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Physical properties of raw material (cotton): Fibre Length: Short staple Medium staple Long staple Extra Long Staple 1 in. or less 1 1/32- 1 1/8 in. 1 5/32- 1 3/8 in. 1 13/32 in. above. Fibre Fineness: Micronaire Value Fineness up to 3.1 3.1 to 3.9 4.0 to 4.9 5.0 to 5.9 6.0 & above Very fine fine Medium Slightly Coarse Coarse
Fibre Strength: Pressley value 93 & above 87 to 92 81 to 86 75 to 80 70 to 74 Below 70 Grading Excellent Very strong Strong Medium strong Fair strong Weak Fibre Cleanliness: Trash % Grading Up to 1.2% 1.2 to 2% 2 to 4% 4 to 7% above 7% Very clean Clean Medium Dirty Very dirty
Dust: Grading particle size (micro meter) Trash Dust Micro dust Breathable dust above 500 50-500 15-50 below 15 Chemical deposits: Secretions: Fungi and Bacteria Vegetable substances Honeydew Decomposition products Sugar from plant juices, leaf nectar, overproduction of wax Seed oil from ginning, pathogens defoliants, insecticides, fertilizers, oil from harvesting machines. Fats, oil Synthetic substances
Mixing and blending of cotton fiber in blow room Mixing: If different grade of same fibers are kept together, then it is called mixing. Blending: When different fibers of same or different grades are kept together, then it is called blending. Types of Mixing: 1. volume mixing 2. weight mixing 3. hand stock mixing 4. bin mixing 5. mixing by hopper 6. lap mixing 7. card mixing 8. sliver mixing Types of Blending: 1. hand stock blending 2. bin blending 3. lap blending 4. card blending 5. draw frame blending
Model of optimum cotton mixing: The program is written on the basis of principles of linear programming. The constraints of the mixing used in the program are cotton fiber minimum length in mm, strength in grams per Tex, Micronaire value in a range, maximum trash percentage, and price per kilogram of the cotton. Also some of the practical constrains are considered while formulating the mixing like maximum and minimum bales to be taken for mixing from a lot. The software generated system is, in generally, known as Bale Management. Some branded software are BIAS, Bale Manager.
Blow room: Cotton fibre is compressed in a bale of 200 to 250 kg. This highly compressed cotton firbe need to be open at first as a part of yarn manufacturing. And there are 1.5% to 7% trash in cotton bale which is also needed to be removed before further processing. This process of opening & cleaning is knows as blow room process. Blow room consists of a number of m/c used in succession to open & clean the cotton fibre to the required degree. 40% to 70% of total trash is removed in this section. Process parameter in the blow room: Size of the flocks in the feed Type of clothing of the beater Point density of clothing Type of grid and grid settings Air flow through the grid Position of the machine in the sequence Amount of trash in the material Type of trash in the material Temp and relative humidity in the blow room department Number of opening machines Type of beater Type of beating Beater speed Setting between feed roller and beater Production rate of individual machine Production rate of the entire line Thickness of the feed web Density of the feed web Fibre micronaire
Objects of blow room process: To open the compressed layer of bale of cotton or any staple fibres with minimum damage to the fibres. To remove the impurities like sand, seed, bits, neps & short fibres present in the cotton with minimum loss of lint by opening & blending. To effect a through blending with minimum neps formation. To convert the mass of cotton fibres into a uniform thick sheet of cotton both longitudinally & transversely & fed as it in the case of chute feed system or wound in the form of a compactly built lap with minimum lap rejection. Intensive de-dusting of cotton fibres to extract micro- dust in order to improve the working of opened spinning m/c. Fibre recovery from the waste produced by the various processes during the conversion of fibre to yarn in order to reduce the consumption of raw material.
Technological performance of a blow room line and influencing factors
Basic operation in blow room: Opening:The first operation required in the blowroom line is opening. Tuft weight can be reduced to about 0,1 mg in the blowroom. The figure indicate that the degree of opening changes along a blowroom line. This line is a theoretical layout for study purposes only. The flattening of the curve toward the end shows that the line is far too long. It should end somewhere at machine No. 3 or (at least) No. 4. The small improvements by each of the subsequent machines are obtained only by considerable additional effort, stressing of the material, unnecessary fiber loss and a striking increase in neppiness. Openness of the fiber material after the various blowroom machine stages; axis A: Degree of opening (specific volume); axis B: Blowroom stages
Cleaning: approximately 40 - 70% of the impurities. The result is dependent on the raw material, the machines and the environmental conditions. The diagram by illustrates the dependence of cleaning on raw material type, in this case on the level of impurities. A blowroom installation removes The cleaning effect is a matter of adjustment. It is shown in bottom figure that, increasing the degree of cleaning also increases the negative effect on cotton when trying to improve cleaning by intensifying the operation, and this occurs mostly exponentially. Therefore each machine in the line has an optimum range of treatment. It is essential to know this range and to operate within it. Figure: Degree of cleaning (A) as a function of the trash content (B) of the raw material in % Normally, fibers represent about 40 - 60% of blowroom waste. Since the proportion of fibers in waste differs from one machine to another, and can be strongly influenced, the fiber loss at each machine should be known. It can be expressed as a percentage of good fiber loss in relation to total material eliminated, i.e. in cleaning efficiency (CE): AT = total waste (%); AF = good fibers eliminated (%). Figure: Operational efficiency and side effects For example, if AT = 2.1% and AF = 0.65%:
Dust Removal: Almost all manufacturers of blowroom machinery now offer dust-removing machines or equipment in addition to opening and cleaning machines. Dust removal is not an easy operation, since the dust particles are completely enclosed within the flocks and hence are held back during suction. Fig. 5 – Dust removal as a percentage of the dust content of the raw cotton (A) at the various processing stages (B): 1 - 5, blowroom machines; 6, card; 7, draw frames; (a) filter deposit; (b) licker-in deposit; I, dust in the waste; II, dust in the exhaust air. It is mainly the suction units that remove dust (in this example 64%), dust removal will be more intensive the smaller the tufts. It follows that dust elimination takes place at all stages of the spinning process as shown in figure.
Blending: intensive blending in a suitable blending machine must be carried out after separate tuft extraction from individual bales of the layout. This blending operation must collect the bunches sequentially from individual bales and mix them thoroughly. Multi mixer is the machine of blow room where the uniform blending is carried out. of fibers arriving Figure – Sandwich blending of raw material components In conventional machineries, lap blending was the most significant one. doubling scutcher is required in this case; this has a conveyor lattice on which four to six laps (L) could be laid and jointly rolled-off. Lap blending produces very good transverse blends and also a good longitudinal blend, Figure – Lap blending on an old scutcher
Even feed of material of the card: Finally the blow room must ensure that raw material is evenly delivered to the cards. Previously, this was carried out by means of precisely weighed laps from the scutcher, but automatic flock feeding installations are increasingly being used. While in the introductory phase such installations were subject to problem regarding evenness of flock deliver, today they generally operate well or at least adequately.
Introduction of blow room line: Figure – Rieter blowroom line; 1. Bale opener UNIfloc A11; 2. Pre-cleaner UNIclean B 12; 3. Homogenous mixer UNImix B 75; 4. Storage and feeding machine UNIstore A 78; 5. Condenser A 21; 6. Card C 60; 7. Sliver Coiler CBA 4
Components of the blow room machine: Feeding Apparatus: Feed with an upper roller and a bottom table In a device with a feed roller and table the clamping distance (a) can be very small. This results in intensive opening. Feed to a beater with two clamping rollers Operating with two clamping cylinders gives the best forward motion, but unfortunately also the greatest clamping distance (a) between the cylinders and the beating elements. Feed with a roller and pedals Where pedals are used (Fig. 12), the table is divided into many sections, each of which individually presses the web against the roller, e.g. via spring pressure. This provides secure clamping with a small clamping distance (a).
Opening devices: Opening units can be classified as: •endless path •gripping devices •rotating assemblies Depending on their design, construction, adjustment, etc., these assemblies exert enormous influence on the whole process. 1. End less path device: Spiked lattices is known as endless path device. It serves as forwarding and opening devices in bale openers and hopper feeders. They consist of circulating, endless lattices or belts with transverse bars at short intervals. The bars are of wood or aluminum; steel spikes are set into the bars at an angle and at greater or lesser spacing. The intensity of the opening action is dependent upon: the distance between the devices; the speed ratios; the total working surface; the number of points.
2. Gripping elements (plucking spring): Some Schubert & Salzer and Trützschler, have used plucking springs for opening. Two spring systems, facing each other like the jaws of a pair of tongs, are parted and dropped into the feed material and are then closed before being lifted clear. They grasp the material like fingers. This type of gripping is the most gentle of all methods of opening, but it produces mostly large to very large clumps of uneven size. This type of opening device is therefore no longer used. manufacturers, for example former
3. Rotating Devices (Roller with teeth, blades or spikes): Flat, oval or round bars are welded, riveted or screwed to closed cylinders. The rollers are therefore called spiked rollers. Various spacing of the striker elements are used. These devices are incorporated mainly in modern horizontal cleaners, chute feeds, mixing bale openers, step cleaners, etc., which are located from the start to the middle of the blowroom line. At the start of the line, the spacing of the striker elements on the roller is greater; finer spacing are used in the middle (to the end) of the line. The rollers rotate at speeds in the range of 600 - 1 000 rpm.
The grid: In the final analysis, it is the grid or a grid-like structure under the opening assembly that determines the level composition in terms of impurities and good fibers. Grids are segment-shaped devices under the opening assemblies and consist of several (or many) individual polygonal bars or blades (i.e. elements with edges) and together these form a trough. The grid encircles at least 1/4, at most 3/4 and usually 1/3 to 1/2 of the opening assembly. of waste and its The grid has a major influence on the cleaning effect via: the section of the bars; the grasping effect of the edges of the polygonal bars; the setting angle of the bars relative to the opening elements; the width of the gaps between the bars; the overall surface area of the grid. Figure:Two-part grid
The following elements can be used in the grid: •slotted sheets (a): poor cleaning; •perforated sheets (b): poor cleaning; •triangular section bars (c): the most widely used grid bars; •angle bars (d): somewhat weak; •blades (e): strong and effective. These elements can be used individually or in combination. Modern grids are mostly made up of triangular bars. They are robust, easy to manipulate and produce a good cleaning effect. The same is true of blade-grids. Blades have been used as grid elements for a long time (the mote knife), almost always in combination with triangular section bars.
Gridadjustment: Three basic adjustments: •Distance of the complete grid from the beater; • width of the gaps between the bars (a=closed, b=open); •setting angle relative to the beater envelope
Conventional Machine of Blow room line: Bale breaker: Opening is mainly emphasized in this machine rather cleaning. This machine is designed to take layer of cotton directly taken from bale and tear them apart leaving the cotton partially opened.
Porcupine opener: The cotton fed by the previous opener is carried forward by the feed lattice. 16 circular disc are mounted on the shaft of this opener. 14 to 18 striker blades are riveted alternatively on each circular disc. The compressed sheet of cotton delivered from the feed roller is heavily beated by the rapidly revolving striker of the porcupine beater against grid bar. Because of this beating action, the cotton is effectively opened and extracted trash particles are passed through the spacing of the grid bar.
Step cleaner: The material falls into the feed hopper and passes to the first beater. From there it is transported upward by the six (sometimes three or four) beater rollers, each carrying profiled bars. The beaters are arranged on a line inclined upward at 45°. Elimination of impurities takes place during the continual passage of the material over the grids arranged under the rollers
Air Jet cleaner: Object of this cleaner is to open and clean the cotton, but this cleaning unit introduces the idea of dirt separation from cotton by air force. The function of the Kirschner beater section is to open and clean the cotton and prepare the cotton for air jet section. The tuft of cotton from the kirschner beater section is entered in to the aero dynamic constricting duct. The air current from the booster fan carry the cotton toward the bend in the duct. The duct makes a sharp turn of about 120 degree.
Axi flow Cleaner: This is known as dual roller cleaner. This machine has two beaters having 6 to 8 rows of spikes with flattened edge which perform cleaning action. Beater speed is 400-600 rpm. Material through entire length of first beater pass over the grid bars where trash is collected and comes in contact with second beater.
Scutcher: To feed the material to card is very important because it should be homogeneous, uniform from card to card, fulfill this requirement scutcher machine is used. It is less problematical. No need of using pipes to provide the material to separate machine. It can be provide universally and this can be used with many blends. Less economical as compared to chute feed system. Its function is to clean the material and form a uniform lap for card.
Kirschner beater: In this type of beater, instead of beater bars, pinned bars (pinned lags) are secured to the ends of the cast-iron arms. The relatively high degree of penetration results in good opening. Kirschner beaters were therefore often used at the last opening position in the blowroom line. Beaters with pinned bars Modern designed as closed rollers rather than three- armed beater units. The design is simpler and the flow conditions are more favorable. Kirschner openers are often Rollers with pinned bars
Modern Blow room line ABO= Automatic Bale Opener CPC= Crosrol Pre-Cleaner CBO= Crosrol Blending Opener CFC= Crosrol Fine Cleaner CDR= Crosrol Dust Removal
Trutzschler Blow room line: 1 3 4 2 5 6 1= Automatic Bale opener BLENDOMAT BO-A 2= TUFTOMAT SYSTEM 3= Metal Detector 4= Universal Mixture MX-U 5= SECURO PROOF SP-FPU 6= Universal Cleaner CP-U
Rieter Blow room line: The UNIfloc A 11 processes the fiber material gently and efficiently into microtufts, from which impurities can be removed very readily in the subsequent processes. •The UNIfloc is designed for output of up to 1 400 kg/h (carded sliver). •Bales are laid down over a length of 7.2 to 47.2 meters. •The UNIfloc can process up to 4 assortments simultaneously. •The width of the take-off unit can be selected between 1 700 and 2 300 mm.
Uniclean B12 The UNIclean B 12 pre-cleaner cleans the microtufts in the first cleaning stage immediately after the UNIfloc A 11 •The UNIclean is designed for output of up to 1 400 kg/h (carded sliver). •Fiber yield with simultaneous efficient cleaning is up to 2% higher than on conventional units. •Pre-cleaning without nipping and the use of mote knives results in fiber- preserving cleaning. •The large dedusting surface ensures intensive dedusting even at high production performance.
Unimix B76 The guarantees homogeneous, intimate mixing of the bale feed in a minimum of space, even with unfavorable bale lay-down. B 72 / B 76 mixing machine Eight mixing chambers ensure not only effective mixing, but also high production performance. The easy addition of an opening or cleaner module provides flexibility capability to respond to changes in market conditions. with the Bypass facility for the cleaner module (e.g. with man-made fibers) for rapid mix change.
Uniflex B60 Material comes from preceding machine and then filling the chute. Thus in the chute, a very homogeneous batting lay down is formed both lengthwise and crosswise. The material is carried further by a perforated drum (2) and a plain drum. The feed roll (3) supplies the material to the opening cylinder (5). A grid (4) made of carding segments and knives forms the cleaning surface and extracts impurities. 1= Filling Chute 2= Perforated drum 3= Feed zone 4= Grid 5= Opening Cylinder 6= Delivery
Operating Principle of carding machine In modern installations, raw material is supplied via pipe ducting into the feed chute (of different designs) (2) of the card. An evenly compressed batt of about 500 - 900 ktex is formed in the chute. A transport roller (3) forwards this batt to the feed arrangement (4). This consists of a feed roller and a feeder plate designed to push the sheet of fiber slowly into the operating range of the licker-in (5) while maintaining optimal clamping. The portion of the sheet projecting from the feed roller must be combed through and opened into tufts by the licker-in. These tufts are passed over grid equipment (6) and transferred to the main cylinder (8). In moving past mote knives, grids, carding segments (6), etc., the material loses the majority of its impurities. Suction ducts (7) carry away the waste. The tufts themselves are carried along with the main cylinder and opened up into individual fibers between the cylinder and the flats in the actual carding process.
The flats (10) comprise 80 - 116 individual carding bars combined into a belt moving on an endless path. Nowadays some 30 - 46 (modern cards about 27) of the flats are located in the carding position relative to the main cylinder; the rest are on the return run. During this return, a cleaning unit (11) strips fibers, neps and foreign matter from the bars. Fixed carding bars (9) and (12) are designed to assist the operation of the card. Grids or cover plates (13) enclose the underside of the main cylinder. After the carding operation has been completed, the main cylinder carries along the fibers that are loose and lie parallel without hooks. However, in this condition the fibers do not form a transportable intermediate product. An additional cylinder, the doffer (14), is required for this purpose. The doffer combines the fibers into a web because of its substantially lower peripheral speed relative to the main cylinder. A stripping device (15) draws the web from the doffer. After calendar rolls (16) have compressed the sliver to some extent, the coiler (18) deposits it in cans (17). The working rollers, cylinder and flats are provided with clothing, which becomes worn during fiber processing, and these parts must be reground at regular intervals.
Licker-in This is a cast roller with a diameter usually of around 250 mm. Saw-tooth clothing is applied to it. Beneath the licker-in there is an enclosure of grid elements or carding segments; above it is a protective casing of sheet metal. The purpose of the licker- in is to pluck finely opened tufts out of the feed batt, lead them over the dirt- eliminating parts under the roller and then deliver them to the main cylinder. In high-performance cards, rotation speeds are in the range of 800 - 2 000 rpm for cotton and about 600 rpm for synthetics.
Carding Bar An aluminium carding profile (1) consists of 2 carding bars (2). One of the advantages of bars is that they can be provided in different finenesses, e.g. they can become finer in the through-flow direction. Different manufacturers use differing numbers of elements (between one and four) per position. Special clothing is required that must not be allowed to choke. Most modern high-performance cards are already fitted with these carding aids as integral equipment; all other machines can be retrofitted by, for example, Graf of Switzerland or Wolters of Germany. In use are also other carding devices of different design and with different components, e.g. mote knives (4) with guiding element (5) and suction tubes (3), etc.
Cylinder The cylinder is usually manufactured from cast iron, but is now sometimes made of steel. Most cylinders have a diameter of 1 280 - 1 300 mm (Rieter C 60 card 814 mm, speed up to 900 rpm) and rotate at speeds between 250 and 500 (to 600) rpm. The roundness tolerance must be maintained within extremely tight limits – the narrowest setting distance (between the cylinder and the doffer) is only about 0.1 mm. The cylinder is generally supported in roller bearings. Clothing configuration between main cylinder and doffer
Doffer • The cylinder is followed by the doffer, which is designed to take the individual fibers from the cylinder and condense them to a web. The doffer is mostly formed as a cast iron (or steel) drum with a diameter of about 600 - 707 mm. (680 mm on Rieter machines) . It is fitted with metallic clothing and runs at speeds up to about 300 m/min.
• Point density (Number of points per unit surface area) The populations of the main cylinder and doffer clothing have to be adapted to each other. In general, the higher the point population, the better the carding effect – up to a certain optimum. Above that optimum, the positive influence becomes a negative one. This optimum is very dependent upon the material. Coarse fibers need fewer points, as they need more space in the card clothing; finer fibers must be processed with more points, since more fibers are present if the material throughput is the same. Point density is specified in terms of points per square inch or per square centimeter, and can be calculated as follows:
• Base width (a1) This influences the point density. The narrower the base, the greater the number of turns that can be wound on the cylinder and, correspondingly, the higher the point population. Height of the clothing (h1) The height of metallic clothing on the cylinder today varies between 2 mm and 3.8 mm. The height must be very uniform. It can also exert an influence on the population, since shorter teeth – for a given tooth carding angle – leave space for more teeth. Where shorter teeth are used, the fibers are less able to escape into the clothing during carding and better carding over the total surface is obtained. Clothing with smaller teeth is also less inclined to choke with dirt particles. Tooth pitch (T) The population is also determined by the tip-to-tip spacing. • •
