developments in blowroom, card & draw frame
TRANSCRIPT
Developments in blowroom, card & draw frame April , 2009 “Indian Textile Journal”
The trend in Indian spinning mills is now to replace manual bale opener with automatic bale opener, and
carding and draw frames have also gone through an evolution in the last one decade. So, what are the
changes that have happened in these pre-spinning departments? Reeti Pal Singh and V K Kothari
highlight the developments.
The conventional short staple spinning system involves different machines to convert raw cotton to
quality yarn. The quality of a yarn is judged by many parameters, like evenness, count CV%, strength,
imperfections, yarn appearance, etc. Now-a-days, various parameters relating to comfort like yarn water
absorbency, yarn surface friction, etc, are also given importance. Thus, in short staple spinning system,
to produce yarn of acceptable quality, the raw material has to be processed through a sequence of
machine. Developments in these machines are carried out to enhance yarn quality. The machine
manufacturers are coming out with different models of the machines featuring different
modification/innovations, which enhance quality.
Different categories of developments
These developments or innovations can be divided in different categories:
1. Minor modifications.
2. Modification related to quality/production monitoring or enhancement in production/speed.
3. Major modifications.
Minor modifications are the simple alteration of the previous version/model of the machine that has
nothing to do much with the quality or production/speed of the machine. So these modifications are
aimed at just giving the customers a new look to the machine. Second type of modification relates with
enhancement in production/speed or with the online quality/production monitoring. Major modifications
are really significant modifications, which are helpful in improving the product quality.
There are the changes that have been brought in the machine to improve the product quality not only on
the same machine but also at subsequent machines. As so far machine manufacturers are concerned,
they are providing machines with all the above stated categories, but publicised the machines under the
category of major developments though these developments may be coming under first two categories.
These developments will be analysed in the subsequent section.
To discuss modern developments in detail, subsequent sections are divided in the categories according
to the machines used to spin the yarn. I.
Developments in blowroom
Main objective of the blowroom is opening and cleaning of the material without over-stressing or
damaging the fibres. The opening means to increase the specific volume (cc/g) of the feed material and
is adjudged from the tuft size whereas cleaning means to remove impurities. The tuft size of 2 - 3 mg is
considered to be optimum, but as low as 0.1 mg is achievable[1]
. The visual appearance of the waste
extracted at different stages of opening and cleaning is shown in Figure 1 [2]
. Increase in the
opening/cleaning intensity increases waste removal, but also leads to fibre damage, fibre loss and
increase in neps level (Figure 2). Hence it is very important to find out optimum opening/cleaning. The
modern developments in blowroom will be discussed in the subsequent sections.
1. Difference between types of plucking roller of automatic bale opener
The trend in Indian spinning mills is now to replace manual bale opener to automatic bale opener. The
automatic bale opener gives smaller tuft size (Figure 3), thus results in better opening and cleaning
efficiency of the subsequent machines [3]
. The manual bale opening process relies more on the sincerity
and efficacy of the worker, and has more variation in the tuft size fed to the bale opener.
1.1. Rieter Automatic Bale Opener (UNIfloc A 11)
Rieter UNIfloc A 11 uses single plucking roller, called as take-off roller (Figure 4). The take-off roller
(Figure 5) along with narrow grid results in small tufts size [3]
. The same roller can be used for
processing cotton as well as man-made fibres. The roller teeth can also be replaced individually. The
automatic bale opener regularly measures the profile of the lay down material for gradual level out the
bales as shown in Figure 6 [4].
1.2. Trützschler Automatic Bale Opener (BLENDOMAT BO-A)
Trützschler's BLENDOMAT BO-A is fitted with two plucking rollers rotating in opposite direction
(Figure 7). But at any given time, only one plucking roller is working while other is raised according to
the travel direction of the machine (Figures 8 a, b). Thus, direction reversal of the plucking roller and,
hence wear-intensive braking and acceleration after every passage of the bales is avoided. The plucking
roller strips off the tufts by penetrating into the bale surface while the three supporting rollers give a firm
grip over the bales [5]
. This is what they call 'Penetration inversion mechanism', which ensures gentle
fibre removal and gives good opening. It can process three different cotton/blend lots simultaneously
that can be fed into three separate cleaning lines as shown in Figure 9 [6]
.
1.3. Marzoli Automatic Bale Opener (SuperBlender B12SB)
Marzoli automatic bale opening Super Blender B12SB (Figure 10) has two plucking rollers with 254
blades on each roller, which ensures small flock size [7]
. Automatic bale opener can process four
different mixings. The detacher of the bale opener follows the contour of the lay-down and plucks the
raw material down to the ground (Figure 11). The production, with a working width of 2,250 mm, is
stated to be 1,600 kg/hr.
1.4. Lakshmi Bale Plucking Machine LA 17/LA 28
Lakshmi Automatic Bale Plucker LA 17/LA 28 is fitted with twin plucking rollers (Figure 12). The
depth of the cut can be programmed as per the requirement. The varying production rate can be achieved
by varying the traverse speed, depth of cut and the type of grill[8]
. The grills of the plucking rollers are
selectable according to the required tuft size. The plucking roller has replaceable strips with teeth. Thus,
in case of any damage, only that strip can be replaced without removing the grills or contact rollers, thus
reducing downtime. Bale plucker can process four different assortments at a time and can feed into
separate cleaning lines.
2. Compact Blowroom Line (Shorter Blowroom Line)
Automatic bale opener efficiently makes the tuft size smaller leading to better opening/cleaning of the
subsequent machines. The modern cleaners give intensive but gentle cleaning. The use of 3 to 4 beaters
in series (CVT-4 Cleaner of Trützschler) in the same machine rather
than 2 or 4 machines in tandem in line gives same cleaning. Thus, the
modern blowroom line becomes shorter without any compromise on the
quality of the material.
2.1 Compact Blowroom Line of Trützschler
Trützschler compact blowroom line consists of automatic bale opener,
Multi Function Separator along with waste re-feeding, Pre-Cleaner (CL-
P), Integrated Mixer (MX-I with 10 trunks) along with CLEANOMAT
Cleaner (CL-C 4), and Foreign Part Separator (Figure 13). The compact
blowroom requires less space and lower energy consumption in
transporting the fibre tufts to the next machine[9]
. The installation size
comparison of normal blowroom line (1,000 kg/h of blowroom production) against Trützschler compact
blowroom (2,000 kg/h production) has been shown in Figure 14.
2.2 Blowroom Line of Rieter
The Rieter blowroom line consists of automatic bale opener UNIfloc A 11, intensive pre-cleaner
UNIclean B 11, homogeneous mixer/blender UNImix B 70 and gentle fine cleaner UNIflex B 60 as
shown in Figure 15 [2]
.
3. Mote knife with suction in place of grid bars
The trend of using mote knife with an open slot along suction was initially incorporated on carding in
the pre-carding and post-carding zones. Recently, the same principle was adopted by Trützschler on
cleaning machines in blowroom. Such a cleaning system consists of deflector blade, mote knife and
suction hood (Figure 16). Trash particles released due to centrifugal forces are separated at the knives
and are continuously taken away by suction keeping the hood clean permanently. The deflector blade
setting depends upon the type of cotton processing.
When processing clean cottons or for low degree of cleaning, deflector blades can be kept almost closed,
but fully opened for high trashy cotton and/or high degree of cleaning. The blade adjustment can be
made manually or via, motor. It also gives trouble free processing of sticky cottons as such cotton
otherwise sticks to the grid bars [10]
. The removal of dust by suction results into good running behaviour
in OE and ring spinning and gives better yarn quality (Figure 17).
4. Multiple beaters instead of single beater in a single machine
The trend of using multiple beaters/cleaners in tandem on the same
machine has been introduced by Trützschler. The machine has the
combination of clamped and unclamped feeding of the material to the
beaters. The initial feeding of the material to the first beater is clamped
through the feed rollers, thus giving intensive beating. Subsequently,
material is transferred to other beaters in web form in unclamped
manner, thus giving gentle cleaning action.
Gradual increase in the speed of the beater, clothing fineness and angle of clothing teeth from first to last
beater give progressive cleaning of the material. It is claimed by manufacturer that multiple beater can
replace 3 to 4 conventional blowroom cleaners [10]
. A study was conducted in a spinning mill, where a
conventional blowroom line was replaced with Cleanomat CVT 3. The results shown in Figure 18
indicate overall improvement in cleaning efficiency and reduction in yarn imperfections, power
consumption along with saving of good fibres [5]
.
5. Better mixing/blending of raw material
The cotton fibre parameters, being a natural fibre, differ from bale to
bale. Thus bales coming from different stations and/or varieties should
be mixed thoroughly to spin yarn of consistent quality. Similarly,
blending of dissimilar fibres should also be done properly at blowroom
stage. Mix homogeneity depends on the methods of mixing and type of
mixing/blending machine used. When mixing the different bales in tuft
form, smaller the tuft size better would be the homogeneity [11]
. More
number of reverse chutes in mixing equipment gives better
homogeneity. Two blenders working in series or tandem produces better
homogeneity than one with similar, total capacity.
5.1 Rieter UNImix B71/B75 blending machine
Rieter UNImix blending machine claims to have random distribution of the tufts to the 8 mixing
chambers and then the fibre blending takes place at three different points within the UNImix. This
technology has been termed as a '3-point mixing process' [12]
. The first stage is a controlled time offset of
the tuft layers in the mixing chambers by 90° deflection of the tufts in the tuft storage. The second
mixing point comprises a spiked feed lattice, which picks small tufts at random out of the layers of the 8
mixing chambers and transports them to the next mixing point. The third blending level is achieved by
mixing of the fine tufts in the active mixing chamber above the spiked feed lattice (Figure 19). This
results in constant homogeneity of the fibre blend and constant yarn quality subsequently. Different raw
materials can be processed and required setting can be made via, the control panel during machine
operation [13]
.
5.2 Rieter UNIblend A 81 Blending Machine
Rieter 'UNIblend A 81' can be used for multi-component blending. It can precisely measure deviation in
fibre percentage less than 1%, and, thus avoid colour non-uniformity in
the end product. It can even mix/blend 98% white with 2% black fibres
[14]. This blending machine can mix from two to eight individual
components in any desired ratio. It is also possible to split the line, after
the dosing blender, into four different carding lines, each of which can
contain a different blend ratio of the same components (Figure 20).
5.3 Difference between continuous dosage and weighing System
In continuous dosage system, different components are filled into each chute accordingly (Figure 20).
Each chute has an individually, continuously working dosage system. A conveyer belt transports the
evenly sandwich layered material to the compressing/opening take-off unit. Thus, the each tuft contains
all components in right proportion (Figure 21 a). The blend ratio, in case of continuous dosage system is
maintained, which otherwise varies with weighing pan method (Figure 21 b)
5.4 Trützschler Multimix MPM
Trützschler mixer can have 6 or 10 trunks depending upon the
application. The rotating flaps forward the material in sequence to the
individual trunks but these trunks are emptied at the same time resulting
in homogeneity of the mix (Figure 22 a). Once all the trunks are filled,
the transport air is routed past the trunks to prevent material compaction.
As soon as the trunks are empty, refilling starts immediately so that a
loose layer of tufts is formed on the conveyor belt from the individual
trunks. At the end of the conveyor belt, material from all the trunks lies
in layers in a sandwich form that ensures ideal feeding for the CLEANOMAT Cleaner. For better
mixing and homogeneity, two mixers can also be set in tandem (Figure 22 b).
6. Removal of colour contaminants and other impurities
The cotton that reaches the mills has natural as well as other added contaminants. Contaminants and
other foreign parts can either be sorted out manually or with machine. But the advantage of machine
sorting over manual sorting is that this system does not depend upon the efficacy and sincerity of the
worker. Thus, modern blowroom line incorporates system, which eliminates such impurities. The system
is also equipped with fire-protection devices.
6.1 Barco Cotton Sorter for detection and removal of contaminants
in raw cotton
Cotton Sorter of BarcoVision uses ultra-fast CCD cameras to detect
contaminants from raw cotton in the blowroom line and then removed
by means of high speed air guns. The system can be installed in an
existing blowroom line without adding any fan capacity to elevate the
cotton and drop it through the inspection zone. This system has a
transparent tunnel where cotton is diffusely illuminated in the inspection zone. The individual tufts are
observed by means of 4 high resolution CCD line scan cameras that acquire images from both the sides
simultaneously, thus enhancing the detection capability (Figure 23).
Contaminants are described as a deviation in colour and size from raw cotton in terms of contaminant
width (number of pixels) and length (number of scan lines). Tolerances in colour are defined by means
of threshold levels (limits). The objects with a colour value below this limit is being identified as a
contaminant. On the horizontal X-axis, the number of camera pixels is indicated, whereas the Y-axis
displays the colour level. A value of zero corresponds with black, whereas 255 means white. The normal
cotton is recognised as close to the white level [15,16]
.
6.2Trützschler Multi Function Separator
Trützschler Multi Function Separator SP-MF (Figure 24) is positioned
immediately after the automatic bale opener, and includes fire
protection, heavy part and metal separation along with dedusting and
waste re-feeding. This machine has an integrated micro-computer
control system to control all the functions.
6.3 Rieter Vision Shield, Metal Shield, Fire Shield and the Combo
Shield
Rieter blowroom line is fitted with Vision Shield, Metal Shield, Fire Shield and the Combo Shield of
JOSSI Systems AG, Switzerland to detect foreign material. The vision shield detects and eliminates
foreign fibres whereas metal shield is for detection and diversion of any metallic particle (size 2 mm, at
velocities of 33 m/s) through sensor and digital signal processing. Metal Shield can extract metallic as
well as non-magnetic metallic particles hidden inside tufts. The Fire Shield detects and diverts any
incandescent particles like sparks or embers and immediately shuts down the machine. It evacuates all
materials from the ember infected duct, and activates various alarm functions. The Combo Shield
combines the function of both Metal Shield and Fire Shield.
6.4 Trützschler Foreign Part Separator SECUROPROP SP-FP
Trützschler's patent-pending process, Foreign Part Separator SECUROPROP SP-FP, detects coloured as
well as white and transparent particles such as PP or PE foil. Foreign fibres can only be separated, if
these are optically detected. To avoid tiny foreign particles hiding in or behind the tufts, a fibre web is
formed by an opening roll within the SECUROMAT [17].
A colour camera scans the web on the surface
of the opening roll and on detection of a foreign particle compressed air
impulse of a nozzle blows it into a waste suction device (Figure 25).
The distance between the place of detection and the separating unit is
very short, thus ensuring a high reliability of the separation.
SECUROPROP SP-FP uses the physical properties of plastics, which
make them appear coloured in polarized light (Figure 25). This light is
generated in the background of a rectangular fibre channel and the tufts
are scanned by two cameras. These detect the false colours or contrasts generated by the polarisation in
light polypropylene and transparent or semi-transparent PE foils and can detect contaminants of as small
size as 2 x 2 mm [9]
.
6.5 Loptex Optosonic Sorter
The Loptex Optosonic Sorter is equipped with an Optical Sensor to detect coloured contamination and
Acoustic Sensor for colourless material. The raw material is first passed in front of the Acoustic Sensor
and then the Optical Sensor (Figure 26). The Acoustic Sensor emits ultrasonic waves and detects any
contamination with a compact surface structure like plastic and reflects these waves into the receiver.
The receiver then triggers the ejection device. The Optical Sensor consists of standard fluorescent light
tubes and photo sensor arrays [18]
. The coloured contaminations reflect less light to the photo sensor
arrays, which then trigger the ejection device thorough pneumatic valves, blowing them into the waste
container.
7. On-line parameter settings
One of the most significant modernisations, which has been brought in the blowroom line, is the online
setting of opening/cleaning machine parameters like beater speed, distance between grid bars, distance
between grid bars and beater, distance between beater and feed roller, etc. The cleaning intensity and
amount of waste extracted can be programmed and adjusted while the machine is in production.
7.1 Rieter VarioSet
The opening and cleaning intensity depends, apart from other
parameters, on distance between beater and feed roller, speed of beater
and grid bars setting. The Rieter VarioSet System adjusts these
parameters while the machine is in running state. The cleaning intensity
(0.0 to 1.0) and relative quantity of waste (1 to 10) are entered to the
VarioSet through the operator's panel or remotely via, the ABC-Control
system. On Rieter UNIclean B12 cleaner, these two parameters, adjust
the beater speed and grid bars setting to get the required level of waste
extracted (Figure 27). In case of Rieter UNIflex B 60 cleaner, the parameters entered are fibre length,
relative amount of waste (1 to 10) and cleaning intensity (0.0 to 1.0). The staple length of the fibres is
converted for the basic setting of the feed trough nip. The relative amount of waste primarily adjusts the
grid bars setting and the cleaning intensity adjusts the rotational speed of the beater and the feed trough
nip (Figure 28).
7.2 Trützschler WASTECONTROL and CLEANCOMMANDER
The Trützschler's waste sensor WASTECONTROL BR-WCT is attached to a Cleaner CLEANOMAT
and optically measures good fibres in the waste and amount of suction for fibres. This system detects the
waste quality and automatically sets the deflector blades of the cleaner by servo-motors (Figure 29).
Thus the degree of cleaning for each cotton quality can be optimised. The Figure 30 shows the
relationship between the waste extracted and the total amount of waste. Ideally for example, with cotton
having a trash content of 2%, the total waste removed would be 2%. The degree of cleaning would then
be 100% (green line). But the aim is to achieve optimum cleaning (yellow line). This point represents a
compromise between a high level of cleaning and low fibre loss. It is claimed that with the
CLEANOMAT cleaners, the actual achievable line lies very close to the theoretical ideal, ie, the good
cleaning with minimum good fibre loss.
II. Modern developments in card
The card is the heart of the spinning mill because if we see the card
sliver, it is just the magnified replica of the yarn. Quality of yarn is
directly related to the quality of card sliver. Thus the modern
developments, in the carding machine, are carried out to produce better
sliver. The following sections discuss some of the modern developments
in the carding machine.
1. Unidirectional feed Unidirectional feed
results in gentle fibre treatment because fibre feed and licker-in rotation
is in the same direction. The latest version of Rieter card C60 (Figure
31) and Trützschler TC 07 (Figure 32) feature with unidirectional feed
system.
2. Multiple Licker-in
The concept of using three licker-in place of one is basically for better cleaning of the feed material.
Here the concept of clamped and unclamped feeding is used. The latest version of Rieter card (Figure
32) and Trützschler card (Figure 32) feature with multiple licker-in system. The modular design of
Rieter C 60 card makes it possible to convert from 3 licker-in units to 1 unit.
3. Increase in the carding zone/width of card
The modern machines achieve production rates of 60 - 220 kg/h, compared with output of 5 - 15 kg/h in
1970 [19]. One of the many factors behind increase in the production, without deteriorating quality, is
increase in the carding zone area, particularly width of the card and/or
long carding section.
3.1 Rieter C 60 wide width card
Compare with the previous version of the card (C 51), Rieter C 60 Card
has 50% more working width (from 1 m to 1.5 m) as shown in Figure
33. The diameter of the cylinder has been reduced (but RPM is
increased) whereas the take-off roller diameter is increased [20]. Thus,
the cylinder can take higher fibre mass, resulting in higher production
without deterioration in carding intensity. An increase in production is
equivalent to increased fibre mass on the cylinder that will result in poor
sliver and yarn quality. But because of more carding width, the available
carding surface is more, hence this enables output to be increased by
50% without deterioration in sliver or yarn quality[21]
.
3.2 Trützschler TC 07 Card with longest carding section
Trützschler TC 07 has 2.82 m carding section as shown in Figure 34. The pre-carding area ensures
optimal fibre web preparation for better carding. Better the pre-opening, more intensive the carding and
higher the production [22]
.
4. Use of Pre and Post-carding segments
The opening/individualisation of fibres achieved by the carding action between the cylinder and the flats
is expressed by the number of wire points per fibre. Higher production rate decreases wire points per
fibre and thus deteriorate carding action. So pre and post-carding elements are used to achieve better
carding action.
4.1 Rieter Pre and Post-carding area on C 60 Card
Pre-carding zone of Rieter C 60 Card has 6 carding units along with guiding elements and mote knife.
The guiding element and the associated mote knife extract impurities while suctions hoods take these
extracted impurities to centralised waste chamber. Similarly, post-carding zone has 2 carding elements,
one guiding element and a mote knife are used.
4.2 Trützschler Pre and Post-carding area on TC 07 Card
Pre-carding zone of Trützschler TC 07 card has 3 carding elements (2 clothing strips each) and 3
cleaning elements whereas post-carding area has 6 carding segments (12 clothing strips) with 3 cleaning
elements. The pre- and post-carding area has total ten elements each.
Cleaning element, carding element and control element are standard parts whereas the remaining eight
elements can be flexibly selected according to the required task. Cleaning element has a mote knife with
a suction hood and is designed to separate tiny dirt particles, seed coat fragments, dust particles, and
fibre fragments (Figure 35). Carding element consists of two clothing strips equipped with different
clothing types and finenesses depending on raw material. The control element is similar to a cleaning
element, but it manipulates air-stream on the cylinder surface thus optimise the function of the cleaning
elements. When none of the elements described above is used in the pre- and post-carding area, a cover
element is mounted.
4.3 Marzoli Pre and Post-carding area on C601 N Card
The pre-carding zone of Marzoli C601 N Card has nine carding segments and a knife to eliminate the
waste[23]
. The total length of the pre-carding zone is stated to be 720 mm whereas that of post-carding
zone is 550 mm[24]. The post-carding zone has six carding segments with two suction and knives to
eliminate remaining trash.
5. Integrated grinding system
Card wire grinding is not only a troublesome job but also time consuming. The machine manufacturers
are now coming out with a unique idea of wire grinding on the machine itself while the machine is in
production.
5.1 Rieter Integrated Grinding System (IGS-Top and IGS-classic)
Rieter IGS-System comes in two versions; IGS-Classic for cylinder wire grinding and IGS-Top for flat
wire grinding. IGS-Classic has a grindstone, which moves across the cylinder under automatic control
during production (Figure 36). This process is performed 400 times during the planned lifecycle of the
clothing as compared with every 80 to 100 tonnes in case of manual grinding [25]. This results in better
quality in terms of reduction in neps and trash of card sliver [15]. IGS-Top is installed permanently over
the returning flats after the flats cleaning unit and it performs automatically more than 100 grinding
cycles per clothing lifecycle. The flats rods are raised one after the other by spring force and pressed
against the rotating grinding brush (Figure 36). Short, hard bristles grind the flat points while longer,
softer bristles keep the later edges sharp. IGS-System gives prolonged cylinder clothing life to the tune
of 10 to 20% [25].
6. Use of Autoleveller
To control card sliver count variations, count CV% and unevenness, modern cards are equipped with
autoleveller.
6.1 Rieter medium and long term autoleveller on C 60 card
Medium-term leveller of Rieter C 60 card measures the feed mat thickness at the feed trough and, as
required, the feed roller speed is adjusted through the control system (Figure 37). Similarly, long-term
leveller measures the sliver thickness by the step roller pair and adjusts the chute system accordingly.
6.2 Trützschler short-wave and long-wave autolevelling system
For the short-term autolevelling, the Integral Feed Tray SENSOFEED of Trützschler TC 07 card
constantly scans the thickness of the tuft web and the required adjustment in the speed of the feed roll is
made through the card control system (Figure 38). Similarly, long-term autoleveller measures the sliver
mass through the sensor in the card's sliver trumpet and controls the speed of the feed roller accordingly.
A single sensor can be used for the entire card sliver counts.
6.3 Marzoli Short Term and Medium Term Levelling System
The short term leveller senses the web thickness (weight) through the load cell. When the web weight
exceeds by ±10% of its basic, the sliver draft is adjusted via, microcomputer (Figure 39 a). This system
functions over a sliver length as low as 4 cm[26]. The MT leveller senses the mat thickness (weight) and
varies card draft as required (Figure 39 b). This system functions over a sliver length as low as 1 m
(40").
7. Online flats setting and Licker-in waste setting
All the major machine manufacturers are improving the card with manual or motorized reproducible
setting of licker-in mote knife and fats. The setting can be optimised while the machine is in running
conditions.
7.1 Rieter flat and licker-in setting system
The C 60 Card of Rieter has a central flat setting system to adjust and reproduce the flats setting
precisely. The licker-in under casing is also fitted with adjustable knife (manually or electronically) to
alter the setting. Thus the optimal trash removal at the licker-in during the card production can be
determined[13].
7.2 Trützschler precision setting and measuring system (PMS, PFS and TC-FCT)
Precision Knife Setting (PMS) System of Trützschler Card adjusts the distance of the knife to the needle
points and clamping point between feed roll and needle roll to alter the degree of cleaning. The knife
setting can be adjusted manually or through motor while the carding is running and can be seen through
the transparent suction ducts (Figure 40 a). Similarly Precision Flat Setting (PFS) System adjusts the
flat-cylinder gauge manually or through motor (Figure 40 b). A scale fitted on the frame shows the
actual setting. The Flat Measuring System (FLATCONTROL TC-FCT) is used to measure the distance
between cylinder and flat. For measurements, three regular flats are removed with measuring flat as
shown in Figure 40 c.
7.3 Marzoli C601 N Card with deflector blade to adjust droppings
The licker-in undercasing of Marzoli C601 N Card has mote knives, carding segments, deflector blade
and suction hoods [23]
. The deflector blade can be adjusted to adjust the licker-in droppings as shown in
Figure 41 [26]
.
8. Online neps monitoring
Trützschler NEP CONTROL TC-NCT monitors the card web during production and provides
information regarding neps in card sliver. An optical electronic camera films the web under the take-off
roll approximately 20 times per second (Figure 42). The camera moves about the whole working width
of the card in a special, fully closed profile. The computer attached to the profile, evaluates the pictures
with special analysis software, and indicates neps, trash particles and seed coat fragments in the card
web.
9. Integrated draw frames
Now-a-days, the cards are available with integrated 3-over-3 drafting. Such cards are able to reduce one
draw frame passage, particularly for low demand yarn or for OE spinning.
9.1 Rieter RSB Coiler for C 60 card
Rieter C 60 card can either be fitted with RSB series of coiler or SB series of coiler. The RSB coiler is
essentially a complete autoleveller draw frame for sliver weight > 6.6 ktex at 120 kg/h whereas non-
levelling SB series coiler is for a lighter sliver (3.5 - 6 ktex) at high production rates. The auto-leveller
version is used for the OE direct process application.
9.2 Trützschler Integrated Draw Frame IDF with Card TC 07
Similarly, Trützschler can also supply Integrated Draw Frame IDF with Card TC 07 and claims to
eliminate one draw frame passage, particularly for rotor spinning. This levelling draw frame has 3 over 3
two-zone drafting system with a draft of 3-fold and delivery speeds 500 m/min (maximum).
10. Trützschler Magnotop system
Trützschler MAGNOTOP System uses high energy 'Superstrong neodymium magnets' to hold the
clothing strips on the flat bars. One neodymium magnet, smaller than a cigarette pack, can hold or lift a
weight of 100 kg. . The strong magnetic force exceeds the carding force by a multiple, thus keeps the
strips exactly in place (Figure 43). When mounting conventional flat tops to the flat bars, the clothing
strips are inevitably subject to deformation and thus grinding is necessary to get evenness that can be
eliminated with MAGNOTOP. Strips can simply be peeled off from the side and removed with little
effort in the card itself for replacement purpose. This significantly reduces the card mounting time from
14 hours to less than 2 hours.
11. Trützschler carding setting measurement system T-Con
Higher card productions result in higher heat, so increase in card temperature. The increase in
temperature leads to different expansions of the machine parts, thus disturbing the card settings. T-Con
calculates the distance of the carding elements objectively, based on various measuring values under
production conditions (Figure 44 a). The various settings displayed on the card monitor include the flat-
cylinder gauge, fixed carding segments, cylinder gauge, etc, and hence these settings can be optimised
(Figure 44 b). T-Con also registers even slightest contacts of the clothing and shuts down the card long
before damage can occur and protects against clothing damages.
III. Developments in draw frame
As far as draw frame is concerned, not much significant developments have been carried out, except one
or two that will be discussed in the following section. All the machine manufacturers are supplying the
draw frame with almost same kind of specifications (Table 1).
Table .1 Specifications of different makes of Draw frame
Particular
Lakshmi
Machine Works
Lts [27]
Rieter Machine
works Ltd [28] Vouk spa [29]
TOYOTA
Textile
Machinery [30]
Trützschler
GmbH & Co.
[31]
Model LR SB 851 RSB Unimax DX8 TD 03
Delivery speed
(max) 800 m/min 1100 m/min 1050 m/min 1000 m/min 1000 m/min
Drafting system 3-over-3 With
pressure bar
4-over-3 With
pressure bar
3-over-4 With
pressure bar
3-over-3 With
pressure bar
4-over-3 With
pressure bar
Draft range 3.05 to 11.6 4.5 to 11.6 4 to 11.6 4 to 14 4 to 11
Roller loading Pneumatic Pneumatic Spring or
hydraulic Spring Pneumatic
Autoleveller Yes Yes Yes Yes Yes
No of deliveries Single or twin
(LD0/6)
Single or twin
(SB)
Single or twin
(Duomax) Single or twin Sigle
Can system
(delivery)
Auto doffing
(round cans)
Auto doffing
(round or
rectangulatr
cans)
Auto doffing
(round cans)
Auto doffing
(round cans)
Auto doffing
(round or
rectangulatr
cans)
Particular Lakshmi Machine works Ltd. [27] Rieter Machine works Ltd. [28] Vouk spa[29] TOYOTA
Textile Machinery [30] Model LR SB 851 RSB Unimax DX8 TD 03 Delivery Speed (max.) 800
m/min. 1100 m/min. 1050 m/min. 1000 m/min. 1000 m/min. Drafting System 3-over- 3 With pressure
bar 4-over- 3 With pressure bar 3-over-4 With pressure bar 3-over-3 With pressure bar 4-over-3 with
pressure bar Draft Range 3.5 to 11.6 4.5 to 11.6 4 to 11.6 4 to 14 4 to 11 Roller loading Pneumatic
Pneumatic Spring or hydraulic Spring Pneumatic Autoleveller Yes Yes Yes Yes Yes No. of Deliveries
Single or twin (LD0/6) Single or twin (SB) Single or twin (duomax) Single or twin Single Can system
(Delivery) Auto doffing (Round cans) Auto doffing (Round or Rectangular cans) Auto doffing (Round
cans) Auto doffing (Round cans) Auto doffing (Round or Rectangular cans)
1. Auto break-draft setting
Incorrect break draft increases yarn U%, imperfections and neps whereas the total draft does not affect
yarn quality much. Break draft plays a very significant role in yarn quality, thus must be set correctly.
1.1 Trützschler TD 03 draw frame with AUTO DRAFT Technology
AUTO DRAFT of Trützschler TD 03 draw frame optimises break draft of draw frame under the
prevailing conditions. It estimates the corresponding values of the break draft merely in one minute and
takes important parameters, like fibre-fibre friction, fibre to metal friction, etc, into consideration while
calculating the break draft (Figure 45).
2. CLEANcoil by Rieter
The deposition of spin finish on the underside of the coiler plate of draw frame when processing MMF
leads to displacement of the sliver layer in can. To avoid this, the coiler has to be cleaned frequently
resulting in production loss. Rieter has patented a coiler plate that has honeycomb like surface and
claimed to reduce cleaning frequency from 2 to 3 hours to 1 - 7 days depending upon the type and
quantity of finishing agents as shown in Figure 46[32]
.
References
1. K R Salhotra: Significance of Modern Developments in Blowroom, NCUTE Pilot Program on
Spinning-Blowroom and Carding, IIT Delhi, Oct 9-11,1998
2. Blowroom System: Variations on Success, Rieter Textile System Information Brochure.
3.UNIfloc A 11: Efficient Cleaning Starts with Small Tufts, Rieter Textile System Information
Brochure.
4. Hans Roosli: Rieter Blowroom and Carding - The Choice for Success in The New Millennium, Rieter
Textile System Information Brochure.
5. Rajendra Ghatage: Modern Concept in Blowroom and Carding, NCUTE -- Program on Latest Textile
Machinery Used Globally, D K T E, Ichalkaranji.
6. Fibre+Sliver Technology, Trützschler GmbH & Co KG Textilmaschinenfabrik, Information
Brochure.
7. Blowroom Machines, Marzoli Spa, Information Brochure.
8. Spinning Value: Lakshmi Automatic Bale Plucker LA 17/LA 28, Lakshmi Machine Works Ltd
Information Brochure.
9. Blow-Room Machines, Trützschler GmbH & Co KG Textilmaschinenfabrik, Information Brochure.
10. Installations for Fibre Preparation, Trützschler GmbH & Co KG Textilmaschinenfabrik, Information
Brochure.
11. R Chattopadhyay: Quality Consideration in Blowroom, NCUTE Pilot Program on Spinning-
Blowroom and Carding, IIT Delhi, Oct 9-11, 1998.
12.UNImix B 70 Blending Machine: Unique Blending Technology, Rieter Textile System, Information
Brochure.
13.Rieter -- the Frontrunner in Summer 2008 and Beyond, Press Release April 28, 2008, Rieter Machine
Works Ltd, Winterthur.
14. Rieter 2000: Blowroom and Carding, Rieter Textile System Information Brochure.
15. Barco CottonSorter, BARCO-Loepfe Srl, Italy Information Brochure.
16. Cotton Sorter, BarcoVision, Belgium Information Brochure.
17. Specialists Form Bale to Sliver, Trützschler GmbH & Co KG Textilmaschinenfabrik, Information
Brochure.
18. Loptex Optosonic Sorter Digit +, Loptex SrL, Italy Information brochure.
19. Report on Experience with the Rieter C 60 Card, Link -- The Customer Magazine of Rieter Spun
Yarn Systems, Vol 19/No: 51, December 2007.
20. C 60 Card -- a New Dimension in Carding, Link -- The Customer Magazine of Rieter Spun Yarn
Systems, Vol 14/No: 30, Dec 2002.
21. The C 60- Card Technology and Flexibility for the Future, Link --The Customer Magazine of Rieter
Spun Yarn Systems, Vol 16/No: 43, Sept 2004.
22.Trützschler TC 07, Trützschler GmbH & Co KG Textilmaschinenfabrik, Information Brochure.
23.The New Concept of Spinning Mill has Taken Shape, Marzoli spa, Italy Information Brochure.
24. www.marzoli.it (English translation of Italian version).
25. IGS-System: For Consistent Carding Quality, Rieter Textile System, Information Brochure.
26. C 501 -- High Production Card, Marzoli Spa, Italy Information Brochure.
27. Spinning Value: Autoleveller Draw Frame LRSB 851, Lakshmi Machine Works Ltd, Information
Brochure.
28. Draw Frames: Drawing in Perfection, Rieter Textile System, Information Brochure.
29. Unimax: Single Delivery Draw frame, Vouk Spa, Information Brochure.
30. Draw Frame DX8, Toyota Textile Machinery Division, Information Brochure.
31. Draw Frame TD 03, Trützschler GmbH & Co KG Textilmaschinenfabrik, Information Brochure.
32. The New RSB-D 40 Autoleveller Draw Frame -- A Firework Display of Innovations, Link -- The
Customer Magazine of Rieter Spun Yarn Systems, Vol 17/No: 46, Sept 2005.
Reeti Pal Singh Department of Textile Engineering, GZS College of Engg and Technology,
Bathinda 151001. V K Kothari Department of Textile Technology, Indian Institute of Technology,
New Delhi 110016.