Yarn Manufacture I : Principal of Carding & Drawing

Prof. R. Chattopadhyay
Department of Textile Technology
Indian Institute of Technology, Delhi

Lecture – 08
Card Setting, Draft, Production

We are going to discuss settings, drafted, cleaning efficiency and production in the
carding machine.

(Refer Slide Time: 00:35)

We start with first settings, setting means maintaining the right tolerance of space or
closeness between two walking organs of the machine, such as let us say licker in to
cylinder, cylinder to flat or cylinder to doffer. Incorrect settings affect the working
efficiency of the machine and it can also deteriorate the quality of the processed material.
Therefore, settings are very very important and crucial for the process.

Now, setting depends upon many factors some of which are listed here, which is fiber;
that is whether it is cotton or synthetics or whether it is manmade fibers like, viscose
rayon or polynosic fiber. And it also depends upon the dimensions of the fiber. That is
their length and fineness, it also is affected by the level of trash content in the case of
cotton. So, quite a few factors are there which affect settings.
(Refer Slide Time: 02:07)

Some typical settings are shown in the following table. These numbers indicates the
distance between the two organs and the unit is 1 by 1000 of an inch. This is what is
generally practiced in the industry and 1000 of an inch is normally know that is thou in
the industry. Let us look at the settings as shown let us say between feed plate and licker
in. The setting is 10-12 thou between for viscose rayon the same setting will be between
12-15 thou, for polyester it will be 12-15 or maybe little more for acrylic it could be also
little more.

In the next table, the settings as well as the some comments about those settings have
been shown. What we see here, the settings are basically very difficult to remember, but
they are generally available. There are few crucial settings which we must remember
also. If we look the zone feed plate to licker in, then we find that the setting is widened
for synthetic fiber being generally long to reduce the level of stress on the fibers.

So, when you go from cotton to fibers like viscose rayon, polyester, acrylic, these fibers
do not have any short fibers. So, on an average their lengths are more than the cotton and
therefore, when you want to switch over from cotton to processing viscose rayon or
polyester or acrylic or such fibers; we have to widen the setting between the feed plate
and the licker in, otherwise the fibers are going to get damaged.

The other setting is licker into cylinder and generally this setting is fixed almost for all
types of fiber. It is usually 7000 7 thou that is what is generally known as and typically 4
by 1000 inch is 0.1 millimeter. It has go to cylinder and flat settings, we can also see the
values here and we see that these settings are little more for synthetic fiber like polyester
and acrylic. And why it is more? The setting is widened because; these fibers are
voluminous.

So, we have to reduce the level of stress on them, the space is very narrow between
cylinder and flat. The fibers are voluminous and there is going to be a lot of abrasive
stretch which will be there on the fibers. So, we have to reduce the level of stress, in
order to protect the fiber from getting damaged. Also the other possibilities which are
there is the development of heat or temperatures. That also we have to avoid because of
the tremendous abrasive actions that could be lot of heat generations, that also we have
to avoid. And the other thing which may result is the formation of neps by these fibers.

So, to avoid all such possibilities, we have to increase the settings when we try to process
voluminous fiber like; polyesters or acrylic or the we nylon. Cylinder to doffer settings is
generally 4-5 thou where, the fibers are generally transferred so, these settings once it is
fixed it is not changed as we switch over from one fiber to another fiber. Back plate to
cylinder settings is also shown here, if we look at these values we see these values a little
more that basically indicates that entry to the plate is wider than the exit. And this is what
is done practiced for all types of fiber; entry point the tufts which are coming a little
more voluminous and then they are made to pass through a narrow zone.

So, that is how we set the plate and the other thing would which you can see is that the
there is a difference in the settings. When we compared between cotton and the rest of
the fibers the reason is same that the synthetic fiber are basically bulky in nature. Front
plate to cylinder settings you can also see that the entry to the plate is narrower than the
exit end. Licker in to combing segments that is which are there below the licker in.
These, settings are fairly constant; for cotton a little less 16 at the entry point and 22 at
the exit and rest are all same. So, these settings one set is not changed, unless there is a
specific need.

The other important setting is the under casing of the cylinder from licker end to doffer
end the values are shown here. The doffer end is wider than the licker in side that is what
we can observe and this also because of the fiber being bulky in nature there is another
point that we can see.
That for synthetic fiber the settings are little on the higher side and not necessarily that is
very very high, but now it is in its case is almost constant because, this setting is not
really very very important setting. And hence once it is fixed it is nearly not changed
from fiber to fiber. It really does not make much difference since the settings are not so
crucial from the processing point of view. Doffer to Doffer stripping roller if we see the
settings it is 12-15 for cotton around similar values for viscose rayon for polyester
acrylic little higher.

And this is also because of the fact that this fiber a little bulky especially, polyester and
acrylic viscose is not that bulky in comparison to cotton. But the proportion of short fiber
which are there it is very high in cotton, but it will be almost negligible in the case of
viscose rayon or for polyester or acrylic. So, the differences that we observed in the
setting is mainly, because of the bulky nature of the fiber and mainly because of absence
of shorter variety of fiber in the case of manmade fibers. These are typical values so, the
actual settings for a given situations may differ from it in the industry.

(Refer Slide Time: 11:03)

Parameters that affect settings fiber length, fiber fineness, type of fiber and production
rate.
(Refer Slide Time: 11:11)

How fiber length is going to affect setting? What a given fiber if we go from shorter
length to longer length. The most important setting that we need to change, it is setting
between feed plate to licker in. Because this is the point where, a lot of force will be
acting on the tufts, tufts which are being fed relatively unopened state at this stage. And
therefore, to avoid fiber damage we have to very careful about the speeds and speeds of
the licker in and the setting between the feed plate and the licker in.

So, as a length is increased we have to widen the setting especially at this point. And we
may also need to change the setting between cylinder and flat because, long fiber means
lot of friction between the fiber and the teeth of the cylinder and flat. And there is chance
a lot of frictional heat may be generated, at the same time lot of force will be acting on
the fibers. Which may create neps may generate or may lead to damage also and hence
the length is too long we have to also adds at the setting between cylinder and flat.

Next go to fiber fineness with finer fiber cylinder flat setting becomes very very crucial.
This setting should be reduced in order to achieve thorough opening so that the fiber
clusters do not pass through. In the case of cotton finite fiber are generally longer also
hence the widening of feed roller to licker in setting also may be required. So, for cotton
we not only need to adjust the setting between cylinder and flat, but also between licker
in and feed rollers, because long cotton fiber are also finer or vice versa.
Finite cotton fiber also longer and hence we need to adjust these two most important
settings. The production rate can also affect setting generally in high production cards all
the settings are steadily widened. However, the most important ones are feed plate to
licker in and cylinder to flat, these are the most crucial sitting in the entire the machine.

(Refer Slide Time: 14:01)

Type of fibers if we discuss as I already mentioned that manmade fibers are free from
short fibers like, the short fiber we see in the case of cotton. The other thing is they are
bulky and resilient in nature.

(Refer Slide Time: 14:23)

There is a high fiber to metal friction between all synthetic fiber and metal. For polyester
and acrylic the cylinder flat and feed plate licker in settings need to be widened in
comparison to cotton, which we have already discussed. And the reasons also have been
told that the reasons are mentioned here, greater average length absence of short fiber,
bulky resilient nature of the fiber and high fiber to metal friction. Because of all this the
stress level goes up when these fiber are teased by the licker in or they are opened by the
cylinder and flats in the carding zone.

(Refer Slide Time: 15:28)

The other thing that may happen is that these synthetic fibers other than viscose are
elastic in nature and will be more prone to nep formations. When certain stress acts on
them and the fiber gets released from the teeth of either the flat or the cylinder. The fibers
will spring back and the internal energy of the fiber will cause the fiber to recoil and
while doing so, it may take up some fiber from the neighbors and roll them in the form of
neps. Therefore, this aspect you have to keep in mind while possessing these synthetic
fibers.

The other thing is synthetic fiber are more prone to static generation, this is very very
serious we all know that synthetic fiber because they are generally hydrophobic in
nature. They do not absorb any moistures, moisture helps in dissipating your static
charge, but these fiber do not absorb much moistures and therefore, there is a chance a
lot of static charge may generate.
Though these fiber have some spin finish on them, but the spin finish may not be
sufficient enough to take care of the static charge. And generally it has been seen that
these fibers lead to generation of static electricity. And because of that they get stuck to
the machine surface to the metallic odd points and do not get transferred easily from
cylinder to doffer. They do not want to get removed or stripped also from the doffer
surface.

So, we face such problems hence, we have to think what to do to reduce the intensity of
the rubbing actions. The rubbing action can also increase the temperature also told earlier
and this temperature may go so high that fibers may sometimes melt especially
thermoplastic fibers. Therefore to reduce intensity of rubbing to avoid fiber damage nep
generation, heat generation. What we can do? Is to reduce or is to not reduce to widen
the setting and to reduce the speed. That also is another alternative or we can play with
both, that we reduce the speeds of processing and also we can widen the setting so, that
these fiber can be processed nicely.

(Refer Slide Time: 19:02)

So after discussing setting now we go to draft, the draft is a measure of degree of

attenuation, that is degree of reduction in weight per unit length of the material being
processed. Draft in a way is stretch that we are generally understand. So, draft in this
machine could be of two types we call it mechanical draft and actual draft.
(Refer Slide Time: 19:34)

Now, we will discuss: what is mechanical draft and what is actual draft? Before that let
us see the drive of a carding machine, today’s carding machines are driven by number of
motors. The typical gearing diagrams of a machine along with the motors are shown
here, we can see there is a motor here number 1 another motor there, another motor here,
another motor here, another motor here. So, there are 5 motors which are driving these
carding machines.

In the old version of cards that used to be only a single motor, but today’s machines will
always have multiple motors. Each motor takes care of one section of the card. So that
the speed of these sections can be controlled independently and quickly from a central
computer control controller, that is the purpose that we have quite a few motors. Now, if
we look at this diagram what we can say? Let us say motor number 2. This is driving the
feed part of the machine, which is from here to there this part is the feed part. All these
elements or organs are driven by motor number 2 which is here. Similarly motor number
1 is driving licker in cylinder and flats. Motor number 3 is driving the delivery section of
the machine along with doffer.

Motor number 4 is driving it is a fan which is sucking the dust laden air, that the machine
generates. The machine generate lost of dust because of this teasing action which is
going on at different points of the machines. So, you exploit the opportunity to suck out
the dust laden air in order to clean the cotton. In the case of processing synthetic fiber
dust is not there and therefore, the sucking action may not be required or it will not so
important.

(Refer Slide Time: 22:40)

Now, let us discuss this draft mechanical draft, what is mechanical draft? Mechanical
draft is calculated based on speed of the machine elements who is based on the speeds.
So, we need to know the speeds of the different organs of the machines to find out the
mechanical draft. So, mechanical draft is the surface speed of delivery roller they are
read by surface speed of the feed roller or mechanical draft can also be length of sliver
delivered per unit rotation of the delivery roller.

Length of lap fed per unit rotation of the delivery roller or mechanical draft could be
length of sliver delivered per unit rotation of feed roller or length of lap fed per unit
rotation of feed roller. So, this is the definition of draft which is ratio or surface speed or
length of sliver delivered and length of material fed per unit rotation of either delivery
roller or feed roller.
(Refer Slide Time: 24:03)

How draft can be determined, for mechanical draft determination one needs to calculate
the speed from the gearing diagram. So, if we have the gearing diagram of the machine
with us then we will be able to calculate or estimate the speed the different parts of the
machines, different rotating parts of the machines or moving parts of the machines.
Otherwise we have to use a tachometer to measure the speeds.

The other thing is actual draft; actual draft is the ratio of linear density of the lap and the
linear density of the sliver. So, if we take the ratio of the linear density of the lap and
linear density of sliver then the value that we get that is all known as actual draft. The
actual draft is not based on the gears or not based on measurement of speeds. Typically
draft over carding machine varies between; 80-110 that is the typically most of the
machines can have these values of draft.
(Refer Slide Time: 25:39)

In the machine there are so many rotating elements and therefore, one can find out the
overall draft of the machine and also one can find out the draft between two successive
elements of the machines because, both are important for us. So, if the feed roller surface
speed is represented by V F taker in by V T cylinder by V C as shown in this table.

Then we can find out the draft between two successive elements by taking the ratio of
surface speed as shown in column 4th column, this is your 4th column, this is the 3rd
column, this is 1st column. This is 2nd column and this is the 5th column, in the 4th
column the ratios are shown. So, these ratios will give you the actual value of the draft in
different zones. The 5th column is the name of the draft that we have given, like; the
draft between cylinder and doffer is known as condensation draft. Because here there is
really no stretching of the material on the contrary, there is going to be condensation of
the material which is coming from the cylinder side and falling on the doffered.

So, here material from a large surface area of the cylinder is falling on a small surface
area of the doffer. And therefore, there is going to be a condensation process and we call
it condensation draft. And the draft between doffer and web stripping roller, web
stripping roller, calendar roller, calendar roller coiler, calendar roller these are known as
tension drafts. So, these drafts in terms of their magnitude is very very low, slightly more
than one they are very close to one and therefore, they are known as tension drafts. The
total draft is the multiplication of all these individual drafts. So, we have drafts V T by V
F multiplied by V C by V T V D by V C V S by V D V C R by V S V C C by V C R.

If we do this can you see that these quantities they cancel each other and we are left with
V C C by V F. So, the total draft, if we try to find out then we need not to find out the
individual drafts, we can find out the surface speed of the coiler calendar roller V C C
and we can find out the surface speed of the feed roller take the ratio of these two that
will give me total draft. That is how we can find out total draft, but if we are interested in
the individual drafts then we need to calculate the individual draft by taking the ratios as
shown in the table.

(Refer Slide Time: 29:25)

In this slide some values of drafts are shown, lap roller to feed roller, this is for an older
version of card where we are feeding the lap. So, there is a lap roller is there and there is
a feed roller, which is feeding the lap to the licker in and typical draft between lap and
feed roller is 1.06 between feed roller and licker in it goes 1000 very very high. Because
the surface speed of licker in is 1000 times more than the surface speed of the feed roller.

That for the lap that we are feeding or the mat of fiber that we feed that gets traced 1000
times, when it comes on the licker in surface. Then between licker in to cylinder the draft
is 2; that means, the cylinder surface speed is twice the surface speed of the licker in.
And because of this surface speed differences the tufts or the tuflets which are there on
the licker in surface, they get stripped easily by the tips of the cylinder.
So, here the draft is 2 cylinder to doffer the draft is 0.04, because this is the condensation
and the draft is less than 1. Doffer to calendar roller is around 1.10 calendar roller to
coiler calendar roller is 1.05. So, in this case 1.06 1.10 1.05 these are the tension draft
and the cylinder to doffer draft 0.04 we will call it condensation draft. Total draft if we
try to calculate we have to multiply this individual drafts and we get a value 97.94 it is
close to 98. So, for a typical machine, in the present case the draft could be close to 98.

(Refer Slide Time: 31:45)

Actual draft as we discussed little bit earlier is based on the linear densities of the
material fed and delivered. So, feed material is a lap or mat of fiber or delivered material
is a sliver. So, actual draft becomes the ratio of lap linear density divided by sliver linear
density both expressed in terms of kilo tex.

If we express in terms of indirect count that is Ne, in that case actual draft is sliver count
by lap count a sliver count in terms of Ne and lap count in terms of also Ne. So, actual
draft is weight per unit length of the lap divided by weight per unit length of the sliver.
This is what we have to remember the units may vary from text to Ne.
(Refer Slide Time: 32:40)

Relation between actual and mechanical draft; in a steady state operation amount fed per
unit time should be equal to amount deliver per unit time in a machines. Whatever we
feed the same as to move out here the assumption is that the machine is not extracting
any waste. So, for the time being let us assume that the machine is not extracting any
waste and therefore, whatever we feed per unit time that must move out from the
machine per unit time.

How much we feed per unit time? It is weight per unit length of the feed material
multiplied by a surface speed of the feed roller. And what we deliver per unit time? Is
weight per unit length of the delivered material into surface speed of the delivery roller?
Therefore, these two must be equal. From this relationship we can say that weight per
unit length fed divided by weight per unit length delivered should be equal to surface
speed of the delivery roller divided by surface speed of feed roller. Whereas, the left
hand side now becomes by definition actual draft and the right hand side becomes by
definitions mechanical draft hence actual draft should be equal to mechanical draft.
Ideally when the machine is not really generating any waste.
(Refer Slide Time: 34:25)

But, because the waste extraction these two drafts will never be same, an actual draft
equal to mechanical draft into100 by 100 minus waste percentage as shown here. If we
rewrite the equation in different manner we can write waste percentage is this and
therefore, it could be 100 into 1 minus mechanical draft by actual draft the little mistakes
in the spelling please take care of it.

(Refer Slide Time: 35:04)

Now, let us go to cleaning efficiency, here is a diagram that indicates the combination of
trash and lint in the input, in the output and the waste percentage also shown. This is
schematic diagram let x is the trash percentage in the input material, y is the percentage
of waste collected and z is the trash percentage in the output material. So, trash in the
output with respect to input is going to be what z z into 100 minus y by 100. And
therefore, the cleaning efficiency will be the percentage of trash removed with respect to
percentage of trash feed.

And hence the formula is going to be this x minus z into 100 minus y by 100 divided by
x into 100. This numerator defines the trash removed and x is the input. So, how much
you have removed with respect to input expressed in percentage is basically cleaning
efficiency. The waste percentage in the case of cotton varies between 4-6 percent hence;
trash percentage in output with respect to input will change by a factor of 0.96 or 0.94.
For all practical purposes it may be considered close to 1 and in that case cleaning
efficiency formula can be simplified it is x minus z divided by x into 100, that becomes a
simplified formula where we ignored the waste; that for cleaning efficiency become trash
in feed minus trash in delivery divided by trash percentage in feed into 100.

(Refer Slide Time: 37:27)

It was go to production calculation, production means how much material is delivered

per unit time? So, we need to know the delivery rate, for the delivery rate if how to
calculate delivery rate? The speed of the coiler calendar roller let us say is n c the last
rotating element of the machine which is delivering the sliver is the coiler calendar roller
it is diameter is let us say d cc the hank of the sliver in indirect system is any that is what
is mostly practiced in India. And let us say epsilon is the efficiency part.

Since there is very little draft between doffer and coiler calendar roller the production for
all practical purpose can be calculated from the doffer speed also, this we must
remember that in industrial practice people calculate the production on the basis of doffer
speed. Otherwise we can also calculate on the basis of coiler calendar roller or even
calendar roller as well it will not make much of a difference. Since, that draft between
them is very little there are all tension drafts. Therefore, production in kg per hour
becomes doffer surface speed which is pi into doffer speed into doffer diameter in inch
divided by this factor 36 into 840 multiplied by h, where h is the sliver hank. And if we
want to include efficiency part, then this is the value which will come, if we multiply
them we will be able to find out the production per kg.

(Refer Slide Time: 39:26)

The other concept which comes to our mind is production constant. Now, the formula of
production calculation is giving at the top from this formula, now we have to find out
what is production constant? In the calculation of production for a machine producing a
sliver of given linear density and ignoring efficiency part we will see all the parameters
in the above equation remains constant.

So, here if we see that the parameter pi is constant, doffer diameter is always constant 36
840 h for a given sliver is also constant. And if we for the time being we do not take care
of the efficiency part, then we find out the production constant is basically pi into doffer
diameter divide by 36 into 840 into h. This value becomes a constant factor and this is
known as production constant.

So, production therefore, becomes production constant into doffer speed for ease of
calculations, in industrial practice, the production constant is determined in advance. And
we can quickly calculate the production by multiplying the doffer speed with the
production constant. But obviously, the constant may change if the value of sliver hank
that is h changes that we have to remember.

(Refer Slide Time: 41:24)

The next is selection of production rate, the practical production level of any card
depends upon the characteristics of the raw material. The linear density of the sliver, that
we are going to produce and the count and the quality of the yarn that we are going to
produce. What sort of quality is required in the yarn? Accordingly we have to choose the
production rate.
(Refer Slide Time: 41:58)

Typical production rates are shown in this table, what we see typically that broadly we
can say when the fibers are shorter in length and they are coarse in nature it has this
value and this the productions values could be high. So, short and coarse fiber can be
processed at a faster rate.

Whereas fine and long fibers you go to the lower values of the table fibers are fine, the
stable length is also more, the production rate has to be brought down. That means, short
and coarse fiber is processed at a faster rate, long and fine fiber are to be processed at a
slower rate why? Because long fine cotton needs to be processed as a slower rate than
coarser and shorter cotton as they are more prone to nep formations and rupture at high
production levels.

This is what we have to avoid and therefore, we have to go for slower production rate
when you try to process fine fibers, fine fibers spending rigidity is very very low being
very fine. And therefore, we have to ensure that they do not land up forming neps
therefore, we have to reduce the level of productions. Generally long and fine fiber we
used to produce fine hank count and the sliver hank is also greater or more for finer
variety of cotton. If we look at this we can see that they are generally more. This is not
kilo tex, this would be hank value of the sliver.
(Refer Slide Time: 44:22)

Production level for manmade fibers, production levels for manmade fiber is lower than
cotton except for viscose or maybe for polynosic fibers. What are the reasons? The
reasons are basically same as was discussed earlier, we have to see how these synthetic
fibers are different from cotton. Synthetic fiber are prone to static formations inter fiber
cohesion is not strong enough to cause the wave to peel off easily on the doffer surface.
The wave breaks easily due to air current generated I hide doffer speeds for the same
length and fineness viscose rayon and polynosic can be processed at a faster rate than
other fiber because, they are not static prone.

So, the main reason why we have to reduce speed is to avoid the generation of static, to
avoid the development of heat. And therefore, production level has to be brought down
and that is what is all about the settings, the cleaning efficiency, the production and draft
calculations of the carding machines.

Thanks.