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 the same fiber is 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 the 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 the case of cotton, it is measured by the 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 laydown plant should be the same. Which means average micronaire value should be controlled in every cross section.

Written by

Engineer Sheikh Nurja

B.Sc Engineer of Textile

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What is Ginning, Objectives, Types, Ginning Process of Cotton

What is Ginning

To answer the question what is ginning? I would say, the process by which the fibers are separated from the seeds is called ginning. It is one of the most important steps of the spinning process. After collecting seed cotton from the field, cotton moves to nearby gins for separation of lint, seed and any other foreign particles. The production of a typical gin is about 12 bale per hour (here 1 bale = 500 pounds). Earlier the ginning process is to be done by manually but right now for higher production, manufacturers use an automated machine with higher productivity. The machine is well known as a cotton ginning machine.

What is Ginning, Ginning, Ginning of Cotton

Simply to define ginning we can say that the process is used to get the cleaned cotton by separating or removing the seeds, dust or any other foreign particles. So that better cotton can be offered for the cotton spinning mills.

 Objects of Ginning

  1. To make the fiber free from seeds without gin-cut fiber.
  2. To ensure the best quality of cotton and get the fair price of cotton in the market.
  3. To be confident that fiber does not contain excess and unexpected seeds or any other particles.
  4. To make the spinning process easier and effective

ginning process of cotton Ginning of cotton

Ginning Process of Cotton

  1. At first, the cotton is made to go through dryers to reduce moisture content.
  2. Then the cotton is made to go through cleaning equipment to remove foreign particles or materials.
  3. The cotton is then sent to the air conveyed to gin stands where revolving circular saws pull the lint from the saw teeth by air blasts or by rotating brushes.
  4. The cotton is compressed into 500 pounds weigh contained bales.
  5. Then the bales of cotton are shipped to the textile spinning mill for further processes.
  6. To ensure better quality the overall process is monitored by a quality control team.

Types of Ginning

There are two basic types of Ginning you may find. These are:

Saw Ginning

Rather than manual ginning, saw ginning is used which provides more clean cotton compared with manual or handheld separation process of seed from cotton.

Advantage of Saw Ginning

  1. Saw ginned cotton is more uniform
  2. Cotton is more clean than usual.

The Disadvantage of Saw Ginning

  1. Possibility of fiber breakage due to draw up the fiber from the surface of the seed.
  2. Increase neps
  3. Increase short fiber content

Roller Ginning

In the case of modern ginning, an automated roller is used in the ginning process of cotton. Nowadays this type of ginning technology is highly used for industrial purpose.

Advantage Roller Ginning

  1. Fiber quality is better compared with saw ginned cotton.
  2. High production because of the use of advanced technology in the ginning process.

Disadvantage Roller Ginning

  1. The moisture of seed mixes up with fiber in processing which causes cake cotton fault.

Faults in Ginning

  1. Gin-cut fiber
  2. Crushed seeds
  3. Neps formation
  4. Too much wastage

Written by

Engineer Sheikh Nurja

B.Sc engineer of textile

And

Md. Nahian Mahmud Shaikat