Lap former

The objective of lap former:

1. Produce a thin sheet of fiber that is suitable for combing.

2. Reducing fiber damage.
3. Reducing (chance of good fiber) waste.
4. Reducing thick and thin places in sliver.
5. Making the fiber more parallel.
6. Reducing strain on combing cylinder
7. Sliver is not suitable for combing so a sheet of a lap is prepared.

Why Lap Former is Needed?

Yarns which are made up of a longer length of fibers, tend to show fewer
irregularities in subsequent processes. Those yarns are superior in quality and carry a
lower percentage of hairiness as well. A comber machine provides us with such uniform
and regular slivers that are free from a predetermined length of short fibers. So,
basically for manufacturing such types of greater quality yarn, the use of a comber
machine is a must in our spinning line.

But before we start to manufacture these uniform slivers in comber which

ultimately lead us to craft extra-ordinary yarn, we need to produce several uniform
laps as well. To produce those laps, there the lap formers come into action.

Requirements of lap feed instead of sliver feed

1. For better nipping

2. For parallelizing the fiber
3. Even no of passage used between card – comber.

For better nipping

➢ Combers are fed with a small lap produced by combining several slivers.
➢ Raw material delivered by the card is unsuitable for combing as regards both
form and fiber arrangement.
➢ If card slivers were just combined and fed to the comber, true nipping by the
nipper plates would occur only on the high points, with the risk that the nippers
could not retain the less firmly compressed edge zones of the slivers. This is
because the slivers are not flattened.
➢ The fibers could then be pulled out as clumps by the circular cobs during
combing.
➢ A sheet with the greatest possible degree of evenness in cross-section, with
uniform thickness, is required as in-feed to comber.

Boogeyman 1
For parallelizing the fiber

➢ Good parallel disposition of the fibers within the sheet, along the length of the
lap sheet is a further prerequisite.
➢ If the fibers lie across the strand even long fibers (b) are presented to the circular
combs as if they were short fibers and get eliminated as noil.
➢ Even though the fiber ‘b’ is longer than “a” its extent along the material passage
is the same as that of a.
➢ Hence it is also treated like fiber ‘a’.
➢ This means a long fiber is unnecessarily lost as noil.
➢ Appropriate preparatory machines are needed to prepare the material so that
it meets requirements.

Even no of passage required between card – comber

➢ Even a number of passages are required between card and comber to feed
trailing hooked fiber as the leading hook to the comber.

Boogeyman 2
 ➢ If the comber is to straighten with leading hooks, as it intended to, then the
fibers must be presented to it with leading hooks.
➢ The carded slivers have trailing hooks as the majority of hooks ( more than 50%)
as the sliver emerges out of the Callender rollers in the carding machine.
➢ Each time the sliver is packed in a can and taken out, the majority of hooks
change.
➢ Having even no of processes in between card and comber will ensure that the
majority hooks as they are presented to combing are leading hooks.

Machine used for lap former

1. Conventional system
a. Sliver lap machine
b. Ribbon lap machine
2. Modern system
a. Super lap machine

Sliver Lap Former:

The object of this machine is to produce a narrow lap from several carded slivers. The
machine is made to make a lap from 18 to 24 slivers depending upon the width and
weight per unit length of the lap required.

1. Each sliver passes through a hole in the guide plate placed at the back of the
machine.
2. Then they are passed over a special spoon and guided over a table which brings
them together in the order in which they lie on the lap.
3. The slivers are then passed through 3 or 4 pairs of drafting rollers.
4. Due to the draft in the drafting zone, the fiber becomes straight and individual.
5. The lap sheet passes over two pairs of calendar rollers which compress it into a
sheet and wound on a spool with the help of two fluted lap rollers.
6. Considerable pressure is applied to the spool in which the lap is wound so that
a long length of compressed lap can be obtained.

Boogeyman 3
Ribbon Lap Machine:

The object of this machine is to double the lap which is produced in a sliver lap
machine. The machine is made to make a lap from 6 to 8 sliver laps depending upon
the width and weight per unit length of the lap required.

1. The lap from the sliver lap machine creeled here and unwind the lap Two fluted
rollers are provided to unwind the lap.
2. Then the laps are guided over a table which brings them together in the order
in which they lie on the lap.
3. The laps are then passed through 3 or 4 pairs of drafting rollers.
4. The lap sheet passes over two pairs of calender rollers which compress it into a
sheet.
5. Then the lap is rolled in a spool Two fluted rollers are responsible to obtain a
compact lap.

Machine Sequence:

Boogeyman 4
Features of modern lap former

1. 16-32 slivers can feed

2. Automatic weight per unit length adjuster
3. Auto Doffing for full laps
4. Automatic Stop Motion for –
a. Full/ Partial Doffing
b. Sliver Breakage
c. Roller Lapping
5. Automatic lap carrying device
6. Lap length measuring unit
7. Indicating lights for different fault locations
8. 2 over 3 and 3 over 3 drafting system
9. high production up to 520kg/hr
10. belt driven drafting system

Comber lap specification

1. Lap dia = 650 mm

2. Lap width = 300mm
3. Lap wt = 18 -20 kg
4. Lap hank = 0.0075 -0.009 Ne
5. Lap wt/yd = 700 -1200 grain

Modern Lap Former passage diagram

Boogeyman 5
UNIlap always follows a normal draw frame. On the UNIlap machine, the material flow
starts with the creel consisting of two feed rails. In normal operation, 12 cans are laid
out under each roller-assisted feed table. All together this gives a total of 24 doublings.
The pre-draw frame slivers run over a guide bridge above the service alley and also
over several guide rollers to the drafting system. The web created by the draft passes
over two deflecting plates onto the web table on which the webs are superimposed.
Calendar rollers draw these superimposed webs from the table to the lap winding
assembly. The strong compression created between calender rollers forms a new web,
which is rolled into a lap in the lap forming assembly. Empty tubes are automatically
exchanged for full laps. Transport of the lap to the combing machine is semi-automatic
or fully automatic.

Lap winding principle

1. After passing the web table, the web runs through 4 calender rollers.
2. The pressure generated by two membrane cylinders can be adjusted up to
16000N.
3. The calender rollers are followed by two winding rollers and a lap tube holding
device with a lap weighting device; these have to cooperate to form the lap.
4. The required weighting pressure (up to 10000 N), derived from a piston, is
transferred via a pivoting lever to the weighting frame and thus to the lap tube.
5. The UNIlap has an automatic lap pressure control that adapts the pressure
according to the lap diameter.
6. An increase in diameter of the lap raises the weighting frame, in the course of
which the pressure increases.
7. The size of the increase can be set by adjustment by using setting screws.
8. The machine stops when a preset lap length is reached, whereupon an
automatic device replaces the full lap with an empty tube.

The latest technology of lap former

1. Since the production speeds using the winding system based on calendar rollers
have reached their limit due to the system itself, Rieter developed a new lap
winding system.
2. In the new lap winding, the system makes use of unique belt tension and
pressure arrangement.
3. The winding belt with a width similar to that of the laps surrounds the lap to
form a circumferential pressure area ranging from 1800 to 2700 from start to full
lap.
4. Fiber guidance and pressure distribution applied by the OMEGA principle allow
constant production at speed up to 180m/min over the entire lap build-up.

Boogeyman 6
Math formula
feed count
Draft = delivery count
× doubling (direct count)

delivery count
= feed count
× doubling (Indirect count)
feed weight
Doffing time = lap production

Production = delivery speed × lap count × time ×efficincy × waste

1. 70 gr/yd drawing sliver is fed in lap former to form a suitable package for
comber, with draft and doubling of 2.5 and 24 respectively. Calculate the
count of the lap?

Given that,

Feed count = 70 grain/yd

Drart = 2.5

Doubling = 24
feed count
We know, Draft = delivery count
× doubling

70
2.5 = 𝑙𝑎𝑝 𝑐𝑜𝑢𝑛𝑡 × 24

lap count = 672 grain/yd.

2. If delivery speed is 90 m/min and lap count is 1000 grain/yd. Find out doffing
time and batt (doffing length) to produce a 20 kg lap?

Given that,
90
Delivery speed = 90 m/min =.9144 yd/min
1000
Lap count= 1000 grain/yd = lb/yd
7000

Lap weight= 20 kg

Production = delivery speed × lap count × time

90 1000
= .9144 × 7000 ×2.2046 × 1 kg/min

= 6.377 kg/hr
feed weight
Doffing time = lap production

20
= 6.377 min

= 3.135 min
90
Doffing length = delivery speed × doffing time = .9144 × 3.135 = 308.562 yd

Boogeyman 7
 3. Find out the production of lap former machine in kg/day=? When delivery
speed 80 m/min, feed sliver count = 0.12 Ne, draft = 2.5, doubling = 24
efficiency = 93% and waste 1%.

Given that,
80
delivery speed = 80 m/min = 0.9144 yd/min

Efficiency = 93% =0.93

Draft = 2.5

Doubling = 24

Waste = 1 %

Feed sliver count = 0.12 Ne

feed sliver count 𝑑𝑟𝑎𝑓𝑡 .12 2.5
Lap count = doubling
× (100−𝑤𝑎𝑠𝑡𝑒) % = 24
× .99= 0.0126

Production of lap former = delivery speed × lap count × efficiency × time

80 1
= 0.9144
× 0.0126 ×840 × 2.2046
× 0.93 × 60 × 24 kg/day

= 5021.34 kg/day.

4. Calculate production of a lap former/shift having following parameters: Feed

sliver hank= 0.12 Ne, no of doubling = 24 Draft = 1.25, delivery speed = 90
m/min and Efficiency = 85%.

Given that,
90
delivery speed = 90 m/min = 0.9144 yd/min

Efficiency = 85% =0.85

Draft = .15

Doubling = 24

Waste = 1 %
feed sliver count 𝑑𝑟𝑎𝑓𝑡 .12 2.5
Lap count = doubling
× (100−𝑤𝑎𝑠𝑡𝑒) % = 24
× .99= 0.0126

Production of lap former = delivery speed × lap count × efficiency × time

80 1
= 0.9144
× 0.0126 ×840 × 2.2046
× 0.85 × 60 × 8 kg/shift

= 1673.77 kg/shift

Boogeyman 8
 5. Find the no. of lap former required to keep running 10,000 kg per day of
combed sliver, which extracts 16% of comber noil. (Assume all necessary
parameters). (L-3 T-1,2014)

Comber production = 10000 kg/day = 10000 × 2.2046 lb/day = 22046 lb/day

Waste = 16%
40
Assume that, delivery speed = 40 m/min = 0.9144 yd/min

Efficiency = 90% =0.90

1200
Delivery lap weight = 1200 grain/ yd = lb/yd
7000

Now, input lap wt of comber m/c = comber production + noil of comber produced
16
= 22046 +22046 × 100 lb/day

= 25573.36 lb/day

Production of lap former = delivery speed × lap count × efficiency × time

40 1200
= 0.9144 × 7000 × .90 × 60 × 24 lb/day

= 9718.79 lb/day
25573.36
No of machine required = = 2.63 = 3
9718.79

6. Calculate production of a lap former in kg/ 3rd shift having following

parameters:lap weight=1100grain/yd, , delivery speed = 110 m/min,
Efficiency = 85% and drawn sliver count =.01 Ne. (L-2 T-2 2017)

Given that,
110
Delivery speed = 110 m/min = yd/min
.9144
1100
Lap count= 1100 grain/yd = 7000 lb/yd

Efficiency = 85% =.85

Production = delivery speed × lap count × time × efficiency

110 1100
= .9144 × 7000 ×2.2046 × 60 × 8 ×0.85 kg/3rd shift

= 3498.496 kg/3rd shift

Boogeyman 9
 Comber
Combing is the process that removes the final proportion of short fibers, neps,
and other impurities such as vegetable matter and seed coat fragments in cotton that
has already been carded. Combed yarns are superior in quality when compared to
carded yarn as they are generally finer, stronger, smoother, and more uniform due to
the removal of short fibers and the alignment of fibers.

The task of the Combing Process :

1. To remove the pre-determined length of short fiber (noil%)

2. To remove neps
3. To remove remaining impurities
4. To straighten hook fiber
5. Produce combed sliver so that spinners enable to produce finer yarn

Why Combing is Essential to Produce Fine Yarn

1. For finer count, a high draft is required but short fiber creates draft irregularity.
After combing short fiber is removed for a higher draft for the next step.
2. Longer fibers are finer than short fibers. After combing higher count is possible
to keep a minimum no. of fiber in yarn dia.
3. Long fiber yarn has less hairiness but more luster.
4. Combing is necessary for better yarn appearance and regularity.

Effect of combing on yarn and fabric quality

1. Improve the spinning value of fiber

2. Better twist distribution improves the strength of the yarn
3. Improve uniformity, smoothness, and luster of yarn
4. Reduce yarn hairiness and imperfection
5. Produce short trash free clear yarn
6. Improve efficiency in the next process
7. Improve yarn regularity & strength

Boogeyman 10
Types of Comber Machine

Many different types of combers are used for different fiber materials, combers can be
classified into the following types:

1. Rectilinear Combers (used for cotton)

2. Circular Combers (used for worsted)
3. Rotary Combers (used for spun silk)
4. Hackling Machines (used for bast fibers)

Mechanism of Comber:

The lap rests on two supports that unroll slowly. On its way into the nipper, the
web passes over an eccentric shaft which is known as a diverter. Forward movement
of the web into nipper done by feed roller (carried out in small steps (5mm)). Then the
feed material passes through the nipper. Here top and the bottom nipper are used to
nip the lap. A circular comb combs the short fiber and carries it away. The top comb
makes the fiber parallel and then the material pass through detaching roller. Cloth
clearer is used here to clean the lap. Then it passes through the condenser and
calender roller and enters the drafting zone. Drafted material then carried away by belt
into the trumpet/condenser. Finally deposited into the can by passing through the
coiler calender roller and coiler head.

Boogeyman 11
The basic principle of the combing/ combing cycle:

1. Lap feeding by feed roller: The feed roller moves the sheet/Lap (4 to 6.5)
forward while the top and bottom nipper are held open (feed).

2. Lap nipping by nipper: The top nipper is lowered onto the bottom nipper. So
that the fibers are clamped between them (nipper).

3. Combing by cylinder: The combing segment mountain on a rotating cylinder

swaps its needle or shows teeth through the fiber & carries away anything not
held by the nipper.

Boogeyman 12
4. Nipper opening & forwarding: The nipper opens again and moves towards
the detaching rollers.

5. Detaching roller backward movement: Meanwhile, the detaching roller has

to return part of the previously drawn-off slack by moves of a reverse rotation.
So that the web produces as from the back of the detaching rollers.

6. Piccing of the web: In the course of the forward movement of the nipper the
projecting fiber is placed upon the returned web.

Boogeyman 13
7. Combing by top comb: Before the short of the detaching operation, the top
comb (H) has thrust its single raw needle into the fiber. As the fibers are pulled
through the needle of the top comb (H) during detaching, the tailing part of
the top is combed. Thus making up for the inability of the cylinder combs to
reach this part of the fiber & thus performing combing.

8. Detaching roller forward movement: The detaching roller is to rotate in the

forward direction again and draw the clamped fiber out of the sheet held first
by the feed rollers.

9. Preparation for next combing cycle: As the nipper assembly is retracted, the
nippers up for the next feeding step the top comb is withdrawn. As new
combing cycle beings.

Boogeyman 14
Parameters influencing the combing operation

The main parameters influencing combing are

1. Raw material
• Fiber type
• Fiber fineness
• Fiber length
• Uniformity of fiber (CV)
• Fiber stiffness
• Moisture content
• Foreign material is associated with fibers.
2. Material preparation
• Parallelization of the fibers in the sheet
• Batt thickness
• Batt evenness
• Orientation of hooks
3. Factors associated with the machine
• Condition of the machine
• Condition of the combs
• Speeds
• Operational performance of the comb
• Type of sliver forming elements
• Accuracy of setting
• Drafting arrangement
• Movements of the elements
• Weights of the elements
• Type of withdrawal of the combed web
4. Machine settings
• Feed distance
• Type of feed
• Detachment settings
• Point density of the combs
• Circular comb clothing
• Depth of penetration of the top comb
• Piecing
• Draft
• Drafting arrangement settings
5. Ambient conditions
• Room temperature
• Relative humidity in the room.

Boogeyman 15
Influence of the feedstock on combing

1. Parallelization of the fibers in the batt

2. Batt/lap thickness (weight)
3. Evenness of batt/lap sheet
4. The disposition of the hooks

Noil extraction theory:

The noil theory was developed by Charles Gegauff. The noil theory is the effects
of detachment setting and feed distance moved per cycle on the elimination of noil. It
shows the correlation between feed amount and noil percentage with either forward
(concurrent) or backward (counter) feeding. However, calculations made on basis of
the theory are often intractable and should therefore not be attempted.

Forward feed implies that feeding of the sheet into nippers occurs while nippers are
moved toward the detaching roller.

Backward feed implies that feeding of the sheet occurs during the return of the
nippers. The triangular areas represent a stylized staple diagram.

Z nippers

A detaching rollers

B fiber fringe protruding from the nippers

K combing segment

E detachment setting

S feed amount (mm) moved per combing cycle

M largest fiber in the staple(mm)

a fiber ≥ E

b fiber= E-S

c fiber < E-S

p noil percentage

Boogeyman 16
Noil elimination with backward feed:

During detachment, the nippers are located at their closest position relative to
detaching rollers. The detaching roller draws off all the fibers extended to its nip line
i.e. all the fibers longer than (detachment setting + half of the diameter = E). All the
fibers to the left of mn pass into sliver.

As the nippers retract towards cylinder comb feed rollers feed the material
through a distance (S). The fringe is presented to the cylinder needles and thus
becomes equal to E + S. Thus all the fibers shorter than E+S are carried away by the
cylinder.

The fibers less than length (E+S) will all go into noil as these fibers are not
gripped by the nippers. This length also has been entered as line qr. In the region
qmnr, there is a chance that fibers will go either into noil or remain in the fringe.

A division can be made based on the mean fiber length represented within this
area, and it can be assumed that the trapezium AopC represents the fiber transferred
to the combed sliver and the OBP represent those passing into the noil. The dividing
line between these areas has a length of E+S/2. Further, in similar triangles, the ratio
of the areas is proportional to squares of the sides, and as the areas represent the noil
percentage based on the ratio of the weight of noil to that of feedstock, the following
relation can be assumed:
s
OpB (OP)2 (E+ )2
Noil (p%)= × 100 = × 100 = 2
× 100
ABC (AC)2 (M)2

Boogeyman 17
Noil extraction with forwarding feed

In this case, after the detaching is over, all the fibers longer than E are carried away to
form a sliver. There is no feeding during the return stroke of the nippers. Thus, the
length of the fringe presented to the cylinder needle is E. All the fibers shorter than E
would go to noil. The feeding occurs during subsequent forward movement of nippers
during which the length of the fringe is increased by a distance S (the feed length).
Detaching rollers take all the fibers longer than E.

The fiber b of the length (E-S) is now moving forward to the nip line by feed through
distance S. That is why fibers longer than (E-S) are now carried away into the combed
web and the trapezium AmnC represents this fiber. In this case, also qmn can be
divided according to the mean fiber length by line op (E-S/2), and thus the following
relationship can be derived—
s
OpB (OP)2 (E− )2
Noil (p%)= × 100 = × 100 = 2
× 100
ABC (AC)2 (M)2

Boogeyman 18
Quality of combing in Concurrent and Counter feed

➢ It is seen that in concurrent (forward) feed, all the fibers longer than (E-S)
instead of (E), will be allowed to pass into sliver. Thus, the quality of the combing
operation also is different.
➢ Consider a fiber with a trailing end, just lying in the nipper bite. During the
forward motion, with concurrent feed, this fiber will be pushed ahead, and
possibly would go into sliver web. In counter feed, however, the fiber still will
maintain its position as there is no feed during detachment. During backward
movement, the feeding takes place and fiber will be pushed ahead and would
be removed by the cylinder.
➢ It may be noted that this fiber had received one extra combing in the earlier
combing cycle.
➢ In counter feed thus, a fiber gets comparatively more combing by cylinder
needles. It helps in more elimination of impurities and neps.

Index Wheel: In comber outside the cylinder shaft, a wheel is attached with 40 equal
parts named Index wheels. There is a pointer on it to indicate the index number. The
various motion of comber m/c and its timing such as nippers, cylinder, top comb, roller,
and different settings and adjustments are done by different index numbers. With the
reference of an index number, Nipper comb, cylinder, and conjugative position,
motion, and adjustment limit are selected.

The function of the Index wheel:

1. The consecutive position, motion, adjustment limit of the nipper, comb cylinder,
etc are selected concerning the Index number.
2. The different settings of comber are arranged with an index number.
3. The top detaching roller weight is selected with an index.

Boogeyman 19
Combing cycle about Index wheel

1. Pointer position 33 to7:

• Combing by cylinder comb
• Nippers closed and at backward most position
2. Pointer positions 17 to 23:
• Delivery and combing by top comb
• Delivery, combing by top comb
• Nipper open, forward most position
• Detaching roller forward rotation
3. Pointer position at 7 to 17: Forward feeding (opening)
4. Pointer position 23 to 33: Backward feeding (closing)
5. Pointer Position 13 to 17: Detaching roller backward rotation

Degree of Combing: The amount of Noil (Noil= Short fibers+neps+impurities)

extracted during combing expressed in percentage is called degree of combing. The
degree of combing depends on the end-use of yarn.

4 Types of combing based on the degree of combing

1. Scratch combing
a. Up to 5% noil removed.
b. Gives no improvement in average yarn properties.
c. Reduce end breakage rage.
2. Half combing
a. Around 9% of noil removed
b. Reduce yarn irregularity
c. Improve spinning performance
3. Ordinary combing
a. 10-18% noil removed
b. Necessary for spinning in the finer end of the count range.
4. Full combing
a. Greater than 18% noil removed
b. Often means double combing to obtain the highest quality yarn.
c. 18% removed in first combing + 7 % in second.

Boogeyman 20
Difference between carded sliver vs combed sliver

Carded sliver Combed sliver

Obtained without combing. Obtained by combing.
More short fibers are present. Less amount of short fiber.
Irregular fiber. Regular fiber.
Low smoothness. More smoothness.
Quality is not better than combed yarn. Quality is better than carded yarn
Less lustrous More lustrous.
More hairy Less hairy
Less costly More costly

Difference between blow room lap vs comber lap

Blow room lap Comber lap

A high amount of short fiber
Low uniformity.
A high amount of trash.
A high amount of impurities.
Lap weight 40-50 lb.
Lap width 1 m.
Lap wt/yds 12-16 once
Low amount of short fiber
High uniformity.
Low amount of trash.
Low amount of impurities.
Lap weight 18-20 kg.
Lap width 300 mm.
Lap wt/yds 700-1100 grain

Recent development:

1. High production rate: 100/250 nip/min to 500/600 nip/min

2. Higher lap wt used: 700 – 800 gr/yd
3. Modern drafting system: 2 over 3
4. Large can size: (20 * 20)inch2
5. Auto lubricating system
6. Auto doffing
7. High rate of noil extraction.
8. Noil measuring system.
9. Fault locating system.
10. Improved piecing mechanism.

Boogeyman 21
Detaching roller setting: It refers to the distance between the clamping line of the
nipper and the nip line of detaching roller when these parts are at their closest
spacings. Wide detachment settings result in a high level of noil extraction. Lower
settings result in lower noil extraction. Detachment settings normally lie between 15 -
25 mm.

Math Formula:
unit weight ×length (yd) w ×L
Lap hank= ==
weight (lb)×unit length W×l
feed sliver weight
Actual draft (Direct count: Tex, Denier)= × no of doubling
delivery sliver weight
delivery sliver weight
Actual draft (Indirect count: Ne, Nm) = × no of doubling
feed sliver weight
DC (Draft Constant)
Mechanical draft =
DCP (Draft Change Pinion)
100
Actual draft = Mechanical draft ×
100 – waste
100−waste
Mechanical Draft = Actual draft ×
100
100−noil
Production = (feed/nip) ×(nip/min)× time × efficiency × ×no of head ×wt of
100
hank
Speed of calender roller
Product constant =
36
Production = product constant × delivered sliver wt × time × efficiency

Boogeyman 22
 1. Calculate production of comber in kg/shift where lap weight = 1000grain/yd,
Nips/min=350, feed/nip=4.7mm, efficiency=90%, no of head per frame=8, noil
extraction 15%. (L-2 T-2, 2018)

Given that,

Nips/min=350,
4.7
feed/nip=4.7mm=1000 × .9114 yd

efficiency=90%=0.9

no of head per frame=8,

noil extraction= 15%

1000
lap weight= 7000 lb/yd

Production =(feed/nip) ×(nips/min)× time × efficiency ×

100−noil
× wt of hank x number of head
100

4.7 100−15 1000

= 1000 × .9144× 350 × 60× 8 × .90 × 100
×7000 ×2.2046 𝑥8 kg/ shift.

= 342.44 kg/ shift

Ans: 42.805 kg/ shift

2. The lap fed to the comber machine having 8 heads is 62kTex and sliver of 5kTex is
required in the cans. The waste percentage is 16% and the draft constant of comber is
1696. Find out the mechanical draft and required DCP. (L-3 T-1,2017)

Given that,

No of head=8,

Lap fed= 62 Ktex

Sliver= 5Ktex

Waste=16%

DC=1696
feed sliver weight 62
Actual draft = delivery sliver weight
× no of doubling = = 5
× 8 = 99.2

100−waste 100−16
Mechanical Draft = Actual draft × 100
=99.2 × 100
= 83.328
DC
Mechanical Draft =DCP
DC 1696
DCP= = = 20.35
Mechanical Draft 83.328

Boogeyman 23
 3. A spinning mill is run with 12 comber machines which process cotton fiber up to staple
3
length 1 inch. Parameter of each machine are: nips/min=550, feed/nip=4.5mm, no of
8
head per machine=8, lap weight = 800gr/yd, waste extraction 16% and efficiency
=85%. Find out production in Kg/shift of those combers. (L-3 T-1,2017)

Given that,

Nips/min=550,
4.5
feed/nip=4.5mm=1000 × .9114 yd

efficiency=85%=0.85

no of head per frame=8,

waste extraction= 16%

800
lap weight= 7000 lb/yd

no of machines = 12

time = 60 × 8
100−noil
production=(feed/nip) ×(nips/min)× time × efficiency × × wt of hank × no of m/c
100
× no of head.
4.5 100−16 800
= 1000 × .9144 × 550 × 60 × 8 × 0.85 × 100
× 7000 ×2.2046 × 12 × 8 kg/shift

= 4616.489073 56kg/shift

Ans: 4616.48073 kg/shift

4. Calculate production of comber in kg/shift where lap weight = 1200grain/yd,

Nips/min=350, feed/nip=6mm, efficiency=80%, combed sliver=0.01 Ne, noil extraction
18%. (L-2 T-2, 2017)

Given that, Nips/min=350,

6
feed/nip=4.7mm= yd
1000 × .9114

efficiency=80%=0.8
1200
noil extraction= 18%lap weight= 7000 lb/yd

100−noil
Production =(feed/nip) ×(nips/min)× time × efficiency × × wt of hank
100
6 100−18 1200
= 1000 × .9144× 350 × 60× 8 × .80 × 100
×7000 ×2.2046 kg/ shift.

=56.2317 kg/ shift

Ans: 56.2317 kg/shift

Boogeyman 24
 Simplex/ Speed frame/ Roving frame
A simplex is a machine that converts the drawn sliver into a thin strand of fibers having
some amount of twist.

Objects of Speed Frame

The purposes or objects of the speed frame are –

1. Attenuating of draw frame sliver to a suitable size for spinning.

2. To convert drawn sliver into roving and to make it suitable for ring frame
process.
3. To reduce the linear density of sliver (weight per unit length).
4. To insert a little amount of twist in the roving to improve its strength of it.
5. To make a large conical package of roving suitable for ring frame.
6. To ensure easy and safe transportation of material by making large packages.

Significant of Roving Frame/Why the Draw Sliver is not Direct Used in Ring
Machine?

There are two principal reasons:

The first reason is related to the required draft. The drawn sliver is to thick,
untwist strand that tends to be hairy and to create a fly. The draft needed to convert
this to yarn is in the resign of 300-500. The speed frame process minimizes the sliver
weight to a suitable size for spinning into yarn and inserting twist, which maintains the
integrity I the draft strands. It is impossible to feed the sliver to the ring frame for yarn
production due to the limitation in the draft in the ring frame. So the fine twisted
roving is better for this purpose.

The second reason is related to transportation and space limitations on ring

frames. The draw frame can represent the worst conceivable mode of transport and
presentation of feed material to the ring-spinning frame.

Manufacturers of simplex

1. Rieter- Switzerland (F15,F35)

2. Toyota- Japan (FL16, FL 100, FL 200)
3. Lakshmi- India
4. Zinser- China
5. Manzoli – Italy

Boogeyman 25
Passage diagram

1. The sliver obtained from the draw frame or after combing is used as feed
material in a simplex or roving machine.
2. This sliver is put into the large can.
3. This sliver, first of all, passes through separators.
4. From this point, the sliver goes over the guide roller and then tensioning rollers.
5. Now the slivers enter into the drafting zone, where it passes between drafting
rollers. Generally, a draft of 6–15 drafts is employed to the fed sliver. The
drafting system attenuates the sliver many times its original length and reduces
the weight per unit length of the sliver
6. The output material(roving) after drafting has very poor strength due to low
linear density, therefore it needs a little amount of twist to hold the fibers
together. The drafted strand of fibers passes through the flyer to provide this
twist, Usually, 30-65 turns per meter are inserted into the roving.
7. There are spindles in the flyers on which the twisted roving gets wound.

The operation involved in Speed Frame

The major tasks of the speed frame process are listed as follows:

Creeling: To feed the sliver with the help of several rows of driven rollers to the
machine. Creel is the place situated at the back of the machine where the raw material
is placed to be fed to the drafting zone. An optimum creel tension draft should be
selected to control sagging or stretch in the drawing sliver.

Boogeyman 26
 Drafting: Drafting is normally carried out by a draft system with a double apron
capable of working with entering sliver counts of 0.12-024 Ne and counts of the
delivered roving of 0.27—3 Ne. The draft given in the roving process will be in the
range between 4 and 20 and can work fibers of a length of up to 60 mm.

Twisting: It is a very important factor that produces strength in the roving and
twist is inserted with the help of a flyer. When the flyer rotates, the twist is produced
in the sliver. The twist level depends upon flyer speed and delivery speed.

Laying: Lay refers to the arrangement of the roving coils wound around the
bobbin in any given layer. The closeness of the lay is measured in “coils per inch,” which
means the number of roving coils wound around the bobbin per inch parallel to the
axis of the bobbin. The purpose of the laying operation is to put the successive coils
of roving side by side in a uniformly spaced arrangement. This regular, uniform
arrangement is achieved by making the bobbins move up and down at a uniform rate
of speed for each layer.

Winding: Winding is the process using which the roving is drawn from the front
roll through the flyer and onto the bobbin. The rate of winding compared to the rate
of delivery at the front roll controls the winding tension.

Building: The building motion is controlled by the steady upward and

downward movements of the bobbin rail containing the bobbins and spindles.

Doffing: To replace an empty bobbin in the place of the full bobbin. It is the
optional function of the speed frame. Doffing could be done manually or
automatically.

Effect of arrangement in the bobbin

In fly frames, the spindles are arranged in two rows (in a zigzag manner). The
arrangement is made to economize on the space requirement. though there is a large
economy in space, the arrangement has some technological disadvantages.

1. The angle of approach of roving to the flyer top is different for two rows of the
bobbin.

Boogeyman 27
 2. Angle swept out by two roving at front roller are different

3. The difference in the unsupported length( the lengths between the drafting
arrangement and flyer top)

The differences result in

• More complicated design

• The operation of the machine is less convenient
• Uneven twisting
• Ultimate count variation between front and back rows

Drafting: Drafting is the reduction of mass per unit length or increase of length per
unit mass of the product.

Basic elements of drafting are—

1. Top roller
2. Bottom roller
3. Pressure arm

Boogeyman 28
Top roller

The top rollers are not positively driven. They can be either one-piece rollers (spinning
preparation machines) or twin rollers (roving frames, ring spinning machines). Ball
bearings are used almost exclusively in roller mountings. The thick coating forming the
roller surface is made of synthetic rubber. An important characteristic of this coating
is its hardness. Soft coats surround the fiber strand to a greater extent than harder
ones and thus guide the fibers better. On the other hand, they wear out more quickly.
A soft coating is therefore used where a good guide is necessary, i.e. where few fibers
have to be moved with high draft levels (e.g. at the front rollers of the ring-spinning
machine). Where this is not required, harder coatings are mostly used. Hardness is
specified in terms of de- grees Shore. The following ranges are defined:

• soft: 65° - 75° Shore

• medium: 75° - 80° Shore
• hard: above 80° Shore

Normally the diameters of top rollers are between 25 and 40 mm.

Bottom roller

Bottom rollers are made of steel and are mounted in roller stands or the frame through
the needle, roller, or ball bearings. They are positively driven from the main gear
transmission or by a separate drive. To improve their ability to carry the fibers along,
they are formed with flutes of one of the following types :

1. axial flutes (a);

2. inclined flutes (spiral flutes) (b);
3. knurled fluting (c).

Knurled fluting is used on rollers receiving aprons, to im- prove the transfer of drive to
the aprons.

Spiral flutes give quieter running and more even clamping of the fibers compared with
axial fluting. Rolling of the top rollers on spiral flutes takes place in a more even manner
and with less jerking. The diameter of the bottom rollers can lie in the range of 20 - 90
mm, but normally diameters between 25 and 50 mm are used.

Boogeyman 29
Pressure arm

In any pair of rollers in a roller drafting system, the bottom roller is positively driven
and gets motion directly from gear. The top roller is negatively driven and gets motion
from the bottom roller through friction between fiber fleece and bottom roller and
friction between fiber fleece and top roller. To get proper friction with fleece self-
weight of the top roller is not sufficient and has to be assisted by some suitable device.
Such a device is called a pressure arm. It is weighted by spring, pneumatic pressure,
etc.

Applying pressure to the top rollers

The top rollers must be pressed with relatively high force against the lower rollers to
ensure the guidance of the fibers. Pressure is in the range of 100 to 300 N. per roller
and they depend on raw material and volume. Adjustment may be continuous or
several steps. Practically all manufacturers wight the top rollers by spring pressure, the
exceptions being Rieter who prefer pneumatic weighting.

Factors considered for roller distance

The bulk of material: For higher bulk roller setting is wider.

Amount of draft: If the draft is higher roller settings will be wider.

The staple length of fiber: For longer fiber, the roller setting will be wider.

Factors considered for roller pressure

The bulk of material: Back zone contains coarser fiber with less amount of pressure
required.

Amount of draft: If the draft is higher roller settings will be wider.

Types of fiber: Cotton is a soft fiber its required high pressure.

Pressure can be applied by—

1. By dead wt and hook

2. By spring (most used)
3. By pneumatic wt
4. By magnetic wt.

Boogeyman 30
Advantages o spring wt

1. It is lighter.
2. It is robust.
3. It is easy to handle.

Advantages of pneumatic pressure

1. It is easy to adjust
2. Uniform pressure from arm to arm
3. Infinite setting
4. Pressure range (1.50- 5 bar)

Relation between staple length and roller distance

Draft zone Roller distance

Front zone staple length +( 1/16” to 1/18”)

Middle zone staple length +( 1/8” to 3/16”)

Back zone staple length +( 1/4” to 5/16”)

Drafting system

Conventional: 4 over 4 without the apron

Modern: 4 over 4 or 3 over 3 with the apron

i. SKF PK 1500
ii. SKF PK 1600

Boogeyman 31
Feature of 3 over 3 drafting system or SKF PK 1500

It is a 3 over 3 drafting system.

Feature:

Draft range:

o Total draft: 10 – 15
o Break draft: 1.05 -1.15

Roller type:

• Top rollers are synthetic rubber-coated.

• Bottom rollers are made of steel & fluted or knurled.

Roller weighting:

Spring loading or sometimes hook and deadweight arrangement.

• Front roller 20-30 daN

• Middle roller 10-20daN
• Back roller 15-25 daN

Roller hardness:

• The hardness of top rollers is about 750 – 850shore.

• The hardness of bottom rollers is about 600 shore.

Apron:

• Used in the front zone.

• The double apron is used
• Inside apron cradle is used.
• Apron thickness is 1 mm.

Advantage:

1. Regular and uniform draft distribution.

2. Better fiber control.
3. Roller setting is not always necessary.
4. Better roving evenness
5. Less influenced by the change in staple length of the fiber.

Disadvantage:

1. If the draft is below the lower limit, then the drafting operation becomes difficult
to control.
2. Cracked open, badly joined leather apron produce bad roving.

Boogeyman 32
Feature of 4 over 4 drafting system or SKF PK 1600

It is a 4 over 4 drafting system.

Feature:

Draft range:

o Total draft: 5 - 20

Roller type:

• Top rollers are synthetic rubber-coated.

• Bottom rollers are made of steel.

Roller weighting:

Spring loading or sometimes hook and deadweight arrangement.

Roller hardness:

• The hardness of rollers is about 800 – 850shore.

Apron:

• The double apron is used

• Inside apron cradle is used.
• Apron thickness is 1 mm.

Advantages:

1. Regular and uniform drafting is possible.

2. Less irregularity.
3. The roller setting is flexible.
4. Better controlling and guiding of fibers occurs.
5. The capability of giving a high range of the draft.
6. Less tendency of roller lapping.

Disadvantage:

1. When the draft is below the lower limit then drafting is difficult to control.
2. Cracked open, badly joined leather apron produce bad roving and end
breakage.

Boogeyman 33
Difference between conventional drafting and modern drafting

Conventional drafting Modern drafting

Roller draft method
No apron is used.
Fiber control is not good
Draft range 6 -10
More tendency of roller lapping and
end breakage rate.
Not able to more production
Various types of settings are needed for
the various staple length of fiber
More time is required to change the
roller settings
Irregular draft distributes
Apron draft method
The apron is used for better drafting
Fiber control is better
Draft range 10-15 maximum 20.
Less tendency of roller lapping and end
breakage rate
Able to more production
Various staples of fiber can be treated in
the same roller setting
Less time required
Regular draft distributes

Condenser

It is mounted on the reciprocating bar behind the drafting arrangement.

Function:

1. It prevents the sliver not to feeding in the drafting zone without elongation.
2. Straighten the sliver.
3. Control the width.
4. Control roving strength.

Apron

An apron is a device used to control the movement of fibers in a drafting system.

• These aprons are endless sheets made of either synthetic rubber or leather.
• Single and double apron systems are available in spinning.
• It may be short or long.
• The thickness is about 1 mm.
• The aprons are held taut by tensioning devices.

Function

• Guiding transport fiber during the drafting

• Reducing loss of short fiber.
• Controlling floating fiber.

Boogeyman 34
Cradle

Cradle is a device that guides the top roller. It is usually made of plastic. Cradle length
varies with the length of staple fiber length.

Function

• To reduce the loss of short fiber.

• Control the floating fiber to a possible extent.
• Help to impart a higher draft.
• Make the roller setting flexible.

Spacer

To maintain the minimum distance spacer are used between the nose bar of the lower
apron and the cradle edge of the top apron. Spacers are different colors according to
distances.

The Flyer

The flyer is an essential part of the speed frame. It is used to impart a twist. Flyers are
mainly made of steel though plastics flyers are also available.

Functions

• To impart a twist on roving.

• Guiding the roving in the proper place over the bobbin during winding.
• To produce a compact bobbin.
• Reduce breakage of roving during winding.
• Helps in the winding.

Mainly 3 types of flyers

1. Spindle mounted flyers ( conventional)

2. Top-mounted flyer (modern)
3. Closed mounted flyer

Spindle mounted flyer: Spindle mounted flyer is simple in design and drive but not
from the service point of view or for automation purposes.

Top-mounted flyer: Top-mounted flyer is a modern flyer that facilities automation

and doffing purposes. This flyer is driven by gear wheels or toothed belts from above.

Closed flyer: Closed flyers are supported both above and below. It has the advantage
of reduced spreading of legs at high operating speed.

Boogeyman 35
Factors considered for selection of twist in roving

1. The staple length of fiber: For higher staple length, lower TPI gives sufficient
strength to roving.

2. The fineness of fiber: If the fiber is fine then more fiber will be in the yarn
cross-section. So inter-fiber friction increases and less amount of twist become
enough for intended roving strength.

3. Yarn count: If the roving hank increases more twists are required for sufficient
strength.

4. Type of fiber: For manmade fiber lower twist is required due to more strength.

Winding Principle

In a speed frame, normal drum winding or cross winding is not possible at high speed
because of its softness and low strength. It is wounded by the help of a flyer in a nearly
parallel way.

There are two winding principle

Bobbin leading principle ( for cotton)

Flyer leading principle (for jute)

Bobbin leading principle

• The bobbin speed is higher than flyer speed at all points of winding.
• The winding speed is constant throughout the process.
• With the increase of bobbin dia, the bobbin speed must be decreased.
• The variation o bobbin speed with the increase of bobbin dia must be constant.
• Less tension on roving or yarn
• Used in cotton spinning.

Boogeyman 36
Let front roller delivery = L inch/ min

Spindle/ flyer = Nf rpm

Bobbin speed = Nb rpm

Speed variation= Nw

So, bobbin circumference = πd

Winding on speed (Nw)= L/ πd

Again,

Nw = bobbin speed – spindle/ flyer speed

L/ πd = Nb – Nf

L = πd(Nb – Nf)

As L, π, and Nf are constant, then with the increase of bobbin dia, the bobbin speed
must be decreased.

Flyer leading principle

• The higher speed is higher than the bobbin speed at all points of winding.
• The winding speed is constant throughout the process.
• With the increase of bobbin dia, the bobbin speed must be increased.
• The variation o bobbin speed with the increase of bobbin dia must be constant.
• Higher tension on the roving yarn.
• Used in jute production.

Let front roller delivery = L inch/ min

Spindle/ flyer = Nf rpm

Bobbin speed = Nb rpm

Speed variation= Nw

So, bobbin circumference = πd

Winding on speed (Nw)= L/ πd

Again,

Nw = spindle/ flyer speed –bobbin speed

L/ πd = Nf – Nb

L = πd(Nf – Nb)

As L, π, and Nf are constant, then with the increase of bobbin dia, the bobbin speed must be increased.

Boogeyman 37
Building Motion

• This device has to perform three important tasks during winding operation—
• Shift the cone belt corresponding to an increase in the bobbin dia.
• Reverse the direction of movement of the bobbin rail at the upper and lower
ends of the lift stroke.
• Shorten the lift after each layer to form a tapered end on the bobbin.

Individual motor drive/modern roving frame

In a multi-motor drive system, drafting rollers, flyers, bobbins, and bobbin rail are
driven directly by individual servomotors and are synchronized throughout the
package built by the control system. The advantage of these systems are, no need for
a heavy counterweight for bobbin rail balancing and differential gear, reduced gear,
reduced maintenance, and lower energy consumption.

Features:

• Microprocessor controlled building mechanism

• Technological parameters are fed to the control panel.
• Bobbin speed and bobbin rail position are sensed by electronic sensors.
• Tapering and rail movement is controlled by a computer.
• Adjustments can be stored and transferred to other machines.

Efficiency loss for different types of stoppage

• Roller lapping in drafting roller

• Roving breaking
• Power failure
• Mechanical fault
• Electrical fault
• Unskilled worker
• Doffing
• Creeling
• Piecing
• Can storage
• Sliver shortage
• Sliver breakage
• Bobbin shortage

Boogeyman 38
The recent development of the speed frame

1. Improved drafting system: By improved drafting system, 6 – 20 drafts can be

imported to a sliver.
2. Higher flyer speed: Modern flyers are capable of a speed of 1000 rpm
whereas conventional flyer rpm was 600. Thus production increased by 50%.
3. Plastic flyer: Lighter in weight and less power consumption.
4. Gearing in bath oil: This causes smooth running of m/c and less wear of m/c
parts.
5. Auto stop motion: Different auto stop motions to reduce waste and increase
efficiency.
a. Sliver stop motion
b. Roving stop motion.
c. Creel stop motion.
d. Doffing stop motion
6. Inching motion: This involves turning the flyer to the correct position for
piecing when m/c stops for any end breakage.
7. Monitoring system: Modern speed frame includes data monitoring system
by direct reading of—
a. Production
b. Efficiency
c. Speed of flyer
d. Stoppage time
e. Quality monitoring
8. Inverter motor:
a. Controls traversing motion
b. Controls tension on roving
c. Controls the fast wheel directly
9. Suction in the drafting zone
10. Improve roving quality
11. Can changing
12. Wide range of roving count (0.5 – 2.5 Ne)

Differential motion

Differential motion is the resultant of two different motions namely—

1. The constant motion of the main shaft is driven by the motor.

2. The variable motion of cone drum.

The differential motion is generated in the differential box and gets the output of
motion from the last wheel.

Boogeyman 39
The necessity of differential motion

• For winding roving onto bobbin we have to keep bobbin speed more than
flyer speed. This excess speed of the bobbin is controlled by differential
motion.
• Bobbin dia increases after winding every layer of roving onto it. So to keep
constant winding on the speed we have to decrease the bobbin speed. For
this purpose differential, motion is used.
• Differential motion helps to transmit the variable speed of the bobbin cone
drum to the bobbin with the increase of bobbin dia.

Change wheel in speed frame

1. Draft change pinion (DCP)

2. Draft constant change pinion (DCCP)
3. Twist change pinion (TCP)
4. Twist constant change pinion (TCCP)
5. Lifter change pinion (LCP)
6. Ratchet wheel (RW)
7. Spindle speed change pinion
8. Pooker wheel (PW)/ Tappet wheel (TW)

Math formula
𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑
TPI = Tm √𝑁𝑒(𝑐𝑜𝑢𝑛𝑡) = 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑦 𝑠𝑝𝑒𝑒𝑑

𝐷𝐶
DCP = 𝐷𝑟𝑎𝑓𝑡

𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑦 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 ℎ𝑎𝑛𝑘

Draft = (indirect)
𝑓𝑒𝑒𝑑 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 ℎ𝑎𝑛𝑘

Present DCP × present draft = required DCP × required draft

𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑 ×𝑛𝑜 𝑜𝑓 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 ×60 ×𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
Production = kg/hr
𝑇𝑃𝐼 ×36 ×840 ×𝑁𝑒 ×2.2046
𝑤𝑡 𝑜𝑓 𝑏𝑜𝑏𝑖𝑛 ×ℎ𝑎𝑛𝑘
Production = 𝑡𝑖𝑚𝑒

Boogeyman 40