1. Flow chart of carded yarn production:
Input Process/ Machine Output
Bale → Blow room → Lap
Lap → Carding m/c → Sliver
Sliver → Breaker Draw Frame → Sliver
Sliver → Finisher Draw Frame → Sliver
Sliver → Roving Frame
/Speed Frame/Simplex
→ Roving
Roving → Ring Frame → Yarn
Flow chart of combed yarn production:
Input Process/ Machine Output
Bale management
↓
Fibre → Blow room → Lap
Lap → Carding m/c → Sliver
Sliver → Pre comb drawing → Sliver
Sliver → Lap former → Lap
Lap → Combing → Sliver
Sliver → Post comb drawing → Sliver
Sliver → Simplex → Roving
Roving → Ring Frame → Yarn
Flow chart of Rotor yarn:
Input Process/Machine Output
Bale management
↓
Fibre → Blow room → Lap
Lap → Carding m/c → Carded sliver
Carded sliver → Draw frame → Drawn sliver
Drawn sliver → Rotor spinning → Rotor yarn
Bale management: Testing, sorting & mixing bales according to properties of fibre for
producing specific good quality yarn at minm cost is called “Bale management”.
Object of Bale management:
 An evening out of the quality characteristics of a yarn.
 A means of avoiding quality jumps.
A possibility of reducing costs, as result of an improved knowledge of the fibre characteristics
Mixing & Blending
Mixing: If different grade of same fibres are kept together, then it is called mixing.
Types of mixing:

2. i) Volume mixing
ii) Wt. mixing.
iii) Hand stock mixing.
iv) Bin mixing.
v) Mixing by hopper.
vi) Lap mixing.
vii) Card mixing.
viii) Sliver mixing.
ix) Automatic mixing.
Blending: When different fibres of same or different grades are kept together, then it is called
blending.
Objects of blending:
 To achieve uniform quality.
 To improve processing performance.
 To reduce and control of production cost.
 To meet function and end used requirement.
 Aesthetic i.e. Fashion, texture, drape luster etc.
 To give the required characteristics to the end product.
 To achieve effects by carrying colour, fiber characteristics and soon.
Ginning:
The freshly picked cotton has seeds in it, this cotton is called seed cotton. The treading is done
in this condition also, but normally the treading is done after separation of the fibres from their
seed. So, the process, involves to separate the cotton fibres from seeds is called ginning.
Objects of ginning:
 To separate fibres fully from its seeds.
 To collect seeds and waste together.
 To collect fibre without any faults.
 To separate whole fibre.
BlowRoom: Blow Room consists of a number of machines used in succession to open and clean
the cotton fiber to the required degree.
40 to 70% trash is removed in this section.
Blow Room Section:
A section in which the supplied compressed bales are opened, cleaned and blending or mixing
to form uniforms lap of specific length is called Blow Room section. The cleaning efficiency of
blow room is 60 to 65%. This is the first section of spinning line for spgn wt cotton yarn.
Operation in Blow Room:

3. I. Opening:
a. To open the compressed bales of fibers &
b. To make the cotton tuft a small size as for as possible.
II. Cleaning: To remove the dirt, dust, broken seeds broken leafs, stalks and another foreign
materials from the fibers.
III. Bending or Mixing: To make good value of yarn and to decrease the production cost by
mixing different grade of fibers.
IV.Lap forming:
a. To transfer the opened and cleaned fibers into
a sheet form of definite width and uniform unit length which is called lap.
b. To roll the lap of predetermined length in a cylindrical shape around a lap pin.
c. To transfer the lap from the lap pin to a rod to suitable handle and feed it to
subsequence processing carding m/c.
Action in blow room:
The actions of the machines in any blow room range fall into one or more of four main groups
namely:
1. Action of opposite spike: (opening)
The action of opposite spikes is opening the cotton fiber. By this action, the large pieces of
cottons have been reduced in size.
2. Action of Air current: (Transport + Cleaning)
During processing, the movement of cotton from machines to machine is done by air current. It
also helps the separation of lint and trash.
3. Action of Beaters: (Cleaning & Opening)
Beaters are responsible for removing almost all of the impurity extracted in the blow room.
Beater also helps in opening of cotton fiber.
4. Action of regulating motion: (Uniform output)
The action of regulating motion gives the uniform output of cotton fiber by the help of swing
door and swing paddle
 Electrical photocell
 Air pressure syatem
Carding: Heart of Spg :
Carding may be defined as the reduction of an entangled mass of fibres to a filmy web by
working betn two closely spaced, relatively moving surface clothed with sharp wire

4. points. The carding is the heart of the spgn mill & well carded is half-spun-demonstrate
the immense significance of carding for the final result of the spgn operation. The
importance of carding is still greater where new spgn systems are concerned.
Object:/ function:/ Task of carding:
1. Opening to individual fibers : The blow room only opens the raw material to flocks
where as the card opens it to the stage of individual fibres. This enables the
elimination of impurities and good performance of the other operation.
2. Elimination of Impurities and dust: Elimination of foreign matter occurs mainly in
the region of the taker in. In addition to free dust, which can be directly sucked
away as in the blow room, the card also removes a large proportion of the micro
particles. The card is a good dust removing m/c.
3. Disentangling of neps: The card reduces the no of neps from the blow room.
Actually neps are not eliminated at the card, they are mostly opened out. An
improvement in disentangling of neps is obtained by: closer spacing between the
clothing; sharper clothing; optimal speeds of the taken- in; low doffer speeds, lower
through put.
4. Elimination of short fibers: Short fibers can only be eliminated if they are pressed
into the clothing. Elimination of short fibers in the card must be viewed in
proportion, actually very small, fewer than, 1% short fibers.
5. Fiber blending: The card is the only m/c to process individual fibers. In formation
of the web and with repeated rotation of the fibers on the main cylinder, intimate
fiber with fiber mixing is achieved.
6. Fiber orientation: It is often attribute the effect of parallelizing. The card can be
given the task of creating partial longitudinal orientation of the fibers.
7. Sliver formation: To deposit the fiber material, to transport it and process it further
, an appropriate product must be formed.
So carding is called Heart of spinning”
Draw frame
Drawing: It is a process of yarn manufacturing in which the sliver is enlongated when passing
through pairs of rollers, each pair faster than the previous one.
This permits combination of several slivers and drawing and enlongating them to straighten
and to create greater uniformity.
Objects of drawing:
I) To straighten the fibres in the slivers.
II) To make them lie is a manner parallel to their neighbours and to the sliver axis.
III) To improve the uniformity and evenness of the slivers.

5. IV) To reduce weight per unit length of sliver.
V) To reduce irregularities of fibre by doubling and drafting.
VI) To remove dust from sliver.
VII) To make perfect blending of the sliver.
Necessity of draw frame:
To parallisation of fibre and blending carded→ Carded sliver.
In carded sliver, fibre present in hook form i.e. trailing hooks and leading hooks.
To parallel those hook, draw frame is used.
Majority of the fibre hooks in a carded sliver are trailing while leading hooks are comparatively
less. Trailing hooks are also known Mazor hooks. While leading hooks are known as Minor
hooks.
Tasks of draw frame:
I) Equalizing.
II) Parallelizing.
III) Blending.
IV) Dust removal.
I) Equalizing: One of the main tasks of the draw frame is improving evenness over short,
medium and especially long terms. Carded slivers fed to the draw frame have degree of
unevenness that can not be tolerated in practice and slivers from the comber contain the
‘infamous’ piecing. It is obscured by draw frame.
Equalizing is always performed by a first process, namely doubling and can optionally also be
performed by a second process, namely autolevelling. The draft and the doublings often
have the same value and lie in the range of 6 to 8
II) Parallelizing: To obtain an optimal value for strength in the yarn characteristics, the fibres
must be arranged parallel in the fibre strand. The draw frame has the task of creating this
parallel arrangement. It fulfils the task by way of the draft, since every drafting step leads to
straightening of the fibres.
III)Blending: In addition to the equalizing effect, doubling also provides a degree of
compensation of raw material variation by blending. This result is exploited in particular in
the production of blended yarns comprising cotton/synthetic or synthetic/synthetic blends.

6. IV)Dust removal: Dust is steadily becoming a great problem both in processing and for
personnel involved. It is therefore important to remove dust to the greatest practical extent
at every possible points within the overall process. Dust removal can only be carried out to a
significant degree when there are high levels of fibre/fibre or fibre/metal friction since a
large friction the smallest particles(dust) adhere relatively strongly to the fibres.
The draw frame is therefore a good dust removing m/c; on high performance draw frame
equipped with appropriate suction removal systems, more than 80% of the incoming dust is
extracted.
Jute Processing
Flow chart of jute yarn manufacturing: Flow chart of jute yarn manufacturing:
Finisher Card
Breaker Card
1st Drawing
2nd Drawing
Selection of jute for a batch
Piecing up
Softening and lubricating
Pilling or conditioning
Carding
Doubling & Drawing
Spinning
3rd Drawing

7. Batching:
All the process form preparatory to carding includes in the bathing. It is the primary stage of
jute yarn processing.
Objects of Batching /Importance of Batching:
 To help the fibre movement freely during processing.
 To get expected dampness and flexibility.
 To reduce harness or stiffness.
 To control and reduce the yarn cost.
 To reduce waste.
 To intermix the batch component effectively.
 To produce improve graded yarn.
 Emulsion:
 A mixture of some lubricating agents which is applied on jute fibre to make the
fibre soften and flexible.
 An emulsion is an intimate mixture of two immiscible liquids where one is
dispersed in small globules on the other and addition of a third substance brings
stability. Emulsion is made by splitting up oil into minute drops which are
prevented from reuniting in water.
 General recipe:
 Water -73%
 Oil -25.4%
 Emulsifier-1.6%
Equipment/Characteristics of good quality emulsion:
Weaving
Finishing
Spinning
Weft Yarn
Cop winding
Warp Yarn
Warp or Spool
Winding
Beaming or
Dressing

8.  It should be stable for certain time.
 It should have no bed effect on jute fibre.
 It should be colorless.
 It should have high softening capacity.
 The droplet of emulsion should be so small that it can easily penetrate on the fibre.
 It must be odorless.
 It must be cheap and available.
 Process flow chartof heavy /Sacking Yarn:
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Root cutting
Emulsification /Softener
Pilling
Mixing with mill wastes
Teaser card
Mixing with long jute
Carding
Spinning
Drawing
Breaker card
Finisher card

9.  Process flow chart of Carpet Batching Yarn / Hessian Warp Yarn:

Pilling/Conditioning:
The process by which after applying emulsion jute fibre is stored at a specific
condition for certain time is called pilling.
Objects:
i) To soften and split up of jute fibre,
ii) To loosen the fibre,
iii) To convert the rooty material into spinnable fibre.
Jute spreader machine
Objects:
 To comb and open the pieced out of long reeds of jute.
 To convert them into an even and continuous sliver which receives an even application
of batching emulsion.
 To prepare ribbon like sliver.
Classification of Carding machine:
According to Cylinder function:
1) Half Circular.
2) Full Circular.
1) Half Circular:
In half-Circular Cards jute travels the half-way round the main cylinder in its journey from the
feed to the delivery. Thus the feed and delivery are approximately 1800 apart.
Example; Breaker Card.
2) Full Circular:
Bale selection Spreader Breaker Card
Finisher Card
1st drawing
2nd drawingFinisher drawingSpinning

10. In this machine jute travels almost full way round the main cylinder in its journey from feed to
delivery. Thus the feed and delivery are almost side by side, nearly 3600 inside the machine.
Example: Finisher Card.
According to Striking:
1. Up Striking.
2. Down Striking.
1. Up Striking:
In this machine the pins of the cylinder approach the feed from under neath and strike up the
fibre. Up striking cards are sued for low quality jute as the dirt and short fibers can not be
collected below it can again mingled with the fibers. Here fibre loss is low.
2. Down striking:
In this machine the cylinder pins approach the feed form the top and strike down into the fibre.
Down striking cards are used for high quality jute. The dirt and short fibers are collected below
and they can not mingle with the fibers again. But here the rate of fibre loss is high. Pins of
down striking cards are thick.
According to processing:
1. Mono carding machine.
2. Dual carding machine

11. 3. Tandem carding machine.
1. Mono Carding machine:
When a single carding machine with one cylinder is sued for carding, its is called Mono carding
machine. It is used for cotton, not successful for jute.
2. Dual carding machine:
When two individual carding machine i.e. breaker card and finisher card are used in carding,
they are called dual carding machine. It is used for jute processing.
3. Tandem carding machine:
When tow carding machines are used at a combination then it is called Tandem Carding
machine. The motion is transferred from 1st machine to the 2nd machine. When one machine
stops the other stops automatically. It is sued in case of Roller spinning in Cotton.
In tandem carding machine, two individual cards make up a unit. The doffer of the 1st card
feeds fibre material to the taker-in of the 2nd card. Double carding of the raw material has a
positive effect on quality and on blending. However the advantage is obtained at high cost
hardware and maintenance. Again additional space is required for tandem card. About 1%
cotton is processed with tandem cards now. Modern cards are considered as a tandem of the
latest generation.