Winding

Winding
The yarn from the spinning is not adequate in quantity and quality for weaving.
It contains a number of imperfections in the form of thick places, thin places and slubs.
These will pose problems in the subsequent process and ultimate hinder the cloth
quality. Also the ring cop is small in size and needs to be converted into a bigger
package. The winding process achieves the twin objectives of reducing the
imperfections in the ring yarn as well as converting it into bibber package in the form of
cone/cheese.
Thus the ring cop which weighs about 60 - 80 grams is converted into a package of 1.5
to 2 kgs. Heavier packages of about 5kgs is used for synthetic textured yarns.
“Winding is the process of transferring yarn from
one type of package to another e.g. from spinners
packages to cones.” It may be electrical or mechanical.
▪ Warp: cone, cheese, flanged bobbin
▪ Weft: pirn, cop
Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 2
 Winding
Objects of winding
▪ To transfer yarn from one package to another package, this can be conveniently used
for the weaving purposes.
▪ To make a continuous supply of yarn in the subsequent process.
▪ To remove yarn faults like hairiness, neps, slubs, and foreign matters.
▪ To produce long length of yarn by serially joining one yarn package with another.
▪ To clean the yarn.
▪ To improve the quality of yarn.
▪ To improve the efficiency of yarn for next process.
▪ To get a suitable package.
▪ To remove thick & thin place of yarns.
▪ Improvement of cops building for uniform dyeing with package dyeing.
▪ Paraffin waxing of the yarn during the winding process.
▪ Introduction into the yarn of a minimum number of knots.
▪ Achievement of high machine efficiency i.e. high production level.
Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 3
 Winding
Requirements of winding
▪ Minimize the yarn fault e.g. slubs, neps, thick and thin places.
▪ During winding the mechanical and physical properties of yarn should not be
impaired.
▪ The winding package should be built so as to ensure an easy running-off of yarn in
warping at a high speed.
▪ The package should contain a yarn of maximum length.
▪ To maintain the size and shape of the package for end use.
▪ The package size should be controlled for the particular economic requirements.
▪ The amount of yarn wastes must be small.
▪ Avoid excess looseness and tightness, the package should be standard.
▪ Winding speed should be uniform.
▪ The package should be cheaper; above all the process must be profitable.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 4

 Winding
Schematic diagram of Winding

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 5

 Winding
Schematic diagram of Winding
It has three sections
1. The unwinding zone,
2. The tension and clearing zone, and
3. The winding zone.

The unwinding zone:

To rewind the yarn on a new package, it must first be removed from the old
package. This is accomplished in the unwinding zone. This zone merely consists of a
creel, which holds the old package in an optimum position for unwinding. The common
yarn withdrawal methods, side withdrawal and over-end withdrawal.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 6

 Winding
The tension and clearing zone:
The next zone is the tension and clearing zone. In this zone, tensions are applied
on the yarns by using tensioners so that yarns are wound on the package with proper
compactness. The objectionable yarn faults (thick & thin spots, slubs) as well as other
contaminants (coloured and foreign fibres) are also removed by using optical or
capacitance based yarn clearer.
This zone consists of a stop motion which causes the winding to stop in the case of a
yarn break or the depletion of a supply package. The yarn is directed into this zone by a
guide.

The winding zone:

In the third and final zone, yarns are wound on the package by means of
rotational motion of the package and traverse motion of the yarn guide. Based on the
operating systems employed in the winding zone, two major winding principles have
evolved.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 7

 Winding
Yarn Withdrawal
Removal or unwinding of yarn from package during weaving is called
withdrawal of yarn.

There are two types of yarn withdrawal:

1. Side withdrawal
2. Over end withdrawal

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 8

 Winding
Side withdrawal
In side withdrawal, the spool must rotate in order for the yarn to be removed.
Typical uses of side withdrawal are to be found in the various operations on a warp. In
view of the multiplicity of ends in a warp it is virtually impossible to use anything but
side withdrawal.

Features:
▪ Package will rotate in side withdrawal.
▪ Yarn twist will be unchanged.
▪ No balloon formation.
▪ It is applied to flanged bobbin.
▪ The rate and speed of unwinding is slow.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 9

 Winding
Advantages:
▪ The yarn does not rotate upon withdrawal.
▪ The yarn twist remains constant.

Disadvantages:
▪ At high winding speeds, due to inertia, the rotation of the spool may lead to tension
variations in the yarn.
▪ This process is costlier for practical use.
▪ High speed impairs the stability of the package.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 10

 Winding
Over end Withdrawal
This method is the simplest and most common method of yarn withdrawal. The
yarn is to take away along a line which roughly coincides with the axis of the package.
Using this technique it is not necessary to rotate the package.
It is used in circumstances where high unwinding speeds are required, such as in high
speed beaming and the removal of yarn from weft packages.

Features:
▪ Package remain stationary during unwinding.
▪ Formation of balloon occurs.
▪ Twist/inch of yarn changed.
▪ Generally cop, pirn, cone, cheese are packages used for over end withdrawal.
▪ The rate of unwinding is high.
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 Winding
Advantages:
▪ Very high rates of yarn withdrawal.
▪ Not so expensive.
▪ Not necessary to rotate the package.
▪ Flanged bobbin is not required.

Disadvantages:
▪ Balloon formation.
▪ There is a chance of one turn twist in the yarn.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 12

 Winding
Difference Between Side Withdrawal and Over End Withdrawal
Side Withdrawal Over End Withdrawal
1. Package must rotate 1. Package is stationary
2. No balloon formation 2. Balloon formation
3. Yarn twist is not changed 3. Yarn twist is changed
4. The process is costlier for practical uses 4. The process is cheap
5. High speed decreases the stability of 5. More stable packages
packages
6. Needs flanged bobbin 6. No need of flanged bobbin
7. Unwinding is not fast 7. Unwinding is fast
8. Possibility of yarn tension variation 8. No possibility of yarn tension
variation

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 13

 Winding
Ballooning/Balloon Theory
▪ The rotation applied to departing yarn drawing at high speed of the yarn unwinding
from a stationary spinning cop, the yarn is thrown by centrifugal force away from the
cop axis and circumscribes in space of plane is called balloon. The theory is called
balloon theory. It is characterized by the height ‘h’ as shown in figure.
▪ In the process of yarn unwinding from the cop every element of the yarn in the
balloon performs a complicate movement along the yarn axis and a rotational
movement around the cop axis.
▪ The shape of the balloon depends on the tension of the yarn at unwinding from the
cop. The balloon is more salient when the tension is reduced and in this case the
conditions of yarn unwinding from the cop are better. When the tension is increased
the balloon becomes gently sloping.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 14

 Winding
Ballooning/Balloon Theory

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 15

 Winding
Balloon size depends on
▪ Yarn count:
Higher the yarn count, lighter the yarn together with higher the balloon size.
▪ Yarn winding/unwinding rate:
Higher the speed of winding/unwinding higher the centrifugal force is produced;
hence larger balloon is formed.
▪ Size of the package:
If the package is larger for the same lift then the height of the balloon will be
larger.
▪ Lift of the package:
Higher the lift of the package then the larger balloon is formed.
▪ Position of the guide:
If the yarn guide is placed at larger distance from the yarn package, then larger
balloon is formed.
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 Types of Winding Packages

There are three types of winding packages, which are pointed out in the below:
1. Parallel winding or parallel wound package
2. Near parallel winding or near parallel wound package
3. Cross winding or cross wound package

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 Parallel winding or parallel wound package

➢In this type of winding package, yarn is wound parallel to each other on the
package containing flanges on both sides of package. In case of parallel winding
package, traversing guide does not required.
➢ It is necessary to have a flanged package.
I. Warp beam
II. Weaver beam

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 18

 Advantages of Parallel winding or parallel wound package
➢In this package, so many yarns can be wound at a time.
➢No change of twist during winding.
➢The package is stable here.
➢There is a possibility of side with drawl here.
➢Yarn density is more.
➢Traversing mechanism is not needed.

Disadvantages of Parallel winding or parallel wound package

➢Here, two sides of the winding package has needed flanged.
➢Over end withdrawal is not possible here.
➢Needed separate mechanism for yarn unwinding.

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 Near parallel winding or near parallel wound package

➢In case of near parallel winding or near parallel wound package, the package
contains one or more yarn which are laid very nearly parallel to the layers and
which are already existing on the winding package.
➢For instance, Pirn, Cop.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 20

 Near parallel winding or near parallel wound package

Advantages:
➢Flanged is not necessary here.
➢During winding, no change of number of yarn turns per inch or twist.
➢The package is comparatively stable.
➢Over end withdrawal is possible here.

Disadvantages:
➢Side withdrawal is not possible here.
➢Traversing mechanism is required here

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 21

 Cross winding or cross wound package

➢In case of cross winding or cross wound package, the winding package contains a
single yarn which is laid on the package at an appreciable helix angle so that the
layers crossing one another to provide stability.
➢For example, Cone, Cheese, Spool etc.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 22

 Cross winding or cross wound package

Advantages:
➢Over end withdrawal is possible here.
➢Stability of yarn package.
➢Flanged is not needed here

Disadvantages:
➢Yarn quality is less here.
➢Yarn twist is changed during winding.
➢Traversing mechanism is required here.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 23

 Types of Winding

According to density:
➢Precision winding (cones & chesses)
➢Non precision winding

According to type of package:

➢Cone winding package
➢Pirn winding package
➢Flange winding package
➢Cheese winding package
➢Cop winding package

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 24

 Types of Winding
According to the build of the package:
➢Parallel winding package
➢Near parallel winding package
➢Cross parallel winding package

According to methods of drive:

➢Positive or direct drive
➢Negative or indirect drive

According to the future of automation:

➢Conventional winding
➢Modern winding

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 25

 Types of Winding
Precision Winding
By precision winding successive coils of yarn are laid close together in a
parallel or near parallel manner. By this process it is possible to produce very dense
package with maximum amount of yarn stored in a given volume.

Features of Precision Winding

➢Package are wound with a reciprocating traverse
➢Patterning and rubbing causes damage of packages
➢Package contains more yarn
➢Package is less stable
➢The package is hard and compact
➢The package is dense
➢Rate of unwinding of package is low and the process of unwinding is hard
➢The unwound coil is arranged in a parallel or near parallel manner

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 26

 Non-Precision Winding
By this type of winding the package is formed by a single thread which is laid
on the package at appreciable helix angle so that the layers cross one another and give
stability to the package. The packages formed by this type of winding are less dense
but is more stable

Features
➢Only one coil is used to make this packages
➢Cross winding technique is used
➢The package density is low
➢Minimum number of yarn is wound
➢The package formed is soft and less compact
➢The stability is high
➢Flanges are not required
➢The rate of unwinding is high and the process is easy
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 Difference between precision and non precision winding

Precision Winding Non-Precision Winding

The wound coil arranged parallel or near parallel. The coil is cross wise-wound.
The yam density of the package is high. The yam density of the package is low.
Flanged bobbin may be used. Not use of flanged.
The yarn package is hard and more compact. The yam package is soft and less compact.
Low stability of the package. High stability of the package.
Winding angle is 90ᵒ or near 90ᵒ Winding angle is less than 80ᵒ
The bobbin is wound with one or more threads. The bobbin is wound with one thread.
Yarn tension is comparatively high. Yarn tension is comparatively less.
Unwinding rate is low. Unwinding rate is high.

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 Auxiliary Function of Winding

Creeling: Creeling is the placement of full packages in position ready to be

unwound as part of the transfer operations. An alternative meaning is the removal of
the exhausted packages & their replacement with full ones.

Piecing: Piecing is the finding & connecting of the ends on the packages. The
connection between the ends can be made by knotting adhesion or welding but the
former is by far the most common. Such connections are required whenever an end
breaks or when a creeling operation has been completed.

Doffing: Doffing is the removal of newly wound packages & the replacement of
these by empty packages which will receive yarn during the transfer process. It will
be noted that creel packages are emptied as the packages to be doffed are filled.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 29

 Winding efficiency
The ratio between the actual production and the calculated production is called
winding efficiency. It is expressed by in percentage:
Winding efficiency η= {(Actual production)/(Calculated production)}×100%

Factors of Winding Efficiency: Winding efficiency depends on the following factors

➢Spindle or drum speed: The higher the speed the more is the winding efficiency
➢Yarn Count: Yarn count is proportional to winding efficiency
➢Yarn quality: If yarn quality increases then winding efficiency increases
➢Worker efficiency: The more efficient the worker is the more efficient the winding
will be.
➢Humidity: Humidity is reciprocal or inversely proportional to winding efficiency.
➢Work load per worker: If the work load on each worker is less, efficiency of
winding will be more.
➢Maintenance and over hauling: If the maintenance and over hauling of the machine
is not correct then efficiency of winding will decrease.

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 Factors of Winding Efficiency
➢Power failure: If power failure rate increases the winding efficiency will decrease.
➢Creeling time: The more the creeling time the less is the efficiency.
➢Doffing time: The more the doffing time the less is the efficiency.
➢Capacity utilization: When capacity utilization decreases then efficiency increases.

Reasons for lower efficiency

➢Power failure
➢Improper maintenance and over hauling
➢Natural disasters
➢Less skilled labor
➢Labor unrest
➢Shortage of machine parts and raw materials
➢Strike
➢Maintenance problems

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 Faults in Winding
1. Slack knots or knots with long tails:
Causes: Slack knots get untied, while long tail cause breakage of an adjacent ends in
weaving and pass with difficulty through the healds and reed.
Remedies: Knots should be given in a proper way.
2. Piecing up:
Causes: Not having found the tail from the package the operative ties the yarn end
from the bobbin to one of the broken yarn coils on the winding package, which
causes breakage in warping.
Remedies: Operator should be careful during knotting.
3. Overlapping:
Causes: The operative does not tie-in the ends, but merely winds them around the
package without knotting, which results in warper stoppage.
Remedies: Double check during knotting.
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 Faults in Winding
4. Winding in of fluffs:
Causes: Dirt and broken end is the result of operative carelessness and of clogged
clearers.
Remedies: Clearer should be clean.
5. Faulty shape of package:
Causes:
➢Faulty yarn guide,
➢Faulty building device,
➢Faulty traverse motion,
➢Faulty drum guide.
Remedies:
➢Correct yarn guide should be used,
➢Accurate building device should be set,
➢Perfect traversing motion should use,
➢Correct drum guide.
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 Faults in Winding
6. Sloughing off: Thick bunches of yarn are woven into the fabric in the weft
direction due to slipping off of coils of yarn from the pirn during weaving.
Causes:
➢Improper package characteristics.
➢Softly wound pirns.
➢Harsh picking and/or poor shuttle checking.
➢Poor humidity conditions during the storage of pirns
Remedies:
➢Employ correct package characteristics in pirn winding.
➢Ensure proper yarn tension during pirn winding in the case of rewound weft and in
spinning in the case of direct weft.
➢Check the picking and checking mechanisms.
➢Condition the weft before putting it on loom.

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 Faults in Winding
7.Jail formation or stitching:
Causes: Improper set-up of cone holder.
Remedies: Accurate set-up of cone holder.
8. Formation of ribbon:
Causes: Improper set-up of cam switch.
Remedies: Perfect set-up of cam switch.
9. Bell shaped cone:
Causes: Faulty set-up of cone holders with winding drum.
Remedies: Set-up should be perfect.
10. Ring shaped cone:
Causes: Faulty setting of cone holder.
Remedies: Accurate set-up of cone holder is necessary.
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 Faults in Winding
11. Soft package:
Causes: Insufficient loading of the cradle.
Remedies: Sufficient loading of the cradle.
12. Collapsed cone:
Causes: Using of faulty cone.
Remedies: Should be used fault free cone
13. Imperfect winding speed:
Remedies: Correct winding speed should be there.
14. Tight bobbin:
Remedies: Bobbin should be perfect.
15. Mixing of yarns of different linear density:
Remedies: Linear density of mixed yarn should be same.

Md. Abdul Alim, Lecturer, Dept. of Textile Engineering, KUET. 36

 Faults in Winding
16. Less removal of neps, slubs, dirt and loose fibres:
Remedies: Should be free from slubs, neps and loose fibres.
17. Excessive full bobbin:
Remedies: Yarn should be wound at a definite length.
18. Variation of tension:
Remedies: Tension have to same throughout the total winding process.

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