Technical Consultancy in Textiles

Key words Contact Me About Me Areas of Consultancy Important Contributions Tips Yarn and Cloth Test Methods Conversion Factors Modern Developments Irregularity of Yarns Training Course Norms article Hairiness Nonwovens ASTM Standards

Links

Contact Me

022 25280767, 044 28116771 Mobile No 9869716298
mail to Balasubramanian.N
1. I, Rajeswari, 36, 17th Road,
Chembur, Mumbai 400 071, 2. 21, Ganesh Street, Ground Floor,Gopalapuram, Chennai 600086

Key words
"Consultancy,Quality, Productivity, Training, Spinning, Nonwovens, Testing"
Name: Dr.N.Balaubramanian

About Me

1. • B.Sc.(Physics), Madras University,
   • B.Sc(Tech) in Textile Technology(Madras Univ.)
   • M.Sc in Textile Physics(Bombay Univ.)
   • Ph.D. in Textile Technology (Leeds Univ.)
   • Associate of Textile Institute, Manchester
   • Fellow of Textile Institute(Manchester),
   • Has been conferred Honorary Fellowship of Textile Institute, Manchester, UK in 2005
     Writeup
2. Has over 45 years of experiance in R&D and Consultancy in spinning, Testing, Quality Control, NonWovens, Training, ISO 9000,
3. Retired Joint Director of BTRA, Mumbai
4. Has been providing consultancy to leading spinning and composite mills and Nonwoven units in India
5. Has over 120 publications in foreign and indegenous journals

• Areas of Consultancy
  Provides Consultancy for improving
  Quality of product
  Productivity
  Waste Control
  Overcoming Trouble shooting problems
  Development of new products like Geotextiles, industrial and Technical Textiles, Nonwovens, Composites etc.
  Introducing ISO 9000 Management systems and get certification
  Statistical Quality Control
  Energy Saving in Spinning
  Training of Supervisors and QC personnelTraining Course
  Project prepararation, appraisal and Machinery selection
  Technical audit and Certification as Chartered Textile Technologist
  Recruitment of staff

  Fields of Consultancy

  • Spinning
  • Nonwovens
  • Testing
  • Geotextiles
  • Technical Textiles
  • Automobile Textiles
  • Medical Textiles
  • Composites
  • Related Fields
  Online Consultancy is also provided in the above areas. To avail this send your query or problem by post or Email. Assistance will be given by Email on chargeable basis.

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  Important Contributions
  
  
  1. Hairiness of yarns, Indian Textile J., 2007 Feb, p31
  2. Tips to mills for getting full benefits of modernisation, I.Textile J, 2005 Dec, p 29
  3. Merits of Lea CSP and Lea Ratio, J. Textile Association, 2005 April, p94article
  4. Relative merits of Polypropylene and Polyester, I Textile Journal, 32, 2004 Dec, p32
  5. Control of count variation in yarn, I. Textile Journal, 2003, Jan, p15article
  6. Intimacy of mixing and Blend variation, J. Textile Association, 2003, Nov, p20article
  7. Influence of cotton quality on yarn and fabric quality and performance, I.Textile Journal, 1995 Nov p46
  8. Developments in Drafting at Ring Frame, I Textile J, 2000 Septr, p31article
  9. Measures for improving yarn quality and ring frame productivity, I.Textile journal, 1995, Feb, p 108 1995 March, p 20
  10. Curbing Yarn faults, I. Textile Journal, 1997 May p 12
  11. Modern Spinning systems, I. Textile Journal, 1995 Dec p 66
  12. A study of short term variations in cotton slivers Part I and II J Textile Institute 1965 56 T551 and T556
  13. Influence of rotor speed, rotor diameter and carding conditions on yarn quality in OE spinning, Textile research J. 1983 Aug p497
  14. Comparative studies on air-jet and ring spun yarn fabrics, J Textile Assn. 1995 May p 23
  15. Friction Spinning A critical Review I Journal Fibre & Textile Research 1992 Dec p246
  16. Control of roller lapping in spinning, I Textile Journal, 1998 March p18
  17. Studies on some factors in carding for upgradation of cotton yarn Quality, J. Textile Assn. 1993 May p11
  18. Effect of top roller weight, apron spacing and top roller setting on yarn quality, Textile Research J 1975 April p 322article
  19. Modifications to drafting system for improvement in yarn quality, I Journal Fibre & Textile Research, 1995 Dec p169article
  20. Developments in drafting at ring frame, I Textile Journal 1995 March p 20article
  21. Influence of fibre and processing factors on yarn Imperfections, I. Textile Journal 1995 July p 14
  22. Fibre properties by HVI and conventional testing at different stages of spinning, I Journal of Fibre & Textile Research 1995 June p 63
  23. Measures to reduce energy consumption in spinning, J. Textile Assn. p 115article
  24. Influence of weft count variation on warp way creases in fabrics, I. Textile Journal, 1996 Oct p 66
  25. Influence of eccentricity in drafting roller on yarn irregularity, I Textile Journal 1998 Dec p 24
  26. Effect of spinning conditions on tensile properties of core spun yarns, J Textile Institute, 1970 Nov p534
  27. Improving yarn appearance and imperfections in the mills J Textile Assn 1977 June p67article
  28. Influence of spinning condtions on tensile properties of core-spun yarns, J. Textile Institute, 1970 Vol61 T534article
  29. Influence of conditioning on U% of sliver, I Textile Journal 1994 June p67
  30. Improving regularity of material at Drawframe and speedframe, I Textile Journal 1994 May p34
  31. Influence of grey cloth width on warp way streakiness in fabric, I Textile Journal 1993 June p82
  32. Measures for upgrading yarn quality with polyester blends, Man-made Textile in India 1993 Jan p14, Feb p51
  33. Optimisation of ringframe parameters, I Textile Journal 1974 Sept. p73
  34. How to effect yarn quality improvements, Textile Magazine 1991 Aug p 25
  35. Contribution of ring frame drfting condition to yarn count variability in fine counts, I Journal Fibre & Textile Research 1990 Dec p198
  36. Improvements in yarn quality from Tandem card, I Journal Textile Research 1981 June p53
  37. Weft bars in man made fibre blend due to torsional vibration ofback rollers at speed frame, J Textile Assn 1985 Nov p183article
  38. Factors affecting doubling tension and strength of voile yarns under mill conditions I Journal Textile Research, 1977 March p13
  39. Strength and elongation of cotton, polyester and polyester,cotton blend at different stages of manufacture, Textile Research J 1974 Feb p106article
  40. Effect of disorientation and direction of feed of hooks in input sliver on drafting irregularities and yarn quality, Textile Research J 1971 Sept. p750
  41. Translation of strength from single yarn to two fold yarn and from multiple strand to fabric with polyester, cotton and polyester/cotton blends, Textile Research J 1978 July p389
  42. Mixing Cost reductions by upgrading through combing, J Textile Assn. 1981 May p85
  43. A study of the relationship of yarn irregularity with fibre properties and its effect on yarn strength I Textile Journal, 1961 Aug 71 p 561
  44. Contribution to the study of B-L curve of cotton yarns Textile Research J 1963 Sept, 33 p697
  45. Upgrading by Apron drafting Textile Research J 1962 Nov
  46. Relation between yarn irregularity, draft and fibre properties, J Textile Institute(Trans) 1964 July 55 T377
  47. A note on the determination of bulk torsional rigidity of cotton fibre, Indian Cotton Growing Review, 1961 Nov 15 p358
  48. Influence of draft distribution on irregularity, I Textile Journal 1964 Jan
  49. A comparative study of visual assessment of yarn irregularity with Uster Evenness Test results, Indian Cotton Growing review 1964 March
  50. B-L curve of cotton yarns, Textile Research J 1965 march
  51. Variance Draft Relations J Textile Institute, 1966 57 T363
  52. A study of irregularity added in apron drafting, Textile Research J, 1969 39 p155
  53. Effect of processing factors and fibre properties on the arrangement of fibres in blended yarns, Textile Research J 1970 40 p129
  54. Effect of mechanical processing variables in drawing on sliver irregularity, Textile Research J 1974 44 p111
  55. Effect of stage of blending on quality of polyester/cotton blends, Indian Textile J 1974 84 p135
  56. Factors affecting irregularity of post combed Drawing sliver, J Textile Association 1974 35 p75
  57. Undercasing settings affect cleaning in the licker-in region, I Textile journal 1974 84 11 p71
  58. Causes of twist variation, J Textile Association 1974 35 p131
  59. Optimisation of Ring frame drafting parameters, I Textile J 1974 84 p73
  60. Effect of input roving hank, roving twist and apron spacing upon yarn quality and ringframe end breakages, J Textile Association 1974 35 p143
  61. Influence of ring rail speed on end breakages at ring frame, J Textile Institute 1974 65 T504article
  62. Fibre breakages in Blow room, J Textile Association 1983 Sept, p167
  63. Breaks due to soft ends in weaving, J Textile Association 1983 July p119
  64. Nep generation with polynosic fibres in relation to surface characteristics of fibres, Indian J Textile Research 1983 8 p95
  65. Weft bars due to torsional vibration of back rollers at speedframe, J Textile Association 1985 Nov p183
  66. Blending small amount of viscose with cotton, J Textile Association 1986 Septr
  68. End breakage variation over the chase length, J Textile Institute 1975 66 T18
  69. Defective loading in Top Arm drafting, J Textile Association 1975 36 p69
  70. Cotton fibre maturity from Micronaire with variable volume of sample, Textile Research J 1975 45 p822
  71. Improving the yarn appearance and imperfections in the mills, J Textile Association 38 p139
  72. Stationary Clearer will reduce roller lapping, I Textile Journal 1979 89 p89
  73. Influence of carding conditions on Rotor spinning performance and yarn quality, I J Textile Research 1985 10 p158
  74. Modifications to shuttle protector and shuttle eye cutter to reduce lashing in, J Textile Association, 1986 47 p49
  75. Measures to reduce fluff liberation at Speed Frame, BTRA Technical Report No 04.2.6 1987 March, J Textile Association 1988 49 p137
  76. Effect of adding viscose or long staple cotton on characteristics of Open End and Ring spun cotton yarns and fabrics, Indian J Textile Research 1987 12 p57
  77. Improvements in yarn quality with short staple cottons by modifications to the top arm drafting at ring frame, I Journal Textile Research, `988 13, p33
  78. Benefits of spraying silica dispersion on cotton, I Textile Journal 1988 98 p102
  79. Characteristics of imperfections in cotton and blend yarns, I Journal of Textile Research 1988 Dec p192article
  80. Influence of Material No setting in Electronic clearer on clearing efficiency, J Textile Association, 1989 50 p151
  81. Some maintenance measures to control hairiness of polyester blend yarns, J Textile Association 1990 50 p297
  82. Influence of twill direction on fabric strength, J Textile Association 1991 May 52 p5
  83. Nonwoven moulded Automobile carpets, I Textile Journal, 2003 June, p13article
  84. Needle punched Nonwovens, I Textile Journal, 1996 Aug, p 18Article
  85. Engineering needle punched nonwovens to achieve desired physical properties, I Journal of fibre & Textile Reearch, 1990 June p 41
  86. Tensile and absorbancy characteristics of cellulosic Non wovens, I Journal Fibre & Textile Research 1994 June p53
  87. Opening size and water permiability in Nonwoven Geotextiles, I Textile Journal 1991 June p 26Abstact
  88. Critical factors affecting properties of thermal bonded Nonwovens, I Journal of Fibre & Textile Research, 1994 Sept. p 209
  89. Some critical manufacturing parameters affecting the properties of nonwoven dust filters, I Journal Fibre & Textile Research, 1993 March p 8
  90. Influence of processing conditions on functional properties of hiigh loft waddings
  
• Tips
  I.Measures to reduce Roller lapping
  1. Avoid low Microanaire and sticky cottons, Check for honey dew(Benedicts solution), sugar content and wax content; reducing sugar should not be more than 20%, wax content should not be more than 1%
  2. Check Pneumafil Pressure at Ring frame, should be above 8inches at off side
  3. Apply Anti Lap solution like Vickelstaff or Liquimix on cots
  4. Increase the schedule for cot buffing, once in 2-3 months
  5. Increase offset of front top roller
  6. Avoid soft cots with p/c & p/v blends
  7. Apply berkolisation treatment to cots or expose them to sunlight for 8 hours
  8. Reduce RH in department
  9. Reduce the amount of tint applied on polyester, should not exceed 0.2%, check compatability of tint to spinfinish
  10. Check polyester fibre for spinfinish, variations in spin finich, static generation, agglomerations of oligomer on surface, abnormalities
  11 Avoid damage to cots by training siders in removal of lapping
  12. Use bigger diameter cots upto 30 mm for cotton and p/c blends
  13. Increase weight of clearer roller, use plush type of clearer cloth
  

  
  II. Measures to improve Yarn quality
  1. Avoid low Micronaire cottons, Minimum Micronaire 20s-4, 40s-3.8, 60s-3.6, 80s -3.4, 100s -3.2, Avoid cottons with high trash and seed coat content
  2. Avoid harsh Blowroom treatment, 8% Trash - 6 beating points, 5% trash i. Micronaire 4 -5 beating points ii Micronaire 3.5 - 3 beating points, 3% trash i. Micronaire 4 - 3 beating points ii. Micronaire 3.5 2.5 beating points, 2% trash - 2 beating points
  3. Carding - i.Higher cylider speed permissible by card design ii.Lowerproduction rate iii. Finer hank of sliver at a given production rate 1v. Higher wire point density for cylinder v. Higher flat speed vi. Petrol washing of cylider vii. Progressive reduction in grinding schedule with age of wire
  4. Combing - i. Use of half laps with higher combing cycle ii. Precision in setting of half lap to nipper and top comb depth
  5. Draw Frames - i. Optimise Roller Setting and Break draft, Front Zone setting - 2.5% span length + 2-3 mm, Break draft, Breaker - 1.3, Finisher - 1.1, post combed - 1.05 2. Use lowest permissible calender roller tension draft 3. Check top roller pressure 4. Check Autoleveller performance, CV of 0.5m should be below 1.2%
  Speedframe 1. Optimise Back Zone setting and spacer in front zone 2. Check top roller pressure 3. Use bigger diam cots 3. Use appropriate condenser size.
  Ring frame 1.Optimise Ringframe draft 2. Use softer cots(65 deg.) for cotton counts 3. Use step nose bar 4. Use bigger cot diam upto 30 mm 5. Employ heavier top roller pressure 6. Optimise spacer 7. Use low break drafts 8. check for drafting defects

  

  
  III. Control of long thin faults
  Long thin faults in yarns are a major source of rejections, particularly in exports. The defect shows up as a thin line in woven and knitted fabric especially in dyed goods. To overcome their occurrence

  • Avoid excessive fibre parallelisation, that leads to fraying of fibres, in drawing sliver. In post combed drawings, it is adequate to have 2 post combed drawing passages. 3 passages will lead to fraying. In blend material with drwframe blends, use only 2 passages after blend drawing for the same reason
  • Minimise tension draft in creel of speed frame and calender roller tension draft at drawframe.
  • Can springs should come up freely as the sliver exhausts in creel of speedframe. They should not get jammed or be tilted. To avoid tilting, tie 3 springs at the bottom of canspring bottom. Distorted and deshaped cans should be promptly reconditioned or replaced
  • Use tongue and grooved calender rollers at drawframe. Increase pressure on calender rollers to make the sliver more compact
  • Sliver can should be aligned in relation to speedframe spindle it feeds.
  • Check back and middle rollers of speedframe for torsional vibration, particularly in polyester blends. This leads to very short wave irregularity in roving which shows up as a wave after drafting at ringframe
  • Minimise stretch at creel of ring frame by proper positioning of creel guide rod
  • Check sensitivity of creel stop motion at drawframe. When a break occurs in creel, the drawframe should stop instantanously without a time lag.
  • Close down the setting for long thin places at winding
  • H₂ and I faults should be nil in wound package
    

  • 
    1V. Control of Count Variation
    Count variability increases strength variability, adds to weak places, causes ring cuts, poor winding efficiency, weft bars and bands, weft tear in Shuttless looms, warp way creases in processed fabrics and in general to rejections.Maintenance of average count within limits set by buyer will be difficult with high count CV. Count CV% should be within 1.2 to 1.6 with autoleveller at Drawframe. To minimise count variability
    • Avoid variation in mechanical draft between frames.Variation in mechanical draft arises from
      1. Lack of sufficient stock of change pinions
      2. Using pinions differing by one tooth on the two sides of a frame, ostensibly to achieve an average count close to nominal
      3. Spinning the same count on frames of different makes and drafting system and age
    • Take precaution to minimise slippage of top roller.Slippage arises from
      1. Inadequate weighting
      2. Insufficient grip. This can be remedied by more frequent buffing, use of bigger diameter cots, by ensuring the required tolerance for taper.
    • Adopt Group control of count and change of cp
    • Avoid stretch of roving in creel of ringframe and front and back of Speedframe. Stretch at creel at ringframe can arise from
      1. low roving twist
      2. Improper positioning of creel guide rod
      3. Misalignment of roving bobbin in relation to roving guide
      Stretch at creel of speedframe can arise from
      1. Excessive fibre parallelisation in sliver due to too many drawing passages
      2. Too wide a trumpet at drawframe
      3. Inadequate weighting of calender rollers at drawframe
    • Use proper wrap block to check wrapping at speedframe
    • Check for any trend in variation of hank of roving from full size to empty position due to use of improper builder wheel
    • Check the sensitivity and functioning of autoleveller. This should be done by checking variance length curve of sliver with and without autoleveller
    • Avoid mechanical defects in drawframe
    • CV of 0.5 m wrapping at drawframe must be within 1.2-1.3
    • Shift to shift variations in average hank of finisher drawing sliver hank and card sliver hank should be minimised
    • Frequent unwarranted changes of change pinion at drawframe cause count variation

Other Places to go:

Links

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N.Balasubramanian