Warping is intermediate process between the winding and the sizing processes. Warping is an essential weaving preparatory process in weaving unit. This is a very common say about warping, “good warping finishes fifty percent weaving.”A warper beam may contain about 500-1000 warp ends.
Fig: Schematic diagram of Warping
The major objective of warping is to prepare a warp sheet of desired length containing a desired number of yarns that are 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 wrapping of the warp beam. The process of warping is dedicated to the conversion of cones into a beam of given specifications.
There are different types of warping, which include beam warping, sectional warping, beam to beam warping, draw-warping and ball warping. In this article I will discuss about beam warping, parts and working principle of beam working machine and way to improve beam warping process.
What is Beam Warping?
Beam warping is a vital process in the weaving preparation stage of textile manufacturing. The beam warping is normally used for grey single yarns or double yarns which require to be sized. The beam warping system is also known as direct warping, as the warp beam is produced directly from cones arranged in the creel. In some mills, beam warping is used even for double and multi-fold yarns where sizing is not required, but weavers beam is prepared by using a dry tape machine, where different beams are just combined and final beam is made. Beam warping is used mostly when several beams of same warp length have to be prepared.
Beam warping is used for preparing warp beams suitable for feeding to sizing machine. Normally, beam warping is done for spun single yarns, and filament yarns those are needed to be sized and used for producing fabrics those are either piece dyed or going for printing. Beam warping is the process of creating the base yarn sheet with specified number of ends of specified count and pattern that runs top to bottom on woven cloth. A set of cones are creeled in warping machine and ends are taken together with a uniform tension in a sheet form and wound on a beam. Number of such beams is combined together in sizing depending on the number of ends required in the fabric.
Beam Warping Machine is used to transfer yarns from the creel directly onto a warp beam, which is later used in weaving or sizing. Unlike sectional warping, beam warping prepares multiple beams with the required number of ends in one operation, making it suitable for large-scale production, especially in filament yarns. The latest beam warping machines have a very simple design, which results in higher speed & consequently in output increase.
Direct warpers are used to warp all conventional staple fibers, regenerated fibers and filaments. In direct warping, a flange beam is used. Since all the yarns are wound at the same time, the flanges provide sufficient yarn stability on the beam. The typical beam flange diameters are 800, 1000, 1250 and 1400 mm with working widths of 1400 to 2800.
Machine specific options include tape applicator, static eliminator, windscreen, comb blowing and dust extraction devices, yarn storage and inspection units, oiler, tension roller unit, beam removal unit and control platform.
Modern beam warping machines have creels with moveable trolleys; inside with 8 rows and 5 stands in each holding 40 cones on each side. The trolleys are movable so that cones can be creeled in reserve when one set is working in the machine. There are 9 such moveable trolleys in working condition, so that 360 cones can be creeled on each side totalling to 720 cones.
Main Parts of Beam Warping Machine:
Beam warping machine is made of various essential parts like
Creel,
Tension and Guide Devices
Measuring roller,
Open reed,
Head stock, and
Warping drum, etc.
Fig: Parts of beam warping machine
Various parts of beam warping machine are discussed below:
1. Creels
Creel is the most space-occupying part of the warping machine. There is a three-dimensional arrangement of pegs to hold the cones. The design of each peg is dedicated to hold the cones by gripping the inside wall of the shell of a cone securely, and be strong enough to support a cone in space at varying angles from neighboring cones.
The creel is a stand for holding the supply packages in the form of wound packages. It enables to hold the supply packages in proper position for warping, and constitutes an important component of the warping machine.
Fig: V-shape creel
A creel that can accommodate 300 pegs must therefore have 300 sets of thread guides, tensioner, and thread detectors. Each peg occupies a different location in the creel.
Fig: Rectangular creel
There are various types of creels: V-shape creel, Rectangular creel, Truck creels, Swiveling creel, Continuous chain creels, Magazine creels, Automatic creel etc.
2. Tension and Guide Devices
These devices regulate yarn tension during unwinding and guide the yarn smoothly toward the beam. They prevent slackness or excessive tightness, ensuring uniform tension across all ends.
Fig: Yarn tensioning device on warping creel
3. Measuring Roller
This roller measures the length of yarn being wound during warping. It ensures that the warp drum or beam contains the exact required length for weaving preparation.
4. Open Reed
The open reed is a comb-like device through which yarns pass after leaving the creel. It keeps yarns parallel, maintains proper spacing, and prevents tangling during winding.
5. Head Stock
The head stock contains the motor, gears, and brakes that drive and control the machine. It regulates the speed, rotation, and tension needed for smooth warping.
6. Warping Drum
The warping drum is a large cylindrical part where warp yarns are wound in layers. It stores the yarns in proper order and tension, preparing them for the next weaving stage.
Working Principle of Beam Warping Machine:
In beam warping, the yarns are withdrawn from the single-end yarn packages on the creel & directly wound on a beam. Direct warping is used in two ways:
A) Beam warping can be used to directly produce the weaver’s beam in a single operation. This is especially suitable for strong yarns that do not require sizing such as continuous filaments & when the number of warp ends on the warp beam is relatively small. This is also called direct beaming.
B) Beam warping 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, hen there would be-say – 10 warper’s beams of 1,000 ends each. If this weaver’s were to be made a one stage, the creel would have to have 10,000 yarn yarn packages, which is impossible to manage.
How to Improve Beam Warping Process?
Beam warping process is the most progressive process ensuring a high quality of produced warps & high efficiency. In cotton weaving, beam warping is mostly used.
Better uniformity in the tension of individual yarns are the provision of adjusting the tension of separate groups of warp yarns over the height of the warping creel.
Enlarging the mass of bobbins & warping beam winding.
Increased number of bobbins when warping yarn of low linear density & a greater number of yarns in the warp.
Improved shape of winding on the warping beams & uniformity of the specific density of winding.
Higher accuracy in warp measuring & reduction of wastes caused by irregular unwinding of warps from the beams at sizing.
Compensation of warp tension at starting & stopping of the machine & slow running at starting a new warping beam.
Increase of labor productivity in warping by partial or full automation of bobbin change.
Conclusion
Beam warping machine is an essential preparatory device in weaving, designed to wind hundreds of warp ends directly from the creel onto a warping beam with uniform tension and spacing. This machine is critical for subsequent weaving operations as it holds yarns in preparation for fabric production, ensuring quality and efficiency in textile manufacturing.
References
[1] Gokerneshan, N. (2023). Weaving preparation technology. Abhishek Publications.
[2] Adanur, S. (2020). Handbook of Weaving. CRC Press.
[3] Purushothama, B. (2016c). Handbook on fabric Manufacturing: Grey Fabrics: Preparation, Weaving to Marketing. Woodhead Publishing India in T.
[4] In, M. K. S. P. (2015). Industrial practices in weaving preparatory.
[5] Reference Books of Weaving (ACIMIT) by Giovanni Castelli, Salvatore Maietta, Giuseppe Sigrisi, Ivo Matteo Slaviero
Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. Mr. Kiron is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.
