Sectional Warping & its Calculations PDF

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What is sectional warping? It is a process in which equal length of yarn is first wound in small sections or sheets on a drum. Then from the drum it is transferred to the beam in the form of a sheet. It is a two stage process and is used to produce fancy fabrics by color and weave effect. It is also...

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What is sectional warping? It is a process in which equal length of yarn is first wound in small sections or sheets on a drum. Then from the drum it is transferred to the beam in the form of a sheet. It is a two stage process and is used to produce fancy fabrics by color and weave effect. It is also known as:    

Indirect warping Pattern warping Band warping Drum warping

Flow Chart of Sectional Warping

Creel

Drum

Beam

• Arrangement of cones as per color repeat in warp

• Transferring of warp sheet in the form of section from creel to drum

• Transferring all the sections in sheet form onto the beam

Process of sectional warping

 It is a two stage process, called the warping and beaming  Warping is done from creel to drum. Creel capacity is small as compared to direct warping.  The drum/swift is tapered at a slight angle to provide support to the yarn and it also prevents the slippage of yarn. Higher the taper angle less will be the package stability.  The yarns are laid section-wise, starting from the conical base side Page 1 of 6

 The first section is supported by the taper of the base and the subsequent sections supported by the taper formed by the preceding section.  Each section has multiple ends per sequence required, while section length is the same.  The number of ends is same in each section, except the last section also known as the cut-able section.  The sections are traversed on the drum during warping along the width of section to form an angle.  Length of the yarn is measured by the measuring roller. Features of Sectional Warping

 This is suitable for making checked, stripped or other fancy fabric.  We directly obtain weaver’s beam from this process.  As sizing is not done, so multi-ply yarns or yarns which do not require sizing are used.  Small amount of yarn is required to produce the weaver’s beam.  Sectional warping is used to produce a warp beam with a greater member if ends.  The production is less in sectional warping.  The yarn tension is less uniform.  It is less efficient than high speed warping.

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Set calculations for given quality and color repeat We were provided with the following fabric:

The steps involved in the set calculations were:    

The count of the warp yarn was found out. The count of weft yarns was determined. The EPI (ends per inch) and PPI (picks per inch) were determined. All the yarns, along the warp side and along the weft were of the same count, except the color.

The quality was found to be: Quality: 30×30 / 91×86, 65” Warp Repeat: 72 ends 35 (white) + 30 (D. blue) + 3 (L. brown) + 4 (L. blue) Page 3 of 6

Total ends: 91×65 = 5915 No. of repeats per section: 4 Creel Capacity Creel Capacity = 4×72 = 288 No. of sections

No of Sections = 5915 / 288 = 20.536 = 21 Cut-able Section Ends Cut-able section ends = 0.536 × 288 = 155 Section Width

Section Width = 2400 / 20.536 = 116.868 mm Reed Count

= (288×25.4) / (116.868×3) = 7315.2 / 350.604 = 20.865

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Yarn weight required for given set length Quality: 30×30 / 91×86, 65” Total ends: 91×65 = 5915 Set length = 5000m Warp Repeat: 72 ends 35 (white) + 30 (D. blue) + 3 (L. brown) + 4 (L. blue) Repeats per section= 4 No. of sections= 21 Ends/section L. blue = 4×4=16 White = 35×4=140 D. blue = 30×4=120 L. brown = 3×4=12 Warp Length Single yarn length to warp all sections = 21×5000 = 105000m Wastages and remainder = 1000m Total length = 105000 + 1000 = 106000m Warp Weight

Warp Weight (lbs) = (106000 × 1.0936) / (30 × 840) = 4.60 lbs

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So, Weight of blue cones = 4.60 × 16 = 73.6 lbs Weight of white cones=4.60 × 140 = 644 lbs Weight of D. blue cones=4.60 × 120 =552 lbs Weight of L. brown cones=4.60 × 3 =55.2 lbs So, Total weight = 1324.8 lbs

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