Warping

1. Presented by:
Md. Nazmul Hassan Rayhan
Department of Textile Engineering
Daffodil International University

3. WARPING:
Warping:
The parallel winding of warp ends from many winding packages (cone or cheese) on to a common
package (warp beam) is called warping.
Types of warping:
1. Beam warping – direct warping.
2. Patterns band or drum warping – Sectioned warping,(Indirect warping)
3. Ball warping

4. TYPES OF WARPING
Beam Warping
A weavers beam may have up to 10,000 ends and if this were to be produced directly it
would be necessary to have up to 10,000 creel packages. Such an arrangement would
be very difficult to accommodate and manage ;consequently it is normal practice to
produce wrappers beams which may contain up to about 1000 ends and these are
combined at the slashing stage. Because of the difficulties involved in combining the
ends ,patterned warped beams are seldom produced on the direct system and any
pattern that is produced is achieved by combining beams of various colors at the later
stage of slashing.
This imposes limitations which can only overcome by changing to pattern weaving.
Sectional Warping Process
In sectional warping sections are made sequentially and because of this the process is
rather slow ;it is the practice therefore to produce no more than is required to fill a single
weavers beam. The result is that the sectional warping is used mainly for short runs or
for complex color patterns.

5. QUALITY OF A GOOD WARP
The essential features of a good warp are as follows:
1. Sufficiently and uniformly strong.
2. Uniform in cross section.
3. Uniform warp tension.
4. Uniformly sized.
5. Less hairy and clean.
6. Minimum no. of knots .
7. Proper or standard size and types of knots.
8. Free from naps, slobs and loose fibers.
9. Parallel arrangement of warp yarn in the weavers beam.

6. IMPORTANCE OF WARPING
Importance of warping:
1. Constructions of beam 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. Finding long length of warp yarn.
7. Accelerating the next process.

7. OBJECTS OF WARPING
Objects of warping:
The object of warping is to convert a predetermined number of single end packages,
such as cones or cheeses into a sheet of yarn of specified length & width. The
individual’s ends in the warp are uniformly spaced across its full width. The warp yarns
comprise one of the systems of yarns required to produce a woven fabric & also for
warp knitting. The objective at warping, as erroneously considered by many is not at all
to remove yarn faults, the breaks due to these being only incidental.

8. WARPING ELEMENTS & MOTION
Each warping m/c has the following warping elements & motion:
1. Warping creel for accommodation the bobbin.
2. A builder motion.
3. A guide reed. Uniformly spreading the yarn over the warp width.
4. A measuring motion registering the warping length.
5. An automatic knocking off motion to stop the m/c up on achieving the required length of
warping in case of yarn breakage.
6. A drive
7. A starting & stopping motion.
8. Warping m/c is furnished with package doffers signal devices, blowers. Fluff -exhaust
system.

9. WARPING PROCESS INVOLVES

10. CHECK LIST BEFORE PRODUCTION
Check List Before Production:
With the production before data control operator will call-up the following for
recording:
1. Warp length shift.
2. Down time.
3. Efficiency.
4. No. of thread breaks.
5. No. of warp beam doffed.
6. Time for thread repair.
7. Time for beam change.
8. Operator must check yarn quality in term of count, material, and color
with customer demand.
9. Operator must check yarn quality in term of strength and record yarn
break rate. Standard for good quality yarn 10 breaks/10,00,000 meter.

11. COMPONENTS OF WARPING MACHINE
HEAD STOCK:
1. Guide Reed : Uniformly spread the yarn over the warp width.
2. Adjustable V-Reed : Guides the yarn to follow the fixed path.
3. Speed Controller : control the speed, crawl speed or full speed.
4. Pressure Roller : Exert required pressure to the warp yarn.
5. Measuring Device : Measures the length of the yarn.
6. Beam Bracket : Holds the warp beam.
7. Emergency Stop Device: For emergency stop.
8. Automatic Knock Off : Stop m/c at achieving required length of beam
or in case of
9. Yarn breaks.
10. Electrical Panel Board : To give the automatic controlled
function.

13. High speeded warping
In this process, the threads are being directly
winding on a beam while unwinding the yarn
from creel

14. HI-SPEED WARPING MACHINE

15. YARN PATH DIAGRAM OF 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

16. Major components of Warping Machine:
Warping machine has three major components:
1. Creel
2. Head Stock
3. Pressure roller
4. Control Device
Creel:
•Parallel creel with travelling package
•Creel capacity of SIM fabric direct
warping m/c:
oNo. of warping m/c: 2
oM/c no 1: Both side: 756

17. Symmetric diagram OF DIRECT
WARPING MACHINE

18. DIRECT I HI-SPEED WARPING MACHINE

19. HI-SPEED WARPING MACHINE
Dispo
↓
Yarn from store
↓
Creeling
↓
Warping

20. Working principle of H.S. Warping
• At the beginning so many beams are prepared
as the following equation
Number of beams =
푡표푡푎푙 푛푢푚푏푒푟 표푓 푤푎푟푝 푦푎푟푛
퐶푟푒푒푙 푐푎푝푎푐푖푡푦
• In which way threads are assembled shows
the number of beams

21. DIRECT I HI-SPEED WARPING MACHINE

22. COMPONENTS OF WARPING MACHINE
CREEL:
1. Cone Holder : Hold the cone or arrange the cone in the creel.
2. Yarn Guide : To guide the yarn.
3. Tension Rod : Maintain yarn tension by upper & lower disc
tensioner.
4. Ceramic Guide Disc : To guide the yarn from creel to warping m/c.
5. Auto Stop Sensor : To sense the breakage yarn.
6. Creel Panel Board : Display where the yarn break

23. Creel:

24. FUNCTION OF COMPONENTS OF CREEL
Function of components of creel:
1. Cone or cheese spindle for high speed warping.
2. Thread guide: To pass through the yarn in the reqd way.
3. Tensioner: To keep the yarn always in a uniform tension.
4. Yarn cleaner: To remove various faults of yarn like slubs, neps etc.
5. Suction fan or blower: To remove the dirt & dust from the yarn.
6. Breakage indicator: To indicate breakage in package.
7. Stop device: To stop the m/c when yarn will be broken.

26. Control device:
Similar to winding, warp yarns are threaded through tension devices , stop
motions, leasing rods and the reed. The stop motion electrically links each warp
end to the warper braking system; when a warp end breaks, the warper stops. A
light indicates the location of the broken end. The warping process is generally
irreversible, unwinding, of the beam would cause yarn entanglement. The stop
motion device which can be mechanical or electronic for quick response, is usually
located near the creel.Fans are used to prevent lint accumulation when warping
staple yarns.

28. High Speed Warping m/c Setting:

29. Use of High-Speed Warping Machine
• Producing one color fabric like gray fabric
• For producing one/single color fabric
• For the same count of yarn
• Example: Shirt , Pant , Polo Shirt etc.

30. Sectional Warping m/c.

31. •Sectional warping is a process of preparing warp beam over two stages.
•First, yarns are wound in narrow tapes on a large drum.
•Second, the rewinding of the warp onto a beam is performed.
Sectional warping machine
Main parts :
•Creel
•Drum or dresser
•Warping comb
•Warping carriage
•Leasing and splitting devices for sizing
•Beam carrying chuck
•Guide
•Levelling roller

32. Features of sectional warping
• To produce fancy fabric of different colors.
• Hand weaving used in sectional warping.
• To produce weavers beam from small amount of warp yarn.
• To produce weavers beam from twisted yarn.
• To produce weavers beam from which do not required any sizing material to
be applied before weaving.
• Weavers beam can be formed immediately after.
• Production is less, so it is costly process.
• Yarn tension can not be kept uniform.
• A tapered beam or drum is used.

33. Process Flow Chart Sectional Warping Machine
Process Flow: Dispo
↓
Yarn from store
↓
Creeling
(According to warp plan)
↓
Machine setup
↓
Section wise warping
↓
Beaming
Warp width:
Total Ends Warp Width
Below 7200 1800 mm
7200 2000 mm
Above 7200 2100 mm

34. SCHEMATIC DIAGRAM OF DIRECT WARPING MACHINE

35. HEAD STOCK OF SECTIONAL WARPING MACHINE:

36. HEAD STOCK OF SECTIONAL WARPING MACHINE:

37. CREEL DIAGRAM

38. REQUIREMENT OF WARPING
Should meet the following requirement:
1. The tension of all wound ends must be uniform and possibly constant during all the
time of withdrawal from supply packages, otherwise the rate of breakage will be
increased & the structure of the ready cloth will be impaired.
2. Warping should not impair the physical & mechanical properties of yarn. The tension
should moderate to allow the yarn to completely retain its elastic properties & strength.
The yarn should not be subjected to sharp abrasive action.
3. The surface of warping package must be cylindrical. Therefore, the spreading of yarn
(density) throughout the whole width of warping must be as uniform as possible.
4. A pre determined length of warping should be observed.
5. The production rate of warping should be as high as possible.

39. REQUIREMENT OF WARPING
1. The yarns in the sheet should be in uniform spacing.
2. The yarns in the sheet should be in uniform tension.
3. The yarns in the sheet should be of a predetermined length.
4. The sheet should be containing a predetermined number of ends.
5. There should be no broken ends in the beam.

40. Faults & Remedies of Warping:
Warp off centre of the beam:
Due to not carefully placing of creel wraith and flanged beam.
Remedy: Beam and wraith placed properly.
Ridgy or uneven warp beam:
This effect due to
Winding of small no of ends on larger beam.
When the dents are bent or the spacing between dents is uneven.
Mixed count.
Remedy: Higher no of ends be used.
Crossed ends:
Due to
Faulty knotting after yarn breakage.
Tying of broken ends.
Loose warp.
Remedy: Knotting and tension controlled.

41. Faults & Remedies of Warping:
Snarl formation in the warp:
Due to
Over tension.
Improper twist.
Position of guide.
Remedy: By proper tension and twist.
Missing ends:
Due to
Faulty stop device.
Exhausted cone or bobbin.
Absence of cone or bobbin on creel.
Remedy: By correct stop device is used
Hard beam:
Due to high tension.
Remedy: Tension and pressure maintained.

42. Faults & Remedies of Warping:
Unequal length :
Due to faulty measuring device.
Remedy: correct measuring device.
Broken ends:
Remedy: To be joined carefully the yarn.
Warp ends round the creel peg.
Unequal length of warp.
Unequal size or weight of cone or cheese in the creel.
Lapped ends.
Piecing.
Soft end on the warping beam.
Warp ends round the creel peg(spindle) and results broke.

43. Causes of yarn breakage in warping:
Causes of yarn breakage in warping:
1. Weak yarn.
2. Sloughing off.
3. Over lapping.
4. Knots/ bad splice.
5. Slubs.
6. Loose yarn.
7. Pig tail.
8. Cut yarn.
9. Bad tip cone.
10. Short cone