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    Yarn Preparation For Weaving

    Uploaded by

    teegalajyothi
    The document discusses yarn preparation methods for weaving fabrics. It describes the key steps as winding the yarns onto beams or sections, then sizing the yarns to improve weavability. There are three main warping methods - beam, sectional, and ball warping - which differ in how the yarns are wound and whether they are sized before or after winding. Sizing involves coating the yarns with polymers to increase strength and abrasion resistance while maintaining flexibility. Modern sizing techniques aim to improve productivity and quality, such as cold sizing, pre-wetting, and dye sizing.

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    Yarn Preparation For Weaving

    Uploaded by

    teegalajyothi
    272 views56 pages
    The document discusses yarn preparation methods for weaving fabrics. It describes the key steps as winding the yarns onto beams or sections, then sizing the yarns to improve weavability. There are three main warping methods - beam, sectional, and ball warping - which differ in how the yarns are wound and whether they are sized before or after winding. Sizing involves coating the yarns with polymers to increase strength and abrasion resistance while maintaining flexibility. Modern sizing techniques aim to improve productivity and quality, such as cold sizing, pre-wetting, and dye sizing.

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    Original Title

    Yarn Preparation for Weaving

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    The document discusses yarn preparation methods for weaving fabrics. It describes the key steps as winding the yarns onto beams or sections, then sizing the yarns to improve weavability. There are three main warping methods - beam, sectional, and ball warping - which differ in how the yarns are wound and whether they are sized before or after winding. Sizing involves coating the yarns with polymers to increase strength and abrasion resistance while maintaining flexibility. Modern sizing techniques aim to improve productivity and quality, such as cold sizing, pre-wetting, and dye sizing.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    272 views56 pages

    Yarn Preparation For Weaving

    Uploaded by

    teegalajyothi
    The document discusses yarn preparation methods for weaving fabrics. It describes the key steps as winding the yarns onto beams or sections, then sizing the yarns to improve weavability. There are three main warping methods - beam, sectional, and ball warping - which differ in how the yarns are wound and whether they are sized before or after winding. Sizing involves coating the yarns with polymers to increase strength and abrasion resistance while maintaining flexibility. Modern sizing techniques aim to improve productivity and quality, such as cold sizing, pre-wetting, and dye sizing.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 56
    At a glance
    Powered by AI
    The key takeaways are the different techniques for fabric manufacturing such as weaving, knitting, braiding, tufting and nonwoven manufacturing. It also discusses the manufacturing steps of woven fabrics including warp and weft yarns.

    The different types of warping discussed are beam/direct warping, sectional/indirect warping and ball warping.

    The steps involved in beam warping are creel, warp yarn, head stock and beam.

    Yarn preparation

    for weaving

    Definition: Textile Fabric

    A textile fabric is defined as an assembly


    of fibres, yarns or combinations of these.

    Techniques for fabric manufacturing:


    Weaving
    Knitting
    Braiding
    Tufting
    Nonwoven manufacturing

    Manufacturing steps of
    woven fabrics

    Weaving: It is the process of interlacement of warp with weft


    Warp: Longitudinal yarn in the fabric is called warp
    Weft: Lateral/crosswise yarn in the fabric is weft

    Yarn preparation for weaving


    Warp yarn preparation

    Weft yarn preparation

    Winding

    Winding

    Warping
    Sizing/slashing
    Drawing-in or tying-in
    Weaving

    Warping

    It is the process of preparing a


    double flanged beam of warp yarns
    arranged parallel to each other.

    Warping (3 Types)
    Beam/Direct

    warping

    (Grey/Monocolour fabric)
    Sectional/Indirect

    warping

    (Warp patterns: Stripes and


    Checks)
    Ball

    warping

    (Denim fabric)

    Beam warping
    It is suitable for grey or
    monocolored fabric preparation.
    The maximum number of warp
    yarns in a beam can be 600.

    Beam warping
    Creel
    Warp
    yarn

    Head
    stock

    Beam warping
    Creel

    Head stock

    Beam warping (Quality aspects)


    Exact thread guidance
    No crossed threads
    Cylindrically wound beams : no slip between press roller and
    yarn package
    Warp length accuracy within 1 per thousand
    No cutting-in by threads on the comb
    Fewer rolled-in ends through short braking distances
    Short braking distance
    Simple insertion of threads into the comb
    Workplace designed according to ergonomic principles

    Sectional warping

    It is suitable for all warp patterned fabrics


    e.g. stripes and checks.
    Warping is carried out section by section.
    A single beam is prepared which may or
    may not be sized.
    Sometimes this process is carried out for
    2-ply synthetic warps where no sizing is
    needed.
    It is a two stage process. Warping onto
    the drum and Beaming.
    Creel capacity can be lower.

    Sectional warping machine

    Creel

    Head stock

    Sectional warping

    Yarn from
    creel

    Section drum

    Head stock

    Creel

    Sectional warping

    The creel

    Head stock

    Section laying

    The yarns are laid sectionwise, starting from the


    conical base side. The first section is supported by
    the conicity of the base and the subsequent sections
    supported by the conicity formed by the preceeding
    section.

    Sectional warping
    The newly developed machine with its reed headstock integrated into the machine
    superstructure allows production speeds never previously achieved, thanks to its
    innovative control system. The machine has the following special technical features:
    Production of warp sections with a minimum width of 4 mm or (depending on yarn
    fineness) minimum 12 24 threads. With maximum end numbers of 480 -560 threads
    and a section width of up to 150 mm, the machine can be fine-tuned for flexible
    production.
    The time for each thread separation at a lease or sizing split is 7 seconds per
    separation process
    A maximum warping speed of 750 m/min allows production to be optimised to suit
    yarn properties.
    The perfect thread tension between creel and machine for the warping process
    ensured by the use of a proven section tension control and a controlled beaming
    tension system forms the basis for warp quality that meets the highest requirements.
    The machine is available with a working width of 2,200 mm for the traditional clothing
    sector and 3,600 mm for decorative fabrics and furniture coverings.

    The leasing function

    Leasing is a process of layer separation to facilitate the


    subsequent drawing-in process and weaving. A lease band is
    inserted between the layers.

    The beaming operation


    In the second step, all yarns
    are simultaneously
    transferred from the section
    drum onto a double flanged
    warpers beam.

    Warpers beam

    Ball warping

    It is a process in which warping is done in


    rope form.
    A ball warp beam is prepared for
    subsequent process.
    It is suitable for denim fabric
    manufacturing, involving rope dyeing
    process.
    It is also a 2 stage process; Ball warp
    winding and Long chain beaming.
    Dyeing is done before beaming operation.

    Ball warping
    Warp sheet

    Initially the warps are wound in rope form on a


    cylindrical barrel.

    Creel

    Ball warping

    Dyeing is carried out in the rope form of the warp yarns.

    Ball warping
    Cans

    Cans
    Beam

    In the second stage: (Long chain beaming), The ends are


    spreaded to open width form.

    Warping machine
    manufacturers worldwide
    Benninger
    Scharer
    Sucker Muller Hacoba
    Yamada
    West point
    Karl Mayer
    Suzuki

    Sizing

    Objectives

    To improve weavability (weaving potential)


    of warp yarn by,
    Increasing strength
    Reducing hairiness
    Improving abrasion resistance
    Retaining elasticity
    Retaining extensibility to some extent
    Maintaining the flexing behavior

    Objectives achieved by

    Coating of yarn surface with a suitable


    film forming polymeric material

    By penetration of the adhesive/binding


    agent into the core of the yarn

    Sizing machine
    Drying zone 1

    Creel zone

    Sizing zone

    Drying zone 2

    Different zones of the machine

    Head stock

    Sizing machine
    Drying

    Creel
    Sizing zone

    Head stock

    Sizing (Quality & Productivity)


    Highest quality
    Uniformly optimal sizing
    Low hairiness
    Low stretch during sizing
    Automatic section tension control
    High reproducibility

    High productivity
    Simple attendance
    Automatic monitoring of all parameters
    Comprehensive recipe management

    Sizing quality achieved


    through
    Flexible squeeze rollers for uniform sizing
    Air-cushion cylinder for hysteresis free pressure
    application
    Textured or structured surface for reduced hairiness
    Programmable squeeze pressure curve
    Simple attendance at the size box
    Clearly defined wet splitting per size box

    The sow box


    Squeeze
    roller

    Immersion roller

    Size roller

    Size pump

    Pre-wetting in sizing
    Savings
    Size savings of up to 50%
    Improved weaving characteristics
    Lower effluent treatment costs

    High productivity
    Optimal weaving efficiency
    Fewer warp beam changes thanks to increased warp
    lengths

    Reproducible size
    preparation

    Stock tank
    Storage
    tank

    Mixing
    device

    Sizing machine
    manufacturers
    Benninger
    Yamada
    Sucker Muller Hacoba
    West Point

    Size materials
    Essential Ingredients
    Adhesive/Binder
    Softener
    Wetting agent

    Size materials
    Desirable Ingredients (Depending upon
    requirement)
    Oxidizing/Reducing agents
    Weighting agents
    Brightening agent
    Antifoaming agent
    Delustering agent
    Antistatic agent

    Adhesive/Binder
    Natural
    Starch from maize, rice, wheat,
    potato etc.
    Gums from plants
    Synthetic
    Polyvinyl Accohol (PVA)
    Carboxymethyl Cellulose (CMC)
    Polyacrylate (PA)
    To bind the fibre material together and consolidation of yarn

    Softener/Lubricating agent
    Oils

    and Fats from Plants

    Oil from Seeds of plants; Castor,


    sunflower etc.
    Vegetable oils
    Animal

    Fats

    Mutton tallow
    To maintain pliability of yarn by softening and lubricating

    Wetting agent

    Turkey Red Oil (TRO)

    To reduce surface tension for spreading of size material on


    yarn surface

    Oxidizing and Reducing


    agent

    Depending upon requirement of the size paste

    Weighting agent
    Gypsum salt (CaSO4, 2H2O)
    CaCO3

    To increase the weight of fabric, if sold on weight basis

    Optical Brightening agent


    Ranipal
    Tinobal blue

    To improve brightness of light coloured yarn and there by


    the fabrics to be sold in gray state

    Antifoaming agents

    Turkey Red Oil (TRO)

    To prevent formation of foam during size paste preparation

    Delustering agent

    Titanium dioxide (TiO2)

    To reduce luster in case of glaring synthetic yarns

    Antistatic agent

    Sapkostat oil

    To dissipate static charge generated in synthetic yarns due to


    friction with other yarns or metal surfaces

    Size paste concentration


    Size

    paste concentration %

    Oven dry weight of size material


    Total weight of size paste

    X 100

    Size pick up
    Size

    pick up % =

    Weight of size paste taken up


    X 100
    Oven dry weight of unsized yarn

    Size add on
    Size

    add on % =

    Oven dry weight of size material


    Oven dry weight of unsized yarn

    X 100

    Size parameters
    relationship

    Size add on % =
    Size paste concentration % X Size pick up %
    100

    Modern techniques in sizing


    Cold sizing
    Pre-wet sizing
    Wet splitting
    Dye sizing (Indigo/Vat)

    Cold sizing
    Properties

    Cold Size
    1

    Cold Size
    2

    Cold Size 3

    Cold Size
    4

    Physical State

    Viscous
    Liquid

    Solid Wax

    Viscous Liquid

    Viscous
    Liquid

    Appearance

    Clear

    Hazy

    Reddish/Brownish

    Clear to
    slightly
    hazy

    Viscosity
    (Time to flow) at
    300 c

    20 + 2
    seconds

    20+ 2 seconds

    18 + 2
    seconds

    PH

    4-5

    6.5 8.5

    5-6

    Solubility

    Soluble in
    cold water

    Soluble in
    warm water

    Soluble in
    cold water

    Easily
    soluble in
    cold water

    Solid Content

    6%

    100%

    6%

    6%

    Chemical
    Constituent

    Poly Methyl
    Acrylate

    Poly Ethylene
    Glycol

    Poly Ethylene Glycol

    Poly Ether
    Glycol

    Chemical Formula

    (C4H6O2)n

    (C2H4O)n

    (C2H4O)n

    (C2H4O)n

    Molecular Weight

    200-400

    500-700

    200-300

    150-200

    Existing Tangential Application

    Modified Version Adopted

    BREAKAGE MECHANISM OF SINGLE UNSIZED YARNS

    BREAKAGE MECHANISM OF SIZED YARNS

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