BLOOWROOM PRODUCT OVERVIEW Mixer Precleaner Mixer Fine Cleaner
BLOOWROOM - PRODUCT OVERVIEW Mixer Pre-cleaner Mixer Fine Cleaner Bale Opener Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1
Short-staple Spinning Blowroom Carding Drawing Roving frame Ring frame A typical process-line for ring spinning system Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2
The Blowroom The blowrooom is the first step of yarn production in the spinning mills. Bales are taken to the blowroom and prepared for the process. Briefly, basic operations in the blowroom are, 1) 2) 3) 4) 5) Opening Cleaning Dust removal Blending Even feed of material to the card RIETER BLOOWROOM - PRODUCT OVERVIEW Dosage blender Bale opener Mixer Pre-cleaner Fine cleaner Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3
OPENING Type of Opening and Degree of Opening Two stages of opening must be distinguished. I. Opening to flocks: in the blowing room. 2. Opening to fibers: in the card and OE spinning machine. Ways of opening: 1) Breaking up of larger tufts into several smaller tufts to create new 2) Opening up of individual tufts to increase the volume. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I surfaces, 4
Opening Devices Type Rollers Appearance Description Small diameter, widely used, e. g. in step cleaners. Drums Larger diameter, little used, e. g. in mono-cylinder cleaners. Quilted shaft Shaft with many beater rods, hardly used. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 5
Opening Devices Type Multiple-bladed beaters Spiked lattice Carding bars or plates Appearance Description Two, three, or more arms. Now used only in old lines. Endless belts with transverse wooden or plastics bars in which needles are set, gives very gentle opening. The devices associated with carding drums of the card. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 6
DUST REMOVAL An often underestimated task of the blowroom line is the removal of dust. However, it is as important as the removal of impurities. Dedusting in the blowroom happens by air suctioning only, either between the machines, e. g. by dust cages, dust extractors , etc. , or within the machine by normal air separation. Every blowroom machine must be capable of extracting dust, so that special dedusting machines should be needed. The efficiency depends not only on the devices but also on the size of the flocks. The smaller the flocks, the higher is the efficiency. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 7
BLENDING Blending of fiber material is an essential preliminary in the production of a yarn. Fibers can be blended at various stages of the process. These possibilities should always be fully exploited, for example, by transverse doubling. However, the starting process is one of the most important stages for blending, since the components are still separate and therefore can be metered exactly and without dependence upon random effects. A well-assembled bale layout and even (and as far as possible, simultaneous) extraction of fibers from all bales is therefore of paramount importance. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 8
EVEN FEED OF MATERIAL TO THE CARD Finally, the blowroom must ensure that raw material is evenly delivered to the cards. Previously, this was carried out by means of precisely weighed laps from the scutcher, but automatic flock-feeding installations are now state of the art. Whereas, in the introductory phase, such installations were subject to problems regarding evenness of flock delivery, today they generally operate well. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 9
BLOWROOM MACHINERY Since blowroom machines have to fulfill various functions, they vary in concept and in design. Basically, five types can be distinguished: 1. 2. 3. 4. 5. Opening machines. Mixing machines. Cleaning machines. Dust-removing equipment or machines. Recycling machines. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 0
In order to be able to perform their assigned tasks optimally, these machines must be located at quite specific positions in the blowroom line. In a normal modem blowroom installation, 4 -5 clearly distinguishable operating zones can be identified Bale Opening to finest flocks Zone-1 Machines Pre-cleaning no nipping: gentle treatment Zone-2 Machines homogenous Zone-3 Machines nipped: intensive treatment Zone-4 Machines Blending Fine cleaning *Fine cleaning II Zone-5 Machines Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 1
Zone 1 Opening Machines Automatic Bale-opening Machines The first-generation automatic bale-opening machines were mostly stationary. Only the bales were moved, either backwards and forwards or in a circle. The second-generation machines are of the travelling type , i. e. they move past the bales of the layout and extract material from top to bottom. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 2
Bale Plucking Machine Model LA 17/LA 28(Lakshmi) Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3 1
Travelling machines have the advantage that more bales can be processed as an over all unit (charge), and thus a better long-term blend is achieved. It should be noted, however, that these machines extract material only in batches, i. e. they can process only one, two, or at most three bales simultaneously. If a long-term blend is to be achieved, then mixing machines must be included downstream from the bale opener. A bale layout can consist of up to 60 bales from between four and six different origins, i. e. from four to six different types of bales per fiber blend. Intervening spaces often have to be left between the individual bale groups so that the extraction roller can be adapted to varying bale heights. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 4
The machines are completely electronically controlled and extract material from all bales evenly, independently of varying bale densities. The machines of this first zone should be able to: • extract material evenly from the bales; • open the material gently; • open up to the smallest flocks; • form flocks of equal size; • process as many bales as possible in a single charge; • be universally applicable, i. e. easy to program; • blend material right at the start of the process; and • permit the putting together of a fiber blend from several components (fiber origins). Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 5
The unifloc of Rieter In concept, this is currently the most widely used type of machine. Machines similar to the UNIfloc are built by Marzoli (B 12), and Trützschler (Blendomat) among others. The Rieter UNIfloc enables up to 130 bales arranged per side as four components (different bale types) per blend over a maximum layout length of 50 m to be processed. The machine can process one or two blends simultaneously. The production rate is normally up to 1400 kg/h. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 6
The feed duct (D) and the two guide rails (5) are secured to the floor. The chassis (A), which moves back and forth on the guide rails, carries a turret (B), which is rotatable through 180° and supports a raisable and lowerable extracting assembly (C). The latter has individually replaceable double-tooth discs and changes its direction of rotation on reversal of the direction of movement of the chassis, so that material can be extracted in both directions of travel. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 7
Zone 2 Machines Pre-cleaning - they generally process the material while it is in free flight; and - the striker elements are widely spaced on the operating rollers. The opening effect is correspondingly small. This is acceptable in zone 2 because an adequate surface area has already been created before that stage. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 8
These machines are preceded by the bale-opening machines that form small flocks and thus large surface areas. The bale-opening machines-themselves cannot clean these surfaces because they are not fitted with cleaning devices, or, where such devices are present, they can eliminate only a fraction of the impurities owing to the high material throughput. In their basic design, pre-cleaning machines are optimal at their given position in the line but not at other positions. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 1 9
The Step Cleaner The step cleaner is disappearing more and more from the market. In this machine, the material falls into the feed hopper and passes to the first beater. From there, it is transported upwards by the six (sometimes four) beater rollers, each carrying profiled bars; the beaters are arranged on a line inclined upwards at 45°. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 0
The elimination of impurities takes place during the continual passage of the material over the grids arranged under the rollers. The grids are always adjustable, and usually the beater speed is also adjustable. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 1
Dual-roller cleaner An example of the dual-roller cleaner is the B 31/1 of Marzoli. Here again, similar models are offered by other manufacturers. The machine consists of a large cleaning chamber containing two drums of 610 -mm diameter rotating in the same direction. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 2
A fan downstream from the dual-roller cleaner (e. g. in a condenser) draws material through the machine by suction. Owing to the larger size of the chamber in comparison with that of the suction duct, the suction effect falls away in the chamber. The exit opening is arranged at a higher level than the infeed opening. Thus, only the smallest flocks can fly straight through. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 3
Most flocks fall into the region of the drums, where, for purpose of cleaning, they are fed either once or more frequently over the grid bars before they can leave the machine. The spikes are arranged in a spiral on the drums in order to improve the passage of the material. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 4
Single roller cleaner A large roller equipped with specially designed pins guides the raw material several times over a set of grid bars between entry and exit , which results in a high cleaning efficiency. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 5
passes The material simultaneously through a dustextraction system, which results in a high dedusting effect of the machine. The material-guidance system within the machine is purely mechanical and independent transportation of air. A system with a lock roller machine automatically removes waste. of the vacuum below the The machine excels in high cleaning efficiencies with the lowest fiber loss. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 6
Zone 3 - Blending Machines The Mixing Battery This was once the most common type of mixing, and it is still used. The mixing battery represents the conventional mode of mixing at the start of the process, from two to five mixing bale openers operate together; usually one of these openers is a waste feeder. A good blend is obtained because each opener can be supplied with a plurality of bales, and the opened material from all bale openers flows together onto a common conveyor belt. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 7
Crosrol Blender (4 CB/6 CB) Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 8
Multiple Mixer The machine consists of several (from six to eight) chute chambers into which the material is blown from above. The chutes are filled successively, and the material is removed from all chutes simultaneously. This gives a good long-term blend. Ejection of flocks onto a collecting conveyor is done by take-off and beating rollers under the chutes. The filling height is held fairly constant by feelers. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 2 9
UNImix of Rieter The machine is made up of three parts: a storage section, an intermediate chamber, and a delivery section. Flocks are fed pneumatically and simultaneously into six Jshaped chutes (2), arranged one behind the other in the storage section. A conveyor belt (3) leads the stock through the intermediate chamber to the take-off unit. The material columns are thus diverted out of the vertical into the horizontal. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3 0
Zone 4 Fine Cleaning (I) machines In contrast to the zone 2 machines, those of zone 4 have again to produce new surfaces, i. e. the cleaning operation must be preceded by opening. Zone 4 machines therefore almost always operate with clamp feeds. Bladed rollers, spiked rollers, or rollers fitted with a coarse sawtooth are generally used. These are often called horizontal openers or cleaners. Crosrol places in its horizontal opener (Three-roller Cleaner) three bladed rollers behind each other in a horizontal line. With a modern blowroom line, for many types of cotton the fine cleaning line (I) is no longer required, only fine cleaning (II). Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 6 5
Horizontal Opener B 34 of Marzoli The machine is fed through a cage condenser. The feeding silo (1) has an adjustable side to vary its capacity according to the required production and the type of material to processed. The material, whose controlled by a conveyed through grooved feeding towards the level is photocell, is pair of a rollers nipping (2) roller and the feelers. Prof. Dr. A. Kirec ci - TE 211 Yarn Man. I 6 6
he speed of the feeding rollers is varied by means of the potentiometer in order to ensure the constant high yield of the machine in line with the requirement of the other machines in the production sequence. The opening-and-cleaning box is equipped with a beater (3) and a grid (4) fitted with adjustable blades. Prof. Dr. A. Kirecci - T E 211 Yarn Man. I 67
Zone 5 Machines - Fine Cleaning II In older installations, this zone was provided by the scutcher in the form of a Kirschner beater and still may be even in modern lines without a scutcher. Alternatively, or possibly in addition to the Kirschner beater, there may be a saw-tooth or needle roller. This form of intensive-cleaning zone, with a carding or combing roller, has been forced on spinners in the past, since cotton stock has become steadily more contaminated, and the impurities have become progressively smaller. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3 4
Where only one machine is used, the carding roller is preferred to the Kirschner beater. In this zone, machines from the individual manufacturers exhibit many similarities. Often, they are universal machines, which can be fitted with different types of opening roller. As a representative example, the Rieter cleaner will be described. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3 5
Fine Cleaning and Dedusting Machine UNIflex B 60 R of Rieter This machine for the opening, cleaning, and dedusting of cotton. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3 6
The Components of Blowroom Machines Feed Apparatus Feed of material to the opening rollers occurs in free flight (gentle but less intensive treatment of the fibers) or in a clamped condition (intensive but less gentle treatment). Free flight requires only a drop chute, suction pipe, or vortex transport from rollers; a clamped-feed condition demands special machine components. Basically, feed devices can be distinguished according to whether they consist of: two co-operating clamping cylinders; a feed roller and a feed table; or a feed roller and pedals. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3 7
Operating with two clamping cylinders gives the best forwarding motion, but unfortunately also the greatest clamping distance (a) between the cylinders and the beating elements. a Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3 8
In a device having a feed roller and a table, the clamping distance a can be made very small. This gives intensive opening. However, clamping over the entire width is poor since the roller presses only on the highest points of the wadding. Thin places in the web can be dragged out of the wadding as a clump by the beaters. a Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 3 9
Where pedals are used, the table is divided into many sections, each of which individually presses the web against the roller, e. g. via spring pressure. This gives secure clamping with a small clamping distance a. As far as the feed system is concerned, influence can be exerted on opening and cleaning only via the type of clamping, mainly via the clamping distance (a) to the opening element. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 4 0
Opening Devices The great majority of operating devices in blowroom machines function as opening devices. Only in co-operation with cleaning apparatus such as grids, etc. , can they be made to function as cleaning units. Consequently, they are designed to operated in both opening and cleaning machines. Opening units can be classified as: endless-path; gripping; rotating assemblies. Depending on their design, construction, adjustment, etc. , these assemblies exert enormous influence on the whole process. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 8 1
Endless-path Devices (Spiked Lattices) Spiked lattices serve as forwarding and opening devices in bale openers and hopper feeders. They consist of circulating endless hoses or belts with transverse bars at short intervals. The bars are of wood or plastics; steel spikes are set into the bars at a special angle and at greater or smaller spacing. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 8 2
Owing to their disposition, inclined lattices usually feed the material upwards at an angle. The material is carried along by the spikes penetrating into the raw material. Opening is obtained because in the upper region of the lattice there is a counter-rotating roller, also clothed with spikes and located fairly close to the lattice. This roller strips the material from the inclined lattice. Prof. Dr. A. Kirecci - 11 arn Man. I Y TE 2 83
Rotating Devices I-Rollers with Teeth (Blades) or Spikes Short, flat, oval, or round iron pegs are welded, riveted or screwed on the surface of short cylinders. Flat and oval pegs are secured with the narrow side facing the direction of rotation. Various spacing of the striker elements are used. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 4 4
These devices are incorporated mainly in modem horizontal cleaners, chute feeds, mixing bale openers, step cleaners, etc. , which are located from the beginning to the middle of the blowroom line. At the start of the line, the spacing of the striker elements on the roller is greater; finer spacings are used in the middle (to the end) of the line. The rollers rotate at speeds in the range of 600 -1000 r/min. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 4 5
II-Drums with Teeth, Small Blades, or Spikes The cylindrical parts are similar to those of the spiked rollers, but they have larger diameters of 600 mm and more. The striking elements are mostly of the same type, though they may differ. In several designs, shafts carrying discs are used in place of cylindrical bodies (porcupine drum). Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 4 6
III-Rollers with Toothed Discs In contrast to spiked rollers or drums, which have quadrilateral or round elements, toothed-disc units have noses triangular plucking elements (coarse sawteeth). The complete opening device is made up of many such toothed discs secured to a shaft with an appropriate number of distance pieces. In this case also, the removal of material in strips is to be avoided. In toothed discs, the teeth are almost always asymmetrically formed, since they have to operate in only one direction and therefore rotate in only one sense. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 4 7
Automatic bale-opening machines often require alternative arrangements, since in many cases they move backwards and that is, the directions of movement and of removal of the material vary. The material-extracting roller should be sometimes in one direction and sometimes in the other. If only one roller is to be used, then it must have symmetrical teeth that are effective in both directions. This requirement can be satisfied if the elements are formed as double teeth. (Rieter Unifloc). Rollers with toothed discs belong in the middle of the blowroom line, except for those included in bale openers. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 4 8
IV-Sawtooth Rollers The impurities have become steadily smaller owing to hard ginning. If the machine is to eliminate even the smallest particles, then more flock surface must be created, i. e. the material must be opened to substantially smaller flocks than before, which is, for that purpose essential to use — sawtooth wire, for example. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 4 9
However, this roller not only gives the finest opening and the best cleaning, but it also stresses the fibers most strongly. Setting the speed of rotation, and other adjustments, demands a ‘feel’ for the operation. Rotational speeds lie between 600 and 1000 r/min. Sawtooth rollers are used at the end of the line. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 5 0
V-Needle Rollers, Pinned Rollers When processing long-staple and extra-long-staple cottons, the sawtooth rollers react very aggressively. Rollers with needles or pins are being used to protect the fibers in this case. With medium-staple cottons having a low trash content, the application of needle rollers is also possible. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 5 1
VI- Beater Arms (Multiple-bladed Beaters) Multiple-bladed beaters consist mainly of two or three beater bars arranged parallel to the supporting shaft and held there by four or five cast-iron arms. In the course of one rotation of the shaft, the web projecting from the feed rollers is subjected to two or three blows over its whole width. The opening effect, and hence the cleaning effect, is small. This machine is hardly used today; when it is found at all, it is only in the form of the double-beater scutcher. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 5 2
VII-Beaters with Pinned or Needle Bars (Kirschner Beaters) These machines are similar to the multiple-bladed beaters, but, instead of beater bars, pinned bars (pinned lags) are secured to the ends of the cast-iron arms. The relatively high degree of penetration gives good opening. Kirschner beaters are therefore often used at the last opening position in the blowroom line, since good pre-opening of the fiber material enables gentle opening to be achieved at the taker-in of the card. Prof. Dr. A. Kirecci - TE 211 Yarn Man. I 5 3
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