The document discusses the carding process in textile manufacturing, highlighting its role in cleaning and preparing fibers for further processing. It details advancements in carding machines, including improved feed systems, increased production rates, and integrated grinding systems, which enhance efficiency and fiber quality. It also addresses the importance of dust extraction systems for maintaining safe working conditions.

1. DR B R AMBEDKAR NATIONAL INSTITUTE OF
TECHNOLOGY, JALANDHAR
DEVELOPMENTS IN CARDING
BY
DHANANJAY BAGHEL

2. INTRODUCTION
 Carding is the immediate process after blow
room.
 Carding is a mechanical process that
disentangles, cleans and intermixes fibres to
produce a continuous web or sliver suitable
for subsequent processing.
 This is achieved due to the clothed rollers
moving with differential speeds.

3. OBJECTS OF CARDING MACHINE
 To individualize the fibres.
 To remove impurities.
 To clean cotton thoroughly off the lighter dirt &
trash as well as to remove a certain proportion of
neps & short fibers from the opened material.
 To convert Blow Room lap/ Chute feed sheet
into the loose, roughly parallel, untwisted strand
fibres called sliver.

4. CARDING MACHINE
 Lap feed system:

5. PARTS OF CARDING MACHINE
 FEED ROLLER AND LICKER-IN
 CYLINDER AND FLATS
 DOFFER
 TRUMPET
 COILER ARRANGEMENT

6. ADVANCEMENTS IN CARDING MACHINE
 CHUTE FEED SYSTEM
 UNIDIRECTIONAL FEED
 MULTIPLE LICKER-IN
 INCREASE IN THE CARDING WIDTH
 INTEGRATED GRINDING SYSTEM
 USE OF AUTOLEVELLERS
 DUST EXTRACTION SYSTEM

7. CHUTE FEED SYSTEM
THE FIBRE TUFTS ARE DIRECTLY FED TO THE CARD
FROM BLOWROOM.
RIETER C70

8. UNIDIRECTIONAL FEED
 It results in gentle fibre treatment because fibre feed and
licker-in rotation is in the same direction.
 The latest version of Rieter card C60 and Trützschler TC 07
feature with unidirectional feed system.

9.  The manufactures have
installed multiple licker-in
in the card.
 Generally, machines come
with 3 licker-in
arrangement.
 The purpose is better and
fine cleaning of the fibre.
MULTIPLE LICKER-IN

10. INCREASE IN THE CARDING WIDTH
 The modern machines achieve production rates of 60 - 220
kg/h, compared with output of 5 - 15 kg/h in 1970.
 Rieter C 60 Card has 50% more working width (from 1 m to
1.5 m).
 Trützschler TC 07 has the longest carding section of about
2.82 m .
 Increase in production is equivalent to increased fibre mass
on cylinder that may reduce the sliver quality and ultimately
the yarn quality.
 But since the carding surface is also increased, the
production is enhanced without hampering the sliver quality.

11. INTEGRATED GRINDING SYSTEM
 Card wire grinding is not only a troublesome job but also
time consuming.
 Therefore, grinding stones are now being installed near the
wire points of cylinder and flats.
 Rieter IGS-system has integrated grinding:
 IGS-Classic for cylinder wire points and performs
400 grinding cycles per clothing lifecycle.
 IGS-Top for flats wire points and performs 100
grinding cycles per clothing lifecycle.

12. FULL WIDTH GRINDING
ROLLER
TRAVERSING GRINDING DISC

13. USE OF AUTOLEVELLERS
 To control card sliver count variations, count CV% and
unevenness, modern cards are equipped with autoleveller.
 Medium-term leveller measures the feed mat thickness at
the feed trough and, as required, the feed roller speed is
adjusted through the control system.
 Long-term leveller measures the sliver thickness by the
step roller pair and adjusts the chute system accordingly.

14. MEDIUM-TERM LEVELLER LONG-TERM LEVELLER

15. DUST EXTRACTION SYSTEM
 There is a lot of dust removal at various stages of
carding machine.
 These areas can be:
 Licker-in
 cylinder and flats
 cylinder and doffer
 This leads to the deterioration of the working conditions
and can cause health hazards.
 Thus to prevent this, suction units are installed near
these regions that collects the dust and pass it to a
specific place.