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What is sectional warping?

It is a process in which equal length of yarn is first wound in small sections or


sheets on a drum. Then from the drum it is transferred to the beam in the form of a
sheet. It is a two stage process and is used to produce fancy fabrics by color and
weave effect. It is also known as:

 Indirect warping
 Pattern warping
 Band warping
 Drum warping
Flow Chart of Sectional Warping

Creel Drum Beam


• Arrangement of • Transferring of • Transferring all
cones as per warp sheet in the sections in
color repeat in the form of sheet form onto
warp section from the beam
creel to drum

Process of sectional warping


 It is a two stage process, called the warping and beaming
 Warping is done from creel to drum. Creel capacity is small as compared to
direct warping.
 The drum/swift is tapered at a slight angle to provide support to the yarn and
it also prevents the slippage of yarn. Higher the taper angle less will be the
package stability.
 The yarns are laid section-wise, starting from the conical base side

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 The first section is supported by the taper of the base and the subsequent
sections supported by the taper formed by the preceding section.
 Each section has multiple ends per sequence required, while section length is
the same.
 The number of ends is same in each section, except the last section also
known as the cut-able section.
 The sections are traversed on the drum during warping along the width of
section to form an angle.
 Length of the yarn is measured by the measuring roller.

Features of Sectional Warping


 This is suitable for making checked, stripped or other fancy fabric.
 We directly obtain weaver’s beam from this process.
 As sizing is not done, so multi-ply yarns or yarns which do not require sizing
are used.
 Small amount of yarn is required to produce the weaver’s beam.
 Sectional warping is used to produce a warp beam with a greater member if
ends.
 The production is less in sectional warping.
 The yarn tension is less uniform.
 It is less efficient than high speed warping.

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Set calculations for given quality and color repeat

We were provided with the following fabric:

The steps involved in the set calculations were:

 The count of the warp yarn was found out.


 The count of weft yarns was determined.
 The EPI (ends per inch) and PPI (picks per inch) were determined.
 All the yarns, along the warp side and along the weft were of the same
count, except the color.

The quality was found to be:


Quality: 30×30 / 91×86, 65”

Warp Repeat: 72 ends


35 (white) + 30 (D. blue) + 3 (L. brown) + 4 (L. blue)

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Total ends: 91×65 = 5915
No. of repeats per section: 4

Creel Capacity
Creel Capacity = 4×72
= 288

No. of sections

No of Sections = 5915 / 288 = 20.536


= 21

Cut-able Section Ends


Cut-able section ends = 0.536 × 288
= 155

Section Width

Section Width = 2400 / 20.536


= 116.868 mm

Reed Count

= (288×25.4) / (116.868×3)
= 7315.2 / 350.604
= 20.865

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Yarn weight required for given set length

Quality: 30×30 / 91×86, 65”

Total ends: 91×65 = 5915


Set length = 5000m

Warp Repeat: 72 ends


35 (white) + 30 (D. blue) + 3 (L. brown) + 4 (L. blue)

Repeats per section= 4


No. of sections= 21

Ends/section
L. blue = 4×4=16
White = 35×4=140
D. blue = 30×4=120
L. brown = 3×4=12

Warp Length

Single yarn length to warp all sections = 21×5000


= 105000m
Wastages and remainder = 1000m
Total length = 105000 + 1000
= 106000m

Warp Weight

Warp Weight (lbs) = (106000 × 1.0936) / (30 × 840)


= 4.60 lbs

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So,
Weight of blue cones = 4.60 × 16
= 73.6 lbs

Weight of white cones=4.60 × 140


= 644 lbs

Weight of D. blue cones=4.60 × 120


=552 lbs

Weight of L. brown cones=4.60 × 3


=55.2 lbs

So,
Total weight = 1324.8 lbs

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