A Comparison of the Carding and Processing Performance of 2.25 with 1.5-Denier Cotton/Polyester Opening-Room Blends

Abstract

Various levels of cotton and polyester fibers blended during opening and picking were investigated to determine their effect on carding efficiency and processing performance. A medium staple cotton of average fiber properties and a high-modulus polyester (2.25 denier) were used in the blends. Shear friction and compression recovery of the blends increased as the percent polyester increased. For the 2.25-den polyester blends, shear friction was slightly lower and compression recovery practically the same as for 1.5-den polyester/cotton blends. Higher polyester content increased friction and cylinder load, thereby reducing carding action so that the short-term sliver variability and neps of the cotton component in the card web increased. Cylinder load and neps in the card web were lower for the 2.25 than the 1.5-den polyester blends. Higher polyester contents slightly improved yarn grade, and the grades for the 2.25-den were higher than those for the 1.5-den polyester blends. Increased friction and length uniformity of the polyester improved drafting so that second-drawing sliver, roving, and yarn uniformity improved when polyester was added to the blend. Carding waste was practically the same whether using 2.25 or 1.5-den polyester; very little polyester was lost in the waste. At constant end breakage, spinning production increased up to a 50/50 blend and then decreased as the percent of 2.25-den polyester was increased. These findings indicate that for cotton and polyester blended in the opening room, one with a high percentage of cotton can be processed more efficiently than the reverse.