Continuous-Flow Fiber Processing.

Problem.

Linen production from flax involves labor-intensive manual processing between retting (fiber separation) and spinning (yarn production). Breaking, scutching, and hackling all require skilled manual labor. Existing batch systems require human intervention between stages, preventing continuous flow and capping industrial scale.

Approach.

A continuous-flow system that automates fiber processing from post-retting input through spinning-ready output. Eliminates batch handoff between stages through novel mechanical mechanisms. Target throughput: 10–50 kg/hour per processing line, with fiber length preserved.

Core innovations.

• Roller Cascade (Breaking). Progressive gap reduction across 8–12 roller pairs with tooth-offset geometry creating alternating S-bends. Controlled fracture at woody nodes while preserving fiber length. Shive liberation through differential velocity.
• Retractable Comb (Stage Handoff). Cam-actuated teeth extend for grip (~300° arc) and retract for release (~60° arc). Solves continuous fiber transfer between processing stages without dropping bundles or requiring manual intervention.
• Internal Press (Between Combing Stages). Transverse compression while fibers are longitudinally constrained by comb teeth. Geometric relationship — compression perpendicular to constraint — is the claimed innovation. Debris displaces without fiber damage.
• Spinning Pipe (Pre-Spinning Alignment). Rotating tube with helical groove texture encloses fiber bundle. Twisted by rotation, with a pressurized sleeve responding to upstream moisture sensors. Output is a pre-twisted bundle ready for final spinning.
• Festoon Drying Tunnel. Folded path with fixed/floating rollers; wet → mid → dry zones with controlled airflow.

Specifications.

Status.

First-principles design complete. Patent application filed. Next step: subsystem prototype of the retractable comb mechanism — the highest-novelty component.

Documentation.