Design and development of semi-automatic polyester fiber carding machine

Abstract

The purpose of this research was to design and build a prototype of a small semi-automatic synthetic fiber carding machine. The main issue in the production process for the textile industry in the production of pillows and blankets by the community enterprise group, Pumpkin Pillow Group, A.S.M., herbal pillow for health, has been reduced. The group is situated at No. 21, Village No. 1, Bahn Lade, Tambon Sree Souk, Ampoeu Kanntharavichay, Maha Sarakham Province. During the process of carding synthetic fibers, a semi-automatic carding machine, sized 142 x 229 x 130 centimeters, was used. The machine was easily movable. Various factors of the machine were tested, including the spin speed of the spinning set, which was set at 4 levels: 250, 300, 350, and 400 rpm. The test results were included the following: 1) Workability: the working capacity was found to be 42.4±0.8 - 51.4±0.5 kg/h. 2) Work efficiency: the machine exhibited an efficiency of 92.5±0.69 - 97.1±1.34 percent, depending on the set winding roller speed. 3) Fiber density: the density of carding fibers was measured in grams per cubic centimeter. From the test, it is observed that increasing the roller speed results in higher work performance and increased fiber density. However, it also leads to higher energy consumption, ranging from 71.4±0.5 to 94.8±0.4 watts per kilogram. Moreover, compared to human labour, the prototype semi-automatic synthetic carding machine demonstrates the ability to work 5 times more efficiently, effectively reducing the need for 3 workers. This reduction in labor costs amounts to 180,000 Thailand Baht, while the increase in sales revenue reached 270,000 baht per month, compared to the original 120,000 Thailand Baht. This presents a revenue increase of 2.25 times. The machine's break-even point is estimated to be 2 years.