Carding( Jute)

Carding:
The process by which long reeds of jute while passing through high speed pinned
rollers are broken down into an entangled mass and delivered into the form of
ribbon of uniform weight per unit length is called Carding. During carding the
network structure is broken and a thin web of separate fibers is obtained which is
condensed into a sliver.

Objects of Carding:
 To break down and split up the fibre.
 To make the sliver of uniform wt per unit length.
 To remove dirt and dust.
 To individualize and parallelize the fibre.
 To straighten the fibre by drafting.
 To reduce wt per unit length.
 To mix different qualities of jute.

Classification of Carding machine:

According to Cylinder function:
1) Half Circular.
2) Full Circular.

1) Half Circular:
In half-Circular Cards jute travels the half-way round the main cylinder in its
journey from the feed to the delivery. Thus the feed and delivery are
approximately 1800 apart.
Example; Breaker Card.
2) Full Circular:
In this machine jute travels almost full way round the main cylinder in its journey
from feed to delivery. Thus the feed and delivery are almost side by side, nearly
3600 inside the machine.
Example: Finisher Card.

According to Striking:
1. Up Striking.
2. Down Striking.
1. Up Striking:
In this machine the pins of the cylinder approach the feed from underneath and
strike up the fibre. Up striking cards are used for low quality jute as the dirt and
short fibers cannot be collected below it can again mingled with the fibers. Here
fibre loss is low.
2)Down striking:
In this machine the cylinder pins approach the feed form the top and strike down
into the fibre. Down striking cards are used for high quality jute. The dirt and
short fibers are collected below and they cannot mingle with the fibers again. But
here the rate of fibre loss is high. Pins of down striking cards are thick.

According to processing:
1. Mono carding machine.
2. Dual carding machine
3. Tandem carding machine.
1)Mono Carding machine:
When a single carding machine with one cylinder is used for carding, it is called
Mono carding machine. It is used for cotton, not successful for jute.

2)Dual carding machine:

When two individual carding machine i.e. breaker card and finisher card are used
in carding, they are called dual carding machine. It is used for jute processing.
3)Tandem carding machine:
When tow carding machines are used at a combination then it is called Tandem
Carding machine. The motion is transferred from 1st machine to the 2nd machine.
When one machine stops the other stops automatically. It is used in case of Roller
spinning in Cotton.
In tandem carding machine, two individual cards make up a unit. The doffer of the
1st card feeds fibre material to the taker-in of the 2nd card. Double carding of the
raw material has a positive effect on quality and on blending. However the
advantage is obtained at high cost hardware and maintenance. Again additional
space is required for tandem card. About 1% cotton is processed with tandem
cards now. Modern cards are considered as a tandem of the latest generation.

According to Roller and Flat:

1. Stationary flat card:
In which the flats on the cylinder are fixed and cylinder moves.
2. Revolving flat card:
In which the flats on the cylinder are moving and cylinder moves.
3. Roller card:
Breaker card, Finisher card, no flat.

Breaker Carding Machine:

Breaker Cards are generally down striking and half-circular. In this machine
the primary function of jute carding is done by the action f worker and cylinder
and the cleaning actions is done between worker and stripper. It is called Breaker
Card because it breaks up to the long reeds of jute.
The main three functions of breaker Card are:
 Individualization of fibre.
 Drafting of fibre.
 Sliver formation.
Main parts:
i) A main cylinder
ii) Shell
iii) Flutted feed Roller
iv) Pin feed Roller
v) A pair of Stripper
vi) A pair of worker
vii) A pair of tin cylinder
viii) Doffer
ix) Drawing Roller
x) Delivery Roller

Working principle:
1) The Roll of 6-8 spreader slivers are feed on to the feed sheet from a creel at
floor level towards the feed roller of the breaker card.
2) The jute now enters the machine through shell feed. This consists of a pin
feed Roller and a cast iron shell.

Fig: X-Sectional diagram of Breaker card m/c

3) The jute enters the space between the pin feed Roller and the shell and
travels towards the swift moving pins of the main cylinder.
4) When the feeding ends of the reeds meet these fast moving pins, they are
split, opened out and converted into a fibrous beard.
 5) When jute fibers come in contact with the slow speed of the workers which
gives carding action together with cylinder but not stripping.
6) The back pointing pins of the worker opposes cylinder pins, point against
point to catch up loose fibers and at the same time open out and card the
fibre.
7) The fibrous raw striped by the workers are carried round with them and
ultimately stripped by pins of the faster running stripper roller.
8) The wastage is then discharged through the tin cylinder.
9) In this way, jute passé 1st ad 2nd worker-stripper pairs.
10)After leaving the 2nd worker-stripper pair fleece of fibers meet the doffer
which stripes jute off the cylinder.
11)Then the fibs pass through drawing Roller into V-shaped condenser.
12)The fibers are delivered to delivery roller and delivery processing roller.
Finally the sliver obtained in the roll form.

Finisher Card:
Finisher card is full circular carding machine. After jute is processed by breaker
card, it is sent to finisher card. The rollers and cylinder are pinned in the same
manner as in breaker card but pins are finer and set closer together in Finisher
Card Machine.
Main Parts:
i) Feed sheet
ii) Pin feed roller
iii) Feed stripper
iv) Top feed Roller
v) 4-worker Rollers (1st,2nd,3rd,4th)
vi) 4-stripper Rollers (1st,2nd,3rd,4th)
vii) 2-Doffers (Top and Bottom)
viii) a main Cylinder
ix) 2-pairs of drawing Roller (Top and bottom)
x) a pair of delivery Roller
Working Principle:
 10-12 slivers obtained from breaker Card are places side by side at the fed
end of finisher card.
 Two types of feed system such as shell feed system and double pinned fed
system.
 Shell fed used for sacking weft cards and light carding loading is possible in
double pinned feed.
 The fibers come in contact with top feed Roller, pin feed Roller and feed
stripper. Pin feed Roller an feed stripper have pins point against back and
only small amount of carding action takes place here.

Fig: X-Sectional diagram of finisher card m/c

 Then the fibre transfer to the worker. The pin direction between the
cylinder and worker is pint against pint and cylinder speed is quite higher
than the worker. Here carding action takes place.
 When the fibers are combed between workers a stripper the stripper takes
the fibre forward to the cylinder surface it to the coming second worker-
stripper. Here the fibers are thinned down and individualized.
  The same action is repeated along the 2nd, 3rd and 4th pair of worker and
stripper.
 While leaving 4th pair of worker-stripper the fibers come to the action of
doffer where the fibre is received and combing action tables place since the
pin direction of doffer and cylinder is opposite.
 Then the fibre are passed through drawing Rollers and are transferred to
the 2nd doffer and drawing Roller and delivery Roller.
Finally the finisher sliver is condensed to delivery in Roll form.

Distinguish between Breaker Card and Finisher Card:

Breaker Card Finisher Card
1. It is half circular carding machine 1. It is full circular carding machine
2. It has single doffer. 2. It has double doffer.
3. It has two pairs of worker and 3. It has four pairs of worker and
stripper. stripper.
4. Less pin density. 4. More pin density.
5. Pins are coarser and set wider. 5. Pins are finer and set closer together.
6. More production (600-650 lb/hr) 6. Less production (400-475 lb/hr)
7. Wider Setting 7. Closer setting
8. Doubling is not done here. 8. Doubling is done here
9. Sliver wt per unit length is high. 9. Sliver wt per unit light is low.

Difference between Cotton Carding and Jute Carding:

Cotton Carding Jute Carding

1. Feed materials is lap.
2. One carding machine is used.
3. It removes dirt, dust and neps.
4. It is easy process.
1. Feed materials is long reeds of jute.
2. Two Carding machine is used. i.e
Breaker Card and Finisher Card.
3. It breaks down and split up of the
fibre.
4. It is difficult process.
Why two types of Carding machine used:
Breaker card only open out the fibre and remove dirt and dust
Breaker sliver obtained from breaker card are not complete free from defaults
and trash, dirt, dust, foreign matters are present in Breaker Sliver. Another
carding machine is required to remove faults i.e. dirt, dust, trash and parallelizing
of the fibre. To perform this function, another carding machine which is used is
finisher carding machine.

Factors which influence carding:

Modern trends and developments of carding:
1) Pin density:
The more pin density of rollers the more carding action and less pin density
will give less carding action.

2) Cylinder speed:
Greater cylinder speed will give more carding action.

3) Feed load:
The more feed load, carding will be bad but if feed load become lighter,
carding will be better. Because small amount of feed material will be
treated by the rollers property.
4) Speed of feed Roller:
Slower speed of feed Roller gives more carding due to feeding of less
material into the machine per unit time. But faster speed will give reverse
effect.

5) Worker speed:
If worker speed is high carding will be low and again higher pin density on
worker will give more carding action.
 6) Stripper speed: Speed of stripper has no effect on carding action. But when
stripper speed is high, good stripping will be.

7) Roller setting:
If the rollers are setting more closely then the carding action may be high.

8) Carding ratio:
S .S .of .cylinder
Carding Ratio =
S .S .of .wor ker
The more carding ratio, the more carding action. Normally 40-45.

9) Carding efficiency:

S .S .of .Cylinder  S .S .of .Wor ker

Carding efficiency:=  100%
S .S .of .Cylinder
More carding will be increase of more carding efficiency.

Function of cylinder:
i) To take the jute fibre form feed Roller so that machine do not jam
due to excess jute.
ii) To open out the fibers.
iii) To take the fibers from stripper.
Function of worker:
i) To take the fibers from cylinder
ii) To open out and card the fibre.
iii) To remove waste, trash, dirt and dust.
Action in carding machine:
1) Carding action:

i) Between worker and cylinder:

 Pin direction is opposite.
 Relative direction of rotation opposite.
 Speed of cylinder is higher than that of worker.

Fig: Carding action

ii) Between cylinder and doffer:
 Pin direction opposite.
 Rotation direction same.
 Speed of cylinder is higher than that of doffer.

2) Stripping Action:
i) Between Worker and Stripper:
 Pin direction same,.
 Rotation direction opposite,
 Speed of stripper is higher than worker.
 Fig: Stripping action
ii) Stripper to Cylinder:
 Pin direction same,
 Rotation direction same,
 Speed of cylinder is higher than stripper.