CURRENT SCENARIO ON DEVELOPMENTS IN CARD

D.Jayaraman & A.SelavakumarDepartment of Textile Technology, Bannari Amman Institute of Technology, Sathyamangalam

CRITICAL ISSUES IN SPINNING INDUSTRY Some of the critical issues are Shortage of skilled labour Increasing power cost Increasing raw material cost Increasing land cost Increasing fuel cost etc., makes the industry to suffer a lot. In this scenario industry is expecting the machinery manufactures to develop the machines that can address a few of these issues

DEMANDS PLACED ON MACHINERY MANUFACTURERS Higher production rates with out compromising quality Less floor space requirement Energy efficient Ergonomically designed Operator friendly Low maintenance These are some of the major expectation in the industry

Concepts of developmentsThe developments that are taken place can be classified as follows: Production related Quality oriented Ergonomics related In these major categories further sub divisions are, Minor modification Modifications in monitoring systems Major modifications

Production related developments Working width is increased significantly from conventional cards of 1 metre (40) MAKE Trutzschler Rieter Marzoli WIDTH 1.28 m 1.50 m 1.50 m MAX.Prodn.Claimed 260kgs./hr. 250 kgs./hr. 250kgs./hr.

Quality related developments Machine geometry is changed by all manufactures to achieve more carding area to improve the quality in tune to production increase. Rieter C70Table 1. Comparison of the active carding index (aci) for different card models. Card model Conventional card 60 card C 70 card Number of flats in rotation 84 79 99 Number of flats in the contact zone 30 22 32 Card width [m] 1.0 1.5 1.5 Active carding index (ACI) = number of active flats x card width 30 33 48 ACI compared to conventional cards + 10% + 60%

Increase in PRE and POST Carding area MARZOLI CARDPre-carding area on C701 Card Post-carding area on C701 Card

Similar type of arrangements with little modifications are provided / offered in Rieter C70 and Trutzschler TC11 cards

Precise setting provisions Rieter by redesigning the components claims that minimum0.1mm setting between cylinder and flats is Possible Trutzschler precision setting and measuring system (PMS & PFS ) ensures accurate setting Marzoli Card with deflector blade to adjust droppings in The licker in zone

INCREASE IN TOTAL CARDING AREA

Trutzschler

Marzoli

OPERATOR FRIENDLY ACCURATE SETTING SYSTEMS

Trutzschler PMS

Trutzschler PFS

Marzoli deflector blade

Autoleveller system in card To control card sliver count variations and unevenness, modern cards are equipped with autoleveller. Rieter medium and long term autoleveller on C 70 card Trutzschler short-wave and long-wave autolevelling System SENSOFEED+ Marzoli short term and medium term leveling system MTA is standard and STA is optional In general all the cards are with medium and long term autolevellers

SPECIAL ATTACHMENTS Rieter card IGS Trutzschler card - T-Con Online NEP monitoring system in Trutzschler MAGNOTOP SYSTEM in Trutzschler with Super strong neodymium magnets Separate card for synthetic development by Trutzschler TC11S Integrated Draw frame by Trutzschler

Rieter integrated grinding system (IGS-top and IGS-classic) Rieter C70 card is with integrated cylinder grinding system IGS an exclusive Rieter product. Rieter IGS-System comes in two versions; IGS-Classic for cylinder wire grinding and IGS-Top for flat wire grinding. IGS-Classic has a grindstone, which moves across the cylinder underautomatic control during production. This process is performed 400 times during the planned lifecycle of the clothing as compared with every 80 to 100 tonnes in case of manual grinding. This results in better quality in terms of reduction in neps and trash of card sliver.

IGS-Top is installed permanently over the returning flats after the flatscleaning unit and it performs automatically more than 100 grinding cycles per clothing lifecycle.

TRUTZSCHLER CARDING SETTING MEASUREMENT SYSTEM T-CON The five T-Con functions, T-Con ACTUAL

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Contact monitoring Distance optimisation Operating status analysis Spacer

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Display of the most important process variable for carding quality Maximum safety against clothing contact Optimal yarn quality due to correct setting parameters Prerequisite for controlled setting Fast, accurate, reproducible settings

TRUTZSCHLER TC 11-S The following areas are different for cotton and manmade fibre card 1 Stainless steel comb instead of screen fabric 2 Stainless steel cleaning flap 3 Stainless steel reserve trunk 4 Segmented feed tray 5 Special opening rolls for higher speeds 6 Stainless steel reserve trunk 7 More carding and less cleaning elements 8 WEBFEED with a large needle roll 9 Man-made fibre T-Con 10 Special sliver trumpet 11 Additional deflection roll 12 New doffer clothing TCC NovoDoff 30 patented