The spinning mill’s beating heart is carding. Let’s see what a carding machine does in the process of spinning.
It’s important to consider the yarn’s quality when observing the finesse that goes into creating a garment. According to the quality of the yarn and fiber, the fabric’s texture is determined, making the carding process crucial in this regard.
The primary goal of the carding procedure is to separate the fibers into individual strands known as slivers. Carding is one of the most important operations in the “spinning process” as it directly determines the final features of the yarn.
Here is what a carding machine does.
What Does a Carding Machine Do?
- Taker In
The overall installation is very flexible and the linear density of the lap is excellent and easy to maintain (uniformity). As laps can be rejected, there will be no deviation in card output. A second cause of the error is the lap run out, which needs to be replaced by a new lap.
Given how tightly packed laps are, there is a greater loss of healthy fibers during lap changes and a greater load on the taker-in. Pass through the small grids on it as it is opened.
The taker-in’s job is to remove finely opened flocks from the feed batt, guide them over the dirt, remove objects like mote knives, combing segments, and waste plates, and then transfer the fibers to the main cylinder. The rotational speed of high-production cards ranges from 700 to 1400.
- Cylinder: With the aid of pointed teeth, the cylinder is split open and then transferred to the doffer. Because the feed web is so open, carding performance is high. The force of the spring presses the cylinder against the plate, which is located below.
- Brushes: The brushes are located in the upper part of the cylinder then clean the cotton fibers that are on the teeth.
- Revolving Flats: The fiber treatment is gentle because the fiber batt descends without detour and enters the taker-in’s teeth. As a result, there are fewer yarn flaws. The brushes on it are rotated by the rotating flats, and the cotton on the cylinder teeth will purge the impurities.
- Doffer: The doffer takes the cleaned cotton the same way to the cylinder from the taker, and passes it to the drawing unit.
- Drawing Unit: The drawing unit stretched and parallelized the cotton, transforming it into individual fiber form before passing it to the trumpet guide.
- Trumpet Guide: Together, the straightened fibers enter the trumpet guide and mix with it to create a sliver.
- Sliver Cane: The sliver is kept inside the sliver cane for use in later procedures.
The Purposes Or Objectives of Carding
Carding fulfills a series of precise objectives, serving:
- to open the blend fibers fully and definitively
- to arrange (as far as their length allows) the fibers parallel with one another
- to remove impurities
- to blend the raw material further
- to reduce the blend to a web of fibers and to divide it up into rovings of the required count, suitable for feeding to the spinning machines.
Carding is an integral part of every spinning cycle, but in the woolen spinning cycle, it takes on a variety of roles that are all necessary to achieve the level of product quality demanded.
In essence, untangling fiber tangles and sweeping the material over the card allows for the removal of all types of impurities. Spikes covering the surfaces of cylinders rotating around parallel axes help achieve this.
The equipment also performs a delicate yet essential additional task: it must ensure the precision and uniformity of the web count, which will then translate into the roving count.
In fact, the woolen spinning cycle’s final spinning machines can only produce a very low draft, so there is currently little chance of intervening to change the yarn count.
Thus, the carding room machinery completes the same tasks that were already completed in the preparation stage, this time more thoroughly, and supplies the divider with rovings of the appropriate count.
Defects in Carding
Following are some of the defects in the Carding process
- Causes of high sliver variation
- Nep formation
- Holes or patches in the card web
- High sliver variation is due to the difference in the draft between the card
- Worn clothing and feed roller bearing also create variation in card sliver
- A malfunctioning automatic leveler will also result in high sliver variation. Check the card wrapping every 30 minutes if an auto leveler is not in use.
Conclusion: What Does a Carding Machine Do?
Fibers are divided during the carding process, and then they are brought back together to form a loose strand (sliver or tow). In order to line up each fiber so that they are nearly parallel to one another, a machine that splits up locks and tangled clumps of fiber is used in the process.
A single large roller and several smaller rollers can be found inside the carding machine. Small spikes completely encircle the rollers.