PROCESS PARAMETERS IN CARDING - 2
DOFFER, LICKER-IN AND FLAT TOPS:
- The basic funtion of doffer is to strip the fibres from
Cylinder. Please remember that the
action between cylinder and doffer is carding action(or combing action or point to point action).
- The doffer wire's front angle plays a very important
role in releasing the fibre from the cylinder.
For most carding applications the optimum angle is 60 degrees.
- Increased population over 400 ppsi does not give any
advantage in the production of quality yarn. For smaller
doffers, 5 mm doffer wire height helps in tranferring the
fibres from cylinder to doffer.
- If the fibre holding capacity of the doffer wire is less
due to fibre friction or due to very
high doffer speed, it is better to use a doffer wire with striations. For high production carding it
is always better to use doffer wire with striations.
- Licker-in plays a major role in opening the fibre tufts.
In general 85 degrees is used both
for synthetic and medium and long cottons. For coarse and dirty cottons 80 degrees can be used.
- Strength, hardness and sharpness are very important for
Lickerin wire. Licker-in wires should neverbe ground.
Thinner blades penetrate the fibres more efficiently and
increase the wire life.
- Higher number of rows per inch gives better results. Now
upto 12 rows per inch is being used. This is always better
compared to 8 rows per inch.
- If the wire pitch is not sufficient, it can be
compensated by increasing the licker-in speed.
Higher licker-in speeds for fine and long cottons will rupture the fibres. Licker-in speed depends upon the fibre type and the production rate.
- It is better to use a flat top with more than one
population. The general combination is 280/450.
This is suitable for both cotton and synthetics. Please remember that the rigidity of the fillets is
different for cotton and synthetic. If cotton flat tops are used for synthetic processing, the load
on the cylinder will be more, more heat will be produced and hence the probability of cylinder loading due to electrostatic charge will be high.
- Instead of using Rigid type flat tops, it is better to
use semi-rigid type flat tops while processing
- The setting between cylinder and doffer is the closest
setting in the card. This setting mainly
depends upon the cylinder speed ,hank of the delivered sliver and the type of wire. Cylinder
speed upto 360, the setting should be 0.1mm. For cylinder speeds more than 450 , the setting
ranges from 0.125 to 0.15.
- If the setting between cylinder and doffer is very
close, the wires will get polished and this
will affect the fibre transfer. If the setting is too wide, the fibres will not be transferred
to doffer from the cylinder, hence cylinder will get loaded. While processing synthetic fibres
cylinder loading will badly affect the yarn quality. Moreover, it is difficult to improve the
wire condition if the loading is severe. The only solution would be to change the wire. Therefore enough care should be taken while processing synthetic fibres.
- The most critical setting in a carding machine is
between cylinder and flat tops. While processing cotton, it
can be as close as 0.175 mm provided the mechanical accuracy
of flat tops is good. Since most of the cards are with
stationary flats at the licker-in side, the setting from the
back to front for flats can be 0.25,0.2.0.2,0.2,0.2mm.
- Closer the setting between cylinder and flats, better
the yarn quality. Neps are directly
affected by this setting. Of course, very close setting increase the flat waste. For processing cotton the setting can be 0.25,0.2,0.2,0.2,0.2mm. For synthetic fibres it can be 0.3,0.25,0.25,0.25,0.25mm
- Most of the cards are with 6 to 11 stationary flats at
the licker-in side. This setting can start
with 0.4 mm and end with 0.25mm.
- The wire points can start with 140 ppsi and end with 320
ppsi. The work done by the first
few stationary flats is very high, therefore the wear of these flats is also high. It would be better
if the first 50% of the flats are changed after 100000 kgs of production and the rest after 150000 kgs of production.
- These stationary flats open the material so that, the
setting between cylinder and flats can be as
close as possible.
- The setting between feed plate and Licker-in depends
upon the type of feed plate. Conventional
feed plate setting is decided mainly by the feed weight and to some extent by the fibre length and type. With the latest feed plate and feed roller arrangements, the setting is decided mainly by the fibre length and to some extent by the feed weight.
- Normally the setting between the feed plate and Lickr-in
is around 0.45 to 0.7mm, depending upon the feed weight and
- The setting between Licker-in and the first mote knife
is around 0.35 to 0.5 mm. This helps to remove the heavier
trash particles and dust. Closer the setting , higher the
waste%ge. The setting between Licker-in and combing segments
is around 0.45 to 0.6. This helps to open
- Some cards have two mote knifes in the Licker-in
undercasing. The setting is around 0.4 to 0.5mm. This helps
to remove the smaller trash and dust particles.
- The setting between the cylinder and stationary flats at
Doffer side, helps to transfer the
fibres to doffer by stripping the fibres to the top of the cylinder wire. This setting can be as
close as 0.15mm. The number of wire points on stationary flats also play a major role . It is
normally around 300 to 400. For a high production application it can be as high as 600.
- For cotton processing, the stationary flats are fixed
with a knife attachement. The setting should
be as close as possible,i.e.around 0.15mm. This helps to remove the trash particles of very
- The setting between cylinder and cylinder undercasing
should be as per the manufacturer's recommendation. The
design of undercasing is different for different
manufacturers. This setting is very important , as wrong
settings will affect the fibre transfer and can also create
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