The document provides information on the physical properties of raw cotton including fiber length, fineness, strength, cleanliness, and chemical deposits. It then discusses the components and processes of a blow room line. The key goals of the blow room are to open compressed cotton fibers with minimal damage, remove impurities, and create an evenly blended sliver. Common blow room machines include bale openers, mixers, cleaners, and scutchers which use beaters, grids, and air flow to open, clean, and blend the fibers into a uniform lap for input to the carding process.
This document compares ring spinning and rotor spinning methods of yarn formation. It discusses that rotor spinning is a more recent method that omits the step of forming a roving. In rotor spinning, fibers are fed into a rotary beater and deposited onto the sides of a rotating disc called a rotor, where they are twisted without requiring package rotation. Rotor spinning allows for higher twisting speeds with lower power usage compared to ring spinning. It provides characteristics like higher productivity, larger sliver/package sizes, less power consumption, and more automation/flexibility. The document provides details on the parts of a rotor spinning machine and compares various parameters of ring-spun and rotor-spun yarns.
The document discusses the carding process which involves opening, cleaning and assembling fibers into a sliver through different sections of a carding machine like feed, licker-in, cylinder and doffer. It explains the objectives, necessities and zones of carding along with details of components like types of clothing, their functioning and settings that are important for quality carding. The document also covers developments in carding technology and types of drives used in modern carding machines.
This document discusses various types of fabric structures and weaves. It begins with an introduction to the main methods of fabric production - weaving, knitting, and non-woven. It then focuses on woven fabrics and provides details on the classification, representation, and basic elements of woven designs. The key woven structures discussed include plain weave, twill weave, and satin/sateen weave. For each weave type, the document explains the weave repeat, shift, characteristics, and examples. It also covers various types of draft plans and their uses for different woven structures.
The comber is a machine that prepares cotton fibers for spinning into yarn by removing short fibers and impurities. It improves the quality characteristics of yarns such as evenness, strength, and cleanliness. To achieve these quality improvements, the comber must eliminate short fibers, remaining impurities, and neps from the fiber material while forming an optimal sliver. Modern comber preparation systems use a draw frame followed by a sliver doubling machine like a UniLap to prepare uniform batts for feeding into rectilinear combers, which have stationary detaching rollers and swinging nippers to further clean and parallelize the fibers.
The document discusses the draw frame machine used in textile processing. It begins by outlining the objectives of studying the necessity, objectives, construction, and working of the draw frame. It then provides details on:
- The drawing process and how it elongates and levels slivers
- The objectives and functions of the draw frame machine
- The main sections of the draw frame including the creel, drafting, sliver condensing, and coiler sections
- Factors that influence drafting such as fiber properties, drafting arrangement design, and drafting conditions
- The behavior of fibers in the drafting zone and the role of fiber-fiber friction
- Types of irregularities that can occur during drafting
The
Cotton is a natural fibre available easily and abundant quantity. It is a most suitable fibre for textile spinning & clothing due to it’s good spinnability & human friendly characteristics. As cotton is a natural fibre hence it’s properties also affected with several other factors which create variation in fibre properties, these variations also affect spinning processes & it’s products Quality in multi dimensions. Each fibre characteristic impact individually and collectively on spinning process or at ultimate product quality. Revolutionary changes observed in last two decade in the field of spinning machineries where processing speeds greatly increased to enhance production rate. Not only production rate of spinning machines increased but speeds of it’s downstream processes also increased simultaneously which requires better quality of yarn for smooth process and without any interruption to get the maximum efficiency. Hence now it is most important to co-relate fibre properties with respect to it’s consumer process competency. In this article we will discuss the different cotton properties and it’s impact on spinning process and product quality in present prospective and will try to minimize the impact of poor fibre properties on process or product Quality through better Mixing plan selection.
The document discusses combing preparatory processes. It describes the need for combing preparatory, which includes fiber straightening, reversing fiber flow, and producing a flat sliver. Traditionally, this involved a sliver lap machine and ribbon lap machine, but now mostly uses a draw frame and sliver lap machine. The objectives of combing preparatory are to straighten fibers, reverse flow, maximize leading fiber hooks, and produce a flat sliver. Different machine types and their functions are explained, including parameters that influence the combing operation and quality of the finished product.
This document compares ring spinning and rotor spinning methods of yarn formation. It discusses that rotor spinning is a more recent method that omits the step of forming a roving. In rotor spinning, fibers are fed into a rotary beater and deposited onto the sides of a rotating disc called a rotor, where they are twisted without requiring package rotation. Rotor spinning allows for higher twisting speeds with lower power usage compared to ring spinning. It provides characteristics like higher productivity, larger sliver/package sizes, less power consumption, and more automation/flexibility. The document provides details on the parts of a rotor spinning machine and compares various parameters of ring-spun and rotor-spun yarns.
The document discusses the carding process which involves opening, cleaning and assembling fibers into a sliver through different sections of a carding machine like feed, licker-in, cylinder and doffer. It explains the objectives, necessities and zones of carding along with details of components like types of clothing, their functioning and settings that are important for quality carding. The document also covers developments in carding technology and types of drives used in modern carding machines.
This document discusses various types of fabric structures and weaves. It begins with an introduction to the main methods of fabric production - weaving, knitting, and non-woven. It then focuses on woven fabrics and provides details on the classification, representation, and basic elements of woven designs. The key woven structures discussed include plain weave, twill weave, and satin/sateen weave. For each weave type, the document explains the weave repeat, shift, characteristics, and examples. It also covers various types of draft plans and their uses for different woven structures.
The comber is a machine that prepares cotton fibers for spinning into yarn by removing short fibers and impurities. It improves the quality characteristics of yarns such as evenness, strength, and cleanliness. To achieve these quality improvements, the comber must eliminate short fibers, remaining impurities, and neps from the fiber material while forming an optimal sliver. Modern comber preparation systems use a draw frame followed by a sliver doubling machine like a UniLap to prepare uniform batts for feeding into rectilinear combers, which have stationary detaching rollers and swinging nippers to further clean and parallelize the fibers.
The document discusses the draw frame machine used in textile processing. It begins by outlining the objectives of studying the necessity, objectives, construction, and working of the draw frame. It then provides details on:
- The drawing process and how it elongates and levels slivers
- The objectives and functions of the draw frame machine
- The main sections of the draw frame including the creel, drafting, sliver condensing, and coiler sections
- Factors that influence drafting such as fiber properties, drafting arrangement design, and drafting conditions
- The behavior of fibers in the drafting zone and the role of fiber-fiber friction
- Types of irregularities that can occur during drafting
The
Cotton is a natural fibre available easily and abundant quantity. It is a most suitable fibre for textile spinning & clothing due to it’s good spinnability & human friendly characteristics. As cotton is a natural fibre hence it’s properties also affected with several other factors which create variation in fibre properties, these variations also affect spinning processes & it’s products Quality in multi dimensions. Each fibre characteristic impact individually and collectively on spinning process or at ultimate product quality. Revolutionary changes observed in last two decade in the field of spinning machineries where processing speeds greatly increased to enhance production rate. Not only production rate of spinning machines increased but speeds of it’s downstream processes also increased simultaneously which requires better quality of yarn for smooth process and without any interruption to get the maximum efficiency. Hence now it is most important to co-relate fibre properties with respect to it’s consumer process competency. In this article we will discuss the different cotton properties and it’s impact on spinning process and product quality in present prospective and will try to minimize the impact of poor fibre properties on process or product Quality through better Mixing plan selection.
The document discusses combing preparatory processes. It describes the need for combing preparatory, which includes fiber straightening, reversing fiber flow, and producing a flat sliver. Traditionally, this involved a sliver lap machine and ribbon lap machine, but now mostly uses a draw frame and sliver lap machine. The objectives of combing preparatory are to straighten fibers, reverse flow, maximize leading fiber hooks, and produce a flat sliver. Different machine types and their functions are explained, including parameters that influence the combing operation and quality of the finished product.
1. The document describes the components and operation of a modern comber machine. It has single or double sided heads with 8 or 12 heads respectively.
2. Key components include the nippers, which grip the lap and present it to the combing cylinder. The top comb combs the trailing end of the fringe.
3. The combing cylinder and top comb remove short fibers and impurities, forming the noil, while the detaching rollers separate the combed fringe to form a web.
This document discusses the rotor spinning process. It begins by describing the basic principle of open-end yarn formation and the different types of open-end spinning processes. It then provides details on the specific features, principles, and settings of rotor spinning machines. This includes descriptions of the feed, sliver opening, fiber transport, yarn formation, and winding processes. It discusses the raw material requirements and preparation for rotor spinning. Overall, the document provides a comprehensive overview of the rotor spinning process from fiber preparation through yarn formation and winding.
This presentation discusses yarn geometry and various types of yarns. It defines textiles and yarn, and classifies yarns into continuous filament, staple, core spun, novelty, stretch, and high bulk yarns. It describes the properties, structures, and manufacturing processes of these different yarns. The presentation also covers yarn designation, ideal yarn properties, fiber packing in yarns, optimum twist factor, twist contraction, and the basic geometry of twisted yarns.
Knowing the basics of raw material, yarn production process and the other factors influencing quality will put the sourcing manager at the same eye level as a spinner /supplier when negotiating quality issues.
As a consequence this puts the sourcing manager in the position to pay the right price for the corresponding quality level.
This kind of know-how supports a retailer enormously in his efforts to establish a reliable supply chain which is based on mutual understanding.
The document discusses the preparation of material for combing. It describes that card slivers alone are unsuitable for combing and must be further processed. It discusses two preparation methods - the conventional method using a sliver lap machine and ribbon lap machine, and the modern method using a draw frame and sliver doubling machine. Key points covered include the importance of an even batt thickness and fiber parallelization, as well as ensuring the majority of fibers have leading hooks for effective combing.
INTRODUCTION
The ring spinning will continue to be the most widely used form of spinning machine in the near future, because it exhibits significant advantages in comparison with the new spinning processes.
Following are the advantages of ring spinning frame
• It is universally applicable, i.e. any material can be spun to any required count
• It delivers a material with optimum characteristics, especially with regard to structure and strength.
• It is simple and easy to master
• The know-how is well established and accessible for everyone
This document discusses jammed fabric structures and provides mathematical models to predict their properties. A jammed fabric is one where the warp and weft yarns are in intimate contact with no mobility between yarns. Pierce's model and the racetrack model are presented to calculate thread spacing, fabric cover, and crimp based on yarn diameters. A truly square jammed fabric has equal warp and weft spacing, crimp, and angles. Such a fabric has 20.9% crimp and cover factors of 16.2. Jammed fabrics are closely woven and used for waterproof, windproof and bulletproof applications.
The document discusses the key processes involved in yarn production, including:
1. Spinning preparatory processes like bale opening, cleaning, and mixing of fibers.
2. Carding to separate and align fibers into slivers.
3. Drawing to further mix and homogenize slivers.
4. Optional combing to remove short fibers for finer yarns.
5. Main spinning systems like ring spinning and open-end spinning to draft and twist fibers into yarn.
6. Winding yarn into packages for further processing or use in textiles.
This presentation summarizes the Jacquard shedding mechanism. It introduces the four presenters and provides background on the Jacquard loom, which can produce complex woven designs through individual control of warp threads. The presentation then covers the scope of Jacquard shedding, including its ability to control thousands of yarns and produce intricate designs. It also classifies different types of Jacquard looms based on their lifting capacity, design capacity, shed formation, and other features. Key aspects of the single lift Jacquard mechanism are explained. Advantages and disadvantages of the Jacquard loom conclude the presentation.
This document provides a syllabus and overview of woven fabric structures and analysis. It discusses the fundamentals of woven design, including the basic elements of design, draft, and peg plan. It then covers specific weave structures like plain weave and its derivatives. Twill weave is classified and examples like pointed twill are outlined. Different types of drafts and their uses are also summarized. The goal is to teach students to analyze and understand the construction and properties of various woven fabrics.
stiffness,Handle,Drape properties of fabric ,Fabric property TTQC-2AtiqFaysal
This presentation discusses the stiffness, handle, and drape properties of fabrics. It will cover stiffness and how it is tested using machines like the Shirley Stiffness tester. It will also discuss fabric handle properties, the factors that influence handle, and how to measure drape properties using a drape tester to determine the drape coefficient. Relevant apparatus and testing procedures will be explained.
Open-end spinning or rotor spinning is a technology for creating yarn without using a spindle. It separates fiber slivers into single fibers using an air stream and deposits them onto a collecting surface where they are twisted into yarn as it is drawn off. The principle is similar to a clothes dryer where individual sheets can be pulled out while twisting together. Fibers are fed onto the collecting surface which is continuously moving, aligning the fibers and twisting them into a thread that is wound onto a bobbin. Open-end spinning allows internal fiber stresses to relax and imparts twist directly onto the yarn end rather than drafting fibers. This makes the process faster and less labor intensive than ring spinning.
The document discusses wrap spinning and friction spinning systems for yarn production, including descriptions of the wrap spinning and DREF friction spinning processes, their advantages and limitations, end uses of wrap yarns, manufacturers of wrap spinning machines, classifications of friction spinning systems, and features of the DREF-II and DREF-III friction spinning machines.
The document describes the blow room process in the yarn manufacturing process. It discusses the five operating zones of the blow room: bale breaker, axe flow cleaner, step cleaner, multi-mixer, and RN cleaner. It also outlines the five actions that occur: opposing spikes, air current, beating, regulating, and gravity/centrifugal forces. Finally, it provides details on the typical machine sequence in a blow room and important precautions to consider.
There are three basic elements of knitting: needles, cams, and sinkers. There are three types of needles - latch needles, spring-bearded needles, and compound needles. Cams convert rotary motion into reciprocating motion and come in two types: engineering cams and knitting cams. Sinkers perform three functions: loop formation, holding down loops, and knocking over loops. Sinkers are divided into three groups based on their functions.
This document is an assignment submission for a course on testing textiles. It describes an experiment conducted on a Yarn Lea Strength Tester to determine the strength of a cotton yarn sample. The experiment found that the yarn strength was 79.32 lbs/lea and the Count Strength Product (CSP) was 2379.6. Since the CSP was greater than the standard of 2200, the document concludes that the yarn sample had good strength fibers.
Details study on apron, condenser, spacer and top roller.Asif Ahmed TONMOY
This document discusses various components used in yarn manufacturing, including aprons, condensers, spacers, and top rollers. It provides details on the materials and construction of aprons, the purpose and placement of different condensers, how spacer size is determined by roving hank, and the properties and functions of top rollers in controlling drafting.
The document provides information about circular knitting machines. It defines knitting as transforming yarn into interlocking loops. Circular knitting creates seamless tubes using circular needles or machines. Machine parts include the frame, power supply, yarn feeding system, and quality control components. Circular knitting machines are used to produce fabrics for various garments and other materials. Modern machines feature computer controls to monitor functions like speed and stops.
This document discusses the combing process used in spinning mills to improve cotton fiber characteristics. It describes how combing removes short fibers and impurities through the actions of different combing elements like the top comb and nippers. The goal is to extract unusable fibers as noil waste while minimizing good fiber losses. The document provides details on combing machine components, the combing cycle, production calculations, and factors that influence the noil percentage. Overall, it serves to explain how combing upgrades raw cotton material to produce smoother, stronger yarn with fewer imperfections.
This document provides information on extra warp and weft figured fabrics. It discusses two methods of producing these fabrics: 1) using extra warp threads and 2) using extra weft threads. For extra warp fabrics, a separate warp beam is needed along with a dobby mechanism. For extra weft, a drop box mechanism is required. Both methods allow figuring in single or multiple colors. The document provides examples of motif designs and how the ground and extra threads interlace to produce the final figured fabric pattern.
Bigagli Made in Italy Self acting spinning mule "B7 Double Drive" working pro...prx-inceoglu
Spinning steps on a Bigagli self-acting mule "B7 Double Drive" model. The process is used today across the world to produce fine and extra fine high quality yarns from specialty fibers such as wool, cashmere, mohair, alpaca, angora, merino and so on...
The Bigagli self-acting mule "B7 Double Drive" model is available with a high degree of automation and a centralized computer that controls all the machine functions, including the carriages movement, the feed carriage speed, the adjustment of yarn feed speed and drafting percentages, the reverse speed, the spooling speed, the cops formation, the alarms operating data recording and the production setting data modification history.
This document provides an overview of the layout and machinery used in a spinning plant. It describes the key processes including blow room, carding, draw frame, combing, speed frame, ring frame, winding, and conditioning. It lists common machinery manufacturers and provides links to related textile technology Facebook pages and the author's blog.
1. The document describes the components and operation of a modern comber machine. It has single or double sided heads with 8 or 12 heads respectively.
2. Key components include the nippers, which grip the lap and present it to the combing cylinder. The top comb combs the trailing end of the fringe.
3. The combing cylinder and top comb remove short fibers and impurities, forming the noil, while the detaching rollers separate the combed fringe to form a web.
This document discusses the rotor spinning process. It begins by describing the basic principle of open-end yarn formation and the different types of open-end spinning processes. It then provides details on the specific features, principles, and settings of rotor spinning machines. This includes descriptions of the feed, sliver opening, fiber transport, yarn formation, and winding processes. It discusses the raw material requirements and preparation for rotor spinning. Overall, the document provides a comprehensive overview of the rotor spinning process from fiber preparation through yarn formation and winding.
This presentation discusses yarn geometry and various types of yarns. It defines textiles and yarn, and classifies yarns into continuous filament, staple, core spun, novelty, stretch, and high bulk yarns. It describes the properties, structures, and manufacturing processes of these different yarns. The presentation also covers yarn designation, ideal yarn properties, fiber packing in yarns, optimum twist factor, twist contraction, and the basic geometry of twisted yarns.
Knowing the basics of raw material, yarn production process and the other factors influencing quality will put the sourcing manager at the same eye level as a spinner /supplier when negotiating quality issues.
As a consequence this puts the sourcing manager in the position to pay the right price for the corresponding quality level.
This kind of know-how supports a retailer enormously in his efforts to establish a reliable supply chain which is based on mutual understanding.
The document discusses the preparation of material for combing. It describes that card slivers alone are unsuitable for combing and must be further processed. It discusses two preparation methods - the conventional method using a sliver lap machine and ribbon lap machine, and the modern method using a draw frame and sliver doubling machine. Key points covered include the importance of an even batt thickness and fiber parallelization, as well as ensuring the majority of fibers have leading hooks for effective combing.
INTRODUCTION
The ring spinning will continue to be the most widely used form of spinning machine in the near future, because it exhibits significant advantages in comparison with the new spinning processes.
Following are the advantages of ring spinning frame
• It is universally applicable, i.e. any material can be spun to any required count
• It delivers a material with optimum characteristics, especially with regard to structure and strength.
• It is simple and easy to master
• The know-how is well established and accessible for everyone
This document discusses jammed fabric structures and provides mathematical models to predict their properties. A jammed fabric is one where the warp and weft yarns are in intimate contact with no mobility between yarns. Pierce's model and the racetrack model are presented to calculate thread spacing, fabric cover, and crimp based on yarn diameters. A truly square jammed fabric has equal warp and weft spacing, crimp, and angles. Such a fabric has 20.9% crimp and cover factors of 16.2. Jammed fabrics are closely woven and used for waterproof, windproof and bulletproof applications.
The document discusses the key processes involved in yarn production, including:
1. Spinning preparatory processes like bale opening, cleaning, and mixing of fibers.
2. Carding to separate and align fibers into slivers.
3. Drawing to further mix and homogenize slivers.
4. Optional combing to remove short fibers for finer yarns.
5. Main spinning systems like ring spinning and open-end spinning to draft and twist fibers into yarn.
6. Winding yarn into packages for further processing or use in textiles.
This presentation summarizes the Jacquard shedding mechanism. It introduces the four presenters and provides background on the Jacquard loom, which can produce complex woven designs through individual control of warp threads. The presentation then covers the scope of Jacquard shedding, including its ability to control thousands of yarns and produce intricate designs. It also classifies different types of Jacquard looms based on their lifting capacity, design capacity, shed formation, and other features. Key aspects of the single lift Jacquard mechanism are explained. Advantages and disadvantages of the Jacquard loom conclude the presentation.
This document provides a syllabus and overview of woven fabric structures and analysis. It discusses the fundamentals of woven design, including the basic elements of design, draft, and peg plan. It then covers specific weave structures like plain weave and its derivatives. Twill weave is classified and examples like pointed twill are outlined. Different types of drafts and their uses are also summarized. The goal is to teach students to analyze and understand the construction and properties of various woven fabrics.
stiffness,Handle,Drape properties of fabric ,Fabric property TTQC-2AtiqFaysal
This presentation discusses the stiffness, handle, and drape properties of fabrics. It will cover stiffness and how it is tested using machines like the Shirley Stiffness tester. It will also discuss fabric handle properties, the factors that influence handle, and how to measure drape properties using a drape tester to determine the drape coefficient. Relevant apparatus and testing procedures will be explained.
Open-end spinning or rotor spinning is a technology for creating yarn without using a spindle. It separates fiber slivers into single fibers using an air stream and deposits them onto a collecting surface where they are twisted into yarn as it is drawn off. The principle is similar to a clothes dryer where individual sheets can be pulled out while twisting together. Fibers are fed onto the collecting surface which is continuously moving, aligning the fibers and twisting them into a thread that is wound onto a bobbin. Open-end spinning allows internal fiber stresses to relax and imparts twist directly onto the yarn end rather than drafting fibers. This makes the process faster and less labor intensive than ring spinning.
The document discusses wrap spinning and friction spinning systems for yarn production, including descriptions of the wrap spinning and DREF friction spinning processes, their advantages and limitations, end uses of wrap yarns, manufacturers of wrap spinning machines, classifications of friction spinning systems, and features of the DREF-II and DREF-III friction spinning machines.
The document describes the blow room process in the yarn manufacturing process. It discusses the five operating zones of the blow room: bale breaker, axe flow cleaner, step cleaner, multi-mixer, and RN cleaner. It also outlines the five actions that occur: opposing spikes, air current, beating, regulating, and gravity/centrifugal forces. Finally, it provides details on the typical machine sequence in a blow room and important precautions to consider.
There are three basic elements of knitting: needles, cams, and sinkers. There are three types of needles - latch needles, spring-bearded needles, and compound needles. Cams convert rotary motion into reciprocating motion and come in two types: engineering cams and knitting cams. Sinkers perform three functions: loop formation, holding down loops, and knocking over loops. Sinkers are divided into three groups based on their functions.
This document is an assignment submission for a course on testing textiles. It describes an experiment conducted on a Yarn Lea Strength Tester to determine the strength of a cotton yarn sample. The experiment found that the yarn strength was 79.32 lbs/lea and the Count Strength Product (CSP) was 2379.6. Since the CSP was greater than the standard of 2200, the document concludes that the yarn sample had good strength fibers.
Details study on apron, condenser, spacer and top roller.Asif Ahmed TONMOY
This document discusses various components used in yarn manufacturing, including aprons, condensers, spacers, and top rollers. It provides details on the materials and construction of aprons, the purpose and placement of different condensers, how spacer size is determined by roving hank, and the properties and functions of top rollers in controlling drafting.
The document provides information about circular knitting machines. It defines knitting as transforming yarn into interlocking loops. Circular knitting creates seamless tubes using circular needles or machines. Machine parts include the frame, power supply, yarn feeding system, and quality control components. Circular knitting machines are used to produce fabrics for various garments and other materials. Modern machines feature computer controls to monitor functions like speed and stops.
This document discusses the combing process used in spinning mills to improve cotton fiber characteristics. It describes how combing removes short fibers and impurities through the actions of different combing elements like the top comb and nippers. The goal is to extract unusable fibers as noil waste while minimizing good fiber losses. The document provides details on combing machine components, the combing cycle, production calculations, and factors that influence the noil percentage. Overall, it serves to explain how combing upgrades raw cotton material to produce smoother, stronger yarn with fewer imperfections.
This document provides information on extra warp and weft figured fabrics. It discusses two methods of producing these fabrics: 1) using extra warp threads and 2) using extra weft threads. For extra warp fabrics, a separate warp beam is needed along with a dobby mechanism. For extra weft, a drop box mechanism is required. Both methods allow figuring in single or multiple colors. The document provides examples of motif designs and how the ground and extra threads interlace to produce the final figured fabric pattern.
Bigagli Made in Italy Self acting spinning mule "B7 Double Drive" working pro...prx-inceoglu
Spinning steps on a Bigagli self-acting mule "B7 Double Drive" model. The process is used today across the world to produce fine and extra fine high quality yarns from specialty fibers such as wool, cashmere, mohair, alpaca, angora, merino and so on...
The Bigagli self-acting mule "B7 Double Drive" model is available with a high degree of automation and a centralized computer that controls all the machine functions, including the carriages movement, the feed carriage speed, the adjustment of yarn feed speed and drafting percentages, the reverse speed, the spooling speed, the cops formation, the alarms operating data recording and the production setting data modification history.
This document provides an overview of the layout and machinery used in a spinning plant. It describes the key processes including blow room, carding, draw frame, combing, speed frame, ring frame, winding, and conditioning. It lists common machinery manufacturers and provides links to related textile technology Facebook pages and the author's blog.
This document provides information on principles of wool spinning. It discusses the classification of wool types, how wool is obtained from sheep, and the processes involved in preparing wool for yarn production. The key steps discussed are:
1. Sorting and grading wool based on fiber length, waviness and quality.
2. Scouring wool to remove grease and other impurities.
3. Mechanically processing wool through carding to disentangle fibers, combing to align fibers, and drafting and spinning to form yarn.
4. The three main mechanical processing routes - worsted, semi-worsted and woollen - which differ in the level of fiber alignment and short fibers in the
This document summarizes man-made fiber spinning technology. There are three main types of spinning - melt, dry, and wet spinning. Melt spinning involves melting the polymer and extruding it through spinnerets. Dry spinning uses a volatile solvent to dissolve the polymer before extrusion. Wet spinning extrudes the polymer solution into a coagulating bath. Each method has advantages and disadvantages related to investment cost, hazard level, heat requirement, and production speed. The document also discusses properties required for fiber-forming polymers and the basic spinning system components like spinnerets.
Worsted yarns are made from long wool fibers that are combed and spun tightly. This makes worsted yarns stronger than woolen yarns. The scouring process removes grease from wool and includes several stages: pre-opening, opening and beating, scouring, drying, and reblending. Worsted yarns are produced through processes like carding, combing, drafting, and ring spinning to align the fibers parallel and produce a smooth yarn. There are two main systems - the English system produces finer yarns through oiling and tight twisting, while the French system does not use oil for softer worsted yarns.
Textile yarn manufacturing involves several key steps. Fibers are first opened and cleaned through blowroom and carding processes. Drawing further arranges fibers into parallel strands called slivers. Roving attenuates slivers and adds twist. Ring frames then spin roving into yarn using drafts and twist. Combing upgrades raw materials by removing short fibers. The processes work to arrange, draft, and twist fibers into consistent yarns for weaving or other uses.
The blowroom section is where compressed cotton bales are opened, cleaned, and blended to form uniform laps of fiber that are fed into the carding process. The main objectives of the blowroom are to open the compressed fibers into small tufts, clean them by removing impurities, mix and blend different fiber grades, and provide an even feed of material to the carding machines. Key operations include opening, cleaning, dust removal, mixing and blending, and forming an even feed. Maintaining consistent lap weight is important for controlling yarn quality and minimizing production issues.
The document summarizes the key steps in yarn production from blow room to post-spinning processes. In the blow room, opening, cleaning, and blending operations prepare fiber tufts for carding. Carding further individualizes and aligns fibers to form slivers. Draw frames improve material evenness and parallelize fibers. Combing removes short fibers and impurities. Roving frames draft and twist slivers to form rovings. Ring and rotor spinning systems draft, twist, and wind rovings into yarns. Post-spinning processes include winding yarns onto larger packages and plying to improve smoothness. The document outlines objectives and components of each major process step in yarn manufacturing
This document discusses the working principles and technical specifications of several machines used in cotton processing:
1. The BDT opens compressed cotton bales by penetrating them with opening rollers fitted with toothed discs, plucking tufts of fiber and converting them to smaller sizes for further processing.
2. The CL-C3 uses a series of rotating beaters to open cotton tufts to the smallest size and clean them by removing trash and dust using grid bars.
3. The SP-FP screens cotton fibers using 3 CCD cameras and detects contaminants, then uses compressed air nozzles and suction to remove the contaminated fibers from the processing line.
Presentation on process control study in spinning dpt.Anchal Aneja
The document provides information about the blow room process in spinning mills. It discusses the objectives and processes that occur in the blow room like pre-opening, pre-cleaning, blending, fine opening and dedusting. It describes the machines used and parameters that need to be considered like beater type, speed, settings and production rate. The goal of the blow room is to supply clean and homogenous fibre tufts to the carding machine without damaging fibres.
2.0 UNIclean Machine in Blow room line.pdfMdShetuMia
1. The document discusses the UNIclean machine in the blow room process for cleaning cotton fibers.
2. It describes the working principle of the UNIclean machine, which uses double hooks to pass the material over a cleaning grid five times to remove dirt and debris.
3. The objectives of the UNIclean machine are to remove particles, dust, and trash from the fibers to individualize and straighten them for subsequent spinning.
The document discusses the process of cotton yarn spinning from start to finish. It begins with the cotton fiber growing in bolls on the cotton plant. The fibers then undergo various cleaning and preparation processes. The main steps of yarn spinning involve blowroom preparation, carding, drawing, combing (optional), roving, ring spinning, and cone winding. Each step performs important functions like opening, cleaning, drafting, twisting, and winding the fibers into yarns of increasing fineness and uniformity ready for further textile manufacturing. Ring spinning is described as the most common method and produces strong, fine yarns suitable for many applications.
Fibers are the smallest elements that make up textile materials. Cotton is a natural fiber obtained from cotton plants, which belongs to the genus Gossypium. Cotton can fulfill 42% of global fiber demand and is produced in countries like the USA, China, India, Australia, and others. The blow room is the first processing section, which opens, cleans, blends, and mixes cotton fibers using machines like the bale opener, cleaner, and mixer to remove 40-70% of impurities. Carding further processes the fibers to individualize them and remove neps and short fibers in preparation for spinning. It drafts and orientates the fibers using components like the taker-in, cylinder, flats
The document discusses fibre mixing, opening, cleaning and blending processes in blow rooms. It provides details on the basic operations in a blow room which include opening, cleaning, blending/mixing and lap forming. It describes the various machines, processes and principles involved in blow room operations like opening using spiked lattices and beaters, cleaning using grid bars and air currents, blending using different systems and regulating the fibre flow.
The document provides information on various processes involved in yarn production including carded yarn production, combed yarn production, rotor yarn production, and jute yarn manufacturing. It includes flow charts showing the input, process, machine, and output for each type of yarn production. It also describes processes like bale management, mixing, blending, ginning, blowroom, carding, draw frame, and jute processing steps.
textile manufacturing mohini create by rizwan qureshiMulti Addiction
The document discusses the various processes involved in textile manufacturing from fibre to fabric, including spinning of fibres into yarn, preparatory processes for weaving like warping and sizing, the weaving process itself using looms, and some details about types of looms and their functions. It provides an overview of the major steps and some technical descriptions of processes like sizing, shedding, picking, and beating-up that are involved in converting yarn into woven fabric.
The document provides details about the working processes in a spinning mill. It begins with an introduction to how spinning technology has modernized over time. It then describes the key processes in a typical spinning mill, including:
1) Blow room - Where cotton is opened, cleaned, blended and evenly fed to carding. This is done using machines like bale breakers and scutchers.
2) Carding - Where cotton fibers are disentangled, cleaned and aligned using rollers covered with card clothing. This produces slivers for subsequent processing.
3) Drawing and spinning processes - Slivers are drawn out and spun into yarn using machines like draw frames, speed frames and ring frames
The document discusses fiber preparation in the blow room process. It describes the key tasks of the blow room line as opening raw materials into fine tufts, eliminating impurities and dust, and providing a good blend. It explains that the blow room installation consists of a sequence of different machines arranged in series to perform opening, cleaning, and blending operations with varying intensities. Proper fiber preparation in the blow room is important to avoid shortcomings in later processing stages. The document provides details on various types of blow room machines and their components, operating principles, and influence on opening and cleaning fibers.
This document provides information about various machines used in the spinning section of textile engineering. It includes flow charts that outline the processes and machines used to produce carded, combed, and rotor yarns. Key machines discussed include blow room, carding, draw frame, and ring frame. It also covers bale management, mixing, blending, ginning, and the functions of blow room and carding machines.
This document presents information about blow rooms in textile mills. It discusses the main components and processes in a blow room, including opening, cleaning, blending, and forming laps of cotton fiber. The blow room is the first step in yarn production and removes 40-70% of trash from compressed cotton bales using various machines like opening, mixing, cleaning and dust removal equipment. It explains the actions that these machines perform through opposite spikes, air currents, beaters and regulating motions to effectively prepare the cotton fibers for subsequent spinning processes.
Opening in blow room means opening into small flocks. Technological operation of opening means the volume of the flock is increased while the number of fibres remains constant
yarn manufacturing I.ppt document for textiledejene1234567
The document discusses cotton grading and quality parameters. It defines key cotton quality metrics such as fiber length, strength, fineness, color, and trash content. It then covers the blowroom process which involves opening, cleaning, mixing, and feeding cotton fibers to the carding machine. The main goals of the blowroom are to remove impurities from the fibers and produce a homogeneous fiber mass for consistent yarn production. Common blowroom machinery and their cleaning efficiencies are also summarized.
1.0 Details study of the Blow-room line ..pdfMdShetuMia
This document provides details about a sessional report for an experiment on studying a blow-room line. It includes:
1) An introduction describing the purpose of a blow-room section in yarn production and the machines used (Uniflock, Uniclean, Unimix, Uniflex).
2) Objectives of the experiment such as forming clean tufts of uniform length and observing machine functions.
3) A diagram and explanation of the blow-room line and its functions like opening, cleaning, and mixing fibers.
4) Workings principles of the individual machines - Unifloc, Uniclean, Unimix - and processes like opening, cleaning, and mixing they
The document provides information about the key machines and processes in a blow room line. It begins with an overview of the blow room section and its purpose of opening, cleaning, blending cotton fibers into a uniform lap. It then details the functions of various machines, including the bale opener, step cleaner, vertical/twin opener, porcupine opener, hopper feeder, and blow room scutcher. It explains the conventional sequence of these machines and provides pictures to illustrate their workings. Newer automatic machines like the bale opener, UNIclean, UNImix, and Uniflex are also summarized.
The document provides an overview of the finishing processes at a textile company. It describes the slitting machine, which cuts fabric from tube form to open form. It then discusses the santax machine, which dries fabric using steam. Finally, it outlines the stenter machine, which controls width, GSM, and shrinkage of fabric during drying and allows for final softener applications. The stenter machine has multiple heating chambers and functions to maintain quality parameters during drying.
Yarn is produced by twisting fibers together. There are different types of yarns including rotor yarn, which is produced using a rotor spinning machine. The properties of cotton fibers that are important for spinning include fineness, length, strength and cleanliness. These properties affect the quality and characteristics of the resulting yarn. The blow room is the first processing stage, where bales of cotton fibers are opened, blended, cleaned and formed into laps to prepare them for further processing into yarn.
This document provides definitions and background information on various textile terms. It begins with an introduction to textiles and defines key terms like fiber, filament, yarn and fabric. It then discusses the history of natural fibers like cotton, wool and silk. The document also summarizes the development of various man-made fibers like rayon, nylon, acrylic and polyester. It provides timelines of when these fibers were first invented and commercialized. The document is intended to serve as a reference for textile engineering students.
This document provides information about garment manufacturing and exporting processes. It was prepared by Md. Kamrul Hasan, a Textile Engineering graduate from Southeast University in Bangladesh. The document contains several sections that discuss key topics like buyers and buying houses, major garment exporting countries, GSP status, garment export procedures, costing, purchase orders, letters of credit, and timelines. It aims to serve as a reference for students and professionals in the garments sector.
This document provides information about carbon fiber, including:
1. What carbon fiber is composed of and its structure.
2. The process of forming carbon fiber from precursor materials like polyacrylonitrile through heating without oxygen.
3. Applications of carbon fiber in composites for aircraft, vehicles, and other products due to its strength and light weight.
4. Major manufacturers of carbon fibers and the growing market for carbon fiber composites.
The document discusses acrylic fiber, including its definition, chemical composition, properties, characteristics, advantages, uses, and commercial applications. Acrylic fiber is a synthetic fiber made from polymers containing acrylonitrile. It is often used as an artificial replacement for wool in applications like sweaters, socks, and blankets due to its softness and insulating properties. Major uses of acrylic fiber include knit apparel, carpets, and home furnishings due to its ability to wick moisture, durability, and resistance to moths and chemicals.
Elastomeric fibers are fibers that can stretch to very high elongations (400-800%) and rapidly recover their original length. They include fibers made from natural and synthetic rubbers as well as spandex and polyacrylates. Elastomeric fibers are produced via a spinning process where polymers are mixed and reacted to form long chains, then extruded through spinnerets into a water bath or air to solidify. The fibers have excellent elasticity and strength even at high elongations. Common applications include clothing, automotive and industrial parts, coatings and more where elasticity is required.
This document provides a project report on applying disperse and reactive dyes to a 65/35 polyester/cotton blended fabric using a two bath system. It acknowledges those who helped with the project and thanks the textile college and company for the opportunity. The abstract discusses challenges in dyeing poly/cotton blends and how dye selection can help control color value, strength, and other properties. Laboratory trials tested compatibility of reactive dyes and analyzed dye fixation using spectrophotometry. The introduction discusses the importance of practical experience and outlines the project goals of studying dye application in different textile industries in Bangladesh.
This document provides a project report on the reaction mechanism of reactive dyes in Bengal Hurricane Group on cellulose fiber. It discusses the raw materials used, including fabrics, dyes, and chemicals. It explains the importance of studying reactive dye usage in major Bangladeshi textile industries. The methods of dyeing and printing cotton with reactive dyes and the technical deficiencies, causes, and remedies are examined.
This document provides information about Interstoff Apparels Ltd., a garment manufacturing company in Bangladesh. It discusses the company profile, including its name, business type, employees, and address. It also describes the knitting, quality control, dyeing, and project work sections of the company. The knitting section details the types of yarns, knitting machines, production calculations, and common knitting faults. The quality control section lists inspection equipment. The dyeing section outlines the dyeing process and possible faults. The project work section explains common knitting defects and their causes and remedies.
The document provides information about GTA Sports Ltd., a knitwear factory in Bangladesh. It includes an organogram of the company's management structure and sections. The knitting section is described in detail, outlining the knitting process, types of knitting machines and their parts. It also discusses methods to increase production quantity. The dyeing and finishing sections are briefly introduced, including raw materials, machinery and quality control processes.
This document provides an overview of Apex Weaving & Finishing Mills Limited, a textile company located in Gazipur, Bangladesh. It describes the company's various subsidiaries and business sections, which include weaving, dyeing, printing, finishing, and garments. The document also lists the types of machinery used in each section of the facility, such as 231 shuttleless looms, rotary printers, loop steamers, and sewing machines. Finally, it includes photos of the different areas of the plant, including the weaving floor, wet processing section, printing area, laboratories, and maintenance facilities.
The document provides information about GTA Sports Ltd., a knitwear factory in Bangladesh. It includes an organogram of the company's management structure and sections. The knitting section is described in detail, outlining the knitting process, types of knitting machines and their parts. It also discusses increasing production quantity and common knitting faults. The dyeing and finishing sections are briefly introduced, including raw materials, machinery and quality control processes.
The document provides information about reactive dyes, including:
- Reactive dyes form covalent bonds with fiber polymers through reactive groups, giving excellent wash and light fastness.
- Important reactive groups include triazine, vinyl sulfone, and halogen groups.
- Reactive dyes were invented in 1956 and became popular for their bright colors, low temperature dyeing, and simple process.
- Common application methods are pad-batch and pad-dry processes at low temperatures. Proper pH, electrolyte, alkali, and time are required for effective dye fixation to the fiber.
This document discusses the development of looms from primitive hand looms to modern automated looms. It outlines the key stages of development including the fly shuttle loom, power looms, semi-automatic looms, and modern shuttle-less looms. The basic mechanisms and motions of weaving are described, including primary, secondary, and tertiary motions. Different parts of a loom and their functions are also summarized.
This document provides information about Urmi Group and one of its concerns, Fakhruddin Textile Mills Ltd. It details the company profile, factory information, manpower and organizational structure, raw materials used, and production process of the textile mill. Fakhruddin Textile Mills Ltd is a leading Bangladeshi manufacturer and exporter of knit garments established in 2004. It has over 1200 employees and uses various natural and synthetic yarns, chemicals, and dyes to produce knitted fabrics and garments for the export market.
This document provides an overview of Sadma Fashion Wear Ltd., a garment manufacturing company in Bangladesh. It details the company's profile, facilities, production capacity, certifications, buyers, and organizational structure. Key points include that it has over 200 employees, a production capacity of 20,000 pieces per day, and major buyers such as Walmart, C&A, and Sears. The company operates departments for knitting, dyeing, finishing, garments production and quality assurance.
This document provides an overview of Mitali Fashions Ltd., a knit composite garment factory in Bangladesh. It discusses the company's establishment in 2000, leadership, expansion, and certification. The factory has various production sections including knitting, dyeing, finishing, garments, and quality control. It employs over 5,000 people and produces knitwear and garments for major international brands. The document also includes organizational charts, maps of the factory premises, and lists of raw materials and major customers.
The document provides information about an industrial training internship at Olio Apparels Ltd, which is part of the Envoy Group. The objectives of the internship are to learn about the different departments of the company and gain practical knowledge about garment manufacturing. It also aims to compare theoretical knowledge learned in class to real-world practices and identify strengths, weaknesses, opportunities, and threats of the company. Olio Apparels Ltd is described as a large garment manufacturing facility that produces high quality products for European and American customers using modern machinery and technologies.
1. The document provides information about Divine Group of Industries Limited (DGI), a textile company in Bangladesh. It details DGI's facilities, production capacity, certifications, and clientele.
2. DGI aims to suit every fashion taste and demand from around the world. It has several factories producing knitted fabrics and garments.
3. The document outlines DGI's management structure, production processes from knitting to garments, and machinery used in key departments like CAD and sampling.
This document provides information about garment merchandising and industrial engineering. It defines merchandising and outlines the key steps in the merchandising process from developing buyers to shipment. It also describes the work of merchandisers, including sourcing, pricing, order follow up, and ensuring on-time shipment. Additionally, it discusses industrial engineering and its focus on improving productivity through methods like time studies, layout optimization, and training. It provides details on cost analysis, production planning, and the different techniques used to set work standards.
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2. Physical properties of raw material (cotton):
Fibre Length:
Short staple
Medium staple
Long staple
Extra Long Staple
1 in. or less
1 1/32- 1 1/8 in.
1 5/32- 1 3/8 in.
1 13/32 in. above.
Fibre Fineness:
Micronaire Value
Fineness
up to 3.1
3.1 to 3.9
4.0 to 4.9
5.0 to 5.9
6.0 & above
Very fine
fine
Medium
Slightly Coarse
Coarse
3. Fibre Strength:
Pressley value
93 & above
87 to 92
81 to 86
75 to 80
70 to 74
Below 70
Grading
Excellent
Very strong
Strong
Medium strong
Fair strong
Weak
Fibre Cleanliness:
Trash %
Grading
Up to 1.2%
1.2 to 2%
2 to 4%
4 to 7%
above 7%
Very clean
Clean
Medium
Dirty
Very dirty
4. Dust:
Grading
particle size (micro meter)
Trash
Dust
Micro dust
Breathable dust
above 500
50-500
15-50
below 15
Chemical deposits:
Secretions:
Fungi and Bacteria
Vegetable substances
Fats, oil
Synthetic substances
Honeydew
Decomposition products
Sugar from plant juices, leaf nectar,
overproduction of wax
Seed oil from ginning, pathogens
defoliants, insecticides, fertilizers, oil from
harvesting machines.
7. Mixing and blending of
cotton fiber in blow room
Mixing:
If different grade of same
fibers are kept together,
then it is called mixing.
Types of Mixing:
1. volume mixing
2. weight mixing
3. hand stock mixing
4. bin mixing
5. mixing by hopper
6. lap mixing
7. card mixing
8. sliver mixing
Blending:
When different fibers of same or different
grades are kept together, then it is called
blending.
Types of Blending:
1. hand stock blending
2. bin blending
3. lap blending
4. card blending
5. draw frame blending
8. Model of optimum cotton mixing:
The program is written on the basis of principles
of linear programming. The constraints of the
mixing used in the program are cotton fiber
minimum length in mm, strength in grams per
Tex, Micronaire value in a range, maximum
trash percentage, and price per kilogram of the
cotton. Also some of the practical constrains are
considered while formulating the mixing like
maximum and minimum bales to be taken for
mixing from a lot.
The software generated system is, in generally, known as Bale Management.
Some branded software are BIAS, Bale Manager.
10. Blow room:
Cotton fibre is compressed in a bale of 200 to 250
kg. This highly compressed cotton firbe need to be
open at first as a part of yarn manufacturing. And
there are 1.5% to 7% trash in cotton bale which is
also needed to be removed before further
processing. This process of opening & cleaning is
knows as blow room process. Blow room consists of
a number of m/c used in succession to open & clean
the cotton fibre to the required degree. 40% to 70%
of total trash is removed in this section.
Process parameter in the blow room:
Number of opening machines
Type of beater
Type of beating
Beater speed
Setting between feed roller and beater
Production rate of individual machine
Production rate of the entire line
Thickness of the feed web
Density of the feed web
Fibre micronaire
Size of the flocks in the feed
Type of clothing of the beater
Point density of clothing
Type of grid and grid settings
Air flow through the grid
Position of the machine in the sequence
Amount of trash in the material
Type of trash in the material
Temp and relative humidity in the blow
room department
11. Objects of blow room process:
To open the compressed layer of bale of cotton or any staple fibres with minimum
damage to the fibres.
To remove the impurities like sand, seed, bits, neps & short fibres present in the
cotton with minimum loss of lint by opening & blending.
To effect a through blending with minimum neps formation.
To convert the mass of cotton fibres into a uniform thick sheet of cotton both
longitudinally & transversely & fed as it in the case of chute feed system or wound
in the form of a compactly built lap with minimum lap rejection.
Intensive de-dusting of cotton fibres to extract micro- dust in order to improve the
working of opened spinning m/c.
Fibre recovery from the waste produced by the various processes during the
conversion of fibre to yarn in order to reduce the consumption of raw material.
13. Basic operation in blow room:
Opening: The first operation required in the blowroom line is opening. Tuft weight can be
reduced to about 0,1 mg in the blowroom. The figure indicate that the degree of opening
changes along a blowroom line. This line is a theoretical layout for study purposes only. The
flattening of the curve toward the end shows that the line is far too long. It should end
somewhere at machine No. 3 or (at least) No. 4. The small improvements by each of the
subsequent machines are obtained only by considerable additional effort, stressing of the
material, unnecessary fiber loss and a striking increase in neppiness.
Openness of the fiber material after the various blowroom machine stages; axis A: Degree of opening (specific
volume); axis B: Blowroom stages
14. Cleaning:
A blowroom
installation
removes
approximately 40 - 70% of the impurities. The result is
dependent on the raw material, the machines and the
environmental conditions. The diagram by illustrates
the dependence of cleaning on raw material type, in
this case on the level of impurities.
The cleaning effect is a matter of adjustment. It is shown
in bottom figure that, increasing the degree of cleaning
also increases the negative effect on cotton when trying
to improve cleaning by intensifying the operation, and
this occurs mostly exponentially. Therefore each
machine in the line has an optimum range of treatment.
It is essential to know this range and to operate within it.
Figure: Degree of cleaning (A) as a function of
the trash content (B) of the raw material in %
Normally, fibers represent about 40 - 60% of blowroom
waste. Since the proportion of fibers in waste differs from one
machine to another, and can be strongly influenced, the fiber
loss at each machine should be known. It can be expressed
as a percentage of good fiber loss in relation to total material
eliminated, i.e. in cleaning efficiency (CE):
AT = total waste (%); AF = good fibers eliminated (%).
For example, if AT = 2.1% and AF = 0.65%:
Figure: Operational efficiency and side effects
15. Dust Removal:
Almost all manufacturers of blowroom
machinery now offer dust-removing
machines or equipment in addition to
opening and cleaning machines.
Dust removal is not an easy operation,
since the dust particles are completely
enclosed within the flocks and hence are
held back during suction.
It is mainly the suction units that remove
dust (in this example 64%), dust removal
will be more intensive the smaller the
tufts.
It follows that dust elimination takes
place at all stages of the spinning
process as shown in figure.
Fig. 5 – Dust removal as a percentage of the dust
content of the raw cotton (A) at the various processing
stages (B): 1 - 5, blowroom machines; 6, card; 7, draw
frames; (a) filter deposit; (b) licker-in deposit; I, dust in
the waste; II, dust in the exhaust air.
16. Blending:
intensive blending in a suitable blending machine
must be carried out after separate tuft extraction from
individual bales of the layout. This blending operation
must collect the bunches of fibers arriving
sequentially from individual bales and mix them
thoroughly. Multi mixer is the machine of blow room
where the uniform blending is carried out.
Figure – Sandwich blending of raw material components
In conventional machineries, lap blending was the most significant one. doubling scutcher is
required in this case; this has a conveyor lattice on which four to six laps (L) could be laid and
jointly rolled-off. Lap blending produces very good transverse blends and also a good
longitudinal blend,
Figure – Lap blending on an old scutcher
17. Even feed of material of the card:
Finally the blow room must ensure that raw material is evenly delivered
to the cards. Previously, this was carried out by means of precisely
weighed laps from the scutcher, but automatic flock feeding installations
are increasingly being used. While in the introductory phase such
installations were subject to problem regarding evenness of flock
deliver, today they generally operate well or at least adequately.
18. Introduction of blow room line:
Figure – Rieter blowroom line; 1. Bale opener UNIfloc A11; 2. Pre-cleaner
UNIclean B 12; 3. Homogenous mixer UNImix B 75; 4. Storage and feeding
machine UNIstore A 78; 5. Condenser A 21; 6. Card C 60; 7. Sliver Coiler CBA 4
19. Components of the blow room machine:
Feeding Apparatus:
Feed with an upper roller and a bottom table
In a device with a feed roller and table the clamping
distance (a) can be very small. This results in intensive
opening.
Feed to a beater with two clamping rollers
Operating with two clamping cylinders gives the best
forward motion, but unfortunately also the greatest
clamping distance (a) between the cylinders and the
beating elements.
Feed with a roller and pedals
Where pedals are used (Fig. 12), the table is divided
into many sections, each of which individually presses
the web against the roller, e.g. via spring pressure. This
provides secure clamping with a small clamping
distance (a).
20. Opening devices:
Opening units can be classified as:
•endless path
•gripping devices
•rotating assemblies
Depending on their design, construction, adjustment, etc., these assemblies exert enormous
influence on the whole process.
1. End less path device:
Spiked lattices is known as endless path device. It
serves as forwarding and opening devices in bale
openers and hopper feeders. They consist of
circulating, endless lattices or belts with transverse
bars at short intervals. The bars are of wood or
aluminum; steel spikes are set into the bars at an
angle and at greater or lesser spacing.
The intensity of the opening action is dependent upon:
the distance between the devices;
the speed ratios;
the total working surface;
the number of points.
21. 2. Gripping elements (plucking spring):
Some manufacturers, for example former
Schubert & Salzer and Trützschler, have used
plucking springs for opening. Two spring systems,
facing each other like the jaws of a pair of tongs,
are parted and dropped into the feed material and
are then closed before being lifted clear. They
grasp the material like fingers. This type of
gripping is the most gentle of all methods of
opening, but it produces mostly large to very large
clumps of uneven size. This type of opening
device is therefore no longer used.
22. 3. Rotating Devices (Roller with teeth, blades or spikes):
Flat, oval or round bars are welded, riveted or
screwed to closed cylinders.
The rollers are therefore called spiked rollers. Various
spacing of the striker elements are used. These
devices are incorporated mainly in modern horizontal
cleaners, chute feeds, mixing bale openers, step
cleaners, etc., which are located from the start to the
middle of the blowroom line.
At the start of the line, the spacing of the striker
elements on the roller is greater; finer spacing are
used in the middle (to the end) of the line. The rollers
rotate at speeds in the range of 600 - 1 000 rpm.
23. The grid:
In the final analysis, it is the grid or a grid-like
structure under the opening assembly that
determines the level of waste and its
composition in terms of impurities and good
fibers. Grids are segment-shaped devices under
the opening assemblies and consist of several
(or many) individual polygonal bars or blades
(i.e. elements with edges) and together these
form a trough. The grid encircles at least 1/4, at
most 3/4 and usually 1/3 to 1/2 of the opening
assembly.
The grid has a major influence on the cleaning effect via:
the section of the bars;
the grasping effect of the edges of the polygonal bars;
the setting angle of the bars relative to the opening elements;
the width of the gaps between the bars;
the overall surface area of the grid.
Figure:Two-part grid
24. The following elements can be used in the grid:
•slotted sheets (a): poor cleaning;
•perforated sheets (b): poor cleaning;
•triangular section bars (c): the most widely used grid bars;
•angle bars (d): somewhat weak;
•blades (e): strong and effective.
These elements can be used individually or in
combination.
Modern grids are mostly made up of triangular
bars. They are robust, easy to manipulate and
produce a good cleaning effect. The same is
true of blade-grids.
Blades have been used as grid elements for
a long time (the mote knife), almost always in
combination with triangular section bars.
25. Grid adjustment:
Three basic adjustments:
•Distance of the complete grid from the beater;
• width of the gaps between the bars
(a=closed, b=open);
•setting angle relative to the beater envelope
26. Conventional Machine of Blow room line:
Bale breaker:
Opening is mainly emphasized in this
machine rather cleaning.
This machine is designed to take layer
of cotton directly taken from bale and
tear them apart leaving the cotton
partially opened.
27. Porcupine opener:
The cotton fed by the previous
opener is carried forward by the
feed lattice.
16 circular disc are mounted on
the shaft of this opener. 14 to
18 striker blades are riveted
alternatively on each circular
disc.
The compressed sheet of cotton delivered from the feed roller is heavily beated by the
rapidly revolving striker of the porcupine beater against grid bar.
Because of this beating action, the cotton is effectively opened and extracted trash
particles are passed through the spacing of the grid bar.
28. Step cleaner:
The material falls into the feed hopper and
passes to the first beater.
From there it is transported upward by the
six (sometimes three or four) beater rollers,
each carrying profiled bars.
The beaters are arranged on a line inclined
upward at 45°.
Elimination of impurities takes place during
the continual passage of the material over
the grids arranged under the rollers
29. Air Jet cleaner:
Object of this cleaner is to
open and clean the cotton, but
this cleaning unit introduces
the idea of dirt separation from
cotton by air force.
The function of the Kirschner
beater section is to open and
clean the cotton and prepare
the cotton for air jet section.
The tuft of cotton from the kirschner beater section is entered in to the aero dynamic
constricting duct.
The air current from the booster fan carry the cotton toward the bend in the duct.
The duct makes a sharp turn of about 120 degree.
30. Axi flow Cleaner:
This is known as dual roller cleaner.
This machine has two beaters having 6 to 8
rows of spikes with flattened edge which perform
cleaning action.
Beater speed is 400-600 rpm.
Material through entire length of first beater pass
over the grid bars where trash is collected and
comes in contact with second beater.
31. Scutcher:
To feed the material to card is very important because it should be homogeneous,
uniform from card to card, fulfill this requirement scutcher machine is used.
It is less problematical. No need of using pipes to provide the material to separate
machine.
It can be provide
universally and this can
be used with many
blends.
Less economical as
compared to chute feed
system.
Its function is to clean the
material and form a
uniform lap for card.
32. Kirschner beater:
In this type of beater, instead of beater bars,
pinned bars (pinned lags) are secured to the
ends of the cast-iron arms.
The relatively high degree of penetration
results in good opening. Kirschner beaters
were therefore often used at the last opening
position in the blowroom line.
Beaters with pinned bars
Modern Kirschner openers are often
designed as closed rollers rather than threearmed beater units. The design is simpler
and the flow conditions are more favorable.
Rollers with pinned bars
33. Modern Blow room line
ABO= Automatic Bale Opener
CPC= Crosrol Pre-Cleaner
CBO= Crosrol Blending Opener
CFC= Crosrol Fine Cleaner
CDR= Crosrol Dust Removal
35. Rieter Blow room line:
The UNIfloc A 11 processes the fiber material gently and
efficiently into microtufts, from which impurities can be
removed very readily in the subsequent processes.
•The UNIfloc is designed for output of up to 1 400 kg/h (carded sliver).
•Bales are laid down over a length of 7.2 to 47.2 meters.
•The UNIfloc can process up to 4 assortments simultaneously.
•The width of the take-off unit can be selected between 1 700
and 2 300 mm.
36. Uniclean B12
The UNIclean B 12 pre-cleaner
cleans the microtufts in the first
cleaning stage immediately after
the UNIfloc A 11
•The UNIclean is designed for output
of up to 1 400 kg/h (carded sliver).
•Fiber yield with simultaneous efficient
cleaning is up to 2% higher than on
conventional units.
•Pre-cleaning without nipping and the
use of mote knives results in fiberpreserving cleaning.
•The large dedusting surface ensures
intensive dedusting even at high
production performance.
37. Unimix B76
The B 72 / B 76 mixing machine
guarantees homogeneous, intimate mixing
of the bale feed in a minimum of space,
even with unfavorable bale lay-down.
Eight mixing chambers ensure not only
effective mixing, but also high production
performance.
The easy addition of an opening or cleaner
module provides flexibility with the
capability to respond to changes in market
conditions.
Bypass facility for the cleaner module (e.g.
with man-made fibers) for rapid mix
change.
38. Uniflex B60
Material comes from preceding machine and
then filling the chute. Thus in the chute, a very
homogeneous batting lay down is formed both
lengthwise and crosswise.
The material is carried further by a perforated
drum (2) and a plain drum.
The feed roll (3) supplies the material to the
opening cylinder (5).
A grid (4) made of carding segments and knives
forms the cleaning surface and extracts
impurities.
1= Filling Chute
2= Perforated drum
3= Feed zone
4= Grid
5= Opening Cylinder
6= Delivery
42. Operating Principle of carding machine
In modern installations, raw material is supplied via pipe ducting into the feed chute (of
different designs) (2) of the card. An evenly compressed batt of about 500 - 900 ktex is
formed in the chute. A transport roller (3) forwards this batt to the feed arrangement (4).
This consists of a feed roller and a feeder plate designed to push the sheet of fiber slowly
into the operating range of the licker-in (5) while maintaining optimal clamping.
The portion of the sheet projecting from the feed roller must be combed through and
opened into tufts by the licker-in. These tufts are passed over grid equipment (6) and
transferred to the main cylinder (8).
In moving past mote knives, grids, carding segments (6), etc., the material loses the
majority of its impurities. Suction ducts (7) carry away the waste. The tufts themselves
are carried along with the main cylinder and opened up into individual fibers between the
cylinder and the flats in the actual carding process.
43. The flats (10) comprise 80 - 116 individual carding bars combined into a belt
moving on an endless path. Nowadays some 30 - 46 (modern cards about 27) of the
flats are located in the carding position relative to the main cylinder; the rest are on
the return run.
During this return, a cleaning unit (11) strips fibers, neps and foreign matter from
the bars. Fixed carding bars (9) and (12) are designed to assist the operation of the
card. Grids or cover plates (13) enclose the underside of the main cylinder. After
the carding operation has been completed, the main cylinder carries along the fibers
that are loose and lie parallel without hooks.
However, in this condition the fibers do not form a transportable intermediate
product. An additional cylinder, the doffer (14), is required for this purpose. The
doffer combines the fibers into a web because of its substantially lower peripheral
speed relative to the main cylinder.
A stripping device (15) draws the web from the doffer. After calendar rolls (16)
have compressed the sliver to some extent, the coiler (18) deposits it in cans (17).
The working rollers, cylinder and flats are provided with clothing, which becomes
worn during fiber processing, and these parts must be reground at regular intervals.
44. Licker-in
This is a cast roller with a diameter usually
of around 250 mm. Saw-tooth clothing is
applied to it. Beneath the licker-in there is
an enclosure of grid elements or carding
segments; above it is a protective casing
of sheet metal. The purpose of the lickerin is to pluck finely opened tufts out of
the feed batt, lead them over the dirteliminating parts under the roller and
then deliver them to the main cylinder. In
high-performance cards, rotation speeds
are in the range of 800 - 2 000 rpm for
cotton and about 600 rpm for synthetics.
45. Carding Bar
An aluminium carding profile (1) consists of 2 carding bars (2). One of the advantages of bars
is that they can be provided in different finenesses, e.g. they can become finer in the
through-flow direction. Different manufacturers use differing numbers of elements (between
one and four) per position. Special clothing is required that must not be allowed to choke.
Most modern high-performance cards are already fitted with these carding aids as integral
equipment; all other machines can be retrofitted by, for example, Graf of Switzerland or
Wolters of Germany.
In use are also other carding devices of different design and with different components, e.g.
mote knives (4) with guiding element (5) and suction tubes (3), etc.
46. Cylinder
The cylinder is usually manufactured
from cast iron, but is now sometimes
made of steel. Most cylinders have
a diameter of 1 280 - 1 300 mm (Rieter C
60 card 814 mm, speed up to 900 rpm)
and rotate at speeds between 250 and
500 (to 600) rpm. The roundness
tolerance must be maintained within
extremely tight limits – the narrowest
setting distance (between the cylinder
and the doffer) is only about 0.1 mm. The
cylinder is generally supported in roller
bearings.
Clothing configuration between main
cylinder and doffer
48. Doffer
• The cylinder is followed by the doffer, which is
designed to take the individual fibers from the
cylinder and condense them to a web. The
doffer is mostly formed as a cast iron (or steel)
drum with a diameter of about 600 - 707 mm.
(680 mm on Rieter machines) . It is fitted with
metallic clothing and runs at speeds up to
about 300 m/min.
49. • Point density (Number of points per unit surface area)
The populations of the main cylinder and doffer clothing have to be adapted to
each other. In general, the higher the point population, the better the carding
effect – up to a certain optimum. Above that optimum, the positive influence
becomes a negative one. This optimum is very dependent upon the material.
Coarse fibers need fewer points, as they need more space in the card clothing;
finer fibers must be processed with more points, since more fibers are present if
the material throughput is the same. Point density is specified in terms of points
per square inch or per square centimeter, and can be calculated as follows:
50. •
•
•
Base width (a1)
This influences the point density. The narrower the base, the greater the number
of turns that can be wound on the cylinder and, correspondingly, the higher the
point population.
Height of the clothing (h1)
The height of metallic clothing on the cylinder today varies between 2 mm and
3.8 mm. The height must be very uniform. It can also exert an influence on the
population, since shorter teeth – for a given tooth carding angle – leave space for
more teeth. Where shorter teeth are used, the fibers are less able to escape into
the clothing during carding and better carding over the total surface is obtained.
Clothing with smaller teeth is also less inclined to choke with dirt particles.
Tooth pitch (T)
The population is also determined by the tip-to-tip spacing.
51. •
Carding Angle (α)
This is the most important angle of the
tooth as it determines :
–
–
the aggressiveness of the clothing; and
the hold on the fibers
The angle specifies the inclination of the
leading face of the tooth to the vertical.
It is described as positive , negative or
neutral. The angle is neutral if the
leading edge of the tooth lies in the
vertical (0°). Clothing with negative
angles is used only in the licker-in
when processing some man-made
fibers. Since the fibers are held less
firmly by this form of tooth, they are
transferred more easily to the cylinder
and the clothing is less inclined to choke.
Carding angles normally fall into the
following ranges:
licker-in: +5° to -10°
Cylinder: +12° to +27°
Doffer: +20° to +40°
Fig. – Positive (a) and negative (b)
carding angle
52. •
The tooth point
Carding is performed at the tips of the teeth
and the formation of the point is therefore
important. For optimum operating conditions
the point should have a surface or land (b) at
its upper end rather than a needle form. This
land should be as small as possible. To
provide retaining power, the land should
terminate in a sharp edge (a) at the front.
Unfortunately, during processing of material
this edge becomes steadily more rounded;
the tooth point must therefore be resharpened from time to time. Formation of
a burr at the edge (a) must be avoided during
re-sharpening. The tooth must only be
ground down to a given depth, otherwise
land (b) becomes too large and satisfactory
carding is impossible – the clothing has to be
replaced.
Fig. The tooth point
53. •
The base of the tooth
The base is broader than the point in order
to give the tooth adequate strength, and
also to hold the individual windings apart.
Various forms can be distinguished. In order
to mount the wire, the normal profile ((a)
for the licker-in, (b) for the cylinder) is
either pressed into a groove milled into the
surface of the licker-in (a) or is simply
wound under high tension onto the plain
cylindrical surface of the main cylinder (b).
(d) represents a locked wire and (c)
a chained wire. Both can be applied to
a smooth surface on the licker-in; in this
case a milled groove is no longer necessary.
Fig: Formation of the tooth base and
mounting on the drum
54. •
Tooth hardness
In order to be able to process
as much material as possible
with one clothing, the tooth
point must not wear away
rapidly. Accordingly, a very
hard point is needed,
although it cannot be too
hard because otherwise it
tends to break off. On the
other hand, to enable winding
of the wire on a round body,
the base must remain flexible.
Each tooth therefore has to
be hard at the tip and soft at
the base. A modern tooth has
hardness structures as shown
in Fig(Graf).
Fig. Metal hardness at various heights in the wire:
A, hardness (A1 = Rockwell, A2 = Vickers); B, tooth
height from the tip to the base
55. Auto leveling equipment for carding
machine
•The material supply should operate with the
greatest possible degree of accuracy as it has
a direct effect on sliver evenness.
•The main regulating position is the feed;
adjusting the feed roller speed (5) usually
performs auto leveling.
•Virtually all auto leveling devices exploit this
possibility; adjustment of the delivery speed is
hardly ever used.
A distinction should also be drawn between:
•short-term leveling systems, regulating lengths
of product from 10 - 12 cm (rarely used in
carding);
•medium-term leveling systems, for lengths
above about 3 m;
•long-term leveling, for lengths above about
20 m (maintaining count).
In addition, regulating can be performed by
open-loop or closed-loop control systems
56. Medium term auto leveler:
•An optical measuring device
detects relative variations in the
cross-section of the fiber layer on
the main cylinder over the whole
width of the cylinder.
•The measuring device is built into
the protective cover above the
doffer.
The device measures reflection of
infrared light from the fibers.
•After comparison with the set
value, a difference signal is
generated and passed to an
electronic regulating unit.
•This operates via a regulating
drive to adjust the infeed speed of
the card so that the depth of the
fiber layer on the main cylinder is
held constant.
57. Long term auto leveler:
•This is the most commonly used
principle of card autoleveling and
serves to keep the sliver count
constant.
•Measuring is performed by
a sensor in the delivery (at the
delivery roller).
•The pulses derived in this way
are processed electronically so
that the speed of the infeed roller
can be adapted to the delivered
sliver weight via mechanical or
electronic regulating devices.
•Long-term autoleveling is an
integral part of modern cards, and
in any case used in production of
carded yarns and in the rotor
spinning mill.
59. Grinding:
•The operating life of clothing is quoted in terms of the total throughput of material.
For the cylinder it normally lies between 300 000 and 600 000 kg, but it can be
higher in some circumstances.
•Processing of materials therefore considerably wears down the teeth – they
become rounded at the top and lose their aggressiveness.
•The direct result is a continuous increase in the nep content of the sliver.
•The points must therefore be sharpened from time to time, in order to give a better
shape to the edges by grinding them. Each new grinding operation reduces the
number of neps, but the level never returns to that prior to the previous grinding
Cylinder
Flats
First grinding after
[kg]
80 000 - 150 000
80 000 - 150 000
Each additional
grinding after [kg]
80 000 - 120 000
80 000 - 120 000
60. Frequency of grinding:
•The deterioration in quality from one
grinding interval to the next arises from
the fact that the teeth are ground down
to successively lower heights, the lands
at the teeth points become steadily
larger, and softer metal layers are
gradually exposed.
•The interval is best selected depending
on the mills nep limit (c).
•Since the doffer clothing works much
less than that of the cylinder, it should be
ground only half as often, or even less
frequently.
•The clothing on the licker-in should not
be ground; it should be renewed after a
throughput of 100 000 - 200 000 kg.
Fig. Increase in neps between grinding
periods: A, number of neps in the web; B,
grinding interval; b, general rise of the
lower nep level; c, mills limit for neps