Blow_Room1232142.pptx31442222444144423422

blowroom

1. What is Short Staple Spinning?
Ans: From 12 mm to 64 mm staple length fibres run on different
machines, making the process of yarn through the twist is called

short staple spinning.
or

From 5 to 2.5 inches staple length fibres by many process passage

are yarn made through the twist is called short staple spinning.

2. Blow Room

Basic Principal of Short Staple Spinning,

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Bales

Tufts

Smallar Tufts:

Opening & Feeding

Opening, cleaning & mining or bending

Carding Orawing-182,

Lap forme, Combing Simples, ing

Oriented res, Ot
[Se Redactor]

Drafting Doubling & Drahing, Twisting
mixing or bending

3. What is blow room? Why it is called blow room?

Ans. The section where the supplied compressed bale is turned into a
uniform lap of particular length by the operation - Opening, Cleaning,
Mixing or Blending is called blow room section.

This is the first section of spinning as a 40% to 70% trash are removed
the process. The cleaning efficiency of blow room is 60% to 65%. Blow
room consists of some number of machines are installed for achieving
the object (Opening, Cleaning, Mixing or Blending and Uniform Lap
Sheet). So this section by flow of air through the fibres transfers from
one machine to another machine (in the next machine). For this reason it
is called "Blow Room".

4. Objects of Blow Room:
a) Opining:
Opening is the first operation, carried out to the stage of flocks in the blow room.
i) To open the compressed bales of fibres and
ii) To make the cotton tuft. a small size as far as possible.
b) Cleaning:
To remove the dirt, dust. broken leafs. stalks, seed, particles, grass and other foreign
matters form the fibres.
c) Blending or Mixing:
To produce a comparatively good quality material and to decrease the production cost by
blending or mixing.
d) Lap forming:
D To convert the opened and cleaned fibre into a sheet of particular width and uniform
weightunit length which is called lap.

Ib To roll the lap of predetermined length in a cylindrical shape around a lap pin.

5. Basic operations involved in the blow room:

i) Opening : By action of opposing spikes

ii) Cleaning A By action of beater.

iii) Dustremoval | By action of air current.

iv) Blendingor mixing : By hand or Machines.

v) Lap forming : a) Scutcher (Fixed), b) Chute feeding (continuous,

Principle action in blow room myc:
To opening. cleaning, transforming. regulating and uniform lap forming
from compressed bale. Mainly four principle action takes place in blow room.
These are -
i) The action of opposing spikes.
ii) The action of beaters.
ii) The action of air current
iv) Theaction of feed regulating.

6. =

+ The action of opposing spikes:

The action of opposing spike is opening the fiber. It makes the compressed
bale in

tuft form. By this action, the large pieces of fibre have been reduced in size.

Object: i) To removed dust and trash. ii) To reduced cotton size from large pieces
Achievement of this action depends on:

i) Proper setting of inclined spiked to evener roller and Beater spiked to
beater spiked.

ii) Speed bet" inclined spiked to evener roller and beater to beater.

i) Hopper bale breaker. ii) Hopper feeder. iii) Multi bale opener. iv) Step
cleaner.

7. + _ The action of beaters:

Beaters are responsible for removing almost all type of impurities extracted in the
blow room, It also helps in opening of fibres,

Object : i) To removal dust, trash from cotton fibre.

ii) To opening and cleaning the cotton.

i, Proper setting of beater to grid bars. ii) Beater Speed. iii) Setting of grid bars angle.

Application of this action:

i) Step cleaner. ii) Crighton or Vertical opener. iii) Bladed beaters.

Types of beater:

i) Supper cleaner. ii) Porcupine beater. iii) Bladed beater. iv) Kirshner beater.

8. #The action of air current:
During processing the movement of the fibre from machine to
machine is done by air current. It also helps the separation of lint and trash.

Object:
i) Transferring cotton fibre from one myc to another myc.
ii) To removal dust and trash.

Achievement of this action depends on:

i. Fan size and speed of fan. ii) Radius of trucking pipe.

i) Shirley wheel. ii) Vertical / Twine opener. iii) Hopper feeder.
Methods of separating the air from cotton:

i) Shirley wheel. ii) Condenser delivery box. iii) A pair of cages.

9. + The action of feed regulating:

The action of regulating motion gives the uniform output of
fibres by the help of swing door and swing paddle.

Object : i) Uniform lap forming.

ii) Controlling feeding from one myc to another mvc.

Achievement of this action depends on:

i. Uniform cotton feeding. ii) Setting between inclined spiked and evener
roller. iii) Control of constant volume of cotton in the hopper or bin
with the help of swing door, pedal, micro switch. iv) Control of feed of
cotton in the reserve box with the help of photo- electric cell. v) Cone-
drum regulator.

10. Opening

“Opening is the first operation, carried out to the stage of flocks in
the blowroom and to the stage of individual fibres in the card.
Flock weight can be reduced to about 0.1mg in the blowroom.

N eel ees

-cetPelb ohh

Openness of fibre material after
various blowroom machine stages
A- Degree of opening(Specific volume)

B- Blowroom stage.

11. Stages of opening

* Two stages of opening must be distinguished:
Y Opening to flocks in the blowroom
Y Opening to fibers ; In the card and OE spinning machine.

* In addition, the technological operation of opening can include:

Y opening out - in which the volume of the flock is increased while the number
of fibers remains constant, i.e. the specific density of the material is reduced;
or

V breaking apart - in which two or more flocks are formed from one flock
without changing the specific density,

12. Table 1- Opening devices

Quilted shaft

Multiple-bla-
des beater

Spiked lattice

Picker

Carding bars or
plates

: Appearance

! Deseri ption

: Small diameter, widely used,
e.g. in step cleaners.

Larger diameter,

e.g. in the mono-cylinder cleaner.
Shaft with many long beater rods,
: hardly used.

Two, three, or more arms. Now
used only in old blowroom lines.

Endless belts
den or plastic bars in which needles
are set, gives very gentle opening.

In the bale picker and blending
grab (both outdated).

The devices associated wi
carding drums of the card.

13. The intensity of opening

The intensity of opening is dependent amongst other things on the following:

+ Raw material:

v Thickness of the feed;

v Density of the feed;

v Fiber coherence;

Y Fiber alignment;

v Size of flocks in the feed.

+ Speeds:
v Speed of the devices;

Y” Throughput speed of the material.

+ Ambient conditions:
Y” Humidity;
Y” Temperature.

Machines/devices:

Type of feed - loose or clamped;
Form of feeding device;

Type of opening device;

Type of clothing;

Point density of clothing;

Arrangement of pins, needles, teeth,
etc., on the surface, i.e. aligned or
staggered;

Spacing of the clamping device from
the opening device.

14. Cleaning

« In cleaning, it is necessary to remove the dirt, dust, broken leafs, stalks,
seed particles, grass and other foreign materials from the fibres.

“The blow room cannot eliminate all the trash present in the raw
material. A blowroom removes approximately 40 — 70% of the
impurities. This depends on raw material, on the machines and on the
environmental conditions

Degree of cleaning (A) as a
function of the trash content
(B) in the raw material in %.

15. Possibilities for cleaning or Classification of cleaning:

The available possibilities for cleaning of natural fibres can be
divided broadly into three groups-

+ Chemical cleaning + Wet cleaning (Washing) + Mechanical cleaning

By mechanical cleaning process, only particles on the surface of the
flocks can be removed. The following procedures can be used:

* Striking
+ Beating
+ Scraping
+ Suction

* Combing

Falling out
Ejection ( Use of centrifugal farce)
Separation
Separation

Extracting

16. Striking; Striking. Carried out by pins, noses etc, on the opening devices, leads to
repeated collisions of the flocks with the grid bars, causing foreign particles to go
through,

Beating: In a beating operation, the flocks are subjected to a sudden strong blow,
The inertia of the impurities is substantially greater than that of the opened flocks
due toe the low air resistance of the impurities. The latter are hurled against the
grid & because of their small size, they pass between the grid bars into the waste
box, while the flocks continue around the periphery of the rotating beater.

: Impurities can be scarped off when the fibres are guided, under
relativ ely high friction, over m/c components, grid bars, mote knives or even other
fibres, This operation is mainly important in dust removal,

Suction: Suction is less suited to the elimination of coarse particles than to
extraction of dust. Transport air is fed through filters or perforated sheets. The
small dust particles which has been released during beating or transport, pass with
the air through the fine openings. The flock cannot pass.

Combing: In combing, needles pass completely through the body of fibres &
draw impurities out of the inner regions of fibres. This is the only form of
mechanical cleaning in which regions other than simple surfaces are cleaned.

17. Q. What is degree of cleaning? Dhaka Textile-'08
Ans:
Degree of cleaning is determined by cleaning index.

D,-D,
D

«, Cleaning index, C, = x100%

F

Here, D; = The dirt content of the feed mtl.

Dp = The dirt content of the delivered mil,

T =Total.
The dirt content is usually determined with the aid of the shirley analyzer. The
cleaning index is strongly dependent on the dirt content but not solely. The
cleaning index may be different for different cotton types with the same dirt
content. There are types which can be cleaned easily & other which can be cleaned
only with difficulty.

18. Degree of cleaning in the blow room

* The following table shows how much trash is normally
removed from cottons with different trash levels.
Original trash content Quantity of trash removed

< 1.2% < 40%

1.3 - 2.0% 40 - 50%
2.1-4.0% 50 — 60%
4.1-7.0% 55 - 65%

>=7.1% 60 - 75%

19. Cleaning efficiency

“The idea in opening and cleaning the cotton is to separate the lint
from trash. The efficiency of the blowroom has to be assessed in
terms of the quantity of the trash it removes or in terms of the
cleaning efficiency.

Trash (%) in | No. of beating Cleaning
mixing points efficiency (%)

Cleaning efficiency of

modern blow room
lines

5.1 and above
3,1 to 5.0

1.0 to 3.0 3 55

trash (%) in mixing - trash (%) in lap

Cleaning efficiency (%) =
— x 100
trash (2%) in mixing

20. Influencing Factors in Cleaning :

U The larger the dirt particles, the better they can be removed. Since almost every blow
room machine can shatter particles, as far as possible a lot of impurities should be
eliminated at the start of the process.

Q Opening should be followed immediately by cleaning (If possible in the same machine)
U The higher the degree of opening, the higher the degree of cleaning.

OA very high cleaning effect is almost always purchased at the cost of a high fibre loss.
Q There should be slightly less cleaning in the blow room and slightly more at the card.

Q Where a waste recycling installation is in use, a somewhat higher waste percentage can
be accepted in the blow room.

Q Higher roller speeds give a better cleaning effect. But also more stress on the fibres.

O Above a certain optimum roller speed, no improvement of the elimination capability is
achieved, but stressing of the fibres goes on rising and so does fibre loss.

O Cleaning is made more difficult if the impurities of dirty cotton are distributed through
a larger quantity of material by mixing with clean cotton.

O Damp stock cannot be cleaned as well as dry. High material through put reduces the
cleaning effect and so does a thick feed sheet.

21. Important Machine Parts of Blowroom.

To perform the operations uniformly several machine parts
are required, among them grid is one of the most important
part which plays an important role for better cleaning.

Grid

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

; at most = and usually = to ; of the opening assembly.

22. Grid

* The grid as an operating device

* The elements of the grid

* Waste collecting chambers under the grid

* Grid adjustment

* Interaction of feed assembly, opening element and grid
* Alternative cleaning possibilities

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.

Fig. 25 — Two-part grid

23. The following elements can be used in the grid:

DODODO

Fig.

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.

rr ))))
26 —The elements of a grid Hl

24. + Function of different grid bar:

|) Slotted sheet: Slotted sheet are formerly placed under cords and used to
a steadily decreasing extent.

II} Perforated sheet: It is formerly placed under cards and used to a steadily
decreasing extent.

111) Triangular section bars: Modern girds are mostly made up of triangular
bars. These are strong easy to manipulate and give a good cleaning effect.

IV) Angle bars: These are some what less robust/strong and can tend to
create blockages.

V) Blades bars: Today girds are made up to knife blade alone, without other
element types. Blades have been used as a gird elements for a long time,
almost always in combination with triangular section bars.

25. Grid adjustment

The grid can be in one, two or three parts. Correspondingly, it can be adjusted
only as a unit or in individual sections.

Three basic adjustments are possible:

Q Distance of the complete grid from the beater;

Q Width of the gaps between the bars (Fig. 28, a=closed, b=0pen);

Q Setting angle relative to the beater envelope (Fig. 27 and Fig. 28c).

It is not common to make all these three adjustments. In most the cases the
machines are so designed that only two adjustment types are possible.

— CALAMA

Py Y AA DEA
Fig. 28 — Adjustment of the grid bars
Fig. 27 — Changing the grid bar angle to the beater

26. Interaction of feed assembly, opening element and grid

Fig. 29 to Fig. 32 demonstrate the influence of adjustments to these elements:
Q Fig. 29, distance between feeding device and beater;

Q Fig. 30, grid gap width;

O Fig. 31, beater speed 740 rpm (and setting angle of the grid bars);

Q Fig. 32, beater speed 550 rpm.

The figures do not show fiber deterioration, or even damage, that can be caused.
Nevertheless, very fine settings and high rotation speeds can produce very negative
effects. On the other hand, the number of neps is scarcely affected. The design of the
machine and its components exerts the strongest influence on neppiness.

ai

Fig. 29— Influence of feed pedal distance (As; B, mm) on waste elimination (A, %)

27. Fig. 30— Dependence of waste elimination: (A,
%) on the width of the grid gaps (B) (1 closed, 4
open). a = proportion of good fibers; b = trash
content.

ars Fiat as] Fa

a a
war ar 0 ur 20 307 a
5 a

si en em

Fig. 31 - Dependence of waste
elimination: (A, %) on the setting angle of
the grid bars relative to the beater (Bin
degrees). |, fiber content; Il, trash content;
111, filter drum loss. (Beater rotation speed:
740 rpm.) Fig. 32 — The same function as
Fig. 31 but with a beater rotation rate of
550 rpm.

28. > Waste chambers under the grid:

Impurities and fibres fall through the grid gaps and accumulate in
large quantities in the chamber under the grid. Waste used to be
periodically removed manually, but pneumatic removal systems are
used today. As far as the cleaning effect is concerned, modern

waste chambers are passive elements, without influence on the

operation.

29. Alternative cleaning possibilities

Fig. 33 — Airflow cleaner

An alternative to the commonly used mechanical clesning was the
airflow cleaner from the former Platt Company.

The ‘Airstream-cleaner’ comprises two parts, 3 Kirchner roller az
opening assembly [and pre-clesner] and the airstream cleaner itself, a5
shown diagrammatically in Fig. 33.

The cotton passes from the Kirschner roller [in front of Aj inte duct A.
The transporting air ir subjected first to acceleration due to
convergence of the duct bore, and te an additional airstream created
by fan (V}.

In region C, the whole airstream undergoes 3 sharp diversion (of more
than 90°] towards E.

While the relatively light cotton tufts ean follow the change of
direction, the heavier foreign particles fly through an opening in the
duct, beyond region C, into the waste chamber

This is an extremely gentie cleaning technique, but it requires foreign
matter significantly less able to float than the fibers, Le. it must be
substantially heavier than the fibers.

Unfortunately, this is no longer true for all cotton varieties, and
therefore this good cleaning ides is not applicable today.

30. Q Assembly of a blow room line depends among other things on:

Type of raw material;

Characteristics of the raw material;

Waste content;

Dirt content;

Material throughput;

Number of different origins of the material in a given blend.

+ The task of the blow room line is to:
* open the material into very fine tufts;
* eliminate most of the impurities;

* eliminate dust;

* provide a good blend.

31. Advantages of modern Blow room: Disadvantages of modern Blow room:

. High production. 1. Very expensive.

. Reduction of human error. 2. No possibility to check contamination.
. A large number of bales can be used for mixing. 3. Unplucking of the last layer of bale.
Up to four assortment con be done.

. Controlled beating.

. Smaller tuft size.

P.L.C (Program Logic Control) System used.

. Auto stop motion.

. Less labour required.

0.Less space required.

210010 ER Ne

32. + Types of machine comprising blow room installation:

The blow room performs with several series of machines and each of
them has separate function like opening, cleaning mixing and blending
etc,

O Opening Machines:

I. Conventional bale openers / Breaker.

II. Bale plucker: a) Horizontal type. b) Vertical type (It is not used at
preset). c) Rotary Type. d) Lateral type.

III. The blending grab of Schubert & Salzer.

IV. Multiple bale opener (MO IV of Hergeth Hollingsworth).

V. Trutzschler automatic bale opener
(BLENDOMAT- BO-A. Bale Opener - BO-U, Bale Opener - BO-C. Bale Opener - BO-R).

VI. The Unifloc of Rieter.

33. + Trützschler automatic bale opener (BLENDOMAT BO-A ):

i} To Open the Compressed bales and made into small tufts.
li) To facilitate the feeding material to the next machine.

Description:

Maximum flexibility in terms of bale lay-down and work-off:

Opening of optimum quality chain

Production capacity 750 kg/h to 2,000 kg/h

Work-off of 1 to 3 bale groups

Lay-down (up to 200 bales) for long, unattended operation

Working width max. 2,300 mm, and machine length of 50 m and more

Two opening rolls ensure uniform production and tuft size

Separate lay-down for parallel lots

Simple and safe operation Here,
1- Opening Rollers
2- Carries caring rollers
3. Carries
4- Separator
5- Safety Rail
6- Bales
7- Outlet

DODODODO

34. Working principle:

It is a bale opening of breaking machine. Bale opening is the first module in a
modern blowroom. Only in this way is an homogeneous tuft flow ensured for optimal
downstream processing. With two opening rolls, it is particularly gently and efficiently
from first to last bales at micro tufts size and supplies to the next machine. The
possibility of planning the unit with a single or double row bale lay-down enables
perfect adaption to the spatial conditions.

Arrangement of 3 bale groups with the BLENDOMAT BO-A

35. 1 Control cabinet
2 Bole la

3 Take-off unit

4 Swivellin,

$ Duet for material
transport

36. The unifloc of Rieter

Objects:
i) To Open the Compressed bales and made into small tufts.
ii} To facilitate the feeding material to the next machine.

Description :
In concept, this is currently the most widely used type of machine.

Machines similar to the UNIfloc are built by Marzoli (8 12), and Trützschler
(Blendomat) among others.

The Rieter UNifoc enables up to 130 bales arranged per side as four
components (different bale types) per blend over a maximum layout length
of 50 m to be processed, The machine can process one or two blends
simultaneously. The production rate is normally up to 1400 kg/h.

37. Working Principle:
The feed duct (D) and the two guide rails (£) are secured to the floor.

The chassis (A), which moves back and forth on the guide rails, carries a
turret (B), which is rotatable through 180° and supports a raisable and
lowerable extracting assembly (C).

The latter has individually replaceable double-tooth discs and changes its
direction of rotation on reversal of the direction of movement of the chassis,
so that material can be extracted in both directions of travel.

A = Chassis
B = Turret
C = Extracting assemble or Opening Roller
D= Feed duct

E E= Two guide rails

38. Universal bale opener

Variants of the Universal Bale Opener BO-U
Extendable feed conveyor
feed lattice and

inclined spiked lattice ensure a good mixing

The evener roll prevents too large tufts from passing

An integrated machine control makes operation simple

By an additional feed trunk, raw material can be mixed with sliver waste

A second Feed Trunk BR-FU allows adding e. g. cleaned waste from the recycling
installation

The feed trunks can optionally be fed by Condensers BR-CO (as shown here) or by
Material Separators BR-MS

aes ND

po

39. Variants of the Universal Bale Opener
BO-U

1. Extendable feed conveyor

2. feed lattice and

3. inclined spiked lattice ensure a good
mixing

4. The evener roll prevents too large
tufts from passing

5. An integrated machine control makes
operation simple

6. By an additional feed trunk, raw
material can be mixed with sliver
waste

7. A second Feed Trunk BR-FU allows
adding e. g. cleaned waste from the
recycling installation

8. The feed trunks can optionally be fed
by Condensers BR-CO (as shown here)
or by Material Separators BR-MS

40. Compact Bale Opener BO-C

Waste Opener BO-R

Extendable feed conveyor

. feed lattice and
. inclined spiked lattice

ensure a good mixing

. The evener roll prevents

too large tufts from
passing

. The evener lattice

prevents lapping of sliver
waste

. The star roll holds the

slivers on the feed
conveyor and tears them
up

. A dust extraction unit

keeps the workplace clean

41. O Beating point/ Cleaning point:

i)
ii)
iii)
iv)
v)

> ~~ For coarse cleaning | Less no. of spiked on the beater)
Ultra cleaner / Step cleaner /super cleaner

Dual roller cleaner or Axi flow cleaner

Mono cylinder cleaner of rieter.

Bladed

Krishner beater.

> For fine cleaning (More no. of spiked on the beater)
RN Cleaner of Trutzschler
Porcupine beater.

. ERM cleaner of Rieter.

Mixing and blending Machine:
Mixing battery
The Multiple Mixer of Hergeth Hollingsworth (U.K)

. Trutzschler Integrated Mixer MX-16 and CLEANOMAT Cleaner CL-C4
iv. The Unimix of rieter.

42. Q Dust Removal m/c:

Rieter Dust extractor

Transport of Material:

i. Mechanical transport equipment.

ii. Pneumatic transport equipment.

Q Auxiliary equipment's of Associated equipment’s.
i. Metal extractor or Heavy particle separator.
ii, Fire eliminator/detector.

ii. Waste disposal.

QO) Regulating Motion:

i. Swing door

ii, Photoelectric cell.

iii. Measuring pressure.

iv. Piano feed regulating system.

O Lap Forming Unit

i. Scutcher — Conventional

ii, Chute - Modern.

43. v

Factors influences the cleaning efficiency:
i. Raw materials type and quality.

ii. M/c design, speed and settings.

iii. Operators performance.

iv. Supervision.

+ A Blow Room comprising a no. of machines where m/cs may be classed in the following way-
a. Major beating/cleaning points.

b. Minor beating/cleaning points.

c. Ancillary equipment's.

List of the above machines generally installed in different Blow-room lines.

a. Major beating/cleaning b. Minor beating/ Cleaning points.
points: i. Bale plucker

i) Step cleaner /super cleaner. + Bele opener
) P ia "ii Sow toothed beater

i) Porcupine bester: iv. Se-dusting elements
iii) Mono cylinder.

. Cond
iv) Axi flow cleaner be ia
w) Krischner beater. a

. By-pass syst
wi) Bladed beater vil. By-pass system
wii) ERM cleaner etc.

c. Ancillary equipment's.
i. Exhaust fan.
Condensing cage.
Hopper feeder/ Feeding.

viii. Two-way distributor
ix. Feed regulating motions
x Filter room etc.

44. O Write a short note on regulating action or regulating motion:

— Regulating action is responsible for maintaining a constant flow of
cotton through each m/c and controlling over the regulating of the material
through out the whole process. The current amount of cotton in the reserve
box may be maintained by the use of
i. Swing door, ii. Photoelectric cell, li. Measuring pressure, iv. Piano feed
regulating system.

+ Importance of regulating motion:

o To produce not only uniformed lap but also uniformed sliver.

o This motion is important in the Blow-room in order to maintain a constant
flow of cotton.

o For uniform feeding.

o To remove dust, dirt and short fibres as required this motion needed.

o To get optimum efficiency of machine in the blow-room.

45. * Describe about regulating motion present in Modern Blow-room:
> The following regulating action is present in modern blow-room-

By photoelectric cell.

By piano feed regulating system
By air current

By Swing door.

By photoelectric cell: Here, the light source and photocell are fitted opposite a window in
each side of the m/c so that the light passes through on to the m/c. while filling the cotton if
the light is broken bet" light source and photocell the feed of cotton is stopped until cotton
again moves away from the light source.

By piano feed regulating system: The pedal movement caused by the thick and thin places of
cotton in employed to shaft the belt in the cone drums by means of lever to after the speed of
the feed roller in order to keep the feed constant per unit time.

By air pressure: When air and cotton are feed, air is sucked by another portion. This air
pressure is measured by sensor and is used to determine the amount of cotton present in the
hoppers. It pressure is more, it stops feeding and if less it allows more cotton to enter.

By swing door: The arrangement of swing door is such that when the hopper is about = to 3

full of cotton, it is forced down against resistance of the counter balance spring, then the drive
to feed lattice is stopped. The swing door is used for the uniform feeding of cotton to spiked
lattice.

46. For Low grade Cotton-
Bale Opener
Ultra Cleaner
Porcupine Beater
Axiflow Cleaner
Bladed Beater
Kirschner Beater

Lap former

Conventional Blow-room line:

For Medium Grade Cotton- For High Grade Cotton. For Synthetic fibre-

Bale Opener
Ultra Cleaner
Porcupine Beater
Axiflow Cleaner
Kirschner Beater

Lap former

Bale Opener
Ultra Cleaner
Porcupine Beater
Kirschner Beater

Lap former

Bale Opener
Ultra Cleaner

Hopper feeder with
reserve box

Lap former

47. Modern Blow-room Line:

Rieter (Switzerlend)

Bale Opener; Unifloc A 11

y Metal detector
and bale opener

Uniclean B 11

PTE B73R

Foreign fibre detector
Y and Separator (FFDS)

Uniflex B 60

Dustex and Fire
detector

Chute feed System

Trützschler (Germany)

Bale opener / Blendomat BO-A
Per cic er CLP
Multimixer MPM 6/MPM8
Fine cant CLCICVT
Dustex
Foreign fibre detector

Chute feed system

48. Fig. — Rieter blowroom line; 1. Bale opener UNIfloc A 11; 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

49. BLOOWROOM - PRODUCT OVERVIEW

Rieter VarioSet blowroom/carding room

50. BLOOWROOM - PRODUCT OVERVIEW

Integrated recycling

Waste from thowraom: 811/569 silver noil

bh fotor spinning
mill

51. BLOOWROOM - PRODUCT OVERVIEW

Matored component fead

cards
tolor spinnin,
mill

52. Trützschler (Germany) Blow room line

Automatic Multi Function Integrated Mixer Foreign Part
Bale Opener Separator MX-I 6 and Separator
BLENDOMAT SP-MF CLEANOMAT SP-F

BO-A Cleaner CL-C 4

53. à Whatis impurity or wastes ?
All the by-product during preparation of yarn can be found in a variety of
machines, he is called impurity or wasres.

à How much type impurity found in the blow room?

Q Mainly two types of impurity found in the blow room.

Such as - i) Usable impurity. ii) Unusable imputiy.

i) Usable impurity - a) Dropping-1. (.5% to 1%) b) Dropping-2 (1.5% to 2%). c) Lap
cut. d) Rejected lap.

ii) Unusable impurity - a) Trash (dirt, dust, broken leafs, stalks, seed, particles,
grass).-1%

Total Impurity found in the blow room - 4% to 5%.

54. O Write the size in um of trash, dust,
micro dust and breath able dust

particle
PARTICLE SIZE ==» (um)
Trash above 500
Dust 50-500
Microdust 15-50
Breathable dust below 15

Q whatis the amount of trash in cotton?

The scale below represents the degree of trash-

up to 1.2% = very clean:
1.2-2.0% = clean;

2.1-4.0% = medium;
4.1-7.0% = dirty;

7.1% and more = very dirty

55. Causes of Neps Formation in Blow Room

Cotton with too high or low
moisture.

Extremely fine cottons with high
trash content.

Reprocessing of laps and mixing
of soft waste.

Rough or blunt blades and bent
pins on beaters.

Damaged and rusty grid bars.

Narrow settings between the
feed roller or pedal and beater.

Long, curved and U-bends in
conveyor pipe lines.

9.

10.
11.
12.

13.

Inappropriate ratio of fan to
beater speed.

Wider setting between
stripping rail and beater.

Too high or low beater speed.
Worn out stripping rails.

Air leakage and obstruction of
cotton flow through pipe line.

Use of more number of beaters
than the requirements.

56. Causes of Excessive lint loss

Grid bars too widely.
Missing grid bars.

Higher number of
beating points.

High short fiber
content in cotton.

Uneven mixing of soft
waste,

6. Weak air current due

to inadequate suction
pressure in the duct.

Improper adjustment
of waste control plates
in modern beaters.

57. Q. What do you mean by Major & Minor beating point?
Noakhali Textile-"08.

Ans:

When we use a beater to clean fibre then it is called major beating point. e.g. Step
cleaner, Porcupine beater, Krischner beater etc.

But when we use a beater to open the fibre, but some cleaning is occurred then it is
called minor beating. e.g. Bale plucker, Bale opener, Saw toothed beater.
condenser etc.

58. LQ. Write down the basic operations involved in B/R (in short).

Ans:
Feeding

1
Opening (by action of opposite spikes)

4
Cleaning (by action of beater)
1
Blending

1]
Dust removal (by action of air current)
4
Transporting’ Transferring
1
Lap sheet formation
(1) Scutcher(fixed) intermittent.
(11) Chute feeding (continuous).

59. Q. Describe briefly about the operations involved in B/R.

Ans:

1. Feeding: We all know that, For doing something by the help of m/c. we have
to put the raw mtls in the nves. In B/R we put cotton (raw mtl) in the mic. So.
this process is called feeding. It is the perquisite of machinery working. As for
example — when we produce nuts & bolts by using lathe m/c, first of all we put
the base metal or feed the base metal into the holder.

. Opening; Opening is the 1" m/c operation req’, carried out to the stage of
flocks in the B/R & to the stage of individual fibres in the card, Flock weight

3. Cleaning: A B'R installation removes approximately (40-70)% of the

impurities. The result is dependent on raw mil, on the mics & on the
environment conditions. From the graph, cleaning effect cannot & should not
be same for all impurity level, since a lot of dirt can be removed more easily
than a little. In order to clean, it is necessary to eliminate about as much fibre
as foreign mils. Percentage of total mtl eliminated, in cleaning efficiency.

ts

_ Total waste — Good fibre eliminated si
Total waste

100

60. Here,

A= Function of row mtl. (%)
B = Function of dirt (9)

4. Blending: Fibres can be blended at various stages of the process. These
possibilities should always be exploited. For example, transverse doubling. The
start of the process is one of the most important stages for blending. Intensive
blending in a suitable blending mc must collect the sequentially arriving
bunches of fibres from individual bales and mixes them througly.

3. Dust Removal: Almost all manufactures of B/R machinery now offer dust
removing machines or equipments in addition, opening and cleaning. Dust
removal is not an easy operation. since dust particles are completely enclosed
in the flock and hence held back during suction.

61. 30

u Here,

= lto5 = Blowroom m/cs.
¿|? 6 = Card

= 7 = Draw frames (1% & 2%)
E a = Filter, b = Takerin.

10 I = Dust in the waster

II = Dust in the exhaust air

Various processing stages

Fig: Dust removal as a percentage of the dust content of the raw cotton at the various processing stages.

62. 6. Transporting/Transferring: To transfer the opened & cleaned fibres into a
sheet form of definite width & uniform unit length. In this step, mtls are
transported from one to another m/c. There is also the transfer of lap from the
lap pin to a rod to suitable handle for facilation the feeding of next process Le
carding.

7. Lap sheet formation: In this step, lap is formed which is in a sheet form of
definite width & uniform unit length. After forming lap, it is rolled in a

eylindrical shape around a lap pin. Lap sheet formation is formed in two ways

a. Scutcher (fixed) intermittent.
b. Chute feeding (continuous).

63. Q. Write a note on “Bale management system”.

Ans :
Bale management: Bale management is defined as the choice of cotton bales
according to the fibre characteristics in order to achieve acceptable & economical
processing conditions & a consistant yam quality,
Objects:

1. To acquire a improved knowledge of the quality characteristics of a yarn,

2. A mean of avoiding quality jumps.

3. A possibility of reducing costs as a result of an improved knowledge of the

fibre characteristics

Importance: If bale management is absent —

1. Lot to lot variation is called fabric barre effect.

2. In weaving. shade variation.

3. In kuitted yarn, colour variation.

e i To manage the bales we need
four modules of fibres & the relation exist between fibres & yarn.
i) Strength.
ii) Length.

iii) Colour grade,
iv) Micronaire value.
If there is 300 bales to manage & the given modules are —

Bale no. MY. Colour grade Scr
1 4.0 GM 100
2 4.1 M. 105
3 42 SM 109

64. 4 43 LM 112

+ - I ”

300 45 GO. 115
Tf the 300 bales can be managed for 10 days taking 30 bales per day then.
MLV. Colour grade SCI No. of bales
4.0 GM 100 100
41 M 105 50
4.2 SM. 109 100
43 LM. 112 =
300
For 30 bales/mixing.
MV. Colour grade SCI No. of bales
4.0 GM 100 10
41 M 105 5
42 8. 109 10
43 LM. 112 2

0

by

65. Q. What is SCI & BIAS?

Ans :

SCI: SCI means spe" consistency index. It is calculated using the average fibre &
yarn of five consecutive yarns of USDA annual crop reports. The SCI could be
used as the first priority of the selection of bales. The mam use of SCI in selecting
bales is to gain the advantage that all major cotton properties have been selected in
a controlled way. The eq” used to calculate the SCI is as follows :

SCI =-414.67 + 2.9 x strength — 9.32 x MV. + 49.17 x UHML + 4.74 x UI + 0.65 x Rd +
0,36x (+b)
Where. UHML = Upper Half Mean Length in inches.

UI = Uniformity Index.

Rd = Reflectance degree.

(+b) = Yellowness of cotton fibre.
BIAS: BIAS means Bale Inventory Analysis system. It is developed by M/s
Zellweger uster. According to this system Mix is formed in a way that bales taken
from stock are having min™ variation in quality parameters from bale to bale &
from day to day.

66. O Factors, Properties considered for bale management:

+ Length & uniformity

+ Fineness (MIC)

> Strength & elongation

+ Color (+b)

+ SCI (Spinning Consistency Index)
+ Maturity.

O Functions of bale management:

+ Cotton procurement
+ Sampling

> Testing

+ Evaluating

+ Receiving

+ Warehousing

+ Mix selection

> Reporting.

67. + Why bale management is important for export quality knitted yarn?

+ The efficiency of production and quality of the end product is determined
by the suitability and quality of the fibre input. So it is very important to
mix. Fibre according to fibre quality to produce specific quality yarn.

+ Bale management is very essential for knitted yarn than woven yarn. The
yarn which has no shade & Lustre or brightness variation, more uniform
and miximum fault can be labeled as good quality yarn.

+ Bale management is important for knitted fabric because of its
construction knitted fabric is made of one set of yarn. So if there have any
variation in yarn that will be highlighted in fabric surface.

> Fineness consistency is essential for kint yarn production, becouse the dye
absorbancy of different (MIC) fibres is not same. When fabrics are dyed,
defferent (MIC) Bivres absorb different amount of dye which introduces a
“barri-mark” problem in knitted fabric. This effect can be avaided by
proper bale management.

> On the other side strength and other uniformity can be maintained by bale
management.

Soto prepare export quality knitted yarn, bale management essential.

68. + Why Bale Management is done in cotton spinning mill?

>

IL

II.
IV.

The efficiency of production and quality of the end product is
determined by the suitability and quality of the fibre input. So it is very
important to maximum Fibre according to fibre quality to produce
specific quality yarn for cotton spinning mills. The importance of bale
management are as below-

To get homogeneous mixing of fibre.

To avoid day to day yarn quality variation

To avoid lustre and shade variation

To get specific good quality of yarn

To reduce cost of production.

69. Q. Describe a Bale opener/breaker mc with near sketch.
Nozkhali Textile-"08.

A= Feed lattice/Bottom lattice.
B = Vertical/imelined lartice.
C = Evener Isttice.

Objects:
1. To open the big jumps of cotton/feed mils.
2. To faciliate the feeding of mels to the next m/c.
3. To carry the mils from one m/c to next m/c.

70. Actions:
1. Action of spike lattice.
2. Action of air current

Working Principle: Bale openers. blending openers, blending bale openers are
manufactured by many companies. Bale opener/Bale breaker is equipped with
bottom lattice, inclined spike lattice, evener roller, wipper roller of suction system.
Its having also some essential accessories. Laying of mtl on the feed table is
performed manually or by a bale opening nyc. The bottom lattice pushes the fibre
mass towards the inclined lattice. Inclined lattice carry cotton with its spike
towards the evener roller for facilitating the feeding. If these cotton lumps are
sufficiently opened, they pass between the inclined lattice & the evener roller.
However. most lumps are too large to pass through the space between the two
units. They are thrown back into the blending hopper by the eve3ner roller & from
the hopper they pass once more info the operating region of the two assemblies.
Each time they become smaller until finally they can pass through to the next unit.
Here evener roller as its name implies it control the amount of passage of cotton
by opposite spike action. Wiper roller wipes the cotton to the surface of evener
roller. Suction fan to the filter room collect the dust & dirt through pipeling.
Blower fans are also activated for transfeming the open cotton suitable for next
mic. This operation continue until m/c stoppage. Production rate & degree of
opening are determined by the speed of operation of the inclined lattice & its
spacing from the evener roller.

71. Setting & their effects:
1) Vertical lattice & evener lattice
wider — More mil passage & less opening.
closer — Less mil passage & more opening.
11) Vertical lattice to evener roller.
wider — Less opening & higher production.
closer — More opening & less production.
111) Vertical lattice & delivery roller.
wider — Higher production.
closer — Less production.

72. Q. Write a note on Two bladed beater.

Ans:

A="Twa bladed beater
B = Grid bar.
Pressure (= Feed Roller.

FE 25 Roller

* Lattice
F ñ
Delivery Waste
roller Box

«Two blades are arranged in both sides and equal distance of shaft.

+ Cotton tuft are passed through feed roller.

+ Then the beater rotate several times until the cotton tufts are not made into
small tufts or individual fibre.

+ Then it is delivered to the next m/e through delivery roller.

+ The seeds or trash are stored in waste box through Grid bar

+ Revolution per minute 800-850

+ To clean broken seeds or heavy impurities of libre.

73. [Q. Write a note on Three bladed beater,

Ans:

Feed Roller wa Pressure A = Three bladed beater.

Roller
ER

Lattice

A

a ae A em bar
Delivery roller

Waste Box
+ Similar to two bladed beater.
+ Three blades are arranged in both sides and equal distance of shaft.
+ It is more effective than two bladed beater,
+ Cotton fibre are passed through feed roller,
+ The beater rotate several times until the cotton fibre are not made into small
tufts or individual fibre.
+ Then it is delivered to the next m/c through delivery roller.
* The seeds or trash are stored in waste box through Grid bar,
+ Revolution per minute is 850-940.

74. ©. Describe efficient Raw Mtl (ERM) cleaner for fine cotton.

Here,

A Fan

B = Mtl filling chute.

© = Condensing roller! Perforated roller/ Filter
drum.

D = Feed roller.

E = Cleaning bealer/roller.
FP = Blind drum

G= Excess air Mowduct.
H - Mtl outlet

I= Waste box.

Objects:

1. To open the fibres to a small tuft.

2. To beat the mtls finally.

3. To separate teh mils from fine dust & trash.
Basic actions:

1. Action of beater:

75. Working principle: A fan (A) draws the flocks by suction from the preceding m/c
& ejects them into a filling chute (B). The rear wall of the chute consists of
individual aluminium lamellae with slot-openings through which the air escape.
The raw mtl remains in the chute, is condensed & is fed to the opening roller by
means of perforated roller (C) & blind drum (F) & the feed roller pair (D). The
opening roller is exchangeable & can be fitted with bladed discs or a saw toothed
clothing. The grid arranged under the roller consists of eight blades. After the grid,
the flocks are removed by suction. The transport air of the fan (A) escapes via the
slotted chute, filter drums & ducts (G).

Mc parameters:

working width > 100mm.

Beater diameter > 400mm

Speed — 1000r.p.m.

Output — Max” 500kg/hr.

76. Q. Describe the mono cylinder cleaner of Reiter for low quality cotton
with near sketch.

Ans:

This is a loose feeding pin opener. Monocylinder cleaner is employed in the
blowing room process between the moang bale opener & Automuxer. The
advantage of this opener is that the impurities are separated without being crushed.

Hose,

À = Entry pipe

B= Exit pipe

C = spike roller

D= Adjustable grid
E= Waste chamber.

1. To separate the impurities from cotton flocks without being crushed.
2. To give the cotton flocks a strong cleaning.

77. Working principle: The cotton tuft is well opened by the bale openers & enter the
míc at right angle to the cylinder axis. The m/c operates in a similar manner to the
dual roller cleaner but has only one drum/cylinder/roller. The mtl enters m/c at one
side & streams through to the other side. In order to prevent flocks being drawn
straight through the mc, the large hood is divided into three chambers by guide
plates. This causes the flocks to fall back into the region of the beater drum after
being hurled out by the roller. In this way, i.e. is to pass three times over the grid.
this gives a strong cleaning effect. The grid is in two parts & these are separately
adjusted.

Mic parameters:

a) No. of beater drum — One.

b) Diameter of drum with spikes — 700mm.

c) Production — 500-800 kg/hr.

d) Speed — 700r.p.m.

e) Width of the m/c — 1500mm.

78. Q. Describe the working principle of Krishner beater
Ans:

A = Spring loaded feed roller.
B = Beater.

C= Grid bar.

D = Condensing cage.

E = Trash chamber.

F =Flap.

79. ‘Object:
1. To open the fibres lumps to individual state as much as possible.
2. To clean the cotton/fibres wath fine action
Basic Action:

1. Action of High Speed Beater.

2. Action of fan
Working Principle:
Raw mils are feed to the Krischner beater through shed feed system & flutted feed
rollers. Beaters high speed cavemg the lumps of mtls to little and separate the trash
finally. With the action of suction fan. mils are carried to next m/c and separated
trash, dusts falls to the dust chamber through grid bars. It is the mvc applicable
equally for processing all sorts of raw mtls irrespevtive of natural artificial fibres.
Setting between beater to grid bars & speed of the beater govem the trash removal
percent.
Mic parameters:
1. Working width: 1200mm.
2. Beater diameter: 406 mm
3. Speed of beater. 820rpm.

80. | Q. Describe Saw-toothed beater with near sketch.

Aus:
The beater which is made by a large cylinder contains tooth like saw tooth is.
called saw-toothed beater. It is used 3 asa major cleaning point in B/R

A =Beater.
B-=Fecding plate.
C= Feed roller

D = Swing door.
E=Reserver

F = Delivery case.
G= Delivery end.

Object:

1. To open the fibres from the cotton tuft.
2. To separate the fibres and

3. To remove the trash from the cotton.

81. Working Process:
Cotion fibres are collected in the reserve box from the previous m/c which are
feeded equally by the feed roller in the m/c. Cotton fibres comes in touch of saw
toothed roller, strikes the cotton fibre. Saw toothed beater push the cotton to the
case, where it is passing between saw-toothed beater de the case, so the fibres have
been extracted & the wastage are fall below the undercase. Cotton fibre cleaned by
this m’c are delivered to the next m/c by air flow.
Uses:

1. To process lower graded cotton fibre.

2. To remove the impuritics from highly trash cotton.

82. Q. Describe Sentcher or Lap former m/c.

Ans:

Scutcher: Scutcher is an unit to form lap sheet from the open & clean raw mtls to
facilitate the feeding to the next processing 1.e. in carding. On the other hand, it is
also known as lap former unit. But scutcher does not work individually. It works
in conjunction with other beater say, K.B, B.B with condenser etc. Scutcher is
designed with some steel polished rollers fabricated one over another. They
creates certain pressure to the mtl processed & form a shect of definite density
depending on the raw mtl characteristics. The rollers are known as calender rollers
from which bottom can lender roller is responsible for delivery 1. c. production. It
15 last m/c of B/R section Uniform laps are produced in this nc.

Here,

A - Kirschner Beater
B - Grid bar

C - Feed Roller

D - Paddle Feed

E - Feed Lattice

F - Cage

G - Calendar Roller
H = Shell Roller
I-Lap

83. Object :

1. Tu produce even lap of predeleamamed length & width.

2. Finally individualization of fibre or small tuft.

3. To remove impurities.

4. To wind the produced lap properly in the lap pin.

Basic function : Beating action.

Working Principle: At first cotton is conveyed by a feed lattice from the hopper
feeder 1, porcupine opener &hopper feeder 2. Then it is brought into contact with
three bladed beater (Krichner beater). It accomplishes a very effective opening &
cleaning operation From the beater chamber cotton passes with the air steam to
the cage & perforated cage. By the help of drawing roller cotton passes to calender
roller. Calender roller reduces the thickness of the fibre. From the calender roller,
cotton is passed te lap roller. The thickness of the fibre in lap roller is half inch.

Thus we get cotton in lap form hy this sentcher m/e.

84. Bottom calender roller ida — 9”
Working width — 40” [Exact to the woeking width of carding engine].
RPM of callender roller — 7-12
Lap weight — 3540/5060 Ths ete.
Lap length — 40450 vds etc
Changeable matter — D.C.P (Draft change pinion}

— Lap length wheel.
Lap formation : In seuteher ınfc, cotton which are coming frem beater are
collected im case À & collected cottons are likely pressed by a calender rollers, In
conventional me, Calender rollers are pressed by backet, weight & liver. But in
modem mic they are kept heavily weighted by air or pmeummtie action Cotton
passed through the top & 2% roller, then 3% Bottom Calender roller. Then by the
help of guide roller, lap is wrap in the roller an two shell roller.

on

Here, A = cage, D = Dead preasure
B= flutted delivery roller S$ Shell roller
CR = Calender roller W = weight

85. Q. Write the causes of lap wt. variation.

Aus:
1. Unsuitable feeding :

a) Irregular feeding of fibres to the feed lattice by the feeders in the bale opener

b) Feed of very large piece of baled cotton.

2. Characteristics of fibre in blending :

a) Ifthe blend contains improper mixing of fibre it may be varying fineness.

b) If there are immature fibres in the blend, irregular lap are produced.

c) lfthere are weak & short fibres, produce regular lap.

3. Incorrect setting of different mc parts :

1) Mechanical swing door or photoelectric cell : Lap variation will produce due
to setting faults in this instrument.

ii) Setting of evener roller : If this setting is incorrect, the opening regularity of
flow of fibre & rate of production of the mc is affected with canses lap
isregullarity.

121) Piano or cone drum regulating arrangement : If this system does not work
effectively. causes lap variation

4. Improper maintenance of the machinery : Due to not well maintained proper
opening, beating, cleaning, disposal of dust, control of air current, fan speed ete
leads to lap variation.

5 Excessive waste content in lap.

6. Incorrect fan speed : If fan speed is too slow, the fibres move on the cages. on
the other hand, if the fan speed/amw flow is too strong, the cotton is dwn

downwards the centre of the cages & will give a barrel shaped lap.

86. Q. Discuss the defects & their remedies of lap due to faulty setting of
míos in B/R.

Aus :
1. Uneven lap : Patchy, sticky, thick & thin places in lap.
Causes : 1. Uneven feed of mil.
i. Faulty regulating motion.
111. Improper m/c maintenance.
Remedies : 1. To casure even iced of mil.
1. Correct bale opening.
ii. Proper m/x maintenance.
2. Irregular lap : Lap should ba definite shape, length de wt/unit length If the lap
is less than the required length them then it is called Irregular lap.
Causes : 1. Uneven feed of fibre to feed lattice.
11) Presence of weak, small & uomature fibres in fibres during muxing,
iit) Faulty regulating motion, cage, swing door.
tv) Improper m/c maintainance.
3. Soft lap : If the lap is less compact, it is called soft lap.
Causes : 1. Low pressure of calender roller.
u. Less relative hunudity.
i. More trash content of fibre.
Remedies : i. Presence of calender seller should be controlled.
ii. Relative humidity should be controlled.
111. Cleaning should be correct.

87. 4. Conical lap : If the width of lap increases or decreases with respect to its initial
width, the lap is called conical lap.
Causes :4 Air suction varies due to fan speed variation So, uneven drawn of mtl
at hoth sides of cage.
il. Pressure vanatıon at both sides of calender roller.

iii, Dirt drain in one side of cage.
iv. More air inlet at one side.
Remedies : 1. To ensure proper au flow.
u. Calender roller pressure must be controlled.
wn. After a certam time, cage must be cleaned.
5, Barrel shaped lap : Tf the thickness of lap in middle is more than that of at the
border sides itis called Barrel shaped lap.
Causes : i More air suction in the middle position of the cage due to excessive fan
speed & so more fibre is drawn in the middle position of cage.
ii) Dine to accumulation of dirt at both sides of the cage.
Remedies : 1) Fan speed should be controlled.
1) After certain time, cage must be cleaned.
6. Licking lap : Not uniform ali over the lap area.
Causes : 4) Low pressure of caleader roller.
ii) Excessive fan speed.
111) Improper roller motion setting.
iv) Low opening of catton.
Remedies : 1) Proper fan speed
1) Proper pressure of calender roller
1) Proper opening of cotton.

88. 7. Defective selvedge : Both sides of lap are uneven.
Causes : i) Waste accumulation at m/c sides
ii) Waste accumulation at grid bars & cage sides
iii) Broken gear teeth or m/c parts.
iv) Faulty cage & faulty surface of lattice.
Remedies : Proper maintenance of cage & lattice.
8. Split lap ; The cotton splits into sheet like a sandwich when unrolling at the
card
Causes : 1) Low pressure of calender roller.
ii) Low temp in B/R section.
iii) Variation of surface speed of top & bottom cage.
Remedies : 1) Proper pressure of Calender roller.
11) Proper temp in B/R.
9. Dirty lap:
Causes : 1) Insufficient dirt removal.
11) Dirty m/c due to improper maintenance.

89. Q. Mention the std. la cification (Approximately)
Ans:

Lap length — 60 yds.

Lap weight — 40-50 Ibs.

Lap wt'yd — 12 to 16 oz -11b

Lap wt. variation — 3%{acceptable
Lap hank/count — 0.0012-0.0018
Lap width — 40-42 inch.
Mechanical draft — 2.5-4

Relative humidity — 55%
Efficiency 70-80%

90. 1.6.3.2. Separation of air and material

By far the most widely used assembly for this purpose is the
perforated drum (Fig. 69). It is used in various machines and
parts, often in so-called suction boxes (condensers).

A partial vacuum is created in the drum, and thus in the duct,
by a fan at one end of the drum. Air and material flow toward
the drum. However, while the air can pass through the perfo- [EN
rations in the drum, and is then passed to filters for cleaning, Material =>
the fiber tufts remain on the surface of the rotating drum and

are carried along with it. In the lower region, the drum sur-

face is screened off from the partial vacuum in its interior. The

tufts are no longer retained by suction and fall into a chute.

Another assembly for separating air and material is the slotted

chute of the Rieter UNIflex (Fig. 57), where the transport air is
extracted through the slot, while the material slides down on

the aluminum ribs of the rear wall of the chute.

91. Q. Describe By-pass system with near sketch. Noakhali Textile-"08,"09.
Ans:

The process by which the fibres are passed through a pipe to the next m/c or
beating point by air flow without using a m/c or beating point is called By-pass
system.

Working Principle : This system 1s used for medium or high grade of cotton.
When the fibre is or medium grade. we can restrict a m/c or beating point. There is
a pipe between the previous m/c de the next m/c. We should off the door of the m/c
which we want to restrict. If the fibre ts of fine grade, we can restrict another m/c
or beating point by the same way.

Advantage :

1. Cotton can be process in the same B/R according to their grade.

2. Cotton processing cost 1s lower.

3. Wastage reduce.

4. Higher graded products are produced.

92. Here,

A- Blender

B - Waste blender

C-Fan

D - Conveyor

Ec 1- Step Cleaner

Fa] -Porcupine Opener

G - Crighton Opener

H&L - Shirley wheel and fan
K - Two way distributor

M - Hopper feeder with Reserve Box
N - Scutcher

O - Lap forming unit

P - Roller Lap extractor

% = Major Beating Point

93. | Q. Short note on — Air Flow system.

Ans:

Object:

1. To transfer the cotton fibres.

2. To remove foreign mil from cotton fibres.

Air Flow System:

Generally the tuft open fibre are flowed by the tension of air and the trash
contents or trash falls down. The open fibres are escaped from the trash by falling
down the trash. This is the principle of air flow system.

A beater or opener is used before this m/c. That beater converts the fibres
into small tuft and the trash contents or trash fibres are separated from the fibres. In
the next process, By the action of air flow, the trash fibres are flowed to the next m/c
and trash contents, Neps, Motes are falls down. This is called “Air Flow System”.

94. 1.8.1.2. Electronic metal extractors

The material is fed from an opening machine such as
Blendomat (Fig. 75, 1), The next device, normally a fan in
front of the mixing machine, extracts the material by suction
(5). Spark sensor (2) detects smoldering material and metal
detector (3) any kind of metal. In either case, active oper-
ating flap (4) is opened by a signal from the detector and
feeds the material into the receiving waste container, which

is equipped with a fire extinguisher device (7) and a temper-

ature sensor (8) to monitor the container (Fig. 75).

Fig. 75 ~ Electronic metal extractor (Tratzschler)

95. 1.8.1.1. Magnetic metal extractors

Magnets have been used for decades in ducting or in spe-
cial parts of machines in order to eliminate pieces of ferrous
material. The most effective form of device is a knee-bend
within the feed duct having permanent magnets at the two
impact surfaces. When tufts are driven against the magnets,
ferrous particles are retained and can be removed from time
to time. Magnetic extractors provide only a partial solu-

tion to the problem because they can eliminate only mag-
netizable metal particles, and let all others pass, Electronic
extractors are needed to remove the other particles, too.

96. 1.4.8.2. Rieter dust extractor

This equipment (Fig. 63) forms part of the pneumatic trans-
port system. A chamber is included in the ducting and con-
tains a pipe which converges and has perforations. As the
material passes from 1 to 2 a special fan draws air from 3
and thus also draws dust from the transport duct, Since the
fiber tufts are vigorously “washed” by air currents in this
ducting, good separation of the smallest dust particles, and
finally their removal, is achieved.

97. 1483 Tiützschler "DUSTEX” dedusting machine 3 e E = 3
= This machine consists mainly of a large chamber with a per-

forated sheet (3), the infeed of the material (1/2) and the
withdrawal of the material at (4). In the chamber itself the
material tufts are blown against the perforated sheet (3).
Here they slide on the sheet down to the tip of the funnel
(4) and pass to the suction after dust is extracted,

1 This fan sucks the material off the CLEANOMAT cleaner

2 The distribution flaps distribute the tufts over the working width of 1.6 m

3 Considerable dedusting is effected by the tufts hitting the perforated surface

4 The material drops into the suction system and is transported to the cards by
‘the variable speed fan

5 The se parated dust is permanently discharged

98. Basic operations in a blow room line(contd..)

Filters

Fig: Filter bags

99. Filters(contd..)

+ Aur filters are essential for modern blow rooms. They are designed to
receive dusty air from fans situated on feeders, condensers and
subsequent to beaters and return clean filtered air into the blow room,
they are responsible to maintain a clean atmosphere in the blow room.

Air filters are available with 2 to 6 filter bags, depending upon the
volume of air be filtered. The bage are made of cotton flannel for
durability and at the same time efficient removal of dust. The smooth
surface of the bags allows the dust, fly and trash to drop into the dust-
bin at the bottom of the bags. The dust bins are divided into
compartments so that the air may be momentarily cut-off from each
one separately while the trash is being removed. This allows the dust
bins to be cleaned out while the filter is in operation.

100. Draft:

Draft is the numerical value which is the ratio of surface speed of
faster roller and surface speed of slower roller.

Draft Measurement:
Here,

A = Slower speed roller
B = Faster speed roller

D, = Diameter of roller A.
D, =r.p.m of roller A.
D
D.

|, = Diameter of roller B.

Surface speed of faster roller (B) ae rpm of roller.
Draft =

— Surface speed of slower roller (A)
_ Dan _ Feed weight / Unit Length Delivery Length / Unit we

= "Dn, OF Delivery weight / Unit Length ©" = Feed Length / Unit weight
— Draft constant

DER ( Mechanical Draft) {D.C.P= Draft Change pinion}

101. Q Draft constant: 1 revolution of feed roller and respective revolution of delivery roller
considering D.C.P is "1" is called draft constant.

Q. How many types of Draft?
Draft are four types: 1.Mechanicaldraft, 2 Technological draft,
3. Assumed draft, 4, Actual / Test draft.

Delivery Count
Feed Count

Q Actual draft =

Desired count of delivery material

O Assume d = Actual count of feed material

Q Count: Count is the no. of #40 yds flacks or hanks in 1 lb cotton. (English Count)

102. Lap Length: The amount of lap which is delivered by bottom calendar roller for 1 revolution of knock-off wheel is called
lap length.

Lap Length Constant: The amount of lap which is delivered by bottom calendar roller for 1 revolution of knock-off wheel
and the number of tooth of change pinion is 1, then it is called lap length constant.

Here,

A = Bottom calendar roller ( Diameter = 7 Inches)

B = Single worm (Teeth = 1)
D C = Warm wheel (Teeth = 24)

D = Change pinion (Teeth = 22)
E E = Knock-off wheel (Teeth = 48 )

z EC. mxDia of bottom calendar roller
Lap Length = 1 Revolution of knock-off wheel X D x 5 x ——s AA

48,24 314x7
=1X 22 x En x 26 yds
=31.97 yds or 32 yds.

E, C
Lap length constant = 1 Revolution of knock-off wheel x D*E*
EA
36

TrX<Dia of bottom calendar roller
36
=1x2x2x

Es 1
=703.36

103. Q Define the cleaning efficiency of carding. i
Ans:

The ratio of trash removed in carding & the trash in lap expressed as percentage, which is
called cleaning efficiency of carding. Cleaning efficiency of carding is 70-85%.

Cleaning efficiency of carding = „ Trash in lap - Trash in sliver , 49

Trash in lap
Trash removed
-————-«100
Trash in lap
Q. What is Neps Removal Efficiency? Noakhali Textile-"09.
Ans:
The neps per grams that is removed from the carding mic is i aby as percentage with
respect to the nep/gms in cotton while passing through the le to the carding m/c is
known as the nep removal efficiency.
NRE = neps/gm of feed mtl - neps/gm of delivered ml «100

neps/gms of feed mt!

104. Mathematical Problem

* 1 1b = 16 ounce = 7000 gram = 453.6 gm
* 1 Metric ton = 2204 Ib.
* 1 kg = 2.2046 Ih.

Q. A lap contains 2% trash after processed in B/R having the cleaning
efficiency of 80%. Find the trash % in raw cotton. Noakhali Textile-"08

Aus:

We know.
E dones 1135) remains after processing
- em Total trash
80 an
sus —
Total Trash

=
Total Trash — — x 100

=> 30 x

= Total Trash - 25% (Ans)

Q. Bottom calender roller dia = 7 inch, rpm = 10 & wt. of every yds lap
is 12 oz and cleaning efficiency 75%. Find out the production of B/R

er hour

Ans
: _3.14x7x10x60x 7512
ES ao ="

= 206.06 Ib (Ans.)

105. Mathematical Problem

* 1 Ib = 16 ounce = 7000 grain = 453.6 gm.
* 1 Metric ton = 2204 Ib
* 1 kg = 2.2046 Ib.

Q. A lap contains 1.5% trash after processed in B/R having the cleaning efficiency of 80%. Find the trash % in raw cotton.

Ans. Given that
Lap trash contains 1.5% after processed in B/R
Cleaning efficiency of B/R = 80%
Raw cotton trash % = ?
We know,
Cleaning efficiency =

Q. Bottom calender roller dia = 7 inch, rpm = 10 & wt. of every yds lap
is 12 oz and cleaning efficiency 75%. Find out the production of BR
hour.

Ans:
3.14x7x10x60x75x12
77T

= 206.06 Ib (Ans.)

106. Q. If lap length const is 720, then set the change pinion for 40 yds lap
ABS:

lp length constant
lap length

a

40

=18T (Ans)

Change pinion =

Q. Tf lap wt. 15 15 oz per yds, find the hank
Ans:

Hank =

1yds x 16 ounce

PR nn nc AE 2
CETTE 0.0012 hank.

If lap wt is 15 oz/m. Find the Hank.
Ams:
Hank - luxidez _ Liye xt6oz

u I = 3
Hydelios Pida 07179 bank.

Q. Find the no. of lap per hour in scutcher m'c of Bottom calender
roller dia = 7 inch, ypm = 12, efficiency 80%. Lap length 40 yds.

Ans;
ig 17512 80560
Production of m'c a yds
= 4351.85 yds.

No of ip = =879=9(Ans)

107. $e on wt. -() 1s biyds, = 15 Ib/m, (111) 15 grain/yds, (iv) 15gt'm,
‚d. 15

1ydsx161b

(1) Hank= UD ydex15 0.0000793 hank. (Ans)
—_ Imxilb 1.1yds « 11b
Hank ———— O = 0.000873
@ 840 ydsx151b> B40ydsx151b om
1ydsx 7000 grain
Hank ERE 0.55
Gi) 840 ydsx15 gram (Ans)
_ lm 700 _1.1x7000 |
(iv) Hank Bad ydex1S gr” B40x15 =0.611 (Ans).
(o) Hank — 1345* 453.6 _ 9 636 (ans)
840 yds x15 gm
(vi) Hank = 12943. a = 11*453.6 00395. (ans)

B40ydsxl5gm 840x135

108. Q. Find the no. of lap per hour in scutcher m/c of Bottom calender
roller dia = 7 mch, rpm = 12. efficicacy 80%. lap wt. 14 oz'yds.
Ans:

-3.14x7x12x0.80x 60x8x14
36x16
= 2461.76 lbs

_ 2461.76

Production Ibs

metric ton

2204
=1.117 metric ton (Ans)

Q. If in a xsutcher m/c, rpm of B.C R. is 10, dia 7 inch, lap wt. 12

oz'yd. Find the production/hr at 90% efficiency. Dhaka Textile- 04
Ans:

. 314x7x10x12x60x90
Done 3616x100 1b

= 2461.76 Ibs. (Ans)

109. ©. Production of BR line with 2 scutchers if B.C BR. dia = 7 inch, rpm
. Efficiency 90%, wastes 4%, lap wt. 14oz'yd.

Dhaka Textile 03

Pr a alts 7x10 «1% 60x 90% (1004): 2:14 7

35x16x100%100
= 553.206 Ibe. (Ane)

Q. Calculate productioa‘he of a B/R line if, rp.m. of B.C.R.= 14, Dis =
18 cm... lap hank = 0.0012. efficiency 80%, no. of scutcher = 2.
Dhaka Textile-'05.'06.
Ans:
Pr _ 34x18 x 14 x 60 x 080x2

— 36*1.546x840x0 0012
=822 2 Ibs.(Ans)

Q. Find the BYR cleaning efficiency, if waste in Raw cotton = 6%.
waste in sliver = 0.4%. Cardin,
Ans:

. Cleaning efficiency 75%.

a a £6; . _ Waste in lap - waste in sliver „

= 100
waste in lap

> 7522294 100
x
=>1-16%.

= BUR cleaning efficiency = ES 100 - 73% (Aas)

110. Q. The trash control of feed cotton is 3%. After passing the beater 2
waste is extracted, of which 15% 35 good fibre, what is the cleaning

efficiency of the beater? Dhaka Textile-06.
Ans:
Of the 2% waste extraction. Bees: = 1.7% of the original trash has been taken

out by beater,

-.(3-1.7) = 1.3% trash remain i the mils, which is delivered from the beater
- Ceffiri „ Original T.C - T.C. in delivered cotton 100

nn 3 Original T.C.

— 56.60% (Ans.)

Q. Find out beats/inch from the following data-
Beater rpm. = 720, no. of striker = 16, Feed roller r.p.m. = 24, Dia of
feed roller = 3 inch Dhaka Textile 02.

Ans:
Beate, min = Bester rpm x no. of striker
=720 16n0:
1152020
Surface speed of fred roller= «DN
31403024
= 226.08
_ Beats/ min
“surface speed of feedroller
11520
226.30
= 30.96(Ans.)

-. Beats! inch =

111. Q. The trash content of a cotton as fed to Beater 3.6%. The waste extraction
is 1.5% of which 80% is trash. What is the cleaning efficiency of the beater?

Ans:

Of the 1.5% waste extraction, "15 = 12% of the original trash has been taken
cuit by beater.
= (3.6-1.2) = 2.4% trash remains in the mtls, which is delivered from the beater.
Original TC -T.C.in delivered cotton
2 €. efficiency = —»x:100
OnginalT C.
_36-24
Zur 100

=33.3% (Ans.)

112. Opening /Cleaning
Action

Major Cleaning Point

Minor Cleaning Point

Major Points

Minor Points

Bladed Beaters

Hopper Bale Breaker

Step Cleaners

Hopper Feeders

Disc Type Openers

Condensers

Dust Cages

* More beating points results in fibre rupture.

114. Multi Function Separator

11 Burning material in the wheeled waste
containers is extinguished by the fire
extinguishing unit.

12 A heat sensor monitors the wheeled waste
container for fire

13 The dusty exhaust air is fed to a filter
installation

14 Opened waste from the Waste Opener BO-
R can be fed back in without an additional fan

1 The material is sucked off from an
Automatic Bale Opener BLENDOMAT BO-A
2 The automatic control of the fan ensures
that the air volume is uniform

3 A new guiding profile has been
developed for the aerodynamic Heavy Part
Separator

4 The spark sensor
material

5 The dusty air is separated out in the air
separator

6 The metal detector detects all types of
metals

7 The extraction flap does not work with
pre-tensioned springs, but is actively
opened and closed

8 The next machine, generally a fan in front
of the mixer, sucks the material off

9 A flap conveys the separated heavy parts
into the wheeled waste container

10 The two wheeled waste containers are
large in size

detects burning

115. Pre-Cleaner CL-P

1 Itis fed by a Condenser BR-CO. The
material drops freely into the cleaning
area

2 The feed trunk ensures a specific,
tangential feeding to the left cleaning roll
3 An optimum fiber guiding in the
cleaning compartment guarantees an
improved cleaning efficiency

4 The two cleaning rolls are equipped
with coarse, fiber protecting spikes

5 The material is tangentially sucked off
the right roll

6 The bucket wheel lock transports the
waste into a suction duct

117. Psa pw ES

9.
10.

The fan is located directly on the mixer

The feed funnel distributes the material over the width of the feed duct
The rotating flaps release one trunk at a time for filling

The large-size mixing chambers

The feed duct distributes the material into the chambers

Light barriers monitor the filling status of the various chambers

The exhaust air is fed to the filter installation via the exhaust air funnel
The perforated plates separate the chambers and ensure a turbulenca-free deposit
of the tufts in the chambers

The delivery rolls empty the chambers

The opening rolls produce small tufts

118. pa) En Mi a ES pl pe

9.

The fan is located directly on the mixer

The feed funnel distributes the material over the width of the feed duct

The rotating flaps release one trunk at a time for filling

The large-size mixing chambers

The feed duct distributes the material into the chambers

Light barriers monitor the filling status of the various chambers

The exhaust air is fed to the filter installation via the exhaust air funnel

The perforated plates separate the chambers and ensure @ turbulence-free deposit of
the tufts in the chambers

The delivery rolls empty the chambers

10. The opening rolls produce small tufts

11. A sandwich-type web is formed on the mixing conveyor belt

12. The mixing duct receives tufts from all chambers at the same time

13. The material transport belt supplies the tuft web to the feed rolls of the cleaner

14. The material suction funnel collects all tufts over the working width of the machine
15. The CLEANOMAT Cleaner CL-C 4 is directly coupled to the mixer

119. CLEANOMAT Clauses CLC 3

Fac cormayoe

Proaaura mb

Feed ils

Nude roll

Mission samacoth roll

Fina sañoath ral

Mata Anas with suction hood

Darling sagrent

eununsune

The CL-C 3 can be universally used as a fine cleaner. As a single cleaner, it can be used
for a very short compact line for processing cottons with a medium level of
contamination.

In combination with a Pre-Cleaner CL-P, such a cleaning line can be used for nearly any
cotton quality.

This flexibility is some sort of securing future operation for the spinning mill.

The speed of the cleaning rolls of the CL-C 3 can be steplessly adapted to the
technological requirements.

120. The TUFTOMAT opener TO-T 4 is an ideal
machine e.g. for bleached cotton

1 Feed conveyor

2 Pressure rolls

3 Feed rolls

4 Needle roll

5 Coarse saw-tooth roll
6 Medium saw-tooth roll
7 Fine saw-tooth roll

8 Mote knives

9 Carding segment

TUFTOMAT Opener TO-T 4 — used for
materials which require a particularly
high degree of opening

The four-roll opener TUFTOMAT TO-T
4 is equipped with one needle roll
and three saw-tooth rolls of different
finenesses.

In this opener the fibres are
transferred from roll to roll in a very
gentle way and without any fibre
breakage. This Is achieved by precise
graduation of the clothings used,
together with different peripheral
speeds of the opening rolls.

The TUFTOMAT opener TO-T 4 is
ideally applicable for bleached cotton
as used in the wadding industry.

In addition, the opener will be used in
all cases where a particularly high
degree of opening is required.

The opener has also done a good job
where material is difficult to open, as

is the case in some spinning mills and
in the non-woven industry.

121. Foreign Part Separator SECUROPROP SP-FP with integrated 1 The dedusting unit is housed in the
dedusting upper part

2 The large 1,600 mm wide sieve
provides a large dedusting surface

3 The distribution flaps distribute the
material over the working width

4 The released dust is permanently
sucked off

5 The opening roll with fine needles is
coated in cotton colour

6 Four neon lamps provide uniform
lighting over the whole width

7 Two special cameras permanently
scan the roll surface

8 The 32 nozzles specifically separate
the foreign parts out

9 and divert them into the suction
system

Tr a
10 Illumination unit with polarised light
11 Special cameras for detecting light and transparent parts
12 64 x 3 nozzles selective separate detected foreign parts out
13 Bucket wheel lock for diverting foreign parts to the suction air flow
14 The dusty exhaust air is used to transport the separated parts away

122. Need for opening

To clean, mix and blend fibers they have to be brought into the
smallest aggregate form. The baled material has to re-opened and
fed in small tufts as part of the overall preparation process.

Only well opened material can be effectively cleaned,

To enable the fibers to be blended they must be thoroughly
opened,

To prepare the fibers for the carding and subsequent operations
they must opened to the point where there will be minimal fiber
damage.

123. Degree of cleaning and resistance to cleaning

+ The cleaning index C is defined as:
c Dr —Dp
A Aa

00%
FFE x 100%

Where

D, = the dirt content of the feed material;

D, = the dirt content of the delivered material; and
T= total.

* The dirt content is usually determined with the aid of gravimetrical
methods such as MDTA3, AFIS or Shirley Analyser.

124. * The cleaning index is heavily, but not solely, dependent on
the dirt content. The particle size and adhesion of the dirt to
the fibers, among other things, also have an influence. Hence,
the cleaning index may be different for different cotton types
with the same dirt content. There are types that can be
cleaned easily and others that can be cleaned only with
difficulty.

* A new concept has been introduced to represent this ease of
cleaning, namely, “cleaning resistance”. Fig. 31 shows the
conditions in a horizontal cleaner:

Y zone | represents a cotton with low cleaning resistance;
Y zone ll a cotton with medium resistance; and
“zone Ill a cotton with high cleaning resistance.

125. General considerations regarding opening and cleaning

The degree of cleaning cannot be better than the degree of
opening. Accordingly, the following should be noted:

* Dirt can be removed practically only from surfaces.

* New surfaces must therefore be created continuously.

The form of the opening machine must therefore be adapted to the degree
of opening already achieved.

+ The Type and degree of opening devices should become continually finer,
ie. within the blowroom line, a specific machine is required at each
position.

* The degree of cleaning is linearly dependent upon the degree of opening.

* Newly exposed surfaces should as far as possible be cleaned immediately.

126. This means that each opening step should be followed immediately by a
cleaning step without intervening transport, during which the surfaces would
be covered up again and would require re-exposure.

Ideally the opening and cleaning machines should form a unit.

A high degree of opening in the blowroom facilitates cleaning in the carding
room.

A high degree of opening out in the blowroom reduces shortening of staple at
the cards.

Opening and cleaning of cotton on only one (universal) opening machine is
very difficult owing to the requirement for continual improvement of the
degree of opening.

On the other hand, each machine in the line represents often considerable
stress on the fibers.

127. * Aside from economy, therefore, quality considerations indicate
the smallest possible number of machine passages in the
blowroom.

* Feeding of flocks in a clamped condition gives an intensive but
usually not very gentle opening action.

* Feeding in a loose condition gives gentle, but not very
intensive opening.

* Opened flocks should approach as closely as possible a
spherical shape. Long narrow flocks lead to entanglements
during rolling movements and pneumatic transport. Finally,
they form neps.

* Narrow setting of the feed device relative to the roller
increases the degree of opening, but also the stress on the
material.

128. 100 100
sa ”
a0 os

ro

40)

50

40) A EN

Y

20 de . ay

10 1 a

oo ”
¥ M, nm ™,

Fig. 30— Increasing degree of cleaning from machine to machine; A, degree
of cleaning of blowroom machines; C, degree of cleaning (on the vertical
axis); V, feed material; M1 — M3, blowroom machines 1-3; C, card

129. ATS) I u mn

o 1 2 > 4 5 6

B [%]
Fig. 31 — Resistance to cleaning (cleaning compliance) of various types of
cotton; A, degree of cleaning of the machine; B, initial dirt content of the

cotton; I, zone of low resistance to cleaning; Il, zone of medium resistance to
cleaning; Ill, zone of high resistance to cleaning.

130. Opening Methods

* Opening is usually the first step in the spinning process and includes
removal of the fibers from the bale by plucking followed by further
opening using pinned cylinders and pinned lift aprons.

* Opening to a fine degree is normally performed using a feed
roll/feed plate combination to restrain the cotton whilst it is opened
into very small tufts by wire wound cylinders, pinned beaters or
blade beaters. At each stage of opening a cleaning operation can be
performed.

+ Cotton has to be opened more than once because trash is removed
only from the surface of tufts and multiple opening actions are
needed to expose all the trash.

131. Observations about fiber opening
Opening and cleaning machines should constitute a unit, so that the tuft surfaces are
cleaned before they are consolidated in the transportation system,

Opening must be performed effectively with the least number of machines,

More than four opening operations, prior to carding, will usually not improve the fiber
quality. Excessive opening increases the number of neps in the cotton.

Feeding tutts in “free motion” permits cleaning but no opening
Feeding the material in a firmly held state is used for intensive opening.
Pins, spikes and teeth open fibers more effectively than bars or slats.

The higher the degree of opening in the blow room, the cleaner can be the material
fed to the card and consequently a cleaner sliver is produced.

The material flow rates through each machine in the blow room should be adjusted to
minimize standing time waiting to feed the next machine. The machines should run
between 85% and 90% of the time

132. Opening /Cleaning
Action

Major Points

Major Cleaning Point

Minor Cleaning Point

Minor Points

Bladed Beaters

Hopper Bale Breaker

Step Cleaners

Hopper Feeders

Disc Type Openers

Condensers

Dust Cages

* More beating points results in fibre rupture.

133. Opening imparted to cotton in
blow room

“The raw material for the manufacture of cotton yarn comes
generally in the form of highly compressed bales of cotton.
Each bale consists of a very large number of highly packed
layers of tufts of cotton, each tuft comprising hundreds of
thousands of fibres.

“The tufts contain a large quantity of foreign matter, leaf and
seed particles embedded between the fibres. In order to produce
yarns of reasonably good quality. these foreign matters are to be
removed thoroughly and in order to remove foreign matter, the
cotton is to be well opened. The degree of opening imparted to
cotton in blow room has a good bearing on the yarn quality as
well as on lint loss.

134. Me ee a

Factors influencing Beater / Cleaner cleaning
efficiency

Beater speed

Fan speed in relation to beater speed

The setting of beater blades to the bars — If it is too close it will tend
te curl the cotton fibres and force them through the bars.

The state of cotton fed to the machine — If the cotton is not sufficiently loosened
up before feeding to this machine, the bigger, matted lumps find it difficult to rise
up and thereby get overbeaten.

Leakage through machine casing H, If the air leaks through outer casing H, it will
try to follow the inside air current which moves in the upward direction. The
partial vacuum initiated by the suction fan will, thus, induce outside air to enter
through the bars. This will force the trash and impurities back inside the beater
chamber remixing the lint and trash. Naturally, it will affect the cleaning efficiency
of the beater.

Periodic observation of lint droppings — the angle of bars and their spacing should
be such that beater extracts maximum trash at minimum lint loss. A periodic
observation would easily reveal this.

Building up of droppings outside beater chamber — An excessive piling - up trash
outside the beater chamber, not only would impair the cleaning action of the
crighton but it may also allow the impurities to return into beater chamber
recombining the lint and trash.

135. Table- Opening variants

Opening seperation Opening device ‘Type of opening: intensity | Geatieness | Remarks
Opening oat | Breaking apart
- - -
Hearing wp Fo! 1 = ” see | Alte bale opener, Maps are produced
en there is. consideraba testi in the
ae: Sapper
Picking apart axe wo. . At the card amd the cotos ginning machine,
The only meats of separating 1 ledividuat
pl ers
ii ® = +. ee Bale picker. Wery geeste,

Peking out = . . .. . ‘Walely ened. e.g. on horivemtal cleaners
Tie intensity i. dependent on the père
density of the clothing,