The Carding Process in Spinning

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INTRODUCTION

• Known as the 'heart of spinning', it is the
  second and stage of spinning.
• The carding stage is all about fibre
  individualisation of the cotton material leading
  to formation of sliver material.
• The efficiency of carding machines and spinning
  cans determine the end result of yarn produced,
  therefore, it is important to make the choice
  carefully.

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WHAT IS CARDING?

• It is the process of removing clumps and locks
  from the cotton fibres that is received from
  blowroom and aligning them in parallel positions
  to create sliver.
• Carding is done to boost the processing
  efficiency levels, and render the best-quality
  yarns.
• In order to maximise the productivity of carded
  sliver, mills should always use advanced carding
  machines and quality-assured HDPE spinning cans,
  with high dimensional accuracy for efficient
  carding.
• The lapping stage eliminates impurities, the
  willowing process loosens the fibre, and then
  they are individualised into proper strands.

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IMPORTANCE OF CARDING STAGE

• The carding process eliminates all the neps that
  are generated in the mixing and the blowroom
  phases.
• Ensuring optimal cleanliness of cotton lies at
  the very heart of quality yarn production which
  is achieved during the carding phase.
• Fibre blending is also another extremely
  important result of the carding process.
• The sliver produced during this stage is very
  delicate in nature, hence the use of mechanically
  strong card cans and spinning cans is required.

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ROLE OF CARDING MACHINES

• After fibre individualisation and
  parallelisation, the remaining neps and
  impurities are removed from the cotton fibre.
• After the short fibres are eliminated as well,
  the fibre blending and orientation is done.
• Then finally, the slivers are formed in the
  carding machine, preparing them for the next
  stage, i.e. drawframing.
• Given the importance of carding in the overall
  textile yarn spinning process, it is only
  natural that leading OEMs are consistently coming
  up with advanced features in their carding
  machines.

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CARDING MACHINE STRUCTURE

• Carding Machines usually have a large number of
  different units like
• Chute Feed (for feeding the fibre in the machine)
• Pipe ducts
• Main cylinder
• Stripping device
• The flats
• Grid plates
• Transport and calendar rollers

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THE FINAL WORD

• Glitches in the carding stage can lead to a
  myriad of problems right from sagging and/or
  patchy cotton webs to sliver breakage.
• Therefore, Mills need to make sure that the
  carding machinery is being operated optimally,
  and HDPE spinning cans are being used for
  making the sliver handling process secure and
  seamless.

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In the world of textile yarn spinning, it is
often said that well carding is half spun and
that sums up the importance of carding in the
spinning process quite nicely.
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Carding Machine Functions