An ideal line for processing short-staple cotton

An ideal line for processing cotton or Erection for the new blow room line basic setting is

1- Bale opening and  mixing

Blendomate/unifloc/autoplucker

2- Coarse opening and cleaning

Uniclean/ maxi flow/CLP

3- Fibre mixing

MXI/MPM/unimix (8-chamber multimixer)

4- Fine opening/Cleaning

Uniflex/CLC3/CLU

5- Contamination sorting

Jossi magic eye 2/Sp-FPU/TS-T5/loptex opto-sonic

6- Dedusting

Condensor/dust-ex

7- Carding

Reiter C-70,C-60/trutzschler TC15, TC11

• These are essential for an  ideal cotton fibre opening and cleaning
• Metal fire detection is vital to prevent hazards and machinery damage.

Essential for fibre opening  cleaning and mixing

1. Bale opening and homogenous mixing
2. Coarse opening
3. Fibre mixing
4. Fibre opening
5. Contamination sorters
6. Dedusting
7. Carding

These steps are essential for the proper opening of any type of cotton Pima Giza, Turkmen, Tajik, Sadani, Chad, Mali, Ivory Coast, Australian, USA, Brazillian, Shanker, MCU5, DCH32 Spanish and Pakistani. all these steps must be followed. Beaters types speed etc may vary but sequencing should be always there.

Unifloc A-11

1. Production Level =15
2. 2.7-1.5-2.7-1.5mm
3. Beater rpm =1600O(468 pins on the beater)
4. Traversing speed 8.0 m/min
5. Penetration depth 1.5mm/reverse
6. lifting speed 25.3 mm/sec
7. Air Vaccum-400~-480 Pa
8. Material fan speed =1420×190/140= 1925rpm
9. Pressure before fan -1100 Pa
10. Pressure for dust extraction -600 Pa
11. maximum bale width = 2.0m and height = 1.6 m

Uniclean B-11

1. Cleaning intensity 0.8
2. Relative waste amount 5
3. Beater speed 835 rpm
4. Grid angle 9.8
5. Cylinder position 66mm
6. Inlet pressure 200 Pa
7. Outlet pressure 130 Pa
8. Dust vacuum -800Pa
9. Waste Vacuum -2300 Pa

Unimix B-70

1. Pressure set to stop A-11 300Pa
2. Setting to start feeding 200 Pa
3. Outlet pressure for B-60 100 Pa
4. Cleaning roller to feed 3 (0~6) roller setting
5. Gridbar setting 3 (0~5)
6. Stripping plate 25
7. Evener roller setting 15mm
8. Stripping roller setting 5mm
9. Spiked lattice geared motor 5.0
10. Feed roller geared motor 4.2
11. Approximate speeds
12. Spike lattice= motor(57~280) X 104/184 = 24.87~122.17 (95 rpm)
13. Stripper roll =1380 x 94/144 =900 rpm
14. Opening roll 1420 x 94/144 =800 rpm
15. Take off roll =1380 x 79/194 =560 rpm
16. Pressure in storage suction 0~50 Pa

Uniflex B-60

1. Production step 15
2. Feed roll rpm 6
3. Cleaning intensity 0.2
4. Beater speed 552 RPM
5. Relative waste amount 5
6. Grid angle 45mm
7. Commercial staple 30.1mm
8. Outlet pressure -200 Pa
9. Dust vacuum -200 Pa
10. Waste vacuum -1800Pa

Blow room fibre growth report

Fibro graph report

Description	UHML	SFI	UNF
Bales	31.58	8.35	82.26
Plucker	31.81	8.56	81.93
Auto plucker	32.11	8.43	81.90
Maxi-flow	32.55	8.86	81.00
MPM	31.34	9.3	80.80
CVT1	31.28	10.20	80.6
CXL3	31.13	8.8	80.5
Chute	31.83	9.5	80.5

Blow room fibre growth AFIS Pima cotton

Description	UQL”	SFC%	IFC%	Mat ratio	Neps ct/gm
Mixing	1.45	14.6	3.2	1.00	92
B0	1.39	14.4	3.3	1.00	96
B11	1.39	16.1	3.6	0.98	124
MPM	1.39	15.9	3.6	0.99	130
B-60 I	1.38	17.5	4.3	0.97	204
B-60 II	1.40	20.0	5.0	0.95	208
SME-1	1.39	18.8	4.1	0.96	213
SME-2	1.41	18.9	4.5	0.96	237
SME-3	1.40	20.1	5.0	0.95	214
SME-4	1.41	20.6	4.9	0.94	223

 

Blow room Checkpoint

• Consumption of bales
• Blend consistency
• Mixing conditions
• Tuft-size feed to the breaker
• Cutting of stock by tenter
• Condition of feed lattice and spike lattice etc.
• The setting of the evener roller and spike lattice
• Magnets cleaning
• Condition of grid bars
• Condition of beaters at overhauling
• Lap conditions
• Inspection of trash chambers to check the richness of lint in waste.
• Working on piano motion
• Condition of condensers at overhauling
• Material level in reserve tank and feeding trunk and signal of start and stop feeding.
• Feed at card
• Balance of air currents (one week)
• Lap shape, splitting licking, selvedge etc.
• Cutting and doffing of the lap, the width of the lap
• Lap weight and meters calibration.
• Lap rejection percentage
• Stoppages and reasons
• Contamination picking monitoring at different stages in the blow room
• The lap width should be 5 cm less than the card width to prevent side blowing of fibres
• Lap handling and colour of lap rod at each scutcher
• General overhauling of the machine.

Card C-51

1. Feed through setting 16mm
2. Chute pressure setting 400~500 Pa
3. Plate setting fully opened
4. Delivery speed 118m/min
5. Production 30 kg/hr
6. Grain/yd 60
7. Sliver weight 18 kg(4230m)
8. Cylinder speed 400 rpm
9. Flats speed is 0.19 m/min
10. Total draft 124
11. Sliver weight of batt 525 gram/m

Carding fibre growth (AFIS ) Pima cotton

Card #	Nep ct/ gm	Nep removal %
13	42	81.05
14	56	74.74
15	42	81.05
16	48	78.35
17	41	81.51
18	39	82.41
19	43	80.60
20	55	75.19
21	42	81.05

 

Gearing diagram howa CMK-3

Specification of carding (  carding gauges)

Description	Gauges	Rough speed
Feed roll	57 mm	5 rpm
Taker-in	249.5mm	900 rpm
CRC	99.6mm	120 rpm
Cylinder	1289mm	360 rpm
Doffer	706mm	30 rpm
Doffing roll	66mm	150 rpm
Take off roll	42mm	220 rpm
Flats	1  5/16”	5 inches/min
Flate brush	–	50 rpm
Calender roll	102 mm	250 rpm
C. calender roll	75 mm	360 rpm
Top crush roll	75 mm	300 rpm
Bottom crush roll	150 mm	165 rpm
Trumpet	11 mm	–
Coiler trumpet	7 mm	–

Calculation from gearing

Cylinder  speed

= 960 x 171.5/457 =360 rpm

=360 x 1289 x π /1000

= 1457.8 m/min

Taker-in  speed

= 360 x 457/178 = 924 rpm

= 924 x π x 249.5/1000

=724 m/min

Flats  speed

= 360 x 102/305 x 1/24 x 2/14 x 14x 36.5/24.5

=5.05 inches/ minutes

Tension draft between lap and feed

D₁ = πx57x5.0/(πx150x1.75)

=1.08

Major draft between feed and offer

D₂ = π x 706 x 30/(π x 57 x 5)

=74.31

Web tension between  doffer and C.C.R

D₃ = π x 102 x 250/(π x 706 x30)

= 1.204

The tension between C.R and C.C.R

D₄ = π x 75 x 260/(π x 102 x250)

=1.059

 Total draft  of the machine

D= 1.086 x 74.32 x 1.204 x 1.059

=102.86

Transfer ratio (stripping power)

=Surface speed of cylinder/surface speed of taker-in

= π x 1289 x360 /(π x 249.5 x 900)

= 2.07

Hence, 1:2.07

Carding power

=Surface speed of cylinder in inches/min/linear speed of flat inches/min

=1457.8 x 39.37/5.05

=113654

Condensation power

=surface speed of cylinder/surface speed of doffer

=π x 1289 x 360/π x 705 x30=21.09

Coiling ratio

= RPM of cooler tube/RPM of can

i.e. =1 x 172 x 24 x 18/(2 x 19 x 65) =30

Hence 1:30

False twist

= RPM of coiler tube/ surface speed of C.C. Roll

i.e. = 1 x (250 x 32/34 x 18/65)/(π x 75/1000 x 360)

=0.77

Actual twist

= RPM of can/ surface speed of C.C.R

= (250 x 32/34 x 19/24 x 2/172)/(π x 75/1000 x 360)

=0.026

Carding checkpoint

• Check feeding conditions(patchiness, distribution layers, ragged selvedge etc centrally feeding lap is necessary.
• The lap width is 50mm lower than the card width
• Feed roller grip gauge 0.005” between the feed roller and feed plate through out width of the card.
• Condition of the scavenger rod, the conical build is an indication of an uneven setting between the licker-in and feed roller.
• Condition of licker-in dropping for the richness of lint.
• Condition of wires at the overhauling  stage
• Flats cleaning by brush
• The density of flat strip
• Condition of the web. A good web should not have ragged selvedge, holes thick and thin patches or lumps of fibres called snowballs. A cloudy web  is a sign of poor carding
• Condition and size of the trumpet
• Inside coiler and can
• Can filling

Stop-motion of the card

1. Feed roller (too thick and too thin lap)
2. C.C.R (Lapping)
3. Doffer ( Lapping)
4. Calander roll( low tension in web, lapping)
5. Empty lap and empty can
6. Sliver breakage C.R and coiler C.R