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Carding is known as the heart of spinning in textile manufacturing process. Carding is the second process conducted in spinning after blow room followed by combining, drawing, roving, and cone winding in textile manufacturing process. Carding in spinning process cracks up the locks and the unorganized clumps present in the fiber. This is done to make the fibers parallel to each other. Carding machine includes a single big roller covered by small roller surrounded with small spikes. Overall, the carding process removes impurities, decreases the blend to fiber mesh and divides it into roving required i.e. performing various functions. Carding plays a significant role in spinning cycles especially in woolen spinning cycle incorporating various functions.
The functions of carding in spinning process are explained as follows:
1. Opening into single fibers
Carding opens the biers into single and independent fibers. Blowroom process makes out flocks of fibers from the raw material; whereas, carding divides fiber in individual fibers. If this process gives authentic result further process also works in required smooth manner. Mainly, impurities are removed by opening into individual fibers.
2. Removal of neps
Over here, the small entanglements of fibers are formed. These entanglements cannot be ever mixed up or united. Here neps are not subtracted in fact they are just separated or indirectly removed.
3. Removal of neps
Very less proportion of hardly 10% are been removed from the card. This can only be eliminated if they are pressed into clothing.
4. Fiber blending for further process
Appropriate fiber along with fiber mixing is resulted for web formation and repetition of rotation of fibers in the cylinder. Carding is the only mechanical device to process out the individual fibers.
5. Silver formation
The chief layout attained from carding is silver. This silver formation is held to provide the fiber material for further operation. It is also conducted to shift the fiber from blow room to draw frame procedure.
The process of carding results into good quality of yarn due to spikes. Huge rope of fibers of silver colour is formed during the same process. Carding is significant playing the major role in spinning process specifically in woolen spinning cycle. To attain superior woolen quality, carding suits the best for the same. Blended fibers can also be produced including different types of fibers along with colours.
6. Problems during carding process
Defects can occur easily in third carding in spinning process related to nep formation, creation of holes or patches in web card. Some of the issues during the process can be noted as high silver formation, nep formation, uneven flat setting, high roller speed, under casing choked with waste, damaged cylinders and much more.
7. Preventions for the defects in carding process
Above are some of the issues arriving during the process of carding which can be eliminated. Lack of maintenance of carding machine makes an issue of silver variation problem. The maintenance of silver do effects the layout produced in the whole procedure including lack of variation in silver. The fragments of machine used should be removed at a time when expired to attain improved results. Instead of machine been automated it is still required to check out the weight of silver. The formation of nep can also be prevented by making sure that the machine is repaired on the time. Flat setting is very important for reduction of nep thus the setting should not be uneven. Also suction waste point should not be chocked and is to be checked manually. The inspection of each and every fragment of the machinery is necessary to be held after a particular period of time.
The drums line up the fibers by bringing up the thread. The attachment of drums to the soft bristled brush ensures that fibers are straightened to the condensed fibers,. Cottage carding machines are differ from these drum fibers i.e. these do not store the fiber in card cloth instead it is worked with a different process by other machines.
8. Conclusion to carding process
Carding process is the chief process defining the quality of yarn and the finalized product. It is considered as one of the superior tools to create good quality of yarn.
9. Recommended Tongda Ring Spinning
