Carding — Fibre Individualisation
topic
The card individualises fibres from tufts to single fibres using the interaction between cylinder (revolving at 350–500 RPM), flats (or stationary working elements), and doffer, at production rates of 60–150 kg/hr (modern high-production cards). Card eliminates: neps (NK% from 250/g input to 80–120/g output), short fibres (UHML loss 0.5–1.0 mm), and residual trash (50–70% removal of blow room residual). Sliver CVm% output: 2.5–4.5%.
Role
Carding quality defines the nep baseline for all downstream yarn quality. Neps generated in carding cannot be removed in drawing, combing, or ring spinning — they appear in the final fabric as white specks, which is one of the most common and visible fabric defects. Understanding card setting and clothing condition, and how they affect nep generation, is the most impactful quality knowledge in the preparation room.