Bale management refers to the process of inventory control & selection of fibre according to its properties and also to mix fibre homogeneously to get consistent production & quality of yarn.
The function of Bale Management is very much unique to the Spinning Industry. The module should have a function in such a way that the system should automatically generate the issues for Mix or a Count, where all the Lay down or Issues should have a consistent quality parameter both in terms of average and SD.The system should be capable of generating the Issues or Lay down as per the User requirements like:
- Standard Distribution – The average Quality of all Parameters are same from the first issue to the final issue.
- Normal Distribution – The Issue should contain the required average for the selected Quality parameters and it should follow the theory of normal distribution.
- Moving point distribution – If the user prefers to have a very narrow working range for the selected Quality parameter, the system should generate the issue and according to the availability the shift in the parameter should happen gradually till all the bales are exhausted in the Lot. For example if the User would like to have the Micronaire working range of 4.2 to 4.6. After exhausting the bales in 4.6 Micronaire, the system should automatically shift to 4.1 to 4.5. After exhausting 4.5, the system should go for 4.0 to 4.4.
Factors considered for efficient Bale management system:
- Origin (Country of origin)
- Length & Length uniformity
- Fibre fineness (MIC value, ugm/inch)
- Strength & Elongation
- SIC (Spinning Consistency Index)
- Trash% etc.
Which should be Consider in a particular lot?
- Micronaire range of the cotton bales used should be same for all the mixings of a lot.
- Micronaire average of the cotton bales used should be same for all the mixings of a lot.
- Range of color of cotton bales used should be same for all the mixings of a lot.
- Average of color of cotton bales used should be same for all the mixings of a lot.
- Range of maturity coefficient of cotton bales used should be same for all mixings of a lot.
- Average of maturity coefficient of cotton bales used should be same for all mixings of a lot.
It is important to have an effective bale management system to ensure correct fiber combinations. In cotton lines we employ automatic bale management systems to certify correct mixing percentages for consistent fibre properties to avoid shade variation during fabric dyeing. Cotton bales are stocked up to 6 months in order to provide our repeat customers with consistent quality from the same batch of fibers. In synthetic lines, automatic weighing blenders are used to measure exact blending percentages. Blended fibers are maintained up to 20 days to ensure that every customer receives a homogenous blend of yarns with low barrenness.