Welcome to our presentation

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 Project Title

Impact of cross-doubling in drawframe

on the quality of carded yarn

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 Presented by

Amit Chakrabortty 13-01-06-118

Asikul Mustafa 13-01-06-125

Imtiaz Shahriar 13-01-06-130

Al-Amin Jiku 12-02-06-105

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 Project Overview

1 Introduction

2 Aim of the project

3 Literature Review

4 Machinery and Methodology

5 Graphical Representations & Explanation

6 Key Findings, Limitation & Conclusion

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Introduction

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 Carding is called the “Heart of Spinning”.
Blow room
Quality of
Carding carded slivers

Directly influence
Breaker
drawframe

Finisher
drawframe

Simplex
Quality of
carded yarn
Ring frame
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 The performance of the machine is greatly affected by different technical
parameters such as gauge settings, wire sharpness, roller rpm & material
throughput rate etc.

 Different improvements in the machine as well as processes were

proposed and practiced. The most economic and practically viable
solution was to introduce cross-doubling.

 Therefore, in this study we are focusing on assessing the impact of cross-

doubling on the consistency of quality level of the produced sliver as well
as yarn.

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Aim of the project

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 Analyzing the performance of carding machine depending on the quality of
carded sliver & produced breaker drawn sliver by using good, moderate
and poor quality of carded sliver & continue the processes up to ring yarn

 Production of breaker sliver using cross-doubling & continue the processes

up to ring yarn

 Conducting all the tests using Uster AFIS and Evenness tester at each stage
of processing

 Analyzing the test results and assess the significance of cross-doubling

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Literature Review

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 Carding
Carding is a mechanical process that disentangles, cleans and intermixes fibres
to produce a continuous web or sliver suitable for subsequent processing.

Figure: Carding machine

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Objective
1. Opening to individual fibres
2. Disentangling of neps & Elimination of short fibres
3. Elimination of dust & impurities
4. Sliver formation

1, 2 ,3

1 4
3

Figure: Cross-sectional view of carding machine 12

 Action involved in carding
machine

1. Carding action

 Occurring between cylinder and flat

 Different wire and speed direction

Function:

 Maximum individualization of fibers Figure: Carding action

 Disentangling of neps

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2. Stripping action

 Occurring between licker in

and cylinder
 Same wire direction but same or
different speed direction

Function:

 Opening & individualization

of fibres
Figure: Stripping action

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3. Doffing action

 Occurring between cylinder

& doffer

 Opposite wire direction &

same speed direction

Function:
 Web transfer Figure : Doffing action

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 Drawframe
 Draw frame is a machine for combining and drawing slivers of a textile
fibre.

Figure: Drawframe

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Necessity of drawframe

 From the carding machine, we get the carded slivers but the fibres
orientation in this carded sliver is not so good. This disorientation of
fibres is caused by the condensation of the fibre web by forming carded
sliver. For proper orientation and straightening the fiber in the sliver, draw
frame is also necessary.

Zoom in

Doffer web Condensation of fibre Carded sliver

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 Task of drawframe
 Equalizing
During doubling, the thick and thin place will tend to be distributed and
compensate each other. This effect is known as an equalizing effect.

Figure: The averaging-out effect

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 Parallelizing
To obtain an optimal value for strength in the yarn characteristics, the fibres
must be arranged parallel in the fibre strand. The draw frame does the task of
creating this parallel arrangement.

 Dust removal
Dust removal can only be carried out to a significant degree when there are
high levels of fibre/fibre or fibre/ metal friction.

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 Actions Involved in Draw
Frame
1. Doubling

Doubling is the combination of several slivers that are attenuated by draft.

Doubling serves two purposes: i) it enables the reduction of sliver irregularity
and ii) improves the blend or mix of fibres.

Figure: Doubling 20
2. Drafting
 It is the process of reducing weight per unit length of strands.

3. Drawing
 Drawing is the term applied to the operation involving the doubling and drafting
of slivers.

Drafting Doubling.

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Figure :Drawing process in draw Frame
However, doubling has some limitations:
 Doubling can average out only short to medium term variation, not long
term variations.
 Doubling cannot correct periodic variations when repeatedly occur side by
side.
 Doubling can only reduce the coefficient of variation value of any
occurring variation by the total number of doublings.

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Limitation of drafting :

 Drafting is also necessary to increase length per unit weight of strands but
higher draft increases the irregularity of strands.
Irregularity of strands

Drafting

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 Imperfection index (IPI)
IPI stands for Imperfection Index of yarns. Imperfection are the description of
thick places, thin places, and neps in 1000m of yarn.

1.Thick place:
If a place in the yarn exceeds +35% with respect to mean yarn cross-section
then it is called a thick place.

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Figure: Different imperfection in a ring yarn
2.Thin place:

If a place in the yarn exceeds

-30% with respect to mean yarn
cross-section then it is called a
thin place.

3.Neps: Figure: Different imperfection in a ring yarn

A nep is very short thick place or

entangled mass of fibres in the
yarn. A more recent classification
defines neps as biological or
mechanical.

Figure: Different imperfection in a ring yarn

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Count Strength Product(CSP)

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Methodology & Machineries

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 Raw materials used
 Fibre used: Cotton
 Country of origin: Cameroon

Table : Properties of fibres

UHML Strength Elong. Rd

SCI MIC MAT Unf SFI +b Tr.cont
[mm] (g/tex) (%) (%)

125 4.4 0.87 28.89 81 9.2 29.4 5.96 75 14 12.76

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 List of Machineries used
Carding

Machine name Carding

Model C70
Manufacturing company Rieter

Manufacturing year 2015

Country of origin Switzerland

Function
Figure: Carding
 Fibre individualization
 Disentangling of neps
 Elimination of dust and dirt particles.
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 Breaker Drawframe

Machine name Breaker drawframe

Model SB D22
Manufacturing Rieter
company
Country of origin Switzerland

Manufacturing year 2015

Function: Figure: Breaker Drawframe

 Equalizing

 Parallelizing & straightening

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 Finisher Drawframe

Machine name Finisher drawframe

Model RSB D24

Manufacturing Rieter
company
Country of origin Switzerland

Manufacturing year 2015

Function: Figure: Finisher Drawframe

 Equalizing

 Parallelizing & straightening

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 Simplex

Machine name Simplex

Model CMT 1801
Manufacturing Hicorp
company
Country of origin China
Manufacturing year 2015

Function:
Figure: Simplex
Drafting
Twisting
Winding

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 Ring frame

Machine name Ring frame

Model G32
Manufacturing Rieter
company
Country of origin Switzerland
Manufacturing year 2015

Function:
Drafting Figure : Rieter G32

Twisting
Winding

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 Quality control equipment
1. USTER® HVI-1000

Name Company Origin

USTER® USTER®
USA
HVI-1000 technologies, Inc.

This equipment contains three modules.

They are:
Figure : USTER Evenness Tester
 Micronaire

 Color and trash

 Length and strength

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2. USTER® AFIS PRO-2

Name Company Origin

USTER® USTER®
AFIS technologies, USA
PRO-2 Inc.

This equipment has three modules.

 NC Module (Nep classification)

 L & M Module (Length and Figure : USTER® AFIS PRO-2

Maturity)

 Trash Module

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3.Uster evenness tester

Name Company Origin

USTER USTER®
USA
TESTER 5 technologies, Inc.

Testing Results

 Mass variation (U%, CV %)

 Imperfections (Thick/km, Thin/km,

Figure : USTER TESTER 5
Neps/km)

 Hairiness

 Diagram

 Spectrogram and simulation of fabric 36

3.Wrap Reel

Name Company Origin

China textile
Wrap Reel China
machineries co.

Function:
A wrap reel is a device for producing
lea of yarn. Figure : Wrap Reel

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4. Lea strength tester

Name Company Origin

Precitronic
Lea strength
Instrument & India
tester
Controls
.

Function

 To test bundle (120 yds. of skein) yarn

strength Figure : Lea Strength tester

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 Working Procedure
Carding

 At first 7 carding machines were chosen and their NRE% were analyzed
through testing by USTER® AFIS PRO-2

Card-1 Card-2 Card-3 Card-4 Card-5 Card-6 Card-7

NRE% NRE% NRE% NRE% NRE% NRE% NRE%

81.71 72.83 71.25 75.29 67.58 68.95 60.61

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 Working Procedure
 Based on the values of NRE%, three carding machines were selected where,
1. Machine no. 01, gives high NRE%. It was referred as sample A
2. Machine no. 03, gives moderate NRE%. It was referred as sample B
3. Machine no. 07, gives low NRE%. It was referred as sample C
Sample D
Sample A Sample B Sample C

Card-1 Card-3
NRE% NRE%
81.71 71.25

Card-1 Card-3 Card-7 Card-7

NRE% NRE% NRE% NRE%
81.71 71.25 60.61 60.61

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 Working Procedure
Breaker draw frame

 Six cans of card slivers of 0.11 Ne were fed to breaker draw frame and
eight cans of 0.11 Ne of breaker drawn sliver were produced.

Carded sliver Breaker drawframe Breaker drawn sliver

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 Working Procedure
Finisher draw frame

 Eight cans of breaker drawn slivers of 0.11 Ne were fed to finisher draw
frame and six cans of 0.11 Ne of finisher drawn sliver were produced.

Breaker drawn sliver Finisher drawframe Finisher drawn sliver

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 Working Procedure
Simplex

 After that, six cans of finisher drawn slivers were fed to the roving frame
which produced eight rovings of 0.8 Ne.

Finisher drawn sliver Simplex Roving

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 Working Procedure
Ring frame
 These eight rovings of 0.8 Ne were fed to the ring frame and produced ten
ring cops of 20 Ne.

Roving Ring frame Ring cop

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 Working Procedure
 This process was repeated for sample B , sample C and sample D in the same
manner with the same machines.

 Evenness and AFIS tests were carried out at each processing stages for
sample A, B, C and D respectively.

 Then sample D was compared against yarn produced from sample A, B and
C.

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Graphical Representations
&
Explanations

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 Sample A was produced from high performance carding machine whereas sample B &
sample C were produced from moderate and lower performance of carding machine.
 Here the three bars indicate the mass variation (CVm%) of carded sliver of individual
carding machine. The carded slivers show lower mass variation because the three machines
were equipped with autoleveller. 47
 The trend of variation of nep content in breaker drawn slivers show the similar variation
which was found in carded slivers. In the breaker drawframe, the fibres which are present as
tailing hooks are straightening by drawing.
 The bar diagram in the above chart indicates the mass variation (CVm%) of different breaker
drawn slivers. Same trend has been continued which variation was found in carded slivers.
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 The bar diagram in the above chart indicates the nep content in finisher drawn slivers.
Similar trend has been observed which was found in breaker drawn slivers.
 This bar diagram represents the mass variation (CVm%) of different samples of finisher
drawn slivers. From this bar diagram, it can be easily explained that there are slight
variation among these samples which was found in carded slivers. 49
This bar diagram represents the mass variation (CVm%) of different samples of
rovings. From this chart it can be easily explained that the trend of variation which
was found in carded sliver was continued upto rovings.
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This bar diagram denotes the mass variation (CVm%) of different samples of yarns.
From this chart it can be seen that there are slight variation among these sample. So, it
can be noticed that cross doubling has a very little impact on the mass variation (CVm
%) not only on slivers but also in yarn.
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No thin place was found for the threshold value (-50%)/km. That’s why the thin places were
compared against the threshold value (-30%)/km..
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Thick places were observed against the threshold value (+50%)/km whereas sample A,
B and C represents the lower, moderate and higher value respectively but sample D
represents the average value of sample A and B. 53
From this chart, it can be described sample A, B and C represent lower, moderate
and higher neps (+200%)/km accordingly whereas sample D represents the average
closest value of sample B and C. It can be seen that, as the sample A produced from
higher efficiency of neps removal carding machine whereas sample D produced
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from the slivers which are the combination of three carding machine.
From this chart, it can be explained that sample A, B and C represents the lower,
moderate and high imperfection index whereas sample D represents the average
value of sample A, B and C. Sample D shows the average value of IPI which was
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produced from the combination of sample A, B and C.
In this bar diagram, sample A showed the highest value of CSP followed by sample B and C.
Sample D shows a value closer to the average level of the three samples. As the nep content in
sample C was higher, it produced more number of weak places in yarn. This resulted in lower
CSP value i.e. yarn strength. As in sample B and C the number of neps i.e. imperfections
gradually decreased, the strength of the resultant yarn also increased gradually 56
Key Findings, Limitations
&
Conclusion

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 Key findings
 The yarn produced from cross-doubling minimized the variation at
breaker drawing stage and this result trend continued upto the
imperfection level of final yarn.

 The presence of imperfection in the yarn created weak places in yarn

resulting in loss of yarn strength.

 No noticeable improvement was observed in case of mass variation as

there was very little variation among the carded sliver samples.

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 Limitations

 The project was carried out only for one count (20Ne). The study would
have been more enriched if we could conduct the test on multiple fineness
of yarn.

 The number of observation per test was limited by the factory

management. More number of observations would have increased the
accuracy of the results.

 Standard atmospheric condition could not be controlled at the QA

laboratory due to absence of humidification plant.

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 Conclusion
 Nowadays, consistent quality level of yarn is a pre-requisite for any customer
as well as spinner. To obtain this, different practices as well as specialized
equipment are incorporated into processes by the spinners.

 Among them, cross-doubling is a very simple practice which involves no

extra cost. Upon studying its effectiveness, it was observed that by using this
practice the variation in imperfection as well as strength of the yarn caused
by the carding machines can be effectively controlled at a certain level.

 Although the minimization in mass variation observed was negligible,

therefore, it can be referred as an effective practice in obtaining consistent
quality level and should be performed in production floor.

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