Spinning technologyFibre pre-processing; Carding

Textile Technology I

Ing. Eva Moučková, Ph.D.Faculty of Textile Engineering

Department of Technologies and Structures

Textile Technology I | 2018/2019

Repetition

What is it a staple-spun yarn?

Is it possible to produce single staple-spun yarn from multifilament yarn?

What kind of semi-products do we encounter in the staple-spun yarn production?

Is any difference between sliver and tow?

What is produced in the spinning mill?

Basic general technologicalscheme of staple spun yarn manufacture

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Sliver

OpeningCleaning, Mixing

Carding

Fibrous rawmaterial

Roving forming

Spinning

Yarn

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Sliver

Fibrous tufts

Doublingand drawing

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Combing

Doubling and Drawing

Preparation for combing

Repetition

Combed sliver

Sliver lap/sliver

Fibre pre-processing

Opening, cleaning, mixing (i.e. Fibre pre-processing or Preparation of fibres for spinning)

- Fibrous raw material comes to a spinning mill in a pressed form - usually in bales; naturefibres contain a lot of impurities, fibres properties vary (in terms of fibre fineness, length,colour, .. ) within the bale, and also between the bales ⇒ opening, cleaning, mixing(blending) must be done .

Opening- The aim: breaking up bales of fibres into large tufts and progressively dividing these large

tufts into smaller ones (mutual cohesion of tufts becomes weak, elimination of impurities becomes easy, the fibres raw material prepares for further processing)

Processes can not be clearly separated from each other ⇒ by opening, the tufts are divided into smaller ones. Impurities can loosen and fall down ( = cleaning). During processing, the tufts change their position ( = mixing).Principle: gradual processing of the fibre raw material with minimal fibre damage and removal of impurities which are not crushed into smaller during processing

- Realization of initial opening: Opening machine – for example.:

- Automatic bale opener- Bale opener (bale breaker)

OpeningAutomatic bale opener

- Main part: opening unit (take-off unit) with tooth discs - it gently extracts material from the bales, forms small flocks of equal mass.

- The raw material is extracted from larger amount of bales (up to 200) – mixing is also realized

- Use: Cotton, cotton type of man-made fibres

1 …bales2… take-off unit3 … swivelling tower4 … channel for material transport

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Scheme of automatic bale opener [1][1] www.rieter.com cit. 5.8.2004[2] www.truetzschler.de cit. 7.6.2013 [3] www.rieter.com cit. 4.2.2016

Details of opening units (discs) [2],[3]

Scheme of opening unit – fa Trützschler [2]

Fibre pre-processing

OpeningBale opener (blending bale opener)

- Main part: inclined spiked lattice – it releases fibre tufts from large fibrous mass in the mixing chamber, tufts are mixed there

- Use: Cotton, cotton type of man-made fibres

1 ... Feed conveyor2 ... Feed lattice3 … Inclined spiked lattice4 … Fibrous material in mixing chamber5 … Evener roller6 … Stripping roller

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Scheme of bale opener [1]

[1] Trützschler Gmbh & CO KG: From bale to web, edition 03/2011

Fibre pre-processing

Cleaning- The aim: to release and remove impurities

Various ways of cleaning:

Main types of impurities in raw material:Cotton: Wool:

- Rests of seed-coats, leaves, stems, - Fibre neps- Dust - Others (sand, soil, metal particles, rest of wrapping

material, rest of textiles …)

[1] www.truetzschler.de cit. 6.7.2013 [2] http://textilelearner.blogspot.com/2011/05/definition-and-classification-of_7981.html, připojení 2.8.2018

Seed-coat fragment [1] Leaf fragments [1] Rests of cotton-plant stems [1]

- Suint (sheep’s sweat)- Wool grease - Vegetable impurities

(so called burrs)- Others: (urea, dirt, dust,

soil, sand, … )

Dry cleaning – mechanical, it proceeds together with tufts opening (for cotton, wool fibres); separation of foreign coloured particles (only for cotton) Wet cleaning - chemical (for example: scouring, carbonizing = chemical deburring) – only for wool fibres

Fibrous nep [2]

Fibre pre-processing

Fibre pre-processingDry cleaning (mechanical) - Opening and cleaning

- Task: gradual opening of fibrous tufts into smaller ones, releasing and removing impurities by mechanical way

- Principle: Acting of the rollers covered with various spikes, pins or saw-teeth clothing on fibrous tufts.

Fine saw-tooth clothing of openingroller [1]Opening roller with pins [1]

Opening roller with spikes [1]

[1] www.truetzschler.de cit. 6.7.2013[2] www.rieter.com cit. 4.7. 2013[3] Trützschler Gmbh & CO KG: From bale to web, edition 03/2011

- Impurities are removed by betting the tufts against grid bars or by air flow (knife-edge suction slot).

1 .. Opening roller2 …Pin of opening roller3… Adjustable grid

1 … Cleaning roller2 … Deflector blade3 …. Mote knives4 … Suction hood

Removing of impurities using grid bars [2] Removing of impurities using knife-edge suction slot [3]

Realization: opening and cleaning machines (openers and cleaners)

Fibre pre-processingOpening and cleaning

Opening can be done:- In loose state (in free flight)- In the pressed formOpening in free flight:- Raw material is not pressed by a feeding device. Less intensive cleaning – only free

heavier particles are removed - Opening and cleaning machines – for example: Opener Uniclean; coarse opener.

1 … cleaning and cleaning cylinder2 … cleaning grids3 … airlock cylinder4 … material feed5 … material outlet6 … fibre exhaust air7 … waste removal

Scheme of opener UNIclean – Rieter [4][1] www.rieter.com cit. 4.7. 2013[2] http://www.truetzschler-spinning.com, cit 2016-02-11

Scheme of coarse opener - Trützschler [2]

1 .. Openingand cleaningrollers withspikes2 ... grids

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Fibre pre-processingOpening and cleaningOpening in pressed form:- Fibrous raw material is pressed by the set of feeding rollers – more intensive cleaning- Opening machine – for example - drum opener

- opener UNIstore- machines with set of opening roller (tzv. Cleanomat)

Double drum opener [1]- Today is used for wool fibres only

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[1] Ursíny, P.: Spřádání vlnařským způsobem, VŠST Liberec, 1987[2] www.rieter.com cit. 4.2.2018

1 … feeding conveyor2 … feeding rollers

Opener UNIstore – by Rieter [2]- For cotton fibres

1 … storage chamber2 … feeding roller3 … opening roller4 … grid

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3 … opening and cleaning drum4 … grids

Fibre pre-processingOpeningOpening in the pressed form:

Multi-roller cleaner (Cleanomat) - by Trützschler [1]- For cotton fibres

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1 … Feeding conveyor 2 … Feeding roller3 … Opening and cleaning roller4 … Knife-edge suction slot

- Gradually finer clothing of opening rollers

[1] www.truetzschler.com cit. 5.4.2011

Fibre pre-processingDry cleaning Foreign parts separators

Foreign part separator - by Trützschler [1]

1 … camera2 … exhaust nozzle3 … feed roller4 … opening roller5 … waste suction6 … tuft delivery channel

[1] Trützschler Gmbh & CO KG: From bale to web, edition 03/2011[2] www.jossi.ch cit. 2.5.2011

- The quick colour camera scans the colour of thetufts and compare it with reference colour. Whenforeign fibre (or tuft with different colour) is detected,it is blow into a waste suction device by means ofcompressed air impulse coming from the nozzle.

- It detects and separates foreign (different in colour) from fibrous material (remains of wrapping, fibres covered with oil, grease, the remains of coloured material from the cotton bales, foreign fabric, feathers, etc.

- It is used only in the cotton spinning technology

Foreign part separator - by Jossi [2]

Fibre pre-processingWet (chemical) cleaning

a) Scouring- It is realized only in the case of wool fibres processing - The tasks: elimination of all mineral impurities (dust, sand) and suint; vegetable

impurities and wool grease are removed partially. Vegetable impurities (burrs) –held on fibres.

- It is necessary to carry out this gently with respect to the wool fibres - (temperature: approx. 50 - 60 °C)- Realization: scouring machine (Leviathan) – several scouring bowls

[1] Jirásková, P. Výroba délkových textilií. Studijní text pro distanční vzdělávání. Liberec: Technická univerzita v Liberci, 2004.[2] http://amassfarminginfo.blogspot.com/2014/06/wool-processing.html , citace 25.6.2018

Scouring machine (leviathan) [2]Scouring machine (leviathan) – scheme of first bowl [1]

1 … loading belt2 … inclined spiked lattice3 … stripping roller4 … feeding belt

5 … ducker6 … conveying rake7 … elevator8 … squeeze rollers

Fibre pre-processingWet (chemical) cleaning

b) Carbonising - The tasks: elimination of vegetable impurities (burrs) form wool - Realization: carbonising line – by acting sulphuric acid (H2SO4) and following drying at

high temperature (cca 105°C) , the burrs carbonize (cellulose transforms on the hydrocellulose ) and they can be removed mechanically

- The use: only for wool fibres of worse quality (for example: for carpet, furnishingtextiles, berets, fezzes ) - sulphuric acid damages wool fibres

How to remove burrs from wool at processing quality fibres?

Mixing- The tasks: intensive mixing of fibre tufts (or individual fibres) of one raw material to

each other so that the properties of the fibres (fineness, length, colour, maturity, etc.) are uniformized in order to ensure the required and „invariant“ yarn properties along the yarn.

Fibre pre-processing

Mixing is realized: - a) spontaneously at initial opening (take-off raw material from more bales, mixing parts

of fleece sheep) and at opening and cleaning.b) intentionaly by means of mixing machines – mixers or mixing boxes

Principal of mixing – mixer UNImix – by Rieter [1]

[1] www.rieter.com cit. 4.7. 2013[2] http://andar.co.nz/textiles/loose-stock-clean-prep/

Mixing box – by Andar [2]

- Several kinds of fibres can also be mixed together in a from of tufts (at production of so called blended yarns) – it is necessary to ensure even distribution of fibres of each component in the yarn – individual components must be weighed.

Fibre pre-processingMixing

Example of cross-section of fibre distribution in a blended yarn [1]

[1] www.rieter.com cit. 28.6.2018[2] Truetzschler GmbH: Blow Room. Monchengladbach, Gernany, 2011.

Weighing feeder – for cotton spinning technologies [2]

Fibre pre-processingPreparation for spinning is different for cotton, wool, and man-made fibres ⇒ it dependson sort of fibrous raw material, because each of them contains various type of impurities.Cotton fibre pre-processing

- Machines for bale opening, opening and cleaning, and mixing are connected into the line - so called blow room. Machines are connected via a ducting.

Blow room: - The task: Release fibrous tuft from the bales, open tufts into smaller, very fine tufts

mechanically Eliminate most of impurities and dust (mechanically) Provide a good blendEvenly fed the tufts to the tuft feeder of carding machine

Input (supply) product: bales of fibres Output product: fibre tufts

Equipment of blow room:

- It depends on kind of fibrous raw material, amount of impurities, and spinning technology

- The beginning of the blow room: bale opener /or automatic bale opener- The last machine of blow room: Foreign particle separator and the tuft feeder of

carding machine

Cotton fibre pre-processing Example of blow room for cotton fibre – by Trützschler [1]- The line is connected with carding machines

[1] www.truetzschler.com cit. 5.4.2011

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1 … automatic bale opener2 … opener and cleaner – opening in free flight3 … mixer4 … cleaner - opening in pressed form (cleanomat)5 … foreign fibre separator6 … tuft feeder of carding machine 7 ... carding machines

Wool fibre pre-processing

Principle:

- Classification and separation of parts of fleece according to wool fibre quality,- Gradually removing of impurities - chemically (scouring, carbonising), eventually

mechanically (mechanical de-burring)- Dividing tufts into smaller ones by mechanical way.

During processing, tufts are mixed. Wool fibres must be also oiled concurrently.

Input: sheep fleece (raw sweat wool) Output: cleaned fibrous tufts (i.e. free of most impurities), which are transported into the hopper of carding machines.

For more details, please see the subject of Spinning

CardingTasks of the carding:

- Opening fibre flocks into individual fibres - Elimination of remaining impurities (for example burrs from wool fibres) - Elimination of short, un-spinable fibres- Creating partial longitudinal orientation of the fibres- Formation of even web, which :

- is usually condensed into the sliver, - eventually rovings are formed from it (only in the case of woollen spinning)

Realization: Carding machine (Card)Input (supply product): fibrous layer consisting of fibre tufts Output: usually sliver (roving is also possible)

Principle of carding: Two saw-teeth (or small wire hooks) clothing areoppositely disposed. Both clothing move at different speed. One of themis fast (very fast). Second one is very slow. Points of super-fast clothingpull out individual fibres from flocks. Opening of flocks into fibres isrealized. Fibres are straightened simultaneously. Short fibres pressinto slow clothing, which must be cleaned.

- Flat carding machine – used for cotton and cotton type of man-made fibresTypes of carding machines:

- Roller carding machine – used for wool and woollen type of man-made fibres

CardingFlat carding machine:

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1 … tuft feeder2 … fibre tufts from blow room 3 … feeding device4 … opening device5 … main cylinder6 … revolving flats

7… stationary flats 8 … doffing roller9 ... stripping device, web former and condensing device 10 … sliver 11 … coiler12 … can with sliver

Carding zoneFlat carding machine TC07 - Trützschler [1]

[1] www.truetzschler.de Accessed 2010-07-06

CardingFlat carding machine

Carding zone of flat carding machine [1]

[1] Ursíny, P.: Předení I, Technická univerzita v Liberci, Liberec, 2006.

Carding zone: main cylinder – flats Why is it important?

Arrangement of flats and detail of flat– fa Trützschler [2]

Flats

Main cylinder

[2] www.truetzschler.de Accessed 2010-07-06

Flats

Maincylinder

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Carding

[1] Ursíny, P.: Předení I, Technická univerzita v Liberci, Liberec, 2006.

Roller carding machine- More main cylinders, or multi-machine composition- Machine arrangements and the way of their ends differs according to spinning technology

(woollen, worsted)

Roller carding machine for worsted spinning technology [1]

1 … weighing hopper feeder2 … breast apparatus3 … de-burring device4 … worker

5 … stripper6 … fancy roller7 … doffer8 … doffing comb and sliver formation 9 … main cylinder

Fibre tufts Sliver

Why?

Carding

[1] Dostálová, M., Křivánková, M.: Základy textilní a oděvní výroby, Technická univerzita v Liberci, Liberec, 2004.

Roller carding machine

Roller carding machine for woollen spinning technology

- See the subject Spinning

- Machine output: roving (slubbing) – roller carding machine is equipped with the so called tape condenser – the card web is divided into narrow strips, they are rounded, the roving is formed and wound onto a condenser bobbin.

- Then, the yarn is spun from the roving in the ring spinning machine

Scheme of web dividing [1]

Cheese on the condenser bobbin [1]

Carding

[1] Dostálová, M., Křivánková, M.: Základy textilní a oděvní výroby, Technická univerzita v Liberci, Liberec, 2004.

- Carding zone: main cylinder – worker – stripper

Roller carding machine:

Carding zone of roller carding machine

Carding zone of roller carding machine – scheme [1]

Maincylinder

worker

stripper

worker

stripper

main cylinder

Carding

[1] Ursíny, P.: Předení I, Technická univerzita v Liberci, Liberec, 2006.[2] Dostálová, M., Křivánková, M.: Základy textilní a oděvní výroby, Technická univerzita v Liberci, Liberec, 2004.

Card clothing [1 - 5]

Elastic wire (flexible clothing)

Semi-metallic (semi-rigid) clothing

Metallic (saw-tooth) clothingSemi-rigid clothing of stationary flats– fa GRAF

Saw-tooth clothing – by Groz-Beckert

[3] https://www.groz-beckert.com/en/services/product-services/carding/ cit. 29.6.2018[4] http://www.graf.ch Accessed: 2011-07-14[5] http://www.jamesholdsworth.com Accessed: 2009-06-24

- They differs according to processed fibrous raw material, - Individual rollers - different saw-tooth (or wires) inclination, saw-tooth (wire) height, point

density

Carding

Dostálová, M., Křivánková, M.: Základy textilní a oděvní výroby, Technická univerzita v Liberci, Liberec, 2004.

Clothing arrangement - Depending on the position of the saw teeth (or wires) of the two adjacent clothing and their function we recognize the three basic arrangement of the card clothing:

2) Carding disposition- Clothing function: opening fibre tufts onto individual fibres, fibre straightening, and aligning

1) Doffing disposition - Clothing function: transition of fibres from one roller on the another

Main cylinder

StripperFlats

Stripper

Worker

Worker

Main cylinder

Worker

Stripper

Main cylinder

Carding

Dostálová, M., Křivánková, M.: Základy textilní a oděvní výroby, Technická univerzita v Liberci, Liberec, 2004.

3) Stripping disposition- Clothing function: To lift up fibres from the clothing on the surface of main

cylinder and prepare it for doffing- Only in the case of roller carding machine for woollen spinning technology

Clothing arrangement

Fancy roller

Main cylinder