Warping and its Types

Warping:

Warping is a process in which number of the yarns end from the yarn packages or cones are wound on the warping beams.

Or

Warping is transferring many yarns from a creel of the single end package forming a parallel sheet of the yarn wound on to a beam.

Objectives of the warping:

         

The object of warp preparation is to transfer yarn from the spinner's package to a weaver's beam that can be placed behind a loom ready for weaving. A weaver's beam usually contains several thousand ends and for a variety of reasons, it can seldom be made in one operation.

There are two main objective of the warping

Ø Collection of the number of the yarns end required in the fabrics

Ø Winding a specific type of the package as required by subsequent process i.e. warper’s beam or ball etc

Types of the warping:

There are three common types of the warping

Ø High speed warping (Direct warping)

Ø Section warping (Indirect warping)

Ø Ball warping

High Speed Warping:

          In this system single end of the yarn from the cones or packages are directly wounded on the warping beams. This is the winding of total number of warp ends in full width in a single operation from creeled bobbin.

This process or system is used for the mass production. This is used to make smaller intermediate beams called warper’s beams. These smaller beams are combined later at the sizing stage to produce the weaver’s beam. This process is called beaming. Therefore, for if the weaver’s beam contains 10,000 warp ends, then there would be-say – 10 warper’s beams of 1,000 ends each. If this weaver’s were to be made in one stage, the creel would have to have 10,000 yarn packages, which is impossible to manage.

Section of High Speed Warping:

Ø Creel

Ø Warp Break Sensor

Ø Expanding comb

Ø Pressure roller

Ø Beam

Section Warping:

          In the section warping, first the yarn ends from the creel are wounded on the warping section beams which are winding section. After this, this section yarn are then wounded on the warping beams. Then the warping beams without sizing are applied to the loom to produce the grey fabrics. This system takes time so the production will not so good. It is clear from the above it is two step processes.

Feature of Sectional Warping:

Ø This is suitable for making checked, stripped or other fancy fabric.

Ø Fabrics which don’t required sizing

Ø Fabric with strip of different colors or different type of yarns

Ø Less no of ends of warp in the sheet

Ø The production is less in sectional warping

Ø It is less efficient than high speed warping

Where length of the warp are comparatively small as this is slow speed process and can’t coup up with mass production orders.

Ball Warping:

                   In this system the large no the strands of the yarn of specific length in the form of loose untwist rope are wounded.

This system is mainly used when the yarn is dyed for denim fabrics. This rope consists of the 50 to 100 yarns. Such a beam is termed as ball. After the dying process the rope ends are again separated and wound on another warping beams (long chain beaming). Warp beam so produced are then combined on the sizing machine for applying the size and then wound on a weaver’s beams.

Machine of warping:

         

There are two main parts of the machine of the warping:

Ø Creel   

Ø Head Stock

Creel:

      The creel is a structure which is used to hold the cones on the spindle.

Creel structure:

Spindle:

          Spindle is a part of a machine around which cone turns at the time of withdrawal of yarn or place for supply package.

Pegs:

        This is used to hold the cones on the creel

Guides:

          Guides are a component for controlling the path of a running material.

Tensioners:

     This is device which is use the keep the strength in warp yarn constant.

Stop motion pins.

Creel capacity:

    Creel capacity depend upon the

Ø No the rod of the creel

Ø No the spindles that holds the cones on the creel

Types of the creel:

       There are two type of creel according to the shape:

Ø V-Shape Creels

Ø H-Shape Creels

Ø Mobile Creels

Ø Magazine Creel

Ø Swivel Frame Creel

Differences between Sectional and High Speed Warping

High Speed Warping	Sectional Warping
1. Beam warping is used for long runs of grey fabrics & simple pattern.	1. Sectional warping is used for short runs especially for fancy pattern fabrics.
2. The amount of colored yarn is less than 15% of the total.	2. Greater amount of colored yarn is used.
3. High production.	3. Low production.
4. Large amount of yarn required.	4. Small amount of yarn required.
5. Single yarn is used.	5. Twisted yarn is used.
6. Less expensive.	6. More expensive.
7. It is most widely used for cotton, linen, woolen & worsted yarn.	7. It is most widely used for cotton, silk & synthetic yarn.
8. Uniform tension of yarn.	8. Less uniform tension of yarn.
9. Weavers beam is produced after sizing.	9. Weavers beam is produced after warping.
10. Creel capacity is more.	10. Creel capacity is less.
11. Beam warping is more widely used.	11. Sectional warping is not widely used.