CARDING

Carding is a mechanical process that disentangles, cleans and intermixes fibers to produce a continuous web or sliver suitable for subsequent processing.
This is achieved by passing the fibers between differentially moving surfaces covered with card clothing. It breaks up locks and unorganised clumps of fibre and then aligns the individual fibres to be parallel with each other.
The carding is the most important factor for spinning and for this reason the carder is the heart of the spinning mill.

Ramella has an experience of almost 70 years in building carders and carding sets. Our machines are sold worldwide and are known for their solidity and quality.

CARDING MACHINE

Thanks to our experience in the industrial field we have developed a compact carding machine ideal for mini-mills and laboratories.
This carder is characterized by a long feeding table that introduces the fibers in a unit composed of 3 cylinders and a licker-in roller.
The central part is formed by a drum with a large surface and 5 carding units.
The output consists of a doffer roller machined with extreme precision and a high-speed fly comb.

All these components are mounted on a solid steel structure and externally the carder is completely protected by a safety cage.

BOTH BATT AND SLIVER OUTPUT

For maximum flexibility this carder is equipped with both a sliver and a web output.
In the first case, it is possible to obtain a continuous ribbon (sliver) that can be processed on the spinning frame to make yarn.
In the second case, the web can be rolled up on a cylinder to create a batt of the desired thickness.

These two outputs may be provided in a standard economic version with mechanical connection or mounted on a carriage.
This latter configuration enables a rapid replacement or the possibility of obtaining a very large batt.

Carder trolley - Big batt roller

Carder trolley - Sliver

Carder trolley - Small batt roller

AVAILABLE SIZES: 80cm - 100cm - 120cm (32" - 40" - 48")

To better follow the needs of our customers we can offer carding machines with 3 different working width:

• 80 cm (32") suitable for small productions and laboratories
• 100 cm (40") the standard ideal for minimills with medium production
• 120 cm (48") to achieve maximum production without using automatic feeding systems

Productivity of the carder depends strongly on the type of fibre worked but generally using sheep wool the carder version 100cm (40") can process about 10 kg (20lb) of fibers per hour.

HIGH RANGE OF WORKABLE FIBERS

The configuration of the carder, the use of specific wire and the complete control of speeds allow you to work with many different fibers.
Minimills use our carding machine to process fibers like sheep wool, alpaca (huacaya and suri), angora, silk, cotton, yak, bamboo.
Industrial laboratories test synthetic fibers such as polyester, polyethylene, nylon, aramid, bicomponents.

The maximum length of the fibers that can be processed on the carding machine depends of the material used: approximately the maximum length of the filament is 150 mm. With standard card clothing you can work up to 2-3 den fiber, with the use of specific wire you can card fibers with thickness of less than 1 den.

Fiber sample - Sheep wool

Fiber sample - Alpaca

Fiber sample - Merino

Fiber sample - Viscose rayon

Fiber sample - Polyester

Fiber sample - Aramid

INDEPENDENT MOTORS DRIVEN BY INVERTERS

The carding machine is driven by 4 independent motors that are electronically controlled by inverters.
With this configuration, it is possible to change the speed of the rollers in a simple and immediate way.

Electronic devices are contained in an electric panel with ventilation filtered to protect sensitive electronic parts.
Outside of the panel are positioned the control knobs and speeds are displayed on large displays.
Two button panels located on both sides of the dehairer allow a simple starting and stopping of the machine.

ALUMINUM PROTECTIVE CAGE

For maximum safety, our carder is fully protected by an external cage made of aluminum.
This structure consists of 5 panels that can be removed with the appropriate key.
The choice of anodized aluminum was made to allow greater lightness of the removable panels, and to ensure a shiny appearance over time.

These protections are available in two versions: protective mesh made of galvanized steel or transparent polycarbonate panels.
Both versions allow a wide view and the complete control of the dehairer during the process.

HIGH-SPEED FLY COMB

The carding machine is equipped with a high-speed fly comb that removes the fibers from the doffer roller.
The structure of the fly comb is balanced so as to reduce the vibrations and minimize the consumption of bearings.

The lever control allows an easy adjustment and a quick maintenance of the blade.
The fly comb is mounted on oscillating bearings with seals that can be easily lubricated, 4 screws allow to position it accurately compared to the doffer.
The blade of the fly comb is connected to the structure by many screws covered with tin, this allows a perfectly smooth surface that prevents the fibers to stop.

WHAT MAKES THE DIFFERENCE

The drum carder is the heart of the spinning mill and the quality of the final product depends heavily on how the fibers are processed with this machine.
Every detail is important in building this machine so we would like to emphasize the benefits that our carder can offer:

• An extremely solid and stable structure, made to resist in time .
• The components machined for maximum precision and quality in the final product.
• The cylinders are driven independently by 4 motors with electronic speed control .
• The rigid card clothing that allows a quick cleaning and to last long.
• All cylinders mounted on ball bearings, no bushings.
• A modern design created to meet the needs of minimills and laboratories.

SOLID STRUCTURE - ALL MACHINED PARTS

In carding machines two factors are critical: the solidity of the structure and the precision of the mechanical parts.
The solidity is involved in reducing vibrations and forces that are generated during the process.
The accuracy of the rotating parts and the supports allows you to maintain a constant distance between the rollers by determining the quality of the final product.

The Ramella carder is characterized by a steel frame 4 cm (1.6") thick fully machined, this structure is connected by solid steel crossbeams.
This structure is approximately 10 times stronger than one formed from welded tubes.
All the rotating parts are equipped with micro adjustment of the position and locking screw.
All surfaces are painted or chemically treated to last long.

CAD DESIGN - INDUSTRIAL MANUFACTURING

Every single detail of the Ramella carding machine has been designed using modern 3D CAD.
All components have been designed to obtain a high-performance machine with an excellent quality/price ratio.
Even the electric panel has been designed to make the use of the carder simple and intuitive.

For the production of components are used CNC lathes, milling machines and modern laser cuts.
The steel used is of premium quality and all the commercial components come from suppliers with well-known brands.

SLIVER STRENGTHENER Fiber strengthener

A rotating device placed at the exit of the carder allows you to adjust the strength of the sliver.
This system consists of a rotating funnel with electronically controlled speed and a pair of rollers that pulls the sliver.
Thanks to controlled rotation of the funnel you can give to a real regular twist to the fibers: with higher speed the sliver will be more resistant and compact, with lower speed it will be softer.

This real twist system was invented and developed by Ramella and is especially useful in the case of low cohesion fibers such as alpaca.

ADDITIONAL CHARACTERISTICS

In addition to the features mentioned above many other details give value to our carding machine:

• The use of sealed bearings only and not bushings that wear out much more quickly changing distance between the rotating parts.
• The supports of the worker and stripper rollers have an upper cover that can be easily removed for a quicker maintenance.
• The use of rigid carc clothing that allows a quick cleaning of the machine.
• An input unit with 3 rollers + licker-in roller very solid that opens effectively the fibers.
• Spare parts easily available on the market.

PRODUCT SPECIFICATIONS

Electric specifications:

Power consumption: 5.0 kW
Single phase 230V 50/60Hz

Size:

Download layout - Carder version 800 mm - 32''(pdf version)

Download layout - Carder version 1000 mm - 40''(pdf version)

SOME SAMPLES OF THE FINAL PRODUCTS

Final product sample

DEMONSTRATION VIDEO

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