Warping

Objective of Winding
The objective of warping process is to convert the yarn packages into a warper’s beam having desired width
and containing requisite number of ends. Uniform tension is maintained on individual yarns during warping.
The yarns are would on the warper’s beam in the form of a sheet composed of parallel bands of yarns each
coming out from a package placed on the creel. A simplified view of the warping process is shown in Figure
1.1

Figure 1.1: Simplified representation of warping process

Let us take the following hypothetical example to understand the various options of warping process.
A woven fabric roll of 2 m width and 10,000 m length is to be produced from warp yarn of 15 tex. There should be 40
yarns per cm in the fabric. The total number of ends in the fabric will be 40×200 = 8,000. Considering that 10 beams
will be combined in sizing, the number of ends on each warper’s beam will be 800. Ignoring the yarn crimp and
wastage of yarns, the mass of a single end having 10,000 m length will be 150 g. Therefore, there will be the following
options:
P × R indicates the number of packages used × number of warping runs

 800 × 1: Each cone should contain 10,000 m yarn, weighing 150 g.

 400 × 2: Each cone should contain 20,000 m yarn, weighing 300 g
 200 × 4: Each cone should contain 40,000 m yarn, weighing 600 g
 100 × 8: Each cone should contain 80,000 m yarn, weighing 1200 g
 50 × 16: Each cone should contain 160,000 m yarn, weighing 2400 g

Now, option 1 and option 2 represent two extreme situations. Option 1 (direct warping or beam warping) can
be executed when the lot being processed is having significantly higher (15-20 times) length than that of the
fabric considered (10,000 m) in this example. Considering the mass of a full cone as 2.1 kg, if the ordered
length is 140,000 m, then the entire cone (150 × 14 = 2100 g) will be consumed.
On the other hand, option 2 (sectional warping or indirect warping) is practiced when fancy warp patterns or
specialized yarns are used for manufacturing customized products. In this case, the production planning
officer does not see the possibility of repeat order in near future. Therefore, he or she wants to consume the
entire package to minimize the wastage and inventory carrying cost. Therefore, the beam is made by section
by section and the operation is repeated large number of times to complete the entire width of the warper’s
beam. This is also followed by the beaming operation when all the sections of warp are transferred to a
flanged beam.
In synthetic filament weaving systems, each supply package contains a very high length of yarn. Such
packages are therefore fairly expensive. It is also very difficult to store such packages with unspent yarn.
Hence synthetic yarn weaving units prefer to opt for sectional warping.
For direct warping the typical length of lot can be as follows:
 40s count: 1.65 lakhs m
 50s count: 1.80 lakhs m
 60s count: 1.9 lakhs m

Components of Warping Machine

 Creel (Figure 1.2)
 Headstock
 Control devices

Types of Creel
 Single end creel
 Magazine creel
 Traveling or multiple package creel

Figure 1.2: A simple creel of warping machine

Single End Creel
In single end creel, one position of the creel is used for one end on the warper’s beam. Single end creel can be
of two types namely truck creels and duplicated creels. The creel is movable in case of the former whereas the
headstock is movable in case of the latter. In case of truck creel, when the packages from the running creel are
exhausted, it is moved sideways and the reserve creel moves into the vacant space (Figure 1.3). Thus, the
time for removing huge number of exhausted package and replenishing them with full packages is saved.
However, extra space is required for the reserve creel.

Figure 1.3: Single end truck creel

Magazine Creel
In magazine creel, the tail end of yarn from one cone is tied with the tip of the yarn of another neighbouring
cone. When the first cone is exhausted, the transfer of yarn withdrawal to the second cone takes place
automatically and machine does not stop. This has been depicted in Figure 1.4. Thus the creeling time is
completely eliminated which helps to improve the running efficiency of warping process. However, due to
sudden change in unwinding position and tension variation associated with this, some of the yarns break
during the transfer (known as transfer failure). The magazine creel has reduced capacity. If the creel has 1000
package holders, then the warp sheet can actually have 500 ends.

Figure 1.4: Magazine creel

Travelling or Swivelling Creel
In swivelling creel, the pegs (package holders) with full packages can move from inside (reserve) position to
the outside (working) position when the running packages are exhausted. Thus considerable time is saved.
Then the operator replaces the exhausted packages with full packages when the machine is running.
Fig 1.5 shows the swivelling creel.

Figure 1.5: Swivelling creel

Calculation for Warping Efficiency with Different Creels
The yarn mass on full beam is 300 kg, number of ends is 500, yarn count is 30 tex, warping speed is 1000
m/min, cone weight is 2 kg, end break rate 0.1/100 end/ 1000 m, time to repair a break is 0.5 min, Beam
doffing time is 5 min, Creeling time is 45 min/ creel, Headstock change time is 3 min/ beam, transfer failure is
2%.
The calculation which follows has been done considering the time required for various operation with respect
to one warper’s beam. Table 1.1 shows the time required for various operations.
The mass contributed by a single yarn = 300/500= 0.6 kg

Running time = 20,000/1000= 20 minutes.

Creeling time = 45 minutes/ creel.
In case of single end creel, this 45 minutes will be divided between three warper’s beam as from one cone of 2
kg mass at least three beams will be made.
So, creeling time assigned to one warper’s beam = 15 minutes.
For duplicated creel, the headstock is moved in front of the new creel which is ready with full packages. So,
no creeling time is considered. However, it needs the headstock moving time i.e. 3 minutes.

Repair time = Number of breaks × repair time per break =10 × 0.5 = 5 min
Transfer failure = 2 % of 500 ends = 10
Time for repairing the transfer failure = 10× 0.5 = 5 minutes.
This 5 minutes should be equally allocated among multiple warper’s beam as from one cone of 2 kg mass at
least three beams will be made. So, when the yarns of two cones are tied, six warper’s beam can be made
without any further creeling.
So, repair time for transfer failure assigned to one warper’s beam = 5/6 minutes= 0.83 minutes.

Table 1.1: Time required for various operations

From this example, it can be seen that the type of creel can greatly influence the efficiency of the warping operation .

Drive to Warper’s Beam

The warper’s beam can be driven by two ways.
 Direct drive
 Indirect drive

In case of direct drive, the warper’s beam is driven by gears. As the diameter of the beam increases, the
rotational speed of the beam is reduced in order to keep constant warping speed. In case of indirect drive, the
warper’s beam is rotated by frictional contact with another drum. In this case, the rotational speed of the
warper’s beam reduces as its diameter increases. Thus the warping speed remains constant.
In modern warping machine (Benninger), the warping speed is around 1200-1400 m/min. The full beam
diameter is 1-1.4 m.
Sectional Warping
Sectional warping is preferred over beam warping for multi-coloured warp. Here the entire width of the
warping drum is not developed simultaneously. It is developed section by section as depicted in Figure 1.6. As
only one section is built at a time, a support is needed at one side of the drum. This is provided by making one
side of the drum inclined. The inclination can be of two types.
 Fixed angle
 Variable angle (70, 90, 110 etc.)

As the winding of one layer is completed on the drum, the section of ends is given a requisite traverse so that
the end at one extreme corner touches the inclined surface. Thus it gets support from the inclined surface.

Figure 1.6: Schematic representation of sectional warping principle

As the process continues, the thickness (or height) of the section gradually increases. When requisite length
has been wound in a section, next section is started by shifting the expandable reed assembly by suitable
distance (distance s of Figure 1.7)

The flow chart of the warping process can be represented as shown in Figure 1.8.

Figure 1.8: Sequence of warping process

Leasing: It is asystem by which the position of the ends is maintained in the warp sheet. Generally it is done
by dividing the ends in two groups (odd and even). If odd ends are passing over the lease rods then the even
ends will pass below the rod. The relative positions of the ends will reverse in case of second lease rod.

Expandable reed: It is used to control the spacing between consecutive ends. The two limbs of V shaped
expandable reed can be expanded or collapsed as per the required spacing of ends. Figure 1.9 shows the
expandable reed and lease rods in a sectional warping machine.
Beaming system: In the beaming process, all the sections are simultaneously transferred to the flanged
warper’s beam (Figure 1.10). The drum is rotated by the tension of warp sheet whereas positive drives are
given to the warper’s beam. The speed of beaming process in sectional warping is quite slow (around 300
m/min).

Figure 1.9: Expandable reed and lease rods

Figure 1.10: Sectional warping drum and beam

 Beam warping Sectional warping
Used for high volume production Used for small volume and customised
production (stripes and specialised yarns)

One step process Two step process

High creel capacity is required Low creel capacity is sufficient
Comparatively less expensive Comparatively more expensive
Beaming speed is high Beaming speed is low
More common Less common

Comparison between beam warping and sectional warping

Common Faults of warping and their remedies

Warping means winding of warp yarns onto a beam usually in preparation for slashing, weaving, or
warp knitting. It is also called Beaming. When warping operation is done some defects occur as
well as other operations. Now we will discuss faults and its remedies.

Common Faults in Warping

1. Lapped Ends

2. Piecing

3. Soft ends on the warping beam

4. Incorrect form of build

5. Slacks and irregular yarn tension

6. Broken Ends of beam

7. Conical winding on the beam

8. Improper length of warping

Faults Causes and Their Remedies

1. Lapped Ends
Cause: The broken end of yarn is not tied to the end on the warp beam & overlaps the adjoining
yarn. The beam is not properly brake & the signal hook fails to operate.

Remedies –

1. Tying the broken end to the end on warp beam

2. Proper signal hook

2. Piecing
Cause: One broken end is pieced to another yarn end on the warping beam.

Remedies – By proper joining

3. Soft ends on the warping beam

Cause: Breakage of a group of ends & piecing them in bundle by lapping. This defect is caused by
the careless of the operator.

Remedies –

1. Careful operation
2. Broken End should be piece up properly

4. Incorrect form of build

Cause: Caused by non uniform spreading of ends in the guide reed& its improper setting & conical
winding in case of non uniform pressure of the warping beam.

Remedies –

1. Uniform spreading of ends

2. Appropriate setting

5. Slacks & irregular yarn tension

Cause: It happens due to any one of these reasons improper threading of the yarn into the tension
devices, ejection of yarn from under the disc of the yarn tensioning device , or yarn tension
devices of poor quality.

Remedies –

1. Proper threading of tension device

2. Good quality of tension device

6. Broken ends on the beam

Cause: A group of ends is broken & tied as a brunch or worked- in with overlapping.
Remedies – Broken ends should be removed
 7. Conical winding on the beam
Cause: It occurs due to on correct load applied by the pressure rollers.

Remedies – Correct load applied.

8. Improper length of warping

Cause: It is due to malfunction of the counter & the brakes of the measuring device & warp beams.

Remedies – Good measuring device.

Sizing
Sizing is the most important terms for weaving technology. After winding and warping, sizing of
yarn is done during beam preparation. Sizing is done by applying various types of size materials
on the yarn. During application of size materials steam is needed.

Sizing is a protective process. The process of applying a protective adhesive coating upon the
yarns surface is called sizing. This is the most important operation to attain maximum weaving
efficiency especially for blended and filament yarns. Sizing is called the heart of weaving.

Purpose of sizing: Sizing is done during beam preparation for getting some advantage of
weaving. Sizing has lots of objects which are given below:

1. To improve the weave ability of warp yarn by making it more resistance to action of
weaving like absorption, friction, tension etc.
2. To maintaining good fabric quality by reducing hairiness, weakness and by increasing
smoothness and absorbency of yarn.
3. Tensile or breaking strength of cellulosic yarn is increased by sizing.
4. Elasticity of the yarn is also increased.
5. By adding size materials, yarn weight is increased.
6. To increase the frictional resistance.
7. Projected fibers are removed by this process.
8. To reduce electrostatic formation.

Properties of sized yarn: Generally size ingredients are used for warp yarn but sometimes it
applies on weft yarn. Anyhow, by applying size ingredients on the yarn, following properties are
obtained. Properties of sized yarns are given below:

1. Higher elasticity
2. Higher yarn strength
3. Lower flexibility
4. Lower extension or elongation
5. Lower frictional resistance
6. Increased smoothness
7. Less weakness
8. Insensible to over drying
9. Less hairiness
 So, size ingredients change the physical properties of cellulosic fibers which is used for
making a weavers beam.

What is Size Ingredients? List of Size Ingredients and their functions

Sizing is called heart of weaving. The materials which are used for sizing that is called size
ingredients. A gelatinous film forming substance in solution or dispersion applied normally used
for warp yarn but sometimes used for weft yarn before weaving is called size.

Size ingredients and their functions: Different types of sized ingredients are used for
sizing. Followings are the main size ingredients used for sizing:-

1. Adhesive: Generally starch of maize, corn, rice, potato and CMC, PVC are used as

adhesive. Tamarine is used as adhesive on jute yarn, the adhesive is in granule form that is mixed
with water and heated to form a paste which ultimately becomes viscose fluid.

Functions:
I. To increase strength.
II. To impart adhesion making the yarn less hairy.
III. To increase abrasion resistance.
IV. To increase smoothness.
V. To increase elasticity a stiffness.
VI. To reduce extensibility.
2. Lubricants/Softener: Japan wax, Tallow, Mineral waxes, Vegetable waxes,
Animal fats, Mineral oils and Vegetables are used as lubricants.

Functions:
I. It makes the yarn soft and slippery.
II. It reduces stiffness.
III. It increases yarn smoothness.
IV. It increases elasticity.
3. Anti septic or anti mildew agent: Salicylic acid, Carbolic acid, Zinc chloride,
Phenol is used as anti septic agent.

Functions:
I. It prevents mildew formation.
II. To preserve size materials for a long time.
III. It helps to store the yarn for a long time.
IV. To protect yarn from bacteria or fungus.
4. Deliquescent or hydroscopic agent: Glycerin, Calcium chloride are used as
deliquescent agent. Deliquescent agent is those substances which absorb moisture from air.

Functions:
I. It prevents excess drying of yarn.
II. It helps to absorb moisture from air.
III. To prevent the brittleness of size.
 5. Weighting agent: China clay, Sodium phosphate are used as weighting agent.
These are used especially for those fabric or yarn that is to be solid or grey state.

Functions:
I. It increases the weight of yarn.
II. To impart fullness and fell to the fabric.
6. Anti foaming agent: Pyridine, Benzene are used as anti foaming agent.
Function: To prevent foam formation.

7. Tinting agent: Blue is used as tinting agent.

Function: To increase lusture or brightness.

8. Wetting agent: Sulphanol A, soap, avirol, magnesium chloride are used as wetting
agent. The drawback of these substances is their high foaming ability and the foam is very stable.

Functions:
I. It increases size exhaust.
II. To obtain a uniform distribution of sizing solution on yarn surface.
III. It helps to wet yarn instantly.

So, when we will choose size ingredient for sizing we should remember the functions of size
ingredients. Various dyes and chemicals manufacturing companies produce size ingredients,
choose your favourite one from there.

Requirements of Sizing | Choice Of Size Ingredients

Sizing is important for weaving but if the process does not done with proper accuracy then every
things will be hampered. For this reason a textile engineer should be very careful during sizing
operation. Sizing is done for grey or stripped fabric production. In denim; sizing is done after
scouring, bleaching and dyeing process.

Requirements of sizing: A sizing process should fulfil the following requirements, which is
important for fabric production:

1. Sized warp must be sufficiently strong, smooth and elastic.

2. The sizing process must ensure the application of the required amount of size on the yarn
or the required size regain.
3. The tension of warp yarn at sizing must be regular and constant all the time of warp
unwinding from warp beam.
4. Yarn strength and loss in elongation should be admitted limits.
5. The package, i.e. the weavers beam produced must have cylindrical shape, necessary
winding density and yarn strength.
6. The sizing process must be efficient, economical and must ensure the production of high
quality sized warp.
Choice of size ingredients: Different size ingredients have different characteristics which I
have given in one of my blog. Choice of size ingredients are given below:

1. The recipe should give the fewest breakage during weaving.

2. It should give least amount of exfoliation.
3. It should permit easy size removal in later operation.
4. It should give good fabric characteristics.
5. The recipe should be compatible with the machinery.
6. The recipe should not cause any health hazard.
7. The recipe should not cause any degradation of textile materials.
8. It should be cheap but not necessarily.
9. PH should lie between 7 to 7.4.

So, that’s all about requirements of sizing and choice of size ingredients.

Faults And Defects In Winding | Wastage In Winding

In winding; transformation of spinning bobbin yarn to the yarn package is done by manually for
this reason it has chance to occur some faults. During winding, different types of winding defects
are found. Followings are the main faults or defects of winding.

Faults and defects of winding:

 If patches are formed on the yarn.
 If winding speed is incorrect.
 Variation of yarn tension.
 If packages are dirty.
 Incorrect shape of yarn package.
 Too much knots in the yarn.
 Excessive full bobbin.
 Piecing up.
 Over lapping.
 Two end winding.
 Mixing yarns of different linear density.
 Pattern winding which is the result of the coincidence.
 Greasy and dirty yarn.
 Poor yarn cleaning and snarling.

So, during winding process; production officer should be concern about the defects and faults of
winding.

Wastage in winding: In winding section; wastage is produced due to different causes. Followings
are the main causes of winding wastage.

 Due to knots.
 Ends remaining after tying.
 Yarn slough off.
 Remains of coil on the yarn package.
  Short ends dropped at threading.
 Greasy and dirty yarn.
 Workers negligence.

The amount of wastage depends upon the size of the spinning bobbin and breakage rate. With the
increase of the package size and reduced of breakage rate of yarn, wastage of winding is reduced.

So, we should reduce the wastage of winding

Slasher Sizing Machine | Main Parts of Slasher Sizing Machine

Slasher Sizing Machine:

This is the most used sizing process. About all types of yarns can be sized by slazer sizing
process. In this process the warp is passed through a size liquor bath then through a separating
unit and cooling unit.

The Slasher Sizing Machine consists of the following seven units:

1. Back beam unit

2. Sizing unit
3. Drying unit
4. Cooling unit
5. Dividing unit/Separating unit
6. Measuring and marking unit
7. Beaming unit

Slasher Sizing Machine

Main Parts of Slasher Sizing Machine:

B = guide bar

C = Tension roller

E = Emersion roller

F = sizing roller

G = squeeze roller

H = Drying cylinder

I = cooling fan

J = guide bar

K, L = lease rods

M = coloring bowl

N = wraith
O = measuring roller

P = tension roller

Q = Nipper roller

R = warp beam

S = Pressure roller , U = reserve box, V = marking roller

Parameters of the Process Control of Yarn Sizing

Process Control of Sizing

Sizing of Warp Yarn: The sizing of yarn absolutely essential to render it weavable; without
sizing the end breakage rate of warp, particularly in the case of single yarns, is so high that
weaving becomes impossible. The objective of sizing, however, sizing cannot be looked upon as a
process that improves the basic quality of yarn. The fact is that by endowing the yarn with
abrasion resistance, proper sizing bring out the full potential of a yarn to weave. A properly sized
yarn should have adequate improvement in abrasion resistance, indirectly indicated by the
increase in tensile strength, minimum loss of extensibility and required amount of moisture. For
satisfactory weaving the quality of the beam also important; the beam should be firm and it
should not have excessive missing ends, crossed ends, taped ends (sticky ends) etc., so that it
unwind smoothly in the loom shed.

We also want that in the sized yarn there should be:

1. Some increase in tensile strength in the yarn

2. Minimum loss of extensibility in yarn ( about 4.4-4.6% elongation at break is required for
cotton)
3. Required moisture content ( 8-10% of cotton)
4. Good quality of sized beam (neither too soft nor too firm + free from yarn defects)
5. Good productivity and efficiency
6. Reduced Cost

Some Important Parameters for the Process Control of Sizing:

Process Control in Sizing:

The process control program in sizing should, therefore, comprise of the following aspects:

1. Selecting the correct size recipe and size pick -up level.

2. Ensuring correct ratio of size paste.

3. Control of the followings:

 size pick up
 stretch
 moisture content
 quality of beam
 machine speed
 machine efficiency
 a method to calculate the expected level of productivity

Effects of Sizing on Yarn Properties:

The following properties of yarn are affected by sizing:

 Yarn elasticity decreases.

 Yarn strength increases.
 Hairiness of yarn increases.
 Flexibility of yarn decreases.
 Smoothness of yarn increases.
 Irregularity of yarn decreases.
 Yarn diameter increases.
 Yarn weight increases.
 Factor on which Sizing Recipe depends on:
 Composition of yarn
 Yarn count
 Total no. of ends
 Weight of yarn

Factors Influencing Size Pick up%

1. Viscosity of size paste in size box: Any variation in the concentration or temperature
alters the viscosity of the paste which in turn affects both the level of size pick up and
extent of penetration. Initially as the viscosity increases, the size pick-up also increases.
But as the viscosity increases beyond a point, the size pick up is reduced.
2. Squeezing pressure and condition of squeezing nip: The squeezing pressure determines
the extent of penetration of the size paste between the fibers of the yarn and also of the
removal of excess size paste and hence the level of the size pick up.
3. Speed of the sizing machine: Other sizing conditions remaining unchanged, the size pick
up increases with increasing sizing speed and vice versa. This is because the time
available to squeeze the surplus size from the yarn is less at high speeds.
4. Depth of immersion roller in size paste: the depth of immersion roller in the paste
determines the duration for which the yarn remains immersed in the paste. This duration in
turn influences both the level of size pick up and the extent of size penetration.
5. Level of size paste in the size box: Variation in the level of size paste is an important
source of size pick-up variations both within and between beams.
6. Density of ends: When the density of ends is high, difficulties are encountered in
obtaining adequate and uniform size penetration. Therefore size pick up may vary at these
fabrics.
7. Yarn tension: In case of higher tension during sizing the set of warp yarns encounter a
stretch of comparatively higher tension and thus the set of yarn increases in length. If this
increase is too high then the elongation property of the yarn will be decreased. So the yarn
will face comparatively higher breakage in subsequent processes. On the other hand lower
yarn tension leads to uneven sizing. So the yarn tension must be optimal.
8. Yarn twist: In case of high twisted yarn penetration time should be increased in order to
obtain the optimal pick up %.
9. Dia. of the yarns: Yarn with greater dia consumes higher size paste. Therefore, the higher
the dia of yarn, the higher the pickup will be added.
Drying, Drying Systems Used in Sizing, Cylinder Drying / Hot Air Drying

Drying is a mass transfer process consisting of the removal of water or another solvent by
evaporation from a solid, semi-solid or liquid. This process is often used as a final production step
before selling or packaging products. In sizing, drying is necessary to bring the sized material
hard.

1. Cylinder Drying: In this type of m/c, drying is done by passing over hot cylinders.

a) Two Cylinder Drying: In this drying process, two copper cylinder are used in which one
cylinder is large diameter & other is small comparatively. Firstly warp sheet is passed below the
small cylinder & then over the bigger one. The yarn is dried while traveling through the
circumstances of the cylinder.

Two Cylinder Drying Advantages:

I. Simple process & cheap.

II. Less risky.
III. Temp. uniform.
IV. Almost uniform drying.

Disadvantages:

I. Slow process.
II. Drying efficiency is low.
III. Irregular drying.
IV. Due to sticky property of cylinder uneven drying.

(b) Multi Cylinder Drying:

In this type of m/c, the drying unit consists of 5 to 7 or 11 cylinders having same diameter are
used. All cylinders may be steel cylinders or first two cylinders are teflon coated & rest of aresteel
cylinder. The cylinders are heated by passing steam. Heat in initial cylinder is low & gradually
increases when moved towards final cylinder. If large amount of heat is given to the initial, the
sized may be backed. If finer yarn is used, then no need to use excess cylinder.

Multi Cylinder Drying Advantages:

1. High speed process.

2. Uniform drying.
3. Non- sticky so smooth drying.
4. Drying efficiency high.
5. Less time required.

Disadvantages:

1. For high viscosity, stick properly may observed.

2. For friction, yarn hairiness.
3. Shinning effect.
4. Yarn shape may hamper.
5. Possibility of yarn flaten.
2. Hot Air Drying:

In this m/c, the drying unit is a closed chamber containing a number of guide rollers through warp
yarn. Hot air blown into the chamber causing the moisture in the yarn to evaporate. Exhaustion
should be used to throw away the moisture. If moisture remains inside the chamber it may
condense & again fall on the yarn. Hot air should be continuously passed through the chamber, so
the process becomes somewhat costly.

Hot Air Drying Advantages:

1. Regular drying.
2. Not shinning effect.
3. Non-sticky property.
4. High speed drying.

Disadvantages:

1. Costly process.
2. For closed chamber, required more time.
3. Less suitable for fine yarn.
4. Difficult to maintain temperature.