Automation in Warping and Sizing Process

Last Updated on 18/02/2021

Automation in Warping and Sizing Process

Hafiz Abdul Mannan
National Textile University, Faisalabad, Pakistan
Phone: 0092-3236052101


Warping Process:
Warping is a preparatory process of weaving. A woven fabric is made up of two sets of yarn called as warp and weft. Warp is the set of yarn that run along the length of fabric and weft yarn goes across the width. The main purpose of warping is to prepare a warp sheet of desired length containing a specific number of yarns. During this process, the warp sheet is wrapped on a flanged barrel in such a manner that tension in each yarn and density of yarn mass in the cylindrical assembly are maintained within a given tolerance level throughout the body of the product known as a warp beam.

There are different types of warping, which include beam warping, sectional warping, beam to beam warping, draw-warping and ball warping. Different types of machines are used in different types of warping process. Nowadays automation is widely used in warping and sizing machine in weaving industry.

Automation in Warping Process:

  1. Feeler roller to apply material specific pressure to obtain exact cylindrical warp build-up;
  2. Lease and sizing band magazines
  3. Constant warp tension over the full warp width;
  4. Automatic section positioning with photo-optical section width measurement;
  5. Pneumatic stop brakes;
  6. Warp tension regulation for uniform build-up;
  7. Automatic warp beam loading, doffing and chucking.
  8. Head stocks are equipped with advanced design features such as precision direct drive, advanced electronics, smooth doffing and programmable breaking
  9. Stop motion sensors are used when yarn breaks.
  10. Automatic creel movement
  11. Yarn length measuring devices are used to measure the warp yarn length.
automated sectional warping machine
Fig: Automated sectional warping machine

Sizing Process:
Sizing machine control systems provide a tool for management to insure that all warps are sized identically under standard operating conditions. These monitoring and control capabilities can be included in a computer network of a weaving mill. For years knitting machine manufacturers have been making excellent use of electronics to provide machines that are more automatic and versatile and many refinements of these advances have been made. These automatic machines are already ‘islands of automation’ that can be incorporated into a CIM network.

Automated weaving plants are on the drawing boards. None is yet in operation but should be a reality within a few years. The six production steps winding, warping, sizing, weaving inspection and packing include 16 points of automation. Of these, 12 deal with materials handling or transport. Only four applications deal with automating the machine operations themselves.

Automation in Sizing Process:

  1. This includes automated process control on the slasher of
  2. Automation on creel zone by pneumatic cylinder
  3. Control the tension of yarn by sensors or pendulum roller
  4. Control the temperature and level of size paste in size box
  5. Control the temperature and level of size paste in size cooker
  6. In drying zone, control the temperature
  7. Control the percentage of moisture content by sensor
  8. Control the headstock system
Automated size pressure cooker
Fig: Automated size pressure cooker

You may also like:

  1. Loom Data Monitoring System in Weaving Mill
  2. Yarn Sizing: Important Warp Preparatory Process
  3. How to Improve Productivity and Efficiency in Weaving Mill
  4. Loom Motions: Primary, Secondary and Stop Motions of Loom
  5. Warping Calculation | Calculation for Direct Warping and Sectional Warping

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