4th Unit Warping

UNIT 4 Objectives of warping, material flow in beam warping and creels used in warping machines;
sectional warping machines. Sizing objectives of sizing; sizing materials and recipe used for different
types of fibers; size preparation equipment; sizing machines; sizing filament yarns; concept of single end
sizing, combined dyeing and sizing. Control concepts in modern sizing; energy conservation in sizing,
Performance assessment and calculations.

Objectives of warping

Warping: In textile Language warping is defined as the parallel winding of yarn from a cone or
cheese package onto a warp beam. It is needed to conform that the warp beam is made from
good warp yarn otherwise weaving performance will be hampered. Faulty weaving beam is one
of the causes of wastage in weaving section.

Warping is the first step of fabric manufacturing process. After winding, the warping process is
done for making a weaver beam. Weaver beam is produced from a set of yarn of the same yarn
count or different. Production of weaver’s plays an important role in the fabric manufacturing
process.

Objectives of warping,

 Firstly to wound up-to fixed length of yarn on to a warp beam.

 Secondly, to increase the weavability of yarn
 Thirdly, it use to increase the quality of yarn.
 After that, to make re-useable small package.
 Therefor, it use to make convenient yarn sheet for next sizing process.
 Then, to increase the production.
 Lastly to make dynamic next process.

Types of Warping:

1. Beam/ Direct Warping (Preparatory beam warping)

2. Sectional Indirect Warping (Conical drum or dresser warping)

Flow Chart of Warping Process:

 Warping is two types. So warping process flowcharts are given in separately.
Flow Chart of Direct Warping:
Creel
↓
Sensor/Guide
↓
V-Reed
↓
Beam for Sizing

Flow Chart of Sectional Warping

Creel
↓
Drum
↓
Beam (Weaver’s Beam)

Material flow in beam warping:

Definition Of Beam Warping

The warping process is intermediate between the winding and sizing processes. It produces the
warper beams that are combined together as a single weavers beam in the next process of
sizing. A warper beam may contain about 500-1000 warp ends. The direct or beam warping is
suitable only for grey or mono-colored warps that require sizing. It involves only one operation
namely warping and hence the speed and production are considerably higher than the sectional.
The machine consists of a creel, a headstock, and control devices.
Working of beam warping machine:

Creel zone: The supply packages usually consist of cones. The creel made up of wooden frame
and above 400 to 1000 supply package are arrange in the creel. Cones are mounted on the creel
in a horizontal position by a wooden peg. The yarn is withdrawn from the side of each bobbin
which revolves on the peg supporting it/ The creel is of “V” shape.

Head stock zone: The yarn from the creel is first of all passed separately through the dents of
BACK REED. & than over a smooth roller called measuring roller in a S form. The roller move
due to friction of yarn running sheet at a surface speed of about to that of the yarn sheet. The
yarn sheet next passes under a pair of light stainless pipe, turned falling roller in between which
is a guide roller. The falling roller give alight tension to the warp due to their weight. But the
main function of these roller is to keep the warp sheet straight in the case of machine stopping.
Each thread I now passes through inverted “U” shaped drop pins which causes the machine to
stop in case of end breaks. The yarn is then passed through the dents of expending onto the
guide roller which it deflects downwards to wind onto a double flange beam. The beam is held
in position at both ends by two brackets & inside beam pipe between the flanged. Rest on the
drum from which it receives the motion due to friction.

As the beam increase the diameter the arm of the bracket holding the beam pivot also rise
accordingly. These machine usually run at about 100 RPM. High speed are not possible due to
mechanical limitation.

Creels used in warping machines:

Definition of 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. No individual type of creel can be suitable for all types of
yarn, counts, set lengths and different applications. In other words no single type of creel can
give the same beaming efficiency for different types of yarns or applications. Hence different
types of creels are to be used for different purposes. The creels used in warping are of the
following types:

1. V shaped creel
2. Rectangular creel
3. Truck creel
4. Continuous chain creel
5. Magazine creel
6. Automatic creel
7. Special creels

V-Creel

As the name implies, the type of creel is V-shaped. It consists of wooden pegs horizontally to
hold the supply packages. This is arranged so that the apex is in line with the center of the
machine. The arm of this V-shaped wooden frame. This arrangement enables the ends to be
withdrawn easily from the supply package without touching or getting entangled with one
another during passing to the back reed of the head stock of the machine.

Rectangular
This is rectangular in shape and hence its name. The frames are provided with pegs to hold
supply packages horizontally. The frames can be increased to accommodate more number of
supply packages vice versa. Each frame consists of thread guides, indicator lamps etc. It is
mostly used in the slow speed warping machine.

 Truck creel

Fig. Truck creel.

Magazine

This provides with arrangements to hold reserve package. 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.
  Automatic and

 Special creels

Sectional warping machines:

Passage Of Yarn Through The Machine

Introduction
The sectional warping machine prepares multicolored warps to be woven as striped or checked design
fabrics. It is additionally used for doubled grey or mono-colored warps that do not require sizing. Unlike
the beam or direct warping, where a warper's beam is manufactured and sent to the consequent sizing
processes, in the case of sectional warping, the weaver's beam is manufactured and hence does not
require sizing. The yarn is wound in sections, each section having a particular width. Thus the total
number of warp ends for the weaver's beam is arranged into a suitable number of sections on a warping
drum. The sections are then consolidated to form the weaver's beam. Therefore, there are two separate
operations involved, namely, warping and beaming.

Working Procedure of Sectional Warping Machine in Textile Weaving:

The passage of material through the sectional warping the machine is shown in the following
figure –

The supply packages are in the form of cones or cheeses.

They are placed on a V-shaped creel or a semi-circular creel depending upon whether stop
motion is used or not.

The yarn from the creel moves through the back reed.
The reed controls the uniform spacing of the yarn throughout the width of the warp.
Then the yarn moves over and under the guide and drop rollers. The drop rollers impart
tension to the yarn passing under them and hold the yarn tight when the machine is
paused (stop). 

From there, the yarn goes through a stop motion device which stops the machine in the
event of an end breakage in the supply package, getting exhausted.

From the stop motion device, the yarn moves through a leasing reed. The reed is to
form an end and end lease at the start and completion of each section. The depth of the
reed is comparatively much more than that of the common reed. Each end of the warp
passes separately inserted in the warp after one section of warp, and the reed is
lowered. 
The purpose of this leasing is to wind and unwind the warp without any entanglement
between threads to distribute evenly. It also helps the yarn maintain in position and
helps to detect the broken end and mend it properly. 
The yarn next passes through a V-reed, enabling the warp's width through it to be
adjusted according to the width of the sections to be made.
Then the yarn passes over a measuring roller and is wound on a wooden block called
swift. After winding the predetermined length of warp, leasing is carried out. The
sections of threads are continued to the swift in a bunch form. Next, the section is
wound in the side of the previous one. The exact process is continued until the required
numbers of sections are made on the wooden swift. Then all the sections are taken and
transferred to a beam using the running-off machine. The beam is driven by a motor or
manually. The section width may vary from 10 cm to 20 cm.

Merits And Demerits

The sectional warping machine has the following advantages –

 It is suitable for striped warp yarn.

 The labor charge is not so high.
 Low power is required to drive the machine.
 There is no sizing process.

The demerits are –

 There are two stages, namely, warping and beaming.
 Warp will have to be dyed, sized, and dried separately by slow and expensive processes
before warping.
 Some amount of size will be removed from the warp during the process of sectional
warping.