Weaving preparatory Process

There are three main steps of weaving preparatory process.

1. Winding
2. Warping
3. Sizing

Flow chart of weaving preparatory process

• Transferring yarn from one type of package to other which is

Winding more suitable for subsequent process.

• Transferring a number of yarns from a creel of single end

Warping packages, forming a parallel sheet on to a beam

• Application of size material on the warp sheet, to induce desired

Sizing properties

Winding

Winding is a process in which yarn from ring bobbins are wound into convenient form of
package. Transferring a yarn from one type of package, more suitable for subsequent process is
also called winding. It occurs both in spinning & weaving. Main objectives of winding include:

 Increase package size according to the requirement of subsequent process

 Clearing yarn defects like slub, thick and thin places, neps, etc.
 Package dying
 Doubling

Winding rate

Winding rate is the speed at which the yarn is wound on package surface. In case of parallel
package; traverse is very slow, so winding rate is approximately equal to the surface speed.

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Production of Winding Machine

Production of winding machine can be calculated by the following formula:

Flow chart of Yarn Passage Through winding machine:

Stop
Magazine Motion
Splicer

Baloon
Waxing Cradle
Breaker

Pre Tension
Cleaner Device Drum

Warping
Warping is the process of transferring a number of yarns from a creel of single end packages,
forming a parallel sheet on to a beam. The main objectives of warping are:

 To get the required number of ends as per set calculation.

 To get the required length of yarn on each beam of the set.
 To wind a specific type of package required by subsequent process.

Types of Warping Machines

 High speed Warping
 Sectional Warping
 Ball Warping
 Draw Warping

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 1. High speed Warping:
In direct warping, the yarns are withdrawn from the single-end yarn packages on the creel and
directly wound on a beam.

2. Sectional Warping:
Sectional warping is a two stage machine method of preparing a warp on a beam, mostly used
for yarn dyed fabrics.

3. Ball Warping:
Ball warping is the process in which warping is performed in rope form onto balls. A ball warped
beam is prepared for subsequent process. It is suitable for denim fabric manufacturing,
involving rope dyeing process.

4. Draw Warping:
Draw warping is combining the drawing of filament yarns with heat setting and warping process
to achieve uniform stretching and heating for improved dye uniformity, end to end. It is used
for weaving of thermoplastic yarns.

Flow chart of Yarn Passage through Warping Machine

Warp
Guide
Creel sheet on
to comb
Roller

Warping
Spindles Headstock
Beam

Tension
Stop
motion
Pressing
Rods
sensor Drum

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Sizing
The weaving requires warp yarn to be strong, smooth and elastic to a certain degree. To
achieve these properties, protective coating of a film forming agent is applied to the warp yarns
prior to weaving. The application of size material on the warp sheet, to induce the desired
properties is called slashing or sizing. Sizing is to produce Quality Fabric economically and
efficiently.

Objectives
The main objectives of sizing are as follows:

 To get the required number of ends

 To increase the strength of yarn
 To cover the hairiness of yarn
 To maintain flexibility in yarn
 To make yarn surface smooth and pliable.

Parameters Affecting Performance of Sized Yarn

Parameters affecting performance of warp yarns during weaving include:

 Yarn Type: Staple, filament, ring, open end, comber, carded, etc.
 Material: cotton, viscose, polyester, etc
 Quality: Hairiness, thick and thin places, etc
 Sizing Machine: pre wetting, cylinder or hot air drying, etc
 Size recipe: Starch, PVA, CMC, etc
 Size pick up: more or less, core sized, surface sized
 Loom type: shuttle, air jet, rapier, etc
 Weave: plain, twill, satin
 Loom RPM: slow or high
 Personnel: trained properly or not
 Handling: machine speed, cylinder temp, etc
 Adjustment: squeezing pressure, moisture, etc

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Flow chart of Yarn Passage through Sizing Machine

Mini
Creel Drying
Cylinder
Drying
Cylinder

Warp Squeeze Waxing

Sheet Roller Device

Size Box
Immersion Splitting Press
Roller Zone
Trolley

Measuring Pendulum Weavers

Headstock
Roller Roller Beam

Feeding Press Guide

Comb
Roller Roller Roller