Blending in Spinning Mill

Blending may be defined as a condition in which every fibre characteristic is found in the same proportion as in the original blending within every unit cross section of the yarn .Fibre blending has been practiced since the beginning of the cotton textile industry due to the variation in the physical properties of cotton fibres like scrapple length, fineness, strength & cleanliness.

Blending in Spinning Mill

blending in spinning millObjects of blending

  • To achieve uniform quality of product for a longer duration.
  • To improve processing performance, increase yarn strength.
  • To reduce & control cost of production.
  • To facilitate the cotton for regaining its moisture content lost during baling.

Blending procedure

Stages in Blending operation, Blending is carried our three stages:

  • Metering determination & precise establishment of quantities of the individual components.
  • Mixing that is bringing together of the metered quantities.
  • Intermingling distributing the components evenly in the body of fibres.

Types of blending operation

Blending type     

Process stage

Bale Mixing Before the blow room
Flock blending Within the blow room
Lap blending By using scatters
Web blending At the ribbon-lap m/c or the blending
Sliver blending At the D/F,the sliver-lap m/c the comber
Fibre blending At the card or the OE- spinning m/c
Roving blending At the Ring Spinning m/c

Blending Techniques

To achieve homogeneous blend the following techniques were adopted.

  • Lap Blending
  • Card Blending.
  • Bin Blending.
  • Hand-stock Blending.
  • D/F Blending.
  • Massive Blending.

Here detailing about some common technique of blending

Lap blending

The blending technique is still used successfully to permit the blending of cotton of contrasting fiber properties to produce a variety of end users. A doubling scutcher is requires, this has a conveyor lattice in feed on which from four to six laps could be laid. The lap sheets from these laps passed doubled through a beater position followed by pair of cages &lap winding device.

Advantage of Lap blending

Procedure very good transverse blends & also a good longitudinal blend.

  • It is very easy process.

Disadvantages of Lap blending

  • Blend proportions are limited.
  • Need for control of lap wt.

Card Blending

Blending by doubling with laps at the card is sometimes used in high production cards. The procedure involves use of a double lap roll attachment whose feed rolls are positively driven by a link chain by the regular lap roll gear.

Advantages of Card Blending

  • Most intimate blend is obtained.
  • This method is used to randomly mix two laps differing in color.

Disadvantages of Card Blending

  • It can’t be obtained from wide range.
  • Controlled metered blending can’t be carried out.
  • Only make a previously proceeded blend more intimate.

D/F Blending

With D/F blending the card slivers are doubled at the drawing process in a predetermined fashion. The percentage of the blending depends on the number of slivers processed. In processing of cotton this method is not used for blending purposes, but it is the most popular method for blending man-made fiber fiber with cotton.

Advantage of D/F Blending

  • Suitable for blending two different cotton qualities.
  • Provide best blend in the longitudinal direction.
  • Working procedure is not complex.

Disadvantage of D/F Blending

  • Require additional blending passage.
  • Stripiness may be produce in the finished product.
  • Poor transverse blending in the product.
  • Fiber heterogeneity produced.

Written by

Engineer Sheikh Nurja

B.Sc engineer of textile

Merchandiser at buying house

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Mixing in the Spinning Mill

Mixing is the first and important process in the spinning process. Mixing is a process by which different grade of same fiber are kept together.

Types of Mixing

  • Volume mixing.
  • Bin mixing.
  • Card mixing.
  • Weight mixing.
  • Automatic mixing.
  • Hand stock mixing.
  • Lap mixing.
  • Sliver mixing.
  • Mixing by hopper.

Mixing in the Spinning Mill

mixing in the spinning mill

Mixing in a Spinning Mill

Factors to be Considered Before Doing Mixing

Length of cotton

The length of the fibers should be equal otherwise various types of problem will create. Fibers having different length causes problem in drafting zone &also in simplex or ring frame.

Micronaire of cotton

The second considerable factor for mixing is the micronaire value of fiber, the higher, the micronaire value, the fibers are regarded coarser.

Color of cotton

Color is also a very important factor in mixing. In case of cotton, it is measured by brightness of cotton and the presence of yellow color in cotton.

Micronaire CV % of mixing bales

The micronaire CV % of mixing bales should be 5%.

Micronaire deviation

The micronaire deviation of cotton fibers should be (+-0.1) or (+-0.05). Otherwise mixing quality cannot be classified as good quality.

Length deviation

Length deviation should not exceed 10% deviation from mixing to mixing for the same lot.

Color deviation

in mixing, two lot of adjacent color can be mixed, such as white and light spotted or light spotted and can be mixed. But white and spotted cannot be mixed.

Lay down

Every cross section of the lay down plant should be same. Which means average micronaire value should be controlled in every cross section.

Written by

Engineer Sheikh Nurja

B.Sc engineer of textile

Merchandiser at buying house

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Ginning Process of Cotton

Ginning

The process by which the fibers are separated from the seeds is called ginning. It is one the most important step of spinning process. After collecting from field, Seed cotton moves to nearby gins for separation of lint and seed. The production of a typical gin is about 12 bale per hour. (here 1 bale = 500 pound)

 Objects of ginning

  1. To make the fiber free from seeds without gin-cut fiber
  2. To get fair price of the cotton
  3. To be confident that fiber does not contains excess and unexpected seeds
  4. To make the spinning process easier and effective
ginning process of cotton

Ginning of cotton

Ginning process of cotton

  • At first the cotton is made to go through dryers to reduce moisture content.
  • Then cotton is made to go through cleaning equipment to remove foreign matters.
  • The cotton is then air conveyed to gin stands where revolving circular saws pull the lint from the saw teeth by air blasts or by rotating brushes.
  • The cotton is compressed into 500 pounds weigh contained bales.
  • Then the bales of cotton are shipped to textile mill for further processes.

Type of ginning

Saw ginning

Advantage of saw ginning

  • Saw ginned cotton is more uniform
  • Cotton is more clean

Disadvantage of saw ginning

  • Possibility of fiber breakage due to drawn up the fiber from the surface of seed
  • Increase neps
  • Increase short fiber content

Roller ginning

Advantage Roller ginning

  • Fiber quality is better than saw ginned cotton
  • High production

Disadvantage Roller ginning

  • The moisture of seed mix up with fiber in processing which cause cake cotton fault.

Faults in ginning

  • Gin-cut fiber
  • Crushed seeds
  • Neps formation
  • Too much wastage

Written by

Engineer Sheikh Nurja

B.Sc engineer of textile

Merchandiser at buying house

If you like this article please do not forget to share on facebook and put your valuable comment