Spinning Technician

ITI Spinning Technician Syllabus (English)

Course Overview

• Trade Name: Spinning Technician
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in operating, maintaining, and troubleshooting spinning machinery for yarn production, equipping them for roles as spinning technicians, shift supervisors, or quality controllers in textile mills, spinning units, or garment industries, or for self-employment in textile maintenance or consultancy services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Textile Industry: Overview of spinning, types of fibers (cotton, polyester, wool), yarn applications.
• Safety Practices: PPE (gloves, masks, earplugs), machine guarding, fire safety, handling fibers.
• Fiber Technology: Natural fibers (cotton, jute), synthetic fibers (nylon, acrylic), fiber properties (length, strength).
• Spinning Process Basics: Ginning, carding, combing, drawing; role in yarn formation.
• Spinning Machinery: Blowroom, carding machines, draw frames; components and functions.
• Tools and Instruments: Wrenches, vernier calipers, tachometers; usage in maintenance.
• Engineering Drawing: Reading machine layouts, spinning process flowcharts, component diagrams.

Trade Practical

• Safety Drills: Using PPE, handling fiber dust, operating fire extinguishers, securing machines.
• Fiber Handling: Sorting cotton, polyester fibers, checking for impurities.
• Machine Operation: Running blowroom machines, feeding fibers, monitoring output.
• Carding Practice: Setting up carding machines, adjusting rollers, cleaning waste.
• Measurement Tasks: Using vernier calipers to check roller gaps (±0.1mm), measuring spindle speed.
• Drawing Interpretation: Marking machine components based on spinning process diagrams.
• Project Work: Setting up a blowroom-to-carding sequence, producing clean sliver output.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Spinning Processes: Roving, ring spinning, open-end spinning; yarn twist, count systems (Ne, Nm).
• Machinery Maintenance: Lubrication, belt tensioning, roller alignment; preventive maintenance schedules.
• Yarn Properties: Strength, elongation, evenness; factors affecting yarn quality.
• Quality Control: Testing yarn count, twist per inch (TPI), detecting neps and slubs.
• Pneumatic Systems: Air jets, suction systems in spinning; maintenance basics.
• Electrical Basics: Motors, starters, sensors in spinning machines; safe handling.
• Textile Calculations: Draft calculations, production rates, waste percentage estimation.

Trade Practical

• Roving Operations: Operating speed frames, adjusting draft zones, producing roving bobbins.
• Maintenance Tasks: Lubricating bearings, aligning rollers, replacing worn belts.
• Yarn Testing: Measuring yarn count with wrap reel, testing TPI with twist tester.
• Quality Checks: Inspecting slivers/rovings for unevenness, removing defects.
• Pneumatic Work: Cleaning air filters, checking suction systems for blockages.
• Electrical Checks: Inspecting motor connections, resetting tripped starters.
• Project Work: Producing a batch of roving from sliver, ensuring uniform twist and count.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Advanced Spinning Systems: Compact spinning, air-jet spinning, vortex spinning; advantages.
• Troubleshooting: Diagnosing machine faults (roller slippage, yarn breaks), root cause analysis.
• Automation in Spinning: PLC basics, sensors for yarn monitoring, automated doffing systems.
• Yarn Faults: Causes of thick/thin places, hairiness, weak yarn; corrective measures.
• Textile Testing: Uster tester, tensile strength testing, evenness testing standards.
• Energy Efficiency: Optimizing machine settings, reducing power consumption in spinning.
• Safety Standards: OSHA guidelines, textile dust control, machine safety audits.

Trade Practical

• Advanced Operations: Running ring frames, setting up air-jet spinning machines, monitoring yarn.
• Troubleshooting Tasks: Fixing yarn breaks, adjusting draft rollers, recalibrating spindles.
• Automation Practice: Monitoring PLC displays, resetting sensors, checking auto-doffing.
• Yarn Testing: Using Uster tester for evenness, conducting tensile strength tests.
• Energy Optimization: Adjusting machine speeds, measuring power usage reductions.
• Safety Audits: Inspecting dust extraction systems, conducting mock safety drills.
• Project Work: Operating a ring frame to produce yarn with specified count (e.g., 30 Ne), testing quality.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Modern Spinning Technologies: Rotor spinning advancements, IoT for predictive maintenance.
• Production Management: Planning spinning schedules, optimizing output, waste management.
• Quality Assurance: ISO 9001 standards, six sigma in yarn production, defect tracking.
• Environmental Practices: Recycling textile waste, effluent treatment in spinning mills.
• Entrepreneurship: Starting a spinning consultancy, costing, trends in textile markets.
• Textile Trends: Sustainable fibers (organic cotton, recycled polyester), smart yarns.
• Regulatory Compliance: Textile pollution norms, safety audits for spinning units.

Trade Practical

• Modern Machine Operations: Running rotor spinning machines, optimizing settings for output.
• Production Tasks: Planning a shift’s yarn production, minimizing downtime, logging data.
• Quality Assurance: Conducting full yarn testing (count, strength, evenness), preparing QA reports.
• Environmental Work: Sorting recyclable waste, inspecting effluent treatment systems.
• Field Exposure: Hands-on training in textile mills or spinning units (4-6 weeks).
• Maintenance Practice: Overhauling a spinning machine, replacing critical components.
• Project Work: Producing a batch of yarn (e.g., 40 Ne) with complete quality testing and documentation.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Yarn count conversions, draft ratios, production efficiency formulas.
  • Science: Fiber friction, tensile properties, air dynamics in spinning.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Spinning machine assemblies, roller arrangements, process flow diagrams.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Technical reporting, client interaction, teamwork in mills.
  • IT Literacy: Using textile software, PLC interfaces, online textile resources.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like machine operation, yarn testing, troubleshooting, maintenance.
• Evaluation Criteria: Yarn quality, machine uptime, safety adherence, production efficiency.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Spinning technician, shift supervisor, quality controller in textile mills, spinning units, or garment industries.
• Self-Employment: Textile maintenance services, consultancy for spinning units, fiber trading.
• Further Studies: Diploma in Textile Technology, certifications in quality control or automation.