BLOW ROOM

The yarn production process sequence

generally has five stages
Stage I. Opening and cleaning.
Stage II. Disentangling and further cleaning.
Stage III. Fiber straightening and parallelizing (with
short fiber removal and additional cleaning)
Stage IV. Additional fiber straightening, parallelizing,
and attenuation.
Stage IV. Yarn formation.

Definition
Compressed bale is turn into a uniform lap of
particular length by opening, cleaning, blending
or mixing is called blow room section. It is the
first steps of spinning.

Objects of Blow Room

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

The Objects of the blow room are :
1.To open the compressed layer of bale of cotton or any staple
fibres.
2.To blend different varieties of cotton in the desired
proportion to prepare the raw material for the spinning
process.
3.To extract the impurities like broken seeds, husks, leaves,
sand, stone & iron particles, short fibres, immature fibres,
dust, dirt and other foreign materials from the cotton by
opening and beating.
4.To convert the mass of cotton fibres in to a uniform thick
sheet of cotton both longitudinally and transversely and to
wound in the form of compactly built lap.

Opening
The first operation required in the blowroom line
is opening.
A Blowroom installation removes approximately
40 - 70% of the impurities.
The result is dependent on the raw material, the
machines and the environmental conditions
All opening & cleaning machines can may be broadly
classified following types :
Loose feeding and beating technique - Free beating
pointed led type of feeding by air suction :
1. Vertical opener ( Bladed beater type)
2. Step cleaner ( Pin opener type)
3. S.R.R.L opener ( Saw tooth opener type)
4. Axi flow cleaner/ Spiro cleaner. ( Pin opener type)
5. Mono cylinder ( Pin opener type )
6. Air jet cleaner (Dust extraction from cotton by air
force)

Semi fast gripped and controlled feeding and
beating technique :
1. Porcupine opener ( Bladed beater type)
2. 3 or 2 Bladed beater ( Bladed beater type)
3. Kirschner beater
4. Improved porcupine beater
5. E.R.M cleaner

Major & Minor cleaning points
The machine where heavier trash particles are
extracted from cotton by heavier beating action is
called Major cleaning Point.
Ex : Vertical opener, Porcupine opener, step cleaner
S.R.L.L. Opener, Shirley opener
The Machines where only fine dust & lighter
impurities extracted by giving light beating or
combing action on cotton by air current is called
minor cleaning point.
EX: Kirschner beater, condensing cages, Dust Trunk,
Dust filters,

HOPPER FEEDER in Blowroom:
Objects are achieved :
The material is thoroughly blended in main bin.
The material is combed by the spikes of the inclined lattice.
The cotton is well opened when passes in between evener roller
and spiked inclined lattice.
Sand, heavy trashes are extracted through grid bars and iron
particles are removed from the cotton by the magnet.
Fan is provided in the top of the machine and sucks the dusty air
which is settled down in the cellar.
Also, the principle object of the Hopper Feeder is to provide
uniform feeding of cotton on lattice across the full width of the
machine.

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 by means of an expanding pulley, according to
the requirement production and degree of opening.
knitting1\New Folder\1 Animation _ Bale Opener _
AVINASH bidwe.mp4

Mixing Bale Opener

UNIFLOC A-11
The A 11 UNI-floc processes cotton from all
sources and manmade fibres in staple lengths of
up to 65 mm.
The bales being opened are placed lengthwise
or crosswise on both sides of the bale opener,
and the take-off unit can process up to four
different assortments.
knitting1\New Folder\2 Blowroom.mp4
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.


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.



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.

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.
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."

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
knitting1\New Folder\Fiber Mixing and Blending Machine.mp4
MONO CYLINDER CLEANER
Object :
To open and clean the cotton.
Advantages :
Impurities are separated without being crushed.
This proves favorable during subsequent operations.
Type : Loose feeding pin opener.

The pin cylinder has 8
rows of six pins each,
arranged spirally -around
its circumference
The grids are arranged in
two separate section
which can be adjusted
individually.
The grid can be adjusted
regarding spacing ( 0 to
12 mm) between the grid
bar, as well as inclination (
angular setting of the grid
bar -0 to 30).

PORCUPINE OPENER
OBJECT :
To open and clean the cotton.
Type :
Semi fast controlled feeding bladed beater.
The cotton fed by the previous opener is carried
forward by the feed lattice.
The sheet of cotton now pass between pedal and
pedal roller. The weight of cotton fed per unit
time is maintained constant by this pedal feed
regulating motion.

Pedal roller feed the sheet of cotton in between pair of
feed roller which is weighted to give necessary grip on
the cotton.
16 circular disc are mounted on the shaft of this opener.
14 to 18 striker blades are rivitted alternatively on each
circular disc.
Each striker is bent to a slightly different angle.
The compressed sheet of cotton delivered from the feed
roller is heavily beated by the rapidly revolving striker of
the porcupine beater against grid bar.

Because of this beating action, the cotton is
effectively opened and extracted trash particles
are passed through the spacing of the grid bar.
At the end of the grid bar, stripping rail is
provided, this is a metal bar which is set about
1/16 inch away from the end of the striker.
This small clearance between stripping rail and
striker prevents bunches of cotton being carried
around by the beater.
cotton from the beater region is taken out by the
air current set by the fan and is deposited on to
the cages.
Setting particulars :
Slightly wider setting is generally used for medium long stapled cotton to avoid fibre
damage.
Also wider setting is recommended when a very heavy feed is used, so as not to crush
the fibres.
Setting between beater and feed roller = 3/16 inch
Setting between beater and first gridbar=3/16 inch
Setting between beater and last gridbar = 7/16 inch
Setting between beater and stripping rail.=1/16 inch;
Inclination of the grid bars are so arranged that the resistance to the movement of cotton
gradual1y decreases, from feeding end to the delivery end.
Setting between grid bar and beater will be gradual1y increased from first grid bar to
the last grid in gradual stages.
Wider setting between stripping rail and beater causes unnecessary reprocessing of fibre
in the beater section, because of this over treated cotton or repeatedly beated cotton,
curely cotton is produced.

STEP CLEANER
Step cleaner machine is an important machine in ring
spinning for cleaning and opening impurities from
cotton.
This machine is set normally after porcupine opener
machine.
Object of Step/ ultra/Super Cleaner Machine
i. To open & clear the cotton by combinations of
opposite spike action & the beating action.
ii. To remove the impurities such as leaves, stalk, motes
& sand without damage the fiber.
Step cleaner in Blowroom
Condenser is employed to feed cotton to the step cleaner. Photo-
cell arrangement in the reserve tower unit monitor the height of
reserve fibre and signals stop or start commands to the
proceeding machine.
Cotton is fed from the reserve tower by pair of feed roller.
According to the height of cotton level, photo cell in the reserve
tower of subsequent machine, drive the feed Roller intermittently
by motorised gear reduction unit.
Beating section :
The rapid revolution of 6 beating cylinders (multiple beater) and
beating of the spikes on cotton against grid bar centrifugal force
and gravity combine effectively to open the cotton and remove
the heavier impurities.

Main Parts :
i. Motor.
ii. Motor pulley.
iii. Beaters.
iv. Baffle plate.
v. Grid.
Specification :
i. Motor r.p.m = 695
ii. Dia of the beater = 18.6``
iii. Dia of two pulley = 21.2``
iv. Dia of one pulley = 16``
v. No. of striker = 26
Main Setting Point :
Set to do the require amount as cleaning close
grid bars, setting gives good opening
Large grid bar setting gives poor opening,
other setting points are,
Beater to Grid bar = 1`` &
Beater to Beater = 8``.
SALIENT Features OF STEP CLEANER ARE:
i) Effective Micro dust Extraction by dust hood.
ii) The degree of opening and trash extraction can be
adjusted for a very wide range of cotton types and grades
by changing the speed of beater, (460,640 and 800 rpm)
and the profile of grid to beater.
iii) Action of multiple beater and grid bars Removes heavy
impurities iv) maximum trash extraction.
v) Simple efficient unit suitable for all classes of cotton.
vi) Design features facilitate integration with Centralised
waste extraction system.
vii) Adjustable grid bar profile to optimise cleaning
efficiency.

Advantages:
Because the beaters are driven with same
motor and they are same in size there gauges
are also same so they have following
advantages;
Less neps are produced
Less power consumption
Good beating is accomplished
They occupy less space
Less damage to fibers

Axi flow cleaner
This is also known as dual roller cleaner, used for
opening and cleaning purposes.
This has two beaters having 6-8 rows of spikes with
flattened edges which perform cleaning actions.
The speed range of the beaters varies from 400-600
rpm.
Large cleaning chamber contains two drums moving
in the same direction of same diameter of about
610mm.

Material from input comes in process with
drumbeaters, which is opened due to high speed of the
beaters.
Material through entire length of first beater passes
over the grid bars where trash is collected and comes
in contact with second beater.
Same action is applied here and cotton is entirely
opened and trash is removed in better way.

Advantages:
This machine occupies less space than other
machine.
There are no feed rolls due to stock are not held
at anytime during passage.
Machine has a capacity of 1800 pounds/hour

3 Bladed Beater AND 2 Bladed Beater
Object : To open and clean the cotton,
Type : Semi fast controlled feeding bladed beater Type.
2 Bladed beater has 2 arms while 3 Bladed beater has 3 arms which are
fixed on central shaft.
Steel blade running across the width of the scutcher is firmly revetted to
each edge of the arm.
Each edge of the blade is bevelled inorder to strike the cotton clearly and
also reverse the blade whenever the sharpness of the blade is reduced by
its continuous usage. Frequency for reversing the blade is 1 year.
The cotton fed by the previous opener is carried forward by the feed
lattice. The sheet of cotton now pass through pedal & pedal roller and
weighted pair of feed roller to give necessary grip on cotton.



The weight of cotton fed per unit time is maintained
constant by the pedal feed control mechanism.
At the end of grid bar, stripping rail(metal bar) is set
about 1/16 inch away from the end of blade.
This small setting prevents the cleaned bunches of
cotton being carried around by the beater again.
It prevents the production of curly cotton and neps.
KIRSCHNER BEATER
Object:
To comb and extract the lighter impurities from cotton.
Kirschner Beater has 3 arms like 3 Bladed beater but in
place of blades there are wooden lag(5.5 inch wide)
carrying a large no. of steel pins (24 Rows) and
inclined in the direction of rotation and project about
3/8 inch from surface of wooden lag.
So, instead of beating ,here combing action is achieved.

The sheet of cotton delivered from feed roll is combed by the revolving steel
pins of the beater against the grid across the width of the machine.
Lighter impurities are thoroughly extracted from cotton and passed through
the grid bars.
This beater has three sides of beating with pins about 3000 on one side, which
pass through material and trash and dust fall.
Grid bars at a distance of about 3mm are under the beater, which collects the
impurities.
When material after beating comes out it has to be in uniform sheet.
For this it is passes through process named as PIANO FEED MOTION.
Its function is that where is less quantity of the material in this sheet it is
completed by this motion
With help of Cone Drum, in the same way if more quantity of a material is
passing it is uniformed by this motion.