Waste in Spinning:
Waste is the material which is eliminated or generated during processing of material. These wastes can be reused as they extracted or eliminated by the machine during yarn manufacturing and some can be reused after processing either by the same industries or by other industries. Wastes that are usable are generally use for the coarser count yarn and open-end spinning. Wastes that are not reusable are sold out to the market at low prices. These wastes are seeds, coats, leafy matter, hard waste, etc. I have also published an article on List of Waste in Spinning Mill.
The waste occurring in the spinning mill can be classified normally as:
- Soft waste
- Hard waste
Soft waste: Soft waste is the waste in which fibers are in a relatively open structure and can be reused directly at an earlier feed stage. The soft waste is generated from the blow room to the ring frame. These soft wastes are reusable for producing a low quality of yarn.
Hard waste: Hard waste is the waste in which fibers are packed in a closed structure and need additional operations before reusing them with soft waste. These wastes are produced in ring frame, winding, weaving preparatory, and during weaving operations.
The waste can also be mentioned in the form of process and product waste:
- The process waste taken out in the blowroom, cards, and combers accounts for nearly 80% of the total wastes losses in cotton spinning and 50% in man-made and blends spinning. The process waste is decided by arriving at optimum levels required to achieve the desired yarn quality.
- In the product wastes which are incurred at each stage of processing, the control over product wastes has to be exercised through effective floor supervision.
Concept of Waste:
Waste Control (Previous Concept) = Waste Production + Waste Reduction
Waste Management (Present concept) = Waste Production + Waste Utilization
List of Waste in Cotton Spinning Mill with Percentage:
- Blowroom waste = [3%]
- Carding waste = [3-5%]
- Draw frame waste = [0.5%]
- Lap former waste = [0.5%]
- Comber waste = [12-18%]
- Simplex waste = [0.5%]
- Ring frame waste = [2-3%]
- Winding section waste = [1%]
Major Factors for Waste Generation in Spinning Mill:
- Errors and mistakes during weighing
- Loose cotton falling from bales while transportation
- Rejection from faulty work
- Poor sliver can topping and replenishing procedure
- Poor housekeeping
- Quality standards not met
- Poor work practices
- Improper material handling
- Poor condition and performance of machines
- Higher end breakage rate and lapping tendency
Waste Management in Spinning Mill:
Waste management refers to the use of source reduction and/or environmentally sound recycling methods prior to energy recovery, treatment, or disposal of wastes. It does not include waste treatment, that is, any process designed to change the physical, chemical or biological composition of waste streams. Waste minimization refers to strategies that are aiming to prevent waste through upstream interventions.
Waste management involves redesigning products and/or changing societal patterns, concerning consumption and production, of waste generation, to prevent the creation of waste.
The objective of any spinning mill is to produce a quality yarn at low cost which can be achieved with better quality of the raw material and the proper waste management system. Many mills are facing losses due to improper waste management. In the economics of the spinning mill the waste management plays a significant role. To illustrate, even an 1℅ improvement in the waste management would lead to saving of 20 lakhs Taka per year for a about 30,000 spindle of 20–40s count.
With the ever-increasing price of cotton, huge investments on sophisticated machines, and increasing labor wages, it is a highly challenging task for any spinning mills to enhance the productivity. To survive the huge competition, it is absolutely essential that waste incurred during the yarn manufacturing processes should be kept under control.
Controlling process wastes such as blow room and card droppings, flat strips, comber noil, sweep waste, and yarn waste, equal emphasis should also be laid on the control of soft wastes such as lap bits, sliver bits, roving ends, pneumafil and roller waste. This is because, apart from loss in production, reprocessing of soft wastes involves extra handling and deteriorates yarn quality. It should be noted here that the control on waste has to be concomitant with achieving the desired level of cleaning.
Textile wastes can be divided into two main groups: production wastes and post-production wastes. Production wastes are basically raw materials of each production step that cannot be put into end product due to different reasons. For yarn spinners, these wastes can occur during cleaning of the fibers or combing out short staple fibers from the long ones in comber machine, etc. These clean/unclean wastes in fiber form can be reused. After spinning mill, there are wastes in yarn and fabric forms, and they need recycling to be put again in production. Post-production wastes are generally worn out cloths, which can be recycled and may be used again in textiles or utilized in other products.
Factors for Waste Management in Spinning Mill:
- Raw materials selection
- Spindle speed
- Setting (Rollers, R/T, Traveller cleaner etc)
- Twist of yarn
- Machinery condition
- RH% and Temperature
- Proper material handling
- Adequate supervision
For the management or controlling of waste in spinning mill need waste investigation. The waste investigation should be done in order to take preventive measure as well as to take action where abnormality is noted in processes. Investigate the existing system of waste collection for different types of waste. Follow up waste collection procedure. More effective and reliable method of collecting and reporting of wastes could be considered where there is malfunctioning. Besides for reducing waste and control in spinning mill these steps may taken. Such as investigation of waste problems, suggestions needed, work out details, and set-up control. Every textile industry should pay attention on waste management in order to get improve the productivity and profitability of the organization. I think these will be effective to control waste in spinning mill.
- Waste Management in the Fashion and Textile Industries Edited by Rajkishore Nayak & Asis Patnaik
- Pollution Control in Textile Industry By S. C. Bhatia
- Sustainable Technologies for Fashion and Textiles Edited by Rajkishore Nayak
- Process Management in Spinning by R. Senthil Kumar
- Process Control and Yarn Quality in Spinning By G. Thilagavathi, and T. Karthik
You may also like:
- Types of Waste in Spinning Mill
- Process of Controlling Waste in Comber
- Blowroom: Objectives, Functions and Operations
- Cotton Yarn Spinning Process Step by Step
- Ring Spinning Machine: Drafting System, Different Parts and Functions
Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.