Lecture 12: Warping Calculations

W. A. Wimalaweera
OUSL
Contents
• Beam Warping calculations
• Sectional Warping Calculations
 Beam Warping Calculation

• The first stage of beam warping is the preparation of a set of back beams (or section
beams) each containing a fraction of the total number of ends to be in the fabric. Then
we have to assemble these back beams to one beam in a second stage. Let’s consider
the following example.
• Example 1:
A weaver has an order for 25,000 metres from a loom state plain weave fabric having
following construction:
 
Cotton 45s x Cotton 45s X 48 inches
103 EPI x 65 PPI
 
Assume C1 = 5% and C 2 =7%. Assume a waste percentage of 2% for warp yarn.
Calculate the number of section beams to be prepared, number of supply packages
(Warp) to be ordered, amount of warp in each package and the requirement of warp
and weft yarns
 Calculation of number of beams and
packages
• The weaver has to produce a large quantity of a plain weave
loom state fabric. To produce such a quantity, best method of
warping is direct warping. As the warp yarn is a single yarn it has
to be sized after warping. During sizing we can assemble the
back beams to the final weavers beam.

• The construction details are given for the loom state fabric.
Loom state fabric is the fabric delivered by the weaving
machine. After finishing the fabric specifications such as warp
yarn density, weft yarn density, area density etc. may change a
little. We are not concerned about this in this particular example
 Calculation of warp beams
• First of all we must calculate the number of
back beams to be prepared and how many
warp ends must be there in one beam. For that
we must know the details about the warping
machine creel capacity available in the mill.
• Assume that the creel capacity of the warping
machine is 750. That means the maximum
number of ends we can warp at a time is 750.
 Calculation of the number of beams

• Total number of warp ends in the fabric = 103 ends/inch x 48 inches

= 4944
• The number of back beams = Total number of ends in the fabric
Creel capacity

• = 4944 / 750
 
• = 6.592 7

• We have to make 7 back beams to have the total number of ends of

4944 . Each bean contains (4944 / 7 = 706.28 ) 707 ends.
• The exact number of ends in one back beam = 707
• That means we are using only 707 spindles of the creel
although we have a total number of spindles of 750.
• The weaver has to order from the winding department
707 yarn packages each containing sufficient weight of
yarn for 25000 m of fabric. Yarn requirement is calculated
as follows.
 
• The width of the beam = warp width at reed = un-crimped
length of the weft
= 48 inches (1.07) = 51.4 inches
 Yarn requirement
First of all let us calculate the total amount of warp yarn requirement.
 
• Total length of the warp yarn requirement = 4944 x 25000 m x (1.05)
= 129,780,000 m

• Total length of the warp yarn requirement= 129780000 m x 1.083

yds/m
= 140,594,957 yards
• Total weight of warp yarn requirement= 140594957 lbs (pounds)
45 x 840
= 3719.44 lbs

• Total weight to be ordered (consider waste) = 3719.44 x 1.02 lbs

= 3793.88 lbs
• The weight in of yarn in one package = 3793.88 / 707
= 5.37 lbs
• The weaver has to order 707 yarn packages each containing 5.37 lbs from the
winding factory so that he can prepare the beam on his warping machine.
 Beam warping calculation 2

• An order for 24200 m of the following finished fabric has been received.
Cotton 15 tex X Cotton 15 tex X 1.2 m
38 1/cm X 35 1/cm

• Warp Crimp, C1 = 9%, Weft Crimp, C2 = 8%, Warp and weft waste = each
2.5%

• A beam warper with a creel capacity of 600 is available. Calculate,

a) The number of back beams to be prepared and the width of the beams.
b) Total requirement of warp and weft yarn.
c) Number of yarn packages required for warping and the weight of yarn to
be wound on to each package.
 Sectional Warping Calculation
 In sectional warping also we have two stages.
 In the first stage we wind a certain number of warp ends,
which depends on the creel capacity, on to a warping drum.
The density of the warp ends wound on to the drum is similar
to the warp density on the weavers beam. Therefore the
number of warp ends wound on to the drum represents only a
section of the complete warp beam.
 To complete the total number of ends required on the weavers
beam we have to wind several sections on to the drum.
 Once all the sections are wound on to the drum we have to
transfer the whole set of ends to the weavers beam. This is the
second stage of sectional warping. This step is known as
“Beaming”.
 Sectional Warping Calculation
Example
• A weaver receives an order to weave 2500 m of a fabric having following
specifications:
 
Nylon 75d/24f X Nylon 75d/24f
X 48 inches
102 1/inches X 83 1/inches
 
• The above details are of the finished fabric. The finished fabric has
following crimps: Warp crimp, C1 = 6%, Weft crimo, C2 = 5%, assume a
warp waste of 3%. The fabric has warp way strips in white and red colours
of 0.5 inch width.
 
• Now the weaver has to determine the warping details and yarn
requirements.
 Why Sectional warping?
• The fabric quantity ordered is small (2500 m),
and it has warp way stripes. Therefore the
most suitable method of warping is sectional
warping.
• The sectional warping machine available in the
factory has a creel capacity of 600.
• First of all let us calculate the total number of
warp ends in the fabric.
 Total number of ends in the beam
• Total number of warp ends in the fabric= 102 1/inch x 48
inches
= 4896
The warp and weft crimps of the finished fabric are given.
When we consider the weft, the un-crimped length of the
weft is equal to the width of the warp sheet at the reed. The
width of the warp sheet at reed (reed-in width) is
approximately equal to the width of the warp on the beam.

• Width of the Finished fabric = 48 inches

 Calculation of the width of the warp sheet
If the width of the warp sheet at reed is “W”,

The crimp of the weft of finished fabric is defined as follows:

 
Length of the un-crimped weft – Width of the fabric
Weft Crimp, % = C2 = _________________________________________x 100

Width of the fabric

 
Therefore, C2, % = (W – 48”) 100/ 48”
 
W = (48” x 5/100) x + 48”
• = 50.4 inches
 Reed-in width and beam width
• In this calculation we assume that any permanent change of
the length of the weft takes place due to finishing or weaving
processes.

• Width of the warp sheet at the reed = 50.4 inches

• Therefore width of the warp to be wound on to the drum =
50.4 inches {This can be little larger than 50.4 (reed-in
width) for practical reasons}

• Number of sections to be wound onto the drum = 4896 /

600
= 8.16 Sections
 Number of sections to be wound
In this case,
• We can either wind 8 sections with 600 ends and
then a 9th section with a reduced number of ends
(600 x 0.16 = 96) or
• We can wind 9 sections with 4896/9 (= 544) ends
per section or
• we can select the width of a section depending
on the numbers of threads in the colour repeat
of the warp.
 Which method is better?
The second method is better than method 1because
1. We have to creel a lesser number of yarn packages at the
beginning and we do not have to remove some packages after 8
sections.
2. Further we can use 544 packages with the same amount of yarn in
each package.
However we must be careful to maintain the number of threads in
the colour repeat. If the number of threads in one section (544) is
not equal to a multiple of the threads in the colour repeat we will
have to change the packages in the creel during change overs from
one section to the other.
 
 Consider the method 2

If we are going to wind 9 equal sections on to the drum,

• The width of one section on the drum = 50.4 / 9 = 5.6 inches
 
• So we have to wind 9 sections each having 544 ends amounting to 4896 ends
per beam. We do not use the available creel capacity of 600 spindles.
• This fabric has two colours, white and red in the warp. In the case fabrics
with coloured stripes we have to consider colour repeat also when we
decide for the width of one section.
• Number of yarns in one 0.5 inch wide strip = 102 /2 = 51
• Therefore we have to arrange warp yarns in the following order for warping:
51 Black, 51 White, 51 Black , 51 White so on (48 white strips and 48 black
strips)
• The number of threads in one section (544) is not a multiple of 51. Hence it
is better to change the number of threads per one section to 510 and wind
9 sections with 510 threads (9 x 510 = 4590) and to have 4896 – 4590 (=
306=51 x6) ends for the last section.
 Now Consider the method 3
If we want to select a section width depending on the colour repeat we have
to follow the following method.
• Total number of coloured strips in the fabric = 4896 /51 = 96
• Maximum number of colour strips in one section = 600 / 51 = 11.7
 
• The number of cololur strips in one section must be less than 11. It is
better if this number is equal to a multiple of 2 as we have two colours of
same width. Further is advisable to select a number which is a fraction of
96. The largest number which fulfils both the conditions is 8.
Therefore the number of colour strips per section = 8
• Number of threads per section = 8 x 51 = 408
(We use only 408 positions of the creel which has 600 capacity.)
• Number of sections to be wound = 96 / 8 = 12
This method is the best method as we do not have to change the creeling
during the process of warping.
 Requirement of warp yarn
The requirement of warp has to be calculated separately for white and red
threads.

• Total length of the fabric = 2500 m

• Total length of the warp yarn = 2500 x 1.06 x 4896 = 12,974,400 m
• Length of the warp yarn with waste = 12974400 x 1.03 m
= 13,363,632 m
• Total weight = 13363632 x 75 g
9000
= 111363.6 = 111.36 kg
• Amount of white yarn = amount of red yarn = 111.36/2 = 55.68 kg
 
Now we must calculate the amount of yarn to be wound onto individual
packages. It depends on the which of the above mentioned methods we
want to use
 Yarn amount per package
If we use the method 2 above
• Each of 204 (510 -306) packages must have a length of 2500 x 9 x 1.03 x
1.06 m of yarn.
• Each of 204 packages must have 24566 m of yarn from which 102 must be
wound with white yarn and other 102 with red yarn.
• Each of 306 packages must have a length of 2500 x 10 x 1.06 x1.03 m
(=25750 m) of yarn from which 153 must be wound with white and other
153 with red yarn.
1.
• Yarn No. ofispackages
Yarn requirement Length /
as follows: Weight / Total /kg
package package
2. White 102 24566 m 204.71 g 20.88

153 27295 m 227.5 g 34.80

3. Red 102 24566 m 204.71 g 20.88

153 27295 m 227.5 g 34.80

4. Total 510 111.36

 Yarn amount per package
If we use the method 3 above
• Total number of packages = 408
• Total number of white packages = 204
• Total number of red packages = 204
• Number of sections = 12
• The length of yarn to be wound
• to each package = 2500 x 12 x 1.03 x 1.06 m
• The mass of yarn to be wound
to each package = 2500 x 12 x 1.03 x 1.06 x 75/9000 g
= 275.95 g
 Yarn amount per package
• Yarn requirement is as follows:
Yarn No. of Length / Weight / Total /kg
packages package package

White 204 32754 m 272.95 g 55.68

Red 204 32754 m 272.95 g 55.68

Total 408 32754 m 272.95 g 111.36

Even though we use a higher creel capacity in the case 2, it

appears to be difficult to carry out. We have to take more
care in winding of packages and creeling has to be changed
after winding of 9 sections.
 Exercise – Sectional Warping
A warper has to prepare a beam to weave 3000 m of the following polyester
gabardine fabric using his sectional warping machine.

PE, 150 dTex/36f x PE, 150 dTex/36f x 130 cm

25 1/cm X 24 1/cm
The finished fabric has warp way stripes of 1 cm width of grey and white
colours.
C1 = 6%, C2 = 5 %, Warp waste = 3%
Calculate,
a. Number of sections to be wound on to the warping drum and width of each
section.
b. Number of yarn packages required from each colour and
c. The quantity of yarn to be wound on to each package so that winding of
yarn packages as well as warping is carried out efficiently.
END