Sectional warping

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

In sectional warping 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.
By this process we directly get the weavers
beam. This is a two stage method and is used for
making fancy fabrics.
Working Principle:

Sectional warping is used for short runs

especially for fancy pattern fabrics.
2.
In this case sections of the warp which may
contain up to 1000 ends are first wound onto a
drum tapered with a given cone angle.
1.

So cross wound sections are combined on the

drum & thus each layer of warp contains the
same number of ends on the drum.
4.
Then the warp threads altogether are
transferred onto a weavers beam by unwinding
the drum.
5.
In this method the warp threads are not
necessarily processed in sizing.
3.

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
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 cutable 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.
Sectional warping machine:

Warp Creel:

A warp creel for a beam warping machine is

disclosed which comprises a number of bobbins
arranged in horizontal and vertical rows, a thread
or yarn or the like being continuously withdrawn
from such bobbins. At the region of a

predetermined portion or section of the warp

creel, at the rear region of such creel, there
extend a multiplicity of rods which rise vertically
over all of the levels or storeys of the warp creel
and impart a deflection or turning motion to the
threads of at least one vertical bobbin row. The
rods are displaceable supported between a
preparatory position orienting the individual rods
in front of the thread tensioning and monitoring
devices of the related bobbin rows and a
bunched together or clustered terminal position
located towards the creel delivery or outfeed side
and serving to separate the threads. Due to
these measures it is possible to adequately
separate the threads practically without any
additional friction, and the accessibility for
drawing-in the threads during bobbin change
operations or thread rupture is completely
maintained.
Section laying:

The yarns are laid section wise, starting from the

conical base side. The first section is supported
by the conicity of the base and the subsequent
sections supported by the conicity formed by the
preceding

section.

Sectional warping:

The newly developed machine with its reed

headstock integrated into the machine
superstructure allows production speeds never
previously achieved, thanks to its innovative
control system. The machine has the following
special technical features:
Production of warp sections with a minimum
width of 4 mm or (depending on yarn fineness)
minimum 12 - 24 threads. With maximum end
numbers of 480 -560 threads and a section width
of up to 150 mm, the machine can be fine-tuned
for flexible production.
The time for each thread separation at a lease
or sizing split is 7 seconds per separation
process.

 A maximum warping speed of 750 m/min

allows production to be optimized to suit yarn
properties.
The perfect thread tension between creel and
machine for the warping process ensured by the
use of a proven section tension control and a
controlled beaming tension system forms the
basis for warp quality that meets the highest
requirements.
The machine is available with a working width
of 2,200 mm for the traditional clothing sector
and 3,600 mm for decorative fabrics and
furniture coverings.
The leasing function:

Leasing is a process of layer separation to

facilitate the subsequent drawing-in process and
weaving. A lease band is inserted between the
layers

The beaming operation:

In the second step, all yarns are simultaneously
transferred from the section drum onto a double
flanged warpers beam

Features of Sectional Warping:

This is suitable for making checked, stripped
or other fancy fabric.
2.
We directly obtain weavers beam from this
process
3.
As sizing is not done, so multi-ply yarns or
yarns which do not require sizing are used
4.
Small amount of yarn is required to produce
the weavers beam
5.
Sectional warping is used to produce a warp
beam with a greater member if ends
1.

6.
7.
8.

The production is less in sectional warping

The yarn tension is less uniform
It is less efficient than high speed warping

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: 3030 / 9186, 65
Warp Repeat: 72 ends
35 (white) + 30 (D. blue) + 3 (L. brown) + 4 (L.
blue)
Total ends: 9165 = 5915 No. of repeats per
section: 4
Creel Capacity
Creel Capacity = 472 = 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
= (28825.4) / (116.8683) = 7315.2 / 350.604
= 20.865
Yarn weight required for given set length
Quality: 3030 / 9186, 65
Total ends: 9165 = 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 = 44=16 White = 354=140 D. blue =
304=120 L. brown = 34=12
Warp Length
Single yarn length to warp all sections =
215000 = 105000m
Wastages and remainder = 1000m Total length =
105000 + 1000 = 106000m
Warp Weight

Warp Weight (lbs) = (106000 1.0936) / (30

840) = 4.60 lbs
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