Introduction

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Warping is the first step of fabric manufacturing. After winding yarn packages are
undergoing warping process to prepare warp beam. 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. The latest beam warping machines have a very
simple design, which results in higher speed & consequently in output increase. In
order to keep pace with the ever-growing demand of increasing productivity
many developments and automations are done in the High-Speed Warping
Machine. In warping pressure is applied on the warp beam to prepare uniform
and circular warp beam. This pressure applied on the beam maintain uniform
density and hardness of the beam. Soft beam shows lower beam content, conical
cross-section of the beam and missing end problem, thus It is important to apply
tension on the warp beam [1-3]. The amount of increase in the beam drum
pressure related with the elongation of the warp yarn during the warping. The
number of cut yarns increases when the yarns are intruded from the guide reed.
When the amount of tension increases on the warp yarns the breakage rate
increases because of the increase in the beam drum pressure. Thus, lower the
beam drum pressure, lower will be the breakage rate at warping, leads to
increase the production rate. Thus, beam pressure is to be optimized set to get
lower end breakages at lower beam pressure as well as higher warp content with
higher beam pressure. The quality of the warp beam i.e. number of breaks, loss in
yarn quality during warping highly affects the warp breakage rate at sizing and
weaving. If the number of breakages is more in warping more breakages will
occur in sizing and subsequently in weaving. Quality of the fabric weave and
number of defects depends up on the breakages occurred in the loom.
Types of warping

1:Beam warping

2: sectional warping
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Direct Warping:

Direct warping is used mainly for producing beams containing mono colored warp threads. The machine
comprises of two main elements namely, the creel and the beadstock. The process involves use of a
creel, where the given numbers of warp bobbins are mounted and from each bobbin, the warp thread is
taken forward up to head stock and then, it is wound on a beam named warper's beam. Due to
limitations of accommodating a very large creel, the number of bobbins which can be taken will be
limited to 1000-1200 only (Adanur, 2001). This number is smaller than the requirement of several
thousands of warp threads in the final woven fabric. So, there is one more process after direct warping
for agglomerating few of the warper's beams to get the final beam suitable for use on the loom. This
final beam is named weaver's beam. The process can be carried out through sizing operation, where, a
costing of size film is applied on the final warp sheet. Alternatively, the beams can be combined by a
simple re-beaming process if the sizing is not required to be done.The process of direct warping is
simple, but has limitation that only single colored warp can be used. Also, the length of yarn to be
wound per beam should be sufficiently large, as the machine is running at speeds of more than 600
mpm. So, direct warping is not a preferred choice for small length production. Warper's beams have the
full width required finelly, but the number of threads is only few hundred as mentioned earlier. So,
length of yarn wound on warper's beam can be very large. As many beams are to be combined at a later
stage, it is very difficult to process warp yarns having patterns. Matching of the patterns will become
highly complicated issue and in complex patterns will be impossible. On the other hand, the production
of the system is very high so suitable and preferred for producing simple varieties at mass scale.

Sectional Warping

There are three main parts of this system: the creel, head stock and the beaming system. The creel is
more or less same as that used in direct warping. Yarn is taken from creel and is brought up to the head
stock in the form of a small width section. As the winding of the yarn takes place section by section
(Majumdar, 2014), there is need to support the yarn sheet particularly when the flanges are not there.
The head stock consists mainly of a one side conical shaped large drum. The angle of the cone can be
fixed or variable depending on the manufacturer Today most of the machines are sold with fixed cone
angle. The yarn is mounted on the flot part of the conical drum. The width occupied by the yarn on drum
will be exactly the width the same yam will occupy on weaver's beam. As the drum starts rotating the
section of the yarn is wound on the drum and at the same time, there is provision to traverse section of
the yam in such a way that shifting of the section occurs towards the raised conical part of the drum.
After completion of winding of the required length, the yarn section is cut and the whole section is
brought back to a point where, second section will start. In similar way, the winding of all the sections,
as per requirement, will be carried out. So, in the end the entire yarn length is now stored on the
drum.Now, transferring the yarn stored on the drum to beam is carried out through a separate beaming
device- an integral part of

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Importance of warping:

1: Construction of Beam warp yarn.

2: Construction of a perrallel Yarn Sheet

3: Modiyifing the faults of yarn like Thick & thin place, large knots etc

4: Combination of Small Package

5 Accelerating the next processes.

Warping process:
Cone from winding

Creeling

Control system

Reed

Measuring device

Winding on beam

Components of warping machine:

 Creel
 Head stock
 Control Device

Warping machine
Warping machine on

Basis on head stock

Sectional Warping machine

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.

Breakages:

1. SIUBS

• Cause: Thick place in warp slubs in the passing through the drop wires heald wires & reedonce Spotted
it is weaver responsibility to remove it to avoid warp break it the Slub: does not pass the reed or to
avoid a Fault in the Slubs goes into the cloth

2. Extra end

• Cause: Guide it through the quide eyes to the winding device.

3. Missing end

• Cause: Take the nearest position extra end and guide it through the guide eyes. To the missing and
postion.

4 Crossed end

• Cause: To be corrected by Weaver

5. Lap end on warp beam

• Cause: It can be an extra end fouse Coming up previously missing end

Coming backFears d boddin.

6. Thick end

• Cause: wrong Ne Take out guide to the winding devide Identify

theendreplaceas incorrect with a labble &with normal end from the extra end reverse

7 Stuck end.

• Cause: Sizing Fault Sperate the end with the help of the guide

8. Spare end bobbin.

• Cause: The extra end provided on the warp beary need to be quide It through the quide eyes to the
guide Spare end bar to the side of the foom then wound onto the spore end bobbin These need to the
leept tidy othewise the tangled raeans will quickly result when the boddin is fulled It need to be stripped
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9 Fluff and fly

• Cause: When pieces of fluff or fly have Settled the worp they on Should be removed immediately to
prevent them from being in fly and fluff attached to woven. machinery should be removed before it
became detached and also into the Cloth

10 Waste/ wild yarn

• Cause: extra piece of yarn which have either been left on a beaty or have dropped in to a loorg remove
then implediately they became entagled on in before woven

11 Broken ends

• Cause: A group of ends is broken & tied as a bouch or worked in With overlapping

12. Snarl

• Cause: Yarn with briks due to insufficent tension after twisting

Minimize end breaks at warping:

1 Control or tension in the yarn

2 Satisfactory maintenance of machineSetting Condition of the machine that

affect

3 minimize the defect of the pacabageproduce at the winding.

4 A reqular Check on the end breakagerate for Corapasion with the normas.

5 The stoppage of the machine due to an end break is likely todeceriorate

the qulity of bears due to three reason.

Quality of warping Beams:

• Condition of beam flanges

• Stop motion and breaks

• Condition of virgs ving drung

• Barrel diametere of Beam

• length measuring motion

• Density of beam
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MACHINE INFO:

• Machine Name: Benninger

Speed settings count wise:

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The sectional warping machine prepares multicolored warps to be woven as striped or checked design
fabrics. It is additionally used for doubled grey or mono-colored warps that do not require sizing. Unlike
the beam or direct warping, where a warper's beam is manufactured and sent to the consequent sizing
processes, in the case of sectional warping, the weaver's beam is manufactured and hence does not
require sizing. In the case of single yarns that are multicolored, the yarns are sized and then coiled on
the sectional warp beam. The yarn is wound in sections, each section having a particular width. Thus the
total number of warp ends for the weaver's beam is arranged into a suitable number of sections on a
warping drum. The sections are then consolidated to form the weaver's beam. Therefore, there are two
sequences of sectional warping:
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Sequence of warping:

Creel

Leasing System

Expandable reed

Length measuring System

Beaming System

Drum for (sectional warping)

Process flow:

Dispo

Yarn from store Machine setup

Creeling

Section wise warping

Beaming
features of Sectional warping:

1. To Produce Fancy fabric of different colour

2. Hand weaving used in sectional warpings

3. To Produce weaver beam from Samall amount of warp yarn

4. To produce weaver beam from two sted

5. A trapped beam drum is used

6. production is less So it is costly processes

7. Yarn tension can not be kept uniform.

Breakages.

1 Snarl formation in the Warp

• Cause: over tension.

• Important twist.

• Postion of guide

2 missing end

• Cause: faulty Stop device

• Absense Cone or bobbin

3 Hard Beam

• Cause: loose warp

4 Crossed end

• Cause: loose warp

5 unequal length

• Cause: Due to faulty measuring device

Sequence of Sectional warping process.

> It is a two stage process, called the warping and beaming Warping is done from creel to drum. Creel
capacity is small as compared to direct warping.

The drum/swift is tapered at a slight angle to provide support to the yarn and

it also prevents the slippage of yarn. Higher the taper angle less will be the package stability

The yams are laid section-wise, starting from the conical base side

The first section is supported by the taper of the base and the subsequent sectionssupported by the
taper formed by the preceding section

. > Each section has multiple ends per sequence required, while section length is the same.

> The number of ends is same in each section, except the last section also known as the cut able
section..

> The sections are traversed on the drum during warping along the width of section to form an angle.

Length of the yarn is measured by the measuring roller.

In this study it is observed that the speed and beam pressure both effects on the end breakage rate at
warping. The increase in speed increases ends, breakage rate, for courser count rise in speed increases
rapidly as compared with medium count. This is due to breakages of weak places and splices in the yarn.
In case of finer count increase in speed shows increment in the end breakage rate with linear
relationship. In warping drum pressure is applied to prepare compact and cylindrical warp beam. This
pressure needs to be optimized as it is observed that beam pressure effects on the end breakage rate of
the warping. The increase in beam pressure increases hardness of the beam consequently tension in the
warp
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