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To reduce card waste by SFD inactive and its impact on yarn quality

Article · January 2016

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 International Journal on Textile Engineering and Processes ISSN 2395-3578
Vol 2, Issue 1
January 2016
To reduce card waste by SFD inactive and its impact on yarn
quality
Bhushan Patil1, R.D.Parsi2, Madhuri Kakde3, S.T.Jadhav4
1
Research scholar, 2, 3 Faculty of Centre for Textile Functions, NMIMS, MPSTME, Shirpur, Dhule,
Maharashtra,
4
General Managers, Alok Industries, India, rajendra_parsi@yahoo.com

Abstract
Flat setting and the flat waste plays a vital role in quality of carding sliver. Hence trails have to be taken to optimize
the flat setting and amount of flat waste to be extracted. This project work mainly deals to reduced card waste by SFD
inactive and its impact on yarn quality and the trials have been conducted to justify the waste reduction and yarn
quality. The card waste evaluated by taking a card waste study before SFD active and after SFD inactive and yarn test
evaluated by taking a sample for RKM, CSP and Uster Tester-5 and to make comparison between them. The trials
have been given and obtained results of reducing card waste by 2% and in yarn quality IPI is increased by 12%, CSP
is decreased by 3.25%, RKM is decreased by 3%, hairiness is decreased by 2% and Classimat faults also deteriorated.
The SFD inactive has major influence on the card waste.

Keywords: SFD, Card waste, yarn quality, Classimat faults.

I. Introduction
Flats are an important partner of cylinder for accomplishing carding actions. Apart from individualizing of the
fibers, flats also contribute significantly to the cleaning achieved in the card. Increase of flat waste up to a point
is associated with improved yarn appearance, while waste extraction beyond this level does not contribute much
to quality. In past many researchers have investigated about SFL waste (stationary Flats above licker-in) and SFD
waste (stationary Flats above Doffer). The waste in pre-carding zone i.e. SFL waste (stationary Flats above licker-
in) can be optimized by waste plate setting and gap between knife and waste plate. The research shows that wider
setting leads to more waste and vice versa. More gap results in higher waste and vice versa. The waste in post-
carding zone i.e. SFD waste (stationary Flats above Doffer) can be optimized by front top plate setting and gap
between the knife and front top plate. Many works has been carried out to optimize the SFD waste and it shows
that wider front top plate setting in the middle leads to more waste and more gaps between the knife and front top
plate resulted in more waste and vice versa. The basic purpose of this study was to reduce the card waste as well
as to maintain the yarn quality.

II. Material & Method

In the present study trials have taken for 4.38 Tex (135Ne) CW compact yarn. For this experiment was conducted
on card C 60 with three SFD active and SFD inactive.

III. Experimental Plan

In order to reduce card waste, Experiment was conducted on card C 60 with three SFD active and SFD inactive.
Silver was processed through Reiter draw frame SBD 40 without auto leveling, Unilap E32and comber E65 and
finally draw frame RSB D40 with auto leveling.

Then the single drawn sliver passed through speed frame F15 to Rieter K41 compact spinning frame operating at
14000 rpm spindle speed. The properties of fibers in the mixing and properties of ring spun yarns are laid down
in Table 1.

Table no. 01: Cotton properties

Mixing DM SPL
Length (mm) 36.56
Micronaire 3.81
Maturity 0.88
G/tex 39.71
Elongation (%) 4.8
SFI 4.7

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 International Journal on Textile Engineering and Processes ISSN 2395-3578
Vol 2, Issue 1
January 2016
IV. Results and Discussion
The card waste was evaluated by taking a card waste study before SFD active and after SFD inactive. To analyze
the flat waste, AFIS test has to be done for the flat waste and yarn quality evaluated by taking a sample for RKM,
CSP and Uster Tester-5.
Card waste percentage:
Table No. 02: AFIS Report of card and comber
Card Comber
SFD active SFD in-active SFD active SFD in-active
Mixing DM SPL DM SPL DM SPL DM SPL
Nep cnt/g 148 128 24 23
Nep [um] 664 632 612 594
SCN cnt/g 20 11 0 0
SCN [um] 1148 977 875 875
length(w) 27 27 28.2 28.4
SFC (w)% 8.8 8.4 4 3.9
UQL (w)mm 34.1 34.2 34.5 35
SFC (N)% 29.7 27.9 12.9 12.6
5.0% (MM) 39.4 39.5 41 41.3
Actual noil% --- --- 19.06 19.77

Table No. 03: Card waste percentage of SFD active and inactive
CONTENT SFD active SFD in-active
Liker-in waste% 2.62 1.59
Flat waste% 4.06 4.36
SFL waste% 1.11 1.16
SFD waste% 1.64 0.31
Total Card waste% 9.43 7.42

Figure 01: Effect of SFD inactive on card waste %9.43

10
7.42

5 4.06 4.36
2.62
1.59 1.11 1.16 1.64
0.31
0
Liker-in Flat waste% SFL waste% SFD waste% Total Card
waste% SFD ACTIVE SFD IN-ACTIVE waste%

Inference:
It is observed from the above table and figure that the card waste was reduced by 2% in SFD inactive and SFD
waste mainly reduced by 1.33%. The short fiber, micro dust and remaining impurities are removed in SFD active.
This is due to the fact that the SFD waste is increased by more gaps between the knife and front top plate but the
trial was taken on SFD inactive so material is goes through the process and card waste reduced.

Imperfections and CSP

Table No. 04: USTER - 5 report cops as well as cone

Cops Cops Cone Cone

SFD Active SFD Inactive SFD Active SFD Inactive
-40 % Thin 158 191 200 226
+35 % Thick 224.5 288 293 330
+140 % Neps 361.5 378 398 437

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 International Journal on Textile Engineering and Processes ISSN 2395-3578
Vol 2, Issue 1
January 2016
Table No. 05: CSP report cops as well as cone

Cops Cops Cone Cone

SFD SFD
SFD Active SFD Inactive
Active Inactive
Actual count 136.59 136.22 136.14 136.60
CV% 1.38 1.48 1.43 1.57
Strength 21.0 21.3 21.84 20.43
Strength
4.25 3.60 6.10 5.21
CV%
CSP 2875 2775 2943 2810

4000
2875 2775
3000

2000

1000 744 857

0
CSP IPI
SFD ACTIVE SFD IN-ACTIVE

Figure 02: Effect of SFD inactive on CSP and IPI

Inference
It is found that CSP was slightly decreases and increases in IPI values when SFD is inactive. Because the short
fiber and micro dust are remains in the material so the CSP deceases and imperfection increases.
Single Yarn Strength and hairiness
Table No. 06: Single yarn strength report
Cops Cops Cone Cone
SFD SFD
SFD Active SFD Inactive
Active Inactive
RKM 19.16 18.5 18.41 17.46
CV% 9.25 9.6 11.11 12.14
Elongation 5.11 5.51 4.48 4.90
CV% 9.84 9.35 10.15 11.12

Table No. 07: Classimat report (cone)

SFD Active SFD Inactive

th 0 2
7 CLASS
8th CLASS 0 2
4th CLASS 40 48
5th CLASS 4316.7 5045
16th CLASS 4356.7 5095
Long thick (E+F+G) 39 38
Long thin(H1+H2+I1+I2) 829 846

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 International Journal on Textile Engineering and Processes ISSN 2395-3578
Vol 2, Issue 1
January 2016

25
19.16 18.5
20

15

10

5 2.57 2.51

0
RKM hairiness
SFD active SFD inactive

Figure 02: Effect of SFD inactive on RKM and hairiness

Inference
From the above figure and table it is clear that RKM was slightly decreased and no more variation found in
hairiness. As the CSP is decreases RKM is also decreases, and because of compact spinning all short fibers
contribute in twisting and complete fiber binding so hairiness is reduced.

Conclusion
Cleaning that is done in a card has a pronounced influence on yarn and fabric quality and also performance of the
material in spinning and subsequent processes. The effect of SFD inactive on card waste and yarn quality was
observed in the present study. It is found that with SFD inactive total card waste reduced by 2.01 % (SFD waste
reduced by 1.33 %). There is no significant effect on carding, unilap, comber and draw frame AFIS Report.
135CW compact cops as well as cone CSP, IPI, RKM and CLASSIMAT deteriorated and end break increased by
1.29%. By this research project mixing cost is slightly reduced and yarn realization is slightly improved.

Reference
1. W. Klein, A practical guide to the blow room and carding, The Textile Institute 2000, volume-2,2nd edition.
2. A.R. Garde, T. A. Subramanian, Process control in spinning Third Edition,1987 pp160 -202.
3. Shailendrakumar shrivastav, spinning handbook of quality control, Mahajan Ahmadabad,1991.
5. Glibert R. Merrill, cotton carding,Gilbert R. Merrill,1955.
6. A.R. Khare, Elements of carding and drawing, Sai book Mumbai,2007.

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