The Art and Science of Carding - The Heart of Spinning

Carding is widely recognised as the heart of the spinning mill, with the saying "well carded is half spun" underlining its importance. The primary goal of the carding process is to separate and individualize fibers, resulting in a strand known as the sliver.

The carding process involves a series of mechanical actions that work to align, individualize, reduce neps (knots) and blend the fibers. As the fibers pass through the carding machine, they are subjected to a series of rotating drums or cylinders, each with a unique purpose. These drums are covered in fine, wire-like teeth or points, which grip and open the fibers as they pass through the machine. This crucial step in the spinning process significantly influences the final characteristics of the yarn.

A typical carding machine consists of several key components, each playing a crucial role in the carding process. The first stage of the carding process is known as "opening," where the raw fibers are fed into the machine and broken down into individual strands. The taker-in or licker-in is the initial component that feeds fibers into the machine.

The next stage is "carding," where the fibers are subjected to a series of rotating drums that work to align and blend the fibers. The main cylinder is the heart of the carding machine, responsible for brushing and aligning the fibers. Here the component surrounding the main cylinder is called flats, which work in conjunction to further refine the fiber alignment and separation, breaking down any clumps and ensuring a uniform fiber web and quality of the final product. The LMW’s LC636 SX Card offers the highest active carding area (1.95 sq. m.) and a generous cylinder area (3.95 sq. m.), by achieving production rates of up to 250 kg/hr while maintaining quality. It saves space, power, and manpower, making it an excellent investment for modern spinners. As the fibers pass through the machine, they are subjected to a complex interplay of forces, including friction, tension, and centrifugal force. These forces work to untangle, straighten, and align the fibers, creating a cohesive web or sliver. The LC636 SX Card features an optimum cylinder diameter of 1017 mm, reducing thermal expansion and increasing centrifugal force.

Then doffer removes the fiber web from the main cylinder. It rotates in the opposite direction to the main cylinder and gently lifts the aligned fiber web off the main cylinder, transferring it to the drawing unit.

The final stage of the carding process is known as "drawing," where the carded web or sliver is further refined and drawn out to achieve the desired thickness and consistency. Then the output from the card is taken to the breaker draw frame for further processing. However, LMW’s revolutionary CDS (Card with Drafting System) offers a significant advancement by allowing the process to skip the breaker draw frame. This system integrates the drafting process directly with the carding machine, which helps in maintaining consistent sliver quality and optimizing overall performance. It operates at speeds of up to 700 m/min with a 2/2 drafting system controlled by servos. Pneumatic loading of top rollers ensures easy adjustment and autolevelling of sliver.