NED UNIVERSITY

TEXTILE ENGINEERING DEPARTMENT

WEAVING PREPARATORY PROCESSES
TS-208

‘’MAIN PARTS OF WARPING AND THEIR FUNCTIONS’’

Submitted to:

DR. QURATALAIN MOHTASHIM

Prepared by:

SAFFAN IRFAN SIDDIQUI TS-21074

ATHER UDDIN TS-21072
SYED USMAN SHAMIM TS-21068

Date of submission: 18-May-

2023

Table of Contents
ABSTRACT: ........................................................................................................................................................
5
INTRODUCTION: ...............................................................................................................................................
5
1. WARPING AND ITS MAIN PARTS: .........................................................................................................
7
 1.1. TYPES OF WARPING: ...............................................................................................................................
7
1.12. DIRECT WARPING AND ITS COMPONENTS: ......................................................................................
8
1.13. SECTIONAL WARPING: ........................................................................................................................
10
2. FUCTION OF MAIN PARTS OF WARPING MACHINE: .........................................................................
12
2.1. CREEL AND ITS FUNCTION: ................................................................................................................
12
2.12. TYPES:.............................................................................................................................................. 12
2.2. TENSIONING UNIT: ................................................................................................................................
14
2.21. TYPES OF TENSIONING UNITS: ..........................................................................................................
14
2.3. STOP MOTION: ........................................................................................................................................
16
2.4. CARRAIGE: ..............................................................................................................................................
16
2.41. EXPANDING COMBS: ............................................................................................................................
16
2.5. HEADSTOCK: ..........................................................................................................................................
17
2.51. PARTS OF HEADSTOCK AND THEIR FUNCTION: ........................................................................... 17
2.52. Adjustable or variable v-reed or wraith: ....................................................................................................
17
2.53. Measuring & making device: .....................................................................................................................
17
2.54. Yarn speed controlling device: .................................................................................................................. 17
2.55. PRESSURE ROLLER: ..............................................................................................................................
18
2.56. BREAK ASSEMBLY: ...............................................................................................................................
18
2.57. DRIVING DRUM: .....................................................................................................................................
18
BEAM BRACKET: ............................................................................................................................................
18
BEAM: ................................................................................................................................................................
18
 LEASE RODS: ...................................................................................................................................................
19
IONIZING DEVICES: ............................................................................................................................................
19
2.6. ADDITIONAL PARTS OF SECTIONAL WARPING MACHINE: ........................................................ 19
METERING ROLLER: ......................................................................................................................................
19
FEELER ROLLER: ............................................................................................................................................
20
LEASE BANDS: ................................................................................................................................................
20
CONCLUSION: .................................................................................................................................................
21
References ...........................................................................................................................................................
23

LIST OF FIGURES:

Figure 1: Flowchart of Warp and weft preparation courtesy DSPAT TEXTILE .............................................. 2
Figure 2: Indirect warping machine courtesy google ....................................................................................
7
Figure 3: Direct warping machine courtesy google ......................................................................................
7
Figure 4: Layout of a direct warping machine. Courtesy PETRA TEXIMA. ...................................................
8
Figure 5: Schematic diagram of direct warping machine, courtesy TEXTILE TRIANGLE ...............................
9
Figure 6: Layout of a sectional or indirect warping machine. Courtesy SCIENCE DIRECT. ......................... 10
Figure 7: Schematic diagram of indirect warping machine, courtesy ASIA INCH. ......................................
11
Figure 8: Multiple packages placed on creel. Courtesy SHANGZHOU TEXTILE MACHINES. .......................
12
Figure 9: Design of a V-creel. Courtesy KARL MAYER. ................................................................................
13
Figure 10: Schematic diagram of magazine creel. Courtesy TEXTILE APEX. ...............................................
13
Figure 11: Picture of a swivel frame/creel. Courtesy TEXTILE COACH. .......................................................
14
Figure 12: Different types of tensioning devices, courtesy textile learner .................................................
14
Figure 13: Disc tensioner, courtesy KARL MAYER. ......................................................................................
15
Figure 14: Electronic tension meter, courtesy CHECK LINE .......................................................................
15
Figure 15: Picture of stop motion, courtesy KARL MAER ...........................................................................
16
Figure 16: Picture of expanding comb. Courtesy INDIAMART ....................................................................
16
Figure 17: Schematic diagram of a part of headstock. Courtesy SCIENCEDIRECT ......................................
17
Figure 18:This figure depicts a V-reed. Courtesy BLUEREED ......................................................................
17
Figure 19: This figure depicts pressure roller. Courtesy PRISM TEXTILE TECHNOLOGY ............................. 18
Figure 20: This figure depicts an empty beam. Courtesy SUNTECH TEXTILE MACHINERY .........................
18
Figure 21: This figure shows feeler roller.................................................................................................... 20
Figure 22: This figure is showing the leasing process. ................................................................................
20

LIST OF ABBRIVIATIONS:
RT = Removable bobbin Trucks

Nm = Normal Metric FC =

Fixed Creel m/c = Machine

m/min = Meters Per Minute

MDS = Machine Data Station

A/C = Alternating Current

PLC = Programmable Leasing Control

Main part of warping machine and their funtion

ABSTRACT:

The aim of this report is to provide knowledge about warping machine, its components and their
functions. The warping process in textile manufacturing involves the preparation of warp yarns,
and its key components and functions are essential for understanding the process. The creel holds
the yarn cones or packages, ensuring controlled unwinding with proper tension. Tensioning
devices maintain consistent tension along the warp yarns. Lease rods or lease reeds maintain
separation and order of the yarns, preventing entanglement. The harness or reed guides and
separates the yarns as they are wound onto the beam, ensuring alignment. The beam securely holds
and winds the yarns, while the drum provides tension and control during winding. The trolley
supports and transports the warp beams, facilitating their movement and positioning.
Understanding these main parts is crucial for achieving high-quality warp yarns and ensuring
efficient textile production.

Keywords: Warping, Components of warping machine, creels, headstock, controlling devices.

INTRODUCTION:

Weft yarn doesn't need to be prepared in any particular way, whereas warp yarn must go through
a series of steps known as warp preparation before being converted into fabric. The procedures
that make up the warp preparation process are winding, warping, sizing, and drawing-in.
Spinning produces yarns that are incorporated into the warp preparation process. The yarn can be
better prepared for a package that needs shape and size by winding. The weft yarn is then
delivered to the loom, and the warp yarns are processed through the warping process to create a
sheet of yarns on the warp beam. In the process that follows, a coating of size material is placed
to the yarn to give it strength and smoothness. This warp sheet is then drawn in from the
droppers, heald frames and the reed. [1] Each place in the warp yarn must have thousands of
different tensions applied by the weaving machine. To put it briefly, warping is the process of
moving a number of yarns from a creel of single-end packages to produce a parallel sheet of
yarns wound onto a beam or section beam. Warping machines can now process the great majority
of materials, including staple yarns, coarse and fine filament, and both. Warping is done to get
the weaver's beam ready for setup on the weaving machine, depending on the kind of
intermediate carrier that is being utilized. [2]

There are two distinct technologies that can be used in industrial warping: [3]

Beam warping or direct warping (preparatory beam warping)

P a g e 1 | 19
Main part of warping machine and their funtion

Sectional warping (conical drum or dresser warping)

Figure 1: Flowchart of Warp and weft preparation courtesy DSPAT TEXTILE

Due to quicker weaving speeds and the use of insertion mechanisms other than the shuttle,
modern weaving machines have raised the requirements for warp preparation; warp yarn must
have uniform qualities. Uniform tension is required to ensure that all the warp ends behave
consistently during weaving and have enough strength to sustain tension and frictional abrasion.
[2]

1. WARPING AND ITS MAIN PARTS:

The definition of warping is Warping entails wrapping parts of the warp yarns, typically from
bobbins, on a warping beam, whereby successive parts are twisted next to each other until the
complete weaving width is covered. The warping beam is typically utilized for beaming in the
following stage of warp preparation. While beaming is described as "Beaming comprises

P a g e 2 | 19
 Main part of warping machine and their funtion

winding the full width of the warp yarns on the weaving beam (i.e. the beam that is to be placed
on the loom) in a single winding operation." A creel or a warping beam can be used to wind the
warp strands. The yarns are moved from a number of supply packages (cones) to the warp beam
during the warping process in the shape of a parallel sheet. The primary goal of warping is to
obtain the necessary number of ends. High speed/direct warping, sectional/indirect warping, and
ball warping are the three primary types of warping. In direct warping, the yarns are taken out of
the cone-shaped single-end yarn bundles that are located on the creel and wound right on a beam.
To obtain the necessary number of ends, a number of beams are twisted. For instance, 8 beams
with 755 ends each will be warped to create a fabric with 6040 warp ends. The sizing process
then combines these beams into a single beam. [1]

1.1. TYPES OF WARPING:

There are two most popular methods of carrying out the warping process as below: [4]

• Direct warping • Sectional warping

Figure 2: Direct warping machine courtesy google

Figure 3: Indirect warping machine courtesy google
1.12. DIRECT WARPING AND ITS COMPONENTS:
Direct warping is typically used to create beams with only one color of warp thread. The creel
and the headstock are the two primary components of the machine. The procedure makes use of a
creel, on which the specified number of warp bobbins are mounted. The warp thread is then
brought forward from each bobbin up to the head stock and wound onto a beam known as the
warper's beam. The number of bobbins that can be taken will be restricted to 1000–1200 only
due to the restrictions of accommodating a very large creel. [2] This amount is less than the final
woven fabric's requirement of thousands of warp threads. So, after direct warping, there is
another process for combining a few of the warper's beams to produce the ultimate beam
suitable for use on the loom. Weaver's beam is the name of the last beam. The procedure can be
completed by performing a sizing operation, which involves covering the final warp sheet with a

P a g e 3 | 19
Main part of warping machine and their funtion

size film. If the sizing is not necessary, the beams can also be blended using a straightforward
rebeaming procedure.

Figure 4: Layout of a direct warping machine. Courtesy PETRA TEXIMA.

Direct warping is a straightforward method, although it has the drawback of only supporting one
color of warp. Additionally, given that the machine runs at speeds of more than 600 mpm, the
length of yarn that must be wound onto each beam must be sufficient. Direct warping is therefore
not the best option for manufacture of short lengths. Finally, the warper's beams are the full
width required, but as was already mentioned, there are only a few hundred threads. So, the yarn
length wound on the warper's beam can be quite long. Processing warp yarns with designs is
quite complex because several beams will be combined afterwards. Pattern matching will

become a very difficult problem and unattainable in complex patterns. On the other hand, the
production of the system is very high so suitable and preferred for producing simple varieties at
mass scale. (1) In direct warping, the yarns are withdrawn from the single-end yarn packages on
the creel and directly wound on a beam. Direct warping is used in two ways:

a) Direct warping can be used to directly produce the weaver's beam in a single operation.
This is especially suitable for strong yarns that do not require sizing such as continuous filaments
or monofilaments and when the number of warp ends on the warp beam is relatively small. This
is also called direct beaming.

b) Direct warping is used to make smaller, intermediate beams called warper's beams.
These smaller beams are combined later at the slashing stage to produce the weaver's beam. This
process is called beaming. [3]

P a g e 4 | 19
Main part of warping machine and their funtion

COMPONENTS OF DIRECT WARPING:

The latest beam warping machines have a very simple design, which results in higher speed and
consequently in output increase. The main machine elements are: [3]

• Creel

• Expanding comb

• Pressure roller

• Beam.

Figure 5: Schematic diagram of direct warping machine, courtesy TEXTILE

TRIANGLE
1.13. SECTIONAL WARPING:

The yarns from the yarn package are wound in bands onto an intermediate drum called Pattern
Drum and are then transferred onto a warp beam in a separate operation. This method of warping
is employed when fancy colored patterns of warp are need or the capacity of creel is limited. [5]
This method of warping is generally carried out for yarns under the conditions where there is no
need for any application of starch, such as twofold cotton or woolen/ worsted warps, for shorter
runs of high-class goods, for colored yarns, that is, patterned warps for wool and worsted fabrics,
etc., where a small number of cones is to be used because of the quality of the fabric to be
produced, mostly colored warps Compared to direct warping, the number of cones used is
generally much smaller. Warper’s beams are not produced in this process and the warp is directly

P a g e 5 | 19
Main part of warping machine and their funtion

transferred from the drum onto the weaver’s beam(s). The process involves two stages: 1.
Warping of a number of sections with the required number of yarns onto a conical drum. 2.
Beaming off, that is, transferring the yarns from all the sections in a sheet form onto a weaver’s
beam. [4]

Figure 6: Layout of a sectional or indirect warping machine. Courtesy

SCIENCE DIRECT.

MAIN COMPONENTS OF SECTIONAL WARPING:

A sectional warping plant is composed of: [3]

Creel

Dresser or drum

Trolley

Warping carriage

Leasing and splitting devices for sizing

Beam carrying chuck

P a g e 6 | 19
Main part of warping machine and their funtion

Figure 7: Schematic diagram of indirect warping machine, courtesy ASIA

INCH.

2. FUCTION OF MAIN PARTS OF WARPING MACHINE:

2.1. CREEL AND ITS FUNCTION:

The problem of positioning the packages from which the yarn is taken in such a manner so as to
facilitate the removal of yarn, it is logical, therefore, to build a frame of some sort to hold the
packages this frame is known as a creel and its function is to hold the supply packages in a
manner so as to facilitate warping to accomplish this purpose creels are equipped with package
holders on which the supply packages are placed, tension devices to help maintain uniform
tension throughout the creel, guides to direct charges created by the rubbing of the yarn against
the various surfaces and stop motions to detect
broken ends and/or empty packages. [6]

2.12. TYPES:
There are different types of creels that are used
according to the situation:

P a g e 7 | 19
Main part of warping machine and their funtion

single-end creel fixed frame creel magazine creel duplicate creel creel with removable bobbin

trucks (RT) swiveling frame creel. [1]

Figure 8: Multiple packages placed on creel.

Courtesy SHANGZHOU TEXTILE MACHINES.
Creel with removable bobbin trucks (RT)

Trolley creels have generally two series of trolleys: one in operation and one waiting for being
creeled, this system is suitable for staple fiber yarns in counts ranging from Nm 10 to Nm 140,
for staple fiber yarns also mobile creels are used. These can be equipped with a series of trolleys
for the transport of the reserve cones; as an alternative, two creels with stationary cone carrier
frame are used together with the warper, in both cases the bobbins are creeled during warping.

V-creel

For cotton, viscose, polyester/cotton mixed yarns, and

colored wool, we can use parallel creels with swiveling
package frame portions or V-creels with reversible frames;
nevertheless, for polypropylene and monofilaments, we can
use parallel creels with unrolling draw-off. creel
Single-end creel

This type of creel is generally used when the factory requires the Figure MAYER.9 : Design of a V-creel.

Courtesy KARL running of short lengths of warp or where it is necessary to make frequent changes in
yarn counts or quality. Only one cone holder is provided for each package.
When the packages are exhausted, the empty cones are removed and replaced with fresh ones.
During this period, the warping machine remains idle.
Magazine creel

For luxury yarns and synthetic filaments, the

socalled magazine creels are used, which enable
to creel two cones per creeling position and to
piece head-tail end of two cones creel.
Trolley creels Trolley creels have generally two

series of
Figure 10: Schematic diagram of magazine creel. Courtesy
trolleys: one in operation and one waiting for being TEXTILE APEX.

P a g e 8 | 19
Main part of warping machine and their funtion

creeled, this system is suitable for staple fiber yarns in counts ranging from Nm 10 to Nm 140,
for staple fiber yarns also mobile creels are used. These can be equipped with a series of trolleys
for the transport of the reserve cones; as an alternative, two creels with stationary cone carrier
frame are used together with the warper, in both cases the bobbins are creeled during warping.
[4]
Fixed frame creels
Fixed creels are often used in pairs enabling one creel to be running, whilst the other is being
preloaded. shows the design of a fixed creel (FC) with a fixed double-sided package frame. By
opening the tensioned frames which are mounted on ball bearings, the distance between the
package top and the yarn tension units can be adjusted, depending on the ballooning of the yarn.
The creel can be hydraulically opened and closed by means of a push button. Another widely
used new fixed frame creel is available.

P a g e 9 | 19
Main part of warping machine and their funtion

Swivel frames
While yarns are unwound from the bobbins placed in
the inside of the creel, it is possible to creel at the
outside of the creel the new lot of cones

Figure1 : Picture of a swivel frame/creel. Courtesy

TEXTILE
1 COACH.
2.2. TENSIONING UNIT:
Every contemporary creel has a tensioning unit for each bundle. These come in mechanical and
electrical varieties. There are numerous tensioning systems that can accommodate a wide variety
of yarn counts and varieties. The disc tension device is the most basic. Before proceeding from
the creel, the thread is taken from the packaging,
guided through an eyelet, and then wrapped around
two tiny pins. Weighted discs are positioned over the
yarn to tighten it up if necessary. For the most part, this
technique works with cotton and wool. However,
porcelain adapters are added to the steel posts or pins
for delicate yarns like silk and filament.

2.21. TYPES OF TENSIONING UNITS:

Different types of tensioning devices exist:

Figure 12: Different types of tensioning devices,
Self-compensating tensioner-type DTR courtesy textile learner

Regardless of speed or package size, it is intended to keep a consistent yarn tension on a specific
setting with cops, conical, or cross-wound packets as well as to maintain a constant yarn tension
from full to empty packages. Differences in tension are maintained to a minimal since the tension
unit compensates for the package's reduction in diameter during warping. The compensating
wing's hydraulic dampening action reduces tension peaks, allowing the yarn sheet to flow
smoothly. For a wide range of yarn counts, various varieties are offered.

P a g e 10 | 19
Main part of warping machine and their funtion

Adjustable disc tensioner-type DT

The high tension technological applications for which this tensioner DT was developed. A
ceramic roller with a large deflecting radius of 12mm is used to deflect the yarn. Fiberglass,
industrial, or thick filaments and spun yarns are perfect for it.
Mechanical self-compensating tensioner

Regardless of the many colors on the creel, the various types and counts of yarn, or the
variations in package diameter, these units maintain a constant tension. The tension units
reset themselves as the vehicle comes to a stop, maintaining the yarn's stretch.
Electronic tension units

Figure 13: Disc tensioner, courtesy KARL MAYER.

The majority of contemporary warping machines
come with various kinds of electrical tension units for
packages on the creel. It has a fully programmable
tension control system, stores 999 styles, a custom
application for speedy installation, an automatic
tension profile from front to back, constant tension
across the yarn sheet, constant tension regardless of
speed, is computer calibrated, has motion sensors for
detecting broken ends, can identify individual ends,
has a programmable response time to reduce lost ends,
and is touch screen. Figure 14: Electronic tension meter, courtesy CHECK
LINE
FCO type (exterior yarn sheet)

The FCO type consists of movable outside tensioner frames and a fixed central package
frame. The easiest way to access the yarn sheet makes this structure the most popular because
it allows for quick yarn break repairs. [4]

P a g e 11 | 19
Main part of warping machine and their funtion

FCI type (Inside yarn sheet)

The FCI type consists of a center moveable tensioner frame and a fixed outside package
frame. This approach offers the least amount of angle deviation, making it especially ideal for
fine and fragile yarns. [4]

2.3. STOP MOTION:

When any fluff, broken filament, fluff ball, or loop is detected, the machine is stopped at a
fixed position. Defects on yarns are easily removed.
[2] A thread stop motion is included with every
warping machine. When a thread breaks, the stop
motion stops the machine right away, saving the
damaged thread from getting lost behind later
layers of yarn on the beam. To help the operator
locate the exact spot where the end is damaged and
fix it, a light at the stop motion unit lights. When an
end breaks, the operator finds the broken end from
the cone, moves it forward to the Figure 15: Picture of
stop motion, courtesy KARL
MAER
beam and ties it to the broken end from the beam
after passing it through the tension unit and thread stop motion. When any co or cheese is
finished and the machine stops, the same procedure is followed. [4]

2.4. CARRAIGE:
The levelling roller, the guiding and measuring roller, and the expanding or warping comb are
all carried by the carriage, which moves in a traverse motion.

2.41. EXPANDING COMBS:

The expanding comb aims to keep the threads organized and

free of tangles by positioning them all on a width that
corresponds to the beam width. The comb's zigzag design
allows it to be adjusted to fit various beam lengths. The comb
includes two traverse motions: a horizontal traverse to evenly
distribute the threads on the beam and a vertical traverse to

P a g e 12 | 19
Main part of warping machine and their funtion

prevent local wear of the dents. The blowing system makes Figure 16: Picture of expanding comb. Courtesy
sure that the comb is always free of dust. [3] INDIAMART

2.5. HEADSTOCK:

The dresser or drum is made of a large sheet of steel that has had its outside surface precisely
turned, and it has a series of slope control knives (rulers) attached to the end of it that
together form a cone with changeable taper. However, there exist warping devices with set
taper as well. The dresser is a creel component on which the carriage-guided threads from the
creel are wound, section by section or directly. The initial taper ratio effectively functions as
a backing flange by supporting the different thread layers that superimpose one another
during warping in indirect warping..

2.51. PARTS OF HEADSTOCK AND THEIR

FUNCTION:

ADJUSTABLE OR VARIABLE V-REED:

Figure 17: Schematic diagram of a part of headstock. Courtesy SCIENCEDIRECT

P a g e 13 | 19
Main part of warping machine and their funtion

To control the width of the warp beam adjustable or

variable V-reed is used. It is an essential component of
headstock.

MEASURING AND MAKING DEVICES:

Measure the amount of warp yarn on the beam & marks

the yarn. The system incorporates continuous measuring and
monitoring of yarn built-up by a contact-less laser sensor system right from the first section and offers a
very high accuracy. [4]

YARN SPEED CONTROLLING DEVICES:

To control the speed of yarn, yarn speed controlling devices are used. ISOWARP provides
warping speed of 800m/min and beaming speed of 200m/min. [4]

PRESSURE ROLLER:

Hard cardboard is used to cover the pressure roller. The

pressure roller rolls backward in opposition to the
resistance provided by the pressure at the predetermined
value as the thickness of the yarn wound around the beam
increases. This compression results in precisely
cylindrical beams. The pressure roller is instantly raised
by a hydraulic control device during the braking period.
Figure19: This figure depicts pressure roller.
When creating dye beams, the pressure is set at extremely Courtesy PRISM TEXTILE TECHNOLOGY
low levels to permit the creation of beams with supple
winding that the dyeing liquids may easily penetrate. [3]

BREAK ASSEMBLY:

It is a part of warping machine that works as the name suggests, it stops the m/c after read length
is wound on beam. [4]

2.57. DRIVING DRUM:

In the warping process, The Beam is in contact with the driving drum and it is been controlled
with the driving drum. [4]

BEAM BRACKET:

In warping machine a beam bracket or beam holder is present to support the beam and to hold
the beam. [4]

P a g e 14 | 19
Main part of warping machine and their funtion

BEAM:

A three-phase induction motor that requires no

maintenance drives the beam in contemporary warping
machines. Since it is a direct drive, the frequency of the
feeding current is changed using an inverter to provide
a constant winding speed while the diameter of the
beam increases. In certain warping machines, the beams
are driven by pins, whereas in other warpers, the beams
are driven by self-centering conical toothing that
meshes with the matching bevel wheels on the beam
flanges. The beams from the same warping batch must Figure20: This figure depicts an empty beam.
be coiled with yarn that is exactly the same length Courtesy SUNTECH TEXTILE MACHINERY
throughout. The reason is that the batch must be finished as soon as the initial beam runs out
of fuel during the following beaming. The extra lengths of yarn which remain on the other
beams are therefore to be considered as waste.

DIRECT BEAM: Low-thread-count warps can be coiled up directly from the creel onto the
weaver's beam. An expandable comb and other essential thread guiding components are installed
on a moveable platform. A motor propels the comb in a horizontal traverse action.

LEASE RODS:

Used for separation of yarn individually.

OPTIONAL DEVICES:

IONIZING DEVICE:

It is used in modern warping machines to prevent the formation of electrostatic charges during
the processing of non-conductive yarns.

BEAM INERTIA COMPENSATOR:

In the warping process the beam braking pressure appropriate for the winding diameter reduces
excess tension during deceleration.

2.6. ADDITIONAL PARTS OF SECTIONAL WARPING MACHINE:

METERING ROLLER:

P a g e 15 | 19
Main part of warping machine and their funtion

The section is precisely guided by the guide and metering roller, which is located a very small
distance from the section's point of contact with the dresser. Additionally, it must measure the
tension in the area just before the point of contact and provide this information to the computer.
An impulse is generated if the measured tension differs from the setup tension.

FEELER ROLLER:

A precise uniform height on the warping drum is not always possible with constant yam
tension in the creel. A feeler roller can be used to create an exact uniform height. The feeler
roller is firmly pressed up against the warping drum before the warping process begins. As
soon as the warping process begins, the roller begins monitoring the yarn's accumulation
using an electrical sensor. Depending on the yarn's density, a force opposes the feeler roller.
Additionally, each succeeding portion places less force at the same height on the feeler roller.
The yarn gathers up and pushes the feeler roller back. [2]

A feeler roll guided by pneumatic closed loop A/C servo drive is

provided on warp table to offer high precision, uniform,

Figure 21: This figure shows feeler roller.

compact, and tidy warping. This actuates controlled pressure over warp section on drum. On
stopping of warping operation, the feeler roll retracts automatically so as to avoid partial
abrasion on yarn resulting in the formation of a compact package at low thread tension. [4]

LEASE BANDS:

Section warping makes use of lease bands. A lease band is introduced in the
axial direction of the beam after a few initial spins. The lease bands can be

P a g e 16 | 19
Main part of warping machine and their funtion

used to count the amount of yarn layers during unwinding. The warping speed with a
conventional leased reed is up to 600 m/min. [2]

Pneumatic leasing device is provided to ensure precise and smooth operation and is
programmed by programmable leasing control (PLC) for tilting the split rod frame
simultaneously for seven lease operations. [4]

Figure 22: This figure is

showing the leasing

process.
SECTION TENSION CONTROL:
In spite of package diameter and speed, this control feature ensures constant thread tension at all
times. Once determined, the needed yarn tension in the warp section is continuously monitored
by a load cell, which then sends a signal to the creel PLC in a closed loop with the main machine
PLC, accurately regulating the yarn tension. [4]

CONCLUSION:

In conclusion, the warping process plays an essential role in preparation of warp yarn which
facilitates weaving. The warping process in textile manufacturing involves several key
components, each playing a vital role in ensuring the successful preparation of warp yarns. The
creel ensures controlled unwinding of yarns, while tensioning devices maintain consistent
tension throughout the process. Lease rods or lease reeds prevent entanglement and maintain
yarn order, and the harness or reed guides and separates the yarns during winding. The beam
securely holds and winds the yarns, while the drum provides tension and control. The trolley
facilitates the movement and positioning of warp beams. Understanding the functions of these
main parts is essential for achieving high-quality warp yarns and ensuring efficient textile
production. By optimizing the performance of each component, textile manufacturers can
enhance productivity and produce fabrics of superior quality.

P a g e 17 | 19
Main part of warping machine and their funtion

P a g e 18 | 19
REFERENCES FOR FIGURES:
FIG 1: https://www.dspattextile.com/2022/06/preparatory-process-of-weaving.html
FIG 4: https://petratextima.com/wp-content/uploads/2020/07/Direct-Warping-Machine.png
FIG 6: https://textiletriangle.com/sm/weaving/
FIG 3&7: https://ars.els-cdn.com/content/image/3-s2.0-B9780081006863000062-f06-
049780081006863.jpg
FIG 8: https://encrypted-
tbn0.gstatic.com/images?q=tbn:ANd9GcQL3bBPvsQPvOyHCbaMas_dR_Ad7sTCce4QbQ&usq
p=CAU
FIG 2&9: https://www.prismtextilemachinery.com/warping-creels.html
FIG 10: https://www.karlmayer.com/en/products/warp-preparation/creels/creels-for-spun-
yarnsand-filament-yarns/
FIG 11: https://www.textilecoach.net/post/types-of-creels-creels-in-warping
FIG 12: https://www.karlmayer.com/en/products/warp-preparation/creels/creels-for-spun-
yarnsand-filament-yarns/
FIG 13: https://www.pinterest.com/pin/361625045086445858/
FIG 14: https://www.amazon.com/VICASKY-Warping-Tensioner-AdjustingTensioning/dp/
B09YQZNDMH
FIG 15: https://www.checkline.com/product/KXE
FIG 16: https://www.karlmayer.com/en/news-and-media/news/constant-control-of-yarn-tension/
FIG 17: https://www.indiamart.com/mpindustries-mumbai/other-products.html
FIG 18: https://www.sciencedirect.com/topics/engineering/headstock
FIG 19: https://bluereed.es/en/reeds/front-reeds-of-sectional-warping-machines/
FIG 20: https://www.prismtextilemachinery.com/warping-machine.html
FIG 21: https://www.suntech-machine.com/product/warp-beam-70.html
FIG 22: https://www.kyangyhe.com/en/category/Yarn-Warping-Machine-Series/CATE-
warpingmachine.html

P a g e 19 | 19
FIG 23: https://www.youtube.com/watch?reload=9&v=UXY-l0ePpXI

References

[1] Khubab Shaker, Muhammad Umair, Waqas Ashraf, Yasir Nawab, "Textile Engineering," in Textile
Engineering, D. Y. Nawab, Ed., pp. 47-83.

[2] S. Adanur, Hand book of weaving, 1st ed., Suzler, Ed., Alabama: CRC Press, 2001.

[3] Giovanni Castelli, Salvatore Maietta, Giuseppe Sigrisi, Ivo Matteo Slaviero, "Weaving," in REFERENCE
BOOKS OF TEXTILE TECHNOLOGY, ACIMIT, 2000, pp. 1-93.

[4] K. Gandhi, "Warping," in Yarn preparation for weaving, Manchester, The Textile Institute, pp. 82118.

[5] Mr. Mohammed Javed, Ms. Shubhangi Yadav, Woven Textiles, Gandhinagar, Mumbai: Shiksha Kendra,
October 2013.

[6] D. ME, "Warp Yarn Material and Cone position on Warping Creel," Journal of Textile Science &
Engineering, pp. 1-6, Aug 2014.

[7] Recep Eren, Merve ihtiyar, Ozge Celik, "Experimental Investigation Of The Performance of feedback
tension control system designed for warping machine," Tekstil ve konfeksiyon, vol. 29, no. 4, pp.
289-299, 10 2019.

P a g e 20 | 19