How carpet woollen yarn is produced

Detailed narration of how carpet woollen yarn is produced using woollen system carding system and semi worsted carding system. The yarn is then used in producing broadloom tufting, axminster & wilton carpets

The first process of carpet woollen yarn spinning is carding, this is done on a carding machine which is basically a collection of large and small rollers covered in card clothing which due to the spikes in the clothing and the different directions and speeds of the rollers, combs the wool straight much as you would comb your hair.

At the end of the machine a flat web of wool is produced this is divided by tapes, which act like scissors to cut the wool into strips, which are rubbed to produce a round thread, which at this stage has no strength. The strength is given to the thread by the next process on a spinning frame, which literally spins the thread round to put in a pre-determined number of turns per inch there by making a strong level yarn.

Yarns are produced in single or multiple-ply construction. To make a multiple-ply yarn two or more bobbins are taken from the spinning frame and twisted together on a Ring Twisting machine again to a pre-determined number of turns per inch. The yarn is then put onto hanks, which form a loose package suitable for dyeing

Semi wosted yarn are prepared by making fibres as parallel as possible by applying controlled drafting of the fibres. Finer microns and longer length wools are pre-requisites for semi worsted woollen blends.

In a semi worsted carding machine the wool sliver is collected in a Can. This carded sliver is than processed three times through intersecting gill box machines. One of these gill boxes is an auto leveller.

An auto leveller is a machine which automatically maintains same density of wool fibres by regulating the sliver output by varying the speed of drafting shafts. The sliver is being passed through sensor rollers which increase or decrease the draft of the sliver which are recorded into a mechanical memory wheel. Normally 15% plus and 15% minus variation is controlled in an Autoleveller.

After third such processes the sliver is then passed to the spinning frame, which further draft the sliver into required count of woollen yarn. After spinning the yarn is forwarded to twisting and winding to process as per requirement of the customer.

A very low percentage of Oil is required in semi worsted spinning system making it ideal for dry spinning.

For more depth details please visit our website http://www.bwmpl.com