Contents

 What is Warping
 Objects of Warping
 Importance of Warping
 Requirements of Warping
 Types of Warping
 Comparison between High Speed & Sectional Warping.
 Components of Warping
 Types of Creels
 Warping Process
 Yarn Path Diagram
 Quality of a good Warp
 WARPING
The parallel winding of yarn from cone or cheese package on to a warp beam
is called warping.

 Objects of Warping:
✓ To wound up fixed length of yarn on to a warp beam.

✓ To make progressive next step of fabric manufacturing.

✓ To increase weave-ability of yarns.

✓ To increase the quality of fabric.

✓ To make reusable small package.

✓ To make suitable warp yarn sheet for the next process named sizing.

✓ To increase fabric manufacturing production.

Importants of Warping

1. Constructions of a beam of 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. Re-using small packages.

7. Accelerating next process.

8. Finding long length of warp

Requirements Of Warping
Warping should meet the following requirements.

1.The tension of all wound end must be uniform and possibly constant during all
time of withdrawal for supplying packages. Otherwise the rate of breakage
will be increased and the substance of the ready cloth will be impaired.

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

3. The package surface must be cylindrical.

4.Higher production should be obtain during warping .
5.During warping, yarn should not be damaged.
6.Pre determined length of warping should be observed.
Types of warping:

1. High speed Warping.

2. Sectional warping
3. Ball warping
High Speed Warping
The process of preparing warp beam directly from yarn
package.

Features:
 It is a simple flanged bobbin which is used as beam.
 It is used to produce weavers beam from a large amount
of yarn
 Here, the weavers beam is produced after sizing.
 It is used for high speed production.

 It also used to produce common/solid color fabrics in

higher number of quantities.
 Here, large amount of yarn required.
 Creel capacity is higher than sectional warping.
 Cone, cheese winding is used here.
 It is a cheap process.
Sectional Warping
A process of preparing warp beam over two stages,
first winding the yarn in narrow takes on a large
drum and then rewinding the warp on to the beam.
Features:
 This is suitable for making checked, stripped or
other fancy fabric.
 Beam can be found immediately after sectional
warping.
 Sizing materials are applied before warping.
 Small amount of yarn is required to produce the
weaver’s beam.
 The production is less in sectional warping
 The yarn tension is less uniform
 It is less efficient than high speed warping
Ball Warping
 Ball warping is also a kind of beam warping where small beams are made
with cross wound yarns from all the packages placed in the creel. The yarns
are wound by a traversing motion across the width of the beam. In this system
the large number of strands of the yarn of specific length in the form of loose
untwist rope are wounded. This system is mainly used when yarn is dyed for
denim fabric. This rope consists of the 50 to 100 yarns. Such beam termed as
ball.
Differences between High Speed & Sectional Warping:
High Speed Warping
1. To produce common fabric in large
quantities.
3. High production.
4. Large amount of yarn required.
5. Single yarn is used.
6. Less expensive.
7. It is most widely used for cotton,
linen, woolen & worsted yarn.
8. Uniform tension of yarn.
9. Weavers beam is produced after
sizing.
10. Higher creel capacity.
Cone or cheese bobbin is used.
11. Beam warping is more widely used.
12. One stage is involved.
13. Single color yarn is used.
Sectional Warping
1. To produce fancy pattern fabrics.
3. Low production.
4. Small amount of yarn required.
5. Twisted yarn is used.
6. More expensive.
7. It is most widely used for silk &
synthetic yarn.
8. Less uniform tension of yarn.
9. Weavers beam is produced after
sectional warping.
10. Lower creel capacity.
Flanged bobbion is used.
11. Sectional warping is not widely
used.
12. Two stages are involved.
13. Multi color yarn is used.
Components of Warping Machine
CREEL:

1. Yarn Cleaner: To remove various faults of yarn like

slubs , neps etc.
2. Indicator: To indicate yarn breakage in package.
3. Package base : To house the package .
4. Yarn Guide : To guide the yarn.
5. Tension Rod : Maintain yarn tension by upper & lower
disc tensioner.
6. Auto Stop Sensor: To stop the machine when yarn
will be broken.
7. Blower or Suction fan: To remove the dirt & dust
from the yarn.
Head Stock :
1. Yarn speed controlling device : To control the speed of yarn provided with
a meter.
2. Adjustable V-Reed : To control the width of the warp beam.
3. Building device : To control the space between driving drum and beam
while dyeing or sizing.
4. Driving drum : Beam is in contact and control with driving drum.
5. Measuring and marking device : Measures the amount of warp yarn
on the beam and marks the yarn for definite use.
6. Beam Bracket : To support and hold the warp beam.
7. Stop motion: It is used to stop the machine after the required length is
wound.
8. Break assembly: It stops the machine instantly in case of yarn breakage.
9. Pneumetic or hydraulic pressure unit : To press the warp beam surface
contact driving drum
Creel
It is a stand which gives housing to the small yarn package.

Types of Creel
There are four types of creel.

1. Single end creels: In this creel,single package is associated

with each end being wound. It is a fixed system.

2.Truck creels: In the case of the fixed Headstock only two

creels are used but one extra space is required into which the
exhausted creel can be moved before the full one can be brought
into action . This is known as truck creels.
3. Magazine creels: 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.

4. Traveling creels: In this system the package carriers

move in loops so that , while the yarn is being withdrawn
from the outside of the inside carriers may be creeled them .
 Yarn Path Diagram of High 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
Quality of a Good Warp

The essential features of good warp is mentioned

bellow-
 The yarn must be uniform, clean and free from knots as much as possible.
 The yarn must be sufficiently strong with withstand the stress and friction
without end breakage.
 Knots should be a standard size and type. So that they can pass the heald eye,
dropper, read easily.
 The warp must be uniformly sized and size coating should be thick enough to
protect the yarn various function.
 The ends of warp must be parallel and each must be wound onto a weaver’s
beam at an even and equal tension.
 All warp yarn should of same size in length