Process of Blowing-Carding Unit Modification

Benefit Analysis of Carding System Transformation

I. Reduction in Labor Costs for Cleaning and Carding Processes:

Taking a 10,000-spindle system (8-16 carding machines) as an example. Before transformation: 6 workers per shift for cleaning and carding, totaling 18 workers for three shifts; after transformation, only 2 workers per shift are needed, totaling 6 workers for three shifts. Assuming an annual salary, benefits, and insurance cost of 20,000 yuan per person, each set of cleaning and carding equipment saves 240,000 yuan in labor costs annually.

II. Reduction in Electricity Expenses:

Taking a 10,000-spindle system (8 carding machines) as an example: After transformation, the power consumption of machines such as the lap former (10.35kw×2), vibrating cotton box (3.4kw×2), and condenser (4kw×2) is eliminated, totaling 35.5kw. The added power consumption of machines like the cotton conveying fan (3.75kw) and feeding box (1.32kw×8) is 4.31kw. It is evident that the power consumption for the cleaning and carding processes per 10,000 spindles is reduced by 21.04kw. At an electricity price of 0.7 yuan/kwh, working 20 hours per day and 340 days per year, the annual electricity cost savings amount to approximately 100,000 yuan. (The more machines transformed, the greater the savings!)

III. Reduction in Equipment, Material, and Other Loss Costs:

After the transformation of the cleaning and carding system, the lap former—the machine most prone to malfunctions,最难调整, and with the highest number of faulty parts—is removed from the cleaning system. This correspondingly reduces maintenance costs and downtime.

IV. Reduction in Workshop Dust Levels:

Since the cleaning and carding system is connected by sealed pipelines from cleaning to carding, dust and fine impurities cannot escape outside the machines. According to tests by relevant experts, the dust content in workshops using the cleaning and carding system is reduced by 62.5% compared to traditional lap processes, significantly improving the working environment, making it more environmentally friendly and healthier.

V. Improvement in Sliver Weight Uniformity Quality:

Due to the use of advanced continuous feeding devices and automatic cotton supply boxes like FA178A in the process, the weight unevenness of the sliver is effectively ensured. Under normal workshop temperatures, even without an auto-leveling device, the external unevenness of the carded sliver can be controlled within 3.0%. If carding machines with auto-leveling are added, the external unevenness of the carded sliver can be controlled within 2.5%, fully matching the standards of mainstream cleaning and carding systems today.

VI. Improvement in Operational Efficiency and Yield Rate:

Due to the significant reduction in故障率 in the cleaning section after transformation, operational efficiency is ensured. The cleaning and carding system avoids the adhesion of cotton layers during unwinding and the waste cotton layers caused by lap splicing during卷 changes, thereby improving the yield rate by 1%.