Double air suctioned carding process: A method for achieving improved quality ring-spun carded yarn

This study aims to maximize yarn realization by minimizing hard waste generation. A new method has been evaluated in a conventional carding machine for this purpose by adding extra air suction units immediately above the doffer and in the brush roller above the stripping roller. Various yarn samples were spun using the double air suction carding (DASC) method and the traditional carding process, and the yarn quality parameters were compared. The results indicated that the DASC yarn had considerable technical improvements in all yarn characteristics (U%, CVm%, thick place, thin place, neps, hairiness) and mechanical properties (breaking strength and elongation). The number of classimat faults in the DASC yarn has also significantly decreased. Even though the DASC technique produced more droppings-1, it generated less pneumafil and hard waste, resulting in improved yarn realization. This research also examined cost analysis, advantages, and limitations. Overall, the findings indicate that the newly introduced DASC yarn has the potential to be a superior product in terms of both quality and cost. [Display omitted] •Developed a novel process for producing improved quality ring-spun yarn.•Reduction of wastage (40.15% less pneumafil, 29.55% less hard waste) and economic advantages (223.56 USD profit per day) for it was highlighted.•Important quality parameters (U%, CVm%, hairiness, thin place, thick place, neps, elongation, tenacity, breaking strength) of the DASC process products were compared with the conventional process products of the same raw materials.•DASC process yarn was found to be a superior alternative (7.22% less U%, 7.02% less CVm%, 47.22% less thick place, 50% less thin place, 15.38% less neps, 8.94% less hairiness, 47.51% more breaking strength, 15.93% more elongation, 63.09% less classimat faults) to conventional process yarn in terms of cost and quality.