Principle and Function of the Carding Machine — A Core System in Nonwoven Production
- dkfiber2004
- Nov 7
- 3 min read
In the nonwoven industry, the carding machine is often referred to as the heart of the production line.
It plays a critical role in aligning fibers and forming them into a uniform web, directly influencing the thickness, density, uniformity, and strength of the final product.
In this post, we will take a closer look at the principles of the carding machine and introduce leading carding machine manufacturers in the industry.
What Is a Carding Machine?
A carding machine is a device that separates tangled fiber masses into individual fibers, arranges them in a uniform direction, and forms them into a consistent web.
In other words, it is the machine that builds the fundamental framework of nonwoven fabrics — the first stage where fibers transition from entanglement to alignment.
The web formed at this stage is then processed through subsequent steps such as cross-lapping, needle punching, or thermal bonding, eventually becoming materials like acoustic insulation panels, filters, padding, and automotive interior components.
Operating Principle of the Carding Machine
The internal structure of a carding machine consists of several rotating rollers such as the drum, doffer, and cylinder.
Each roller is covered with fine metal wires known as card cloth (or card wire), which serve to grip, comb, and open the fibers, transforming disordered fiber masses into a smooth, uniform web.
Main Components | Function |
Feed Roller | Feeds raw fibers in a consistent and controlled manner |
Main Cylinder | Separates and aligns fibers through high-speed rotation |
Worker & Stripper Rollers | Improve the uniformity of the fiber layer |
Doffer | Delivers the aligned fibers as a web sheet |
Condensing Roller | Adjusts the web thickness and transfers it to the next process |
Through this process, the fibers are oriented in a consistent direction, resulting in a uniform web with minimized fiber entanglement.
Why the Performance of the Carding Machine Matters
The quality of the carding machine directly determines the quality of the nonwoven fabric.
Below are key properties that are directly influenced by the performance of the carding machine:
Property | Influence of the Carding Machine |
Web Uniformity | Determined by the degree of fiber alignment and speed consistency |
Tensile Strength | Improves as fibers are oriented consistently in the machine direction (MD) |
Thickness Control | Maintains stable thickness through precise control of doffer speed and feed rate |
Minimized Fiber Damage | Prevents fiber breakage through accurate roller spacing and gentle handling |
A uniform web is essential to ensure that, during subsequent processes such as needle punching, thermal bonding, and lamination, the product remains dimensionally stable and maintains consistent tensile strength without distortion.
Major Industries Using Carding Machines
Industry Sector | Example Applications |
Acoustic Materials | PET sound-absorbing panels, automotive acoustic insulation |
Filter Industry | Air filters, water filters, mask filters |
Bedding & Apparel Padding | Thermal clothing, mattress pads, quilt fillings |
Geotextiles & Construction Materials | Geotextiles, insulation layers, waterproof sheets |
Industrial Nonwovens | Automotive seat backs, insulation sheets, protective fabrics |
In particular, nonwovens made from PET staple fibers are rapidly expanding in the automotive, construction, and interior sectors due to their lightweight nature, moisture resistance, and excellent recyclability.
Leading Carding Machine Manufacturers
The following are some of the leading carding machine manufacturers active in the global nonwoven industry:
Manufacturer | Country | Key Features | Official Website |
ANDRITZ Nonwoven & Textile | Austria | High-speed large carding lines; strong in automation and quality control | |
AUTEFA Solutions | Germany | “Web Master” series, precision control technology, energy-efficient lines | |
Bonino Carding Machines | Italy | Specialized in customized carding machines; designed by fiber type | |
Qingdao Huarui Jiahe Machinery Co., Ltd. | China | Cost-effective; supplies medium and small-scale nonwoven lines | |
SNK Nonwoven Machinery | China | Provides full lines from carding to needle punching; numerous installation cases |
A carding machine is not merely a “fiber aligner” — it is a core process that determines the overall quality of nonwoven products.
Through a uniform carding process, the durability, strength, and acoustic performance of nonwovens are significantly enhanced. DK FIBER supplies polyester staple fibers optimized for such high-precision processes.
Moreover, DK FIBER provides GRS-certified recycled polyester staple fibers (rPET fibers) that are standardized for stable operation on nonwoven carding lines, ensuring consistent performance and quality.
