Carding Machine

The carding machine is the heart of the line. It takes opened fiber and turns it into a uniform web ready for cross-lapping or direct bonding, using a train of rotating rollers clothed in metallic wire to disentangle, align and spread the stock evenly. The KS-HC 100DD is a high-output model that works with low to high denier fiber, synthetic or natural.

Fiber can be fed by hopper feeder type or vertical hopper type. From there it runs through the main cylinder, breast, doffer and condensers. Carding happens in two stages: coarse-wire rollers running slower first open and untangle the bundles, then fine-wire rollers running faster straighten the strands and refine the layer. The doffer hands the aligned fiber to the condenser, which forms either an equilibrium or a random web depending on the product.

Wire choice follows the fiber. Coarse wire grips thick, high-denier stock; finer wire handles delicate low-denier fiber without damaging it. Feeding matches the same logic, 4-roller feed for high denier for a firmer, steadier grip, and nose bar feed for low denier for smooth flow without breakage. Every feed line carries a metal detector that stops the feed the instant it senses metal.

Drive and control are built for continuous running. EURO Drive motors give precise, quiet, stable carding speed; the inverter-based system synchronizes the whole line for smooth start-up and shutdown, and an interlock matches machine timing so the web is not torn between stages. Door locks and safety sensors stop the machine when a cover opens. Wool packing, in-side suction and a continuous suction system keep the carding area clean, recover loose fiber and hold quality through long runs.

At the top end the main cylinder reaches a surface speed of 1,300 m/min, producing webs of 15 to 50 g/m² at up to 70 m/min. A touch-screen panel handles speed, suction and operating parameters.