CLASSIFICATION WARPING METHODS

1.Beam Warping

2. Section Warping

3. Ball Warping
1. Beam warping

❑Yarn is directly wound from cone onto the beam.

❑This process is suitable for single color weaving
❑The end product is called warp beam and must sent to the sizing
department for further process.
TYPES OF BEAM WARPING MACHINE
1. Direct Driven
2. Surface Driven
 2. Section Warping

❑Yarn is wound firstly wound onto a drum and then wound onto
the beam
❑This process can be used for both single or multi colour
weaving
❑The end product is called Weavers beam and can be directly
installed onto the weaving loom
3. Ball Warping

❑Ball warping is an intermediate process for storing yarn for

transport, dyeing or reserve.
❑It does not produce a beam.
❑The usual form is a cross wound cheese in which multiple ends
are wound at the same time in a ribbon whi contains perhaps
50 or a 100 ends
FLOW CHART OF WARPING

CREEL
CONTROL SYSTEM
REED
MEASURING ROLLER

WINDING ON A ROLLER OR BEAM

Direct warping Sectional warping

Major Component Of Warping Machine

There are two main parts of warping machine

❑ Creel: A structure for holding supply packages in textile processes
❑ Headstock: the major component of the warping machine that
actually rotates and winds the warp sheet or package
Function of component of creel

❖ Cone or cheese, spindle of high speed & peg for sectional warping
❖ Thread guide: To pass through the yarn in the required way.
❖ Tensioner: To keep the yarn always in a uniform tension
❖ Yarn cleaner: To remove various faults of yarn like slubs, neps etc.
❖ Suction fan or blower: To remove the dirt & dust from the yarn
❖ Breakage indicator: To indicate breakage in package.
❖ Stop device: To stop the m/c when yarn will be broken
Feature of components of head stock:
1. Adjustable or variable v-reed or wraith: To control the width of the warp beam.
2. Measuring & making device: Measure the amount of warp yarn on the beam & marks the yarn
3. Yarn speed controlling device: To control the speed of yarn.
4. Pneumatic pressure unit: To press the warp beam with the surface contact of driving drum.
5. Break assembly: It stop the mic after required length is wound on beam...
6. Driving drum: Beam is in contact & control with driving drum.
7. Stop notion: Used to stop the mic after required length is wound on beam.
8. Beam bracket: Ta support & hold the beam.
9. Lease rod: Used for separation of yam individually
 CREEL

➢ Independently of the warping system, the threads are fed from bobbins placed on creels.
➢ The creels are simply metallic frames on which the feeding bobbins are fitted; they are equipped
with yarn tensioning devices, which in modern machines are provided with automatic control and
centralized tension variation.
➢ The number of packages in a creel must be decided on the economic merit of any given situation
with warper's bobbin its capacity is from 400-600 packages, while with cones and cheeses the range
is wider, 600-1000 packages
➢ In deciding about creel size, weight of yarn on supply packages, floor space available and number
of beams required must all be considered.
 TYPES OF CREEL
1. AS PER THE SHAPE
a) H Shaped (Horizontal) Creel
 b) V Shaped Creel
❑ This type of creel is in the shape of V and it diverges on both sides from its
apex. And this apex is in line with the center of the machine.
❑ It is the most popular creel which is used for superspeed operations.
❑ Each column has package of capacity 540 ends.
❑ All the bottom threads from each column are taken and deposited at the
bottom of the column.
❑ Merit of this creel is that open space available for creeling during working of
the creel. So that the ends cannot touch or entangle with each other and
provides easy withdrawal of yarn from supply package.
❑ Tensioners are not available in this creel but the tensioning is by means of air
drag.
 TYPES OF CREEL
2. AS PER THE CONSTRUCTION
a) Truck/ Trolly Type
b) Continuous Chain Creel
c) Magazine Creel
d) Swivel Frame Creel
a) Truck/ Trolly Type

❑This is a readymade creel which

is moved by wheels to take the
position of the runout creel.
❑In truck creel, creel is variable
and headstock is rigid. Which
means the creel moves.
b). Continuous Chain Creel
❑ This type of creel is in the form of 2 arms and that forms an acute angle.
❑ The yarn from the supply package holders carry an endless chain and it also moves the exhausted
package away from the working position
 TYPES OF CREEL
c). Magazine Creel
❑ In this type of creel, the tail end of the yarn is tied up with the tip of the yarn
of another neighboring cone. So that the yarn in the first cone is exhausted
or completed, the transfer second cone takes place automatically.
❑ In this type of creel only half of the creel capacity can be used because for
every active there is a reserve package. Means if the creel has 1000 package
holders, then there are only have 500 ends in the warp sheet.
❑ The advantage of this creel is that the creel is continuous in working as the
yarn is shifted from active to reserve package.
❑ When the same kinds of yarns to be processed, one has to go with magazine
creel.
 TYPES OF CREEL
d). Swivel Frame Creel
❑ It acts as a variation to mobile creel.
❑ The bobbins which are weighing 5 to 25 kg cannot
be pinned on trolleys.
❑ So that the double-sided bobbin holder is used. In
this type of bobbin holder, the threads are
unwound from one side and an afresh series of
bobbins are creeled up on the other side.
 BEAM (HIGH SPEED) WARPING
❖High speed warping also called Beam warping/Direct warping.
❖In high speed warping the yarn is wound parallel of the warping beam.
❖All the yarns are wound at once and simple flanged beam is used.
❖It is a very high speed process and is used for making fabric of single colour.

FLOW CHART OF HIGH SPEED WARPING

CREEL
BEAM FOR SIZING
WEAVER’S BEAM
BEAM (HIGH SPEED) WARPING

Expanding Comb

Pressure Roller
MAIN PARTS OF BEAM WARPING MACHINE

1.Creel: Generally for this kind of warping a V-shaped creel is preferred, because it permits high running speeds (up to 1200
m/min) and high productivity
2.Expanding comb: The expanding comb has the aim of placing all threads on a width corresponding to beam width and the
aim of maintaining them in order and without entanglements. The comb has a zig zag shape, which permits its adjustment to
the different beam widths. The comb has two traverse motion ( horizontal motion to deposit uniformly the threads on the
beam and a vertical motion to avoid the local of the dents. A blowing system ensures that the comb remains constantly free
from dust.
3.Pressure roller: The pressure roller is coated with hard cardboard. The increasing winding thickness of yarn on the beam
moves the pressure roller backwards, thus opposing the resistance offered by the pressure at the set value. Thanks to this
compression, perfectly cylindrical beams are obtained. In the braking phase the pressure roller is immediately
lifted by an hydraulic control device.
4.Beam: Poly beam is use in present time.
FEATURES OF HIGH SPEED WARPING

1. It is used to make common fabrics in large quantities

2. It is used to produce weavers beam from single yarn
3. The production is high
4. Large amount of yam is required to produce a weavers beam
5. Sizing is done
6. Simple flanged beam is used and drums are not required
 SECTIONAL WARPING
❑In sectional warping equal length of yarn is first wound in small sections or sheets on a drum.
❑Then the drum it is transferred to the beam. By this process we directly get the weavers beam.
❑This is a two method and is used for making fancy fabrics.
❑Sectional warping is cost-effective for short and striped warps (cotton and wool fabrics).
❑The warn speed is about 800 m/min, while the beaming speed is about 300 m/min
FLOW CHART OF SECTIONAL WARPING
CREEL
DRUM
WEAVER’S BEAM
SECTIONAL WARPING
MAIN PARTS OF SECTIONAL WARPING MACHINE

1. Creel
2. Tensioner
3. Central powered tensioner control
4. Computer
5. Leasing and splitting device for sizing
6. Dresser
7. Carriage bearing