e-F@ctory For Synthetic Spinning

Synthetic spinning could have actually been made much more simpler and cleaner then the current process. Synthetic fibres unlike cotton have exactly the same staple lengths, the same tenacity, elongation, moisture and uniformity.

Given the profile of the fiber, the spinning does not really need a rigorous set up for parallelism and homogeneity. Which practically means, that on the carding machines, the sliver only needs a set of extended draw rollers and is already good enough for feeding the simplex machine in conventional spinning.

The blow room with a simple bale opener and fibre individualize r is good enough to chute it into a Carding Engine. Current blow room with beaters etc is not required at all. However, a good carding engine will deliver a good yarn spec.

Drawing is totally superfluous for synthetic spinning. The whole purpose of drawing is getting the right hank and homogenizing the sliver line. Homogeneity is not required for man made fibers and paralleling is already enough in the carding stage and can be further extended by having a set of draw rollers on the carding machine itself.

So, if one is spinning on MVS system, then the carding cans can be directly used on the machine and you are ready with spun yarn.

Carding and MVS is already a spinning mill. All it needs is less then 50 operators to give a production same as that of 25,000 spindles of ring spinning.

A good designer would rather have a track laid out for central repository of card cans so the cans move automatically on getting loaded. From the central repository, they get automatically moved to the MVS with a blue tooth call and replaces the runout can. A robot hand then fixes the sliver into the chute of MVS, which sucks and does the needful.

Cans to have artificial intelligence loaded on it to respond to all wireless calls and the toy motor then drives it to the calling station. All of which is programmed automatically with the requirement of the machine. ( If you can control a toy aircraft and toy cars with radio waves, then moving cans is another child`s play)

Final packages from MVS get picked by the moving belt on the top of the machine and is unloaded directly at the end of the machine, where the Trolley collects it and makes it pass the water shower chamber and then a small RF chamber for getting the right conditioning

Conditioning machines in the current form are a disaster. ( Next Blog Coming soon on this system)

Packaging is already well automated. Only that at the MVS winding head, after doffing ,it should have a bar coding system on the cone to track it all the way till the warping machine.

A control room with a closed loop vision system monitors the process and vision sensors show real time quality of yarn.

The extension of this mill is the Polyester staple fibre plant or viscose stable fibre plant itself, where after the cutter, one needs to chute the fibre directly to the carding and no blow room would be required. From the carding , follow the MVS route. Hence a PSF/ VSF plant is now making synthetic yarns by just adding two sets of machines.