Optimizing Carding Speed Parameters and C-60 RSB Draft to Improve Sliver Quality

ABSTRACT

The optimization of settings of spinning machinery is one of the technically most urgent tasks when it comes to achieving the best possible raw material utilization for a high-quality yarn. Carding, as part of an integrated draw frame, is the very critical process in spinning preparation for open end rotor spun yarn manufacturing. The aim of the integrated draw frame process in a spinning line is to produce uniform slivers (with low deviation in mass per unit length) where the fibers are laid parallel and the sliver has relatively low neps, short fiber, trash and dust contents. This work examined the potential effects of a range of speed settings on the physical properties of sliver. Optimization results of the study showed that 3.5 CVm% and 2.8 U% of sliver achieved with 96.3% desirability with optimum predicted value of neps 252 cnt/g, short fiber content by number 25.8%, trash 29 cnt/g and dust 234 cnt/g satisfied at licker in speed of 1250 rpm, cylinder speed of 650 rpm, flat speed 0.29 m/min, and C 60 RSB total draft of 2.11 for processing the cotton variety of Deltapine 90 (DP-90).

摘要

优化纺纱机械的设置是实现高质量纱线的最佳原材料利用率的技术上最紧迫的任务之一. 梳棉作为整体牵伸机构的一部分，是开口转杯纱生产中纺纱准备的关键工序. 纺纱线上的整体并条机工艺的目的是生产均匀的条子（单位长度质量偏差小），其中纤维平行排列，条子的棉结、短纤维、杂质和灰尘含量相对较低. 这项工作考察了一系列速度设置对棉条物理性能的潜在影响. 优化研究结果表明，在转速为1250rpm、滚筒转速为650rpm、平速为0.29 m/min、C60RSB总牵伸为2.11的条件下，棉结252 cnt/g、短纤含量为25.8%、杂质29 cnt/g和粉尘234 cnt/g的最佳预测值，对德尔塔平90棉品种（DP-90）的加工效果分别达到3.5CVm%和2.8 U%，切条率达到96.3%.

KEYWORDS:

• Deltapine 90
• IDF sliver
• carding speed
• optimization
• RSB draft
• box-behnken design

关键词:

• Deltapine 90
• IDF条子
• 梳理速度
• 优化
• RSB草案
• 箱线图

Research highlights

Process optimization of the carding machine C 60 RSB to produce quality sliver designed for rotor spun yarn from 100% DP-90 upland cotton was studied. Research highlights are presented hereunder:

(i) The average HVI fiber property of the cotton was: Moisture content (6.4%), Micronaire (4.2), Maturity coefficient (0.86), Upper half mean length (28.5 mm), Uniformity index (81.1), Short fiber index (10.1%), Strength 21cN/tex, Elongation (5.3%), Trash Grade (4), Colour grade (31–1) & Spinning consistency index (97.5). The number of bales participated in the mix was 118.

(ii) The study is conducted to produce 0.11Ne sliver designed for rotor spun yarn. The predicted optimum process parameters were: coefficient of variation of mass (3.5%), unevenness (2.8%), level of neps (252 cnt/g), SFC by number (25.8%), count of trash (29 cnt/g) and count of dust (234 cnt/g). This predicted optimum process parameters allows the spinner to produce quality sliver with the following USTER^Ⓡ Statistics 2023 level: 25% in SFC, 65% in level of neps, 95% in level of dust and 95% in level of trash.

(iii) The optimum machine parameters for achieving this sliver quality level was: licker in speed 1250 rpm, cylinder speed 650 rpm, flat speed 0.29 m/min, and C 60 RSB total draft 2.11.

(iv) The finding can help the spinner to estimate process parameters of C 60 RSB carding machine when processing upland cotton genotypes (varieties) with similar HVI fiber properties.

(v) The results of the study can also help the cotton breeder to breed high quality cultivars which can satisfy optimum speed requirements of modern high speed C 60 RSB carding machine.

Acknowledgments

Authors are thankful to the Bahir Dar Textile Share Company for their valuable cooperation during the sampling and spinning of the genotype used in this research work.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Disclaimer

Research findings presented in this research work are the author’s contribution. The machines trade name used in this study are properly mentioned by keeping the format of standard scholarly article writing.

Ethical approval and consent

This study was part of M.Sc. thesis which was received ethical approval from Ethiopian Institute of Textile and Fashion Technology, Bahir Dar University (identification number BDU1302320).

This publishing agreement has been approved by and entered into between:

Addisu Temesgen Alamirew (M.Sc.), Department of Textile Engineering; Dire Dawa University, Dire Dawa, Ethiopia and Getnet Belay Tesema (Dr.-Ing.), Ethiopian Institute of Textile and Fashion Technology, Faculty of Textile; Bahir Dar University, Bahir Dar, Ethiopia.