Skema Proses Produksi

1. Blowroom

This is the first step of yarn making. In blowing area, The LAKSHMI, TRUTZSCHLER machine works automatically open and taking clump of cotton fiber from 25 to 30 bale of raw material. For PV yarn, on this process also there is mixing of polyester fiber with viscose fiber and cleansing/ separating fiber from dirt within. Blendomat will produce an even mixture of fiber. Then it will go to carding machine.

2. Carding

From blowroom, clump of fiber opened and transform to length shape called sliver carding with The LAKSHMI, TRUTZSCHLER machine. It is straightened, stretched for the first time and separated as  short and long fiber. This is to keep the yarn strength as expected.  The carding machine can produce good quality sliver with low nep. The production capacity is 65 kg/hour. Sliver which already through the carding process stack neatly in some cans which automatically replaced when the can is full. The next process is drawing breaker machine.

3. Drawing Breaker

From carding process, sliver carding will be changed to drawing breaker sliver, where there is fiber stretching and parallelized ion process. The comparison of fiber and the length of drawing breaker sliver will determine the number of yarn produced. The RIETER, TOYODA machine completed with auto leveller which produce sliver with good evenness to be brought to drawing finisher machine.

4. Drawing Finisher

The functions of this process same with the drawing breaker machine. The result of this process is called drawing finisher sliver. The fiber within RIETER, TOYODA machine are more straight and already separated between the short and the long fiber. Same as drawing breaker, drawing finisher also have auto leveller which produce sliver with good evenness. Sliver then moved to roving machine.

5. Speed Frame

After through drawing finisher process, sliver transform to a long and smaller shape, called roving. It is rolled into bobbin roving using LAKSHMI, TOYODA, HOWA machine. Roving fiber will be stretched and parallelized again. The comparison of roving’s weight and length will also affect the number of yarn produced. Bobbin roving then transfered to ring spinning machine.

6. Ring Spinning/ Ring Frame

To be yarn, roving will through stretching, twist apply, and winding process. The yarn will be rolled in a cop which have different color. The purpose of this process is that every yarn can be differentiated to avoid mistake in the next process. Ring spinning RIETER, ZINSER, HOWA, TOYODA machine has capacity of 1008 spindle, completed with automatic droffing with maximal rolling. The rolling speed of this machine can reach 15.000 – 17.000 rotation perminute. Ring spinning machine can produce good quality yarn for knitting and weaving process. To avoid the machine stop work for a long time period, usually there are some staff specially assigned to take the output or droffing.

7. Winding

This LOEPE, MURATA QPRO, SAVIO machine are used to transfer rolls of yarn from cop to cone and all at once remove parts of yarn that to thick or too thin in certain length / weight into cone or  bobbin. Yarn shape can be paper cone or plastic cone which by then ready to pack or transfer to the next process. The winding machine is equipped with yarn clearer uster quantum and loefpe which produce best quality yarn for knitting and weaving.

8. Doubling

winding process, yarn will be entering the doubling process. Doubling function to double the yarn, here the single yarn will be change to double yarn and the rolls transferred to bobbin cylinder with certain dimension. Doubling MURATEC machine also equipped with yarn clearer which function is to avoid deviation of numbers of yarn which need to double and automatically will stop if the yarn that has been doubled less than two or more.

9. TFO (Two for One) Twister

In TFO area, yarn from doubling OERLIKON, MURATA, LEEWHA machine will be give antihan/twist; the rolls will be transferred to cone. TFO machine can produce product with low variant of twist and supplied with double winder which equipped with yarn clearer to support good quality of production, which function as to avoid any deviation from the number of yarn need to be doubling. The yarn produced can use paper cone or plastic cone, which by then ready to pack.

10. Packing

After all process finished, yarn are transferred to ultra violet room, the quality control will check the rolls of yarn’s perfection, and the yarn ready to pack. Yarns packed in a sack or carton/pallets is single yarn which produced from winding machine or double yarn which produced  from TFO machine. In this process, yarn must be separated as per kind number to avoid complain from customer.

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