Difficulties and Control Measures in Lyocell Fiber

CardingAbstract: This paper summarizes the carding difficulties and control measures for Lyocell fiber. Addressing issues like fibrillation, poor fiber transfer, excessive hard slabs, and static electricity during Lyocell carding, a series of technical measures were implemented. The process principle follows “heavy sliver weight, multiple carding and stripping actions, high transfer rate, high tension, no web floating or dropping, sufficient carding, and reduced fiber damage.” The card clothing selection principle aims to improve transfer, reduce fibrillation, and control static. A “three highs and two lows” speed strategy is adopted for the cylinder, doffer, and hopper beater (high speed) versus the licker-in and flats (low speed) to enhance carding while minimizing fiber damage. Reasonable carding gauge design helps eliminate hard slabs while balancing waste removal and fiber damage. Temperature and humidity management, combining humidification and moisture retention, reduces static electricity. In practice, these measures effectively solved Lyocell fiber carding difficulties, improving carding quality and production efficiency. Keywords:​ Lyocell fiber; Carding; Fibrillation; Gauge; Card clothing; Process; Fiber damage; Temperature and humidity Core Challenges & Solutions (Condensed from Sections 1, 2, 3):

• Challenges:​ Lyocell’s circular cross-section and skin-core structure lead to poor cohesion, easy fibrillation, hard/soft slabs, and static electricity due to rapid moisture absorption/desorption. This causes web breakage, poor web clarity, difficult web formation, high waste, and thick flat strips, ultimately affecting yarn quality and fabric appearance.
• Solutions:
  • Process Principle:​ Heavy sliver weight (>25g/5m), multiple carding/stripping, high transfer, high tension, prevent wrapping/blocking, reasonable speeds, no floating/dropping, sufficient carding, reduced damage.
  • Card Clothing:​ Optimized selection for high transfer, reduced fibrillation/static. Key specs: larger working angles, thinner tooth tips, higher densities, shallower tooth depths, thinner bases for cylinder, doffer, licker-in, fixed flats, and revolving flats.
  • Speeds (“Three Highs, Two Lows”):​ High cylinder, doffer, hopper beater speeds; low licker-in and flat speeds.
  • Gauges:​ Tight gauges in main carding zones (e.g., cylinder-flats: 0.15-0.20mm) for intense carding; larger gauges in pre-opening zones to reduce fiber rubbing.
  • Tension & Pressure:​ Higher web tension between doffer and calender rolls (~1.06 to 1.30 draft), increased feed roller pressure (20%-50% higher than cotton).
  • Temperature & Humidity Control:​ Workshop temp 26-30°C, relative humidity 60-70%, sliver moisture regain 10-11%.

Optimization Results (From Section 4.3): For Lyocell 14.6tex Siro compact spinning, after optimization:

• Slab removal rate increased from 86% to 95%.
• Carding waste rate decreased from 2.1% to 0.9%.
• Short fiber content (16.5mm) in sliver reduced from 3.6% to 2.1%.
• Production output exceeded 50 kg/h.
• Key quality indicators and yarn fault cuts were superior to USTER 2023 Statistics 5% levels.

2. Draft for Website Graphic Promotional Material(Note: This text is designed to be part of a web page with supporting images/illustrations.)Meta Title:​ Master Lyocell Fiber Carding: Solutions for High Quality & High Yield | [Your Company Name] Meta Description:​ Struggling with Lyocell fibrillation, static, or low carding efficiency? Discover proven carding strategies, needle configurations, and process settings to boost quality and output. Expert insights from Jiangsu Yueda Textile & Guangshan Baisha. Page Title (H1): Unlock Superior Lyocell Fiber Carding PerformanceIntroductory Paragraph: Lyocell fiber, prized for its eco-friendly properties, presents unique carding challenges like fibrillation, poor transfer, and static electricity, often leading to reduced quality and productivity. Based on extensive research and practical application by experts from Jiangsu Yueda Textile Group​ and Guangshan Baisha Card Clothing, this guide reveals effective strategies to overcome these hurdles. Learn how optimized card clothing, precise process parameters, and environmental control can transform your Lyocell carding operations, enabling higher speeds, superior yarn quality, and significantly increased output. Subheading (H2): Key Challenges in Lyocell Fiber Carding(Accompanied by an icon or simple graphic for each point)

• Fibrillation:​ Fiber surface splitting causing fuzz and pilling.
• Poor Fiber Transfer:​ Leading to web instability and defects.
• Hard/Soft Slabs:​ Difficult to remove impurities affecting yarn evenness.
• Static Electricity:​ Causing fiber control issues and fly.

Subheading (H2): Proven Solutions for Efficient Lyocell CardingSolution 1: Strategic Card Clothing Selection(Use a diagram showing different carding zones with recommended needle types) The right needle profile is crucial. Our findings recommend:

• Cylinder Wires:​ Larger working angle (35°-40°), high density (~1000 teeth/(25.4mm)²), shallow depth (0.30mm) for gentle handling and improved transfer. Example: AC2035x01645TR-3
• Doffer Wires:​ Larger angle (30°-35°), high density (505-551 teeth/(25.4mm)²), increased depth (1.9-2.3mm) for strong control and high transfer. Example: AD4030x02065
• Licker-in Wires:​ Large angle (10°-20°), thin tooth tip (<0.17mm) for gentle opening, reducing damage and fibrillation.
• Flats & Fixed Flats:​ High density, specific angles, and shallow depths to prevent loading, intercept slabs, and enhance fiber alignment.

Solution 2: The “Three Highs & Two Lows” Speed Principle(Use an infographic comparing traditional vs. optimized Lyocell speeds – see table below as inspiration) Optimizing component speeds is key to balancing carding intensity and fiber protection.

Solution 3: Precision Gauge Settings Tight gauges in main carding areas (e.g., Cylinder-Flats: 0.15-0.20 mm) ensure thorough fiber individualization. Carefully adjusted larger gauges in pre-carding zones help manage airflow and reduce fiber rubbing. Solution 4: Controlled Environment Maintain workshop conditions at 26-30°C and 60-70% Relative Humidity​ to effectively control static and manage fibrillation. Subheading (H2): Real-World Results: From Challenge to Success After implementing these optimized parameters for a 14.6tex Lyocell yarn: (Use a bold, visual highlight box or a simple bar chart graphic)

• ▶ Production Output Increased by over 100%​ (from 26 kg/h to 53 kg/h)
• ▶ Slab Removal Rate Jumped to 95%​ (from 86%)
• ▶ Card Waste Reduced to 0.9%​ (from 2.1%)
• ▶ Yarn Quality Surpassed USTER 2023 5% Levels