Jute Manufacturing Process

 

Jute Manufacturing Process:

Raw jute, received in bales, is processed in jute mills to create various products like hessian, sacking, yarn, and bags. The entire process involves multiple stages from raw material handling to final packaging.

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Step-by-Step Jute Processing:

1. Selection:

• Raw jute bales (150 kg or 180 kg) are opened and inspected manually.

• Defective portions are removed.

• Bales are sorted based on their intended end-use (e.g., hessian, sacking wrap/weft).

• Selected jute is sent to the softening section.

2. Softening:

• Makes jute pliable and easy to process.

• Done by:

  • Softening machine.

  • Jute good spreader.

• Emulsion is applied using an emulsion plant to lubricate the fibers.

• Softened jute is now ready for piling.

3. Piling & Pile Breaking:

• Softened jute is stacked (piled) for 24 hours to allow moisture to penetrate.

• "Thermo fillip" action softens the tough root portions.

• Pile breakers feed the material into the carding machine.

• Root cutting is done before carding (5–7% of weight).

4. Carding:

• Jute fibers are disentangled and cleaned to form slivers (flat, ribbon-like fibers).

• Carding stages:

  • Breaker Carding:

    • Hand-fed or roll-fed.

    • Raw jute is turned into rough slivers.

  • Finisher Carding:

    • Makes slivers uniform in size and weight.

    • Prepares material for the drawing process.

5. Drawing:

• Reduces sliver width and thickness.

• Combines and levels several slivers to ensure uniform quality.

• Drawing Passages:

  • First Drawing: Blends and levels slivers from carding.

  • Second Drawing: Further smoothens and thins the sliver.

  • Third Drawing: Makes sliver ready for spinning by crimpling and finalizing.

6. Spinning:

• Slivers are twisted into yarns using spinning frame machines.

• Yarn is wound on bobbins.

• Machines have slip-draft zones and auto-doffing (bobbin replacement).

• Produces various types of yarns (e.g., Hessian Weft, Sacking Wrap).

• Yarn count: 8 lbs to 28 lbs, with flyer speeds up to 4000 RPM.

7. Winding:

• Converts yarn from bobbins into usable forms:

  • Spool Winding: For warp yarns.

  • Cop Winding: For weft yarns.

• Spools are larger packages, while cops are hollow cylindrical forms.

8. Beaming:

• Spool yarns are wound on beams for weaving.

• Warp yarns are treated with starch paste (includes TKP and antiseptic).

• Maintains moisture and improves weaving efficiency.

9. Weaving:

• Interlacing of warp and weft yarns to make fabric.

• Hessian looms require manual shuttle changes.

• Sacking looms have automatic cop loaders.

10. Damping:

• Finished fabric is unrolled and sprinkled with water to add moisture before finishing.

11. Calendaring:

• Fabric is passed through heavy rollers (like ironing).

• Enhances fabric appearance and smoothness.

12. Lapping:

• Folding hessian fabric into standard sizes for packaging.

13. Cutting, Hemming & Heracles Sewing:

• Cutting: Fabric cut into specified lengths for bags.

• Hemming: Edges folded and stitched to prevent fraying.

• Heracles Sewing: Side stitching to complete the bag formation.

14. Bailing:

• Finished products (bags or cloth) are stacked and pressed.

• Hydraulic press compresses and secures bundles using iron strips.