16 oR owatonna 2. Bemreom &Canig 1.4.1.2. The last generation blowroom tine To illustrate this new concept we have to start with the card Figs. 88 and 92 show the initial feed chutes of cards as a simple square structure. Inthe course of time substantial improvements were developed, eg. integrated opening roll. er, controlled material compressing, transport air elimina tion, de-dusting etc. (Fig. 93). At this stage of development ‘some engineers in the research department discovered that an ideal fine cleaner could be obtained with some minor changes in the design of the card chute and with only ttle effort, since the infrastructure already existed. All that was, required was to replace the coarse opening rall by a pinned roll with a new kind of feed raller infront and a scraping, knife underneath the roll (Fig, 94), This design made a separate fine cleaner in the blawroom {ine superfluous. The most modern blowroom tines there- fore no longer feature a separate fine cleaner in front of the card. This function has now been transferred to the card feed chute as an integrated part ofthis unit. This solution results in a remarkable improvement in quality, since the ‘material is treated more gently. Asan integrated machine (only one) of a blowroom line the fine cleaner has to treat the total amount of material tobe processed in this line, id does this with a saw-toothed roll operating in a some- what aggressive manner. In the new line the same amount ‘of material (up to 1.200 kg/h) is divided, for example, among 2 x 6 chutes equipped with pinned opening rolls, (2 tines of cards with 6 cards each). ‘Another improvement, in this case in terms of rationaliza- tion, was introduced at the same time as this development, ‘ce. joining the card tothe first passage drawframe (Fig. 36) The latter is placed directly following sliver delivery from the doffer. Incorporating these innovations, the mast mod- erm material treatment system at the beginning of the spin- ning process is a combined, integrated, homogenous unit comprising: + bale opener + pre-cleaner + blender + card (combined with the fist passage drawframe). It can be described as the material Preparatory section”, and a modem spinning plant for coarse to medium counts then consists of three divisions: + Material preparatory section (with only a few possible variations) + Spinning preparatory section (with or without the combing section), and the + Final spinning section. Fed chute with ecleaner Orawtcome Fig. 36 The compound card1.4.2. Machines for “opening” 1.4.2.1. Automatic bate opening machines The fiest generation automatic bale opening machines, wore mostly stationary. Only the bales were moved, cither backward and forward or in a circle. The second generation machines are ofthe traveling type, i.e. they ove past the stationary bales of the layout and extract ‘material {rom top to bottom, Traveling machines have the advantage that more bales can be processed a5 an overall unit (charge). and thus a better long-term blend is achieved. Ii should be noted, however, that these machines extract rnaterial only in batches, ie. they can process only one, two of at most three bales simultaneously. Ifa long-term blend is to be achieved, then mixing machines must be included downstream from the bale opener. ‘bale layout can comprise up to 130 bales from 4 to 6 different sources. i.e. 4 to 6 different types of bale per fiber blend. Intervening spaces sometimes have to be left between the individual bale groups so that the extraction roller can be adapted to varying bale heights. The machines are completely electronically controlled and extract material from all bates evenly. independently ‘of varying bale densities and heights. The machines of this first zone should be able to: extract material evenly {rom all the bales of a lay ut: en the material gently: + open up to the smalfest tufts: = fore tufts of equal size: = process as many bales as possible in a single charges be universally applicable, ie. easy to program: blend material right at the start of the process: «permit the composition of a fiber blend from several components (fiber origins) eter Nae automatic bale opener rte Reena Seming Yoline2.Blewwoe Arti 27 1.4.2.2. The Rieter UNIfioc A 11 In concept, this is the most widely used type of machine today. Machines similar to the UNiftoc are built by other manufacturers too, e.g. Marzoli and Tritzschler (Blendomat). 1. Opening roller 2.Geid 3. Mot Safety sail Fig. 38 Tut extracting device ofthe UNIROe The Rieter UNifloc enables up to 130 bales arranged for up to four components (different bale types) pet blend over a maximum bale layout length of 47.2 m to bbe processed. The machine can process one blend or up to 4 blends simultaneously. The production rate is normally up to 1 400 kg/h Fig. 39 The opening device The feed duct (Fig. 40, 1) and the two tottom rails are secured to the floor. A chassis, which moves back and28 forth on the guide rails, carries a turret (2), which swiv- els through 180° and supports an extracting assembly (3) which can be raised and lowered. The latter has indi vidually replaceable double-teeth and changes its direc- tion of rotation on reversal ofthe direction of movement of the chassis, so that material can be extracted in both directions of travel Fig, 40 Uc, ston system forthe tts ‘A microprocessor is provided for fully automatic extrac tion of material from the bales. The production rate and the total weight of feed material can be entered manually on the numerical keyboard. On the basis of the automatically detected bale heights, the machine then calculates al data required for fully automatic operation, including the pen- etration depth for extraction. The bales are laid out to left and right of the machine and + bales can be processed from both sides simultaneously into one blend; + from both sides simultaneously into several blends: oF + from one side only. Inthe latter case, new bales can be prepared on one side and left to acclimatize, while other bales are processed on the other side. 1.4.2.3. Tritzschler Blendomat BOT 020 automatic bale opener This bale opener’s extraction method differs from that of ‘other openers. Whereas with normal openers a certain number of bales (the bale layout) are processed, and after that another bale layout is worked off, and then another, and so on, ie. charge by charge, extraction of material an he BD 020 takes place continuously. For that purpose material has to be extracted from the bales in an inclined position. This means that the moment a bale is exhausted completely it will be replaced by new ‘one, and the next exhausted bale by another new one. Feeding of the new bales is automatic. Bales ranging from the maximum height to the minimum height are there fore always to be found on the bale transport conveyer, as already mentioned, in an inctined line (Fig. 41). A reserve belt, on which a certain number of bales can be placed for acclimatization, is usually installed in front of the transport conveyer belt. The extraction of the material occurs in the same way as on other bale openers. The only difference is that the opening device has to have the same angle of incl nation as the bales fed toit (Fig. 42). The advantage ofthis opening method is very good long- term blending (continuous, not charge by charge). the dis- advantage a limited number of bales in the feed. Fig. 41 — Incline ine ofthe exhausted bale inthe feed Fig. A2— Inlined opening device af the bale opener14.2.8. Conventional bale openers ale openers, blending openers, blending bale open: +r, mixing openers, waste openers (or machines under such names) are manufactured by many compa: ies, Previously, these were the standard bale openers: ‘9 newer installations, however, they are found mainly as rnaste feeders or for opening and blending of man-made “bers, Laying of material on the feed apron (Fig. 43) is, erformed manually or via condenser from a bale opening machine. The feed apron (2) pushes the fiber mass toward ‘inclined lattice (4). In its rapid rotation, the latter car ‘clumps of material upward. If these clumps are suff- cently opened, they pass between the inclined lattice and ‘se evener rollers (atthe top). However, most clumps are large to pass through the space between the two units They are thrown back into the blending hopper by the cevener rollers, and from the hopper they pass once more into the operating region of the two assemblies (lattice and ollers). 4 Mig ehember 5 Uprighanice (aning and opening ut ach te they become smaller until finally they can pass ‘through to the next unit, Production rate and degree of ‘opening are determined by the speed of operation of the ‘clined lattice and its spacing from the evener roller. When processing wastes, which tend to form laps around the evener caller, this evener roller can be replaced by an veneer tatice. fe Tels Mamatt Song Yee? Mme 8g 29 Some auxiliary units, depending on the material to be processed and in coordination with the other blowroom ‘machines, can augment the basic units of the blending. opener. These auxiliary units can, for example, involve deposit: + onto a conveyor: + Into a suction duct; + into a weighing unit; + into an opening and cleaning unit (Fig. 44). Fig. A4~ Aeteaing unit behing he opener (2) 1.4.3. Machines for “coarse cleaning” (pre-cleaners) 13.1. Basics These machines are preceded by the opening machines (bale openers), which create a large quantity of tufts, i.e. large surface areas (at least, the high-performance bale openers). The opening machines themselves can- rot clean these surfaces because they are not fitted with cleaning devices, or, where such devices are pres- cent, they can eliminate only a fraction of the impurit owing to the high material throughput. But high-per- formance bale openers also require high-performance pre-cleaners in front of them with a high capacity for removing impurities from the surfaces presented. Old pre-cleaners are inefficient for this job. sie lenee UNleeve Fig. 45 ~ Cleaning capacity of igh pertrmance pre- addition to the other functions of blowroom machines, ne scutcher has to form a lap for supplying material to the cards. Previously, mast of these machines were double ‘scutchers: they had two beater positions and two pairs of perforated drums. Machines delivered in recent years have ‘een almost exclusively single scutchers: they have only beater position (Kirschner beater) and only one pair of forated drums or even a single drum. LAP WEIGHING. A lap-weighing device connected with the lap apparatus detects any deviation of lap weight from a set value. The result is registered on the output strip from a printer. Simultaneously, the deviation is indicated as a signal. When the deviation exceeds a preset value, the weighing device sends a pulse to a servomotor of a variable speed transmis- sion, which regulates the weight per unit length ofthe lap. 1.4.7.4, Rieter UNIstore A 78 feeding machine Stent input 5 Pevorted metal plate fr ar discharge 2 etenatescharge 6 Ught barter for monitoring material eight Doesingroler 7 Open exhaust ae transfer Tete Monel Spig aume 7 lamenting 37 ‘The UNIstore A78 is used asa storage, dedusting and feeder ‘machine in the blowroom, Its main purpose isto provide inter- mediate storage for material in order to ensure trouble-free blowroom operation. Long piping distances are frequently found to interfere with the smooth running ofthe processes and intermediate storage is necessary in many cases. The UNTIstore N78 is used where a mixing opener proves unsuitable for finan ial, technical or technological reasons. The integration of a imesh screen fiter inside the UNIstore A78 eliminates the trans- port air, and creates an efficient dedusting, The structure ofthe feeding and opening unit guarantees gentle fiber opening 1.4.8, Dust removal 1 Basics Removal ofthe finest particles of trash, contaminants and fiber fragments (dust) can be carried out by + releasing the dust into the ar, eg, by turing the material ‘over and over, and then removing the dust-contaminated ait: + separating the particles directly from the fibers through suction or scraping. Inthe latter case, care must be taken to ensure that fibers are not carried along: a fber-retaining device is required. Release of dust into the air occurs wherever the raw mate- fial is rolled, beaten or thrown about ‘Today, the air at such positions is therefore extracted by suc tion. However in these arrangements, itis not only the removal ‘of dust from the material which is important. Maintenance of a dust fre atmosphere in the workroom is of stil greater signif cance, since in many countries laws have already been passed to prescribe the maximum permissible quantities of dustin the ar. With the second method, however, environmental conditions inthe workroom are not of interest, only the elimination of the disturbing particles. Nevertheless, dust removal always arises as a side effect if material is transported by air. This happens at the end of the duct where, for example, the fibers are separated from the transport air. The following are used as direct and indirect means of dust removal: + perforated drums (a rapidly rotating perforated drum follow ing a carding roller can extract 50% of the dust in the stock); + non-rotating perforated surfaces (Rieter and Tritzschler): + circulating perforated belts: + stationary combs. ‘so, peutic transport in itself has an elec that should not be underestimated, since dusts always released during such trans- port. Inthe folowing section, a simple assembly ard one machine (Gor dedusting) are described as representative ofall others.18 Mees saat pong. Vlae2. Bmram 8 anig 1.4.8.2. Rieter dust extractor This equipment (Fig. 63) forms part ofthe pneumatic trans: port system. A chamber is included in the ducting and con tains a pipe which converges and has perforations. As the material passes from 1 to 2 a special fan draws air from 3 and thus also draws dust from the transport duct. Since the fiber tufts are vigorously “washed” by air currents in this ducting, good separation of the smallest dust particles, and finally their removal, is achieved. Fig. 63 ~ Dodusting witha the anspor dct 1.4.8.3. Tritzschler “DUSTEX” dedusting machine sche mati of he CLEANOMAT cles “tution ge ante the soe the wok with of 1.5 Sons arable desig elected ye sting te pvaated suace 1 seater ops te suo Syste ads tant othe cary 3 Tre sepatsted uss permanent ashore Fig. 64 Trateschler DUSTEX This machine consists mainly of a large chamber with a per forated sheet (3), the infeed ofthe material (1/2) and the withdrawal of the material at (4). In the chamber itself the material tufts are blown against the perforated sheet (3). Here they slide on the sheet down to the tip of the funnel (4) and pass to the suction after dust is extracted. 1.5. High-performance machines ought to be easy to handle 1.5.1. Demands The subjects dealt with in the previous chapters are the ‘main technological demands on a modern high-perfor- mance blowroom line, but another aspect is becoming ‘more and more important: easy handling of machines everywhere. In detall this means: + simple, time-saving adjustment; + flexible adjustments, i.e. adaptable to all requirements, + reproducible adjustments; + durable adjustments, i.e. no uncontrolled changing of settings by the machines. ‘Above all, reliability and operational safety are vital In this respect. A system of this kind will be explained by means of the Rieter VarioSet, a component of the UNIclean B 12 and UNIfiex B 60. 1.5.2. Rieter VarioSet en ; | & 4 | | oo —- Fstve amount of wae Ms Fig. 65 —Varaset cleaning fl All performance and treatment alterations on both machines mentioned can be made very easily and elec- tronically during the normal operation of the machin€ . from outside the machine without any stoppages. ©f ° a8 CD EF GH stig W vostepaties Fer 5 10 Rea quant waste (4) Fig. 66 Practical examples an their elect on waste composition ‘An easily understandable and clearly arranged display 's available at one side of the machine for this purpose. This display includes a special setting arrangement called ‘VarioSet (Fig. 65). It enables operating personnel to adjust the degree of cleaning and the cleaning efficiency (to a certain extent the unavoidable loss of fibers) exactly 0 the raw material and the requirements of the mill. All at is needed is to push a few buttons an the operating dare! at the side of the machine. Various setting positions can be fixed on the screen, e.g, fr the degree of cleaning ‘fom 1 10 10 (marked here in the example from A to 2), and for cleaning efficiency from 0.0 to 1.0 (marked here. from Ato X), VarioSet, Changes in the extraction of trash and good fibers when changing the settings from A to X, Z till H. Netter dal a Snag Yoline 2 orn Ring 39 Example: Indian cotton: 1 1/8 inch, 2.2% trash Fromite Setting ASX AGE AoW Waste amount 062 090 06108 Tash 1 9 8ST Good ives{anoun] 007 «02208055 Good bes] 10 use Ratoof vashiibers 1 aera The example from the UNlclean B 12 clearly shows that 4 change in the horizontal direction (A to Z, opening of the eid) results ima far higher loss of fibers than the change in the vertical direction (A to X, increasing roller revolutions). [the display itis possible to choose any point of opera tion adjustment within the complete cleaning field (the square A/XIZ/M): see Fig. 65. 1.6. Transport of material 16.1. The need for transport Blowroom installations consist ofa combination of anum- ber of individual machines arranged in sequence In pro cessing, the material must be forwarded from one machine tothe next. Previously, this was performed manually but ‘ow itis done mechanically or pneumatically 2. using airasa transport medium. Mechanical transports limited exclusively to forwarding within the machine: outside the ‘machine, material is now transported only pneumatically 1.6.2. Mechanical transport equipment This comprises conveyor belts, latices and spiked lattices. Conveyor belts permit high speeds. Fig. 67 ~ Georg Kainzer tice0 nog ne? Boweam A Cating They ate used as collector belts in mixing batteries of asin: feed or horizontal conveyors in openers and hopper feeders, They have the disadvantage that sometimes the material sips on them, 68 Habast conveyor belt The forwarding effect is often better on latices (Fig. 67). They are used as horizontal feed lattices and as short trans Port belts within a machine. They are endless and consist of Circulating bets to which closely spaced, individual hard ‘wood crossbars are screwed or riveted. Today's conveyor bets (Fig. 68) no longer use crossbars. The belts consist of different layers with afiber-free surface, The belts are driven by shafts that simultaneously serve for belt tensioning. The forwarding speed is usually very low. Inclined tattices or spiked lattices (Fig. 13) are the same in ms of structure and drive. However, steel spikes are set at an angle in the crossbars, so that the raw material can be transported upward. Inclined lattices are operated at speeds ‘up to 100 m/min. They usually interact with evener rollers, and thus function mainly as opening devices. 1.6.3. Pneumatic transport 1.6.3.1. Basic principle ‘iris not inherently a very efficient transport medium. Very large quantities must be moved at high speeds in order to keep the tufts that are being transported floating. The cur- ‘ent of air itself is a further disadvantage, since the air flows in a turbulent fashion through the ducting, ie. vor texes are created. Since the tufts are subjected to these vortexes, entangling of tufts can arise in long ducts and finally neps can be formed. A closed duct (generally a pipe) and a source of partial vacuum (a fan) at one end of the: {uct are needed to move the air. The air speed should be at least 10 m/sec, and 12 - 15 m/sec is better; it should never ‘exceed 20- 24 m/sec. Ata given air speed, the required ‘quantity of air can be calculated as: L (mis) Fig. 69 Separation of at and material 1.7. Control of material flow 1.7.1. Classification Since, 2s already discussed, the blowroor ie 82 of individual machines, each machine must a5 ‘exact quantity of material per unit of time from the PR Jing machine, and must pass onthe same quertty PS time tothe next To ensure an adequate fow of machines are adapted to eachother so tat ea¢ produce alittle more than the succeeding machine Sree exh mane ses pay 0 be provided to ensure the correct delivery aU principles ae used: batch operation an continvm dj Iino hopper feeder, for example, the convey places material into the hopper until sensi td 50 far tothe right that a contact is made to sitFp 70 - Regulated eed of material inthe hopper feeder of conveyor bet (1). In exactly the same way, during filing of the reserve hopper (R), the pressure exerted by the column of ‘material eventually becomes so great that sensing lever (b) is ‘pressed: this causes the preceding machine to be switched off, When the column of material has again been largely removed by conveyor (1), the sensing lever rises, the preceding ‘rachine is switched on and the reserve chute i refiled. Unfortunately, in practice the individual machines actually pro- ‘duce during a period that is often only 50% of operating time {and are unproductive during the remainder ofthe operating Thee Manali, one 2 Aemoem &Carsing 4] time. On the other hand, in continuous operation created by changing the speeds of the machines, the machies' production Fates are much more closely adapted to each other. They oper ate almost continuously and without stops. A fine contral device serves to maintain material throughput by adjusting the pro- Auction speeds ofthe individual machines. Batch operation has the advantage that the machines always run atthe same speed and with the same production rate when they are in operation The treatment ofthe material remains uniform all he time. That means that the raw material is always processed under the same conditions, since there ae only two treatment levels full (n or off. In continuous operation, however, there are continual slowdowns and accelerations, with possibly varying intensities of treatment ofthe raw material. Data provided by Tritzschler indicate that there ae no negative effects, provided variations in production rates do not exceed + 20%, The disadvantage of ‘batch operation lies inthe incorrect handling ofthe material throughput. As machines often do not operate during 50% of the time, in their productive periods they are not working at, 8. 300 kg/h as calculated by the spinner; instead they are actually processing material ata rate of 600 kg/h. The loading ‘of the machine is high, and that might lead to a correspondingly poor cleaning effect. In the mill, therefore ~ and this is very important - an attempt should be made to regulate the instal- lation so that the productive time of the individual machines is very high, and only few non-productve periods occur 1.7.2. Optical regulating systems in batch operation (Example: Marzoli horizontal cleaner) i Maintenance ae variable speed motor 3 Contes inciudigadustment for base rotation sped and age vale Twusener onnFeED82 Wetter Steg, Yee? amo aig Four optical monitoring devices (Fig. 72) ate mounted in the filing chute, conveyor belt and mixing chamber of the machine. Fi. 72 ~ Optica regulation I the columo of material falls below light barrier (2), the receding machine is switched on and delivers material. ‘When the chute has been filled to such an extent that the Inaterial interrupts the light beam in light barrier (1), the ‘machine is switched off again. Light barrier (1) is also 20 over fil safety monitor, Light barier (3) monitors the amount of material inthe mixing chamber and controls the rive to conveyor belt (6) and the feed roller of the chute Light barrier (4) will trigger an alarm if there is no material left on feed conveyor (5) 1.7.3. Continuous operation 8.75 -Utcoemand conta system A concept, this ot ew inthe woo thas eed tse for along tine nthe seth peal regulon the feed tothe beater Whats ew stat nome a biowroom tne operates continuous and epaton performed electoncaly. This instalation developed oy Tetescher. willbe presented bret esi Te central regulating unt to whichall thea machines ar connected ithe CONTIFEED™ Ti oe 2 analog signal om the acho genertors ol the eee the instantaneous demand format‘ isconinoset calculated from this signal. Using this demand, the micoe Computer can establish the base speads ofall dren determine the throughput and the drives eo be Spondingy controled. second signals superna on this bask speed signa, derwed fom themed the storage nif the succeeding machine Init the succesive machines ar inked via individual se loops The programs for speeds, rotction quanti, allocation ae fst established manual ahchremecit 2 Foy substantial tial outay. When balanced pares is achieved, they canbe transfered tothe “CONTIbceor and stored there 1.7.4, Rieter UNIcommand Asalready mentioned, the blawroom ln is a sequence o sa ral machines In thei operation these chines have o be ‘ery wel coordinated, requiring a good, liable system fort ‘monitoring and controling the individual machines, goupschmachines and the total blowroom line. UNIcommand works on an electronic basis, and is a combination of PLCs (program ‘rable logic) and PCs with a central control unit somewhere near the blowroom line, plus an additional PC in the supervi or's office as an option, No computer or software knowledge ‘required to handle the system. As everywhere, Rieter stand: erdized panels are used. A language independent color graphic ‘representation and touch-sensitive monitors are chosen for the ‘splay. The main functional and operational requirements are: + switching on/off; + display of operational status ofall system components; simple switch-over of the process sequence, e.g from ‘one: to two: or three-blend operation; sutomatic shift switch referring to the shift schedule; + alarm indication of malfunction; + machine remote control for adjusting and changing the opersting mode The user interface is exactly the same as on the machine itself 1.8. Damage prevention and fire protection 1.8.1. Metal detection 1.8.1.1. Magnetic metal extractors F014 Magnet extactr(Marzob) Magnets have been used for decades in ducting or in spe- al parts of machines in order to eliminate pieces of ferrous ‘material. The most effective form of device is a knee-bend within the feed duct having permanent magnets atthe two impact surfaces. When tufts are driven against the magnets, ferrous particles are retained and can be removed from time ‘atime. Magnetic extractors provide only a partial solu ‘on fo the problem because they can eliminate only mag. Retizable metal particles, and let all others pass. Electronic "utractors are needed to remove the other particles, too Teeter Mant Spang Yoon? een 8 ring 43 1.8.1.2. Electronic metal extractors The material is fed from an opening machine such as Blendomat (Fig. 75, 1). The next device, normally ofan in front of the mixing machine, extracts the material by suction (5). Spark sensor (2) detects smoldering material and metal detector (3) any kind of metal. In either case, active oper- ating flap (4) is opened by a signal from the detector and feeds the material into the receiving waste container, which ‘is equipped with a fre extinguisher device (7) and a temper ature sensor (8) to monitor the container (Fig. 75), fg. 75 ~Electonic metal extractor (esc) 1.8.1.3. ComboShield (Rieter) This comprises a spark detector, a metal extractor and an elim: ‘nating device, and is built into the transport duct (Fig, 76) The spark detector pivots the rapidly operating flap as soon as the latter detects sparks or burning material. The material passes into a receiving container, which preferably stands out side the room. Simultaneously, an alarm is given and the blow: ‘oom line as well asthe filter installation js switched off. Te pivoting flap remains in the eliminating condition until the \ine is switched on again. This device has a second function, the detection of metallic material. If such a piece of material 's detected, the same rapidly operating lap is pivoted and the foreign material is ejected into a container. After an adjustable time the flap moves back into its normal position. n contrast to,detected sparks. the blowroom line remains switched onSe opener Canesten 76 Comboshild (Rieter) 1.9. Waste management 1.9.1. Economy of raw material utilization ‘Raw material costs make up more than half the yarn costs. tis unlikely that much can be done about this, since rising ‘raw material prices are to be expected in future. Increasingly, therefore, spinners willbe forced to improve exploitation of the ‘aw material. Without doubt, one possibilty ies in recovery of fibers from waste: after al, on average about 50% of blowroom {and carding droppings consist of good fibers. Their recovery 's not especially dificult and the saving in raw material costs 's significant, as illustrated by the following very approximate, ‘and not very exact calculation fr a small spinning mill: vanity of am material processed per year 10000 Total meste om blowroom and carding room 800 Rocoverable waste 3001 Pace ofthe rw materia (at) perks (US$) 132 ‘Sowing on cam material per yer (USS) 475000 ‘An additional advantage of such recycling installations is. that @ somewhat higher degree of cleaning can be used in the blowroom machines, since with recovery of waste fibers the {evel oftheir elimination in blowroom and cards becomes, selatively insignificant. Wixog mackie Fi. 77 - Material fow diagram foram material and waste 4s .2. Quantity of waste material il In spite ofthe emphasis on the proportion of waste in tha: diagram, itis clear that the quantities to be expected herd ate relatively small. On average, about 6 8% primary waste, consisting of 50% good bers and 50% contami gf nants, can be expected. About 90% of the good fiber elimi: nation can be recovered as secondary raw material, = still contains about 6% trash. Such secondary raw mate rial can be mixed into the same blend up to a proportion. of 2.5% without any effect on quality. Up to 5% can be blended with hardly noticeable changes in quality. . As far as possible, no more than 5% should be returned the blend (For ring spinning).REELS TFs 5 Netra ipmg, Yn temaee Catag 45 #4 78 Integrated seycing plot by Rieter 1.9.3. Classification of spinning mill waste 1.9.4.2. Recycling of dirty waste ‘spinning mill produces the following waste, some in significant quantities: ows Ctg tion practon 50h + directiy reusable waste; + dirty waste; and + dust and fy Waste material falling into the fist group can be collected ‘without difficulty and can be fed back into the blowroom line in always the same admixing quantities. The other two groups cannot be dealt with so easly, since handling of these waste materials unpleasant for mill personnel, Accordingly. Foden mils, waste material is now removed pneumatically Alri used exclusively ast he collecting and transport medium, 1.9.8. Recycling of waste 1.9.8.1 Recycling instalation for reusable waste AS mentioned abave, a considerable amount of waste can be Cogan the same mil by feeding it through a bale opener {ast opener) into the normal Bowroom lin. Beyond et e212 sPinning itis common to spin useful yarns from Fein oY ading waste tothe normal raw materia, Since mount of waste is larger, the admixing fees performed bya single waste opener, a complete | waste suction asco its ee instalation as shown i the ilustation (Fig, 79) 'Y waste first has to pass through a special lant before a portion af it (about 30 - 40% ” be reused Waste recycling 0d fibers) can 79 Rieter recycling installation46 Tete Maal oSpmaey ome 2. omoem Cain The various processes inthe blowroom create various waste "materials which cannot be reused for textile purposes, such as: + coarse dirt remaining after recycling: + fly rom the preliminary filters; + dust from the fine filters. Dirty waste consists of a large amount of impurities and « smaller amount of fibers. The latter can be recycled in dif- ferent recycling plants, {In Rieter installations, for example (see Fig. 79), waste from all blowroom machines and cards is sucked directly through the UNIclean B 12 cleaner of the recycling equipment (1) to a mixing bale opener (2). The mixing bale opener continu: ously feeds the cleaned material back into the blowroom line (3). If dirty waste is involved, an additional UNiIfex 8 60 cleaner should be inserted between the mixing bale ‘opener (2) and the point of feed into the blowroom line. This installation can also be operated in off-line mode if the %_arsaly SS, Damper a 508 Fires Stands Legend Rotary Pre Filter SZ __Firedetection& Spark Discharge Unit Dustea lector Rotary Air Filter 8 Material Handling Fan a ‘Shut off damper Radial Flow Fan SS) wasteseparator Balepress 80 Reeycing system secondary raw material is not re-blended immediately but pressed into bales in abale press (4). 1.9.4.3. Recycling plant for al types of waste ‘Almost all manufacturers of blowroom machines, and severa ‘others, now offer recycling installations. That of Rieter in com junction with LUWA (Fig. 80) willbe described here as ep- resentative of all the others. Primary waste is pneumatically fed via condensers into the B 34 mixing opener, pre-cleaned inthe UNclean B 12, dedusted in the A21 condenser and cleaned further inthe BS1R fine cleaner. The transport aris always separated from material and fed tothe pre-ilter. The yield of good ivers is ed into the bale press, Secondary waste from the recycling machines and pre-fitris fed into the bale press for black waste. Since the same types of ‘machines are used in this recycling installation asin the blowroom, handling is easy forthe operators. ‘manually Damper =X ;1.9.4.8. On-line recycting plant for the entire "sted equipment can be designed for continuous (or-tine) batch (of ine) operation. Continuous operation implies that secondary raw materials blended withthe primary raw mate. ‘ai again in the same quantity, and that this takes plac per manentiy and immediately ater recovery. For this purpose, the claiming installation can deliver to a bale opener (e.g. waste ‘perer), or the material can be blown directly into the duet ingot the blowroom line. Here, the reclaiming installation isan integra gato the blowraom. On the atherhand, batch opera "on implies thatthe secondary raw material sist pressed "to ales following recovery. and is then fed tothe blowroom inthe same may as ather bales, In this system, all waste cham ets othe blowroom machines, cards and combing machines ore connected by suction ducts to central suction equipment Sela deserted ere bi byway ofan eal a ») Maco 870 P Webco Bo | | HEA coo | 200 ! oi. a Beets anagem fre depsal a iy wate 2000 2000 ‘0000 ‘occ @aoaaa +The mt pm. Yin? mn 8 aig {hat leads to pneumatic bale presses (r sls) In order to keep the various types of waste comber waste, licker in droppings, et.) separate from each other, a bale pressis required foreach Specific type. Such presses are availabe fom Autefa,Bisinger, tc I only one bale press is available, an individual silo must be provided fr each type of waste. About three bale presses {or tos) shouldbe suficent fora normal cotton sping mil Waste chambers (one or more at atime) are selected intermit. tently and cyclically for suction, and the contents are blown into the presses, e.g. fist from all blowroom machines, After ‘automatic changeover tothe second press, suction draw-off, for ‘example ofthe lat strippings. is carried out Ifthe installation ‘does not operate intermittently, then an extra ducts needed for each waste group. Both systems are used in practice 9.5. Handling dust and fly ‘5.1. The problem of dust and fly a “1 tontames(combigoom (pat station wth sos (1-3) sad bale Presses, disposal instalation wt eizontal al presses, a“6 Dust is released at each machine, often in great quantities, ‘owing to turning-over, plucking apart, et. ofthe materia. In processing it is important to ensure that this dust cannot bind with the fibers again and also that it cannot settle in the atmosphere. Today, almost all machines up tothe drawframe are enclosed as far as possible and connected to dust extrac tion lines. Released dust passes immediately into this suction system, in which it must be separated from the ar and carried away. 19. - Dust filtering Usually two filter stages are used because a great deal of fy 's carried along in the removal af dust by suction. The stages are preliminary filtering and fine filtering. These operations «can be performed with individual fiters or a centrat iter. Hi 4 no aaemre Fig. 82 ~ Principe diagram of tration |i new installations in new buildings a central filter (part of the airconditioning plant) will probably be chosen; individ al filters may have to be used in older premises for reasons of space availability and room height. The dust-laden air flows against a slowly rotating fiter drum (Fig. 83, 1). ‘layer of dust and fly forms, is removed by rollers and falls into a carriage located beneath the drum. Before the air returns into the room, i is passed through the fine filter in the form of a filter drum (Fig. 83,2). 1.9.5.3. Central filter installations Complete disposal of fy, dust and waste requires high air circu lation with corresponding energy consumption, Simultaneously, a second system with high circulation is required, namely the air-conditioning installation. OF course it is possible to install 4 self-contained, independently operating wast disposal sys tem with its own air circulating arrangements, and additionally «second system -the air-conditioning installation - with simi- {arly high air circulation. But itis more rational and economi Calin energy terms to combine these two systems into an inte Brated unit and to use the air circulation required for the waste disposal system as part ofthe air circulation in the air-condi- Lioning installation. The waste disposal installation should then be incorporated into the air-conditioning system, Fig. 84 Panel prefer (LUWA) Fig. 85~ Rotary fine filter (UWA)cE 1.9.6. Final disposal of waste Dirty waste materials are preferably collected, baled, packed are removed so that manual handling is excluded as far as, possible. There are several possibilities for baling and packing: ling ewsity (g/m er eassope tough a condenser, ejector 100 0 Sock via oer separators 60-40 ster ale presses 80-120 ow duty ale gesses 200-250 135 no cakes o briquettes by 600-1200 ‘When waste is pressed into containers, or formed into bales or briquettes, handling and transport are simple. {n this form, mainly as briquettes, waste can be composted F burned. The heating value is approximately 4 kWh] kg (for comparison, the value for heating oli just over 12 kWh/kg) ete isleSpeig. eles Bean NCrng 49, Functional description of the Bale Press System (BPS, Fig. 86): ~ The textile waste (material) is usually pneumatically con- veyed (1) (and separated according to quality) directly from the production plant to the ber separators The fiber or wast separators are used as standard sepa ‘ators. Is essential thatthe dusty conveying cr inthe fiber separators discharged into a filtering installation. + The waste i discharged from the fiber separator (2) into the material silo (3). + The discharge unit (4) moves the waste from the mate Fal silo tothe intemal material conveying system (8) + The material can then be fed tothe bale press (11) by means of waste separator WS (9). + Subsequent pressing ofthe material is performed in the bale press (12). 1 Matera con 2 Fiber 5. Discharge cone 6. Shut of damper nS 4 Dienage ani 8. Conveying line 5086 -Eramoe Bale Pes System wh peumatic mae conveying 7 Scavenging at shut of dumper 9. Waste separator WS 10. Transport fan 11, Bale press feeding hopper 12. Bale press