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MIXING
MIXING(COTTON)
Cotton is a hygroscopic material , hence it easily adopts to the atmospheric airconditions.
Air temperature inside the mxing and blowroom area should be more than 25 degree
centigrade and the relative humidity(RH%) should be around 45 to 60 %, because high
moisture in the fibre leads to poor cleaning and dryness in the fibre leads to fibre
damages which ultimately reduces the spinnability of cotton.
Cotton is a natural fibre. The following properties vary very much between bales
(between fibres) fibre micronaire fibre length fibre strength fibre color fibre maturity
Out of these , fibre micronaire, color, maturity and the origin of growth results in dye
absorption variation. There fore it is a good practice to check the maturity , color and
micronaire of all the bales and to maintain the following to avoid dye pick up variation
and barre in the finished fabric.
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BALE MANAGEMENT :
In a particular lot
Micronaire range of the cotton bales used should be same for all the mixings of a
lot
Micronaire average of the cotton bales used should be same for all the mixings of
a lot
Range of color of cotton bales used should be same for all the mixings of a lot
Average of color of cotton bales used should be same for all the mixings of a lot
Range of matutrity coefficient of cotton bales used should be same for all mixings
of a lot
Average of maturity coefficient of cotton bales used should be same for all
mixings of a lot
Please note, In practice people do not consider maturity coefficient since
Micronaire variation and maturity variation are related to each other for a
particular cotton.
It the cotton received is from different ginners, it is better to maintain the percentage of
cotton from different ginners throught the lot, even though the type of cotton is same.
It is not advisable to mix the yarn made of out of two different shipments of same
cotton. For example , the first shipment of west african cotton is in january and the
second shipment is in march, it is not advisable to mix the yarn made out of these two
different shipments. If there is no shadevariation after dyeing, then it can be mixed.
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According to me, stack mixing is the best way of doing the mixing compared to using
automatic bale openers which picks up the material from 40 to 70 bales depending on the
length of the machine and bale size, provided stack mixing is done perfectly. Improper
stack mixing will lead to BARRE or SHADE VARIATION problem. Stack mixing with
Bale opener takes care of short term blending and two mixers in series takes care of long
term blending.
why?
Tuft sizes can be as low as 10 grams and it is the best way of opening the
material(nep creation will be less, care has to be taken to reduce recyling in the
inclined lattice)
contaminations can be removed before mixing is made
The raw material gets acclamatised to the required temp and R.H.%, since it is
allowed to stay in the room for more than 24 hours and the fibre is opened , the
fibre gets conditioned well.
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Disadvantages:
more labour is required
more space is required
mixing may not be 100% homogeneous( can be overcome by installing double
mixers)
If automatic bale opening machine is used the bales should be arranged as follows
Let us assume that there are five different micronaires and five different colors in
the mixing, 50 bales are used in the mxing. 5 to 10 groups should be made by
grouping the bales in a mixing so that each group will have average micronaire
and average color as that of the overall mixing. The position of a bale for
micronaire and color should be fixed for the group and it should repeat in the
same order for all the groups
It is always advisable to use a mixing with very low Micronaire [Link]
.6 to 1.0 . Because
It is easy to optimise the process parameters in blow room and cards
drafting faults will be less
dyed cloth appearance will be better because of uniform dye pickup etc
It is advisable to use single cotton in a mixing , provided the length, strength
micronaire ,
maturity coefficient and trash content of the cotton will be suitable for producing
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the required counts. Automatic bale opener is a must if more than two cottons are
used in the mixing, to avoid BARRE or SHADE VARIATION problem.
It is better to avoid using the following cottons
cottons with inseparable trash (very small size), even though the trash % is less
sticky cotton (with honey dew or sugar)
cotton with low maturity co-efficient
Stickiness of cotton consists of two major causes. Honeydew from Whiteflies and
aphids and high level of natural plant sugars. The problems with the randomly
distributed honey dew contamination often results in costly proudction
interruptions and requires immediate action often as severe as discontinuing the
use of contaminated [Link] effective way to control cotton stickiness in
processing is to blend sticky and non-sticky cotton. Sticky cotton percentage
should be less than 25%.
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