Jute Yarn
Flow chart of jute Yarn
Selection of jute for a Batch
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Piecing- Up
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Conditioning or Pilling
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Breaker Carding
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Finisher Carding
First Drawing
Second Drawing
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Third Drawing
Spinning
Batch: A blend of different types of jute is made up to suit particular class of yarns being spun, this blend is known as batch.
Batching: All the process from preparatory to carding includes in the batching. It is the primary stage of jute yarn processing.
Object of Batching:
I. To help the fiber movement freely during processing.
II. To get expected dampness and flexibility.
III. To reduce hairiness or stiffness.
IV. To control and reduce the yarn cost.
V. To reduce waste.
VI. To intermix the batch components effectively.
VII. To produce improved graded yarn.
Emulsion:
An emulsion is an intimate mixture of two immiscible liquids (water and oil) where one (oil) is dispersed in small globules on the other (water) and addition of a third substance (emulsifier) brings stability.
A Standard Permanent Emulsion’s Recipe is Given Below:
Water: 79.5%
Mineral oil: 20%
Emulsifier: 0.5%
Functions of Emulsion Ingredients:-
[A] Function of Water:
I. It increases extensibility of fiber which resists fiber breakage during processing.
II. It gives sufficient dampness and flexibility.
[B] Function of Mineral Oil:
I. It lubricates the fiber
II. It helps free movement of fiber during processing.
III. It cleans pins and rollers of the machine
IV. IT makes fiber soften and gives good spinning property.
[C] Function of Emulsifier:
I. It helps emulsion to be in stable form.
II. It removes temporary hardness of water.
III. IT makes droplet formation easier.
IV. It prevents separation of oil from water.
V. It reduces surface tension.
Piling/ Conditioning:
The process by which after applying emulsion jute is stored at a specific condition for certain time is called piling.
Objects of Piling:
[a] To soften and split up of jute fiber.
[b] To loosen the fiber
[c] To convert the rooty material into spinnable fiber.
Spreader Machine
Objectives:
[a] To comb and open the pieced out of long reeds of jute.
[b] To convert them into an even and continuous silver which receives an even application of batching emulsion.
[c] To prepare ribbon like silver.
[d] To remove some dirt, sands and jute sticks.
Working Principle:
The machine consist of two sections a slow chain and a fast chain. Jute is feed manually on the feed lattice and a slave pointer regulates this feeding. After feeding the material enters the slow section via a pair of flutted feed roller. In slow section, it is carried over a slow moving gill bed or pin bed. The fibers are pressed on this pin- bed by three heavy lantern rollers. This gill bed contains 32 gill bars. Then the materials goes to fast section or combing section, which is formed by a gill bed with 10-12 times faster than slow sections. Generally draft is 10.
Essential Figure:
Then it goes to conductor plate while emulsion is applied on it. After spraying emulsion, jute is received by a roll former in roll form.
Softener Machine:
Classification of Jute Softener Machine:
a) Single softener machine
b) Tandem softener machine
c) Good softener machine
Working Principle of Single Softener Machine:
In this machine, material is feed manually on feed sheet which is 6 feet long. Then through the fluted feed roller the material the material goes through a series of spirally fluted rollers. Spirally fluted rollers have right hand and left hand spiral flutes alternative. After passing 1/3 area between the feed rollers and delivery roller emulsion is applied over the material, which soften jute, and a tray below the machine collets excess emulsion. Then through delivery roller, the material is delivered from delivery sheet.
Essential Figure:
Difference between Spreader and Softener Machine:
S.N.
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Spreader Machine
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Softener Machine
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01
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Presence of chain of pinned bars- slow chain and fast chain.
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Absence of chain of pinned bars.
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02
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Only long jute is feed.
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All kinds of jute including cutting is feed.
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03
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Easy controlling of emulsion applies.
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Difficult to maintain emulsion apply.
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04
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High maintain cost.
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Low maintain cost.
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05
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Used for high quality yarn.
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Used for low quality yarn.
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06
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Can be given draft.
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No drafting.
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07
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Needs less labor.
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Needs more labor.
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08
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Emulsion is applied at last after drafting.
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Emulsion is sprayed when fibers have passed 2-3 of rollers.
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09
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Only feed and drawing roller are fluted.
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25-64 pairs of rollers are flutted.
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10
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Prepares roll of certain length and weight.
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No roll is produced.
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11
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Firstly back part of the jute is feed.
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Firstly front part of the jute is feed.
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12
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Draft is given.
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No arrangement for draft or drafting.
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Jute Carding
Objectives of Carding:
[a] To produce long continuous jute fiber from general stage for keeping them nearly and separately.
[b] To straight and parallel the fiber.
[c] To remove the dart, leaves, broken parts and very small fibers.
[d] To finish the different jute blending and mixing by different types of jute in carding.
[e] To paralyze the fiber separately.
Classification of Jute Carding:
[i] In general Conditions:
:
Breaker Carding Machine:
Main Parts of the Machine:
FF = Fluted Roller
F = Pin Feed Roller
C = Cylinder
D = Doffer
W = Worker
S = Stripper
T = Tin Cylinder
B = Drawing Roller
P1 = Top Pressing Roller
Y = Delivery Roller
Z = Conductor
X = Cover
Essential Figure:
Working Principle of Breaker Carding Machine:
Two main functions which take place in carding machine are:
Ø Carding action
Ø Stripping action
The action of the breaker card on the material passing through the machine may be described briefly as fellows:
The pin feed roller F passes the material from the feed cloth and the fluted feed roller FF at a definite rate governed by the cloth length and draft in the machine. The pointing pins of the feed roller F in conjunction with the cast iron I provide the necessary restraining action. The pins on the rollers F and positioned at such an angle that they are sufficiently strong to pull – in the fibers over the cast iron shell I and to hold the fibers against the pull of the faster running cylinder C and thus prevents thus the material from being gulped (Jammed) in the machine.
The pin feed roller F passes the material from the feed cloth and the fluted feed roller FF at a definite rate governed by the cloth length and draft in the machine. The pointing pins of the feed roller F in conjunction with the cast iron I provide the necessary restraining action. The pins on the rollers F and positioned at such an angle that they are sufficiently strong to pull – in the fibers over the cast iron shell I and to hold the fibers against the pull of the faster running cylinder C and thus prevents thus the material from being gulped (Jammed) in the machine.
As jute is feed in, the pins of the faster moving cylinder C split up and vigorously comb away the ribbon of fibers so that it is fleeced out and carried on the cylinder. Pins of the cylinder are set such an angle so that material is being combed. The inclination of the pins together with the surface of the worker rollers W1 and W2 is such that the material is being carded and not stripped from the cylinder pins. The back pointer pins of the workers opposing cylinder pins point against point catch – up loose fibers and at the same time open – out and card the fibers held by the cylinder as they are carried passed. The fibrous tow retained by the workers are carried round with them and is ultimately stripped away b y the pins of the faster running stripper rollers S1 and S2 respectively whose pins are forward pointing.
The attenuated fibrous tow carried round by the strippers is carried away from their surface by the faster running cylinder. The Fleece is so much thinned – down at this stage that the cylinder pins take the material from the stripper pins mainly in the form of individual fibers which merge with the bulk on the cylinder.
As the angle of the pins of the doffer D is comparable to those of the worker rollers, it follows that there is similarity in action. But as the surface speed of the doffer D is about three times to that of the worker rollers, the fleece of fibers carried by the cylinder C is worked and stripped from its surface by the doffer D. The fleece of fibers now carried round by the doffer is stripped from its surface by the drawing and pressing rollers B the V- shaped tin conductor Z and then delivered by the delivery roller Y and delivery pressing roller P2. Boxing and in cylinder T1, T2 and T3 are introduced at suitable points to conserve fibers losses.
