Warping

WARPING:
Warping:
The parallel winding of warp ends from many winding packages (cone or cheese) on to
a common package (warp beam) is called warping.
Types of warping:
1.

Beam warping direct warping.

2.

Patterns band or drum warping Sectioned warping,(Indirect warping)

3.

Ball warping

TYPES OF WARPING
Direct Warping Denotes the transference of yarns from single-end yarn packages,
wound packages, directly to a beam in a one step process. This means that there are
an equal number of packages in the creel area as there are ends on the beam, except
in the case of a magazine creel. A magazine creel connects the tail of one wound
package to the beginning of a new wound package for an easy package transfer. from
the wound packages in the creel.
Beam Warping
A weavers beam may have upto 10,000 ends and if this were to be produced directly
it would be necessary to have upto 10,000 creel packages.such an arrangement
would be very difficult to accommodate and manage ;consequently it is normal
practice to produce warpers beams which may contain upto about 1000 ends and
these are combined at the slashing stage.because of the difficulties involved in
combining the ends ,patterned warper beams are seldom produced on the direct
system and any pattern that is produced is achieved by combining beams of various
colors at the later stage of slashing.
This imposes limitations which can only overcome by changing to pattern weaving.

TYPES OF WARPING
Sectional Warping Process
In sectional warping sections are made sequentially and because of this the process
is rather slow ;it is the practice therefore to produce no more than is required to fill a
single weavers beam.the result is that the sectional warping is used mainly for short
runs or for complex color patterns.
Pattern, Band or Drum Warping
Because many warpers beams are combined in the direct system,this is usually
regarded as a high speed process particularly suitable for single color work .providing
the warpers beams are of single color ,it is possible to combine them to produce
simple patterns distributed over the warp width.
Ball warping
Ball Warping is an intermediate process for storing yarn for transport ,dyeing or
reserve; It does not produce a beam.the usual form is a cross wound cheese in which
multiple ends are wound at the same time in a ribbon which contains perhaps 50 or
100 ends.

QUALITY OF A GOOD WARP

The essential features of a good warp are as follows:
1.

Sufficiently and uniformly strong

2.

Uniform in cross section

3.

Uniform warp tension

4.

Uniformly sized

5.

Less hairy and clean

6.

Minimum no of knots

7.

Proper or standard size and types of knots

8.

Free from neps, slubs and loose fibres

9.

Parallel arrangement of warp yarn in the weavers beam

WARPING ELEMENTS & MOTION

Each warping m/c has the following warping elements & motion:
1.

Warping creel for accommodation the bobbin.

2.

A builder motion.

3.

A guide reed. Uniformly spreading the yarn over the warp width.

4.

A measuring motion registering the warping length.

5.

An automatic knocking off motion to stop the m/c up on achieving the

required length of warping in case of yarn breakage.

6.

A drive

7.

A starting & stopping motion.

8.

Warping m/c is furnished with package doffers signal devices, blowers.

Fluff -exhaust system.

REQUIREMENT OF WARPING
Should meet the following requirement:
1.

The tension of all wound ends must be uniform and possibly constant during
all the time of withdrawal from supply packages, otherwise the rate of
breakage will be increased & the structure of the ready cloth will be
impaired.

2.

Warping should not impair the physical & mechanical properties of yarn. The
tension should moderate to allow the yarn to completely retain its elastic
properties & strength. The yarn should not be subjected to sharp abrasive
action.

3.

The surface of warping package must be cylindrical. Therefore, the spreading

of yarn (density) throughout the whole width of warping must be as uniform
as possible.

4.

A pre determined length of warping should be observed.

5.

The production rate of warping should be as high as possible.

REQUIREMENT OF WARPING

1.

The yarns in the sheet should be in uniform spacing.

2.

The yarns in the sheet should be in uniform tension.

3.

The yarns in the sheet should be of a predetermined length.

4.

The sheet should be containing a predetermined number of ends.

5.

There should be no broken ends in the beam.

OBJECTS OF WARPING
Objects of warping:
The object of warping is to convert a predetermined number of single end packages,
such as cones or cheeses into a sheet of yarn of specified length & width. The
individuals ends in the warp are uniformly spaced across its full width. The warp yarns
comprise one of the systems of yarns required to produce a woven fabric & also for warp
knitting. The objective at warping, as erroneously considered by many is not at all to
remove yarn faults, the breaks due to these being only incidental.

WARPING PROCESS INVOLVES

CHECK LIST BEFORE PRODUCTION

Check List Before Production:
1. With the production before data control operator will call-up the following for
recording:
2. Warp length shift
3. Down time.
4. Efficiency.
5. No. of thread breaks.
6. No. of warp beam doffed.
7. Time for thread repair.
8. Time for beam change.
9. Operator must check yarn quality in term of count, material, and color with
customer demand. No mixing is allowed.
10.Operator must check yarn quality in term of strength and record yarn break
rate. Standard for good quality yarn 10 breaks/1000000 meter.

IMPORTANCE OF WARPING
Importance of warping:
1.

Constructions of beam warp yarn.

2.

Constructions of a parallel yarn sheet.

3.

Modifying the faults of yarn like thick & thin places, large knots etc.

4.

Winding the predetermined length of yarn.

5.

Combination of small packages.

6.

Finding long length of warp yarn.

7.

Accelerating the next process.

PRODUCT QUALITY CHECK

QUALITY PARAMETER CHECK

Beam surface smoothness
Homogeneous beam diameter
Yarn exhaustion
Yarn break

RESPONSE
No ridge beam allowed, clean the yarn
guide & check the tension for uniformity.
Check the alignment of beam & drum, drum
and creel etc.
Replace exhaustion cone with new one.
Tying the head end with tail end with
standard with fail size <3 mm.

Operational Stuff
Operational Stuff:
1. SUPERVISING OFFICER.
2. OPERATOR.
3. CREEL MAN.
4. HELPER.

Operational Staff:
Section in Charge
Senior Executive

Quality Control Officer

Supervising officer

Senior Operator

Creel man

Helper

OPERATION PROCEDURE:

As per production program given by Assistant Manager, preparation through the

yarn. Warped Record Register; the Supervising Officer collect greige yarn from the
store as per required count Lot no. & quality.

The m/c operators and helpers and helpers open/break the yarn cartons & place
the yarn cones on the creel peg as per program & draw the head end of each cone
through pre-tensioner rods feeler wire, yarn guide & then through expanded comb
of beaming unit.

The basic creel data setting& m/c data setting are done according for the required
as pr m/c manufacturer instruction.

An empty beam is set between driving clutch & engaged by means of electric
switch.

All the ends from the creel is warped around the beam manually one round.

The press roller is moved toward the beam by means of electric switch.

OPERATION PROCEDURE:

The m/c is then run slowly and checked for yarn alignment with beam
flange on both sides. To ensure perfect alignment the expended comb may
be moved either to the Right side or Left side as required by switch.

Then the m/c is ready & operational & the switch is to be turned on.

As the present length is achieved the m/c will stop automatically. The beam
is doffed by switch. Another empty beam is mounted.

In this way a set of beam are made to feed the subsequent sizing process.

Production is recorded in the yarn Warped Record Register. Each beam is

set with warping Data sticker for identification in the next process.

WARPING PROCEDURE
1.

Based on weave plan supervising officer and/or senior operator receive the
required dyed yarn from winding section of specific customer order no. as per
color and quantity.

2.

As per worked out warp pattern scheme senior operator arrange the yarns on the
creel following the color pattern. Quality control officer will check any shade
variation within the same color. If any variation is found, necessary steps should
be taken to use them lot by lot. Quality control officer will sign on the warping
program register.

3.

The operator & creel man draw the yarn through feeler wire on creel & splits of
the leasing reed & then through guide reed & tie in.

4.

Then the main switch of main control panel is turned on & cone alignment is done
by respective switch.

5.

Senior operator will put necessary data entry on the warping data sheet by taking
some figure from yarn warped record register & by calculating some values as per
prescribed formula in the m/c manufacturers operating instruction book. He will
also input these required figurers in the control data unit of the m/c.

WARPING PROCEDURE
6.

Hook warp section on to the drum by opening & closing the guide roller.

7.

Start warping by pressing foot pedal at the head stock. Machine will run slowly
at crawl speed. After 15 meter being wound on, stop the m/c and insert leasing
threads. Then again start m/c with run switch at the head stock and finish
warping of the section.

8.

Then by section alignment switch set the m/c ready for next section. Repeat
step-7, and 8 to finish the warping.

WARPING PROCEDURE
All the section thatare wounded up over the drum is doffed in the beam from by
beaming process as follows:

Turn the switch from warping to beaming.

Set an empty beam in the beam during unit by beam barrel by an adhesive tape
and rotate the beam manually.

Set beam flange with measured warp width.

Set winding tension value range from 1-6 (calculated value as attached).

Run at crawl speed to see alignment either left side or right side by drum
alignment switch.

Set the winding speed within a range of 1-160 m/min, depending on yarn quality.

Run the m/c with run switch.

Doff the beam by unloading switch.

Warping data sheet is failed as a production record. Each beam is set with a
warping data sticker for identification in the next process.

Hi-speed warping

HI-SPEED WARPING MACHINE

YARN PATH DIAGRAM OF HI-SPEED WARPING MACHINE

Main Parts:
1. Yarn cone or Chase
2. Balloon Breaker
3. Yarn tensioner
4. Yarn guide
5. Ceramic guide
6. Auto stopper
7. V-reed
8. Lease rod
9. Roller
10. Pressure Roller
11. Pre-beam

SCHEMATIC DIAGRAM OF DIRECT WARPING MACHINE

DIRECT I HI-SPEED WARPING MACHINE

PROCESS FLOW CHART HI-SPEED WARPING MACHINE

Dispo

Yarn from store

Creeling

Warping

DIRECT I HI-SPEED WARPING MACHINE

COMPONENTS OF WARPING MACHINE

CREEL:
1. ConeHolder
2. Yarn Guide
3. Tension Rod
4. Ceramic Guide Disc
5. Auto Stop Sensor
6. Creel Panel Board

: Hold the cone or arrange the cone in the creel.

: To guide the yarn.
: Maintain yarn tension by upper & lower disc tensioner.
: To guide the yarn from creel to warping m/c.
: To sense the breakage yarn.
: Display where the yarn break.

HEAD STOCK:
1. Guide Reed
: Uniformly spread the yarn over the warp width.
2. Adjustable V-Reed
: Guides the yarn to follow the fixed path.
3. Speed Controller
: control the speed, crawl speed or full speed.
4. Pressure Roller
: Exert required pressure to the warp yarn.
5. Measuring Device
: Measures the length of the yarn.
6. Beam Bracket
: Holds the warp beam.
7. Emergency Stop Device: For emergency stop.
8. Automatic Knock Off : Stop m/c at achieving required length of beam or in case of
9. Yarn breaks.
10. Electrical Panel Board : To give the automatic controlled function.

Major components of Warping Machine:

Warping machine has three major components:
1.

Creel

2.

Head Stock

3.

Control Device

Creel:
Parallel creel with travelling package
Creel capacity of SIM fabric direct warping m/c:
oNo. of warping m/c: 2
oM/c no 1: Both side: 756

Creel:

FUNCTION OF COMPONENTS OF CREEL

Function of components of creel:
1. Cone or cheese spindle for high speed warping.
2. Thread guide: To pass through the yarn in the reqd way.
3. Tensioner: To keep the yarn always in a uniform tension.
4. Yarn cleaner: To remove various faults of yarn like slubs, neps etc.
5. Suction fan or blower: To remove the dirt & dust from the yarn.
6. Breakage indicator: To indicate breakage in package.
7. Stop device: To stop the m/c when yarn will be broken.

HEAD STOCK
Features of components of headstock:
1. Adjustable or variable v-reed or wraith: To control the width of the warp
beam.
2. Measuring & making device: Measure the amount of warp yarn on the beam
& marks the yarn.
3. Yarn speed controlling device: To control the speed of yarn.
4. Pneumatic pressure unit: To press the warp beam with the surface contact of
driving drum.
5. Break assembly: It stop the m/c after read length is wound on beam.
6. Driving drum: Beam is in contact & control with driving drum.
7. Stop motion: Used to stop the m/c after read length is wound on beam.
8. Beam bracket: To support & hold the beam.
9. Lease rod: Used for separation of yarn individually.

Control device:
Similar to winding, warp yarns are threaded through tension devices , stop
motions, leasing rods and the reed. The stop motion electrically links each warp
end to the warper braking system; when a warp end breaks, the warper stops. A
light indicates the location of the broken end. The warping process is generally
irreversible, unwinding, of the beam would cause yarn entanglement. The stop
motion device which can be mechanical or electronic for quick response, is usually
located near the creel.Fans are used to prevent lint accumulation when warping
staple yarns.

# Pressure setting of stop motion & tensioner: (Off Creel)

Setting is adjustable by rotary button, which activate stop motion drop wire & pressure.

Stop motion

Tension

Setting range

Yarn Count (Ne)

Coarse

4-30S

B`

Medium

4-60S

Fine

15-120s

High Speed Warping m/c Setting:

Set up parameters

Range

Set value

Cone no. of Creel

400-600

As required

Warping Speed

1-1200 m/min

Warping length

1-999999 m

Shift selection

1-5

Beaming drum pressure

1-11 mm scale

5 mm scale

Stop drop wire

1, 2, 3.

1 higher

Tensioner

A, B, C.

C higher

Depth of penetration

1-40 mm

As required

Beam barrel dia

315 mm

Fixed

Beam flange dia.

987 mm

Fixed

Beam width

1800 mm

As required

DIFFERENCE BETWEEN DIRECT & SECTIONAL WARPING

PARAMETERS
Object / Use

Method of
production

No. of
Ends/beam

Stage of
Production

DIRECT WARPING
It is generally used to produce
warp beam for grey fabric or
solid color fabric.

SECTIONAL WARPING
It is generally used to produce warp
beam for yarn dyed (check/stripe)
fabric.

Several Warpers beam are

produced here for getting one
weavers beam.

One Warpers beam is produced

here for getting one weavers
beam.

Ends/beam is less here. Direct

Ends/beam is higher here. Sectional
warping beams contain 1/n no. of warping beam contains equal no. of
ends of weavers beam.
ends as weavers beam.
(n=no. of warping beam/set).
One stage Production.(Yarns are
directly wound on Warpers
beam).

Two stage Production. (Yarns are

directly wound on warping drum
section by section; then the sheet is
transferred to warpersbeam).

DIFFERENCE BETWEEN DIRECT & SECTIONAL WARPING

PARAMETERS
Yarn Tension
Yarn length on
beam
Creel Capacity
Sizing Operation

Efficiency

DIRECT WARPING
Yarn tension is comparatively
higher than sectional warping.
Higher length of yarn is
wound on a beam.
Usually lower than sectional
warping.
One sized beam is produced
from several no. of Warpers
beam.
Efficiency is higher than
sectional warping.
(Single stage operation).

SECTIONAL WARPING
Yarn tension is comparatively
lower than sectional warping.
Length of yarn in the beam is
comparatively lower than direct
warping.
Usually higher than sectional
warping.
One sized beam is produced from
one Warpers beam.
Efficiency is comparatively lower
than direct warping. (One
additional operation beaming-off
is required).

Sectional Warping m/c.

Process Flow Chart Sectional Warping Machine

Process Flow:

Dispo

Yarn from store

Creeling
(According to warp plan)

Machine setup

Section wise warping

Beaming

Warp width:

Total Ends

Warp Width

Below 7200

1800 mm

7200

2000 mm

Above 7200

2100 mm

Control Data Parameter Evaluation:

Feed- 1 =

Decitex Total Ends 0.5

Density Total Warp width

Feed 2= Measured feed X 0.85 ( For Cotton)

= Measured feed X 0.95
(For Synthetic)
Feed -1= Drum Movement with revolution per minute.
Feed -2= Actual movement of Drum.
Measured feed=> It find out the variation between Feed -1 to Feed -2 Variation +/- 15%
Piece length= Machine stop before wound 10 -15 meter of required length.

SCHEMATIC DIAGRAM OF DIRECT WARPING MACHINE

HEAD STOCK OF SECTIONAL WARPING MACHINE:

HEAD STOCK OF SECTIONAL WARPING MACHINE:

CREEL DIAGRAM

Ball Warping

Ball warping Machine

In ball warping process, individual strands of yarn are removed from yarn packages
and collected into rope form suitable for rope dyeing (Fig. 2). Threads, about 350-500
in number are formed into ropes. Individual warp yarn are collected into rope form
and wound onto a log and produce a ball warp on Ball warping machine.
In ball warping, all the packages are loaded into the adapters of the creel of ball
warping machine. The creel is normally designed to accommodate about 330 to 430
packages. The creel may be of different types, such as Magazine Creels and Traveling
Package Creels. The passage of yarn in ball warping are shown in Fig..

Passage of yarn in ball warping

The Magazine creels are straight-line creels having a reserve yarn package placed
beside the running packages (Fig. 4). The tail end of the running package is knotted
with the start end of the reserve package. When the running package is depleted, the
warper continues to run with the from the reserve package.

Faults & Remedies of Warping:

Warp off centre of the beam:
Due to not carefully placing of creel wraith and flanged beam.
Remedy: Beam and wraith placed properly.
Ridgy or uneven warp beam:
This effect due to
Winding of small no of ends on larger beam.
When the dents are bent or the spacing between dents is uneven.
Mixed count.
Remedy: Higher no of ends be used.
Crossed ends:
Due to
Faulty knotting after yarn breakage.
Tying of broken ends.
Loose warp.
Remedy: Knotting and tension controlled.

Faults & Remedies of Warping:

Snarl formation in the warp:
Due to
Over tension.
Improper twist.
Position of guide.
Remedy: By proper tension and twist.
Missing ends:
Due to
Faulty stop device.
Exhausted cone or bobbin.
Absence of cone or bobbin on creel.
Remedy: By correct stop device is used

Hard beam:
Due to high tension.
Remedy: Tension and pressure maintained.

Faults & Remedies of Warping:

Unequal length :
Due to faulty measuring device.
Remedy: correct measuring device.
Broken ends:
Remedy: To be joined carefully the yarn.
Warp ends round the creel peg.
Unequal length of warp.
Unequal size or weight of cone or cheese in the creel.
Lapped ends.
Piecing.
Soft end on the warping beam.
Warp ends round the creel peg(spindle) and results broke.

Causes of yarn breakage in warping:

Causes of yarn breakage in warping:
1. Weak yarn.
2. Sloughing off.
3. Over lapping.
4. Knots/ bad splice.
5. Slubs.
6. Loose yarn.
7. Pig tail.
8. Cut yarn.
9. Bad tip cone.
10. Short cone

Warping Calculation
Calculation:
For

construction(6815yds fabric)
Total number of yarn =7344 7250
Length of ordered fabric = 6815yds

Warping Calculation
Breakage calculation:

Number of total ends: 7500

Number of yarn per warper beam: 625
Number of creel: 12
Length: 9250 yards
Total breakage: 162
Now, total length: number of total ends length
: 7500 9250
: 72150000
Breakage in 72150000 yards length = 16
Breakage in 1000000 yards length
= 2.24

Giving some example of breakage rate whose are classified depending on yarn
manufacture company name and their yarn count and warping machine speed.

COMPANY NAME
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ

COUNT
40/2
40/2
30/1
30/1
30/1
60/1
30/1
16/1
60/1
30/1
30/1
40/2
30/1
40/2
30/1

SPEED
350
350
350
350
350
350
350
350
350
350
350
300
350
350
350

BREAKAGE RATE
1.01
1.8
1.92
1.95
2.65
2.1
1.25
2.13
3.31
1.13
1.24
0.45
0.73
4.04
1.41

Warping Calculation

Warping Calculation
Warping efficiency:

Efficiency is calculated depended on worker working shift

Actual Production: (200003) +14000 = 74000 yards
Machine speed= 350 yards/min
Production time= 74000 yards 350 = 3.32 hour (total length speed)
Creel time= 1.00 hour
Breakage= (962) = 3.23 hour
Cleaning time = 0 hour
Electrical = 0 hour
Mechanical= 0 hour
Total time used= 7.44 hour
Idle time= 0.16 hour
Calculated production= total time machine speed
= 8.00hour 350 yards/ min
= 480 min 350 yards/ min
=168000 yards

Warping Calculation

Warping Calculation