of this invention is to provide hassle free ready to use cotton with homogeneous blend of different fibre which can be directly used by spinning mills.
Other object is the optimum utilization of cotton fibre.
Another object is to reduce spinning which makes the finished product commercially more viable.
Yet another object is to increase the efficiency of Blow Room and Carding in Spinning.
Further object is to reduce manpower in the process.
Other object is also to reduce the power consumption in the process.
Yet another object is to increase finished product (yarn) realization.
Another object is also to increase the utilization of the old generation machines.
Further object is to improve consistency in the quality of the finished product.
The final object is also the develop the product keeping in mind the end use of finished product which will improve overall productivity of all manufacturing process form spinning to weaving to processing in the total supply chain.
STATEMENT OF INVENTION
This invention relates to a vastram ready to use cotton with homogeneous blend of different fibre with fibre reconciliation which can be directly used by spinning mills and the manufacturing process thereof comprising the steps of, preparation involving Ginning of Virgin cotton and reclamation of fibres from waste generated during spinning process
like blow room dropping, carding dropping, carding flat waste, comber noils, processing involving the steps of Bale plucker, Bale opener, super waste cleaner, grading for Ring spinning and open end' spinning, Weighing Hopper, Multi mixer, condenser, step cleaner/tumbling machine, moisture and chemical treatment, finishing involving steps, cleaning, pre-opening and cleaning, Bale pressing.
DETAILED DESCRIPTION OF INVENTION
There are mainly three processes involved in the manufacturing process of Vastram Processed Clean Cotton (with fibre reconciliation). Three processes are given below: -
1. Preparation
2. Processing
3. Finishing
Preparation; -
The preparation process involves mainly in two sub processes: -
1. Ginning of Virgin Cotton
2. Reclamation of fibres from waste generated during spinning
process like Blow Room Dropping, Carding Dropping, Carding Flat
waste, Comber Noils etc.
Ginning of Virgin cotton: - Extraction, separation and pre cleaning of Cotton lint from the raw cotton and feeding to processing unit.
Process flow of Ginning: -
(Figure Removed)
Reclamation of Fibres from waste: - Reclamation and recovery of rich fibres from wastes like Blow Room Dropping, Carding Dropping, Carding Flat waste, Comber Noils etc.
Process flow of Waste Reconciliation: -
(Figure Removed)
Machine Design and Accessories:
Fibre Reclaimation System
The Recovery plant is available with or without Bale Plucker, and is specially engineered modular system with gradually increasing cleaning and opening intensity levels thereby ensuring the retainment of fibre properties. It consists of:
• Bale Pucker / Bale opener
• Super Waste Cleaner
• Cage / Suction device
• Filter unit with Primary / Secondary idea & Compactor
Process:
Various types of wastes are fed in initial lattice which under suction goes to cleaning and opening zone, and the delivery is in form of fleece being collected manually, and then sent for Bale Press.

Bale Plucker: -
A fiber-bale plucker comprises a cutting device which is movable over a row of fiber bales. A collector passage is open on top below the cutting device which travels to and fro. An air passage in a cutting device through which the cut fibers are drawn from the vicinity of the cutting mechanism communicates with the passage. A cover strip at least partially covers the top of the collector passage to maintain a reduced pressure therein. Guide rollers for the cover strip are provided on the cutting device, to lift the cover strip from the collector passage at the location, at which the air passage opens into the collector passage and guide the cover strip over the portion of the air passage opening into the collector passage.
Bale Opener; -
From stripping roller, the cotton flocks are thrown into trunk, which guides them into the pair of feed roller which is spring loaded.
The compressed sheet of cotton which are delivered from feed roller are heavily beat by saw toothed cylinder. This beating action divides the material ' into smallest flock. Saw toothed cylinder projects the flocks over the grid, where sand and heavy trash particles are extracted.
The cotton falls into an outlet funnel are taken away Pneumatically to the next machine.
In addition to the cleaning through grid bar system an exhaust fan at the top of the machine will suck the dust, air and short fibres from inside of the machine through perforated sheet.
This pepper trash is taken by pneumatic pipe to the cellar (dust chamber).
Super Waste Cleaner: -
Acetex Super waste cleaner is specially engineered modular system with gradually increasing cleaning & opening intensity levels thereby ensuring the retainment of fibre properties.
This system comprises of the following: -
Robust Bale opener
Ulti Cleaner Super waste cleaner
This system "has been incorporated with intensive cleaning so as to provide flexibility in perfect treatment of fibres. Air suction cleaning devices for separation of micro dust without harshly treating of the fibres. Nearly four types of such suction devices have been incorporated in this system.

This process is meant to release maximum amount of dust, care has been taken by introducing most efficient dust & waste handling system.
Vastram Ready to Use Cotton Grading for Ring Spinning & Open End Spinning
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• VRI - Vastram Cotton for Ring Spinning (Ne 6s to Ne 12s)
• VR2 - Vastram Cotton for Ring Spinning (Ne 13s to Ne 20s)
• VR3 - Vastram Cotton for Ring Spinning (Ne 20s to Ne 30s)
• VO1 - Vastram Cotton for Open End Spinning (Ne 4s to Ne 8s)
• V02 - Vastram Cotton for Open End Spinning (Ne 9s to Ne 16s)
• V03 - Vastram Cotton for Open End Spinning Slub Yarn (Ne 6s to Ne 10s)
• V04 - Vastram Cotton for Open End Spinning Slub Yarn (Ne 10s to Ne 16s)
Vastram Ready to use Cotton process; -
This process consists of following Lines: -
Line 1 - Virgin Cotton line from Ginning Line
Line 2 - Recovered Fibres line from Fibres Reclamation System
Vastram Ready to use Cotton process consists of follQwing sub processes:-
Weighing Hopper: -
In Hopper Feeder the following objects are achieved: -
The material is thoroughly blended in main bin.
The material is combed by the spikes of the inclined lattice.
The cotton is well opened when passes in between evener roller and spiked inclined lattice.
Heavy trashes are extracted through grid bars and iron particles are removed from the cotton by the magnet.
Fan is provided in the top of the machine and sucks the dusty air which is settled down in the cellar.
Also, the principle object of the Hopper Feeder is to provide uniform feeding of cotton on lattice across the full width of the machine.
Process: -
The cotton from Line 1 & Line 2 are mixed according to the defined ratio and then feed to further process. The proportion of material (from Line 1 & 2) is maintained by the control of Weighing load cells.
Multimixer: -
Perfect and Homogeneous blend is achieved
Simultaneous mixing by doublings' over an extended period of time is
achieved.
The cotton bales are opened and premixed by bale opener. This blend is blown by the material transport fan and conveyed into the feed duct above the multimixer chamber. The charging of the multimixer starts with the first mixing chamber at the end of the feed duct. It is filled only to just below the photo cell situated in the adjacent chamber, then the closing flap of the second hopper.
Second chamber is charged" to a rather higher than the first. The charging level of the hopper rises uniformly up to the last chamber which is fully charged, when the last chamber is full the Closing flap shuts automatically and charging restarts with first chamber, the base of each hopper is closed by a pair of deliver roller which transfers the material gradually and uniformly to an opening roller. The delivery rollers of the entire hopper are two variable speed motor with control range up to 1 : 6 in this way it is possible to adjust the output of multimixer to the feed requirement of the subsequent machine. Opening roller gently loosen the material into tufts and deliver them into the blending channel from which they are sucked by the subsequent condenser.
Condenser: -
Fan connected with Condenser suck the material from previous machine through pneumatic pipe and deposit it into the Reserve tower which feeds to the next machine in the blow room line.
This condensor is employed to feed cotton to Hopper feeder of, step cleaner, etc, Suction for conveying the fibre from machine to machine is created by the fan connected to the condenser.
The fibre condensed on to the rotating surface of the cage is removed by the wiper roller and deposited into the reserve feed tower.
The condenser and reserve tower unit provide sufficient
production and reserve of fibre to meet all demands by the next machine.
Control or production is exercised by a photo cell
arrangement in the tower unit which monitor the height of reserve fibres and signals stop or start commands to the preceding machine.
Step Cleaner / Tumbling Machine: -
Condenser is employed to feed cotton to the step cleaner. Photo-cell arrangement in the reserve tower unit monitor the height of reserve fibre and signals stop or start commands to the proceeding machine. Cotton is fed from the reserve tower by pair of feed roller. According to the height of cotton level, photo cell in the reserve tower of subsequent machine, drive the feed Roller intermittently by motorized gear reduction unit. Beating section. The rapid revolution of 6 beating cylinders (multiple beater) and beating of the spikes on cotton against grid bar centrifugal force and gravity combine effectively to open the cotton and remove the heavier impurities.
Heavier impurities, dust & dirt particles, short fibres, etc, from the cotton are passed through the spacing of the bars and is collected outside the grid bar.
Micro dust Extraction:
Micro dust & fine impurities are liberated by the action of multiple beater, is transferred through the perforated screen of the dust hood and removed by an air stream. Rapidly rotating six beating cylinder takes the tufts upwards & after opening and cleaning, the cotton from the last beating cylinder is conveyed pneumatically to the next machine through outlet pipe.
Moisture & Chemical Treatment
In this process moisture and chemical treatment done on the fibres by using spray nozzles.
Process flow Chart
(Figure Removed)
Schematic Diagram of Pretreatment of cotton
(Figure Removed)
Finishing
The finishing jprocess consists of the following process: -
1. Step Cleaning
2. Pre - opening 8B Cleaning
3. Bale Pressing
Process flow Diagram of Finishing process: -
(Figure Removed)
Bale Pressing; -
The material is fed to bale pressing machine & packing is done after bale pressing.
Process Flow Chart
Vastram Ready to Use Cotton (with fibre reconciliation)
(Figure Removed)
Power Saving; -
Total Power consumption per day for Blow Room for Normal Cotton = 3390 units
Total Power consumption per day for Blow Room for Clean Cotton = 2070 units
Total Power saving per day for Clean Cotton = 1320 units Advantages of Using Clean Cotton
1. No. of beating points in the Blow room line will be shortened, i.e if the spinning mill uses Clean cotton then two beaters in Blow, room line can be reduced.
2. Power Saving. (By reducing two beaters from Blow Room line there will be power saving around 35% to 40% cost of the total power consumption in normal Blow room line.
3. As the clean cotton is already processed so there is no need of mixing of different bales.
4. The mixing of cotton will be consistent throughout the complete lot of Clean cotton.
5. The Yarn faults like patta, barre (due to Improper Mixing) will be minimized by using clean cotton.
Vastram Ready to Use Cotton Grading for Ring Spinning & Open End Spinning
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• VRI - Vastram Cotton for Ring Spinning (Ne 6s to Ne 12 s)
• VR2 - Vastram Cotton for Ring Spinning (Ne 13s to Ne 20s)
• VR3 - Vastram Cotton for Ring Spinning (Ne 20s to Ne 30s)
• VO1 - Vastram Cotton for Open End Spinning (Ne 4s to Ne 8s)
• V02 - Vastram Cotton for Open End Spinning (Ne 9s to Ne 16s)
• V03 - Vastram Cotton for Open End Spinning Slub Yarn (Ne 6s to Ne 10s)
• V04 - Vastram Cotton for Open End Spinning Slub Yarn (Ne 10s
to Ne 16s)

We Claim
1. A vastram ready to use cotton with homogeneous blend of different
fibre with fibre reconciliation which can be directly used by
spinning mills and the manufacturing process thereof comprising
the steps of : -
i) preparation involving Ginning of Virgin cotton and reclamation
of fibres from waste generated during spinning process like blow room dropping, carding dropping, carding flat waste, comber noils.
ii) processing involving the steps of Bale plucker, Bale opener, super waste cleaner, grading for Ring spinning and open end spinning, Weighing Hopper, Multi mixer, condenser, step cleaner/tumbling machine, moisture and chemical treatment
iii) Finishing involving steps, cleaning, pre-opening and cleaning, Bale pressing.
2. A vastram ready to use cotton and the manufacturing process
thereof as claimed in claim 1, wherein the process consists of
following lines, line -virgin cotton line from Ginning line, line 2-
recovered fibres line from fibres reclamation system.
3. A vastram ready to use cotton and the manufacturing process there of as claimed in claim 1, wherein the recovery plant is available with or without Bale plucker and is specially engineered modular system with gradually increasing cleaning and opening intensity levels so that the retainment of fibre properties is ensured.
4. A vasteam ready to use cotton and the manufacturing process there of as claimed in claim 1, wherein in super waster cleaner system, 4 types of air suction cleaning devices has been incorporated for separation of micro dust without harshly treating of the fibres.
5. A vastram ready to use cotton and the manufacturing process there of as claimed in claim 1, wherein in weighing hopper feeder, the material is thoroughly blended in main bin, combed by the spikes of the inclined lattice and cotton is well opened when passes in between evener roller and spiked inclined lattice.
6. A vastram ready to use cotton and the manufacturing process there of as claimed in claim 1, wherein in the tumbling machine, rapid revolution of 6 beating cylinders and beating of the spikes on cotton against grid bar centrifugal force and gravity combine effectively to open the cotton and remove the heavier impurities.
7. A vastram ready to use cotton and the manufacturing process there of as claimed in claim 1, wherein micro dust and fine impurities are liberated by the action of multiple beater, transferred through the perforated screen of the dust hood and removed by an air stream.
8. A vastram ready to use cotton and the manufacturing process there of as claimed in claim 1, wherein chemical treatment on fibres is done using spray nozzles.
9. A vastram ready to use cotton and the manufacturing process thereof as described and illustrated herein.