Department of Fashion Design and Technology

Uttara University
 Course Title: Textile Technology -I

course Code : IE1015

Assignment on : Carding and Draw Frame Process

Submitted By : Submitted To :
Rafeuzzaman Mr.Sudipta Bain

ID : 2201401055 Assistant Professor and

Coordinator

Semester : 4th Department of FDT

Batch : 23rd Uttara University
 Index

Serial Number Description

1. Introduction

2. Details procedure of carding

3. Machine used in carding

4. Modern Machine used in carding

5. Controlling point of carding

6. Details procedure of Drawing

7. Machine used in Drawing

8. Modern machine in Drawing

9. Controlling point of Drawing

10. Conclusion
Introduction

Spinning is the process of taking textile fibers and filaments and making them into yarn. For
thousands of years, people spun natural fibers into yarn by hand. Today, spinning involves
many methods and different machines, depending on what kind of yarn is being made. There
are various process in spinning among them carding and drawing are most important process .

CARDING

The carding is the second process of spinning which converts fed material (lap) into uniform
strand of fibres called “sliver”. "The carding is called heart of spinning". In the carding process,
the material gets passed through carding machine. The carding, stripping and raising action
take place during carding operation. In this way, continuous uniform sliver having parallel fibre
arrangement almost free of impurities is obtained after carding process.

Objectives Of Carding

 To open the cotton tufts fully (individual fibres of cotton tuft get opened in carding
process).
  To make the fibres parallel to one another along the length of sliver.
 To eliminate maximum impurities present in the cotton. (to achieve higher degree of
cleanness. Today’s carding machine achieves 90 to 95% degree of cleanness.
 To remove very short fibres which could not be spun into yarn.
 To remove all the neps present in the material generating in the previous process like
blow room and mixing.
 To blend the fibres and to achieve fibre to fibre mixing.
 To finally convert the web of cotton into uniform sliver

Tasks Of Carding
 Opening of individual fibres.
 Elimination impurities.
 Elimination of dust.
 Disentangling of naps.
 Elimination of short fibres.
 Fibre blending.
 Fibre orientation.
 Sliver format

structure of a carding machine

The common structure of a carding machine is illustrated in below schematic diagram:

o Pipe ducting. 

o Chute feed. 

o Transport roller

o Feed arrangement

o Licker-in,

o Suction duct.l

o Main cylinder.
 o Carding segments.

o Flats.

o Cleaning unit.

o Grid or cover plate.

o Doffer.

o Stripping device.

o Calendar rollers.

o Sliver can.

WORKING PROCEDURE OF CARDING MACHINE:

CHUTE FEED SYSTEM:

 The main objective of chute feed system is to maintain continuous and consistent feeding of
fibre sheet of a uniform packing density and uniform linear density (weight per unit length) to
the carding machine. A chute feed system of a carding machine has following common parts in
it:

 High volume upper trunk.

 Integrated air volume separator.

 Feed roll, electrically coupled to the feed roll of the card.

 Segmented tray to secure clamping.

 Opening roll with pins.

 Closed air circuit with integrated fan.

 Self cleaning air outlet combs.

FEEDING SYSTEM:

The uniform fibres mat coming out from the chute feed system is supplied to the carding
machine with the help of feed roller. The linear density (weight per unit length) of the fibre
mat typically ranges from 400 to 1000 gram per metre (K tex). Weight per metre depends
upon the number of fibres present in the mat cross section which ranges from 2 to 6millions of
fibres depending on fibre fineness.

OPENING SYSTEM:
The fed material needs maximum opening and the linear density of material is reduced up to 3
– 5 grams per metre as per sliver count to be produced. The number of fibres in the card sliver
cross section downs to approximately 40,000. It rotates at a speed of 700 – 1200 rpm for
cotton fibres and 400 – 600 rpm for synthetic fibres. The draft between licker-in and feed roll
is kept around 100. The ratio of surface speed between the licker-in and the feed roll is equal
to draft.. The licker-in eliminates about half of all trashes present in the cotton fibres.

The carding zone:

The opened and cleaned fibres by licker-in gets transferred to the main cylinder using
stripping action. The cylinder strips the fibres from licker-in. The surface speed of the licker-in
varies between 700 – 950 metres per minute. The surface speed of the cylinder ranges from
1000 metres per minute to 2400 metres per minute. ( at diameter is 1290 mm, and 260 to 600
rpm.). In this way, the draft varies between1.5 to 2.5.
The flats are the bars which are covered with wire clothing. These flats rotate at very slow
speed in the opposite direction of cylinder rotating at high speed. The speed of he flats varies
with in the range of 8 – 20 centimetres per minute. Both are closely set to each other. The
clearance between flats and cylinder is set by considering following factors:

Cleaning system:
The cleaning system consists of a mote knife with a hood under permanent suction. It
separates dirt particles, seed coat fragments and dust particles.

Carding segment consists of two clothing strips with one support (twin top). A number of
different clothing types and point populations are available depending upon the installation
and the raw material.

The Doffing system:

The fibres come out of carding region in the form of a very thin web. The weight of carding
web depends upon setting of flats v/s cylinder, carding speed, type of wire clothing used on
the both cylinder and flats. Formed web is stripped from the main cylinder by another cylinder
called a doffer. It has diameter of 700 mm. and rotates at up to 96 rpm. It is then passed
through a pair of squeezing or crush rolls before it is finally accumulated width wise into a
fibre stand form..
Coil formation system:
The fibre strand (the card sliver) proceeds upward over guide pulleys then it  enters into the
coil formation system. The coil formation system has a trumpet guide and a second pair of
calendar rollers. These calendar rollers sends the sliver in to the sliver can with the help of
revolving tube.

The sliver web speed forms the web to a sliver and helps to  guide it into the measuring
funnel. The  sliver former is opened by pushing a button when sample for optical assessment
of web quality is made.

Neps controller:

This system registers the number of neps, trash particles and seed coat fragments. These data
are transferred to the main control system of machine. These data are evaluated and
displayed on the machine monitor.

Card Auto levelling System:

An auto levelling system controls the variation of linear density of sliver and  helps to maintain
the uniformity consistently. The main objectives of an auto leveller are given below:

 To measure sliver thickness variation on real-time basis.

 To alter the machine draft, so that a high consistent sliver linear density is continuously
produced.

 Generally two types of auto levelling systems are use depending upon the working
principle. Which are:

o Open-loop auto levellers

o Closed-loop auto levellers.

Open-loop auto levelling system:

The open-loop system is generally used to correct the short-term variations of sliver.

Closed loop auto levelling system:

it is generally used to correct long-term variations in linear density of sliver. This system takes
the measurements of the delivered sliver. In other words, we can say that the closed loop auto
leveller monitors the results of corrective actions taken by it to maintain the sliver uniformity.
Machine used and company Name

Rieter C50 & 51

Manufacturer: Rieter carding machines

Model: Rieter C50

Condition: used
 Year: 1995

Size: 800*1000

Category: Carding Machines

Subcategory: Card machine

Listing ID: 39531408

List of Modern Machine used in Bangladesh

Carding – REITER Card C 80

The card C 80 produces 30% more card sliver compared with the current benchmark. A
maximum technological carding area is the basis for high productivity and raw material
utilization.
The C 80 is simple to maintain as it is easily accessible. The integrated Q-Package and
extremely precise central adjustment of the flats ensure fast and straightforward adjustment
to new raw material. The high quality of the card sliver is based on the large active carding
area and the precise carding gap.
Machine : Card TC 15

(Card with the longest carding section)

The
Truetzschler TC 15 card offers a competitive edge not only because of its excellent productivity
and quality, but also because of its low operating costs. It is highly flexible, allows for quick
and frequent lot, flats, and carding changes. Like other Truetzschler cards, the compact TC 15
features the longest carding section in the market - ensuring the best product quality.
Manufactured by: Trützschler GmbH & Co. KG, Germany

Technical Details 
o Raw material: cotton, man-made fibres

 Key Features 
 Aluminium flat bars without screw connection - Quick flat exchange, without tools 3-
roll WEBFEED Unit - For gentle pre-opening
 Sliver former WEBSPEED - completely maintenance-free
 Approx. 40 percent more production at same compact space
 Setting Optimiser T-Con - For maximum utilisation of the TC 15 potential
 Quick can change for large cans in smallest space with T-MOVE

PROCESS CONTROL IN CARDING

• The required correction in the draft is done to find uniform sliver.
• The weight per unit length of sliver should get analysed three times in a shift of 8 hours
Higher cylinder speed is also improved carding action. Thus imperfection in the sliver also gets
minimized.
• When coarse and dirty cotton is processed in carding, Higher Licker-in speed helps to
remove the trash from the cotton. Thus improved yarn quality results. Higher licker-in speed
causes fibre rupture during processing of fine and long staple cotton. Therefore flat waste is
increased.
• When flat speed is increased, better yarn quality is obtained but same time flat waste
increases.
• The draft between feed roller to doffer is varies between 75 – 95. Very high tension drafts
affects U% of the sliver.
• The flat tops and cylinder wire should be replaced together to find improved and consistent
yarn quality.
• The licker-in wire clothing should be replaced after every 150000 kgs of production.
• The stationary flats should be replaced after every 150000 kgs of production.
• The stationary first 3 to 6 flats at licker-in side work than remaining flats, so that these flats
need early replacement. Replacement of these flats after every 100000 kgs of production

Drawing or Draw Frame

Drawing is one of the process which comes after carding in the manufacturing of yarn.
Drawing process (draw frame) plays very big role to improve the quality of yarn in many
respects such as evenness, strength, elongation at break and degree of hairiness. Two actions
are taken place in draw frame process : One is doubling and other one is drafting.
Doubling
In the process of doubling, two or more carded slivers are taken and they are fed together.
Mostly 6 or 8 slivers are combined together in doubling process and single sliver is produced.
The resulting sliver has improved uniformity and linear density. Doubling process helps to
improve the evenness of sliver and drafting helps to achieve the maximum parallelisation of
fibre along the sliver length and reduce the linear density of sliver too.

Drafting
The weight per unit length of the input sliver is reduced in the process of drafting. The hooked
and curled fibres are straightened and fibre arrangement in the sliver is improved by making
fibres parallel along the sliver length. The fibres are blended together in drafting process. The
drafting also helps to eliminate dust from the sliver.

Objects Of Drawing ( Draw Frame) Process:

  To improve the uniformity (linear density) of sliver up to optimum level.
 To improve the fibre arrangement in the sliver and to make the fibres parallel
to the sliver length.
 To straighten the hooked, curled and crimped fibres present in the sliver.
 To draft the material and to reduce the weight per unit length of sliver.
 To eliminate the dust and impurities present in the sliver.

Common Structure Of Draw Frame Machine:

 Creel or sliver feeding system.

 Drafting system.
 Suction system for drafting arrangement.
 Sliver coiling system.
 Can changing system.
 Auto levelling system.

Functions of Draw Frame

Equalizing: One of the focal responsibilities of the draw frame is refining evenness over the short,
medium and long term. Card slivers served to the draw frame possess a degree of unevenness that
cannot be acknowledged for producing yarn.

Parallelizing: Attaining an optimum value for tenacity in the yarn, the fibers need to be aligned
parallel in the fiber strands by drafting process.

Blending: Into the bargain of equalizing influence, doubling also offers a top notch of compensation of
raw material disparity by blending. Here diverse types of fiber can be combined altogether to acquire a
particular blend ratio. E.g. 65:35 PC, 55:45 CVC etc.

Dust removal: The draw frame is an upright dust eliminating instrument. High performance draw
frames are fitted out with proper suction systems. The draw frame extracts more than 80 % of the
incoming dust
 Passage diagram of draw frame

Machine used and company Name

Drawing machine RIETER SBD 10

Drawing machines RIETER RSB D35

List of Modern Machine used in Bangladesh

RSB-D 26 – Double-Head Autoleveler Draw Frame

SB-D 26 – Double Head Draw Frame without Autoleveler

Controlling point of Draw Frame

o The fibre length of a fibre gets affected due to the presence of

hooked fibres in the sliver to be processed.
o The hooked fibres present in the sliver affect the drafting efficiency
of a draw frame machine.
o A draft of 7.5 is used to achieve better performance in both breaker
and finisher draw frame.
o A draft of 7.0 may also be used in breaker. A draft of 7.5 to 8.0 is
applied for combed material in single passage draw frame.
o A draft of 8.0 is used in breaker and finisher to process synthetic
material having staple length of 44 – 51 mm.
o Plus 8 – 12 mm break draft setting is used for longest cotton fibres
processing in 3 over 3 or 4 over 3 drafting system both.
o The value of break draft ranges between1.16 to 1.26. This value
varies between 1.42 to1.6 for synthetic fibre processing.
o Coiler is selected according to the material to be processed. Bigger
coiler tubes size is used for processing of synthetic fibres. This
bigger coiler size helps to prevent coiler choking and kinks in the
slivers due to coiling in the can.
o The setting of sliver monitor is done precisely. The open loop auto
leveller acts immediately to stop the machine in case of linear
density variation in sliver.
o The mechanical draft is selected accurately in draw frame equipped
with auto leveller.

Conclusion
From the above discussion it can be said that carding and drawing are the most
important process in spinning and carding is called the heart of spinning .After
carding and drawing yarn is prepared for the next process .