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Abstract
The waste produced in a cotton textile mill is an important factor in determining the operating cost and therefore in influencing mill profits. In
this paper, we examine the waste percentage and the good fibre fraction for two cleaning machines and a card. The cleaning behaviour in spinning
preparation, of each waste, is predicted by determining the trash content and the preparatory processing. The quality of recovered fibres is discussed
and compared to other virgin cotton. In order to appreciate these fibres, we study the effect of cotton wastes on the rotor yarn quality. The results
indicate that generated wastes contain about 50% good fibre. This secondary raw material showed good cleanability and characteristics; therefore
it can be blended in a proportion between 15 and 25% without hardly noticeable changes in rotor yarn quality.
© 2007 Elsevier B.V. All rights reserved.
0921-3449/$ – see front matter © 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.resconrec.2007.11.009
786 M.T. Halimi et al. / Resources, Conservation and Recycling 52 (2008) 785–791
Table 1
Spinning parameters and setting
Spinning parameters Value/setting
Table 2
Waste and fibre content for an AXI-FLO cleaner
Line Waste (%) Fibre content in waste
sample (%)
Mean Standard Mean Standard
deviation deviation
1 2.50 0.21 41.83 1.29 Fig. 2. Trützschler cleaners (AXI-FLO). (1) Feeding mechanism, (2) roller
2 2.00 0.20 43.22 2.37 cleaner, and (3) waste separator.
3 1.80 0.26 40.48 2.67
4 2.21 0.31 41.98 2.76 Table 3
5 1.61 0.30 42.56 1.87 Waste and fibre content for CVT4 cleaner
6 1.80 0.21 45.40 2.43
Line Waste (%) Fibre content in
Mean 1.99 – 42.58 – waste sample (%)
Standard deviation 0.32 – 1.65 –
Mean Standard Mean Standard
deviation deviation
ered as a single roll cleaner) was used as a reference machine. 1 0.52 0.12 49.5 1.58
After that, the number of passage is determined in order to 2 0.50 0.11 50.79 1.47
compare wastes cleaning behaviours. 3 0.34 0.07 45.39 2.40
4 0.39 0.09 41.98 3.44
Once the waste fibre properties are analysed, important infor- 5 0.45 0.06 42.56 2.29
mation can be gained as far as the machine setting and quality 6 0.39 0.05 44.20 2.3
of the end product. The recovered fibres from different cotton
Mean 0.43 – 45.74 –
wastes were tested on both Uster HVI (Hight Volume Instru- Standard deviation 0.07 – 3.64 –
ment) and AFIS testers (Advanced Fiber Information System).
2.2. Spinning parameters The processing steps and machinery used are shown in Fig. 1.
The blend was processed after carding at the first passage in the
In order to study the effect of cotton waste on the rotor yarn drawing frame. Another passage was used in order to improve
quality, yarns with a count of 100 tex are produced with different the homogeneity of the blend. The linear density of the second
waste portion. In total, the waste percentage (Wp) in yarn takes drawing sliver was 4.45 ktex. Slivers were used to produce yarns
eight levels varying from 0 to 100%. After this, the mechanical on a Schlafhorst Autocorro rotor spinning machine. Ten spindles
properties of yarns were tested by the USTER TENSORAPID were used for each blend, these being selected at random within
and analysed. the machine. Spinning parameters are given in Table 1.
Fig. 3. Trützschler cleanomat (CVT4). (1) Feeding roller, (2) cotton, (3) roll clothed with pins, (4) roll with finer clothing, and (5) knife of separation.
788 M.T. Halimi et al. / Resources, Conservation and Recycling 52 (2008) 785–791
3. Results and discussion nate small trash particles (Fig. 3). Results illustrated in Table 3
indicate that CVT4 wastes are about 0.43% of treated mate-
3.1. Waste rate rial. From these wastes, we can recuperate 45% of good fibres.
Typically, recoverable fibres from AXI-FLO cleaner were about
3.1.1. AXI-FLO waste 32,700 Kg. These results confirm that generated wastes contain
The main functions of the opening and cleaning machines considerable rate of fibres (Table 3).
are the further separation of the fibre flocks and the removal of
contamination particles and dust from the cotton. The AXI-FLO
cleaner is designed to eliminate large trash particles at the first 3.1.3. Cards waste
stage of the blowroom (Fig. 2). Table 2 shows the waste and The main card tasks are the removal of dirt particles and short
fibre contents of the AXI-FLO cleaner. Six cleaning lines were fibres, fibre alignment and sliver formation. The major part of
used in the analysis and each data point shown in Table 2 is the carding action is accomplished between the tambour and the
the mean of 10 waste samples. For this machine, waste repre- flats whose teeth are positioned toward each other for carding
sents 2% of treated material, while the fibre rate is about 42%. action (Fig. 4). This causes separation into single fibres and the
The waste produced in the blowroom and carding sections of parallelization of the fibres. At the same time, contaminants and
a Tunisian cotton textile mill was about 850,000 kg in 2005. short fibres are removed. In this work, under card waste include
In this mill, waste mixture was passed into a filter in order motes and fly removed material. Six carding lines are concerned.
to reduce impurity which will be then compacted into bales. Results illustrated in Table 4 indicate that the sum of card wastes
Typically, recoverable fibre from AXI-FLO cleaner was about are about 4% of treated material. In flat and under card wastes, we
130,800 kg. can recover respectively 65 and 56% of fibre. Typically, recov-
erable fibres from AXI-FLO cleaner were about 261,600 Kg.
3.1.2. CVT4 waste In spite of the technical improvements in cards, these results
The Cleanomat CVT4 has four rollers cleaner consequently confirm that wastes generated contain a large fraction of good
it has a high cleaning efficiency and it’s designed to elimi- fibres.
Table 4
Waste and fibre content for card
Mean Standard deviation Mean Standard deviation Mean Standard deviation Mean Standard deviation
ties and the trash content are the main factors that reduce card
Fig. 5. Relationship between T% and passage number for under card and flat wastes cleanability and change the processing stages of spinning
wastes. Values presented as mean ± S.D. based on eight experimental measure-
preparation. Thus, these wastes need a more intense opening and
ments.
cleaning than other wastes.
In this study, we are interested in determining the number 3.4. Recovered fibres quality
of passages necessary to produce a waste sample with under
5% trash content. Each point in Fig. 5 represents the mean of The neps count, mean length, short fibre content, and fibre
eight waste samples. In addition, AXI-FLO and CVT4 wastes maturity are the most important parameters that indicate cotton
need only one passage on the mono-cylinder cleaner to have a quality. The measure of these properties is very important to
trash content of 4.3%. While card wastes need two passages, as determine: the recovered fibres usefulness and their proportion
shown in Fig. 5. These results can be explained by the fact that in the end product.
card wastes contain more small particles (seed-coat fragments) Obviously, primary raw material has better properties than
which hang up fibres. Consequently, it is too hard to eliminate recovered fibres as given in Figs. 7–10. In fact, the comparison
by only one passage. However, the cleaner wastes (AXI-FLO of properties indicates that AXI-FLO and CVT4 wastes are very
and CVT4) contain larger particles which separate easily during close to the initial cotton properties especially for mean length,
the first passage. From these results it seems that fibre proper- short fibre content and maturity. These data are in agreement
Fig. 7. Neps count (g) of wastes and initial cotton. Fig. 9. Short fibre count (%) of wastes and initial cotton.
790 M.T. Halimi et al. / Resources, Conservation and Recycling 52 (2008) 785–791
Acknowledgements
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