Calender Machine Cotton Rolls -Calendering process has a vital importance in Textile industry so all Calender Machine manufacturers know the importance of quality of the cotton rolls which they are using in their calender Machine. Many companies now these days are manufacturing Calender Machine Cotton Rolls in India.
But the major difference comes in the quality of the cotton rolls with the yarn which is used as raw material for making these rolls. Yarn is used as a main raw material in the manufacturing of these rolls, but the quality of Yarn is very specific not every type of yarn can be used So the selection of the Yarn is very important from a manufacturer point of view. Another important factor in the manufacturing is the technical excellence and experience of the Manufacturer.
Manufacturing Process-- As this product is very important and complex in nature, so not a single process is involved. It consists of a number of different activities which are performed to make a quality product such as selection of Solid Shaft & Machining, Selection of Yarn, Carding of the raw material, Conversion of Lap in form of cakes, Mounting of the Cotton Cakes on solid Shafts, Compression of the cakes, Machining of the Roll & Packing.
Selection of Solid Shaft & Machining--The life of the roll is totally depended on the quality of the shaft on which one is going to make a whole roll always requires too much attention so very deep knowledge of the shaft quality is required in this step because very specific quality is required and it can not be done without experience and knowledge. After the procurement of the required quality shaft machining of the shaft is done according to the final size & diameter of the roll which is required by the end user is done. Dimension of shaft varies according to the final diameter and length parameters of the roll.
The next step after the procurement of the shaft is the selection of the very specific cotton yarn now here again a very deep knowledge of the Cotton Count is required when selection of the material is done. Fine counts are preferred because course count is no doubt is less expensive but it can never contribute in making quality Calender Machine Cotton Rolls.
Carding of the material-- The next step is carding of the yarn. Carding is done to form a lap of the yarn, which further will be used to form a cake of yarn which will be mounted on the solid shaft.
Conversion of laps into cake -- In this step laps of yarn get converted in the form of cakes with the use of hydraulic machine and vessels This is also one of the most important processes as a very deep knowledge of hydraulic is required as without deep knowledge one can not make proper cakes of the yarn and this is the process which will decide the quality of the product. if any kind of ignorance comes here one can not expect to get a quality final product.
Mounting of cakes on Solid Shafts-After making the cakes of the yarn the mounting of these cakes on solid shaft is done. This process also requires very much attention because if once the mounting of the cakes on the shaft is not properly done it can further result in a faulty product.
Compression or Pressing of the roll on hydraulic machine -After mounting the cakes on the solid shaft now here comes the next step which is pressing of the cakes. Hydraulic Machine is required to do this but high performance Hydraulic Machine is required. Hydraulic Pressure varies from Roll to Roll as Pressure will be decided according to the diameter and size of the roll.
Machining of the Cotton Roll- This is already discussed in the starting that this product is used for the processing or finishing of the fabric so then also the finishing of this roll should be very excellent. For this the machining of the roll should be done by an expert. Basically in machining process cutting and grinding of the roll is done. It is always preferred to perform this task on a CNC Machine not on a normal lathe machine.
Packing-This is the final stage of the roll so again here the completion of this activity should be excellent because the final product should be packed in a manner so that there should be no problem in moving it from the manufacturer premises to the end user place.
