Card TC 11

2 Card TC 11

Trützschler Card TC 11:

Precision and efficiency
 Card TC 11 3

4 Innovations

16 Carding

38 Control, operation

42 Maintenance

44 Man-made fibre card

48 IDF 2

52 Technical data
4 Card TC 11
Trützschler Card TC 11 – 
THE NEW SUCCESS FORMULA FOR CARDING
INTERACTION OF EFFI­
CIEN­CY, QUALITY AND
PRODUCTIVITY
The cost pressure in the textile
industry grows from year to year.
This is also due to the fact that the
spinning mills cannot pass on the
climbing cotton prices 1:1. At the
same time, the quality requirements
of the consumers increase.
Hence, a future-oriented card must
not only set record highs in terms of
efficiency and productivity, but also
in terms of quality. Of key impor-
tance is also the handling of valu-
able raw material. The TC 11 offers
optimal material utilisation.
APPROX. 40% ADDITIONAL
PRODUCTIVITY AT HIGH­
EST QUALITY LEVEL
Trützschler identified the challenges
at an early stage and, in response,
developed the new card generation
TC 11. It meets even highest ex-
pectations thanks to characteristics
that are unique in high-production
carding:
 Approx. 40 % more production at
same compact space
 Highest quality due to longest
carding section on the market
 Lowest operating costs
 Lowest waste quantities
FLEXIBILITY TO ENSURE
EVEN MORE EFFICIENCY
The TC 11 supports the competitive-
ness of your spinning mill not only by
its excellent productivity and qual-
ity, but also by the lowest operating
costs. It also features a flexibility
that allows quick and frequent lot
changes without any problems. Even
important, quality-relevant settings
such as of the flats, carding segments
or mote knife, are completed within
minutes. Immediately after restart
of the machine, T-Con indicates
whether and where there is still a
potential for optimisation.
 Card TC 11 5

This result appeals to sober analysts

and the quality conscious:

Trützschler efficiency =
circumference x width of card cylinder
6 Card TC 11
Exclusive from Trützschler: 5.3 m2
THE PERFECT SPACE FOR QUALITY AND ECONOMIC EFFICIENCY
LONGER CARDING
SECTION = MORE QUALITY!
A simple formula states: The great­
er the distance covered by the
fibres on the cylinder, the ­better
the carding quality.
With a carding section of more than
2.8 metres, only Trützschler cards
offer optimal quality. It is precisely
this carding section that – in addition
to the ideal number of flats – also
ensures a sufficient number of card-
ing segments and cleaning units.
MORE CARDING WIDTH =
MORE PRODUCTIVITY?
There is a formula for this as well:
More width while maintaining
roll geometries means generally
more productivity.
However, the accuracy required
in the setting limits the desire for
more width. Starting at a certain
width, the elements surrounding
the cylinder would have to be so
massive that the resulting costs
would be in no economic relation
to productivity.
BALANCE OF QUALITY
AND PRODUCTIVITY
We have included everything in the
TC 11 that Trützschler stands for:
More than 120 years of experience,
a team of first-class engineers, as
well as countless analyses, simula-
tions and field tests. The end result
was clear: A working width of 1.28 m
represents the perfect balance be­
tween productivity and efficiency.
Any occurring forces can be optimally
handled up to this width by an intel-
ligent design.
Card TC 11 7
8 Card TC 11
[1 m card = 100]
100
Performance/price ratio
80
60
40
20
0
0.7
You are searching for optimal efficiency?
THE ANSWER IS TC 11
MORE ECONOMICAL THAN
ALL ITS PREDECESSORS
The technical qualities of the new
TC 11 are impressive. However, it
shows its strengths also in terms of
efficiency. Compared to its pred-
ecessors – which were already very
good in this regard – it offers three
tangible advantages:
 Best performance/price ratio
 Lowest operating costs
 approx. 40 % more production at
same space requirement.
1.0
LOWER INVESTMENT
COSTS*
Compared to the predecessor
series TC 7, the investment costs
for carding are considerably lower
for the TC 11. Simply less cards are
required. In addition, this allows a
smaller building size and smaller
filter.
* approx. 14 cards, 140 kg/h 8,000 operating
UP TO 25 % LESS
OPERATING COSTS*
In the end, the life-cycle-costs
determine whether an investment
was successful from an economic
point of view. In case of the TC 11,
you do not have to wait very long
for a RETURN OF INVESTMENT.
Compared to TC 7, your cost
advantages in the areas of energy,
filter and maintenance result in
savings of up to 25 %. This equals
roughly 152,000 US$ per year.
hours per year. The raw material use is
approx. 15,680 t, purchased at a cotton price
of 94 USct./lbs.
 Card TC 11 9

The diagram shows that the best

performance to price ratio is reached
in the range between 1.25 –1.30 m.
With a working width of 1.28 m, the
TC 11 is precisely in this range.

Working width [m]

1.5 2.0

A fictional „spinning mill example“

produces 1000 kg/h card sliver,
carded ring, Ne 20. The calculation
is based on costs for cards, filters
and building.
The spinning mill ex-
ample is identified on
the following pages by
this symbol:
10 Card TC 11
Perfection can be measured –
WITH T-CON
PRODUCTIVITY CANNOT
BE INCREASED THROUGH
ESTIMATED VALUES
Efficient production requires utilisa-
tion of the card‘s full potential at all
times. The prerequisite for this are
optimal settings of the work ele-
ments. However, this process is fre-
quently carried out when the card is
in cold condition and is usually based
on „empirical values“. Changes in
ambient temperatures or changes
caused by high production quantities
are not considered.
THE PERFECT SOLUTION
FOR IMPERFECTIONS
The patented Trützschler T-Con low-
ers the number of imperfections by
up to 10 %.
For this purpose, the actual distanc-
es between cylinder, flats and fixed
carding elements are determined.
The results appear on the card dis-
play and indicate which settings can
be improved. There is no easier way
to accomplish perfect card settings
and thus optimal productivity.
NO ROOM FOR SAFETY
LAPSES
With T-Con, across-the-board set-
tings of safety reserves are a thing
of the past. T-Con registers even
the slightest contact with cloth-
ings and shuts down the card long
before a damage can occur. This
makes it possible to bring produc-
tions closer to an ideal line without
taking a risk.
 Card TC 11 11

The optimisation options are clearly

shown on the screen. The type of fibre and
production level are taken into account.

Considerably lower operating

costs with T-Con
Experiences with T-Con show that
10 % more production and 10 % less
IPI in the yarn are possible, which
in case of our spinning mill exam-
ple equals annual operating costs
savings of approx.
280,000 US$.
12 Card TC 11
MAGNOTOP –
THIS IS HOW SIMPLE OPTIMAL FLAT TOPS CAN BE
SECURE ECONOMIC
­ADVANTAGES DURING EACH
CLOTHING CHANGE
Maintaining consistent high quality re-
quires regular change of flat tops. For
this purpose, Trützschler has developed
the patented MAGNOTOP system
together with Trützschler Card Cloth-
ing. Its clothing strips, which are easy
and quick to replace, offer unbeatable
economic advantages: Depending on
labour costs, savings of 300  – 1100 US$
per card re-clothing can be realised.
Investments in a flats workshop (usu-
ally 170 – 210,000 US$) are completely
eliminated.
UNNECESSARY FEATURES HIGHER ACCURACY WITH­
TRANSLATE INTO SAVINGS OUT INITIAL GRINDING
The improved efficiency achieved With MAGNOTOP, the clothing
by the easy replacement of the strips fit perfect from the start.
clothing strips without flats work- This is due to the reduced toler­
shop results in an immediate reduc- ances; the clothing strips are
tion of operating costs. Use of the attached to the flat bar via super-
­MAGNOTOP system also eliminates strong neodymium magnets. The
the otherwise unavoidable extra usual levelling that compensates
costs: deformations caused by assembly
can be eliminated. This prolongs
 No spare flat sets required the service life by one grinding
 No service costs for re-clothing cycle.
 No transport costs
 Card TC 11 13

The perfect points of new flat tops

are preserved because levelling after
replacement of flat tops is not necessary.

The clothing strips can be easily

replaced without any tools.
14 Card TC 11
Higher efficiency
DUE TO FEWER PROCESS STEPS
FEWER STEPS
TO REACH THE GOAL
The "best" process steps are those
that do not exist in the first place.
Thus, problems can be avoided,
errors ruled out and money saved. A
reduction of draw frames is of par-
ticular interest in the spinning mill.
And this is precisely what the Inte-
grated Draw Frame IDF 2 achieves
by direct coupling to the Trützschler
Card TC 11 in the rotor spinning
mill. Efficiency is increased by a
multiple. Because the Trützschler
card/draw frame couplings combine
all the advantages of the Card TC
11 with a proven and reliable draw
frame technology, the quality is
improved as well.
ALSO SHORT SPINNING
PROCESS
There is no shorter spinning process
than feeding the card sliver directly to
the OE rotor spinning machine. This
requirement is also perfectly met by
the Integrated Draw Frame IDF 2.
 Card TC 11 15

Open leveller draw frame unit

For rotor spinning, a sliver

with a lower level of paral-
lelisation is of advantage; for
this reason, the drafts should
be kept small. The 1 zone
drafting system of the IDF 2
provides an excellent sliver
evenness and a significantly
improved yarn evenness. The
better quality is evident in the
uniform fabric appearance.
16 Card TC 11

Features and advantages only

offered by Trützschler cards

Fully-integrated tuft feeder DIRECTFEED • High production with even card feeding

Setting Optimiser T-Con • For maximum utilisation of the TC 11 potential

Flexible Integral Feed Tray SENSOFEED+ • Short-wave levelling for a low sliver count variation

Sliver former WEBSPEED • Completely maintenance-free

Precision Knife Setting System PMS • Adjustment of waste amount in no time at all

Aluminium flat bars without screw connection • Quick flat exchange, without tools

Magnet Flat System MAGNOTOP • Replacement of flat tops directly on the machine without tools

Precision Flat Setting System PFS • Reproducible flat setting in only a few seconds

Flat Measuring System FLATCONTROL • Objective and very precise flat adjustment

Infinitely variable setting of the flat speed • Exact adaptation to the fibre quality in only a few seconds

Electronic cylinder brake • Reduces cleaning and maintenance time

Nep sensor NEPCONTROL • Online measurement of neps and trash particles

Computer control with touch screen • Simple operation and targeted maintenance

Digital motor controls • Maintenance-free and high-precision

Spectrogram monitoring • Stops the card in case of faults in the spectrogram

Thick place monitoring • Stops the card in case of excessive thick places in the sliver

Spectrogram analysis • Assists in finding the cause of spectrogram errors

Management of maintenance and card clothing • Targeted maintenance support

3-roll WEBFEED Unit • For gentle pre-opening

WEBFEED with one roll • For the carding of man-made fibres or ELS cotton

Needle or clothed rolls • Perfectly tailored to your product

Thick place monitoring and metal detection

• For quality assurance and protection of the card
in the feed area

Long- and short-wave levelling system • For perfect card sliver evenness

Special toothed belts for flat guiding • Flat replacement without tools

 remium clothings from TCC, made of high-grade

P
• Extended service life ensures longer maintenance intervals
steel for licker-in, main cylinder and doffer

High-precision aluminium elements with

• Gentle material guidance in the fibre-carrying areas
­super-smooth surfaces

Central safety locking system • High operational safety

Nearly all the points listed here are protected by international

patents to secure the technical and technological lead for all
users of Trützschler cards.
19 Card TC 11

Highlights at a glance

Computer control with touch screen

Flexible Integral Feed Tray SENSOFEED+ for Fully-integrated Tuft Feeder DIRECTFEED with Setting Optimiser T-Con
perfect clamping and very precise short-term built-in air volume separator and segmented feed
levelling tray

Precision Flat Setting System PFS The measuring bar is a precision instrument Magnet Flat System MAGNOTOP
„Made by Trützschler“

Nep Sensor NEPCONTROL TC-NCT Precision Knife Setting System PMS MULTI WEBCLEAN – flexible for all applications
Card TC 11 18
Carding Control / operation Maintenance
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 21

SENSOFEED+ and DIRECTFEED:

The specialists for optimal feeding

More than 20,000 cards delivered with

DIRECTFEED
The Tuft Feeder DIRECTFEED is an integral part
of the Card TC 11. The delivery roll of tuft feed-
ing is identical to the card‘s feed roll. Hence,
faulty drafts due to wrong or suboptimal settings
have no chance to develop.
DIRECTFEED utilises the successful Trützschler
double trunk principle: The upper trunk has a
significantly larger volume for a 60 –180 % higher
material reserve, whereas the special geometry
of the lower trunk and the extended material
fly form the foundation for excellent sliver CV
values. The air outlet comb with direct and per-
manent suction is positioned right in front of the
feed roll. It is only here, just a few centimetres
in front of the nip line of the feed roll, that the
actual web is formed.
The feeding of material slubs leads to a minimal deformation at this point of the tray edge.
In the simulation the effective forces are highlighted in colour.

SENSOFEED+
1 The flexible Integral Feed Tray SENSOFEED+
ensures controlled web feeding to the ­WEBFEED
Unit. Its feed table compacts the tuft web and
guides it to a knife-shaped feed tray tip. The
material at this top allows a partial elastic defor-
2
mation that occurs when material slubs are fed.
This deformation is only a few hundredth of a
millimetre and has hardly any influence on the
overall deflection of the feed tray. As additional
function, the Integral Feed Plate SENSOFEED+
can also include feed monitoring for the card.
3
4

7 8

Tuft Feeder DIRECTFEED

1 New high-volume upper trunk

2 Integrated air volume separator
3 Feed roll, electrically coupled to the feed roll of the card
4 Segmented tray for secure clamping
5 Opening roll with gentle needling
6 Closed air circuit with integrated fan
7 Self cleaning air outlet comb
8 Flexible Feed Tray SENSOFEED+
22 Card TC 11 Carding Control / operation Maintenance

WEBFEED:
The plus for gentle but efficient opening

The WEBFEED system consists of one large Fibre pre-opening is of decisive importance for
or three opening rolls connected in series. The the carding process. Therefore it makes sense
tufts are opened in a gentler way and to a higher here to precisely adapt to the respective applica-
degree than is the case with conventional licker- tion. In the process, the different versions are
ins. This results in an even and fine web that flexible and easy to replace:
increases the carding efficiency at the actual
main working points (between cylinder and flats/
carding segments) during the transfer to the
main cylinder.

• 3 rolls – first roll: Needles e.g. cotton at high production rates

• 3 rolls – first roll: Metallic wires e.g. cotton/man-made fibre blend yarns

• 1 roll: Needles e.g. man-made fibres + ELS cotton

For a ten-fold durability

compared to metallic wires,
the needles are made of
special steel.

Gradual opening
for maximum fibre
Tuft
size protection
ed
l spe (3-roll WEBFEED)
hera
Perip
ss
nene
ing fi
Cloth

g angle
Clothin
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 23

PMS:
Adjustment in no time at all

The main cleaning zone of the TC 11 lies in the Through the circular
area of the first roll of the WEBFEED system. adjustment the top edge of
the knife always remains at
Here, an optimal waste composition requires an an optimum distance to the
accurate mote knife setting. This is exactly what needles.
the successful Precision Knife Setting System
1 Feed roll
PMS provides. 2 The adjusting slide moves with
the knife on a circular path
The knife, which circles around the centre of the
around the centre of the needle
needle roll, is infinitely adjustable within sec- roll
3 With this lever the position of
onds. Thus, the distance of the knife point to the the knife is adjusted in no time
1
needles is exactly the same in every position. 4 The permanent suction keeps
the card clean in this area as
well
2

There is no need to stop the card, since the set-

ting lever is freely accessible on the left machine
side. A glance into the transparent suction ducts
immediately shows the success of the readjust-
ment.
With this lever the mote knife is adjusted.

PMS with motor: Perfect setting within seconds

With this system, a small servo motor is the key This small servomotor
to increased user-friendliness and precision: The adjusts the knife circularly
around the centre of the first
knife can be circularly adjusted around the cen- roll of the WEBFEED.
tre of the first WEBFEED roll via touch screen –
and that even while the machine is running.
All values can be stored according to lot. For
extremely short transitions from one material to
the next, the setting values of the PFS and of
the PMS system, as well as the speeds of the
cylinder roll and WEBFEED roll, can be stored
according to lot in the memory of the control.
24 Card TC 11 Carding Control / operation Maintenance

3.7 m2: The largest ”active carding area“ in the

market ensures maximum productivity

1.28 m

The new width of the Trützschler cards of 1.28 m
is the result of an intensive development proc-
ess. Initial analyses concerning an optimal cylin-
der width revealed the following: A larger width
would make the construction so massive that
it would no longer be economically feasible. A
smaller width wastes productivity. Based on this
concept, production parameters of the prede-
cessor model TC 7 were evaluated with the help
of T-Con sensors (see page 38), and the new
design was developed. This also includes new
statics and the application of new materials. The
level of precision used during manufacturing
contributes to the growth in productivity. During
countless tests the technical concept was tried
out, refined and, last but not least, tested as
prototype in customer facilities. The results fully
met our expectations.

”active carding area“

4.0
3.7 Pre-carding

1.1
Flat
”active carding area“ [m2]

3.0
3.0 Post-carding
0.6
2,4
2.1 1.5
0.5 1.8
0.5
2.0 0.5
1.3
1.1

1.0 1.1

0.6 0.6
0.5
0
other card manufacturers TC 11 
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 25

2.8 m: The longest carding section on the

market ensures perfect quality

Pre-carding

Flat

Post-carding

The Trützschler Card TC 11 features the longest
carding section on the market. Carding quality
is ensured by optimal distribution over the three
carding areas.
In this regard, the cylinder area is of particular
importance. The main focus is on the revolving
flat: With an optimal number of flat bars, it is re-
sponsible for cleaning as well as extracting neps
and short fibres. To ensure its optimal function,
the fibre web must be prepared accordingly.
This job is assigned to the pre-carding area
with its cleaning and carding elements.
The higher the pre-opening, the more intense
the carding, which in turn results in increased
production. The large post-carding area takes
care of the rest, thus ensuring even cleaner
sliver and higher fibre parallelism.

Of importance is
the proper balance
Carding section between pre- and
post-carding zone and
3.5
Pre-carding the flat

3.0 2.8
Flat
Carding section [m]

0.8
2.4 Post-carding
2.1
0.5 2.0
2.0 0.5
0.4 1.2
1.3
1.1 1.2

1.0
0.8
0.6
0.5
0.4
0
other card manufacturers TC 11 
26 Card TC 11 Carding Control / operation Maintenance

MAGNOTOP flat tops:

Magnetic attraction of quality

In the past, each one of the

84 flat bars had to be manually
handled six times during the
replacement of flat tops.
With MAGNOTOP this is only

14 h 2h
necessary once – which reduc-
es the approximately 14 hours
spent by personnel to less
than 2 hours.
MAGNOTOP-change of flat tops

1.  Pick up set of new MAGNOTOP

Up to now, replacement of flat tops required
clothing strips and unpack.
much time and expenditure. Now MAGNOTOP
2.  Take one flat bar each from the card,
provides increased speed and cost efficiency.
remove clothing strip by hand, attach
The system uses so-called neodymium mag-
new clothing strip and put flat bar
nets, which are considered to be the strongest
back into card.
permanent magnets ever: One neodymium
3. Perform basic settings.
magnet, smaller than a cigarette pack, can easily
4. Discard old clothing strips.
hold or lift a weight of 100 kg. Another decisive
advantage: The expensive alloy made of iron,
neodymium and boron, retains its magnetic force
for many decades.

Quick change of flat tops, entirely without

tools
The flat bars of the innovate MAGNOTOP
system for attaching flat tops are equipped with
neodymium high energy magnets in form of
strips. On the back of the clothing strips there is
a matching thin, flexible metal strip.
Once positioned on the flat bar, the clothing strips
remain securely in place, because the magnetic
forces exceed the developing carding forces by a
multiple. Thus, the fastening is 100 % reliable; on
the other hand, the clothing strips can simply be
„peeled off“ from the side and removed with little
effort.

The MAGNOTOP system was developed in cooperation between clothing specialists from
Trützschler Card Clothing and Trützschler card developers.
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 27

Lower costs, higher quality

With MAGNOTOP, there is no longer a need for

inhouse flats workshop, additional space, special
machines, service, maintenance and accord-
ing specialists. This corresponds to savings in
investment costs between 170,000 and 210,000
US$. Operating costs are eliminated entirely.
Another advantage is the quick and easy testing
of new types of flat tops. The previous set of
MAGNOTOP clothing strips can be reused at
any time.
The patented MAGNOTOP fastening system
also compensates tolerances. This simplifies
precision setting of flat tops even more, which
in turn improves the carding results and leads to
less neps in the yarn.

The direct way to increased time

and cost efficiency
Today, replacement of cylinder and doffer cloth-
ings directly on site is a matter of course. In con-
trast, in the past flat bars had to be laboriously
removed and transported to a special workshop
where they were replaced. MAGNOTOP allows
complete flat top service directly at the card.
The clothing strips can be
replaced without any effort
MAGNOTOP-Advantages at a glance and without any tools.
• Improved yarn quality through higher precision
• Elimination of investments in a flats workshop,
operating costs, etc.
• Elimination of providers‘ service costs.
• Elimination of investment for one or several
spare flat bar sets
• No storing of flat sets
• No grinding of flat tops after re-clothing
• No transport costs, instead simplified logistics

3
4
5
3
2

1 1
1 Aluminium flat bar
2 Clothing strips
3 Adhesive and
compensation layer
4 Neodymium magnet
5 Thin metal strip
2

Conventional system with clips MAGNOTOP system

28 Card TC 11 Carding Control / operation Maintenance

Changing flat bars: 1 hour, 0 tools

300

240

Time [min]
180

120

60

0
Conventional high- TC 11
production card

Setting of flat bars

Replacement of flat bars

Via remote control it is
possible to move the flat for
service-purposes also while
card is at a standstill.
Each individual MAGNOTOP flat bar is made
of high-strength aluminium profiles, which are
lightweight and extremely stable. The flat bars
are directly connected via a cam to two toothed
belts that ensure perfect guidance. The hard
metal pins at the ends of the flat bar glide across
Replacement of flat bars requires one person to work only
approx. one hour.
a special plastic strip. This arrangement has the
advantage that a complete flat replacement can
be performed by just one person without tools
in less than one hour.

3
4

Trützschler MAGNOTOP flat bar –

proven millions of times
2
1 Optimised, lightweight aluminium
profile
2 Flat top
3 Wear-resistant hard metal gliding pins
4 Plastic support
5 The cleaning felt keeps the sliding
plastic clean
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 29

Automatically faster: Flat setting 4 5

Trützschler developed the Precision Flat Setting
System PFS for central adjustment of the whole
flat to the cylinder. It performs precision flat set-
ting – during production – within just a few sec-
onds. After the initial setting, the PFS system
can help maintain precise distances throughout
the entire service life of a clothing set. The basic
setting is further facilitated by the use of the Flat
Measuring System FLATCONTROL TC-FCT.

1 2 3 6

Precision Flat Setting System PFS 1 Metal flexible bend

2 Wear-resistant special plastic
slide rail
3 Setting lever
After the basic setting is performed, only a han-
4 High-precision aluminium
dle needs to be turned on each side of the card flat bars
5 Cam toothed belt for the
to increase or decrease the distance of all flat flat drive
bars in working position to the cylinder. A scale 6 The distance setting can be
read directly from a scale
shows the current setting in relation to the basic
The flat bars can be inserted into the cams of the toothed
belt easily without tools. setting.

PFS with motor: Centrally controlled precision

This system performs the motorised adjustment A servo motor performs the
of the flat setting system in a precise, repro- flat setting on both sides of
the card.
ducible manner within seconds. From a central
control it ensures that the distance of all flat
bars in working position to the cylinder in­creases
or decreases. All that is required to select the
respective adjustment on the display of the
machine control. The adjustment is indicated ac-
cordingly and, same as all other settings, can be
managed in the lot memory.
30 Card TC 11 Carding Control / operation Maintenance

MULTI WEBCLEAN:
The tailor-made solution for each application

Cleaning element
This element consists of
a mote knife with a hood
under permanent suction.
It is designed to separate
tiny dirt particles, seed coat
fragments, dust particles,
and fibre fragments.

Carding element
The carding element
consists of two clothing
strips in a support
(TWIN TOP), which
can be equipped with
a number of different
clothing types and
finenesses, depending
on application area and
raw material.

To ensure optimal carding conditions for each

application, they must be adjusted to raw mate-
rial, production volume and targeted quality. For
precisely this purpose Trützschler developed the
MULTI WEBCLEAN system.

It allows the individual attachment of ten special

Cover element
If none of the elements
described above is used on
one of the eight variable
positions in the pre-carding
and post-carding area, a
cover element is mounted.
elements each in the pre- and post-carding area
of the cylinder. Only the first and last element
are specified; the remaining eight elements can
be flexibly selected according to the required
production task.
The three elements of the modular system
• Cleaning element
• Carding element
• Cover element
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 31

Depending on application,
the MULTI WEBCLEAN
consists of the cleaning,
carding and cover
elements.

Replacement within minutes In principle, any element can be mounted to

Once the elements are precisely adjusted, they each of the 16 positions. The card is delivered in
can be mounted and dismounted without the a configuration that has been individually speci-
need for readjustment due to specially devel- fied in advance.
oped fixing elements.

TC-MWC 3: The solution for torn materials

The recycling fibre set offered by Trützschler

is a version of the MULTI WEBCLEAN system,
intended especially for processing of torn fibres
in cards of the TC series. In addition to the two
cleaning elements, seven carding elements are
applied in the pre-carding area. The post-carding
area is equipped with six carding and two clean-
ing elements.

MULTI WEBCLEAN for carding of recycling fibres

32 Card TC 11 Carding Control / operation Maintenance

Continuous suction ensures carding quality

and efficiency

A permanent suction of all points is standard

on Trützschler cards, ensuring increased clean­ Lower energy consumption
liness, cost effectiveness and efficient dust of the card filter
removal. Reduced exhaust air and less
The main reason for the efficiency of the per­ negative pressures lower the
manent suction is the low operating subpres- ­operating costs of the filter.
sure and the low air requirement. At -740 Pa or Based on our spinning mill
4200 m3/h (in relation to a card with 1 m width, example, this results in annual
savings of US$ 29,050.
this is only 3230 m³/h), the values are clearly be-
low those of other systems. This can be attrib-
50,000

Energy costs US$/year

uted to the flow optimisation of each individual 47,250
duct element – an advantage that is obvious not 42,000
only on paper but also on the machine: Transpar-
ent duct parts provide an insight into the suction 35,000

hoods, even while card is in operation. 8000 h/year –

28,000 0.112 US$ / kWh

21,000
The suction ducts are 18,200
fastened entirely without 14,000
tools. They are pulled
off and put on with the
7,000
SNAPLOCK Quick-Change
System.
0
Other cards

TC 11

In comparison:
Other cards: 5500 m3/h at -1250 Pa
TC 11: 4200 m3/h at -740 Pa

[m3/h] Exhaust air volume

[m3/h] [Pa] [Pa] Operating subpressure
60006000 -1500
-1500
5500
-1250

-1200
-1200
4200

40004000 -900 -900

-740

-600 -600

20002000 -300 -300

0 0 0 0

Other cards TC 11

Low exhaust air volumes and operating subpressures reduce the operating costs considerably.
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 33

TC-C:
A can changer as it should be

The can changer TC-C stands freely in front of the card, without mechanical connection. A service aisle between can
changer and card reduces the distances.

Can changer for 500 m/min The free arrangement

The can changer TC-C is an alternative to the can saves space and reduces
operating time.
coiler that is standard on the Trützschler Card
1 A centre distance of only
TC 11. It is designed for cans up to 1500 mm
3.5 m is possible
height and 1000 mm diameter. All can changers 2 The service aisle cuts the
of the TC-C series are new developments distance from card to card

designed for the high delivery speeds of the 1

TC 11.

Optimal accessibility and operation

The can changer stands freely in front of the
card, thus it is optimally accessible from all 2
sides. A service aisle between can changer and
card results in shorter distances between the
cards.
The separate drive allows very fine draft adjust-
ments between card and changer via the card‘s
touch screen. Faulty drafts and sliver breaks due
to excessive tension draft are no longer possi-
ble. Another plus for user-friendliness is pro-
vided by the automatic sliver separation during
can changing.
34 Card TC 11 Carding Control / operation Maintenance

A quality control that does not miss a thing

With TC 11, every metre of card sliver is checked
prior to its deposit in the can. This is made pos-
sible by extensive, integrated quality monitoring
during which the sensor data for all relevant
areas are gathered:
• Sliver count
• Sliver evenness
• Spectrogram
• Frequency of thick places
is clearly superior to random laboratory checks
because it is performed permanently and online.
Thick places are also reliably detected.
Upon request, the quality management can also
be supported by additional systems and tools:
 he online Nep Sensor NEPCONTROL TC-NCT
T
permanently records the number of neps, dirt parti-
cles and seed coat fragments (option)

The data is evaluated by the card control, and

the results appear in form of a diagram on the
touch screen. If predefined limits are exceeded,
the card shuts down automatically. This type of
production control of every metre of card sliver

Display of thick place evaluation

Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 35

The evenness of fed material, card sliver and Pictures or diagrams provide visual information,
draft deviation is clearly displayed on the same which often is superior to text messages (e.g. in
timeline. case of fault messages)

With the virtual roll bars below the continuously The error source calculated by the automatic
calculated spectrograms, the error sources can spectrogram analysis is shown directly in the
be located more quickly. gearing diagram.

Maintenance and clothing management benefit Production parameters can simply and quickly
from concrete additional information. be entered via touch screen.
36 Card TC 11 Carding Control / operation Maintenance

NEPCONTROL TC-NCT: The web always in sight

With the nep sensor NEPCONTROL TC-NCT,

Trützschler offers a unique solution for perma-
nent quality control: TC-NCT monitors the card
web during production and provides concrete
information on quality. In the process, every
single metre of card sliver is tested.

Focus on nep level

A camera takes approx. 20 pictures per second
of the web under the take-off roll. In doing so,
the camera moves about the whole working
width of the card in a special, fully closed profile.
This optical principle copies the visual percep­
tion of a person, and is thus superior to indirect
measuring methods. A high-performance com-
puter directly attached to the profile evaluates
the pictures with a special software, distinguish­ The camera view of the web with trash particles
ing between neps, trash particles and seed coat (neps, seed-coat fragments, trash parts).

fragments.
With NEPCONTROL TC-NCT it is also possible
to establish a distribution profile of the nep and
particle level over the working width. Possible
clothing damage becomes immediately visible
this way.

This is how the evaluation

of neps and trash particles
appears on the monitor of
the card.
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 37

FLATCONTROL TC-FCT: The fast flat setting

When it comes to fast and accurate calculation

of the distance between cylinder and flat, the
Measuring System FLATCONTROL TC-FCT from
Trützschler offers numerous benefits:

• Better card sliver quality due to smaller

setting tolerances
• Extended service life of clothing
• Quick flat setting
• Reproducible, objectively verifiable settings
• Independent of personal influences

Basic settings reproducible at any time

When performing basic flat settings with
­FLATCONTROL TC-FCT, first the measuring flat
is moved to the corresponding setting posi-
For the time of the
tion via remote control. The colour monitor of measurement, three normal
the computer shows a diagram of the current flat bars are replaced by a
distance to the cylinder. The technician can now Scope of delivery of Flat Measuring System measuring flat.

adjust the distance of flat to cylinder within FLATCONTROL

seconds – considerably more accurate than with • Measuring flat
feeler gauges. • Notebook PC with accessories
• Calibration device
Measurement covering the entire flat area • Solid metal case for transport and safekeeping
Taking the place of three regular flat bars, the • Service carriage for transport within the spin-
sensors of the FLATCONTROL measuring flat ning mill
record the distance to the cylinder clothing. All
measurement values are automatically saved,
wirelessly transferred to a notebook and dis-
played in form of a diagram.

Targeted quality optimisation

FLATCONTROL TC-FCT is a measuring system
that efficiently prevents losses caused by too
widely set revolving flats. The setting variation
within one card group can also be systemati-
cally reduced with FLATCONTROL TC-FCT. The
result: Each card works within an optimal range,
thus significantly increasing the quality level.

The screen shows the current condition of the flat settings. To perform the setting, the
technician just needs to take one look at the screen.
38 Card TC 11 Carding Control / operation Maintenance

T-Con: Because card setting must be

optimal at all times

The distances of the carding elements to each

other are the most important settings at the
card.
They significantly influence the carding and
therefore the yarn quality. The setting is made
on the standing, i.e. relatively cold machine. Up
to now, dynamic changes during operation such
as centrifugal forces or increases in temperature
are not taken into consideration. In the process,
they change the card settings during operation.
The actual settings during carding have there-
fore been unknown so far. This has changed
fundamentally with the Setting Optimiser T-Con.
Its latest version is applied in the Trützschler
Card TC 11.

The fields highlighted in blue

show the recommended
optimisations determined
by T-Con.

The five T-Con functions

• T-Con ACTUAL Display of the most important process variable for

carding quality

• T-Con contact monitoring Maximum safety against clothing contact

• T-Con distance optimisation Optimal yarn quality due to correct setting parameters

• T-Con operating status analysis Prerequisite for controlled setting

• T-Con-Spacer Fast, accurate, reproducible settings

Information evaluated by T-Con:

Contacts
Temperatures
Rotational speeds
Setting

T-Con
PMS
Setting
PFS Sliver count Production Material Delivery speed
Setting
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 39

For determining exact carding settings and

recommending optimisations
The optimisation tool T-Con is a software pack­
age integrated in the card control. It uses special
sensors to obtain measured values, e.g. current
temperatures or speeds of carding elements,
and carries out a permanent analysis of the
operating conditions.
On the screen of the card control T-Con displays
the current distances and recommends possible
optimisations, depending on the fibres that are
being processed at the time.

Fast and efficient setting optimisation

The flat distance can now be changed within
seconds, e.g. via the Precision Flat Setting Sys-
tem PFS, even during production. T-Con deter-
mines and displays the new operating condition
immediately.
The setting of the fixed carding segments can
also be optimised within minutes without meas-
uring tools. To do so, only the T-Con Spacers –
precise colour-coded distance elements – have
to be replaced.
This sensor determines contacts between the
carding elements.
No chance for clothing damage
T-Con also protects the clothings; if the setting
is too narrow, a warning appears. In case the
metallic wires of two carding elements actually
make contact, the card will be stopped immedi-
ately before any damage can occur.

Operating costs are considerably

lowered with T-Con
Experiences with T-Con show that 10 %
more production and 10 % less IPI values in
the yarn are possible, which in case of our
spinning mill example equals annual savings
in operating costs of approx.
280,000 US$.

The T-Con Spacers can easily be replaced in just a few This sensor monitors the
simple steps and thus enable a reproducible setting of the cylinder temperature.
carding segments.
40 Card TC 11 Carding Control / operation Maintenance

Reliable and user-friendly –

this is how a control should be

The Trützschler card control uses a robust

industrial computer that records all sensor data
and issues according control commands, e.g.
to the drive and servo motors. A large colour
touch screen facilitates trouble-free control for
operators, maintenance specialists and quality
managers.

Easy to understand and individually

Operating level: Machine personnel
A few simple diagrams and symbols,
independent of language, inform
the operator about the status of the
machine.
Operating level: Servicing personnel
Here a variety of password-protected
settings can be performed, among
other things limit values for all quality
shut-downs.
configurable
The most important advantage of monitor
control is the largely language-independent
operation via generally comprehensible symbols,
diagrams and pictures. At the same time it is
possible to display only those operating func-
tions that are currently necessary or useful. In
the event of a malfunction, the point of failure
is clearly classified and precisely identified by
means of a detailed picture or diagram.

Continuous quality and production

Operating level: Plant manager /
Quality manager
Here persons with special access
authorisation have the possibility to
change, among other things, ma-
chine configurations and customer-
specific data.
monitoring
The control of the Card TC 11 gathers and
monitors all machine-relevant data ranging from
tuft feeding, card, can changer all the way to
Operating level: Trützschler service Integrated Draw Frame IDF 2.
technician
Trützschler specialists are able to
call up specific data, to perform the
service call in a fast and effective
manner.

TC-VSD:
Infinitely variable setting, without compromises
With this method, infinitely variable setting of
the required cylinder speed, and thus the WEB-
FEED speeds, is achieved via a frequency con-
verter at the cylinder's drive motor. The control
is carried out directly on the screen of the card,
which significantly simplifies frequent material
changes. Furthermore, the infinitely variable
rotary speed setting TC-VSD can be used to
compensate the wear of the cylinder clothing by
a slightly higher cylinder speed, thus maintaining
a stable nep level.

With TC-VSD, the speeds of cylinder and WEBFEED can be

set infinitely variable on the screen.
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 41

Perfect interaction of the individual levelling

systems

For the production of an even card sliver, a The TC 11 guarantees

number of measures must interact perfectly: 3.00 excellent values concerning
evenness over the entire
2.50

Variation coefficient
length spectrum.
1. Card feeding
2.00
In Trützschler installations, already the material
flow to the card is continuously controlled via 1.50

the CONTIFEED System. Thus, the production 1.00

requirements of all cards of a line determine the
0.50
current production of the last machine in the
blowroom. The result is a continuous card feed- 0
ing that forms the basis for an even sliver. 1 2 5 10 20 50 100
Cutting length

2. Card feeding without levelling TC 11

Additional homogenisation is made possible by
the double trunk principle of the tuft feeder. Its
continuous, pressure-controlled feeding of the
upper and lower trunk prevents unevenness of
the card sliver, which for instance can occur dur-
ing start up and shutdown of the card. In such
cases the speed of the tuft feeder‘s feed roll
is automatically adjusted to the respective card
production.
3. Long-wave levelling
Analogous to the sliver mass measurement
performed by the sensor in the card‘s sliver
trumpet, the feed roll speed is measured and
controlled via a single sensor. It covers the en-
tire spectrum of the regular card sliver counts.
4. Short-wave levelling
The Card TC 11 is also equipped with a short-
wave sliver count regulation. This system, which
is already effective for a sliver length of less
than 1 m, considerably improves card sliver
evenness. While the thickness of the tuft web
is constantly scanned by the Integral Feed Tray
SENSOFEED+, the card control calculates a pos-
sible adjustment of the feed roll speed from the
incoming values.
Four levelling systems adapted to each other
guarantee a perfectly constant sliver fineness and an
excellent evenness.

Controlled Card feeding Unit CONTIFEED

(e.g. feed roll of SP-FP)

Integrated tuft
feeder levelling

Diagram of short-wave levelling

Long-wave levelling
42 Card TC 11
Better access than ever for efficient maintenance
After removal of the doors,
all areas of the card are
optimally accessible.
Carding Control / operation
The TC 11 sets benchmarks in terms of mainte-
nance-friendliness. Thus, the doors can be disas-
sembled without tools in just a few minutes.
The drives are concentrated on the right side
of the machine. The operators are protected by
a central safety locking system. Conventional
drive covers that can obstruct maintenance work
are completely eliminated.
Replacement of the WEBFEED Unit is also
very simple because it can be replaced in one
part. The same applies to the Integral Feed Tray
SENSOFEED+. It is also possible to disassemble
the complete flat cleaning device and the web
doffing within shortest time. And, since the can
changer has no mechanical connection to the
card, cleaning work is simplified in addition to
operation.
Maintenance
Targeted maintenance management
The card control is a valuable tool for the service
technician during maintenance tasks, like cloth-
ing care or regular lubrication. Example cloth-
ing change: The card control shows this early
enough on the screen. Example error detection
and recovery: The control offers special tools for
this as well.
Example operating conditions: In addition to the
distances of the card elements as determined
by the Setting Optimiser T-Con, for instance
rotational speeds, speeds or negative pressures
are also displayed.
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 43

Maintenance efficiency due to digitally controlled

servo drives

Meanwhile more than 25,000 Trützschler cards

are equipped with completely maintenance-free
Costs for energy consumption
servo motors as standard feature. They are used
(example 130 kg/h)
for doffer, web doffing unit and can changer.
Compared to cards that operate
Another advantage of the digital servo drives
without individual drives, Trützschler
is their high efficiency, which reduces electri- cards allow for significant energy
cal power losses. Furthermore, they provide a savings. In our spinning mill exam-
maximum of speed and control accuracy at low ple, this equals more than 43,000
speeds, which results in improved sliver CV US$/year.
values. The control of the digital servo drives 300,000
Energy costs US$/year
communicates directly with the card control.
302,400 291,530

247,919
252,000

201,600

151,200

100,800 130 kg/h – 8000 h/year –

0.112 US$ / kWh

50,400

0
Other cards

TC 11

Completely maintenance-free: The digitally controlled
servo drive has neither carbon, brushes nor fans, and is
completely enclosed.
other
cards: Installed power 42 kVA = 24 kW
consumed power approx. 17 kWh
TC 11: Installed power 36 kVA = 21 kW
consumed power approx. 15 kWh

Assembly of the digital

motor control takes
place at Trützschler
in Mönchengladbach,
Germany.
44 Card TC 11 Carding Control / operation Maintenance

TC 11-S:
The best man-made fibre card ever

The spinning mill example

Our fictional „spinning mill example“ for man-
made fibres clearly shows the savings potentials
that can be achieved with Trützschler technology.
It features more than 10 man-made fibre cards,
with an annual production of 160 kg/h per card
during 8,000 operating hours. This equals a
raw material use of approx. 12,800 t.
The following preinvestment analyses are in
reference to this „spinning mill example“
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 45

Usually card development focused primarily Extremely resistant:

on cotton processing. Hence, it came as no
surprise that the production capacity of cotton
increased significantly from card generation to
card generation: In the coarser yarn segment,
the 100 kg/h limit was quickly exceeded. The
productivity of man-made fibre carding, how-
ever, stagnated.
This is exactly the reason why Trützschler chose
another path: From the beginning, the current
card generation was developed simultaneously
for cotton and man-made fibres. The Card TC
11-S is the result for man-made fibre processing.
12-fold difference: Differences between
man-made fibre card and cotton card
1 Stainless steel comb instead of screen fabric
2 Stainless steel cleaning flap
The fibre-guiding elements
The reviving agent used for many man-made
fibres has an aggressive effect on paint and base
metals. As a result, paint may peel off and metal
surfaces may become sticky, thus impairing op-
timal fibre flow in the card. This leads to produc-
tion limits and frequent production interruptions
in cleaning work.
On the Trützschler Card TC 11-S, all plates in the
tuft feeder and in the transfer section to the
card are made of stainless steel. All covering
elements relating to cylinder and doffer con-
sist of high-precision aluminium elements. An
anodizing process protects these parts from
the aggressiveness of man-made fibres. In the
can changer, hosepipe and coiling plate made of
stainless steel ensure gentle sliver guidance and
sliver coiling.

3 Stainless steel reserve trunk

4 Segmented feed tray

5 Special opening rolls for higher speeds

6 Stainless steel reserve trunk

7 More carding and less cleaning elements

8 WEBFEED with a large needle roll

1
9 Man-made fibre T-Con

10 Special sliver trumpet

11 Additional deflection roll

12 New doffer clothing TCC NovoDoff 30 1) 2

1)
protected by patent

3
9

5
7
7
6
10
The differences between
man-made fibres card and
cotton card are significant.
11
8

12
46 Card TC 11 Carding Control / operation Maintenance

Modified WEBFEED:
Higher efficiency, quality and service life

The enhanced WEBFEED system for the TC11-S

is substantially different from the cotton card.
For high production application of cotton, a pre-
opener system with three rolls is essential. For
processing man-made fibres there is another
solution: A newly developed WEBFEED with
only one large single roll, featuring a 50 % larger
diameter, special needling and a novel surface
finish. These measures combined contribute to
the significant production increases.

Simultaneously, the WEBFEED system results

in improved yarn quality with an average of 30 %
less imperfections.

Another advantage of the especially for man-

made fibre processing developed needle roll is
its significantly longer service life. It is approxi-
mately ten times that of a clothing roll, thus with
greatly improved efficiency.

The fibre-guiding elements, as in

this case the feed trunk, are made of
stainless steel.

Service cost comparison of lickerin

In the course of 10 years, the cloth-
ings in our spinning mill example
must be re-clothed about 20 times
per card. During the same time
frame, a needle roll is maintenance
free.

50,000
Service costs /10 years [US$]

40,000

30,000

High wage country

20,000

10,000

0
Clothing Needle

Needled Trützschler pre-opening rolls have a special surface finish.

Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 47

T-Con for TC 11-S: The right chemistry

Obviously thermal influences affect the carding

of man-made fibres different than processing Comparison of carding costs
of cotton. Without the systematic evaluation of The high productivity of the Trützschler
T-Con data during extensive trials this would not man-made fibre card TC 11-S signifi-
have been discovered. cantly reduces production costs. In our
example, annual savings of 216,000
For instance, the rule “the tighter the flat
US$ are possible even in a low-wage
setting, the better the result”, does not apply to country.
man-made fibres. On the contrary; here it is
50
essential to maintain a certain minimum dis- 70
50 Miscellaneous

tance. It prevents electrostatic charges that have 4060 Waste

40
a negative effect on carding quality and subse- 50 Wage
30
[US$/ t]

quently also on yarn quality. Hence, the T-Con 30

40 Energy
system for man-made fibre carding uses new 2030 Capital
20
algorithms and thus provides the basis for
20
precise setting recommendations. The result 10
10
10
is a clearly increased production.
0
00
Standard card TC 11-S

TC-MMF: Application set for tuft blending

and cards with changing fibres

There are many blends of cotton with man-made

fibres, be it with polyester, viscose or polyacryl-
ic. With the Optional Set TC-MMF, they all can
be processed on the Trützschler Card TC 11. The
TC-MMF features stainless steel surfaces that
take the particular fibre-metal friction values into
account. Its clothings are specifically designed
for cotton/man-made fibre blends, thus eliminat-
ing the settling of finishing. An important dis-
tinguishing feature is also the number and type
of carding segments of the MULTI WEBCLEAN The clear quality advantages can be confirmed in the
system. Because the carding of a blend contain- laboratory.

ing polyacrylic requires, for instance, more seg-

ments than the carding of cotton/viscose.

The Optional Set TC-MMF:

• The fibre-guiding elements in the tuft feeder are made of stainless steel

• Additional carding elements from 90 to 640 points/inch2

• Special clothings for cylinder, doffer and flat

48 Card TC 11 Carding Control / operation Maintenance

The integrated draw frame:

Concept with savings potential

The Integrated
Draw Frame IDF 2
with automatic
can changer

The production-related and economic advan-
tages that can be achieved with the Integrated
Draw Frame IDF 2 are enormous:
• requires less space,
• requires less cans,
• simplifies can transport,
• lowers power consumption and
• reduces personnel and operating costs.
Due to increased sliver adhesion and adapted
fiber orientation, the slivers have a better run-
ning behaviour in downstream processing than
draw frame slivers.
The strength of the IDF 2 system is also appar-
ent in its design. Thanks to the space-saving
arrangement of the draw frame unit above the
can changer, it requires no more space than a
regular can changer.
The IDF 2 allows processing of all fibers com-
mon in rotor spinning. For coarse and medium-
fine high-quality OE yarns up to Ne 24 we rec-
ommend the combination of TC 11 and IDF 2.
This solution offers improved yarn quality and
increased economic efficiency.

Short fibers, waste,

Opening regenerated fibers Card TC 11 with
Cleaning Cotton-rotor-spun yarn Integrated Draw Frame
Blending coarser, approx. Ne 24 IDF 2
(25 tex)

Rotor spinning

Opening Rotor-spun yarns

Cleaning finer, approx. Ne 24 Card TC 11 Draw Frame TD 8
Blending (25 tex)
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 49

Comparisons of direct spinning IDF 2 with one and

two draw frame passages for OE yarn NE 20
Lower energy costs
In our example, the combination of
TC 11 and IDF 2, at a production rate
4.0 of 180 kg/h and 8400 production hours
3.6 The low value per year, results in annual energy
CVm% 10m

3.2
has a positive savings of more than 84,000 US$.
impact on the
fabric appearance,
2.8 particularly
on knitted fabrics
2.4

2.0
È Energy costs US$/year
360,000
323,936

1.6

1.2 240,000
239,187
0.8

0.4

0.0
TC 11 + IDF 2 TC 11 + TD 7 TC 11 + TD 7 + TD 8 120,000

Yarn count variations 180 kg/h – 8400 h/year –

0,112 US$ / kWh

13.8 0

13.6
CV %

other spinning mill with direct drawing

13.4
Example spinning mill with TC 11 and IDF 2
13.2

13.0

12.8

12.6 Can changer

TC 11 + IDF 2 TC 11 + TD 7 TC 11 + TD 7 + TD 8 The can changer for the IDF 2 is largely identical
Yarn evenness to the one of Draw Frame TD 8, and designed for
Neps +280%
the standard can diameters.
Thick places + 50% The can height ranges between 900 and 1525 mm.
Thin places – 50%
60 The sliver is automatically separated during can
50
change.
1/ km

40

30

20 Light barrier strip for fully

automatic synchronisation
10
of the delivery speed with
0 the card by regulating the
TC 11 + IDF 2 TC 11 + TD 7 TC 11 + TD 7 + TD 8 sliver sagging between the
Yarn imperfections machines

14.4

14.0
cN/tex

13.6

13.2

12.8

12.4

12.0
TC 11 + IDF 2 TC 11 + TD 7 TC 11 + TD 7 + TD 8

Yarn strength
50 Card TC 11 Carding
Direct combination for increased efficiency
The combination of the Trützschler Card TC 11
with the Integrated Draw Frame IDF 2 presents
an economically attractive and technologically
practical solution. Instead of a conventional can
changer, the Integrated Draw Frame IDF 2 is
connected directly to the card, thus eliminating
a draw frame passage. This configuration is also
very space saving, since the otherwise required
space for a complete draw frame with can
magazine for the card cans is eliminated.
540 m2
Levelling quality without compromises
Immediately before being fed into the drafting
system, the card sliver is scanned by the reliable
Trützschler sliver sensor; then it is levelled via
the drafting system. The close physical prox-
imity of measuring point and drafting system
Sensor to determine sliver fineness and quality sensor
Control / operation Maintenance
Advantages of direct card and draw frame
combination:
• Less material buffer in the process,
therefore less tied-up capital
• Shorter throughput times
• Reduced operating work
• Reduced building area
280 m2
48% less space requirement due to
Integrated Draw Frame IDF 2
ensures reliable levelling of the draft. A second
sensor is positioned immediately behind the
drafting system. Here the sliver is permanently
checked to ensure that every metre deposited in
the can corresponds to the required quality.
Simple and clear operation via the card display
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2
Never before was a fully-fledged leveller draw
frame more compact
The use of a simple drafting system at the card
was never a satisfying technological solution
since only a fully-fledged levelling draw frame
could guarantee a high degree of quality.
Trützschler combined the compactness of a
simple drafting system with the performance
of a leveller draw frame. The characteristics:
• Maintenance-free, digitally controlled servo
drives
• High levelling dynamics through low mass
inertia
• Draft up to 200% (2-fold)
• Delivery speeds up to 700 m/min
• Controlled material storage for trouble-free
can changing
• Trützschler quality sensors in the feed and
delivery area
• Permanent monitoring of sliver quality
The drafting system is integrated in the produc-
tion flow / sliver run and consists of reliable
components of the Trützschler draw frame.
This includes also technical highlights, like for
instance the pneumatic load of the top rolls.
Very good accessibility
The casing of the Integrated Draw Frame
IDF  2 can be opened quickly without tools. For
operation and maintenance purpose, it is simply
flipped open in front and back. This ensures
quick and uncomplicated performance of service
work.
Drafting system and motor are quickly and easily accessible
Technical data Card TC 11 51
Top rolls in the open drafting system
The service life of the top roll coating is
doubled
Savings are also achieved with the top roll coat-
ings in the new IDF 2. On the one hand, the
top rolls are now in an asymmetric position in
the drafting system, while at the same time the
loading cylinders are symmetrically arranged
in the proven way. This facilitates easy turning
of the top rolls by 180° after the coatings wear
off, thus doubling their service life. On the other
hand, the drafting system has been modified
to a 1 zone drafting system to improve sliver
quality. In addition, the optimization effort and
thus the service costs are lowered by very easy
Top rolls (red) can be turned
settings. by 180° after wear of the top
roll coatings (wear shown in
A strong motor blue)
A more powerful maintenance free levelling
­motor makes the IDF 2 more dynamical and
a­llows it to react faster.
Closed casing
52 Card TC 11 Carding Control / operation Maintenance

Card TC 11: Technical data

3360
2180
1000

600

3410
2150

Floor load: approx. 22,540 N/m2

Max. surface pressure per base plate: approx. 57 N/m2

Production: max. 260 kg/h

Suction (continuous): 4,200 m3/h (-740 Pa)

Net weight: approx. 6,700 kg incl. can changer

Sound pressure level: 75 dB(A)

Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 53

The can coiler or can changer can be freely posi-

tioned in front of the card, since it is not mechani-
cally connected to the card.

2150 mm 2150 mm 2150 mm

3576 mm
3576 mm
3576 mm

L6
L3
L3

500 mm
L1

50

L4
0m
m
L1

L5

L2 L2

The can height can be up to max. 1500 mm

Can diameter (mm) L1 1) L2 L3 2) L4 L5 L6

600 1715 1930 5455-6345 1200 1200 6000

1000 2350 2750 6090-6980 1400 1400 6200

1) without can delivery ramps
2) depending on width of service aisle between card and can changer (under floor)

Apart from production

P [kW]
output, the values for
20
current consumption
18 depend also on the various
settings and the material
Maximum continuous power consumption
(Card + tuft feeder +
automatic can changer)

16
14
12
10
8
6
4
2
0
0 20 40 60 80 100 120 140 160 180 200 220 240 260

Production [kg/h]
54 Card TC 11 Carding Control / operation Maintenance

Equipment, standard

The extensive standard equipment of the TC 11:

Large cylinder with 5.3 m² clothing surface

Function-oriented overall design for excellent accessibility

Setting Optimiser T-Con

MAGNOTOP System TC-MT

Integrated Tuft Feeder DIRECTFEED with moveable feed tray

Integral tray, SENSOFEED+

Thick place monitoring and metal detection in the feed area

WEBFEED Unit with 1 or 3 opening rolls

Precision Knife Setting System PMS

Tooth belt guided aluminium flat bars

Precision Flat Setting System PFS

Premium clothings made by Trützschler Card Clothing TCC

Computer control with large colour touch screen

Quality data entry and display

Spectrogram analysis

Quality and maintenance management

TC-CB electronic main cylinder brake

Digitally controlled, maintenance-free servo motors

Coordinated levelling systems in short and long-wave area

SERVOSPEED drive for high delivery speeds

Infinitely variable flats speed

Data exchange via CF card

Network connection for communication with LINECOMMANDER

Can coiler for cans with 600, 900 or 1000 mm diameter

Monitored continuous central suction above floor

Central safety locking system

Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 55

Options

Options and additional equipment for the individual, tailor-made Trützschler Card TC 11:

Application-oriented optimisation:

Recycling Fibre Set TC-MWC 3

Man-Made Fibre Card TC 11-S

Man-Made Fibre Set TC-MMF for processing fibre blends on TC 11

Infinitely variable speed control of cylinder and WEBFEED TC-VSD

Motorised adjustment for Precision Knife Setting System PMS

Motorised adjustment for the Precision Flat Setting System PFS

Individual project planning:

Monitored continuous central suction under floor

Separate strips suction above or under floor

Tools and accessories:

Nep Sensor NEPCONTROL TC-NCT

Flat Measuring System FLATCONTROL TC-FCT

Flat Grinding Device TC-FG

Grinding Device TC-GD for grinding cylinder and doffer clothing

Wire Mounting Equipment TC-ME

Options for delivery or slivery coiling system:

Automatic Can Changer TC-C above or under floor

Integrated Draw Frame IDF 2 for round cans

56 Card TC 11 Carding Control / operation Maintenance

Integrated Draw Frame IDF 2: Specifications

The drafting system is positioned on the can The can delivery is made onto a can delivery ramp.
changer. For this reason, the Integrated Draw Alternatively, it is also possible to transfer four full
Frame IDF 2 requires no additional space. cans each to a can carriage.

2110 mm

Integrated Draw Frame with can changer for

cans with
450 mm (18) diameter
4067 mm

 450 mm

2750 mm

Integrated Draw Frame with can changer

for cans with
1000 mm (40) diameter
2250 mm

 1000 mm
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 57

Equipment characteristics

Version: – Draw frame + can changer for fitting to a Card TC 11 – With

short-term levelling and sliver count monitoring

Production: max. 260 kg/h

Delivery speed: max. 700 m/min

Material: Fibers up to 60 mm (cotton, man-made fibers, cotton and man-

made fiber blends, recycling spinning materials)

Draft: 2-fold

Drafting system: 2 over 2 with pneumatic loading of top rolls and integrated
suction

Can sizes: – Round can diameter: 400 –1000 mm (18 – 40)

– Height of round cans: 900 – 1525 mm

Installed power: 4.0 kW

Max. continuous power 2.5 kW

consumption:

Suction (continuous): 350 m3/h (– 450 Pa)

Sound pressure level: 79 dB(A)

www.machines-for-textiles.com/blue-competence

Trützschler GmbH & Co. KG Textilmaschinenfabrik

P.O. Box 410164 · 41241 Mönchengladbach, Germany
Duvenstr. 82-92 · 41199 Mönchengladbach, Germany
Phone: +49 (0)2166 607-0 · Fax: +49 (0)2166 607-405
E-mail: info@truetzschler.de · www.truetzschler.com

Disclaimer:
This brochure has been created by us to the best of our knowledge and with great care. We are however not liable for any spelling
mistakes or technical changes. Photographs and illustrations are of informative value only and some show special optional equipment
that is not included in standard delivery.
We provide no guarantee for the current relevance, correctness, completeness or quality of the information provided. All liability
claims against us or the respective author pertaining to material or immaterial damages caused by the use or circulation of the
­provided information, even if found to be incorrect or incomplete, are excluded. Our information is non-binding.

Print No.: 4010-07/14-e · Agentur Brinkmann GmbH, Krefeld

S P I N N I N G N O N W O V E N S MAN-MADE FIBERS CARD CLOTHING

Fiber preparation Opening/Blending Staple fiber lines Metallic wires

- Bale opening Card feeding Filament lines - Spinning
- Blending Cards/Crosslapping - BCF - Nonwovens/
- Cleaning Wet laying lines - Industrial yarn Longstaple
- Opening Web needling Precursor lines - Open End
- Foreign matter Hydro entanglement Carbon fiber lines Flat tops
separation Chemical bonding Fillets
- Dedusting Thermobonding Carding segments
- Tuft blending Finishing Service machines
- Waste recycling Drying Service 24/7
Cards Heatsetting
Draw frames Winding
Combing machinery Slitting

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