What is Emulsion | Characteristics of Emulsion | Recipe for Emulsion | Faults of Emulsion in Jute Spinning

Emulsion: It is a mixture of lubricating agents which is applied on jute fibres to make it soft and flexible.

Characteristics of a good quality emulsion

• It should not damage the fibre
• The emulsion should be colourless
• It should be stable for a certain period of time
• Its softening quality should be high

Finisher Card of Jute Carding Machine

Finisher Card

Finisher Card

D = Delivery roller
Do = Doffer
W = Worker roller
S = Stripper roller
T = Tin cylinder

Breaker Card of Jute Carding Machine

Breaker Card

Breaker Card

D = Delivery roller
Do = Doffer
W = Worker roller
S = Stripper roller
T = Tin cylinder
S = Shell
P = Pin roller
F = Feed roller

Types of Carding Machines inJute Spinning Technology

 Types of carding machines according to number of machines employed.

1. Mono Carding: the breaker and finisher card are to separate machines but the jute is directly delivered from the delivery of the breaker to the feed of the finisher card.

Functions of Emulsion Ingredients in Jute Spinning

Function of oil

• It lubricates the fibre
• It helps fibre to move freely during processing
• It makes the fibre soft and gives more spinning property
• It cleans the pins and rollers of the machine

Types of Jute Yarn | Composition of Jute Yarn | Batch Selection Technique

1. Hassian warp: 

To make this type of yarn clean and defect free jute is required. Hassian warp yarn is good quality, clean and free from speck with high lustre.

            Batch selection: Hard jute →→→ 70%

                                                Soft jute →→→ 30%

            Example: for 8 lbs/spyndle hassian warp

                                                White C →→→ 40%

                                                White X →→→ 40%

                                                Tossa →→→ 20%

Crighton Opener Machine | Verticle Opener Machine | Twine Opener Machine

Crighton opener

Crighton/ twine/ vertical opener machine is used to open cotton tuft in blowroom line.

Object :

i. To strike the cotton while it is being carried by the air current.
ii. To open the cotton in to small fault.
iii. To use low quality cotton (i.e. cotton of short staple & more impurities).

Working Principle of Carding Machine | Action in Carding Machine

Carding Machine

A process in the manufacture of spun yarns whereby the staple is opened, cleaned, aligned, and formed into a continuous, untwisted strand called a sliver.

Objects of Carding Machine

i. Opening to individual fibers.
ii. Elimination of impurities.
iii. Elimination of dust.

Step Cleaner | Ultra Cleaner | Super Cleaner | Object of step/ ultra/ super cleaner machine

Step cleaner machine is an inportant machine in ring spinning for cleaning and opening impurities from cotton. This machine is set normally after porcupine opener machine. 

Object of step/ ultra/ super cleaner machine

i. To open & clear the cotton by combinations of opposite spike action & the beating action.
ii. To remove the impurities such as leaves, stalk, motes & sand without damage the fiber.

Object of Bale Opener Machine | Function of Bale Opener Machine

Bale Opener Machine

Bale Opener Machine is the first major machine in blowroom line for ring spinning.

Object :

i. To open the tuft of cotton.
ii. To mix & blend the fiber.
iii. To remove a considerable amount of trash from fiber which is taken out by fan.
iv. To act as a reserver box for the next machine.

Jute Softener Machine | Working Principle of Jute Softener Machine | Machine Specification of Jute Softener Machine | Parts in Jute Softener Machine |

Jute Softener Machine

These machines consist of 24 to 64 pairs of rollers and these are spirally fluted and jute goes through them. When the jute passes one third of the rollers then the emulsion is added with the spray. Then through the delivery rollers the jute is passed on to the delivery sheet.

Jute Spreader Machine | Parts in Jute Spreader Machine | Working Principle of Jute Spreader Machine

The jute fibres first enter through the feed rollers on to the slow chain. This contains pins or grill bars which have a combing action on the jute. Then the jute moves to the fast chain which moves 10 to 12 times faster than the slow chain. Here combing action occurs and also due to the speed

Jute Draw Frame | Functions of Jute Drawing | Types of Jute Draw Frame

Functions of Jute Drawing

1. Drafting the finisher card sliver to a count suitable for feeding the spinning frames.
2. Reduction of weight irregularities by doubling.
3. Straightening the fibers & laying them along the sliver axis so that when they come to be spun on the spinning frame they will be evenly drafted & twisted to form an acceptable yarn.

Textile Spinning Mills in Bangladesh

Spinning Process of Filament Yarns | Chemical Spinning | Wet spinning | Dry spinning | Melt spinning | Speciality spinning | Bicomponent spinning | Biconstituent spinning

A filament fibre is the fibre which comes in continuous lengths for use. All the man-made fibres and silk is filament in nature. The man-made fibres can also be cut into staple length and spun on usual spinning system for the spun yarn production. The filaments are spun by chemical spinning which includes the process of extruding the polymer extrusion through the spinneret. These filaments are solidified in fibre form. These solidified filaments are brought together and are slightly twisted to produce filament yarns. The different types of chemical spinning are as follows:

Chemical Spinning

•  Wet spinning
•  Dry spinning 
• Melt spinning

Speciality spinning

•  Bicomponent spinning
• Biconstituent spinning

Chemical Spinning

1. Wet Spinning – This method of spinning is more suitable for rayon fibres. The procedure of spinning involves the extrusion of an appropriate liquid solution through the spinneret in a chemical bath that coagulates the solution into filament strands. These filament strands are then drawn out of the bath, washed and dried before being wound on the spools. The fibers are spun in the chemical bath and hence called as wet spinning.

2. Dry Spinning – The process involves the extrusion of the suitable liquid solution through the spinneret into an air chamber. The air reacts with the extruded streams causing them to solidify twisted and/or processed further and then wound onto spools. This method of spinning is used in manufacturing of acetate yarns.

3. Melt Spinning – Melt spinning uses the heat to melt the polymer to a viscosity suitable for the extrusion through the spinneret. As the name indicates the chips of fibers are melted and extruded through the spinneret to obtain the fibers. It is used for the polymers that are not decomposed or degraded by temperatures necessary for extrusion. Polymer chips obtained from previously reacted chemical combinations are melted and then pumped through a spinneret in an air chamber. The extruded stream cool and solidify into continuous filaments and are then drawn out of the chamber twisted and/or processed further and subsequently wound onto spools. This method of spinning is suitable in manufacturing the polyester yarns.

Specialty Spinning

1. Bicomponent spinning – Bicomponent spinning involves the extrusion of two different types of the same polymer through the spinneret. Bicomponent extrusion can be simply thought of as two spinning machines working one inside the other.

There are three different techniques of bicomponent fiber production. One method is the side-by-side extension through one spinneret hole of two varieties of same polymer. As the two variants cool and solidify they adhere together as one filament. The filament is composed of both the fibers. For eg. – when nylon 6 and nylon 6.6 solutions are extruded through one spinneret hole, a filament is obtained which consists of both the polymers attached side by side. Thus the yarn obtained exhibits the characteristics of both nylon 6 and nylon 6.6.

Side-by-side Extrusion

Another means of manufacture of bicomponent is basically that of using one spinneret inside another. One variant of the polymer is pumped through the center or core spinneret while another is pumped though the outer or surrounding spinneret. Both varieties of polymer emerge as one through the common hole of the surrounding spinneret so that the fiber is formed of a core of one polymer variant surrounded by a ring of another variant.

Extrusion by Two Spinnerets – One Inside the Other

The third method of composition of bicomponent fiber is the distribution of drops of one molten polymer variant into another molten form of the same polymer. This composite mixture is then extruded through the single spinneret hole. The result is a matrix or conglomerate, of minute short strands of one fiber suspended inside another variety of the same fiber.

2. Biconstituent spinning – Another variation of filament yarn production is biconstituent spinning. The biconstituent spinning involves the extrusion of two different polymers through the spinneret. The method of extrusion is similar to that of bicomponent spinning. The filament can be obtained by any of the three methods mentioned above. An example of biconstituent spinning is a fiber which contains two different polymers like that of polyester with nylon.

High Speed Spun Yarn Production | Rotor Spinning | Friction Spinning | Self twist Spinning |Twist less Spinning

Much research has been done to develop a spinning system for staple fibres that will shorten the yarn spinning by eliminating some of the steps of the conventional spinning. The research is oriented in simplifying the yarn manufacturing process and to produce yarns more economically. In these recent developments the

Process Flow Chart of Yarn Spinning Technology | Working Process Flow Chart of Yarn Spinning Technology

SPINNING

The cotton fiber grows in the seedpod or boll, of the cotton plant. Each fiber is a single elongated cell that is flat, twisted, and ribbon like with a wide inner hollow (lumen).It is composed of about 90 percent cellulose and about 6 percent moisture; the remainder consists of natural impurities.

Card Clothing | Flexible Card Clothing | Semi-rigid Card Clothing | Advantage of Flexible Card Clothing | Disadvantage of Flexible Card Clothing | Advantage of Semi-rigid Card Clothing

Card clothing: The inclined wire set in base material which are covered around the surface of taker in. Cylinder, doffer and flat in the carding machine is called card clothing.

Card clothing is used on the surface of

Basic Operations in the Blowroom

Carding, process by which fibers are opened, cleaned, and straightened in preparation for spinning. The fingers were first used, then a tool of wood or bone shaped like a hand, then two flat pieces of wood (cards) covered with skin set with thorns or teeth. Primitive cards, rubber-covered

Modern Blow Room Line | The Installation as a Sequence of Blowroom Machines | Modern Blow Room Line for American

In processing the material, different types of machines are necessary, namely those suitable for  opening, those for cleaning and those for blending. Different intensities of processing are also required, because the tufts continually become smaller as they pass from stage to stage.