Define carding

It is always considered by the experts that the card is the heart of the
spinning mill.
The statement “Well-carded is half-spun” demonstrate the immense
significance of the carding for the final result of the spinning operation.
Definition: Carding is a mechanical process that disentangles, cleans and
intermixes fibers to produce a continuous web or sliver suitable for
subsequent processing.
This is achieved by passing the fibers between differentially moving
surfaces covered with "card clothing", a firm flexible material embedded
with metal pins. It breaks up locks and unorganized clumps of fiber and
then aligns the individual fibers to be parallel with each other.
Objectives of Carding
• Opening to individual fibres
• Cleaning
• Elimination of dust
• Mixing & Blending
• Disentanglement of Neps
• Elimination of short fiber
• Sliver Formation
• Fiber Orientation
What carding should and should not do
• Should do • Should not do
• Individualise the fibre • Break the fibres in large amount
• Clean the fibres • Increase neps
• Remove the neps present in lap • Drop spinnable fibres under the
• To form a continuous fibrous licker-in, the cylinder and doffer
strand of the required linear
density
Passage of the material through carding
machine
• Fibres in the form of a blowroom lap pass over a feed plate and are
carried downward to the licker in, which opens up the lap a great as
the surface speed of the licker in is much higher than the feed roller
• the compact tufts of lap are reduced to micro tuflets and individual
fibres, during opening trash particles and neps are released with thye
help of combination of grid bars and perforated plate, the mote knifes
positions close to licker in surface assist with retaining usable fibres
while ejecting the impurities
• The microtuflets and indivisual fibers from taker in clothing are
transferred to cylinder clothing by stripping action
• The fibre mass on the cylinder clothing is transported to the zone of
revolving flats by means of carding action where almost 97 percent of
fibre mass is opened to individual fibre form
• The stationery flats above the licker in transfer is to ensure that any
fibre tufts transferred to the cylinder are quickly opened so that after
arriving under the flats the fibre mass can be easily separated to
individual fibres
• The individual fibres attached to cylinder clothing collectively appear
as a very light web on the cylinder surface. This web moves with
cylinder and comes in contact with fixed flats which ectracts neps,fine
trash particles and comb the fibres.it then come in contact with doffer
clothing which strip this web from cylinder surface
• Surface speed of cylinder is much higher than the doffer there will be
built up of fibres on doffer, forming thick web of fibres which is
removed by a wire covered stripping roller and is passed through a
pair of pressure rollers before being condensed into a sliver and
wound into the sliver can .
Different working regions in card
• Pre opening zone (feed roller and licker in)
A well designed feed device is expected to perform the following tasks:
• Clamp the batt securely over its full width;
• Be able to hold the material back against the action of the licker-in;
• Present the batt to the licker-in in such a manner that opening can be
carried out gently.
Feed Zone
The licker-in
• The licker-in: - The greatest part of opening and cleaning is performed
by the licker-in.
• Cast roller with a diameter usually of around 250 mm. - Rotation
speeds are in the range of 800 - 2000 rpm for cotton and about 600
rpm for synthetics
• The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second), a
circumferential speed of around 21 m/sec (approximately 76 km/h)
and a draft of more than 1600.
The carding zone
Main cylinder
• The cylinder is usually manufactured from cast iron, but is now
sometimes made of steel. - Most cylinders have a diameter of 1280 -
1300 mm (Rieter C 60 card 814 mm, speed up to 900 rpm) and rotate
at speeds between 250 and 500 (to 600) rpm. –
• The roundness tolerance must be maintained within extremely tight
limits – the narrowest setting distance (between the cylinder and the
doffer) is only about 0.1 mm.
• The cylinder is generally supported in roller bearings
Flats
• - Altogether 100 - 120 flats - The bars of the flats are made of cast iron
(nowadays aluminum profiles - Longer than the operating width of
the card –
• Each bar is approximately 32 - 35 mm wide
The doffing zone
The doffer
• The main purpose of the doffer is to take the individual fibres coming
from the cylinder and to condense them to a web form.
• The doffer is mostly formed as a cast iron (or steel) drum with a
diameter of about 600 - 707 mm. (680 mm on Rieter machines)
• It is fitted with metallic clothing and runs at speeds up to about 300
m/min.
Condenser
• The special funnel shape of the trumpet guide forces the web
stripped off the detaching roller to be condensed into a sliver form
Coiler and the sliver can
• The sliver must be coiled in cans for storage and transport. - Can
diameters now lie in the 600 to 1200 mm range and can heights are
between 1000 and 1220 mm.
Types of Spinning Process:
The spinning process is varying depending on the fiber types which we want to
process. There are different methods of spinning for yarn preparation. Such as-
For Staple Yarn:
Different spinning techniques apply for Staple yarn production. When short
and long staple fiber or other material uses for the spinning process. The
following are the different methods of spinning process for staple yarn
production. They are-
1.Ring Spinning
2.Rotor Spinning
3.Friction Spinning
4.Self Twist Spinning
5.Electro-Static Spinning
6.Vortex Spinning
7.Air Jet Spinning
8.Twist Less Spinning
•Ring Spinning: The most popular way of spinning yarn for textiles is called ring spinning,
which drafts and twists strands using a revolving spindle and ring. Ring spinning method is
widely used for producing yarn which is used in different fields such as apparel, bedding,
upholstery, and industrial textiles.
•Rotor Spinning: A high-speed rotor is used in rotor spinning, often referred to as open-end
spinning, to separate and twist fibers into yarn. Rotor yarn is primarily used for producing
denim and terry cloth products.
•Friction Spinning: When friction spinning employs compressed air to spin fibers into yarn, it
offers great production rates and diversity. These spinning techniques produce yarn which is
used in filtration media and technical textiles.
•Self-Twist Spinning: In self-twist spinning, yarn is made straight from roving or sliver
without the need for further twisting steps. The productivity of spinning is increased with this
technique. This yarn is commonly found in producing knitwear and hosiery.
•Electro-Static Spinning: A polymer melt or solution is spun into ultrafine fibers using the
electrostatic spinning process, which utilizes an electric field. It produces various nanofibers
for various applications.
•Vortex Spinning: By twisting and collecting fibers in a vortex, the vortex spinning technique
produces yarn. This yarn is used for knitwear and lightweight fabric production.
•Air Jet Spinning: The production of yarn today uses an air jet spinning process. Compressed
air is used in the draft, twist, and spinning steps of this spinning process to create yarn. High
productivity is provided, nonetheless. Yarn from this spinning process is used for denim and
technical textiles.
For Spinning Filament Yarn:

1.Wet Spinning
2.Dry Spinning
3.Melt Spinning
4. Bi-Component Spinning
•Wet Spinning: Wet spinning involves extruding a polymer solution into a coagulation bath to create
fibers. Wet spinning is widely used for the production of fibers such as rayon, acrylic, and spandex.
•Dry Spinning: Fibers are created by extruding a polymer solution into a heated air or gas
environment in the dry spinning process. It is a common purpose for dry spinning to create fibers that
are insoluble in water or other coagulation solutions. The capacity to produce fibers with great
dimensional stability and high tensile strength is provided. Acetate, acrylic, and aramid fibers are
typical examples of fibers made by dry spinning.
•Melt Spinning: This procedure creates fibers by extruding molten polymer via a spinneret. It is a
very successful and economical way to make synthetic fibers like polyester, nylon, and
polypropylene.
•Bi-Component Spinning: In this type of spinning, two or more polymers are combined during the
extrusion process to produce fibers with various characteristics. It has different applications in
various industries such as textiles, filtration, and medical textiles.