Stitchbonding & Rotor Spinning INDICON, KOlkata

Project Presentation

Stitchbonding & Rotor Spinning By

INDICON, KOlkata

Non Woven Jute Textiles

•Stitchbonding

This is the area completely untouched •It has immense possibility

1.Objectives a) To shorten the processing stages of operation in view of reduction in conversion cost. b ) To avail a fabric structure below 100gsm with good cover factor and make the jute fabric acceptable as apparel , garment, home textiles. c) To increase value addition to jute materials to 3-5 times over the present selling price of USD 833/MT[ INR 41,650] d) It will help jute mills to find ways to come out of traditional product ranges and bring new image for the jute mills and its fiber that is termed as fiber for Gunny.

Stitchbonding A process comprises of Carding, Cross lapper ends at Stitching head - Out put is home

Ranges of Stitchbonding Fabric where Jute can go in the weft and stitch the nonwoven layer by stitching with cotton or polyester yarns

Stitch bonding Process 1 Fiber stage bleaching / Dying 2 Stapling 3 Blending 4 Hopper feeding 5 Carding 6 Cross Lapping 7 Stitchbonding 8 Printing

9 Roll up

Here is the market

Prospect of Textile Grade Fabric lies here.

Non Woven line with Cross lapper

Stitchbonding Technology

Stitchbonding Features: 1) Working width (mm): 1,600, 2,400 2) Speed (r/min): 10 - 800 3) Gauges: 3.5, 5, 7 4) Stitch length variable: 0.5 - 5.0mm 5) Let-off mechanism: roller 6) Warp beam support: 30 or 21 feet free-standing floor creel 7) Fabric take-up: electronic 8) Needle type: slot needle 9) Pattern drive: 1 bar

Delivery End of Stitchbonding Machine

Technology supporters; Karl Mayer, Germany.

Maliwatt lines consisting of 3 FOR cards 2.2m wide 3 cross lappers of lay down 4m and 2 Maliwatt 3.7m machines.

Stitchbonded Fabric

Stitchbonded Fabric

Product out of Stitchbonding Technology

Made up bags for Export. Note: Hemp fiber almost similar to jute is Stitchbonded and made up as shopping bags.

If Hemp can do there is no reason why jute can`t do.

Out Put: 1.Jute will enter into textile application, such as apparel, made up garments, home textiles.Will change the profitability of mills by value addition of products to 3-5 times that of present price. i.e. USD 729 – 938/MT. Minimum target price will be USD1,667/MT

2 Economy of jute industry will be changed. 3 Product ranges will be below 100 gsm for apparel , garments, home furnishing. 1000 gsm for floor covering.

Budget INR 2,85,00,000 USD 598,279 Duration 30 months Location : IJSG to decide

Rotor Spinning at 35,000 rpm

Why Rotor Spinning? •Its speed can go up to 35,000 rpm •While existing Flyer spinning runs at 4,000 rpm •Ring spinning developed for jute runs at 6,000 – 10 000 rpm

Additional advantages are • Packages on to spool •Eliminates conventional spool winding •Spools will straight go to pre beaming/dressing •Per spindle production capacity goes up by 8.75 times.

Will it work on jute? •Yes •It was demonstrated by IRIS Engineering, Coimbator in 1982 to GOI / UNDP team, Headed by Mr. L.V.Saptharishi, I.A.S. • 8 lb yarn Hessian + batch at 36,000 rpm

Technology will be available from IRIS Engineering, Coimbator. Which has done work for ATIRA-

Yarn in spool

Schematic Drawing

Opening roller

Rot or Sliver from can

Budget •INR 77,66,000 •USD 1,61,793 Duration: 25 months

Payback period :4.9 years.

Past work on Rotor: •Pakistan Agriculture University Aziz Jute blended . Optimized 65%Jute and 35% Viscose •BJRI Kibir : Studied Jute blends 30% Jute 70% Cotton •IJT Set and Samanta worked on Rotor with blends •ATIRA In 1992-7 Under GOI/UNDP Studied Rotor Designed 90 mm rotor ran on Jute Cotton blends 30% Jute /70% Cotton . 35,000 rpm 6 `s count Spun 5 MT yarn •90 mm Rotor was satisfactorily •In 1992 -3 Duraiswasmi demonstrated 110 mm rotor at 35,000 rpm. With 100% jute

•In 70`s Russians commercialized Rotor spinning for Jute/Flax •Recently REITER , a pioneer in rotor manufacture agreed that they can design rotor for Jute at 65,000 rpm after seeing fiber in sliver form sent by Kamarhaty Jute Mill •Based on the conviction this project is designed.

Thank you