The document presents a comprehensive study on direct warping in textile engineering, detailing its definition, types, requirements, and the working principles of a high-speed warping machine. It covers the advantages and disadvantages of direct warping, along with typical calculations, components, and methods to improve the warping process. Furthermore, it discusses common faults in warping and their remedies.

1. Study on Direct Warping
DHAKA UNIVERSITY OF ENGINEERING &
TECHNOLOGY, GAZIPUR
Presented By :
Md. Ariful Islam (Arif)
(ID : 175002)
Department of Textile Engineerng
DUET, Gazipur
08-Jan-20

2. What is warping ? 02
• In textile sector, weaving is the first process
of fabric manufacturing. Here, warping is
defined as the parallel winding of warp yarn or
warp ends from cone, cheese winding package
on to a warp beam. According to required quality
of fabric, warping should be done by using
required quality of yarn packages. Otherwise,
fabric quality will be hampered.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

3. Requirement of warping 03
The individual ends of the sheet should be spaced uniformly across
its full width.
All the ends in the sheet should be wound at almost uniform tention.
The density of wound yarn beam should be uniform across the width
and from start to end of winding the sheet.
The yarn breakage during warping should be as minimum as possible.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

4. Requirement of warping 04
Density of the beam should be controlled not by increase yarn
tension but by adjusting the pressure roller on the beam in case of
spindle driven beam.
The production rate of warping should be as high as possible.
A predetermined warping length should be observed.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

5. Types of warping: 05
1. High speed/ beam/ direct warping (preparatory beam
warping).
2. Sectional or pattern warping (conical drum or dresser
warping).
3. Ball/cross warping.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

6. Direct warping 06
• High speed warping also called
beam warping/direct warping In
high speed warping the yarn is
wound parallel on 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 color.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

7. Flow chart of high speed warping: 07
Creel
↓
Beam for sizing
↓
Weaver’s beam
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

8. Features of high speed warping 08
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 yarn is required to produce a weavers beam
5. Sizing is done
6. Simple flanged beam is used and drums are not required
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

9. Main parts of high speed warping machine 09
• Creel
• Expanding comb
• Pressure roller
• Beam
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

10. 10• Creel: Creel is a part of direct warping machine which holds the
yarn packages. The creel capacity is about 600-800 in direct
warping.
• Expanding comb: Yarn pass through the expanding comb.
• Pressure Roller : It presses the warp beam with the surface contact
of driving drum.
• Beam: Beam is the machine parts where warp is wounded.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

11. Working principle of beam warping machine 11
 Based on the production programs operator collects yarn from the store as per
requirement count, name of yarn manufacturer, yarn lot & quality
 The machine operator, creel men and helpers open/break the yarn
cartons/bags and place the cones/chesses on the creel as per program and draw
the head end of each cone/chesses through the hole of vertical disc, tension
disc, yarn guide, stop motion device and then through expanded comb of
beaming unit.
 The creel and direct warping machine setting are done according to the
requirement as per operating instruction.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

12. Merits & demerits of direct warping 12
Merits
High production
Less expensive
 Uniform tension of yarn
Creel capacity is more.
Beam speed is high
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

13. Merits & demerits of direct warping 13
Demerits
Large amount of yarn required.
Weavers beam is produced after sizing.
Direct warping is not suitable to produced stripe effect.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

14. Q-1: What are the components of a headstock of a direct 14
warping machine?
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.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

15. 15
5.Break assembly : It stop the machine instantly in case of yarn breakage.
6.Driving drum: beam is in contact & control with driving drum.
7.Stop motion: used to stop them after read length is wound on beam.
8.Beam bracket: to support & hold the beam.
9.Lease rod: used for separation of yarn individually.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

16. Q-2:Why direct warping is not suitable to 16
produced stripe effect?
To produce stripe effect warp patterning is used. For creating stripe
effect, different types of colored yarn is needed. Warp patterning is not
possible in direct warping. For producing stripe effect sectional warping
must be needed.
That’s why direct warping is not suitable to produced stripe effect.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

17. Q-3: A calculation for direct warping: 17
The no. of cone available in a packet is 24 & total weight of the packet is
100 lbs. Creel capacity 580, length variation is 5%. Find out the length of
yarn per warp beam.
Solution:
We know,
Total no. Of ends = EPI x fabric width
= 100 x 116
= 11600 08-Jan-20Dhaka University of Engineering & Technology, Gazipur

18. A typical calculation for direct warping: 18
No. of warp beam = total no of ends /creel capacity
= 11600/580
= 20
Now 1 cone weight = total weight of the packet/ no. of cone in a packet
=100/24
= 4.16 lbs.
Now 1 cone length = warp count x cone wt. In lbs x 840
=40 x 4.16 x 840 yds.
= 40 x 4.16 x 840/1.0936 m
= 127812.73 m
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

19. A typical calculation for direct warping: 19
• length variation = 127812.73 m x 5%
= 6390.64 m
so, yarn length in 1 cone = calculated length – length variation
=127812.73 m – 6390.64 m
= 121422.90 m
• Length of yarn per warp beam = total length in 1 cone/no of warp
beam
= 121422.90/20
= 6071 m 08-Jan-20Dhaka University of Engineering & Technology, Gazipur

20. Difference between direct & sectional warping 20
Direct Warping Sectional Warping
1.Common fabric is produced 1.Fancy fabric is produced
2.High production 2. Less production
3.Large amount of yarn is required 3.Small amount of yarn required
4.Single yarn is used 4. Twist yarn is used
5.Cheap process 5.Costly process
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

21. Faults of warping 21
• 1. Lapped end
• Cause:
• The broken end of yarn is not tied to the end on the warp beam & overlaps the adjoining yarn. The beam is not
properly brake & the signal hook fails to operate.
• Remedies:
• Tying the broken end to the end on the warp beam.
• Proper signal hook.
• 2. Piecing
• Cause:
• One broken end is pieced to another yarn end on the warping beam.
• Remedies:
• By proper joining.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

22. Faults of warping 22
3.Soft ends on the warping beam
• Cause:
• Breakage of a group of ends & piecing them in bundle or by lapping. This defect is caused by the
careless of the operator.
• Remedies:
• Careful operation.
• Broken end should be piece up properly.
4.Broken ends on the beam
• Cause:
• A group of ends is broken & tied as a brunch or worked-in with overlapping.
• Remedies:
• Broken ends should be removed.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

23. How to improve beam warping process? 23
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.
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

24. How to improve beam warping process? 24
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
08-Jan-20Dhaka University of Engineering & Technology, Gazipur

25. 25
Thank You
08-Jan-20Dhaka University of Engineering & Technology, Gazipur