Home » Process Layout of Yarn Manufacturing System with a Modern Blow Room Line

Process Layout of Yarn Manufacturing System with a Modern Blow Room Line

                                       Bale plucker


                                       Metal detector








                                        Vision shield




                                         Chute feed





6.5 Machines of Blow room

Machine NameUniflocUnicleanUnimixUniflexHeavy partical separator
Machine Number0101020202
Speed of machine wise partsTake off roller 1800 RpmOpening roller speed 500-1000 rpmSpeed of machine wise partsSpeed of machine wise partsCylinder speed 480-900 RPM
Wastage (1-10)%(1-10)%(1-10)% 
Cleaning Intensity 0.1-10.1-10.1-1 
Speed of machine wise partsTake off roller 1800 RpmOpening roller speed 400-1000 rpmSpeed of machine wise partsSpeed of machine wise parts 
Working width And Depth1700mm 2-3.5mm    

6.6 Unifloc A11

Rieter UNIfloc is an automatic bale opening machine. Over the years the company has launched several models with better performance and efficiency in processing. This a second generation type of machine. Where the bales are stationary and the machine moves along a fixed path and collect fibers in small tufts and forward them through transport duct towards the heavy particles depositor box. A bale layout can comprise up to 70 bales from 4 to 6 different sources. Intervening spaces sometimes have to be left between the individual bale groups so that the extraction roller can be adapted to varying bale heights. the machines are completely electronically controlled and extract material from all bales evenly, independently of varying bale densities and height.

6.7 Objectives of Unifloc machine:

• Extract material evenly from all the bales of a lay-out

• Gentle opening of material

• Small tuft size

• Equal tuft size

• Process as many bales as possible in a single charge;

• Easy to program

• Blend material right at the start of the process.

6.8 Heavy Particles Separator: 

With the A 48 Solid Particle Extractor, heavy particles of metal, stone, wood, plastic, rubbers etc. as well as pieces of rope and string are reliably extracted at full production. The A 48 is installed in the Blow-room after the Unifloc.

Unifloc A11
  Figure : Unifloc A11     
Heavy Particle Separator
Figure: Heavy Particle Separator


6.9 Uniclean:

The basic design corresponds to that of the mono-cylinder cleaner, i.e. there is an inlet duct (4), a large cleaning drum (1) with special hooks, a waste suction device and an outlet duct (5). But instead of the material rotating three times inside the machine, it is forced to pass over the grid five times, always presenting new surface areas to it. The tufts not only pass over the grid five times, they also pass over a specially arranged perforated sheet five times. The chamber behind this sheet is a low-pressure chamber. The air suction through this sheet provides very efficient dust remover. The waste is collected inside the machine and fed to the waste transport via an airlock cylinder. Intermittent suction and connection to continuous suction is possible. The airlock prevents good fibers from being sucked through the grid during waste removal. The UNIclean removes loose trash particles, fiber fragments and dust. It is designed for intensive cleaning. Production is up to 1400 kg/h card sliver.

6.10 Unimix:

The machine is made up of three parts: a storage section, an intermediate chamber and a delivery section. Tufts are fed pneumatically and simultaneously into eight chutes arranged one behind the other in the storage section. A conveyor belt feeds the stock through the intermediate chamber to the spiked lattice (3). The material columns are thus diverted from the vertical into the horizontal. In addition to a condensing effect, this 90° deflection in the material flow also produces a shift in the timing and spatial distribution of the fiber packages from the first to the last chutes. This special construction with a deflection of 90°, and thereby different distances from the individual chutes to the lattice (at chute 1: short distance; at chute 8: long distance) in turn results in good long-term blending. Thereafter, as in a blending opener, material is extracted from the intermediate chamber 37

and subjected to a further opening step between an inclined spiked lattice (3) and an evener roller (4) (short-term blending). An optical sensor ensures that only a small quantity of fiber stock is held in the mixing chamber in front of the lattice (3).

Behind the spiked lattice there is a take-off roller and a simple pneumatic suction feed to the next machine. The B 76 mixing machine guarantees homogeneous, intimate mixing of the bale feed in a minimum of space, even with unfavorable bale lay-down. The unique 3-point mixing process is equally suitable for cotton and man-made fibers. Eight mixing chambers ensure not only effective mixing, but also high production performance. The large storage volume of the Unimix provides the ideal preconditions for a high degree of operating autonomy in the Blowroom. The production volume is 1000kg/h (B 76) results in an excellent price/performance ratio with comparably low space requirements.

   Uniclean B11    
  Figure: Uniclean B11    
Unimix B70       
  Figure : Unimix B70       

                                          Figure 6.2.2: Unimix B70             

6.11 Uniflex B60:

1-filling chute

2-perforated drum

3-distance between feed trough


5-opening cylinder



To get a very homogeneous batting lay down is formed both lengthwise and crosswise.

Uniflex B 60
Figure: Uniflex B 60



USTER JOSSI MAGIC EYE is the unique detection system for synthetic contaminants. It deals with the biggest problems – polypropylene and polyethylene – with unbeatable efficiency. It can eliminate all kinds of synthetic material, including white transparent polypropylene. By scanning raw cotton tufts, the USTER® JOSSI MAGIC EYE recognizes the individual fingerprint of each plastic, ready for separation and removal. Nothing escapes detection – not even wrinkles, treatments, colors or odd shapes of foreign matter. The whole production is checked, for every category of synthetic contaminant. The USTER JOSSI MAGIC EYE secures first-grade quality in downstream processing. It means better products, with better profit margins in the most competitive yarn markets. USTER JOSSI MAGIC EYE is the only system on the market that identifies synthetics based on their physical properties. THE VISION SHIELD with MAGIC EYE can be flexibly installed in the line, preferably after Unistore.




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