Weaving Preparation

Prof.Dr.S.Kathirrvelu
EiTEX-BDU.

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The

process

of

weaving

requires

certain

preparatory steps to transfer the spun yarns

from the spinnerspackage to a weavers beam
ready for weaving [1]. The processes involved
are
1. Winding
2. Warping
3. Sizing
4. Drawing-in and tying
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OBJECTS OF YARN PREPARATION

Yarn preparation is important to facilitate the next processes of
weaving. The objects of yarn preparation are mentioned bellow:
To remove yarn faults ( there are 23 types of yarn faults)
To transfer the yarn from spinners package to a convenient form
of package which will facilitate weaving.
To have desired length of yarn on a package.
To clean the yarn for better appearance and performance.
To make good quality fabric.
To reduce labour cost.
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Functions of the Winding

Operation
Important functions of the winding
operation are
1. Clearing of yarn faults
2. Making larger wound packages
3. Preparing soft packages for dyeing
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Yarn Imperfections

Thick places (mass exceeds by at least

+ 50% of the nominal mass)
Thin places (mass is lower than by at
least - 50% of the nominal mass)
Neps (mass exceeds by + 200% of the
nominal mass with reference length of 1
mm)

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Schematics showing
typical
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FAULTS TO BE REMOVED DURING

YARN-PREPARATION
Thick place Thin place
Slubs Place Loose fibers
Count variation Foreign particles (seed,
leaf, dust, bollworm, honeydew)
Neps
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Clearing
Clearing is a process of removing imperfections from the spun
yarn. The clearing operation must be carried out during the
winding process only because the cost of the winding/clearing
operation is usually far lower than that of the subsequent
operations, such as warping, slashing, and weaving [1].
Moreover, attempting to clear faults at a later stage (e.g., in
warping) will be inefficient as a number of good warp yarns
will become inoperative. For example, a break of a single warp
yarn on the loom brings the entire loom to a stop, thus
reducing the efficiency of the loom.
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Additive type tensioner

Multiplicative type tensioner

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Schematic showing the principle of mechanical

slub and thick place removal during winding.
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The type and quality of package prepared

during winding depend upon the winding
systems employed. There are three principal
types of winding that are commonly used on
modern winding machines, namely,
1. Random or open winding
2. Precision winding
3. Digicone winding
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 A more recent development of winding type is Digicone

winding, where the control systems, consisting of digital
microprocessor, produce wellbuilt packages of uniform
density. A schematic of Digicone winding is shown in Fig.
4.7 The control system consists of two sensors, n1 and
n2, to register the revolutions of the package and variable
drive, P. The microprocessor calculates and analyzes the
signals provided by the sensors, placed near the package
holder and the traverse mechanism. These values are in
turn compared with the programmed values (in EPROM)
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Table 2.1: Comparison matrix of winding

principles
Paramete
Drum-driven
r
Angle of Remains
constant
wind

Spindle-driven

Digicone winder

Decreases with
increase in
Varies within a very
package
small rang
diameter

Decreases with
Traverse increase in
Remains
package
constant
ration
diameter

Winding Remains
constant
speed

Generally
increases with
package
building

Increases
Package drastically at

Increases with
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increase in

Remains constants for

some time and then
decreases in step
Reduces slowly due to
the reduction in
traverse speed and then
increases to the original
value
Density does not
change with package25

Some of the systems used to remove foreign fibres are given below:
Loepfe Zenit Yarn Master
Uster Quantum 2
Loepfe Zenit uses Tribo-electric effect, which is a type of contact electrification,
for foreign fibre identification. According to this principle, certain materials
become electrically charged after they come into contact with another
different material and are then separated. Materials have a specific order of
the polarity of charge separation when they are touched or abraded with
another object. A material which acquires higher position the series, when
touched to a material near the bottom of the series, will attain positive charge.
The further away two materials are from each other on the series, the greater
the charge transferred.
Uster Quantum also presents the distribution of foreign fibres in a matrix based
on % deviation in diameter and fault
length
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 The warp yarn supplied to the warping machine

should be uniform, free of all objectionable faults, and
wound on a reasonably large package of a suitable
build that unwinds trouble-free in the warping creel.
Also, the knots or splices, introduced for removing
faults and tying-in yarn from a number of bobbins
during the winding operation, should be reasonably
small and sufficiently strong so as to allow them to
freely pass through the heddle eyes and dents of reed
and withstand the weaving operation.
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Methods for Producing Knot-Free Yarns

The development of methods for producing knotless
yarns began during the early 1970s. Various
methods have been used for producing knot-free
yarn piecing, including
1. Wrapping 2. Gluing 3. Welding or fusing
4. Splicing
a. Mechanical splicing
b. Electrostatic splicing
c. Pneumatic splicing

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Electrostatic Splicing. The yarn ends are separated

and untwisted in the opening zone. The opened-up
yarn

ends

are

then

spread

out

evenly

in

an

electrostatic field, after which they are intermingled

and

bound

again

by

pole

change,

while

simultaneously twist is inserted corresponding to the

twist in the basic yarn, as shown in Fig. 4.10e.
Theoretically, this method of splicing is very suitable as
it provides ideal blending of fibers in the splice zone,
but it suffers from some practical drawbacks
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Pneumatic Splicing. In this method, the yarn

ends are inserted into a splicing chamber and
then overlapped to join them together by means
of a strong current of compressed air, as shown in
Fig. 4.10f. The splicing time and air pressure are
determined according to fiber type and yarn
characteristics [8]. The splicing operation consists
of the vertical application of air to the fibers and a
simultaneous rotational movement of the air to
twist/untwist the yarn.
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Steps of yarn splicing

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QUALITY OF GOOD WARP

The essential features of good warp is mentioned bellowThe yarn must be uniform, clean and free from knots as much as possible.
The yarn must be sufficiently strong with withstand the stress and friction
without end breakage.
Knots should be a standard size and type. So that they can pass the heald
eye, dropper, read easily.
The warp must be uniformly sized and size coating should be thick
enough to protect the yarn various function.
The ends of warp must be parallel and each must be wound onto a
weavers beam at an even and equal tension.
All warp yarn should of same size in length.
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Characteristics of a Good Warp

for Efficient Weaving
Strong
Uniform
Smooth
Knot-free
Slub-free
Withstands abrasion of moving loom parts
Withstands cyclic strains and stresses of
loom
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 Warping Systems
There are two basic systems of warping, namely, the
direct system and the indirect system, as shown in Fig.
4.11. In the direct system the warp yarns from a creel
are wound directly onto a flanged warpers beam. This
system is most widely used for mass production of
warpers beams containing only one type of warp
yarns. Because of the difficulties involved in setting up
a pattern of different types and colors of warp yarns,
the direct system is not normally used for the
preparation of a patterned warpers beam
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Magazine creel

Swivelling creel
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Warping Defects
There are certain major warping defects on beam warpers that can be identified as given
below.
Lapped Ends :The broken end of yarn is not tied to the end on the warp beam and
overlaps the adjoining yarn. The beam is not properly braked and the signal hook fails to
operate.
Bulges : Yarn ends are drawn from the middle and the broken end is not correctly pieced
up to the adjoining yarn.
Broken ends on the beam : It occurs due to reasons mentioned in the above point. A
group of ends is broken and tied as a bunch or worked-in with overlapping.
Yarn cut at the butts of the warp beam/ slackness of extreme yarns : It occurs
when the reed is improperly set with respect to the warp beam flanges or there is a
deformation of the warp beam flange.
Excessive or insufficient number of yarn ends : The number of yarn ends of the beam
becomes excessive or insufficient due to the incorrect number of bobbins in warping.
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 Loose yarn winding :

It happens when the pressure roller is lightly
pressed against the warp roller.
Fluff, oily ends and yarn of different density :
It is due to the careless work of the operater,
creeler and oiler.
Bulgy winding on the warp beam :
It is due to Irregular laying of yarn ends in the reed,
missing a dent and placing two ends in the
adjoining yarn.
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Table 3.1: Comparison between beam warping and

sectional warping

Beam warping
Used for high volume
production

Sectional warping
Used for small volume
and customised
production (stripes and
specialised yarns)

One step process

High creel capacity is
required

Two step process

Low creel capacity is
sufficient

Comparatively less
expensive

Comparatively more
expensive

Beaming speed is high

Beaming speed is low

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 The

success

of

the

weaving

operation

is

considerably influenced by the quality of yarn

and the care taken during the preparatory weaving
processes,

such

as

winding,

warping,

and

sizing. Also, careful consideration of the sizing

ingredients, size add-on levels, process of
slashing, and slasher-related parameters are
a few of the several variables that must be
controlled precisely for the success of an efficient
weaving operation.
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 SIZING
The primary purpose of sizing is to produce warp yarns
that will weave satisfactorily without suffering any
consequential damage due to abrasion with the
moving parts of the loom. The other objective, though
not very common in modern practice, is to impart
special properties to the fabric, such as weight, feel,
softness, and handle. However, the aforementioned
primary

objective

is

of

paramount

technical

significance.
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Sizing Machines
The essential components of a sizing
machine to slash spun warp yarns may
be categorized as follows:
1. Creelsunwinding zone
2. Size boxessizing zone
3. Drying cylindersdrying zone
4. Bust rodssplitting zone
5. Head stockweavers beam preparation
zone
6. Controls and instrumentations
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The major creel types housing

multiple beams are
Over/under
Equi-tension
Inclined
Vertical stack
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 Slacks & irregular yarn tension :

It happens due to any on of these reasons- improper threading of the
yarn into the tension devices, ejection of yarn from under the disc of the
yarn tensioning device, or yarn tension devices of poor quality.
Frequent yarn breakages at the beam edges :
It results due to burrs and nicks on the surface of the warp beam
flanges.
Improper length of warping :
It is due to malfunction of the counter, and the brakes of the measuring
device & warp beams.
Coarse Knots :
It is due to manual tying-up.
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Drying CylindersDrying Zone

There are two principal types of drying methods used, namely,
1. Cylinder, or can, dryers
2. Hot air, or convection, dryers
Cylinder Dryers. These are most widely used as they are the

most energy efficient. The cans or cylinders are about 75 cm

in diameter and are used in a multiple unit containing a
series of five, seven, nine, or eleven cylinders, usually
arranged in two tiers to save floor space. The maximal
working pressure of steam in these cylinders is about 4.92
kg/cm2 (70 psi). The cylinders
are made of stainless steel.
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 Head Stock
The

head

stock

supporting

the

necessary

drive

is

weavers
gears.

take-up

unit

beam

and

The

drive

equipment imparts necessary beaming

tension for compact and straight winding
of the warp yarn on the weavers beam.

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 Multimotor Drive. This system uses two DC

motors, one for driving all components of the

sizing machine, except the beam, and the other
exclusively for driving the beam. The motor
driving the beam provides constant winding
tension as the beam diameter increases. This
system is very simple mechanically but very
complicated electrically. This system does not
require resetting before beginning the new beam.
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Digital Drive. This system comprises

an

electrical

analog

to

the

mechanical line shaft drive. The

components of the sizing machine
such as head end, dryer section and
size box, etc., are driven by an
individual motor. The digital system
used for regulating the speed is
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The following sizing variables should be checked and controlled

where
necessary:
Viscosity of the size solution Sizing machine speed
Size add-on levels

Concentration of the size mixture

Volume of the size box (both quantity and size level)

Threading arrangements
Condition of squeeze rolls Squeezing pressure
Hardness of squeeze rolls Diameter of squeeze rolls
Number of size boxes Yarn count and size box warp density per
unit space
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SINGLE-END SIZING SYSTEMS

Single-end sizing systems are widely used for sizing a wide
variety of multifilament yarns, such as zero twist flat, textured,
and low twisted fine denier yarns.
Modern single-end sizing machines operate at extremely high
speeds of up to 500 m/min. The sizing system is very versatile
and it has simplified the yarn passage to produce high quality
sizing beams. The single-end sizing systems consist of a creel
and a warper, beam-to-beam sizing of the warper beams, and
a beamer to assemble sized section beams into a weavers
beam. Figure 4.39 illustrates the single-end sizing system.
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Factors Influencing Sizing Parameters

Type of yarn, spun or filament
Spun yarn parameters such as twist, count, and fiber blend
Spinning system, i.e., ring, rotor, air-jet, compact, etc.
Type of weaving machine, i.e. shuttle, projectile, rapier,
air-jet, water-jet, multiphase, etc.
Type of fiber, natural or manmade
Fiber blend
Construction and weave of fabric Environmental laws
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PREWETTING OF SPUN YARNS

The concept of prewetting spun yarns with hot water before
impregnating them with size solution is not new, but it has
received considerable attention in recent years [36,37].
Prewetting, in essence, is a washing process which improves
the specific adhesive force of the size on the surface of warp
yarns. The effect of prewetting was tested on 100%cotton,
polyester/cotton blended and 100%polyester ring, and rotorspun yarns [38]. The principle of prewetting spun yarns
before sizing is shown schematically in Fig. 4.47

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Quality Evaluation of Sized Yarns

The real performance of sized yarn can only be
appraised during the weaving operation. However,
the performance of sized yarns can be forecasted
by judging the following quality parameters:
Tenacity and breaking elongation of sized yarn
Cohesiveness and adhesion of the sized film
Abrasion resistance
Fatigue resistance
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 THANK YOU

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