Warping is important for weaving process. Warping process are mainly two types they are as follow:
- Sectional warping or pattern warping.
- High speed warping or beam warping or direct warping.
This two process have lots of features. It is important to know the advantages and disadvantages of two types. If we have idea about the difference between sectional warping and direct warping then it will be very easy to choose the easiest one for the application. For this reason I like to present the comparison between sectional warping and high speed warping.
Difference between sectional warping and high speed warping:
|High Speed Warping
|To produce common fabric in large quantities (grey fabric).
||To produce stripped fabric.
|Production speed is high.
||Lower production speed.
|To produce warp beam from large amount of warp yarn.
||To produce warp beam from small amount of warp yarn.
|Creel capacity is high.
||Lower creel capacity.
|Weavers beam is produced after sizing.
||Weavers beam can be found immediately after sectional warping.
|Higher length of warp sheet is produced.
||Lower length of warp sheet is produced.
|Cone or cheese bobbin is used.
||Flanged bobbin is used.
|Single yarn is used.
||Fly or twisted yarn is used.
|One stage is involved.
||Two stages are involved.
|High speed is less expensive than sectional warping.
||Sectional warping is expensive.
|Uniform tension of yarn is obtained.
||Uniform tension of each yarn can not be maintained.
|Cotton, linen, worsted and woolen yarns are processed by this process.
||Mostly used for processed silk and man-made fibers.
|High speed warping is more popular and widely used than sectional warping.
||Comparatively less used process.
Warping is the first step of fabric manufacturing process. After winding, warping process is done for making a weavers beam. Weavers beam is produced from a set of yarns of same yarn count or different. In most of the cases we see that different yarn count is used for making sacking fabrics in jute mills. But most of the fabrics are produced from same yarn count. It is noted that all requirements are depends on the fabric structure. Production of Weavers beams depending on the fabric structure. Fabric structure plays an important role in fabric manufacturing process.
In textile language; warping is defined as the parallel winding of yarn from cone or cheese package on to a warp beam. It is needed to confirm that warp beam is make from good warp yarn otherwise weaving performance will be hampered. So it needs to require to provide a good warp beam. Faulty weavers beam is one of the causes of wastage in weaving section.
Objects of warping: Followings are the most common objects of warping:
- To wound up fixed length of yarn on to a warp beam.
- To increase the weavability of yarn.
- To increase the quality of yarn.
- To make re-useable small package.
- To make convenient yarn sheet for next sizing process.
- To increase the production.
- To make dynamic next process.
Importance of warping: Warping process plays an important role in fabric manufacturing. Followings are the most common importance of warping.
- Warp beam are constructed by warping.
- Parallel yarn sheets are constructed by this process.
- Predetermined yarns are wound from the yarn package.
- Small packages are combined by this process.
- Long length of warp yarns is found in this process.
- Various yarn faults like thick and thin place, larger knots are modified by this process.
- Small packages become re-useable by this process.
- Warping accelerates the next sizing process.
So, warping is important for accelerating the next sizing process.
In woven fabric manufacturing technology two types of yarns are used they are warp and weft yarn. But in knit fabric manufacturing one set of yarns are used. The yarn which is placed in the longitudinal direction of a woven fabric is called warp yarn. Warp yarn is used for make a weaving beam. The yarn which is used for cross interlacement through the warp beam is called weft yarn. Warp yarn count is finer than the weft yarn count.
Warp yarn should have various qualities which ensure the quality of fabric. Number of warp yarn which is used for making a specific fabric that is fixed by the calculation of fabric construction. Following properties should have a warp yarn; they are as follows:
- Cross section of the warp yarn should be uniform.
- Warp yarn should be sufficiently and uniformly strong.
- Warp yarn should be less hairy.
- Warp yarn must be dust free and clean.
- Knots of a warp yarn should be minimum.
- Application of size materials on warp yarn should be standard and knots must be proper otherwise warp yarn face difficulties during passing into the eye.
- Arrangement of warp yarn in the weavers beam should be parallel.
- Warp yarn should be free from naps, slubs and loose fiber.
- Tension of warp yarn in the weavers beam should be uniform.
So, when we will select warp yarn we should remember the above properties of warp yarn. After making weavers beam, it becomes ready for fabric production. It is note that; woven fabrics may be colored or in grey form. Grey fabrics send for dyeing if needed.