Card setting means adjusting the working distances between different parts of a carding machine, like the cylinder, flats, licker-in, and doffer. So that fibers are opened, cleaned, and straightened effectively. Card setting plays a vital role in achieving consistent quality in spinning. This setting is crucial because it directly influences the quality of the sliver produced, impacting the removal of impurities, fiber individualization, and overall yarn quality. Proper card setting ensures fibers are cleaned, aligned, and formed into a continuous sliver with minimal waste.
Several parts of the carding machine are designed to function automatically for continuous conversion of raw material from lap to sliver. The related organs are required to be set correctly at certain close distances. The optimum setting usually depends on the type of cotton processed, the trash content in the feed material and the percentage of waste to be extracted. The mechanical condition of the machine, dynamic balancing of heavy parts rotating at high speed and the accuracy of various mountings decide the limit of their potentials in giving the required results. These settings can only be used as a guidelines, as the web quality required and the amount and kind of trash to be extracted will ultimately decide their magnitude. The closer settings, though lead to better performance of the machine, they are likely to be risky when the machine condition is poor. Apart from the fire risk, the closer settings may cause the wires to dull quickly. However, at other important places, e.g., the setting between cylinder and doffer or licker-in and cylinder, or even cylinder and flats, it may be essential to precisely carry-out the actual desired setting. Some of the settings must be done periodically, especially those which govern the trash extraction and carding action. Similarly, after every grinding operation, it is necessary to reset the relative components. The normal leaf gauges (Figure 4.1), which are ground to an accurate thickness, are used for setting the various parts.
Types of Card Setting in Carding Machine
The card setting in carding machine involves adjusting these main distances:
1. Lap Guides
The setting is not critical as it merely controls the spread of the outer edges of lap. This, however, restricts the lap selvedges within the wire surface of the licker-in. But too close a setting may fold the selvedges and damage the licker-in wires, owing to a thick, folded portion of the lap suddenly entering the licker-in zone.
2. Feed Plate to Licker-in
The setting of 0.254 mm to 0.305 mm (10–12/1000 in) is generally used. But when there is significant change in the staple length of the fibers, an even wider setting, up to 0.43 mm (17/1000 in) is not uncommon. This is essential for avoiding any fiber breakage or damage. It is observed that a setting smaller than the one suitable for the staple length processed generally lowers the yarn strength. Too wide a setting, on the other hand, results in plucking of the cotton tufts. This leads to insufficient opening of the fibers by the licker-in prior to main carding action and ultimately affects web quality.
3. Licker-in to Cylinder
The licker-in is set to the cylinder at a distance of 0.127 mm (5/1000 in). This closeness is essential so that the cylinder satisfactorily removes (strips-off) the fibers from the licker-in surface. If the setting is too wide, it leads to loading of the fibers on the licker-in and neppiness in the card web.
4. Flats to Cylinder
As the main carding action takes place between these two organs, it is important to set them correctly. Usually, the setting between them is 0.254 mm (10/1000 in); however, in some cases, the gauge is as close as 0.228 mm (9/1000 in) for better carding action. In this case, the web produced is expected to be cleaner, but the flat strip increases. Even then, the removal of neps is always better with a closer setting.
With bulky fibers (polyester, polyamide and acrylic), it is necessary to widen the setting between cylinder and flat (0.38 mm to 0.43 mm, 15/1000 into 17/1000 in), otherwise the fibers are treated too aggressively. In the case of cotton, however, too wide a setting results in poor carding action and inefficient nep removal. This leads to a poor appearance of the card web.
5. Doffer to Cylinder
This is a very important setting and should be adjusted very accurately across the width. The gauge is 0.127 mm (5/1000 in), but when the wire surfaces are ground to perfect uniformity and when the parts are mounted with precision and are balanced perfectly, a still closer setting of 0.101 mm (4/1000 in) is possible.
A closer setting allows the doffer to effectively carry away the fibers from the cylinder. For higher production (through coarser hank), the setting may be slightly widened. However, this should be carefully observed, as a too wide setting results in overloading of the cylinder. This is because the fibers on the cylinder are not transferred efficiently. As a result, the carding action suffers and the web delivered by the doffer becomes patchy and cloudy.
6. Doffer Comb to Doffer and Flat Comb to Flats
As both the combs travel in a circular arc, they must be set at their closest point of approach with the respective surfaces. In the case of doffer comb, the arrangement is comparatively simple and set screws are provided to vary the length of the rod between their fulcrum and a point where the rod holds the comb.
Though both the settings are not critical, they should be adjusted carefully and the distance should be close enough to remove the fibrous material from the respective organs over which they work. Apart from the setting, the condition of the comb blade is also important. The teeth of the comb, if damaged, should be polished or repaired from time to time. Care must also be taken to see that the comb teeth do not touch the wires over which they are required to work.
Importance of Card Setting
To ensure the best quality output, every part of the carding machine must work in proper alignment and at accurate distances. Major importance of card setting in carding machine are point out below.
Correct settings keep continuous, efficient conversion from lap to sliver.
Proper distances improve fiber opening, cleaning, and web quality.
Accurate settings ensure effective trash extraction tailored to material needs.
Closer settings can enhance performance but increase risk if the machine is in poor condition.
Risks of overly close settings include fire hazard and rapid dulling of wires.
Precise setting at critical interfaces—cylinder/doffer, licker-in/cylinder, cylinder/flats—is essential for desired results.
Regular resetting after maintenance preserves consistent production quality and machine safety.
Incorrect or imprecise settings can lead to fiber breakage, poor web quality, uneven sliver, and reduced machine efficiency. Regular inspection and precise resetting after maintenance are essential to maintain consistent carding performance.
Conclusion
Card setting in a carding machine is a critical parameter that influences the entire spinning process’s efficiency and output quality. Correct setting improves cleaning and fiber individualization, while poor or improper setting can cause quality problems, machine damage, or even fire hazards. Regular maintenance and accurate adjustment are key to getting the best results.
Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. Mr. Kiron is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.
