Types Of Creels

Single end Creels

Magazine Creels

Traveling Package or Multiple Package Creels

Types of Warping

Direct warping

Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new wound package for an easy package transfer. from the wound packages in the creel.

Beam Warping

A weavers beam may have upto 10,000 ends and if this were to be produced directly it would be necessary to have upto 10,000 creel packages.such an arrangement would be very difficult to accommodate and manage ;consequently it is normal practice to produce warpers beams which may contain upto about 1000 ends and these are combined at the slashing stage.because of the difficulties involved in combining the ends ,patterned warper beams are seldom produced on the direct system and any pattern that is produced is achieved by combining beams of various colors at the later stage of slashing.

 This imposes limitations which can only overcome by changing to pattern weaving.

 Sectional Warping

In sectional warping sections are made sequentially and because of this the process is rather slow ;it is the practice therefore to produce no more than is required to fill a single weavers beam.the result is that the sectional warping is used mainly for short runs or for complex color patterns.

Pattern, Band or Drum Warping

Because many warpers beams are combined in the direct system,this is usually regarded as a high speed process particularly suitable for single color work .providing the warpers beams are of single color ,it is possible to combine them to produce simple patterns distributed over the warp width.

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 which contains perhaps 50 or 100 ends.

Stages Invoved In Warp Preperation

1) Winding from Spinner's Packages to Cones

2) Winding from Cones to Warp(Warping)

3) Applicaton of Size and Lubricant to Warp(Slashing)

4) Drawing-in or Tying-in

The primary objective of the warping process is to provide a continuous length of yarn from individual wound yarn packages, in sheet form to a beam for the succeeding process. There are several types of warping techniques, including: ball, direct, draw, indirect (also called sectional) and sample warping. This review focuses on the three most popular process types, direct, indirect, and sample warping.

When utilizing any technique in the warping process it is important to minimize end breaks, keep a constant and uniform tension on the yarns, keep a constant yarn speed, and insure quick response braking of the warper. These factors play a large role in the quality of the warp yarns, which in turn influences the runability of that warp yarn in the succeeding process. 

 

Most modern warpers are equipped with electronic stop motions which stop the warper as soon as a broken end is detected. It is crucial that the braking system is fast enough to stop the warper before the end reaches the beam. The end is much harder to find and correct once it has been wound onto the beam. Today's braking systems allow the beams to stop before one full revolution has occurred on the warp beam, in a direct system, or on the pattern drum in an indirect system.

Advancements in electronic technology have made these factors easier to control,but ensuring the quality of the warp beam is still the responsibility of the operator. Warping machines are capable of reaching well over 1000 yards per minute and are now able to stop after an end break without advancing more than one full revolution of the section beam. Warping has gained new respect in weaving plants, and is rightfully referred to sometimes, as the cornerstone of good weaving preparation.

Overview of Warping

Warping gathers yarns from a number of bobbins and wound them close together on a reel or spool. From there they were transferred to a warp beam, which was then mounted on a loom. Warp threads were those that run lengthwise on the loom.

At warping, the goal should be to avoid missing ends. Number of thread breakages should not exceed seven per 10 million meters. This can be achieved by ensuring a top quality yarn package and by following the warping process parameters mentioned below :

• Precise Creel Alignment

• Reliable stop motion on creel and on warping drum, so that broken ends are traceable for knotting.

• Minimum wobbling of warping beams.

• Uniform selvedge with good flanges.

• Yarns should by preferably warped on spindle driven machines to avoid thermal damage due to abrasion.

• Warping machines such as Benninger or Hacoba are preferable. 

With Drum Driven Warpers such as the BC Warper, the following precautionary measures are to be taken :

• Frictional drum should be kept in a polished state.

• Brake should be ver y efficient.

• Aluminium cast flanges should be used to get faulteless selvedges.

• Breakages rate should not exceed 0.3~0.5 breaks per 1000 m / 500 ends.

• For wider width looms, wider warping machines are preferred.