Yarn preparation

for weaving

Definition: Textile Fabric

A textile fabric is defined as an assembly

of fibres, yarns or combinations of these.

Techniques for fabric manufacturing:

Weaving
Knitting
Braiding
Tufting
Nonwoven manufacturing

Manufacturing steps of
woven fabrics

Weaving: It is the process of interlacement of warp with weft

Warp: Longitudinal yarn in the fabric is called warp
Weft: Lateral/crosswise yarn in the fabric is weft

Yarn preparation for weaving

Warp yarn preparation

Weft yarn preparation

Winding

Winding

Warping
Sizing/slashing
Drawing-in or tying-in
Weaving

Warping

It is the process of preparing a

double flanged beam of warp yarns
arranged parallel to each other.

Warping (3 Types)
Beam/Direct

warping

(Grey/Monocolour fabric)
Sectional/Indirect

warping

(Warp patterns: Stripes and

Checks)
Ball

warping

(Denim fabric)

Beam warping
It is suitable for grey or
monocolored fabric preparation.
The maximum number of warp
yarns in a beam can be 600.

Beam warping
Creel
Warp
yarn

Head
stock

Beam warping
Creel

Head stock

Beam warping (Quality aspects)

Exact thread guidance
No crossed threads
Cylindrically wound beams : no slip between press roller and
yarn package
Warp length accuracy within 1 per thousand
No cutting-in by threads on the comb
Fewer rolled-in ends through short braking distances
Short braking distance
Simple insertion of threads into the comb
Workplace designed according to ergonomic principles

Sectional warping

It is suitable for all warp patterned fabrics

e.g. stripes and checks.
Warping is carried out section by section.
A single beam is prepared which may or
may not be sized.
Sometimes this process is carried out for
2-ply synthetic warps where no sizing is
needed.
It is a two stage process. Warping onto
the drum and Beaming.
Creel capacity can be lower.

Sectional warping machine

Creel

Head stock

Sectional warping

Yarn from
creel

Section drum

Head stock

Creel

Sectional warping

The creel

Head stock

Section laying

The yarns are laid sectionwise, starting from the

conical base side. The first section is supported by
the conicity of the base and the subsequent sections
supported by the conicity formed by the preceeding
section.

Sectional warping
The newly developed machine with its reed headstock integrated into the machine
superstructure allows production speeds never previously achieved, thanks to its
innovative control system. The machine has the following special technical features:
Production of warp sections with a minimum width of 4 mm or (depending on yarn
fineness) minimum 12 24 threads. With maximum end numbers of 480 -560 threads
and a section width of up to 150 mm, the machine can be fine-tuned for flexible
production.
The time for each thread separation at a lease or sizing split is 7 seconds per
separation process
A maximum warping speed of 750 m/min allows production to be optimised to suit
yarn properties.
The perfect thread tension between creel and machine for the warping process
ensured by the use of a proven section tension control and a controlled beaming
tension system forms the basis for warp quality that meets the highest requirements.
The machine is available with a working width of 2,200 mm for the traditional clothing
sector and 3,600 mm for decorative fabrics and furniture coverings.

The leasing function

Leasing is a process of layer separation to facilitate the

subsequent drawing-in process and weaving. A lease band is
inserted between the layers.

The beaming operation

In the second step, all yarns
are simultaneously
transferred from the section
drum onto a double flanged
warpers beam.

Warpers beam

Ball warping

It is a process in which warping is done in

rope form.
A ball warp beam is prepared for
subsequent process.
It is suitable for denim fabric
manufacturing, involving rope dyeing
process.
It is also a 2 stage process; Ball warp
winding and Long chain beaming.
Dyeing is done before beaming operation.

Ball warping
Warp sheet

Initially the warps are wound in rope form on a

cylindrical barrel.

Creel

Ball warping

Dyeing is carried out in the rope form of the warp yarns.

Ball warping
Cans

Cans
Beam

In the second stage: (Long chain beaming), The ends are

spreaded to open width form.

Warping machine
manufacturers worldwide
Benninger
Scharer
Sucker Muller Hacoba
Yamada
West point
Karl Mayer
Suzuki

Sizing

Objectives

To improve weavability (weaving potential)

of warp yarn by,
Increasing strength
Reducing hairiness
Improving abrasion resistance
Retaining elasticity
Retaining extensibility to some extent
Maintaining the flexing behavior

Objectives achieved by

Coating of yarn surface with a suitable

film forming polymeric material

By penetration of the adhesive/binding

agent into the core of the yarn

Sizing machine
Drying zone 1

Creel zone

Sizing zone

Drying zone 2

Different zones of the machine

Head stock

Sizing machine
Drying

Creel
Sizing zone

Head stock

Sizing (Quality & Productivity)

Highest quality
Uniformly optimal sizing
Low hairiness
Low stretch during sizing
Automatic section tension control
High reproducibility

High productivity
Simple attendance
Automatic monitoring of all parameters
Comprehensive recipe management

Sizing quality achieved

through
Flexible squeeze rollers for uniform sizing
Air-cushion cylinder for hysteresis free pressure
application
Textured or structured surface for reduced hairiness
Programmable squeeze pressure curve
Simple attendance at the size box
Clearly defined wet splitting per size box

The sow box

Squeeze
roller

Immersion roller

Size roller

Size pump

Pre-wetting in sizing
Savings
Size savings of up to 50%
Improved weaving characteristics
Lower effluent treatment costs

High productivity
Optimal weaving efficiency
Fewer warp beam changes thanks to increased warp
lengths

Reproducible size
preparation

Stock tank
Storage
tank

Mixing
device

Sizing machine
manufacturers
Benninger
Yamada
Sucker Muller Hacoba
West Point

Size materials
Essential Ingredients
Adhesive/Binder
Softener
Wetting agent

Size materials
Desirable Ingredients (Depending upon
requirement)
Oxidizing/Reducing agents
Weighting agents
Brightening agent
Antifoaming agent
Delustering agent
Antistatic agent

Adhesive/Binder
Natural
Starch from maize, rice, wheat,
potato etc.
Gums from plants
Synthetic
Polyvinyl Accohol (PVA)
Carboxymethyl Cellulose (CMC)
Polyacrylate (PA)
To bind the fibre material together and consolidation of yarn

Softener/Lubricating agent
Oils

and Fats from Plants

Oil from Seeds of plants; Castor,

sunflower etc.
Vegetable oils
Animal

Fats

Mutton tallow
To maintain pliability of yarn by softening and lubricating

Wetting agent

Turkey Red Oil (TRO)

To reduce surface tension for spreading of size material on

yarn surface

Oxidizing and Reducing

agent

Depending upon requirement of the size paste

Weighting agent
Gypsum salt (CaSO4, 2H2O)
CaCO3

To increase the weight of fabric, if sold on weight basis

Optical Brightening agent

Ranipal
Tinobal blue

To improve brightness of light coloured yarn and there by

the fabrics to be sold in gray state

Antifoaming agents

Turkey Red Oil (TRO)

To prevent formation of foam during size paste preparation

Delustering agent

Titanium dioxide (TiO2)

To reduce luster in case of glaring synthetic yarns

Antistatic agent

Sapkostat oil

To dissipate static charge generated in synthetic yarns due to

friction with other yarns or metal surfaces

Size paste concentration

Size

paste concentration %

Oven dry weight of size material

Total weight of size paste

X 100

Size pick up
Size

pick up % =

Weight of size paste taken up

X 100
Oven dry weight of unsized yarn

Size add on
Size

add on % =

Oven dry weight of size material

Oven dry weight of unsized yarn

X 100

Size parameters
relationship

Size add on % =
Size paste concentration % X Size pick up %
100

Modern techniques in sizing

Cold sizing
Pre-wet sizing
Wet splitting
Dye sizing (Indigo/Vat)

Cold sizing
Properties

Cold Size
1

Cold Size
2

Cold Size 3

Cold Size
4

Physical State

Viscous
Liquid

Solid Wax

Viscous Liquid

Viscous
Liquid

Appearance

Clear

Hazy

Reddish/Brownish

Clear to
slightly
hazy

Viscosity
(Time to flow) at
300 c

20 + 2
seconds

20+ 2 seconds

18 + 2
seconds

PH

4-5

6.5 8.5

5-6

Solubility

Soluble in
cold water

Soluble in
warm water

Soluble in
cold water

Easily
soluble in
cold water

Solid Content

6%

100%

6%

6%

Chemical
Constituent

Poly Methyl
Acrylate

Poly Ethylene
Glycol

Poly Ethylene Glycol

Poly Ether
Glycol

Chemical Formula

(C4H6O2)n

(C2H4O)n

(C2H4O)n

(C2H4O)n

Molecular Weight

200-400

500-700

200-300

150-200

Existing Tangential Application

Modified Version Adopted

BREAKAGE MECHANISM OF SINGLE UNSIZED YARNS

BREAKAGE MECHANISM OF SIZED YARNS