What are the important setting points in a flat card? What is the setting you will recommend for low grade cotton/for 1.25" cotton /for fine mixing/ for coarse, medium mixing and describe their influence on production & waste
The Knowledge of optimum setting of the various organs of card and their effect on quality are essential for successful maintenance of carding process. The optimum settings are influenced by the following factors.
1. The staple length of the material.
2. The amount of trash to be removed,
3, The hank of lap fed.
4. The expected waste percentage.
5. Type of clothing
6. Mechanical condition of the machine.
Settings :
1. Feed plate to licker -in : 0.009 inch to 0.012 inch
The object of this setting is to detach cotton in very small
tufts from the lap without damaging the fibres.
If the setting is too close, the longer fibres will be
damaged and the waste increased. If it is too wide, the cotton will be detached from the lap fringe in large tufts or even lumps. When this setting is correct the cotton is evenly distributed on the main cylinder surface.
2. Licker - in to mote knives: Upper knife -10 Thou (10 Thou means 0. 010 inch) Bottom knife- 12 to 15 Thou
The object of this setting is to extract vegetable impurities like seed hits, 1 eaves, husks and other Foreign impurities from cotton.
If the setting is too close, loss of good cotton may occur and if it so too wide, the mote knives operate inefficiently.
3. Licker in to under grid. 5/16 inch.
The object of this setting is to hold the good fibre on the Licker in and fall down the dust, dirt, short fibres through under grid.
Close setting increases the fibre extraction with the waste.
4. Licker in to cylinder 0. 007 inch
The object of this setting is to transfer the fibres to the cylinder.
The settings may be as close as 0. 005" for effective transfer of fibres, if the condition of taker-in is good (i. e) dynamically balanced, An unreasonably wide wetting will fail to transfer the fibres leading to formation of neps.
5 Back plate:
Lower edge of 0. 022 inch: Upper edge 0. 017 inch The object of the back plate setting is to control air currents and to some degree licker-in fly.
Wider setting other then given above will result in cloudy web due to uneven distribution of the fibres across the cylinder because of the uncontrolled air currents.
6 Cylinder to flats: 0. 010 inch
The object of this setting is to card the fibres well so as to produce a clean web.
A close setting tends to produce cleaner web whereas wide settings results in more neps in the web.
7. Front plate (Top % plate)
Upper edge- 10 thou to 60 thou. Lower edge-32 Thou Front Bottom plate:
Upper edge - 32 Thou. Lower edge _ 15 thou
The object of Top % plate setting is to control flat strip waste.
Wider front plate setting causes more flat strips waste and good cotton is lost as flat waste. If the setting is very close flat waste will be deposited on the cylinder causing poor web.
The object of bottom plate setting is to transfer cotton from cylinder to the doffer evenly.
Wider settings will cause uneven web due to uncontrolled air currents.
8. Cylinder to doffer 0. 005 inch
The object of this setting is to take off all good cotton from the cylinder by doffer. The setting may be wider as much as 0. 007" for heavier laps. Wider settings will result in patchy or cloudy web.
9. Cylinder to cylinder under casing
Back 0. 012 inch Middle-0. 032 inch Front -0. 064 inch Object of this setting is to keep the fibres on the cylinder and to let the dirt, dust and short fibres fall out.
These settings influence air currents and production of fly and too wide settings causes loss of fibre. 10. Doffer to doffer comb. 12 to 15 Thou
The object of this setting is to remove as much good fibres as possible without touching.
For heavy slivers and production the settings may be little wider,
11. Plats to flat stripping comb: 32 Thou
The correct setting is that the comb should not touch at any point and remove the strips effectively.
| SETTING (in 1/1000 inch) | short stapled cotton | long stapled cotton | viscose | polyester | acrylic | |||
| feed plate to licker-in | 9 | 12 | 12-15 | 12-15 | 10-12 | |||
| Licker-in to cylinder | 7 | 7 | 7 | 7 | 7-9 | |||
| Back Plate |
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| Upper edge | 22 | 17 | 22 | 22 | 10-15 | |||
| Lower edge | 22 | 22 | 27 | 37 | 20-25 | |||
| Cylinder to Flats | 10 | 10 | 10-12 | 17-22 | 12-18 | |||
| Licker-in to mote knife; upper knife | 10 | 10 | 12-15 | 18-22 | - | |||
| lower knife | 12 | 15 | - | - | - | |||
| Lickerin to under grid |
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| Front edge | 17 | 29 | 22 | 30 | 25 | |||
| Back edge | 17 | 34 | 125 | 120 | 120 | |||
| Front plate |
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| Top % plate(Top) | 10 | 34 | 17 | 22 | 20-22 | |||
| Bottom | 32 | 34 | 22 | 34 | 30-35 | |||
| Bottom plate (Top) | 32 | 34 | - | - | - | |||
| (Bottom) | 15 | 34 | - | - | - | |||
| cylinder to doffer | 5 | 7 | 4-5 | 4-5 | 5-7 | |||
| cylinder to under casing back
| 12 | 34 | - | - | - | |||
| Middle | 32 | 68 | - | - | - | |||
| Front | 64 | 187 | - | - | - | |||
| Doffer to doffer comb | 12-15 | 22 | 5 | 5 | 5 | |||
| Doffer to stripping roller |
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