Study On Licker-In and Flat Speeds of Carding Machine and Its Effects On Quality of Cotton Spinning Process
Study On Licker-In and Flat Speeds of Carding Machine and Its Effects On Quality of Cotton Spinning Process
Study On Licker-In and Flat Speeds of Carding Machine and Its Effects On Quality of Cotton Spinning Process
https://www.scirp.org/journal/jtst
ISSN Online: 2379-1551
ISSN Print: 2379-1543
Department of Textile Engineering, BGMEA University of Fashion & Technology, Dhaka, Bangladesh
2
DOI: 10.4236/jtst.2023.93013 Aug. 28, 2023 198 Journal of Textile Science and Technology
Md. M. Motin et al.
sults of this study offer useful information for textile producers and process
engineers to improve the quality of carded sliver and yarn while maximizing
the performance of carding machines. Operators may choose machine set-
tings and parameter adjustments wisely by knowing the impacts of licker-in
and flat speeds, which will increase textile industry efficiency, productivity,
and product quality.
Keywords
Spinning Process, Carding Machine, Yarn Count, Flat, Licker-In, Sliver Hank
1. Introduction
Carding, drawing, twisting, and spinning are the main processes involved in
making yarn. The carding section of a mill is sometimes referred to as the “heart
of a spinning” mill because of its central importance. Everybody in the spinning
industry uses the phrase “to card well is to spin well” often [1] [2] [3]. The func-
tioning of the card has been shown to have the strongest collaboration to both
quality and productivity [4] [5]. The carding process is the most crucial step in
the spinning process. It has a significant impact on the overall quality of the
yarn. Controlling the speeds (flat speed, taker-in speed, and cylinder speed), as
well as the settings (licker-in and feed plate, licker-in and under casing elements,
cylinder and flat tops, between the cylinder and doffer, and so on), are examples
of process parameters that need to be managed in order to produce yarn of high
quality at a cost that is relatively affordable to manufacture [6].
During the carding process, the licker-in is responsible for doing significant
opening and cleaning. More than half of the fibers pass onto the surface of the
main cylinder as tufts and slightly less than half as individual fibers when the
opening is conducted to this level in a carding machine with a single licker-in.
As a result, the licker-in provides harsh, but unfortunately not very delicate,
treatment [7].
Several studies have been conducted to analyze the licker-in and flat speeds of
carding machines and their effects on the quality of the carded sliver and yarn.
Here are some notable past studies in this field [8]. This study investigated the
influence of licker-in speed on carding process parameters and fiber properties.
Experimental results showed that an increase in licker-in speed improved card-
ing efficiency and reduced fiber entanglement. However, excessive licker-in
speed led to increased fiber breakage and Neps [9] [10]. This study explored the
effects of licker-in and flat speeds on yarn quality. It revealed that higher lick-
er-in speeds within a certain range improved fiber opening and separation, re-
sulting in higher yarn strength and improved evenness. However, beyond a cer-
tain limit, the excessive licker-in speed negatively impacted the yarn quality [11]
[12]. This study focused on the impact of flat speed on carded yarn quality. Ex-
perimental findings indicated that higher flat speeds enhanced fiber alignment
during carding, leading to improved evenness and strength of the carded yarn.
However, excessively high flat speeds caused fiber breakage and loss of fiber
length [13]. In their research work, Z. Zhidan and S. Pengiz [14] conducted re-
search to identify the speed of the licker-in cylinder and the layout between the
fixed segments and the licker-in cylinder in the rear carding zone of the card. H.
R. Sheikh [15] also in his research studied the influence of the fixed segments of
the carding machine on the produced carding sliver. D. Simpson [16] and others
looked at how the main drum’s rotation and carding speed affected the produc-
tivity of the spinning process [17]. This study has identified that the quality of
card slivers directly reflects the quality of yarns such as decreasing unevenness,
imperfections and increasing strength. The higher the flat speed, and in this task,
the highest flat speed, the better the quality of the yarn becomes, i.e. 320
mm/min is the optimum flat speed. The peculiarity of low-grade cotton fibers
and fibrous waste is that they contain a large number of defective fibers and
trash. Therefore, this kind of fiber must be given special attention during card-
ing and intensive processing. On a card, the cleaning process is mostly carried
out in the area of the licker-in cylinder. Licker-in cylinder speed is an important
factor in maximizing fiber separation and cleaning. When studying the compo-
sition of fibrous waste, it was determined that they contain many tangled fibers
and seed skins with fibers. Defects in fibrous waste led to the formation of a
number of problems during the process of silver forming and spinning, as well
as a decrease in the quality of the yarn produced.
Table 1. Properties of Benin raw cotton recorded from USTER HVI 1000.
Properties Value
Continued
2.2. Methods
2.2.1. Carding Process
In this experiment, the licker-in and flat of Trutzschler carding machine (TC 19i)
was driven at four different licker-in speeds, that is 960, 1020, 1100 and 1180 rpm
and at three different flat speeds, that is 300, 340, and 380 mm/min, by keeping all
other parameters unchanged. Table 2, Table 3 contains the carding machine’s
process parameters. In Figure 1 the diagram represents Various Parts of a Carding
Machine. Four carded slivers were delivered for every level of licker-in speed to
take care of the output of breaker draw frame. Three carded slivers were delivered
for every level of flat speed to take care of the output of breaker draw frame.
Sliver hank 418 - 422 grain/6 yds. Feed roller to Licker-in 1.22 mm
960/1540/2040,
Licker in speed 1020/1600/2100, Revolving flat to cylinder 0.08 mm &
1st/2nd/3rd 1100/1680/2180 and (Auto-Monitor setting) Fixed-0.15 mm
1180/1760/2260 rpm
(Around 286
No. of flats in action 30 Doffer speed
m/min)
Sliver hank 418 - 422 grain/6 yds. Feed roller to Licker-in 1.22 mm
Unevenness: Unevenness deals with the variation in yarn fineness. This cha-
racteristic is frequently assessed as the difference in mass per unit length along
the yarn. For a complete analysis of the quality of fiber assembly, along with
mass diagram, a numerical value of mass variation is also necessary. The irregu-
larity or unevenness (U%) and the coefficient of variation (CV%) are used in
mathematics to accomplish this [19].
Unevenness = Mean Deviation/Mean * 100
Co-efficient of variation (CV%) = Standard Deviation/Mean * 100
By observing the graph, we can say that the variation in the licker-in speed has an
effect on the variation of the neps content per gram of card sliver. When licker-in
speed is raised, more flat come into touch with the fibre treatment process. So, the
increase of licker-in speeds reduces the neps content per gram in the card sliver.
In the graph, we see that at licker-in speed 1180 rpm neps content per gram
was 96 whereas at licker-in speed 1100 rpm neps content per gram was low 75
and then increases neps gradually with decreasing speed. So, we may conclude that
with the medium licker-in speed neps content per gram of card sliver is reduced.
Figure 3 indicates the variation of NRE% in the carded sliver due to variation
in licker-in speed of carding machine.
Figure 3. Effects of Licker-in speed on Neps Removal Efficiency (NRE%) of the sliver.
In the graph, we see that at licker-in speeds 960, 1020, 1100 and 1180 rpm, the
NRE% are 78.08%, 70.47%, 72.68% and 67.71% respectively which is a decreas-
ing trend.
According to the graph, the variation in licker-in speed does affect the varia-
tion in the NRE% of card sliver. There is more beating and opening of fiber
flocks as licker-in speed is increased. So, the increase of licker-in speeds leads to
decrease in the NRE% of the card sliver.
In the first graph of Figure 7, it was observed that at licker-in speed 1180,
1100 and 1020 rpm, thick places +50% are 157, 123 and 104 respectively which is
a decreasing trend. But, thick places +50% is increased at 960 rpm. So, low and
high licker-in speed are not suitable for low thick places, optimum speed is 1020
rpm.
licker-in speeds 960, 1020, 1100 and 1180 rpm, the Classimat Faults are 62,670.2,
63,853.3, 60,008.4 and 63,652.8 respectively which is a mixed trend. So, at licker-in
speed 960 and 1100 Classimat Faults are increased and at 1020 and 1180 Classi-
mat Faults are decreased.
Figure 9. Effects of licker-in speed on IPI −50%, +50%, +200% of the yarn.
Figure 12 indicates the variation of NRE% in the carded sliver due to varia-
tion in flat speed of carding machine.
Figure 12. Effects of flat speed on Neps Removal Efficiency (NRE%) of the sliver.
In the graph, we see that at flat speeds 300 mm/min, 340 mm/min and 380
mm/min, the NRE% are 68.68%, 70.32% and 72.40% respectively which an in-
creasing trend is.
We can infer from the graph that changes in flat speed do have an impact on
changes in the NRE% of card sliver. When flat speed is increased, more number
of flat comes to the contact with fiber treatment operation. So, the increase of
flat speeds leads to increase in the NRE% of the card sliver.
mm/min to 380 mm/min, there is a steady decrease in the yarn unevenness from
11.52 at flat speed 300 mm/min to 11.06 at flat speed 380 mm/min. It is evident
from the decreasing trend that the yarn unevenness is inversely proportional to
the card flat speed.
Figure 14 makes it clear that yarn CV% decreases with an increase in the card
flat speed. As the card flat speed is increased from 300 mm/min to 380 mm/min,
there is a steady decrease in the yarn CV% from 14.55 at flat speed 300 mm/min
to 14.01 at flat speed 380 mm/min. It is evident from the decreasing trend that
the yarn CV% is inversely proportional to the card flat speed.
Figure 14. Effects of flat speed on Co-Efficient of Variation (CV%) of the yarn.
Hence, it can be said that the increase of flat speed reduces the co-efficient of
variation of yarn.
trend.
Figure 15. Effects of flat speed on Thin Place -50% of the yarn.
In the first graph of Figure 16, it was observed that at flat speed 300, 340 and
380 mm/min thick places +50% are 144, 114 and 95 respectively which is a de-
creasing trend.
Figure 16. Effects of flat speed on Thick Place +50% of the yarn.
Figure 18. Effects of flat speed on IPI -50%, +50%, +200% of the yarn.
4. Conclusions
As natural fibre like cotton which consumes about 30% of annual fibre con-
sumption, its physical & chemical properties vary according to seed, plantation
process, soil condition, natural resources, etc., so consistent quality in yarn is a
crucial issue. In this project work, the actual relationship between the licker-in
speed and flat speed of the yarn quality was studied. The graphical representa-
tions allow us to deduce that as the card is licked in faster, more neps and short
fibers are removed, which results in less unevenness in the card sliver. Card sliv-
ers’ quality, which includes diminishing unevenness, flaws, and yarn classimat
faults, directly represents the quality of yarns. The quality of yarn improves with
the decrease in licker-in speed and in this work; the medium licker-in speed i.e.,
1020 rpm is the optimum licker-in speed. There may be an optimum licker-in
speed lower than 1020 rpm after that yarn quality will start to decrease. Since we
have to employ the minimal licker-in speed of 960 rpm, finding the ideal lick-
er-in speed might be the subject of future research.
This project effort examined the actual connection between flat speed and
yarn quality. It may be inferred from the graphical representations that when flat
speed of card increases, more neps and short fibers are eliminated, resulting in
less unevenness of card sliver. The quality of card slivers directly reflects the
quality of yarns such as decreasing unevenness, imperfections and yarn classimat
fault. The quality of yarn improves as flat speed rises, and in this piece, the maxi-
mum flat speed is used. i.e., 380 mm/min is the optimum flat speed. There may
be an optimum flat speed higher than 380 mm/min after that yarn quality will
start to decrease. Since we were restricted to use maximum flat speed at 380
mm/min, so obtaining optimum flat speed may be the topic of further research.
Author Statement
We certify that all named authors have read and approved the article and that no
other individuals who meet the requirements for authorship but are not listed
have done so. We also reaffirm that we all approved of the order in which the
authors are listed in the manuscript.
Acknowledgements
The authors would like to express thank and guidance towards Mondol Spinning
Mills Ltd. Tangail, Dhaka, Bangladesh, for providing machineries and equip-
ment on time during the research work.
Conflicts of Interest
The authors declare no conflicts of interest regarding the publication of this paper.
References
[1] Rashid, M.M., Motaleb, K.A. and Khan, A.N. (2019) Effect of Flat Speed of Carding
Machine on the Carded Sliver and Yarn Quality. Journal of Engineered Fibers and