Short Staple Spinning: Major Processes Carding

Bale
Open/ Flock Feed (Direct from Blowroom)
Preparation (Blow Room)
Mix/Clean
Lap or Flock
Open/
Carding (Card)
Mix/Clean
Carded Sliver (Can)

Sliver

Can

Flats Carding

Functions:

Cylinder Opening/disentanglement
Cleaning
Lap Feed Mixing
Sliver forming

Cotton Card: Revolving-flat Card

 Card Clothing
Main Types

Flexible: wired teeth protruding from

foundation of laminated
structure

Metallic (rigid): toothed steel strip

 Depth (C) Overall

height (h)
Card Clothing
=Carding (working) angle
Metallic Important parameters
clothing
Working angle
Pitch (t)
Depth
Point density
Base width (a)
Sharpness

Flexible
Clothing

Card Clothing: Arrangement

Point-to-Point

Setting
Possible Actions between Two Surfaces with Card Clothing

Point-to-Back
Carding (Point-to-Point) Action Brushing (Back-to-Back) Action

Fibre clusters divided by two surfaces

Fibres brought to the gap between two surfaces
(not used in cotton card)

Stripping (Point-to-Back) Action

Point to Point: Carding

Point to Back: Stripping

Back to Back: Brushing

Fibres transfer to faster surface

Carding Operations

Feeding
Carding
Doffing / sliver forming
 Feeding Area

Fibres fed by feed roller/feed plate in lap form

Pressure =2V2
Lap opened to small tufts by taker-in

Trash extracted by mote knifes/grids

Fibres transferred to cylinder

=1000V1
Key parameters
S1= Lap density
S3
0.25-0.5 Speeds
S2 Settings
L1 L2 (1’’) Taker-in clothing

Carding Area

Intensive opening
Carding action between flats and cylinder
separates fibre tufts to single fibres

Trash extracted by flats/removed by fly comb

Slow Setting Mixing

Flats
Key parameters
Fast
Cylinder Speeds
Settings
Card clothing
Cylinder loading

Fast

Slow
 Doffing Area
Fibre transfer (cylinder to doffer)
Point to point action
Transfer factor: 20-30%
If too low: over carding of fibres
over loading of cylinder
To increase transfer factor:
• Increase doffer wire working angle and depth
• Increase doffer speed
• Decrease cylinder-doffer setting

Doffer web removed by stripping roller

Web condensed into sliver and

deposited in sliver can by coiler

DRAFT DRAFT

Input Linear Density Output Linear Density Input Linear Density Output Linear Density
L1 L2 L1 L2
Machine Machine
Input (Feed) Speed Output (Delivery) Speed Input (Feed) Speed Output (Delivery) Speed
V1 V2 V1 V2

L1
Technical draft (actual draft) TD Waste (W% of Feed)
L2
V2
Mechanical draft MD
V1 With Wastage: L1xV1=L2xV2+L1xV1xW%
L1 V2
Without Wastage: L1xV1=L2xV2 or = MD=TD (1-W%)
L2 V1

Production Rate
Recommended Production Rates
Vd x 60 x Ls (Platt Type 600)
(Kg/h)
1000

Type Micronaire Staple Length Max. Kg/h

Vd: Sliver delivery speed (m/min) Indian 5.0 16-24 41
Ls: Sliver linear density (Ktex) Low American 4.5 24-26 39
Good American 4.2 26-28 32
Production rate is affected by: Sudan/Egyptian 3.8 29-35 20
Fibre type Long Egyptian/Pima 3.4 >35 16
Fibre length/thickness
Trash content
Machine design, settings, maintenance
 Draft & Production Calculation
Example Fibre Configuration in Card Sliver
Given:
Fibres largely aligned along sliver length
Feed lap linear density: 700 Ktex
Sliver linear density: 5 Ktex Most fibres have hooked ends:
Waste: 5%
Feed roller diameter: 100 mm
50% (majority) trailing hooks
Feed roller speed: 3 rpm
25% leading hooks
15% double hooks
Calculate:
10% straight
Total Technical Draft
Total Mechanical Draft
Production rate (Kg/h)

Leading hook in Trailing hook out

Each process reverses hook direction

Fibre hooks adversely affect:

Yarn strength

Yarn appearance

Performance of subsequent machines

Sliver quality needs further improvement