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Unit – 3
ANCILLARY EQUIPMENTS IN BLOW ROOM

3.1. List of Ancillary Equipment

 Gravity traps
 Safety devices (Metal extractors)
 Delivery cages / Condensers
 Air separators
 Distributors
 Micro dust separators

3.2. Importance and installation of Gravity Traps

Need for gravity traps

The removal of large impurities such as seeds stones and other heavy particles can be
done only by widening the distance between grid bars. However, this will result in
higher lint loss. The seeds, if not removed in the earlier blow room sequence,
ultimately get crushed due to calendaring action and seed oil comes out. The presence
of oily substance in cotton usually leads to many problems like loading on card wires,
lapping of drafting rollers etc. in the subsequent processing and critically affects the
performance of these machines.

Gravity trap in blending hopper balebreaker:

A full width of air opening can be provided in

the receiving chute, at the end of the conveyor
lattice of the blenders. All other air leakages in
the chute system should be plugged; a sliding
door is used to control the width of the air
opening for suitable air pressure. A magnet is
provided to collect light iron particles and a trash receptacle for collecting seeds and
other extraneous matters. The passage of air and of the fibre tufts carried with it. As
also the passage of seeds and other heavy matter, are shown by arrows.

Gravity trap at step cleaner:

The perforated inclined sheet against which the

cotton thrown by the last beater strikes should be
replaced by a plain sheet and an adjustable full
width air opening should be provided (As shown in
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figure) on it at the place where the cotton strikes. The sheet at the bottom of the
chamber should be removed to allow free passage of air from below through the air
opening. All other air openings on the delivery side of the machine should be closed.

3.3. Importance and installations of metal extractors in blow room

a. Magnetic metal extractors

Magnets are used in ducting or in special parts of machines in order to eliminate
pieces of ferrous materials. The most effective form of extractor is a knee –bend
having permanent magnets at the two impact surfaces. When flocks are driven
against the magnets, ferrous particles are retained and can be removed from
time to time.

The limitation of magnetic metal extractors is that they can only eliminate
magnetic metal particles, but cannot remove non metal particles.

b. Electronic metal extractors

The material is fed (1) from an opening machine
such as Blendomat (Automatic Bale opening machine)
by a suction fan (5) which is located in front of the
next machine (usually mixing machine). The spark
sensor (2) detects smoldering material and metal
detector (3) detects any kind of metal. An eliminating
arrangement is provided about 15 metres after this
detector. In both the cases of detecting metal /
spark, the active opening flap (4) is opened by a
signal from the detector and feeds the material into
the receiving waste container. The flaps immediately
return to the normal flow condition, the flap (7) of the
collector chamber opens and the contents fall into a transport container (6)
3.4. Different types of fire protection systems in blow room and explain them.
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Increase of automation in blow room resulted in reduced the presence of operatives

and reduced the chances of detecting the fire in time. Hence the automatic fire
protection system has become very much essential. Fire protection system consists
largely of the following devices.

a. Heat detector
Heat detectors are installed wherever the material can emit excessive heat.
The heat generated when the fire starts is particularly effective in chutes
where material is temporarily retained. The heat detectors signal the
occurrence of fire to the fire warning system when they detect a
temperature greater than 60°C (normally a preset value). They have the
advantage that they react even when no material is flowing through the duct
like when the when the lines are closed for maintenance.

b. Spark detector
Spark detectors react to the low level of infra red radiation emitted by the
spark passing quickly. They are therefore fitted in the ducts for the fan
exhaust and for material transport to the cards.

c. Fire protection tap

Fire protection traps close the ducts for the fan exhaust and the material
transport to the cards when a heat detector or fan detector reacts. This
causes the fan to be throttled and prevents the spread of fire.

d. Fire warning centre

Fire warning centre emits an acoustic and visual alarm signal, stops the
installation and fire protection traps close automatically when a heat
detector or spark detector reacts. The fire warning centre also transmits
pulses which actuates extinguisher system. Normally fire warning system is
supplied by uninterrupted power supply.

3.5. Explain the working principle of Contamination sorter

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1. Cameras for the colour module

2. Polarisation filter for the P module
3. Lighting unit
4. Deflection mirror
5. Lighting units
6. Nozzle beam
7. Bucket wheel lock for extraction of foreign parts
8. Camera for the P module and the UV module
9. Lighting unit for the UV module
10. Large-volume collection bag for foreign parts
11. S peed sensors
Foreign Part Separator SECUROPROP SP-FPU
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In addition to natural contamination, white and transparent particles (e.g. PP or PE foil)

often cause quality problems in the blow room. The further foreign parts get into the
production chain, the greater the damage to value creation. Foreign parts and foreign
fibers must be divided into two completely different groups:

One group consists of parts that differ significantly from cotton by colour, contrast and
structure and that are reliably detected by special cameras.

The other group is made up of bright and transparent foreign parts that hardly differ in
colour from cotton and therefore are invisible to conventional separators
(e.g.polypropylene PP or PE foils).

Trützschler foreign part separators works on five special modules can be

combined and integrated:

• Colour module
• P module
• UV module
• Dust removal module
• CONTIFEED module with opener roll

Detection principles
The modular design is based on three Trützschler modules that are integrated in
different machines individually or in combination.
1. Colour module
Thanks to very high-resolution 3-CCD cameras, the colour module can also detect white,
non transparent PP parts. The high resolution of the camera also ensures the safe
detection of yarn-type and ribbon-type foreign parts.
2. P module
The Trützschler P module reliably detects transparent and semi-transparent parts due to
its patented method with polarised transmitted light. This makes sense when packing
residues from PP fabric are contained in the cotton.
3. UV module
The Trützschler UV module complements the other two systems in case of contamination
with fluorescent parts from bleached cotton threads, PP or PES in the cotton.

3.6. Working principle of Dedusting machine “Dustex” (OR) Dust remover

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Dedusting machine is positioned immediately after an efficient cleaner like saw tooth
openers (Eg CVT, CNT). The functioning of dedusting machine “Dustex” is described
here.

The material enters the Dustex machine through a feed duct (A) with the help of suction
fan (B). The material travels vertically up and enters a chamber (H) though distribution
flaps (C). The material is thus thrown over a perforated plate (D). The perforated flap is
typically shaped so that as the cotton falls down due to gravity and it is made to roll over
the perforated area. Just behind the perforated plate is small vertical channel which
collects the dust and air mixture. This channel is called as “Waste suction” (E) channel.
Heavy waste falls down due to gravity and the air is diverted vertically upward and
enters another zone of dust suction (F). The separation of these compartments helps in
avoiding any unnecessary turbulence. Finally both the fine dust and coarser waste
matter are removed through waste and dust removal duct (G). The cotton falling down
in chamber (H) is collected by a suction funnel (J) and is passed vertically up through a
pipe. The suction K is provided which is able to lift the cotton from J to K.

3.7. Types of wastes in blow room

A spinning mills produces the following some of them in significant quantities

a) Directly re-usable waste
b) Dirty waste and
c) Dust and fly Sad
Directly reusable waste can be collected without difficulty and can be fed back
into the blow room line Dirty waste and dust and fly cannot be dealt with so easily
since handling of this waste material is unpleasant for the mill personnel. In
modern mills, waste material is removed pneumatically.
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3.8. Types of Waste disposal systems in a blow room

Disposal of dirty waste

In this system all waste chambers of the blow room machines, card and
combed machines are connected by suction ducts to central suction equipment
that leads to pneumatic bale presses (or Silos). In order to keep the various
types of waste (Comber waste, Licker in waste) separate from each other, a
bale press is required for each specific type. If only one press is available, an
individual silo is must be provided. About three bale presses / silos will be
sufficient for a normal cotton spinning mill.

Disposal of Dust and Fly

Dust is released at each machine often in great quantities due to turning over,
plucking apart etc., today almost all machines up to the draw frame are
enclosed as far as possible and connected dust suction lines. Released dust
passes immediately into the suction system in which must be separated from
the air and carried away.

Dust filtering and individual filters

Usually two filter stages are used because a great deal of fly is carried along in
suction removal of dust in the two stages preliminary filtering and fine filtering.
These operations can be performed with individual filters or central filter.
Generally fabric filters sre used for filtering dust.

3.9. Material Transport Systems

a) Types of material transport

Blow room consists of combination of any machines arranged in sequence. In

processing, the material must be moved from one machine to another. There are
two methods of transport of material
 Mechanical transport – spiked lattices, lattices and spiked lattices
 Pneumatic transport – using under pressure

Mechanical transport is to transport the material within the machine and where
as pneumatic transport is issued to transport the material from one machine to
the other machine.

b) mechanical transport of material

Mechanical transport uses following devices for transport

 Conveyer belts – these are used to transport the material in horizontal

direction and within the machine. They are usually endless.
 Lattices -
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 Spiked lattices

3.10. Pneumatic transport with separation of air and material using Cylinder
cages

Objects of Cage condenser

• To suck the material from the previous machine
• To eliminate micro dust present in the material.
The cages are perforated thin sheet hallow drum made by
tin sheet with perforations or woven wire mesh. They
always work in conjunction with a suction fan which draws
the air through their perforated surface. Hence the cages
provide suction which is used in drawing the cotton and
gathering on to its surface. Since the perforations are very
small only air is allowed to enter inside and the cotton is
deposited on the surface. The strength of the suction provided by the cages depends
on fan speed and the number and size of perorations. Perforations on the cage also
serve as gate for very fine impurities like dust and fluffy fibres. Normal cotton doesn’t
pass through the perforations.

Working of Cages

The fan connected with condenser suck the material from the previous machine
through pneumatic pipe and deposits it into the reserve tower which feeds to the
next machine in the blow room line. The condenser is employed to feed cotton to the
next machine. Suction for conveying the fibre from machine to machine is created by
the fan connected to the condenser. The fibre condensed on to the rotating surface of
the cage is removed by the wiper roller and deposited into the reserve feed tower.
Control or production is exercised by a photo electric cells arrangement in the tower
unit which monitors the height of reserve fibres and signal stop or start commands to
the preceding machine. Precautions are to be taken to avoid the air leakages at the
joints of the pipes. Long and curved pipes causes nep formation in blow room

3.11. Explain the working principle of Air separators

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Especially when the cotton is transferred to the machine in such a good opened
condition, it is possible that very fine impurities which escape the cleaning action in the
preceding machine are still in the separated condition. Before they reach next
destination where these separated fine impurities get recombined with cotton. They can
be conveniently removed during transit. It is here that the air separators have their role
to play. They separate an air current carrying both the lint and impurities. The material
enters the separator at feed end; the leading pipe has on one side the screen area over
which the combination and fine impurities pass. An adjustable flap is provided to adjust
the gap for the air leading to dust laden air delivery duct. The material however follows
the normal path and is delivered through the normal delivery duct.

Another style of air separator is shown

in the figure. It can be easily seen that
side screen area along the vertical
passage helps in dust extraction at A.
The dust is collected through dust
extraction outlet at B. Where as cotton
is finally delivered to the next machine
at C.

3.12. State the importance of

two way distributer with
simple sketch

A two way distributor is shown in the figure

which distributes the cotton to two scutcher
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lines; say scutcher lines 1 and 2 being served through the outlets A and B
respectively. Usually a micro switch is operated by the control door present in the
hopper feeder of a scutcher. When the hopper feeder is full, control door energises
the solenoid through electrical circuit. The solenoid holds down the plunger and then
the rocker bar so that the door A is closed and door B is opened. During this
condition all the material flows to scutcher 2 through the outlet B. similarly when the
material in the hopper feeder of scutcher 2 is full, the control door operates the micro
switch so that the material to scutcher lines 2 is stopped and flows to scutcher line 1.
Some times the material to both the lines can be transported at a time with slow rate
of flow. In the case of both the scutcher lines are full, the in feed to the distributor is
stopped from the opening and cleaning machines.Working can be summarised under
four cases.

a) When the hopper feeder of scutcher-1 served by out let ‘A’ is full

Swing door of the reserve bin moves backwards. Micro switch is operated, Electric
circuit energizes the solenoid. Solenoid holds down the right hand side plunger.
This causes the rubber covered roller on the left hand rocker bar. It contact and
lift the valve door of the out let ‘A’

b) When the hopper feeder of scutcher-2 served by out let ‘B’is full

Left hand solenoid holds down the left hand side plunger and closes the valve
door of the outlet ‘B’.

c) When both outlets are closed due to both hoppers are full

Further circuit is closed, which stop the delivery of cotton from opening line.
When hopper reserve bins begins to empty, the circuit is opened and switch on
the opening line is automatically operated and feeding recommences.

d) When both outlets are opened

Stock is distributed equally between two hoppers of scutcher.

3.13. State the importance of bypass arrangement with simple sketch

BY PASS ( of cleaning Machine)

Cleaning

Machine
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Objects

• The object of bypass arrangement is to avoid the flow of material through any of
the machines of blow room. In a blow room, the maximum number of machines
should be provided for opening and cleaning of wide varieties of cotton. But the
machines used should be according to trash % in the cotton. In such a case,
some of the machine will not be needed. This arrangement will bypass the cotton
to the next machine.
Scope & Application

• During processing of fine mixing , vertical opener is not recommended

• Porcupine beater is need not be used while processing viscose rayon
• While processing blends & 100% synthetic, less number of beating points are
used in blow room. In such cases many beating points are bypassed.
• Number of beating points required for low grade cotton with high trash % = 7
• Number of beating points required for medium grade cotton with medium trash
% = 5
• Number of beating points required for good grade cotton with low trash % = 3
Advantages of Bypass arrangement

 It avoids excess beating of fiber, causes fiber rupture

 It saves time
 It saves power consumption
 It saves production cost

3.14. Mention the types of control of material flow

a) Requirements
Each machine must always receive an exact quantity of material per unit time
from the preceding machine and it must pass same quantity per time to the
next machine. To ensure ad adequate flow of material, the machines are
adapted to each other so that each machine can produce more than the
succeeding machine requires. Since each machine has excess capacity, a
control system must be provided to ensure correct delivery quantity.

b) Types
 Stop go operation
 Continuous operation

c) Stop go principle
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For example, in the hopper feeder, the conveyor places the material into the
hopper until the sensing lever is pushed to switch off the drive for conveyor
belt. Similarly during filling of reserve hopper, the pressure exerted by the
column of cotton is high so that the sensing lever is depressed; this causes
the preceding machine to be switched off. When the column of reserve bin
gain been largely removed, the preceding machine switched on and the
reserve bin is refilled. In stop go principle, the individual machines run only
for 50% of the production time. i.e the production rate of the machine is
double that of production rate of the overall blowroom system. This increases
the loading of the machine which results in poor cleaning. However during the
run period, the machine always runs at same speed. In the modern
machines, optical regulation system is used in stop go operations.

d) Continuous principle

In continuous operation, the machines’ production rates are much closely

adapted to each other. They operate almost continuously without stops. A
fine control device serves to maintain material throughput by adjusting the
production speeds of the individual machines. But in continuous operation
there are continual delays and accelerations which give possible variations in
treatment of raw material. But this is not a big problem, if the variation in
production rates does not exceed 20 – 30 %.

Nowadays the whole blow room line operates on continuously and

regulation is performed electronically. This installation developed by
Trutzschler is called as Feed commander, is briefly described here.
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There is a central regulating unit, to which all the machines are connected,
is called Feed commander. This receives analogue signals from the
tachometers of the carding machines. The instantaneous demand of the
material is continuously calculated from this signal. Using this demand, the
microcomputer can establish the basics of all drives that determine the
throughput and drives can be correspondingly controlled. A second signal is
superimposed on this basic speed signal, derived from the storage unit of
the succeeding machine. In this way, the successive machines are linked via
individual control loops. The program for speeds, production quantities and
allocation are first established manually. When balanced operation is
achieved, they can be transferred to feed commander and stored there.

3.15. Explain the method of transport of material by chute feed system

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The card feed chute consists of U shaped sheet metal trunk of which the open side is
provided with an adjustable glass wall sealed at the sides. The flock feeder / chute
feeder contains three main elements, namely the beater section, filling and return
trunks and the condenser.

The material is fed to Kirshner beater (G) by way of two ridged rollers (E) and two
feed rollers (F). A light barrier (D) in the following regulates the supply of material
from the blowroom. The return trunk consisting of two chambers (K & L) has the
duty of returning the surplus material to the beater, that also of uniting well opened
material with the supply of fresh material. The quantity of return material is
monitored permanently by means of light barrier on the return trunks. The barrier
stops the flow of material in case the duct is overfilled. The air current is generated
by a centrifugal type of fan. The sheet of material in the chute is drawn off by the
pair of spring-weighted rollers and delivered to the feed roller of the card over a
guide sheet. Uniform separation of tufts from the air current is achieved by adjusting
the nose in the separating head. The weight of the card feed per meter depends on
static excess pressure in the installation. The weiht per meter ranges from 600 – 700
gms.

Defects in Blow room process

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Problems/Faults/Defects in Blow Room:

1. Low cleaning efficiency

2. High nep generation and fibre rupture
3. High variability in the delivered hank
4. Formation of cat's tail
5. Conical lap
6. Lap licking
7. Patchy lap
8. Holes in lap
9. Soft laps
10. Ragged lap selvedge

Causes and Remedies are discussed below:

Low cleaning efficiency:

Lower extraction of wastes than required for that mixing considering the trash
content is one of the main reasons for low cleaning efficiency. Increase the wastes if
the lint in the wastes is normal or nil. If the beater speeds are lesser than required,
we get lower cleaning. Check the beater settings and correct them if needed. Increase
the space between the grid bars. Close slightly the air-inlets under the grid bars
towards the cotton entry side, and open those on the delivery side. Reduce the fan
speed following the beaters by 100 to 200 RPM. If the grip of the feed roller is less,
we shall get low cleaning efficiency. Therefore check for the grip. Also check the
sharpness of the beaters. Check the synchronization of the machine working. The
blending bale openers should work for 80 to 85% of the time of working of the final
machine. If there is a back draught because of not cleaning the wastes under the
machines, the cleaning efficiency shall come down.

High NEP generation and fibre rupture:

The main reasons are blunt beaters, burrs in grid bars, bent pins on beaters, higher
beater speed, lower fan speed and excessive feed. A higher beater speed shall give
more neps, if the material is not moved out of the beating area effectively. If
materials return back to beaters, neps shall generate, hence check the setting of
leather flaps, stripper knife etc. Excessive of soft wastes fed, and cottons with more
immature fibres are major reasons for neps in opened material. Therefore have a
control on the issue of soft wastes to mixing and spread them uniformly throughout
the mixing.

High variability in the delivered hank:

Improper levels in the hoppers, improper action of feed regulators viz, cone drums,
pedals, photocells, direct driving gear motors, etc are the normal reasons for
variability in delivered hanks.

Formation of cat's tail:

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If material movement is less and cottons are over beaten, we get this defect. By
sharpening beater edges, increasing fan speeds, increasing the air in-let below the
grid bar area of cotton entry, closing the striping knife and beater setting shall avoid
cat's tail. The very important step in avoiding cat's tail is to avoid chocking of
materials in beaters. Excessive use of cotton-spray oil, water etc., also causes cat's
tails.

Conical lap:

Conical laps are due to, either higher quantity of cottons coming on one side of the
lap, or due to unequal calendar and rack pressures in scutchers. Ensure equal
opening of air-inlets under grid bars, replace torn leather lining at the cage, clean the
cage thoroughly with emery paper, make pressure on lap spindle uniform on both the
sides, remove the pedals and clean thoroughly, and check the pedals where it rests on
fulcrum and also pedal fulcrum bar.

Lap licking:

Lap licking can be due to excessive addition of soft wastes in mixing, higher rack
pressures, lower compacting of laps and excessive dampness in cotton. In case of
polyesters, this problem shall be mainly due to static charges and higher bulk of
fibres. The problem of lap licking can be reduced by increasing the pressure on
calendar rollers, reducing the pressure on racks, increasing the quantity of antistatic,
use of roving ends or lap fingers behind the calendar roller nip, blocking of top cage
and by reducing the lap length.

Patchy lap:

Patchy lap is a result of unopened tufts. Ensure that the mixing is opened thoroughly,
and increase opening points if feasible. Check tuft size at the delivery of each beater,
and adjust the setting between feed roller and beaters, reduce the gauge between
evener roller and inclined lattice, clean the cages, and increase effective suction at
cages.

Holes in lap:

Holes in the lap can be due to different reasons. Check the cages for damage, and
reduce tension draft.

Soft lap:

Lower calendar pressure makes the laps soft. Increase the calendar roller pressure.

Ragged lap selvedge:

Ragged lap selvedges are mainly due to uneven spots at the edges. Check for the
rough spots on the sides of the feed plates, leather linings for the cages, and keep the
edges of the scutcher clean.