1 of 43

Industrial Training Project�Anant Spinning Mills�A Unit of Vardhman Textiles Limited

Name - Subham Pal

Branch - Textile Technology

Roll No. - 111111101419038

College - Government College of Engineering & Textile Technology, Berhampore

Under the Guidence of

Mr. Vasant K. Bisen ( HOD H1, 2, 3 )

2 of 43

Determine the Faults in the Carding and Increase the Efficiency of the Machines

By Subham Pal ( Internship Trainee at Anant Spinning Mills, Bhopal )

College – Government College of Engineering and Textile Technology, Berhampore

3 of 43

Types of Faults

Sliver Break
Material Lapped in Crush Roller
Chute Feed Faults
Feed is Heavy / Feed material is More
Feed is Light / Feed material is Less
Double Lap
Filter Box Full ( Luwa Jam )
Can Change Problem
Maintenance ( Cleaning / Machine Parts Changes )

4 of 43

Machine Parameters

Card No. - 1-12
Model No. - LC 300A - V3
Mixing - 100% Polyester ( Reliance Semi Dull

1.3 * 38 mm )

Wpg - 4.8 Ktex
Nominal Feed - 17
Piecing Feed Ratio - 1.40
Double Lap - 5.00
Can Capacity - 9000 meters
Delivery Speed - 140 m/mim

Cylinder rpm - 450
Flats speed - 296 mm/min
Doffer Speed - 300 m/min
Licker in rpm - 796
Feed Roler rpm - 10.64
Draft - 70
Avg Production - 280 - 300 KG/Shift
Eff.% - 90 - 95 %
Feed Weight - 331 gm/m
Chute Pressure - 112 Pa.
Feed Thickness - 1.40 mm

5 of 43

Problem – Sliver Breakage

Reasons –

1) RH% Should be in between 52% - 54%. If it increases strength of the sliver

decreases.

2) Variation of thick & thin place

3) Tightening of Coiler Calendar Roller

4) Jam in the Trumpet

5) Increase in tension draft

6) Damaged Card Clothing

7) Air pressure problem

Solutions –

1) Gate of the Blow room Section Should be Closed all the time

2) Reduced Tension draft

3) Cleaning & Maintenance should be done regularly

6 of 43

Problem – Material Lapped in Crush Roller

Reasons –

1) By continuous friction, coiler calendar roller heated up. Polyester are more

sticky in nature. So fibre waves easily

lapped over this roller

Solutions –

1) Use Lubricating powder for smooth

movement of fibre wave between calendar

roller and trumpet

7 of 43

Problem – Chute Feed Fault

Reasons –

1) Soft waste ( like fibre, sliver ) from carding, simplex, ring frame are mixed into

bales. Sometime slivers are not broken properly, so blow room machines (

condenser, uniclean, MCM ) and Fine Feed are jam by this unbroken slivers

Solutions –

1) waste slivers should be broken and mixed properly & spread all over the bales

2) Delivery speed of the fine feed should be control for heavy or low feed problem by increasing or

decreasing the speed of the fine feed roller

3) There two condenser ware installed in between MCM line No. 1 & 2 for even feeding to the carding.

4) The speed of the fan after the uniclean machine increased from 2000 to 2200.

8 of 43

Double Lap

Feed Material Heavy

Feed Material light

9 of 43

Problem – Filter Box Full

Reasons –

1) In waste collection chamber waste should be cleared and taken out. If cleaning

not done the waste pipe suction take reverse this waste and jam the whole line

This is called luwa jam

Solutions –

1) waste collection chamber waste should be cleared after a specific time

10 of 43

Problem – Can Change Problem

Reasons –

1) In some of the machine, in the time of changing the full can the delivery

speed of the machine is geting slow. Thus the sliver are broken due to more

tension and machine stop.

Solutions –

1) It’s solution is not discovered yet. But, it is a electrical fault, so maintenance should be done

after a specific period to decrease this problme.

11 of 43

Problem – Maintenance and cleaning

Reasons –

1) it is nither a problem nor a fault. But its take sometime very long time to complete the

maintenance and cleaning works.

Solutions –

1) try to complete the maintenance and cleaning work as soon as possible

12 of 43

Date – 18/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	2	1	2	1	3	4	1	3	2	3	2	8	32
Material Lapped in Crush Roller	1	2	2	1	1	2	1	3	1	1	2	2	19
Chute Feed Faults	2	1	0	0	0	1	1	1	0	0	1	1	8
Filter Box Full	1	1	1	1	1	1	1	1	1	1	1	1	12
Can Change Problem	0	2	0	2	0	0	1	0	0	1	0	0	6
Maintenance	1	1	1	1	1	1	1	1	1	1	1	1	12
Total	7	8	6	6	6	9	6	9	5	7	7	13

13 of 43

Date – 18/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	275.5	90.6	7.15	0.45
2	279.1	89.0	7.08	0.52
3	289.3	87.3	6.59	1.01
4	298.2	95.1	7.31	0.29
5	280.2	89.3	7.07	0.53
6	172.1	56.6	4.27	3.33
7	301.8	95.4	7.36	0.24
8	185.4	61.6	4.44	3.16
9	209.8	83.6	6.40	1.20
10	242.3	78.8	6.18	1.42
11	246.0	85.2	6.32	1.28
12	165.4	58.0	4.38	3.22
Total/Avg.	2945.1	80.875

14 of 43

Date – 19/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	3	1	2	4	3	2	3	2	3	3	4	5	35
Material Lapped in Crush Roller	0	0	0	1	0	2	0	0	1	0	0	1	5
Chute Feed Faults	2	2	0	2	2	2	3	1	4	1	4	0	23
Filter Box Full	2	2	2	2	2	2	1	1	1	1	1	1	18
Can Change Problem	0	1	0	2	0	0	1	0	0	0	0	0	4
Maintenance	1	1	1	1	1	1	1	1	0	1	0	0	9
Total	8	7	5	12	8	9	9	5	9	6	9	7

15 of 43

Date – 19/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	178.5	61.7	4.42	3.18
2	132.6	42.5	3.20	4.42
3	216.7	64.0	5.04	2.56
4	167.5	55.4	4.15	3.45
5	173.6	57.3	4.20	3.40
6	157.5	54.2	4.01	3.59
7	214.0	67.9	5.24	2.36
8	179.2	60.2	4.31	3.29
9	177.5	67.9	5.18	2.42
10	94.9	47.9	2.26	5.34
11	197.7	68.5	5.05	2.20
12	176.9	58.5	4.40	3.20
Total/Avg.	2066.6	58.83

16 of 43

Date – 20/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	2	3	2	4	5	1	2	3	1	1	1	2	27
Material Lapped in Crush Roller	1	1	1	0	1	0	0	1	0	0	0	0	5
Chute Feed Faults	1	0	1	1	0	2	1	1	1	1	0	1	10
Filter Box Full	1	1	1	1	1	1	1	1	1	1	1	1	12
Can Change Problem	0	1	0	1	0	0	0	0	0	0	0	0	2
Maintenance	0	0	0	0	1	0	0	1	1	1	1	1	6
Total	5	6	5	7	8	4	4	7	4	4	3	5

17 of 43

Date – 20/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	186.5	67.6	5.24	2.36
2	175.0	54.8	4.23	3.37
3	190.5	56.9	4.31	3.23
4	200.4	66.5	5.19	2.41
5	193.8	65.1	5.13	2.47
6	196.8	73.4	5.48	2.12
7	248.1	78.2	6.14	1.46
8	125.9	43.7	3.27	4.33
9	157.6	61.0	4.53	3.07
10	138.9	49.7	3.56	4.04
11	163.5	52.5	4.06	3.54
12	145.4	45.2	3.37	4.23
Total/Avg.	2122.4	59.55

18 of 43

Date – 21/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	3	1	1	1	2	2	2	2	3	2	1	1	21
Material Lapped in Crush Roller	2	0	0	1	0	0	0	0	0	0	0	1	4
Chute Feed Faults	1	1	1	1	1	1	2	2	3	3	3	4	23
Filter Box Full	1	1	1	1	1	1	1	1	1	1	1	1	12
Can Change Problem	0	0	0	1	0	0	0	0	0	1	0	0	2
Maintenance	0	0	1	1	1	0	1	0	0	0	0	0	4
Total	7	3	4	6	5	4	6	5	7	7	5	7

19 of 43

Date – 21/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	194.1	67.1	5.22	2.38
2	238.4	74.7	5.58	2.02
3	229.1	68.2	5.28	2.33
4	189.5	60.2	4.47	3.13
5	213.6	67.6	5.25	2.35
6	136.4	46.6	3.38	4.22
7	168.1	53.7	4.17	3.43
8	171.9	55.9	4.22	3.38
9	188.0	60.3	4.48	3.12
10	205.0	64.1	5.03	2.57
11	87.33	37.0	2.14	5.46
12	195.5	65.2	5.13	2.47
Total/Avg.	2216.93	60.05

20 of 43

Implementation Data with the�Obstacles During Implementation & Solutions �of this Obstacles

21 of 43

Date – 22/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	2	1	3	1	2	1	1	1	1	2	1	2	18
Material Lapped in Crush Roller	0	0	0	3	0	0	0	0	0	0	0	2	5
Chute Feed Faults	1	1	1	1	1	1	1	1	2	2	2	2	16
Filter Box Full	1	1	1	1	1	1	1	1	1	1	1	1	12
Can Change Problem	0	1	0	1	0	0	0	0	0	0	0	0	2
Maintenance	0	0	0	0	1	0	1	0	1	1	1	1	6
Total	4	4	5	7	5	3	4	3	5	6	5	8

22 of 43

Date – 22/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	250.7	82.1	6.34	1.26
2	286.2	89.2	7.08	0.52
3	253.3	74.8	5.56	2.04
4	239.0	76.3	6.03	1.53
5	203.7	76.4	5.10	2.50
6	248.7	79.9	6.14	1.46
7	184.0	69.1	4.37	3.27
8	245.8	90.6	73.05	0.55
9	209.8	66.2	5.15	2.41
10	194.3	61.3	4.54	3.06
11	180.6	58.7	4.32	3.28
12	128.0	44.7	3.35	4.25
Total/Avg.	2624.1	72.44

23 of 43

Date – 23/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	2	2	1	3	2	2	3	1	1	2	1	2	22
Material Lapped in Crush Roller	0	0	1	2	1	0	0	0	0	1	0	1	6
Chute Feed Faults	0	0	0	0	0	0	2	1	2	2	2	2	11
Filter Box Full	1	1	1	1	1	1	1	1	1	1	1	1	12
Can Change Problem	0	0	0	1	0	0	0	0	0	1	0	0	2
Maintenance	1	1	1	1	1	1	1	1	1	1	1	1	12
Total	4	4	4	8	5	4	7	4	5	8	5	7

24 of 43

Date – 23/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	239.1	79.7	6.09	1.51
2	158.8	64.9	3.57	2.08
3	122.6	63.9	3.08	4.52
4	238.0	75.0	6.00	2.00
5	228.7	72.6	5.41	2.19
6	231.5	78.5	6.12	1.42
7	221.5	80.2	6.24	1.35
8	183.0	58.0	4.38	3.22
9	238.3	84.0	6.43	1.17
10	233.6	76.9	6.09	1.51
11	211.3	76.7	6.06	1.54
12	191.0	62.6	5.00	3.00
Total/Avg.	2497.4	72.75

25 of 43

Date – 25/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	2	1	2	2	3	0	1	1	3	0	1	2	18
Material Lapped in Crush Roller	0	0	2	0	1	0	0	1	1	1	0	0	6
Chute Feed Faults	0	0	0	0	0	1	1	1	1	1	1	1	7
Filter Box Full	0	0	0	0	0	0	0	0	0	0	0	0	0
Can Change Problem	0	1	0	1	0	0	0	0	0	0	0	0	2
Maintenance	1	0	0	0	0	0	0	0	0	0	1	1	3
Total	3	2	4	3	4	1	2	3	5	2	3	4

26 of 43

Date – 25/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	110.6	62.5	2.48	5.12
2	226.9	72.9	5.50	2.10
3	264.7	80.6	6.27	1.33
4	282.9	92.0	7.17	0.43
5	222.5	76.2	6.05	1.55
6	230.3	76.5	5.51	2.09
7	245.9	78.0	6.13	2.47
8	236.0	76.4	5.53	2.07
9	188.7	60.2	4.49	3.11
10	225.9	71.2	5.42	2.18
11	205.3	66.6	5.07	2.53
12	209.2	63.7	5.05	2.55
Total/Avg.	2648.9	73.07

27 of 43

Date – 26/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	1	2	2	1	0	1	2	0	1	0	1	1	12
Material Lapped in Crush Roller	1	0	2	0	0	0	0	0	0	0	0	0	3
Chute Feed Faults	0	0	0	0	2	0	0	0	2	3	3	3	13
Filter Box Full	2	2	2	2	2	2	2	2	2	2	2	2	24
Can Change Problem	0	0	0	0	0	0	0	0	0	1	0	0	1
Maintenance	0	1	1	0	2	1	1	1	1	1	1	1	11
Total	4	5	7	3	6	4	5	3	6	7	7	7

28 of 43

Date – 26/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	205.2	69.4	5.34	2.26
2	161.2	56.5	4.31	3.29
3	229.9	68.1	5.27	2.33
4	240.9	76.7	6.08	1.52
5	52.9	20.4	1.26	5.34
6	69.2	27.8	1.58	5.06
7	133.3	46.8	3.44	4.16
8	142.1	47.5	3.46	4.10
9	109.4	34.9	2.46	5.14
10	89.3	28.3	2.16	5.44
11	69.2	23.2	1.46	6.12
12	93.5	28.1	2.15	3.45
Total/Avg.	1596.1	43.98

29 of 43

Obstacles & Their Solutions

Sometime the door of the blowrom remains open & RH% Effects by this.
Sometimes the slivers are not broken & spread correctly
Sometime operators are forget to clean the waste collection chamber
Sometime Cleaning takes too much time

Solution -

Operators have to close the door of the blow room immediately after exit or entering the room.
Operators have to broken the slivers into very small pieces and spread all over the bales corectly.
Operators have to clean te waste collection chamber after a specific time
Operators have to do Cleaning as son as possible

30 of 43

Data and the Final Result

31 of 43

Date – 27/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	1	0	1	0	1	1	0	0	0	1	2	3	10
Material Lapped in Crush Roller	1	0	0	0	0	0	0	0	0	0	0	0	1
Chute Feed Faults	1	0	0	0	0	0	0	0	0	1	0	0	2
Filter Box Full	1	1	1	1	1	1	1	1	1	1	1	1	12
Can Change Problem	0	0	0	0	0	0	0	0	0	0	0	0	0
Maintenance	0	0	0	0	0	0	0	0	1	1	1	1	4
Total	4	1	2	1	2	2	1	1	2	4	2	3

32 of 43

Date – 27/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	244.1	83.8	6.42	1.18
2	277.1	86.9	6.57	1.03
3	290.6	86.2	6.53	1.07
4	281.5	88.7	7.06	0.54
5	266.4	84.4	6.45	1.15
6	270.2	88.1	7.03	0.57
7	301.0	95.0	7.35	0.25
8	286.1	90.4	7.11	0.49
9	298.6	92.3	7.20	0.40
10	216.0	67.8	5.22	2.38
11	193.9	61.4	4.53	3.07
12	219.0	65.2	5.13	2.47
Total/Avg.	3144.5	82.52

33 of 43

Date – 28/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	0	1	1	0	1	0	2	1	0	1	2	2	11
Material Lapped in Crush Roller	0	0	0	1	0	1	0	0	0	0	0	1	3
Chute Feed Faults	1	1	1	1	1	1	1	1	1	1	1	2	13
Filter Box Full	1	1	1	1	1	1	1	1	1	1	1	1	12
Can Change Problem	0	0	0	0	0	0	0	0	0	1	0	0	1
Maintenance	1	1	1	1	1	1	0	0	0	0	0	1	7
Total	3	4	4	4	4	4	4	3	2	4	4	7

34 of 43

Date – 28/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	162.4	59.0	4.43	3.17
2	199.9	62.5	5.00	3.00
3	189.8	57.3	4.35	3.25
4	217.0	67.9	5.26	2.34
5	178.0	59.5	4.46	3.14
6	213.7	67.6	5.23	2.37
7	225.6	73.8	5.53	2.07
8	247.3	78.0	6.13	1.47
9	227.1	72.5	5.48	2.12
10	198.6	64.8	5.07	3.53
11	169.6	58.1	4.36	3.24
12	149.7	46.5	3.43	4.17
Total/Avg.	2378.7	63.96

35 of 43

Date – 29/07/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	2	0	2	0	0	0	1	0	1	2	1	3	12
Material Lapped in Crush Roller	0	0	0	1	1	0	1	0	0	0	0	1	4
Chute Feed Faults	1	1	1	1	1	1	1	1	1	1	2	2	14
Filter Box Full	0	0	0	0	0	0	0	0	0	0	0	0	0
Can Change Problem	0	0	0	1	0	0	0	0	0	0	0	0	1
Maintenance	0	0	0	0	0	0	0	0	1	2	1	1	5
Total	3	1	3	3	2	1	3	1	3	5	4	7

36 of 43

Date – 29/07/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	236.9	74.7	5.58	2.02
2	314.1	97.7	7.49	0.11
3	254.3	75.6	6.03	1.57
4	269.1	84.6	6.46	1.14
5	275.2	87.3	6.59	1.01
6	257.7	81.4	6.26	1.34
7	259.8	85.6	6.32	1.26
8	253.3	80.0	6.21	1.39
9	261.7	82.6	6.33	1.27
10	211.7	67.3	5.19	2.41
11	128.1	48.8	3.54	4.06
12	134.2	39.8	3.11	4.49
Total/Avg.	2856.1	75.45

37 of 43

Date – 02/08/2022 ( Morning shift )

	1	2	3	4	5	6	7	8	9	10	11	12	T.
Sliver Break	1	2	0	1	0	2	2	0	0	1	0	1	10
Material Lapped in Crush Roller	0	0	0	0	0	1	1	0	0	0	0	0	2
Chute Feed Faults	0	0	0	0	0	0	0	0	0	0	0	0	0
Filter Box Full	1	1	1	1	1	1	1	1	1	1	1	1	12
Can Change Problem	0	0	0	0	0	0	0	0	0	0	0	0	0
Maintenance	1	0	1	0	0	0	0	0	1	0	0	0	3
Total	3	3	2	2	1	4	4	1	2	2	1	2

38 of 43

Date – 02/08/2022 ( Morning shift )

	Production in KG	Efficiency (%)	Run Time	Idle Time
1	185.7	62.8	5.01	2.59
2	167.8	55.4	4.23	3.37
3	242.8	72.1	5.46	2.14
4	264.4	82.7	6.34	1.26
5	242.6	7.2	6.10	1.50
6	216.2	71.8	5.41	2.14
7	296.4	99.0	7.53	0.07
8	267.4	88.8	7.01	0.53
9	13.9	70.4	5.36	2.24
10	261.3	81.5	6.32	1.28
11	285.7	90.2	7.13	0.47
12	270.9	80.0	6.20	1.40
Total/Avg.	2715.1	71.83

39 of 43

Comparison Table

	Date
	Data Collection				Implementation				Result
	18	19	20	21	22	23	25	26	27	28	29	2
Prod. (Kg)	2945.1	2066.6	2122.4	2213.9	2624.1	2497.4	2648.9	1596.1	3144.5	2378.7	2856.1	2715.1
Faults	89	94	62	66	59	65	36	64	29	47	36	27
Avg. Eff. (%)	80.9	58.8	59.6	60.1	72.4	72.8	73.1	44	82.5	64	75.5	71.8

	Data Collection	Implementation	Result
Prod. (Kg)	9351.03	9366.55	11094.40
Faults	311	224	139
Avg. Eff. (%)	64.83	65.56	73.44

40 of 43

41 of 43

42 of 43

43 of 43

CONCLUSION

In this Project I determine all the faults for which the machine has stoped & tried to solve this at my best. In this Project the production increased an average 400 kg & machine efficiency increased by 8 % in average.