Warping

Warping
The parallel winding of warp ends from many winding packages (cone,
cheese) on to a common package (warp beam) is called warping. We can also say it
is a process by which a long length of warp yarn is wound on a warpers beam.
Warping is the very important process before sizing.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 2

 Warping
Importance of Warping:
• Construction of a beam of warp yarn.
• Modifying the faults of yarn like thick or thin place.
• Combination of small packages.
• Accelerating the next process.
• To prepare a beam to make a fabric.
• To make a convenient yarn sheet for sizing.
• To wound up required length of yarn onto a warp beam.
• To facilitate the weaving of complex color pattern.
• To make reusable small packages.

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 Warping
Requirements of Warping:
• Here, warping predetermined length should be observed.
• Wounded ends tension must be uniform here.
• Wounded ends beam density must be uniform.
• Warping package surface must be cylindrical.
• Warping production rate should be high.
• During warping, yarn should not be damaged.
• During warping, yarn breakage should be as minimum as possible.
• Here, warp beam should be free from all kinds of faults such as slack ends, cross
ends, missing ends, damaged flanges, wild yarn etc.
• Warping might not impair the mechanical and physical properties of yarn.

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 Warping
Flow Chart of Warping:

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 Warping
Different Control Systems in Warping
• Tension Control: Tension should not be low or high during warping. Because due
to lower tension package will be unstable, entangled and snarling will occur.
Whereas high tension will cause yarn breakage. The tension should be just and
uniform throughout the process.
• Balloon Control: Balloon controlling is necessary so that the yarns does not
entangled with one another. For this, yarn guides should be placed at right
positions.
• Stop Motion: The m/c should stop itself if any yarn breakage occurs at any point.
So, stop motion system is necessary to control.
• Length Control: The Length of warp sheet should be controlled. It is done with a
measuring roller in combination with a suitable counting device by stopping the
device machine after winding pre-determined length of warp yarn onto the beam.

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 Warping
• Yarn Cleaner: Proper setting should be maintained to remove yarn fault.
• Surface Speed: The surface speed of beam should be controlled specially when a
large change in warp diameter is involved.
• Proper Yarn Density: In warp sheet the yarn ends/inch, means yarn density, is to
be controlled. Because without proper yarn density the fabric will be uneven.
• Static Electricity: It is specially required in case of man-made fibres. It is
controlled to avoid yarn entanglement. It is done by: A)Chemical fiber
finishes B)Ionization of air and C)Humidification of air.
• Traverse Control: In sectional warping traverse rate of beam should be
controlled.
• Fly Control: In staple fibres, lints, small trashes may cause problem by flying
around the working area. So, this fly should be controlled to have a pleasant
working atmosphere.

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 Warping
Types of Warping
Mainly there are two types of warping,
1. Direct/ high speed/ Beam warping.
2. Indirect/ Sectional/ Pattern warping.

Some other special types of Warping are available

1. Ball warping
2. Chain warping
3. Cross warping

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 warping
Direct/ high speed/ Beam warping:
High speed warping is a process of preparing warp beam directly from yarn
package. Here all the yarns are wound on a simple flange beam at a time. This
process is suitable for single color pattern.

Features of Direct/ high speed/ Beam warping:

• High speed warping is suitable for producing fabric with same count and same
color yarn.
• To produce common fabrics in large qualities.
• To produce weavers beam from single yarn.
• For high-speed production.
• Weaver's beam is produced after sizing.
• A simple flange beam is used.
• To produce weavers beam from large amount of yarn.

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 warping
Direct/ high speed/ Beam warping working principle:
▪ In beam warping, the yarns are withdrawn from the single-end yarn packages on
the creel and directly wound on a beam. Direct warping is used in two ways:
▪ Beam warping can be used to directly produce the weaver’s beam in a single
operation. This is especially suitable for strong yarns that do not require sizing
such as continuous filaments and when the number of warp ends on the warp
beam is relatively small. This is also called direct beaming.
▪ Beam warping is used to make smaller intermediate beams called warper’s beams.
These smaller beams are combined later at the sizing stage to produce the
weaver’s beam. This process is called beaming. Therefore, for if the weaver’s
beam contains 10,000 warp ends, then there would be – say – 10 warper’s beams
of 1,000 ends each. If this weavers were to be made a one stage, the creel would
have to have 10,000 yarn packages, which is impossible to manage.

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 warping
Main parts:
• Creel
• Expanding comb
• Pressure roller
• Beam.

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 warping

𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑤𝑎𝑟𝑝 𝑦𝑎𝑟𝑛𝑠

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑒𝑎𝑚𝑠 =
𝐶𝑟𝑒𝑒𝑙 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦

Advantages of high-speed warping:

• To produce common fabrics.
• High speed warping machine.
• Capacity of creel is high.
• Production of creel is high.
• Production and efficiency is high.

Disadvantages of high-speed warping:

• Final beam is obtained after sizing.
• High amount of yarn is required for producing beam.

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 warping
Indirect/ Sectional/ Pattern warping
In case of sectional warping, at first, equal length of warp yarn is wound in
small section or sheets on a drum. After that, it is transferred to the warp beam from
the drum in the format of a warp sheet.

Features of Indirect/ Sectional/ Pattern warping

➢It is costly process due to its lower production.
➢It is used to produce warp beam from so many small amount of warp yarn.
➢Here, tension of warp yarn cannot be kept uniform.
➢It is used to produce warp beam by using twisted yarn.
➢Hand weaving process is used.
➢It is used to produce stripe or check fabric.
➢It is also used to produce warp beam by using warp yarns which do not required
any sizing materials to be applied before fabric weaving.
➢In this warping process, a drum is used.
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 warping

Indirect/ Sectional/ Pattern warping working principle:

➢Sectional warping is used for short runs especially for fancy patterned fabrics.
➢In this case sections of the warp which may contain up to 1000 ends are first
wound onto a drum tapered with a given cone angle.
➢So cross wound sections are combined on the drum and thus each layer of warp
contains the same number of ends on the drum.
➢Then the warp threads altogether are transferred onto a weaver's beam by
unwinding the drum.
➢In this method the warp threads are not necessarily processed in sizing.

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 warping
Indirect/ Sectional/ Pattern warping
Main parts:
➢Creel
➢Dresser or drum
➢Trolley
➢Warping carriage
➢Leasing and splitting devices for sizing
➢Beam carrying chuck

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 warping

Indirect/ Sectional/ Pattern warping

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 warping
Indirect/ Sectional/ Pattern warping

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 warping

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 warping

Advantages of Sectional warping:

➢Wastage can be reduced, and a ready weaver’s beam be obtained.
➢Small amount of yarn is required to produce.
➢Beam can be found immediately.
➢To produce fancy fabric.

Disadvantages of Sectional warping:

➢Less productive and slow.
➢The yarn tension is less uniform than high speed warping.
➢Less efficient than high speed warping.

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 Difference between beam and sectional warping
Beam warping
1.Beam warping is used for long runs of
grey fabrics and simple patterns
2.The amount of colored yarn is less than
15% of the total
3.High production
4.Large amount of yarn required
5.Single yarn is used
6.Less expensive
7.It is used for cotton, linen, woolen and
worsted yarn
8.Yarn tension is more uniform
9.Weaver's beam is produced after sizing
10.Creel capacity is more
11.Beam warping is more widely used
Sectional warping
1.Sectional warping is used for short runs
specially of fancy pattern fabrics
2.Greater amount of colored yarn is used
3.Low production
4.Small amount of yarn required
5.Twisted yarn is used
6.More expensive
7.It is used for silk and synthetic yarn
8.Yarn tension is less uniform
9.Weaver's beam is produced after warping
10.Creel capacity is less
11.Sectional warping is not widely used

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Ball warping
 Warping

Factors affecting the efficiency of warping

➢Time taken for creeling.
➢Length of warp wound on a beam.
➢Number of ends per beam.
➢Size of supply package.
➢Count and quality of yarn.
➢Speed of the m/c.
➢Frequency of changes in the quality of warp worked.

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 Different Parts of Warping Machine
There are mainly two components in warping machine:
1. Creel
2. Headstock

Creel:
The creel is a stand for holding the supply packages in the form of wound
packages. It enables to hold the supply packages in proper position for warping and
constitutes an important component of the warping machine.

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 warping
Components of creel
I. Cone or cheese spindle: Holds the package.
II. Thread guide: Permits the passages of warp yarn in definite path.
III. Tensioner: To keep the yarn always in a uniform tension.
IV. Yarn clearer: It helps to remove yarn faults like slubs, neps etc.
V. Suction fan or blower: It is used to remove dirt and dust from the yarn.
VI. Breakage indicator: When the yarn breaks, this device informs.
VII.Stop device: When the yarn breaks, the m/c stops due to this device.

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 warping
Components of Head stock
I. Adjustable or variable V-reed/wraith: Expands or contracts the width of the
warp yarn.
II. Measuring and marking device: Measures the amount of warp yarn on the
beam and marks the yarn for definite use.
III. Yarn speed controlling device: Controls the speed of warp yarn providing with
a meter.
IV. Pneumatic pressure unit: To press the warp beam with winding drum/driving
drum.
V. Break assembly: When the yarn breaks, stop the m/c instantly.
VI. Driving drum: Beam is in contact with driving drum.
VII. Beam bracket: To support and hold the beam.
VIII.Stop motion: To stop the m/c after predetermined length of warp wound.
IX. Lease rod: Used for separation of warp yarn.
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 Warping
Types of creel
1. Mobile creel:
This creel type is similar to the standard
creel but is formed by trolleys which can be taken
individually out of the creel. The bobbins are
creeled up on each trolley outside the creel. During
the creeling up of a series of trolleys, the second
series of trolleys is brought back to the outside of
the creel to feed the warper.
This reduces considerably the waiting time. The
mobile creel comes in handy especially when there
is insufficient room to permit the use of two
standard creels.

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 Warping
2. Magazine creel:
This kind of creel is used when several warps
of similar type must be prepared in sequence, that is
when large lots of similar yarns need to be
processed. Level with each tensioner, two bobbins
are positioned: one operating and the other as
reserve. The tail end of the running package is
knotted with the starting end of the reserve package.
This enables the continuous working of machine
without stoppage for replacing the exhausted
package with a new one. The dimension of the creel
and floor space required is comparatively more than
other types of creel. The creel is usually V shaped.

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 Warping
3. Swivel frame creel:
This type of creel was designed as a
variation of the mobile creel to enable the
creeling up of bobbins which, owing to their
heavy weight (5 to 25 kg), cannot be pinned
on trolleys.
Each bobbin holder is double-sided: the
threads are unwound from one side, while a
new series of bobbins is creeled up on the
other side.

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 warping
4. V-shaped creel:
In this creel type, the creel boards are
assembled in form of endless chains. While warping
is carried out from the outer sides using the already
creeled up bobbins, the subsequent yarn lot can be
creeled up on the empty spindles positioned inside
the creel.
This interior room serves at the same time as storage
and bobbin exchange station. The yarn lot can be
changed by simply pushing a button, which starts
the electrically drive of the chains. The empty
bobbins move towards the inside of the creel, the
full bobbins towards the outside.

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 Warping
V-shaped creel

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 Warping
Relation between Taper Angle and Amount of Yarn on a Beam:
Let,
S- traverse Length
L- axial length of warp on the beam
d- empty beam dia
D- full beam dia
Dm- (D+d)/2= mean dia
X- tape distance
α- taper angle
V- volume of yarn store on the beam.

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 Warping
From the geometry of the figure,
V = (πD²/4 - πd²/4 ) L
= (D+d/2) (D-d/2) πL
= π.dm. x tanα. L
If, s < x, then V> π.dm. s tanα. L
If, s > x, then V < π.dm. s tanα. L
V α s tanα Where π, dm, L constant

This is desired relation between flange angle & amount of yarn to be wound on
beam.
So unlimited amount of yarns can be wound if flange stays perpendicular to beam
barrel. Practically this is impossible. But this type of package permits to wind high
amount of yarn.
If ‘S’ is small, it is required to increase and to get sufficient volume.

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 Warping
Defects and Remedies of Warping
1. Lapped ends:
Cause:
The broken end of yarn is not tied to the end on the warp beam and overlaps the
adjoining yarn. The beam is not properly brake and the signal hook fails to operate.
Remedies:
➢Tying the broken end to the end on the warp beam
➢Proper signal hook
2. Piecing:
Cause:
One broken end is pieced to another yarn end on the warping beam.
Remedies:
➢By proper joining
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 Warping
3. Soft ends on the warping beam:
Cause:
Breakage of a group of ends and piecing them in bundle or by lapping. This
defects is caused by the careless of the operative.
Remedies:
➢Careful operation
➢Broken end should be piece up properly
4. Incorrect form of build:
Cause:
Caused by non uniform spreading of ends in the guide reed and its improper
setting and conical winding in case of non uniform pressure of the warping beam.
Remedies:
➢ Uniform spreading of ends
➢Appropriate setting

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 Warping
5. Yarn cut at the butts of the warp beam/ slackness of extreme yarns:
Cause:
It occurs when the reed is improperly set with respect to the warp beam flanges
or there is a deformation of the warp beam flange.
Remedies:
➢Proper setting of reed
➢Proper position of the warp beam flange
6. Slacks & irregular yarn tension:
Cause:
It happens due to any one of these reasons- improper threading of the yarn into
the tension devices, ejection of yarn from under the disc of the yarn tensioning device,
or yarn tension devices of poor quality.
Remedies:
➢ Proper threading of tension device
➢Good quality of tension device
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 Warping
7. Low selvedge:
Cause:
Caused by non uniform pressure of the warping beam against the surface of
the warping drum or by non uniform pressure or the pressure roller in beam warpers
without drum. The same defect may occur in case of an incorrect shape of the warping
drum or improper setting of supporting levers.
Remedies:
➢Uniform pressure of the warp beam and pressure roller
➢Correct shape of warping drum

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 Warping
8. Bulges:
Cause:
Yarn ends are drawn from the middle and the broken end is not correctly pieced
up to the adjoining yarn.
Remedies:
➢Broken ends are correctly pieced up
➢Yarn ends must not be drawn from the middle
9. Broken ends on the beam:
Cause:
A group of ends is broken and tied as a bunch or worked-in with overlapping.
Remedies:
➢Broken ends should be removed.

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 Warping
10. Excessive or insufficient number of yarn ends:
Cause:
The number of yarn ends of the beam becomes excessive or insufficient due
to the incorrect number of bobbins in warping.
Remedies:
➢Correct number of yarn ends.

11. Conical winding on the beam:

Cause:
It occurs due to incorrect load applied by the pressure roller.
Remedies:
➢Correct load applied

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 Warping
12. Frequent yarn breakages at the beam edges:
Cause:
It results due to burrs and nicks on the surface of the warp beam flanges.
Remedies:
➢Removal of burrs and nicks

13. Improper length of warping:

Cause:
It is due to malfunction of the counter and the brakes of the measuring device
& warp beams.
Remedies:
➢Good measuring device

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 Warping
14. Coarse Knots:
Cause: It is due to manual tying-up.
Remedies:
➢Proper tying up
15. Loose yarn winding:
Cause: It happens when the pressure roller is lightly pressed against the warp roller.
Remedies:
➢Correct presser of the pressure roller
16. Fluff, oily ends and yarn of different density:
Cause: It is due to the careless work of the operator, creeler and oiler.
Remedies:
➢By the carefulness of the worker, oiler

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 Warping
17. Bulgy winding on the warp beam:
Cause:
It is due to irregular lying of yarn ends in the reed, missing a dent and placing
two ends in the adjoining yarn.
Remedies:
➢Correct lying of yarn ends in the reed.
➢Required number of dent

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