The purpose of this study is to determine the impact of pre-carding processes on the quality of the final web. This involves the assessment of fiber properties at various stages of processing as well as the quality of output from each operation. The latter places emphasis on the uniformity of the nonwoven fabrics produced. The study includes various fiber types as well as machine combinations and processing parameters.
Several fiber types were considered and ultimately two different fiber types were used in the experiment, PET and Visil. The machine combinations included the use of a bale opener, mixer, fine opener, scanfeed, card, crosslapper, preneedler and needleloom, all located in NCRC?s Nonwovens Staple Laboratory. Fiber and web samples were collected after each machine in each processing trial and assessed by several testing methods. Fiber property testing was performed with the Favimat and Peyer FL101/AL101 instruments. Web uniformity was assessed using a computer image analysis program in addition to the conventional basis weight uniformity method. An emphasis was placed on the image analysis program and further developing its capabilities.
Data collected from the tests was statistically analyzed to reveal the influence of the machine combinations and processing parameters. Where possible the influence of fiber type was also assessed. ANOVA tests were used to compare the data sets, in order to statistically verify any similarities or differences observed. When significant differences were found Fisher?s Least Significant Difference (LSD) was used to pinpoint particular influences. Conclusions are made and future work suggested.
