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TE-2112 Introduction to
Fabric Manufacturing
Warping
Fall-2018 / TE-2112
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Warping
• Warping is transferring many
yarns from a creel of single end
packages forming a parallel
sheet of yarn wound onto a
beam or a section beam
• Collection of required numbers
of ends and length on a package
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Objectives
▫ Collection of required number of ends in
a fabric
▫ Collection of required length of ends in a
fabric

▫ Winding a specific type of Package as

required by subsequent process i.e.
Warper’s beam, Ball etc
▫ Introducing a design/pattern ( Sequence
of colored yarns such as section beam)
Fall-2018 / TE-2112 4

Warping
 Raw material is Cone/Cheese
 Warper’s beam is produced

Types of
Warping

High Speed Sectional Ball Warping

Warping Warping (Used for Draw Warping
(Direct (Indirect Denim (Heat Set)
Warping) Warping) Fabrics)
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Warping
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High Speed Warping

 Yarns are withdrawn
from the single-end yarn
packages on the creel
and directly wound on a
beam
 Used for longer runs of
fabric
 High production as
compared to other types
of warping
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High Speed Warping

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Sectional Warping
• Process of winding yarn on
tapered or section beam
• Package wound on Drum and
then Warper/weaver beam
produced
• Complex colored patterns, Color
variation is more than 15%.
• Short runs (500-10000)
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Sectional Warping
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Sectional Warping
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Ball Warping

LECTURER: MUHAMMAD USMAN

JAVAID
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Ball Warping
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Ball Warping

Ball warping is the process of winding warp in

rope form onto balls.
Balls are cross wound packages like cheese but warp is
form of rope.
Ball is wounded on special wooden core called “log”.
Balls are specially used for Indigo-dyeing for denim
fabrics.
After production of balls rope dyeing is done.
Re-beaming provides with conversion of rope dyed warp
yarn, stored in cans, into Warper's beams
Used only where mono colour dyeing of warp is required
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Indigo/Denim Dyeing

Ball Warping
(Rope Re-coiling
Winding) (In Drums)

Indigo Re-Beaming
Dyeing (Warper’s
(Rope Beams)
Dyeing)
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Ball Warping

Ball Batches Drying

Dye Bath
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Draw Warping

• Combining the drawing of filament yarns

with heat setting and warping processes
• achieve uniform stretching and heating for
improved dye uniformity, end to end
• Could be hot or cold drawing
• used for weaving of thermoplastic yarns
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Draw Warping
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Major Components of a Warping Machine

• There are two main parts of warping machine
▫ Creel
 A structure for holding supply packages in textile
processes

▫ Headstock
 The major component of the warping machine that
actually rotates and winds the warp sheet on
package (i.e. Warper's beam)

LECTURER: MUHAMMAD USMAN JAVAID

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Creel:
W.r.t shape W.r.t construction

▫ H Shaped Creel ▫ Truck/trolley type

▫ V Shaped Creel ▫ Travelling package
▫ Swivel/swinging
door
▫ Magazine Creel
▫ Duplicate Creel
▫ Roller Creel
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Creel: V & H shaped

H Shaped Creel V Shaped Creel

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Creel Shape
V-Shaped Creel H- Shaped Creel

• Wings/Arms are • Wings are parallel to

placed at certain each other
angle • Yarns may touch each
• Yarns do not touch other
• Suitable for high • Suitable for slow
speed warping speed warping
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Creel Construction

• Usually more than one creel is used to save time

• If headstock is moveable, duplicated creels are used
• If headstock is fixed, a truck/trolley creel is used
• Magazine creel contains a working and a reserve
spindle
• For confined spaces, swivel frame creel can be used
• In Travelling package creel is like a continuous belt.
Once emptied, the creel train is replaced by rotation
and warping continues
• Roller creel is used typically for carbon filaments,
aramid fibers
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Creel Construction

Magazine Creel Swivel Creel

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Parts of a Creel
• Vertical Rods
▫ Each wing contains vertical rods
▫ Capacity is determined with the help of no. of these rods
• Pegs/Spindle
▫ The supports to hold yarn package
• Guides
▫ “A component for controlling path of a running material”
(yarn)
 Tensioners
 A device which keeps yarn under constant tension so that
yarn is kept stretched
 Two rods for one package
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Parts of a creel
 Cutting assembly
 When active yarns are consumed, all clamps are
engaged and yarns are cut
 Sensor
 Used to sense the presence of yarns,
 Vibratory & photoelectric (optosensor)
 Creel Capacity
 Maximum number of yarns that can be wounded at a
time is called creel capacity
 C.C = 2 x no. of rods/wing x no. of spindles/rod
 Creel angle
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Tensioning deices
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Headstock

• Winding Warp Sheet

• Controls:
▫ Tension on yarns
▫ Warping Speed and Production Time
▫ Apply Brakes
▫ Beam Hardness (compactness)
▫ Distributes Threads on whole width of Beam
▫ Yarn on Beam Length
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Headstock
 Consists of:
 Comb
 A structure contain vertical needles to keep yarn parallel
 Zig Zag comb (Extendable)
 Horizontal & vertical traverse
 Blowpipe
 Stainless steel pipe with holes to blow air for fluff removal.
 Guide Roller
 Keeps yarn in proper position and helps locate the broken ends
 Pressing Drum
 Warper’s Beam
 Windshield
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Warp Calculation
• Yarn length from cone weight:
• Usual fine cone cone weight = 4.16 lbs.
• Cone Yarn length
▫ = Yarn weight in lbs. x Nec x length ( yards in one
hank)
• C.L = 4.16 x 40 x 840 = 139776 yards = 127811 m
• Total Ends= 5000
• Creel capacity = 1000
• No. of warper’s beam = TE/C. cap = 5
• Set Length = C.L/ beams = 127811/5 = 25562 m