Warping is transferring many yarns from a creel of single end packages forming a parallel sheet of yarn wound onto a beam or a section beam Collection of required numbers of ends and length on a package
Winding a specific type of Package as required by subsequent process i.e. Warpers beam, Ball etc Introducing a design/pattern ( Sequence of colored yarns such as section beam)
High Speed Warping (Direct Warping) Sectional Warping (Indirect Warping) Ball Warping (Used for Denim Fabrics) Draw Warping (Heat Set)
Yarns are withdrawn from the single-end yarn packages on the creel and directly wound on a beam Used for longer runs of fabric High production as compared to other types of warping
Process of winding yarn on tapered or section beam Package wound on Drum and then Warper/weaver beam produced Complex colored patterns Short runs (500-10000)
Ball warping is the process of winding warp in rope form onto balls.
Balls are cross wound packages like cheese but warp is form of rope. Ball is wounded on special wooden core called log. Balls are specially used for Indigo-dyeing for denim fabrics. After production of balls rope dyeing is done. Re-beaming provides with conversion of rope dyed warp yarn, stored in cans, into Warper's beams Used only where mono colour dyeing of warp is required
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Combining the drawing of filament yarns with heat setting and warping processes achieve uniform stretching and heating for improved dye uniformity, end to end Could be hot or cold drawing used for weaving of thermoplastic yarns
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Headstock
The major component of the warping machine that actually rotates and winds the warp sheet on package (i.e. Warper's beam)
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W.r.t shape
Truck/trolley type Travelling package Swivel/swinging door Magazine Creel Duplicate Creel Roller Creel
W.r.t construction
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H Shaped Creel
V Shaped Creel
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V-Shaped Creel
H- Shaped Creel
Wings/Arms are placed at certain angle Yarns do not touch Suitable for high speed warping
Wings are parallel to each other Yarns may touch each other Suitable for slow speed warping
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Usually more than one creel is used to save time If headstock is moveable, duplicated creels are used If headstock is fixed, a truck/trolley creel is sued Magazine creel contains a working and a reserve spindle For confined spaces, swivel frame creel can be used In Travelling package creel is like a continuous belt. Once emptied, the creel train is replaced by rotation and warping continues Roller creel is used typically for carbon filaments, aramid fibers
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Magazine Creel
Swivel Creel
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Vertical Rods
Pegs/Spindle
Each wing contains vertical rods Capacity is determined with the help of no. of these rods The supports to hold yarn package
A component for controlling path of a running material (yarn) Tensioners A device which keeps yarn under constant tension so that yarn is kept stretched Two tensioners for one package
Guides
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Cutting assembly
When active yarns are consumed, all clamps are engaged and yarns are cut
Sensor
Used to sense the presence of yarns,
Vibratory & photoelectric (optosensor)
Creel Capacity Maximum number of yarns that can be wounded at a time is called creel capacity C.C = 2 x no. of rods/wing x no. of spindles/rod Creel angle
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Blowpipe
A structure contain vertical needles to keep yarn parallel Zig Zag comb (Extendable) Horizontal & vertical traverse
Giude Roller
Stainless steel pipe with holes to blow air for fluff removal. Keeps yarn in proper position and helps locate the broken ends