Hafiz Shahbaz Ahmad Virk

Warping

Introduction to Warping

3

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 apackage

Objective of Warping Collection of required number of ends in a fabric

Collection of required number 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)

Flow process of warping

Types of WarpingWarping Input/output

Raw material is Cone/CheeseWarper beam is produced

Types of Warping High Speed Warping (Direct Warping)

Sectional Warping (Indirect Warping)

Ball Warping (Used for Denim Fabrics)

Draw Warping (Heat Set)

High Speed Warping Yarns are withdrawn from the single-end yarn

packages on the creel and directly wound on a beam

Used for longer run of fabric

High production as compared to other types ofwarping

Directly transfer yarn from package to beam.

Number of packages are equal to the number of ends on beam.

Warping Machine

High Speed Warping High Speed Warping can be used in two ways.

a) Direct warping can be used to directly produce the weaver's beam in a single opration

Used for strong yarns that do not need sizing such as high performance yarns e.g kavlar, dyneema, spctra, UHMWPE etc

b) Direct warping used to make smaller intermediate beams called warper’s beams.

These small beams are combined later at the slashing stage to produce the weaver’s beam

This process is called beaming. For example if weaver’s beam have 9000 warp ends, then there would be say 9 warper’s beam then each warper’s beam will contain 1000 ends.

DIRECT HI-SPEED WARPING MACHINE

Applications of direct warping All conventional staple fibers, regenerated fibers and

filament fibrers

In direct warping flange beam is used. All the yarns are wound at the same time so flanges provide sufficient yarn stability on the beam.

Beam flanges diameter are 800, 1000, 1250, and 1400 mm with working width of 1400 to 2800 mm.

COMPONENTS OF WARPING MACHINE

CREEL:1. ConeHolder : 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.

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 Yarn breaks.9. Electrical Panel Board : To give the automatic controlled function.

Yarn Path of High Speed Warping 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

Sectional Warping

Process of winding yarn on tapered or sectionbeam

Package wound on Drum and then Warper/weaver beam produced

Complex colored patterns

Short runs (500-10000)

Sectional Warping

Difference between direct and sectional warping

Difference between direct and sectional warping

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

The creel is normally designed to accommodate about 330 to 430 packages.

The creel may be of different types, such as Magazine Creels and Traveling

Package Creels.

Ball Warping

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

Faults and Remidies in warpingWarp 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.

Snarl formation in the warp: Due to

Poor 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.

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.

Causes of yarn breakage in warping1. 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

Major Components of Warping Machine There are two main parts of warping machineCreelA structure for holding supply packages in

textile processes

▫ HeadstockThe major component of the warping machine

that actually rotates and winds the warp sheet on package (i.e. Warper's beam)

Types of CreelW.R.T Shape W.R.T

H Shaped Creel

V Shaped Creel

Truck/trolley type

Travelling package

▫ Swivel/swinging door

▫ Magazine Creel

▫ Duplicate Creel

▫ Roller Creel

Creel W.r.t ShapeV-Shaped Creel H- Shaped Creel

Wings/Arms are

placed at certain angle

• Yarns do not touch

• Suitable for high speedwarping

Wings are parallel to

each other

• Yarns may touch each other

• Suitable for slow speed warping

Creel w.r.t Constraction• Usually more than one creel is used to save timeIf headstock is

moveable, duplicated creels are used

• If headstock is fixed, a truck/trolley creel is sued

• 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

Parts of 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 tensioners for one package

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

Tension Devices on creel

Head Stock 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

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.

Giude Roller Keeps yarn in proper position and helps locate the broken ends

Pressing Drum

Warper’s Beam

Windshield