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Mixing:: Basic Tasks of Blow Room

Mixing cotton varieties and grades improves processing and product characteristics. It allows for financial benefits by mixing cheaper cotton with upgraded cotton. Mixing improves carding performance by controlling nep levels and variation. It increases ring frame efficiency by reducing yarn count variation. Mixing also improves efficiency in weaving by producing finer yarn and more uniform fabric. Mixing fulfills end use requirements by combining fibers with different properties. It also improves cotton physical properties like strength, elasticity, and resistance to abrasion and shrinkage.

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235 views9 pages

Mixing:: Basic Tasks of Blow Room

Mixing cotton varieties and grades improves processing and product characteristics. It allows for financial benefits by mixing cheaper cotton with upgraded cotton. Mixing improves carding performance by controlling nep levels and variation. It increases ring frame efficiency by reducing yarn count variation. Mixing also improves efficiency in weaving by producing finer yarn and more uniform fabric. Mixing fulfills end use requirements by combining fibers with different properties. It also improves cotton physical properties like strength, elasticity, and resistance to abrasion and shrinkage.

Uploaded by

mohit
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Mixing:

Mixing is the term used for the arrangement of various cotton varieties or b/w various grades of same variety to
get a product having all the characteristics of different varieties of cotton. The objectives of mixing are given
below:
 Financial reasons that’s why cheaper cotton and cotton waste is mixed with the upgraded cotton to get better
results.
 For better processing performance of cotton fibers in carding and roving formation through control of nep
level and variation.
 It also effects on the working efficiency of ring frame because better mixing results in the form of less
variation in yarn count.
 Like in spinning it also effect the efficiency of machines used for weaving functions and operations because
fine yarn results in the form of uniform fabric. It also has a contribution in dyeing and finishing processes.
 By using different combinations of fibers having different fiber properties fulfill the requirements of given
end use for the spun yarn or the woven fabric.
 To improve physical properties of cotton i.e. tensile and tear strength, elasticity, abrasion and shrinkage
resistance.1

4. Blow room
The name blow room indicates that
“Transfer of fibers from one machine to another machine by pneumatic means is used for supplying reduced air
pressure near to the destination of fibers”
Blow room is the first department in the spinning process. Raw cotton contains a number of different impurities
which we called as “Trash”. These types of impurities are present in cotton i.e. sand, soil, dust, whole seed,
broken seed coats, undeveloped seeds and broken fragments. The extraction of dust and trash is reliant on the
quantity of fiber individualization, which can be obtained from the processing of fibers. Most of the impurities
are removed in this department while other ones are removed in next department. The production capacity of
B.R department is 340 bags/ day. (Spin plan ATM, 2007).
Basic tasks of Blow room
 Opening
 Cleaning (40 – 70 %)
 Mixing or blending
 Micro dust removal (64%)
 Uniform feed to the carding machine
 Recycling the waste

For carrying out the above operations, different machines are installed in blow room deptt.

Carding
5.1 Introduction
The blow room process opens the compressed bales of cotton into small tufts and also removes 75% trash
present in the cotton. Still the cotton has to be opened to individual fibre state and it must be free of impurities
and trash etc. up to the maximum possible extent so, the fibre-to-fibre opening and complete removal of trash is
carried out on the card machine. It is therefore rightly said that “Half Carded, Half Spun” and “Well Carded
Well Spun” because it is the process of carding which plays a very important role in the spinning process and is
called as the Heart of Spinning..3
Following are the main tasks of the card machine: (WG. Byerley, W. Miller, GH Jolly, G.Battersby,
F.Charnley, 1965)
 Opening of fibers to individual state.
 Elimination of impurities present in cotton that were not extracted in the previous cleaning departments.
 Disentangling of the neps
 Removal of the short fibers
 Fibre blending
 Fibre orientation
 Sliver formation

The production of card deptt is 263 bags/day. (Spin Plan ATM, 2007).
6.4 Rieter Unfloc A11

The general arrangement of Rieter Unifloc is shown in the figure below :

The technical data of the machine is as follows :

1. Working width 1700 mm or 2300 mm


2. Suitable for cotton as well as manmade fibres (staple length upto 65 mm) (21/2”).
3. Bale lay down up to 90 bales on each side.
4. Bales can be arranged lengthwise or crosswise.
5. Can process upto from bale groups with different specifications.
6. Production performance for all (2300).
Cotton Manmade Fibres
1. Assortments 1400 kg/h 1000 kg/h
2. Assortments 1000 kg/h 700 kg/h
3. Assortments 750 kg/h 550 kg/h
4. Assortments 600 kg/h 450 kg/h

7. Microprocessor is used to select bale take off sequence.


8. Possible to process two mixings simultaneously.
9. Material lay down length – 7.2 m ---- 47.2 m.
10. Traverse tower can be swiveled manually or automatically.
11. With automatic swiveling alternating take off from both sides is possible.
12. Patented opening roller to take off material in both directions of traverse (double sided, saw
tooth roller).
13. Toothed discs on opening rollers can be replaced in dividedly.
14. Special (diagonal) mounting of discs causes a tumbling action and prevents formation of
grooves on bale surface.
15. Two rotating retaining rollers ensure, along with opening, roller, removal of small tufts.
16. These rollers also assist the complete bale take off down to the floor.
17. Production is adjusted by : a) penetration of toothed disc from grid
b) downward advance of opening roller
prior to each advance.
18. Traverse speed is adjustable – (3 different speeds)
19. Heavy particle separator is installed in the machine. This stops the machine if any foreign
matter is detected on any of the bales.
20. Noise level is extremely low.

A) The following diagram gives the description of the machine.


ZONE-II MACHINES – MILD OPENERS
These machines come next to bale openers in the blow room line. The main design features of the mild
openers are as given below :

1. These machines have free flight feed.


2. The openers are hollow cylinders and the striker elements on these openers are coarse and
widely spaced.
3. The rotational speeds are comparatively less.
4. The action of these machines is mild the opening effect is comparatively small.
5. Generally these machines have large grid area.
6. The cotton passes around the opener a number of times.
7. The machines are found to give very high cleaning. This is mainly because the cotton has a good
amount of trash like sand stones, larger vegetable matter which is loosely held in cotton and only
on small opening and loosening of tufts this type of trash can fall down through the grid.

These machines are optimal in their given position and not in further positions.
The examples of conventional mild openers are :
a) Step cleaner
b) Mono cylinder cleaner (Rieter)
c) Axiflow or duel roller cleaner (Trutzschler, Marzoli)

It became necessary therefore to design a modern mild opener with higher production capacities. The
examples of modern bale openers are :
a) Uniclean (Rieter)
b) Maxiflow (Trutzschler)
c) Vario Clean (LMW)
These modern mild openers have a production capacity of up to 1500 kg/hr.

(A) Uniclean:
Uniclean is a unique mild opener developed by Rieter. The main features of this opener are as given
below:

 Specially designed pins give very efficient opening.


 Material is passed over the grids 5 times.
 The combination of newly developed grid bars optimized material flow and increased dedusting
area guarantees an efficient cleaning effect.
 Very high rates of production – upto 1400 kg/hr.
 Automatic waste removal system (A must).
 Space requirements are small.
 Rieter concept – V/s Trutzschler concept.
 Setting of grid bars can be changed while machine is running.
 Unique multi assortment operation.
 Flexible – all types of cottons.
 Optimum raw material utilization.
 Low maintenance.
(B) Maxi-Flo (Trutzschler)

The maxi-flo is a new high production mild opener from Trutzschler. In design and construction this
opener resembles the previous Axiflo cleaner. However there are a few main differences.

1. The inlet and outlet for cotton are from top of the machine rather than from the sides as in case of
Axiflow. Due to this the cotton remains in the beater chamber for longer time and makes more
revolutions around the openers (5 ½ times) as compared to Axiflow (2½ times). This helps in
increased production.
2. The speeds of the openers are somewhat higher upto 800 rpm.
3. The waste evacuation system is automatic.

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