Warping

Name : MAZADUL HASAN

SHESHIR
PREPARED BY
ID: 2010000400008 right
Batch: 13th Batch (Session
2009-2013)
Department: Wet Processing
Technology
Email:
mazadulhasan@yahoo.com
Blog: www.
Textilelab.blogspot.com
Southeast University
Department of Textile
Engineering

WARPING:
Warping:
The parallel winding of warp ends from many winding packages (cone
or cheese) on to a common package (warp beam) is called warping.
Types of warping:
1. Beam warping direct warping.
2. Patterns band or drum warping Sectioned warping,
(Indirect warping)
3.

Ball warping

TYPES OF WARPING
Direct Warping Denotes the transference of yarns from single-end
yarn packages, wound packages, directly to a beam in a one step
process. This means that there are an equal number of packages in
the creel area as there are ends on the beam, except in the case of a
magazine creel. A magazine creel connects the tail of one wound
package to the beginning of a new wound package for an easy
package transfer. from the wound packages in the creel.
Beam Warping
A weavers beam may have upto 10,000 ends and if this were to be
produced directly it would be necessary to have upto 10,000 creel
packages.such an arrangement would be very difficult to
accommodate and manage ;consequently it is normal practice to
produce warpers beams which may contain upto about 1000 ends
and these are combined at the slashing stage.because of the
difficulties involved in combining the ends ,patterned warper beams
are seldom produced on the direct system and any pattern that is
produced is achieved by combining beams of various colors at the
later stage of slashing.
This imposes limitations which can only overcome by changing to
pattern weaving.

TYPES OF WARPING
Sectional Warping Process
In sectional warping sections are made sequentially and because of
this the process is rather slow ;it is the practice therefore to produce
no more than is required to fill a single weavers beam.the result is
that the sectional warping is used mainly for short runs or for
complex color patterns.
Pattern, Band or Drum Warping
Because many warpers beams are combined in the direct
system,this is usually regarded as a high speed process particularly
suitable for single color work .providing the warpers beams are of
single color ,it is possible to combine them to produce simple
patterns distributed over the warp width.
Ball warping
Ball Warping is an intermediate process for storing yarn for transport
,dyeing or reserve; It does not produce a beam.the usual form is a
cross wound cheese in which multiple ends are wound at the same
time in a ribbon which contains perhaps 50 or 100 ends.

QUALITY OF A GOOD WARP

The essential features of a good warp are as follows:
1. Sufficiently and uniformly strong
2. Uniform in cross section
3. Uniform warp tension
4. Uniformly sized
5. Less hairy and clean
6. Minimum no of knots
7. Proper or standard size and types of knots
8. Free from neps, slubs and loose fibres
9. Parallel arrangement of warp yarn in the weavers beam

WARPING ELEMENTS & MOTION

Each warping m/c has the following warping elements
& motion:
1. Warping creel for accommodation the bobbin.
2. A builder motion.
3. A guide reed. Uniformly spreading the yarn over the warp
width.
4. A measuring motion registering the warping length.
5. An automatic knocking off motion to stop the m/c up on
achieving the required length of warping in case of yarn
breakage.
6. A drive
7. A starting & stopping motion.
8. Warping m/c is furnished with package doffers signal

REQUIREMENT OF WARPING
Should meet the following requirement:
1. The tension of all wound ends must be uniform and possibly
constant during all the time of withdrawal from supply
packages, otherwise the rate of breakage will be increased &
the structure of the ready cloth will be impaired.
2. Warping should not impair the physical & mechanical
properties of yarn. The tension should moderate to allow the
yarn to completely retain its elastic properties & strength. The
yarn should not be subjected to sharp abrasive action.
3. The surface of warping package must be cylindrical.
Therefore, the spreading of yarn (density) throughout the
whole width of warping must be as uniform as possible.
4. A pre determined length of warping should be observed.
5. The production rate of warping should be as high as possible.

REQUIREMENT OF WARPING
1. The yarns in the sheet should be in uniform spacing.
2. The yarns in the sheet should be in uniform tension.
3. The yarns in the sheet should be of a predetermined
length.
4. The sheet should be containing a predetermined number of
ends.
5. There should be no broken ends in the beam.

OBJECTS OF WARPING

Objects of warping:

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 individuals 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.

WARPING PROCESS INVOLVES

CHECK LIST BEFORE PRODUCTION

Check List Before Production:
1. With the production before data control operator will call-up the
following for recording:
2. Warp length shift
3. Down time.
4. Efficiency.
5. No. of thread breaks.
6. No. of warp beam doffed.
7. Time for thread repair.
8. Time for beam change.
9. Operator must check yarn quality in term of count, material,
and color with customer demand. No mixing is allowed.
10.Operator must check yarn quality in term of strength and
record yarn break rate. Standard for good quality yarn 10
breaks/1000000 meter.

IMPORTANCE OF WARPING
Importance of warping:
1. Constructions of beam warp yarn.
2. Constructions of a parallel yarn sheet.
3. Modifying the faults of yarn like thick & thin places, large
knots etc.
4. Winding the predetermined length of yarn.
5. Combination of small packages.
6. Finding long length of warp yarn.
7. Accelerating the next process.

PRODUCT QUALITY CHECK

QUALITY PARAMETER
CHECK

RESPONSE
No ridge beam allowed, clean the

Beam surface smoothness

yarn guide & check the tension for

Homogeneous beam

uniformity.
Check the alignment of beam &

diameter
Yarn exhaustion
Yarn break

drum, drum and creel etc.

Replace exhaustion cone with new
one.
Tying the head end with tail end
with standard with fail size <3 mm.

Operational Stuf

Operational Stuf:
1. SUPERVISING OFFICER.
2. OPERATOR.
3. CREEL MAN.
4. HELPER.

Operational Staf:
Section in Charge
Senior Executive

Quality Control Officer

Supervising officer

Senior Operator

Creel man

Helper

OPERATION PROCEDURE:

As per production program given by Assistant Manager, preparation

through the yarn. Warped Record Register; the Supervising Officer
collect greige yarn from the store as per required count Lot no. &
quality.

The m/c operators and helpers and helpers open/break the yarn
cartons & place the yarn cones on the creel peg as per program &
draw the head end of each cone through pre-tensioner rods feeler
wire, yarn guide & then through expanded comb of beaming unit.

The basic creel data setting& m/c data setting are done according
for the required as pr m/c manufacturer instruction.

An empty beam is set between driving clutch & engaged by means

of electric switch.

All the ends from the creel is warped around the beam manually
one round.

The press roller is moved toward the beam by means of electric

switch.

OPERATION PROCEDURE:

The m/c is then run slowly and checked for yarn alignment
with beam flange on both sides. To ensure perfect alignment
the expended comb may be moved either to the Right side
or Left side as required by switch.

Then the m/c is ready & operational & the switch is to be

turned on.

As the present length is achieved the m/c will stop

automatically. The beam is doffed by switch. Another empty
beam is mounted.

In this way a set of beam are made to feed the subsequent

sizing process.

Production is recorded in the yarn Warped Record Register.

Each beam is set with warping Data sticker for identification
in the next process.

WARPING PROCEDURE

1. Based on weave plan supervising officer and/or senior operator

receive the required dyed yarn from winding section of specific
customer order no. as per color and quantity.
2. As per worked out warp pattern scheme senior operator arrange
the yarns on the creel following the color pattern. Quality control
officer will check any shade variation within the same color. If any
variation is found, necessary steps should be taken to use them
lot by lot. Quality control officer will sign on the warping program
register.
3. The operator & creel man draw the yarn through feeler wire on
creel & splits of the leasing reed & then through guide reed & tie
in.
4. Then the main switch of main control panel is turned on & cone
alignment is done by respective switch.
5. Senior operator will put necessary data entry on the warping data
sheet by taking some figure from yarn warped record register &
by calculating some values as per prescribed formula in the m/c
manufacturers operating instruction book. He will also input these

WARPING PROCEDURE
6.

Hook warp section on to the drum by opening & closing the

guide roller.

7.

Start warping by pressing foot pedal at the head stock. Machine

will run slowly at crawl speed. After 15 meter being wound on,
stop the m/c and insert leasing threads. Then again start m/c
with run switch at the head stock and finish warping of the
section.

8. Then by section alignment switch set the m/c ready for next
section. Repeat step-7, and 8 to finish the warping.

WARPING PROCEDURE
All the section thatare wounded up over the drum is doffed in the
beam from by beaming process as follows:

Turn the switch from warping to beaming.

Set an empty beam in the beam during unit by beam barrel by an

adhesive tape and rotate the beam manually.

Set beam flange with measured warp width.

Set winding tension value range from 1-6 (calculated value as

attached).

Run at crawl speed to see alignment either left side or right side
by drum alignment switch.

Set the winding speed within a range of 1-160 m/min, depending

on yarn quality.

Run the m/c with run switch.

Doff the beam by unloading switch.

Warping data sheet is failed as a production record. Each beam is

Hi-speed warping

HI-SPEED WARPING MACHINE

YARN PATH DIAGRAM OF HI-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

SCHEMATIC DIAGRAM OF DIRECT WARPING

MACHINE

DIRECT

I HI-SPEED

WARPING MACHINE

PROCESS FLOW CHART HI-SPEED WARPING

MACHINE
Dispo

Yarn from store

Creeling

Warping

DIRECT

I HI-SPEED

WARPING MACHINE

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:
7. Guide Reed
: Uniformly spread the yarn over the warp width.
8. Adjustable V-Reed : Guides the yarn to follow the fixed path.
9. Speed Controller : control the speed, crawl speed or full speed.
10. Pressure Roller
: Exert required pressure to the warp yarn.
11. Measuring Device : Measures the length of the yarn.
12. Beam Bracket
: Holds the warp beam.
13. Emergency Stop Device: For emergency stop.
14. Automatic Knock Off : Stop m/c at achieving required length of
beam or in case of
15. Yarn breaks.
16. Electrical Panel Board : To give the automatic controlled function.

Major components of Warping Machine:

Warping machine has three major components:
1. Creel
2. Head Stock
3. Control Device

Creel:
Parallel creel with travelling package
Creel capacity of SIM fabric direct warping m/c:
oNo. of warping m/c: 2
oM/c no 1: Both side: 756

Creel:

FUNCTION OF COMPONENTS OF CREEL

Function of components of creel:

1. Cone or cheese spindle for high speed warping.

2. Thread guide: To pass through the yarn in the reqd way.
3. Tensioner: To keep the yarn always in a uniform tension.
4. Yarn cleaner: To remove various faults of yarn like slubs,
neps etc.
5. Suction fan or blower: To remove the dirt & dust from the
yarn.
6. Breakage indicator: To indicate breakage in package.
7. Stop device: To stop the m/c when yarn will be broken.

HEAD STOCK
Features of components of headstock:
1. Adjustable or variable v-reed or wraith: To control the
width of the warp beam.
2. Measuring & making device: Measure the amount of warp
yarn on the beam & marks the yarn.
3. Yarn speed controlling device: To control the speed of yarn.
4. Pneumatic pressure unit: To press the warp beam with the
surface contact of driving drum.
5. Break assembly: It stop the m/c after read length is wound on
beam.
6. Driving drum: Beam is in contact & control with driving drum.
7. Stop motion: Used to stop the m/c after read length is wound
on beam.
8. Beam bracket: To support & hold the beam.

Control device:
Similar to winding, warp yarns are threaded through tension
devices , stop motions, leasing rods and the reed. The stop motion
electrically links each warp end to the warper braking system;
when a warp end breaks, the warper stops. A light indicates the
location of the broken end. The warping process is generally
irreversible, unwinding, of the beam would cause yarn
entanglement. The stop motion device which can be mechanical or
electronic for quick response, is usually located near the creel.Fans
are used to prevent lint accumulation when warping staple yarns.

# Pressure setting of stop motion & tensioner: (Off Creel)

Setting is adjustable by rotary button, which activate stop motion drop wire &
pressure.

Stop motion
3
2
1

Tension
C
B`
A

Setting

Yarn Count

range

(Ne)

Coarse
Medium
Fine

4-30S
4-60S
15-120s

High Speed Warping m/c Setting:

Set up parameters

Range

Set value

Cone no. of Creel

400-600

As required

Warping Speed

1-1200 m/min

Warping length

1-999999 m

Shift selection

1-5

Beaming drum

1-11 mm scale

5 mm scale

Stop drop wire

1, 2, 3.

1 higher

Tensioner

A, B, C.

C higher

Depth of penetration

1-40 mm

As required

Beam barrel dia

315 mm

Fixed

Beam flange dia.

987 mm

Fixed

Beam width

1800 mm

As required

pressure

DIFFERENCE BETWEEN DIRECT & SECTIONAL

WARPING
PARAMET
ERS

DIRECT WARPING

It is generally used to
Object / Use produce warp beam for
grey fabric or solid color
fabric.
Several Warpers beam are
Method of
produced here for getting
production
one weavers beam.
Ends/beam is less here.
No. of
Direct warping beams
Ends/beam contain 1/n no. of ends of
weavers beam.
(n=no. of warping
beam/set).
One stage Production.
Stage of
(Yarns are directly wound
Production on Warpers beam).

SECTIONAL WARPING
It is generally used to
produce warp beam for yarn
dyed (check/stripe) fabric.
One Warpers beam is
produced here for getting
one weavers beam.
Ends/beam is higher here.
Sectional warping beam
contains equal no. of ends as
weavers beam.

Two stage Production. (Yarns

are directly wound on
warping drum section by

DIFFERENCE BETWEEN DIRECT & SECTIONAL

WARPING
PARAMETERS
Yarn Tension

Yarn length on
beam
Creel Capacity
Sizing
Operation
Efficiency

DIRECT WARPING
Yarn tension is
comparatively higher
than sectional warping.
Higher length of yarn is
wound on a beam.

SECTIONAL WARPING

Yarn tension is
comparatively lower than
sectional warping.
Length of yarn in the beam
is comparatively lower than
direct warping.
Usually lower than
Usually higher than
sectional warping.
sectional warping.
One sized beam is
One sized beam is
produced from several
produced from one
no. of Warpers beam.
Warpers beam.
Efficiency is higher than Efficiency is comparatively
sectional warping.
lower than direct warping.
(Single stage operation). (One additional operation
beaming-off is required).

Sectional Warping m/c.

Process Flow Chart Sectional Warping Machine

Process Flow:
Dispo

Yarn from store

Creeling
(According to warp plan)

Machine setup

Section wise warping

Beaming

Warp width:

Total Ends
Below 7200

Warp Width
1800 mm

7200

2000 mm

Above 7200

2100 mm

Control Data Parameter Evaluation:

Feed- 1 =

Decitex Total Ends 0.5

Density Total Warp width

Feed 2= Measured feed X 0.85 ( For Cotton)

= Measured feed X 0.95 (For Synthetic)
Feed -1= Drum Movement with revolution per minute.
Feed -2= Actual movement of Drum.
Measured feed=> It find out the variation between Feed -1 to Feed -2
Variation +/- 15%
Piece length= Machine stop before wound 10 -15 meter of required
length.

SCHEMATIC DIAGRAM OF DIRECT WARPING

MACHINE

HEAD STOCK OF SECTIONAL WARPING MACHINE:

HEAD STOCK OF SECTIONAL WARPING MACHINE:

CREEL DIAGRAM

Ball Warping

Ball warping Machine

In ball warping process, individual strands of yarn are removed from

yarn packages and collected into rope form suitable for rope dyeing
(Fig. 2). Threads, about 350-500 in number are formed into ropes.
Individual warp yarn are collected into rope form and wound onto a
log and produce a ball warp on Ball warping machine.
In ball warping, all the packages are loaded into the adapters of the
creel of ball warping machine. 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. The passage of yarn in ball warping are shown in Fig..

Passage of yarn in ball warping

The Magazine creels are straight-line creels having a reserve yarn

package placed beside the running packages (Fig. 4). The tail end of
the running package is knotted with the start end of the reserve
package. When the running package is depleted, the warper
continues to run with the from the reserve package.

Faults & Remedies of Warping:

Warp of 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.

Faults & Remedies of Warping:

Snarl formation in the warp:
Due to
Over 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.

Faults & Remedies of Warping:

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 warping:

Causes of yarn breakage in warping:
1. 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

Warping Calculation
Calculation:
For

construction(6815yds fabric)
Total number of yarn =7344 7250
Length of ordered fabric = 6815yds

Warping Calculation
Breakage calculation:
Number of total ends: 7500
Number of yarn per warper beam: 625
Number of creel: 12
Length: 9250 yards
Total breakage: 162
Now, total length: number of total ends length
: 7500 9250
: 72150000
Breakage in 72150000 yards length = 16
Breakage in 1000000 yards length

= 2.24

Giving some example of breakage rate whose are classified

depending on yarn manufacture company name and their yarn count
and warping machine speed.

COMPANY
NAME
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ
AKIJ

COUN
T
40/2
40/2
30/1
30/1
30/1
60/1
30/1
16/1
60/1
30/1
30/1
40/2
30/1
40/2
30/1

SPEED
350
350
350
350
350
350
350
350
350
350
350
300
350
350
350

BREAKAGE
RATE
1.01
1.8
1.92
1.95
2.65
2.1
1.25
2.13
3.31
1.13
1.24
0.45
0.73
4.04
1.41

Warping Calculation

Warping Calculation
Warping efficiency:
Efficiency is calculated depended on worker working shift
Actual Production: (200003) +14000 = 74000 yards
Machine speed= 350 yards/min
Production time= 74000 yards 350 = 3.32 hour (total length
speed)
Creel time= 1.00 hour
Breakage= (962) = 3.23 hour
Cleaning time = 0 hour
Electrical = 0 hour
Mechanical= 0 hour
Total time used= 7.44 hour
Idle time= 0.16 hour
Calculated production= total time machine speed
= 8.00hour 350 yards/ min
= 480 min 350 yards/ min
=168000 yards

Warping Calculation

Warping Calculation