Yarn manufacturing Process : Carding

Include carding process.

1. Subject Code : BTTEX05002 Semester : V
th
Textile Engineering Department
CTF, MPSTME, SVKMs, NMIMS, Shirpur
By: Prof. P. P. Kolte

2. UnitI:Carding
Necessity&Objectsofcarding,Operationsinvolvedincarding,Fundamental
actionsincarding,Detailstudywithconstructionandworkingofcardingmachine,
Varioussectionsofcardingmachine.Typesofcardclothingandtheirsignificanceand
effects.Theoriesofcardingaction,Analysisofflatactionsandcardingforce.
IntroductiontoStripping,GrindingandBurnishingoperations.ContinuousFeedvsLap
Feed.Varioussettingsofcard,itsinfluencesoncardingquality&production.
Unit-II:Carding
Transfermechanismoffibres,Consolidationofwebintosliver,Trumpet&
Calendarrollercondensation.ParametersaffectingSettings,QualityandProduction.
Conceptofdraft,TypesofDraft,Distributionofdraft,ActualandMechanicaldraft.
Carddrive&calculationsrelatedtoEfficiency,Productionofcardingmachine.
Cardingfaultsandtheirorigin,wastecollection,controllingandhandling.Card
autoleveller:Principles,Types,AdvantagesandDisadvantages.Introductionto
developmentsincarding.

3. Unit-III:Drawframe
Introduction,objectiveofdrawframe,operatingprinciple;Attenuation
(draft):thedraft,thedraftingoperation,draftingforce;behaviorofthefibresinthe
draftingzone,frictionfields,natureandroleoffibrefrictionindrafting,distributionof
draft,additionaleffectsofdraft;perfectandrealdrafting;natureofdrafting
irregularities;coiling-delivery,condensing,slivercoiling,canchanging.Draftingforce
inrelationtootherparameters-Draftratio,RollerSetting,FibreCrimp,sliverdensity.
Rollerlappingtendency,Selectionofcreelandwebtensiondraft.Monitoringandauto
leveling:structureofcomputerizeddatacollectionandmonitoringsystems,waste
collection,controllingandhandling.Productioncalculations.
UnitIV:CombingPreparatory
Objects,need,differenttypesofpassagesused.Preparationforcombing:
outline,operatingprinciplesofsliverlapmachine,ribbonlapmachine,sliverdoubling
machineandsuperlapmachines;comparativeassessmentofwebdoublingandsliver
doublingprocesses,Systemsoflappreparationconfigurationoffibrefeedanditseffect
onthequalityofproduct,calculationregardinggearing,draft,productionofsliverlap
ribbonlapandsuperlapmachines.

4. Unit-V: Combing
Combing: Object of combing, introduction, tasks of comber, types of comber,
sequence of operation in a rectilinear comber; Technology of combing: parameters
influencing combing operation-raw material, material preparation parallelization of
fibres in the sheet, sheet thickness (wt.), evenness of the lap sheet, disposition of hooks,
degree of combing, noil percentage and fractionating efficiency of comber.
Unit-VI: Combing
Combing machines: outline, classification, description of functions-feed, feed
of lap sheet, feed device, nipper assembly, cylinder comb, top comb, take-off & the
material, piecing, withdrawal of the web and formation of sliver, sliver take-off,
drafting arrangement, coiling of sliver, waste removal (stripping), timing diagram of
comber motions, automation in comber. Detailed setting of comber machine and gauges
used for setting. Gearing, drafts and production calculation of combing machine.

5. Text Books
1. Spun yarn technology, volume II, carding -A.Ventasubramani.
2. ChattopadhyayR and RengasamayR, “Spinning: Drawing, Combing and Roving”,
NCUTE-Pilot Programme, 1999.
Reference Book
1. KhareA R, “Elements of combing”, Saibook center, Mumbai, 1999.
2. KhareA R “Elements of carding”, Saibook Centre, Mumbai, 1999.
5. Klein W., “The Technology of Short-staple Spinning “, The Textile Institute.
6. Klein W., “ A Practical Guide to Opening and Carding “, The Textile Institute.
8. Technology of Carding –R . Chattopadhaya, NCUTE Publication

7. Objectives:
To have an introduction regarding carding process.
To study working of chute feed system.
To study advantages and disadvantages of chute feed system.
To study various developments in chute feed system.

8. Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards, arranged in a circuit
through pneumatic pipe.

9. A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk.
Fig. Flock
Feeder or
Chute Feed
System

10. The automatic continuous feed directly linked to the blow room
eliminates the lap formation. This increases the working efficiency of the
blow room.
The main power requirement in doffing the lap, weighing,
transportation to card and feeding at the card is eliminated.
The processing of rejected laps in the blow room is avoided.
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted from
fibres by the carding action.

11. Excessive sliver irregularities due to the lap licking during high
humidity, double lap feeding, lap splitting, lap piecing etc, are
eliminated.
When compared to lap fed, there is a reduction of 1 % CV flock
feeding card sliver.
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced.

12. Blow room should run the same number of hours per week as the
cards do.
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems.
Chute feed system control short term variation but not the medium
and long term variations.
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and C.V. value of the
weight per unit length. There is no such control in the chute feeding
system.
Change of mixing will result in more waste in chute feed.

13. Necessity:
It is always considered by the experts that the card is the heart of the
spinning mill.
The statement “Well-carded is half-spun” demonstrate the immense
significance of the carding for the final result of the spinning operation.
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form.
The carding is a very important process because unless the fibres are
separated into individuals, they can not be spun into smooth and uniform
yarns neither can they be blended properly with other fibres.

14. Opening to individual fibres
Cleaning
Elimination of dust
Mixing & Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation

15. Fig. Passage of material through carding

16. -Feed region -Licker-in region -Carding region
-Coiling region -Condensing region
Fig. Passage of material through carding
Fig. Passage of machine through carding m/c

17. Fig. Passage of material through carding

18. Question:
What are the different objectives of the carding?
What are the necessities of carding?
Enlist the different zones in carding.

19. A well designed feed device is expected to perform the following tasks:
Clamp the battsecurely over its full width;
Be able to hold the material back against the action of the licker-in;
Present the battto the licker-in in such a manner that opening can be
carried out gently.

20. Conventional system:
Fig. Conventional feed device
1-Feed plate
2-Feed roller
3-Licker-in
4-Mote knife
5-Licker-in undercasing
Fig. The shape of the feed plate
a-Guide surface
b-Nose of feed plate

21. Modern system:
The feed roller has a diameter of 80 -100 mm
Fig. Unidirectional feed device
1-Feed plate
2-Feed roller
3-Licker-in

22. The licker-in:
-The greatest part of opening and cleaning is performed by the licker-in.
-Cast roller with a diameter usually of around 250 mm.
-Rotation speeds are in the range of 800 -2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second), a
circumferential speed of around 21 m/sec
(approximately 76 km/h) and a draft of
more than 1600.
Fig. The licker-in

23. Degree of deterioration can and must be precisely controlled by
adjustment of:
the thickness of the batt;
the degree of openness of the raw material in the feed-stock;
the spacing between the operating devices;
the degree of orientation of the fibers in the feedstock;
the aggressiveness of the clothing;
the rotation speed of the licker-in;
the material throughput.

24. Elimination of waste:
The cleaning assembly consisted of 1-2 mote knives and a grid, one
half of which was made of slotted sheet and another half of perforated sheet.
1-Licker-in
2-Mote knife
3-Carding plate
3a-Special clothing
4-Grid with carding segment
5-Licker-in cover
Fig. Carding segments under the licker-in of the RieterC 51 card

25. Function:
Opening of tufts into individual fibers;
Elimination of remaining impurities;
Elimination of some of the short fibers;
Untangling neps(possibly their elimination);
Dust removal ;
High degree of longitudinal orientation of the fibers.

26. Main cylinder :
-The cylinder is usually manufactured from cast iron, but is now
sometimes made of steel.
-Most cylinders have adiameter of 1280 -1300 mm (RieterC 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.

27. Flats
-Altogether 100 -120 flats
-The bars of the flats are made of cast iron (nowadays aluminum
profiles
-Longer than the operating width of the card
-Each bar is approximately 32 -35 mm wide
Fig. A modern flat construction Fig. Dirt take-up of the flats
from the entry point

28. Carding plates instead of flats:
Stationary carding plates were used for a short time as carding
elements in place of traveling flats.
Fig. Carding plates instead of flats. C1; C2; C3; C4

29. In carding m/c two basic actions are taking place b/n two wire
covered surfaces, these are:
1. Carding action
2. Stripping action

30. The separation of fibresfrom tuft held in b/n two wire surfaces is called
carding action.
Following conditions.
1] There should be two very closely placed (0.3mm or 20-30 times
dia. of fibre) wire covered surfaces.
2] Wire points on it should face each other, i.e.
point to point arrangement.
3] Interaction surfaces should move either in
opposite direction or in same direction.

31. The process of fibretransfer from one surface to another is called
stripping.
Necessary conditions –
-Two wire covered surfaces facing each other
-The distance b/n them should be around 0.3mm or less ( 20 to
30 times the dia. of fibre)
-One surface should face back of wire from each other i.e. point
to back arrangement
-Interaction surfaces should move either in opposite direction or
in same direction
The intensity of carding action is depends upon following points
-The arrangement and density of wire points
-The setting b/n wire points
-The relative surface speed of the wire clothed surface.

32. Functions of the Doffing Region
(1) Transferring of fibresfrom the main cylinder on to the doffer.
(2) Stripping the fibreweb from the doffer.
(3) Gathering the fibreweb into a twist less strand (sliver).
(4) Condensing or calenderingthe sliver.
(5) Depositing the sliver into the sliver can.

33. The doffer:
-The main purpose of the doffer is to take the individual fibrescoming
from the cylinder and to condense them to a web form.
-The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 -707 mm. (680 mm on Rietermachines).
-It is fitted with metallic clothing and runs
at speeds up to about 300 m/min.
Fig. Clothing configuration between
main cylinder and doffer

34. Detaching:
-On old cards, a fly-comb (a rapidly oscillating comb) oscillating at up
to 2500 strokes per minute takes the web from the doffer.
-A roller (Fig. 116.1) now has the task of separating the web from the
doffer.
Fig. Web detaching using detaching rollers and transverse belts

35. Condensing web into sliver:
The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form.
Fig: Condensor

36. -The sliver must be coiled in cans for storage and transport.
-Can diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm.
Fig. Can filling device (coiler) Fig. Laying down sliver in cans
R -Rotating plate
L -Guide passage
D -The delivery cylinders
C -The turntable can plate

37. A, main drive for the cylinder, licker-in and
flats;
B, drive for the infeed;
C, drive for the delivery, i.e. doffer,
detaching rollers and coiler;
D, drive for the cleaning roller of the
detaching roller;
E, drive for the cleaning roller of the flats
via the strip-ping roller;
F, fan.
Several manufacturers, e.g. Rieter,
also provide aseparate drive for the flats.
Individual drives have the advantage that
transmission of the forces is better, and
adjustments can be performed more quickly
and conveniently. They are also better suited
to operation with control equipment.
Fig. Drive of a
modern card
(Trützschler)

38. Choice of clothing
The clothing has the greatest influence on quality and productivity.
Selection criteria are:
Type and design of card;
Rotation speed of the cylinder;
Production rate;
Material throughput;
Raw material type (natural or man-made fibers);
Fiber characteristics (mainly fineness, length, bulk, dirt content);
Overall quality requirements;
Price of the clothing;
Service offered by the clothing supplier.

39. Classification of card clothing:
1.Flexible clothings
2.Semi-rigid clothings
3.Metallic clothings

40. Flexible clothing:
-Here, hooks of round or oval wire set into elastic, multiple-ply cloth
backings.
-Each hook is bent to a U-shape and is formed with a knee that flexes
under bending load and return to its original position when the load is
removed.
-In the flats, the point density is in the range of 240-500 points/inch.
Fig. Flexible clothing

41. Semi-rigid Clothing:
•Here, flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings.
•More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee.
•These are found in flats
Fig. Semi-rigid Clothing

42. Metallic Clothing:
In manufacturing process, a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a thin
web forming portion for the teeth.
This thin portion is stamped or punched so as to get thin serrated strip,
called as saw tooth wire.
These are found in licker-in, main cylinder and doffer.
Fig. Forming the wire profile for metallic clothing

43. Metallic wire on cylinder & Doffer:
•In comparison to the licker-in wire, metallic wire on cylinder & doffer
are much finer.
•The cylinder wire are much smaller in size compared to doffer wire.
•The points/inch on cylinder wire are higher than the doffer wire.
•The thickness of the rib for doffer wire is more than that for cylinder
wire.
•The angle of leading edge for cylinder wire is more than that for doffer
wire.

44. Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
•The conventional carding efficiency is vary, much effected due to
frequent stoppages for stripping and grinding.
•Further, the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste% and neps
formation.
•Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed, so cannot be run at high speed.

45. •Reduction in stripping cycles-once in 2 or 3 days
•No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis.
•More production & regularity of sliver is improved & labourwork is
reduced.
•NO nepsformation due to better wire condition.
•Saving of good fibres. Lesser variation in card sliver owing to reduced
stripping cycles.
•Card can run at high speed owing to rigid foundation of wires.
•Economic in long run.

46. •Less fibreholding power
•It shows slightly higher fibredamage.
•High fly generation.
•Requires higher power consumption.
•Greater care in maintenance and attention owing closer gauging and
setting.
•It is difficult to replace the damaged wire portion only. (Damaged
portion only can be replaced in flexible fillet clothing).

47. Necessityofstripping
•Duringthecardingprocess,fibresandimpuritiesbecomeembeddedin
thewiresoftheflats,cylinder&dofferwhichmayreducetheir
effectivenessofcardingandincreasesthenepcountincardsliver&
finallyaffectthequalityoftheyarn.
•Sostrippingthedust,fibres&impuritiesfromthecardclothingis
essentialtoregaintheirefficiency

48. Stripping Roller: This is a wooden roller mounted on steel shaft covered
with flexible wire fillet. The roller is about 6 inch in diaand slightly
longer than the width of the cylinder.

49. •It has serious disadvantages of throwing a considerable amount of dust& fly
from card clothing into the card room atmosphere.
•There by creating undesirable and unhealthy working condition & spoils the
machinery and product.
Developments of stripping
Following are some of the developments of stripping
method.
1. Dustless stripper
2. Vacuum stripper
3. Continuous stripper

50. Dustless stripper is used exactly like plain stripper, except that the fan is
connected to the suction fan.

51. A carriage, which supports two suction nozzles(one for cylinder
& the other for doffer) is mounted above doffer and is conveyed across
the full width of the card by means of a traversing screw.

52. This is a nozzle and suction type of stripping.
Here nozzle keeps continuously sucking the fibresfrom beneath the
cylinder and feeds back beneath the lap that is being fed to the m/c for
being worked again.

53. Objects
As a card operates, the action of fibresand dirt with it, gradually wear
the points of wire causing them to become poorcleaning point.
The purpose of card grinding is to maintain the card clothing in a sharp
condition.
Types of Grinding Rollers
Two types of Grinding Roller are available
i) Long roll grinder
ii) Traverse Grinder.

54. It is a steel shaft about 7 inch in diaand 42 to 47 inch long. The roll is
carried on a shaft about 1. 125 " in dia. The grinder roll is entirely
covered with emery fillet.
This roller is equipped with a traverse motion to give the roller a short
endwise traverse for uniform grinding.

55. •It consists of a narrow roll 3.5’’ wide & 7’’ in dia. Mounted on a hollow
steel shell of 46’’ or 51’’ long suitable for 40’’ or 45’’ wide cards.
•A long traverse from one end to the other end of the card is given.

56. A roller similar to the stripping roller but having long, coarse, widely
displaced needle points is used in a manner similar to the stripping roller
once in about a week, and when every grinding is done.
This removes the rough barbs as well as cleans out the embedded dust,
fine seed and leaf particles.

57. Sr.
No.
Conventional method of feeding
material to card
Modern method of feeding material to
card
1 Fibresremain comparatively in bigger
size.
Fibres remain comparatively in small
size.
2Additional costs in terms of scutcher
operation, lap transportation, card
stoppages and lap wastages.
Less additional costs required as
compared to lap feeding.
3From productivity point of view L.F
carding is not advantageous than of C.F
From productivity point of view C.F
carding is advantageous than that of L.F.
4Variation in feed the material may be
there.
A mechanism to feed the material at
uniform weight per unit length & width.
5Stoppage due to lap changes. Direct automatic feed to card increases
B/R working efficiency.

58. Sr.
No.
Conventional method of feeding
material to card
Modern method of feeding material to
card
6Extra labourf or lap transportationElimination of Man power required
during scutcher operation.
7Compression of fibresin the lap poses
problem during opening in carding.
No problem during opening in carding.
8More wastes due to lap tail& damages.Processing of rejected lap is avoided.
9Irregularity of sliver weight due to
improper unwinding of laps.
Elimination of irregularities due to
double laps, lap splitting, lap piecing.
10 Reduction of 1% C.V in chute feed
carding system

59. Fig. Setting positions on the card

61. A
Manufacturer Rieter Trützschler Marzoli
Model C 60 TC 03 C 601N
Working width
[mm] 1 500 1 055 1 026
Licker-in [∅] 180/180/253 3 x 172,5 1 x 350
Licker-in rpm 935 -2 306 930 -2 700 640 -1 640
Main cylinder [∅]814 mm 1 287 mm 1 290 mm
Main cylinder rpm600 -900 300 -560 up to 650
Integrated grindingIGS-classic No, by hand onlyNo, by hand only
Doffer [∅] 680 mm 700 mm 706 mm
Delivery [m/min]
300, 400
mechanically 400, 500 with IDFup to 400
Flat bars 79 84 75

62. In working position27 30 25
Flat direction backward backward backward
Power required for
75 kg/h 15 KW/h 18 KW/h -
Pressure [bar] 6 7 6
Leveling
Medium and long
term Medium and long term
Medium and long
term
Drafting module
SB (unleveled) max.
draft of 5
IDF (leveled) max.
draft of 3
max. 800 m/min
delivery
max. 500 m/min
delivery
RSB (leveled) max.
draft of 5
IDF-R (rectangular
can) max. draft of 3
max. 700 m/min
delivery
max. 500 m/min
delivery

63. Patchy web
Singles
Sagging web
High card waste
Low nep-removal efficiency
Higher U% of sliver
Bulky sliver
Higher breaks

64. Patchy web:
May be due to loading on the cylinder, damaged or pressed wire
points, waste accumulation below cylinder under casing or defective
under casing.
Singles:
May be due to lap licking, less feed in chutes, part of carded web
getting sucked by the waste extractor, damaged doffer wire and direct air
currents hitting the web.
Sagging web:
May be due to insufficient tension draft, very high humidity,
worn out key in the calendar roller gears, heavy material fed to card and
inadequate calendar roller pressure.
High card waste:
High card wastes are due to damaged under casings, higher flat
speed, wider front plate setting, closer setting of flats, and higher
pressure in suction unit and fibresgetting ruptured.

65. Low nep-removal efficiency:
Blunt wire points, too wide setting between feed plate and licker-in,
uneven settings, burrs in front plate/ back plate, and card wires of coarse type are
the main reasons for low nep-removal efficiency.
Higher U% of sliver:
Worn out parts, eccentric movement in coiler calendar or table calendar
rollers, uneven feed, waste accumulation in material patch, improper settings and
loading of fibreson cylinder and flats are some of the reasons for higher U% of
card sliver.
Bulky sliver:
Slivers become bulky by use of trumpet of a very large size and lower
calendar pressure.
Higher breaks:
Very small trumpet, worn out trumpet, uneven sliver with bunches of
fibres, worn out gears, damaged clothing, air currents disturbing the web, improper
temperature and humidity and a very high tension-draft causes higher breakages of
web and sliver.

66. Objectives:
To study various developments in licker-in region
To study Shirley modification system
To study setting of deflector plate
To study fibre retriever

67. Objectives:
To unwind the lap and pass the sheet of cotton at a constant rate
without any uncontrolled stretching
To bring about a preliminary opening of cotton into very small
tufts for effective carding by the cylinder and flats.
To remove impurities like motes, sand etc to clean the cotton
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible, both transversely and longitudinally, on the
cylinder surface

68. Major developments takes place w.r.t.
1] Improve the opening of tuft at high rate of feed in high
production cards.
2] Distribute the tuft as evenly as possible on the cylinder.
3] Extract max. trash with minimum loss of spinnablefibres.
To achieve first objective:
-Licker-in speed is increased in the range of 1150-1800 rpm.
-Introduced 2/3 licker-in for gradual opening of tuft. eg. M/s
Ingolstadt in their super card KU 12 has incorporated three licker-in
roller which resolve at 920, 1350 and 1800 r.p.m. respectively
Fig. Shows 3-licker-in
arrangement

69. To achieve second objective:
-M/s Marzolihas introduced a bottom cylinder of 256mm dia
clothed with special wires at the bottom of licker-in and near the cylinder
in their high production card C300.
-M/s Nagoya introduced card analyzer or uniopener.

70. To achieve third objective:
-mote knives placed in the reverse or inverted.
-M/s Mafatlal Engineering introduced comb bar and waste
control knife.

71. Research done by Shirley institute.
The essential changes in the cleaning region are:
1. The replacement of conventional mote knives by a deflector
plate which is provided under side of the feed plate.
2. The taker-in grid
replaced by shorter grid and setting
between grid and taker-in is made
wider than conventional card.
3. A safety guard is fitted
under the feed plate to cover the
exposed portion of the taker-in.
A -Deflecting plate B -Undercasing
B1 –Grid C,C1 –Making-up piece
B2 -Perforations on the undercasing
D –Guard E,F –Setting plate

72. Deflector plate consist of mild steel strips of 3/16” thick.
The operation edge of the plate nearest to the taker-in is beveled at
45°and is set 1/8” to 3/16” from the taker-in.
The setting between taker-in grid to the taker-in nearest cylinder
should be ¼” to 5/16”.
The setting between the nose of the taker-in grid and taker-in can be
varied w.r.t. amount of lint rejected.
Setting ¼” to ½” :-more lint rejected .
Shorter the grid , more lint is rejected.
For short staple cotton :-8” grid
For medium staple cotton :-7” grid
For long staple cotton :-6” grid

73. -M/s CrosRolLtd.
Introduced fiber retriever.
-Modification in under
screen region.
-1% waste reduced.

74. Questions:
Enlist the modernasationin licker-in.
Explain working of fiber retriever.
Explain Shirley modification.

75. Questions:
1.Enlist licker-in region developments in Trutschler’sExact Card DK-
740 High production card.
2.Enlist licker-in region developments in CrosrolMark-4 High
production card.
3.Enlist licker-in region developments in Ingolstadt Super Card KV-12
High production card.
4.Enlist licker-in region developments in RietersC-4 High production
card.

76. Objectives:
To study various developments in carding zone
To study developments in cylinder back and front zone
To study card master

77. Developments in carding zone / cylinder zone takes place w.r.t.
-Prepare the tuft before the entry of flat region in order to
increase the life of flat clothing & even distribution of tuft on cylinder.
-Improve carding effect of the flats to match with heavy feed.
-Improve parallelisationand removal of further impurities before
the transfer of fibers to the doffer.
-reduce the waste %.

78. 1] Improvement in cylinder construction:
Cylinder must be withstand stresses and strain generated due to high
speed and extra weight of metallic clothing.
All cylinders are provided with ball-bearings and dynamically
balanced.
In Ingolstandtcard cylinder width increase upto1.5 times to cope up
thick feed.
In CrosRolvergaMK4 card cylinder dia. Reduced by 20% to add
stability and strength.

79. 2] Development in cylinder back zone:
Development w.r.t. increase the life of flat tops and preperethe tuft
for better carding at flat zone.
The system offered by Viking: Viking 200 and Viking 400.
For back carding zone Viking 200 pre-carding segment and For front
carding zone Viking 400 post-carding segment.
Unique Features:
-The segment are made up of precision punched teeth sheet,
which are hardened, polished and assembled into carding segment of
around 40” long and 32mm width.
-The teeth surface of the carding segment is cylindrical to fit into
the radius of the cylinder, thus offering maximum carding surface.
Viking 200 pre-carding segment:
width: 64mm teeth density: 60 points/sq.inch

80. 3] Developments in cylinder flat zone:
Development w.r.t.
i] increase the effectiveness of flats
ii] reduce flat waste.
W.r.tfirst objective:
In SACM card running the flats in opposite direction.
Adv. -clean flats at delivery end of cylinder with more efficient
carding and cleaning.
-Choking due to waste avoided
W.r.t. second objective:
-Stationery carding surface in place of flats for reducing flat
waste.
-But it will more applicable for processing synthetic fiber.
-M/s John Hollingsworth develop card master of stationery flats.

81. Consist of four strong, stationery aluminum plates with metallic
clothing.
Providing greater surface than revolving flats.
Each plate is interchangeable in any position on a same or other card
of same width and cylinder dia.
Advantages:
-Weight of card reduced by 320 Kg.
-Reduced maintenance due to lock of moving parts.
-No flat waste.
-Provide max. carding area.
-Improves carding quality.
-Long life since they can be ground.

82. 4] Developments in cylinder front zone:
Objectives:i] to improve the parallelization of fiber.
ii] to extract the waste.
To achieve first objective, Viking 400 post-carding segment developed:
-consist of four teeth segment, total width of 128mm and teeth
density 150 points/sq.inch.
-mounted on doffer side of cylinder.
To achieve second objective, Trash Master TM 2000 developed :
Continue…….

83. Questions:
Enlist the modernasationin cylinder front zone.
Explain working of card master.
Enlist the modernasationin cylinder back zone.
Which developments takes place in carding cylinder.

84. Questions:
1.Enlist carding region developments in Trutschler’sExact Card DK-
740 High production card.
2.Enlist carding region developments in CrosrolMark-4 High
production card.
3.Enlist carding region developments in Ingolstadt Super Card KV-12
High production card.
4.Enlist carding region developments in RietersC-4 High production
card.

85. Objectives:
To study trash master
To study various attachment in carding
To study control of waste in carding

86. Trash Master TM 2000
-Introduced by M/s Hollingsworth.
-Removal of vegetable matter, trash, short fly, sticky particles,
micro-dust and fused man-made fibers.
-A special knife is set to the cylinder wire.
-Requires 165m³ air or 2 millibarlow pressure.
Advantages:
-optimum removal of vegetable matter, trash, short fly, sticky
particles, micro-dust and fused man-made fibers.
-improve yarn quality due to elimination of impurities.
-Reduced cleaning of O.E. spinning rotor.
-Lower card room dust levels.

87. Doffing Devices:
-Improved doffer comb
-Roller doffing device
-Doffing and cleaning devices

88. Introduction
Licker-in waste
-Role of air currents
-Modification/attachment to cards
-Speed and setting
Flat waste
Cylinder under casing waste
Atmospheric condition

89. Questions:
What are different attachments in the carding.
Explain working of trash master.
How can you control card waste.

90. Objectives:
To study need of autoleveller
To study classification of autoleveller
To study working principle of autoleveller

91. Careful control of sliver uniformity is necessary in the spinning
process, to minimize the production of streaky fabrics, waste of raw
material andto waste of production time.
Limitations of traditional methods of controlling sliver uniformity:
Need for Autoleveller:
Continuous checking of sliver weight together with automatic
correction of sliver weight variation at card is necessary.

92. Advantage of installing autolevellerat card draw frame:
They control the thickness of individual slivers.
They are followed by greater no. of doublings.
They are generally cheaper.
Classification of autoleveller:
1] Mechanical system of control
2] Electronic control
Control systems are classified into:
1] Open loop
2] Closed loop

93. Open loop:
-Variation is corrected in draft zone by varying speed of O/P
rollers (on card) or I/P rollers (on D/F).
-Correction follows measurement so there is no check that
correction was correctly applied.

94. Closed loop:
-Variations corrected in draft zone by varying speed of delivery
rollers.
-Correction precedes measurement so system check that
‘correction’ was correctly applied.

95. Working principle:
Measurement of sliver variation
Correction rate and sliver variation
Correction rate and delivery speed
Types:
Long term autoleveller[LTAL]
Short term autoleveller[STAL]
Short term autolevellerand dual
autoleveller
Fig. Mechanical Autolevelling System

96. They are classified as follows:
Very short variations : up to 25cm
Short term variations : from 25cm to 2.5m
Medium term variations : from 25m to 250 m
Very long variations : more than 250 m
Types:
Long term autolevellingUCC-L Model L
Medium term autolevellingUSTER-M controller
Short term autolevellingUCC-S

98. Limitations:
The UsterM-controller is suitable for every bright fiber.
Influences of color, lustre, staple fiber material as well as that of dust and
finishing material deposits are eliminated by the automatic sensitivity
adjuster, as is the reflection of card clothing.
But when the dark
staple fibers are processed
[eg. Heavy blue, black], the
UsterM-controller has to
be switched off.
Advantages:
-Reduction of required test
-Improved carding

99. Fig.Shortterm autoleveller

100. Questions:
What are need of autoleveller.
What are the different types of autoleveller.
Tell me the principles of autoleveller.

101. Objectives:
To study fibre nepsand their assessment
To study dust and waste extraction system in carding
To study improved suction system in carding

102. Nepsare small entanglements or knots of fibers.
In general, two types of nepscan be distinguished: fiber nepsand seedcoat
neps, that is, small knots that consist only of fibers and others containing
foreign particles such as husk, seed or leaf fragments.
Fiber nepspredominate, particularly fiber nepshaving a core mainly of
immature and dead fibers.
Nepsgenerated due to Fiber fineness, picking, hard ginning
Based on UsterTechnologies Inc. amount of nepsper gram in 100% cotton
bales:
up to 150 = very low
150-250 = low
250-350 = average
350-450 = high
above 550 = very high

103. Classification of Neps:
For cotton fiber; there are five types of Neps. These are –
Process Neps:Commonly produced by faulty carding or up to
spinning yarn.
Mixed Neps: Fibres tangle around a foreign materials. For
instance –Grit.
Immature Neps:Generally form by processing immature fibre.
Homogeneous Dead Neps:A tangle of nearly all dead fibres.
Fuzz Neps:A fault of short fuzz fibers .
Count of Neps:
Nepcount is the no. of nepsper 100 square inches of card web
forming ( a standerdhank of sliver of 12 NE on a 40 inch wide card).

104. How To Measure / Assessment the Count of Neps?
At first a web is collected from the card placed on a 10 inch ×10
inch black board. Then the nepsare counted and the no. of nepsfound is
corrected fro any difference in hank or card width.
Mathematically, NepCount, n = m ×100 [ m = no. of nepsper inch
square card web].
Modern Method of NepsAssessment:
With the help of AFIS

105. Necessity:
-To meet the rigid environmental protection, regulations of
advanced countries.
-The control and removal of dust also reduces dust generations
on the machines following the cards.
-The yarn quality is also improved.
-The efficiency of rotor spinning is improved.
To achieve this necessity:
-Shirley institute develop Shirley pressure point exhaust system.
-Improved waste suction system
-Internal suction system
-Under card waste removal system

106. Fig. Shirley Pressure Point Exhaust System

107. Questions:
What is neps.
How can you asses the neps.
Tell me about dust and waste extraction system in carding.

108. Objectives:
To study microprocessor used in carding
Summary of unit
Assignment

109. Improved waste suction system:
Features:
-All the high pressure points must be enclosed.
-Provision to segregate upper card waste from under card waste.
-Continues removal of dust by a central suction system.
-Intermitted blowing system for removal of under card waste.
-Dead spots should be eliminated.
-Complete enclosure of card.
-System to recycle the waste.

110. Internal Suction system:
The integral fan for internal suction creates a vacuum with in the
outer shell. Thus no dust from the card escapes into the workroom.
The suction is very effective in the removal or fly waste, dust and
micro dust which are released during carding.
Dust and wastes are removed at all points of occurrence, feed,
flat entry, flat strips, web delivery and waste chamber under the card.
The internal suction operates continuously there by maintaining
constant aerodynamic conditions in the card.
The exhaust air is conveyed to air conditioning system. The
amount of exhaust air is 2300 m3/h per card.

111. Under card waste removal system:
The under card waste are transferred by programmed periodic
blasts of compressed air into the vicinity of a suction hood and collected
in the rear most filter of the two filters built into the outer shell.
The over card wastes including flat strips are collected in the
foremost filter.
The intermittently acting central suction system

112. Quality Assurance : MIS

113. Summary

114. Questions:
What is MIS.
What improvements are made in carding suction system.
What improvements are made in waste suction system

115. 1.Enlist modern developments in Trutschler’sExact Card DK-740
High production card.
2.Enlist modern developments in CrosrolMark-4 High production
card.
3.Enlist modern developments in Ingolstadt Super Card KV-12 High
production card.
4.Enlist modern developments in RietersC-4 High production card.

116. 1.Explain necessity & objects of carding m/c.
2.Explain construction & working of carding m/c.
3.Elaborate on flat actions and carding force.
4.Elaborate on types of card clothing.
5.What are the objects of taker-in region? Explain with diagram.
6.What are the objects of carding region? Explain with diagram.
7.Explain stripping , grinding and burnishing operations.
8.Explain various settings of carding & its effect on yarn quality.
9.What are the factors affecting fibretransfer at card? Explain.
10.Explain causes for Carding faults and its remedies.

117. 1.What is autolevelling?
2.Explain different types of autolevellerwith their advantages and
disadvantages?
3.How the card waste is control?
4.Explain the modern developments in card.
5.The surface speed of coiler calenderis calculated and found to be 40
mts/min. If the linear density of the sliver is 4.2 ktex(4.2 kg/km).
what is the production of carding m/c per 8 hr shift at 85%
efficiency?
6.Calculate the production of Carding m/c in kgs/8hr shift at 90%
efficiency.
Given data: delivery roller speed= 250 rpm, CCR dia. = 2’’,
Hank of material = 0.012 g/mt.