Blow Room

B. Tech Textile Technology

Jagadish

Blow Room

Technological performance of a Blowroom line and influencing factors

Jagadish

Objects of Blow Room

Opening Cleaning Dust Removal Mixing / Blending Even feed of material to the card

Jagadish

Opening

Jagadish

Openness of the fiber material after the various blowroom machine stages; axis A: Degree of opening (specific volume); axis B: Blowroom stages

Opening
The first operation required in the blowroom line is opening, carried out to the stage of tufts in contrast to the cards, where it is performed to the stage of individual fibers. Tuft weight can be reduced to about 0,1 mg in the blowroom. The flattening of the curve toward the end shows that the line is far too long. It should end somewhere at machine No. 3 or (at least) No. 4.
Jagadish

Opening
impurities can only be eliminated from surfaces of tufts. Within a progressive line of machines it is therefore necessary to create new surfaces continuously by opening the material. And even then the best Blowroom line is not able to eliminate all, or even almost all, of the foreign matter in the raw material. A Blowroom installation removes approximately 40 - 70% of the impurities. The result is dependent on the raw material, the machines and the environmental conditions.
Jagadish

 it is easier to remove a high percentage of dirt from a highly contaminated material than from a less contaminated one.
Jagadish

Degree of cleaning (A) as a function of the trash content (B) of the raw material in %

Cleaning - side effects

increasing the degree of cleaning also increases the negative effect on cotton when trying to improve cleaning by intensifying the operation, and this occurs mostly exponentially. Therefore each machine in the line has an optimum range of treatment. It is essential to know this range and to operate within it.
Jagadish

Operational efficiency and side effects

Jagadish

Cleaning Efficiency
in order to clean, it is necessary to eliminate about as much fibers as foreign material. Since the proportion of fibers in waste differs from one machine to another, and can be strongly influenced, the fiber loss at each machine should be known. It can be expressed as a percentage of good fiber loss in relation to total material eliminated, i.e. in cleaning efficiency (CE):
Jagadish

Cleaning Efficiency

AT = total waste (%); AF = good fibers eliminated (%).

For example, if AT = 2.1% and AF = 0.65%:

Jagadish

Dust Removal
Dust elimination takes place at all stages of the spinning process.

Dust removal as a percentage of the dust content of the raw cotton (A) at the various processing stages (B): 1 - 5, blowroom machines; 6, card; 7, drawframes; (a) filter deposit; (b) licker-in deposit; I, dust in the waste; II, dust in the exhaust air
Jagadish

Mixing / Blending
Stack Mixing -> manual mixing -> not using A well-assembled bale layout and even extraction of fibers from all bales is important. intensive blending in a suitable blending machine must be carried out after separate tuft extraction from individual bales of the layout.
Jagadish

Bale layout in front of an automatic bale opener

Jagadish

Even feed of material to the card

This was carried out by means of precisely weighed laps from the scutcher, In automatic tuft feeding installations are used nowadays (CHUTE FEED).

Jagadish

No. of Beating Points

BEATING POINTS: This denotes the number of blow room machines involved in a blow room line. If the machine intensity of beating cotton is less then is considered as 0.5 The No. of beating points will vary between 2 to 8 depends on the fiber / cotton variety.

Jagadish

No. of Beating Points

low Grade Cotton( Coarser Mixing-below 40s)
Trash % in low grade cotton is high. So, atleast 7 beating points are required to open and clean the cotton.

In case of Medium Grade Cotton(Medium Mixing -40s to 60s)

Trash % in the medium grade cotton is low, so, 5 beating points are enough.

In case of Fine Mixing (Fine Grade Cotton-above 60s)

Trash % in the fine cotton is very low. So, 3 beating points are enough.

Jagadish

Blow room line for Low grade Cotton

Jagadish

BR line for all cottons

The blow room can also be designed for both grade cottons or can design which will be suitable for all types by bypassing certain machines. In earlier example,
Medium Grade Cotton(40s to 60s)
5 beating points are enough. In this case, Double vertical openers are by passed.

Fine Mixing (Above 60s)

3 beating points are enough. In this case, mono cylinder, both the vertical opener and porcupine openers are bypassed.

Jagadish

Automatic Bale Opener

Blendomat Unifloc

Jagadish

Jagadish

Blow room

Jagadish

Opening & Cleaning Points

Number of the opening points is between2 and 5 in blow room. If staple manmade fibres are used, they are just put in blow room in order to be separated and prepared for the next step. They just need cleaning action. However, if it is cotton, which is dirty, it needs more cleaning, like 5 opening points.

Jagadish

Opening & Cleaning Points cont..

Opening points are chosen due to type of fibre and content of impurities. Blowroom eliminates more than 70% to 90% of impurities in cotton. Increasing the waste elimination doesnt mean exactly the separation of impurities since also the good fibres will be eliminated. After a certain level, if the opening points are increased, cleanness of fibres will not change but they will be damaged.
Jagadish

Cleaning Efficiency
Waste content coming out of machinery is important, it should be checked by cleaning efficiency Ce = (At Af) x 100/At
where At = total waste and Af= good fibres eliminated

In blowroom, cotton is tuft or flocks and the separation it is done more in the first machinery.
Jagadish

Blending bale opener or hopper bale breaker

To mix the various varieties of cotton thoroughly To comb the cotton, To open un clean the cotton. To extract the iron particles from cotton. The constructional details of the machine are shown
Objects :

Jagadish

production and degree of opening

A. Distance, between inclined lattice and evener roller will determine degree of opening and production of the machine. This setting can be adjusted sleeplessly by means of hand wheel so as to regulate the flow of material in accordance with the production. Settings : 1/2 inch for fine and 1/4 inch for medium and coarser cotton, closed setting - gives less production and will make the tufts more opening and vice versa. B. i) The speed of the spiked inclined lattice may be varied b means of an expanding pulley, according to the requirement production and degree of opening.
Jagadish

Mixing Bale Opener

From stripping roller, the cotton flocks are thrown into trunk, which guides them into the pair of feed roller which is spring loaded.

Jagadish

Unimix - Rieter
machine used for only blending the cotton by mean of different boxes. It consists of three parts
storage section Intermediate chamber Delivery section

Flocks of cotton are feed to six or eight J shaped chutes arranged one behind other in storage section.
Jagadish

Unimix

Jagadish

Unimix
First of all cotton form the pipes comes into the storage boxes which are filled first. At the top of each box there is a feed roll, which control the level of cotton.. A sensor tells that the boxes are filled and then the cotton from each box falls on the lattice, which is revolving under these boxes. From that it is given to spiked lattice to take it up so that it is blended well. Evener rolls near the spiked lattice make sure that an even amount is passed and excessive amount is thrown back to the lattice. From there it is taken to next cleaning step by mean of suction. Production of the blow room is also controlled here.

Jagadish

Uni Mix B71

Jagadish

Uni Blend

Jagadish

Aero Mixer

Jagadish

Aero Mixer
Storage section:
It consists the material distributing duct into which the tufts are blown. Over a adjustable separating noses, a relevant turbulence is formed which creates a thorough instantaneous blending. Six vertical filling trunks of varying heights are arranged in the direction of flow of material.

Condensing funnel
This, brings about a 2-3 fold mechanical condensation of six layers of material. In this way, holding capacity of 350 kg is obtained. A conveyor belt together with conveying roller carry the material to the opening & mixing section.

Jagadish

Aero Mixer
Opening & mixing section :
This section directs the flow of material to the action of two pairs of pressure roller each with an opening roller. Owing to the different stretches to be traveled the Constituent comprising the mixing, which have been fed simultaneously to the trunks, arrive at the delivery and sucked- off by the subsequent machine.
Jagadish

Trutzschler's MULTI MIXER

Achievements
Perfect and Homogeneous blend is achieved, simultaneous mixing by doublings' over an extended period of time is achieved.

The cotton bales are opened and premixed by bale opener. This blend is blown by the material transport fan and conveyed into the feed duct above the hopper.
Jagadish

Jagadish

MULTI MIXER
The charging of the multimixer starts with the first hopper at the end of the feed duct. It is filled only to just below the photo cell situated in the adjacent hopper, then the closing flap of the second hopper * is opened by push button operation.. Second hopper is charged to a rather higher than the first. The charging level of the hopper rises uniformly up to the last hopper which is fully charged, when the last hopper is full the Closing flap shuts automatically and charging restarts with first hopper, as soon as the level second hopper has dropped below the Photo Electric cell.

Jagadish

MULTI MIXER
whilst the last hopper is being charged, material transport is switched on and material in the hoppers starts to drop. When the charging level rises, more and more of the holes in the perforated plate of the upper part of .hopper are blocked with material. This increases the pressure the conveyor air. Once a pre-selected pressure is reached, which corresponds to a particular charging level, an electronic switch closes the flap of this hopper and opens up the flap of the next hopper."
Jagadish

MULTI MIXER
The base of each hopper is closed by a pair of deliver roller which transfers the material gradually and uniformly to an opening roller. The delivery rollers of the entire hopper are two variable speed motor with control range up to 1 : 6 in this way it is possible to adjust the output of multimixer to the feed requirement of the subsequent machine. Opening roller gently loosen the material into tufts and deliver them into the blending channel from which they are sucked by the subsequent condenser.
Jagadish

Jagadish