Modern mills now a day’s uses automatic bale openers or feeders in place of conventional hopper bale openers for more accurate mixing/ blending and also helps to eliminate mane power.
Modern bale pluckers can be mainly classified into two categories viz.
1. Moving bale type
The first generation bale opening machines were mostly stationary. Only the bales were moved either backward or forward or in a circle. The examples of these types of machines are Trutzschler multi-bale plucker, karousel-beater type opener by Rieter, etc.
2. Moving beater type
The second generation machines are of the travelling type i.e. they move past the bales of the layout and extract material from top to bottom. Travelling machines have the advantages that more bales can be processed as an overall unit, and thus better long-term blend is achieved. It should be noted however that these machines extract material only in batches, i.e. they can process only one, two or maximum three bales simultaneously. If long term blend is needed to be achieved, then mixing machines must be included downstream from the bale opener. These machines are completely electrically controlled and extract material evenly from all bales evenly, independently of varying bale density.
In concept, these machines are most commonly utilized now a day. Machines similar to uni-floc by Rieter are developed by various other manufactures viz. Optimix by Hargeth Hollingsworth, B12 by marzoli and blendomat by Trutzschler. The latest uni-floc provided in modern Rieter blow room line in place of the hopper bale opener is UNI-FLOC A-11.
· OPERATIONAL PRINCIPLE
The A 11 UNI-floc processes cotton from all sources and manmade fibres in staple lengths of up to 65 mm. The bales being opened are placed lengthwise or crosswise on both sides of the bale opener, and the take-off unit can process up to four different assortments.
Reduction of the raw material into micro-tufts is assured by the patented double teeth on the take-off roller and the grid with closely set clamping rails. The unique geometry of the double teeth ensures the uniform treatment of the entire bale surface. Retaining rollers travelling with the take-off unit prevent bale layers from sloughing and ensure precise, controlled operation over the entire height of the bale. The A 11 UNI-floc still produces small tufts, even at maximum output of 1400 kg/h.
The take-off unit is lowered by a preselected or computed distance at each pass. Running-in and running-out programs compensate for the differing hardness of the bales over their cross section and ensure a uniform level of production. The fan incorporated in the swivelling tower extracts the opened tufts and feeds them into the tuft channel running between the guide rails. Transport to the following machine is pneumatic.
Figure 1 OPERATIONAL PRINCIPLE OF UNI-FLOC A-11
· DISTINGUISHING FEATURES OF UNI-FLOC A-11
The UNI-floc is basically one type of opening which is most commonly utilized in place of “hopper bale openers”. The distinguishing features of UNI-floc are:
1. Bale opening into micro-tufts for effective cleaning and dust extraction.
|Figure narrow grid gauge for micro-tufts|
Micro tufts are the basic requirement for the production of yarn quality. Trash and dust can only be removed from natural fibres gently and efficiently on the surface of the tufts.
The take-off unit of the UNI-floc is considered to be the “heart” of the system as it is responsible for micro tuft formation. The patented take-off roller and the grid design with small gaps between the clamping rails enables small fibre tufts ( micro tufts ) to be extracted. The twin-tooth profile ensures uniform, gentle and efficient extraction of the tufts, also irrespective of the take-off roller’s direction of rotation.
Figure comparison of output and tuft size in modern machine(UNI-floc A-11) to conventional bale opener
2. Uniform take-off of bale lay-down by means of “BALE PROFILEING”
Bale Profiling guarantees totally uniform bale take-off. The height profile of the bale lay-down is precisely detected by light barriers and memorized. Scanning is performed at a constant speed of 9 m/min. Tufts are already taken off in the profiling phase. Continuous feeding of the subsequent machines is thus ensured from the outset.
Figure uniform take-off of bale lay-down by means of bale profiling
During the subsequent passes the bales are opened at the preselected speed of travel and take-off depth. In the process the system automatically compensates for differences in height in the bale profile. Labour-intensive manual levelling is eliminated. After the required height range, take-off depth and speed of travel have been entered for each group of bales, take-off proceeds fully automatically.
3. Simultaneous processing of up to 4 assortment
We can lay down as many as 130 bales in four groups on each side of the machine. This means that four assortments can be processed automatically at the preselected take-off speed and with the required production volume.
4. Patented, individually interchangeable double teeth on the opening roller
Figure Patented, individually interchangeable double teeth
The double teeth enable maintenance intervals to be halved. The teeth are mounted individually. They can easily and quickly be replaced if required, without removing the take-off roller. This explains the exceptionally high operational readiness of the A 11Uni-floc
5. Processing of cotton from all sources and man-made fibres in staple lengths of up to 65 mm
6. Output of up to 1 400 kg/h (carded sliver)
7. Bale lay-down over a length of 7.2 to 47.2 meters
A bale lay-down of overall lengths of 7.2 to 47.2 meters and two take-off of unit lengths of 1 700 mm and 2 300 mm. The maximum version is capable of accommodating raw material up to 40 000 kg. This ensures flexible, economical and largely autonomous processing on UNI-floc A-11.
8. Take-off width selectable between 1 700 mm and 2 300 mm
9. Graphic interface for easy, intuitive operation at the control panel
The control panel is placed facing the extraction duct, providing a clear view and safety for operating the machine. Setting and control of the A 11 UNI-floc can easily be performed at the screen.
10. Interface to higher-level control and information systems available
In the interests of optimum monitoring of the installation as a whole, this modern machine control unit can be connected to the UNI-control or UNI-command control system. UNI-control and NI command also provide the interface to Reiter’s higher-level SPIDER web mill monitoring system.
11. Maximum yield due to optimized processes