Lecture 12: Warping

Calculations
W. A. Wimalaweera
OUSL

Contents
Beam Warping calculations
Sectional Warping Calculations

Beam Warping Calculation

The first stage of beam warping is the preparation of a set of back beams
(or section beams) each containing a fraction of the total number of ends
to be in the fabric. Then we have to assemble these back beams to one
beam in a second stage. Lets consider the following example.
Example 1:
A weaver has an order for 25,000 metres from a loom state plain weave
fabric having following construction:

Cotton 45s x Cotton 45s

X 48 inches
103 EPI x 65 PPI

Assume C1 = 5% and C 2 =7%. Assume a waste percentage of 2% for

warp yarn.
Calculate the number of section beams to be prepared, number of supply
packages (Warp) to be ordered, amount of warp in each package and the
requirement of warp and weft yarns

Calculation of number of beams

and packages
The weaver has to produce a large quantity of a plain
weave loom state fabric. To produce such a quantity,
best method of warping is direct warping. As the warp
yarn is a single yarn it has to be sized after warping.
During sizing we can assemble the back beams to the
final weavers beam.
The construction details are given for the loom state
fabric. Loom state fabric is the fabric delivered by the
weaving machine. After finishing the fabric
specifications such as warp yarn density, weft yarn
density, area density etc. may change a little. We are
not concerned about this in this particular example

Calculation of warp beams

First of all we must calculate the number
of back beams to be prepared and how
many warp ends must be there in one
beam. For that we must know the details
about the warping machine creel capacity
available in the mill.
Assume that the creel capacity of the
warping machine is 750. That means the
maximum number of ends we can warp at
a time is 750.

Calculation of the number of beams

Total number of warp ends in the fabric = 103 ends/inch x

48 inches
= 4944
The number of back beams
= Total number of ends in
the fabric
Creel capacity
= 4944 / 750

= 6.592
7
We have to make 7 back beams to have the total number of
ends of 4944 . Each bean contains ( 4944 / 7 = 706.28 )
707 ends.

 The exact number of ends in one back beam = 707

That means we are using only 707 spindles of the
creel although we have a total number of spindles
of 750.
The weaver has to order from the winding
department 707 yarn packages each containing
sufficient weight of yarn for 25000 m of fabric. Yarn
requirement is calculated as follows.

The width of the beam = warp width at reed = uncrimped length of the weft
= 48 inches (1.07) = 51.4 inches

Yarn requirement
First of all let us calculate the total amount of warp yarn requirement.

Total length of the warp yarn requirement = 4944 x 25000 m x

(1.05)
= 129,780,000 m
Total length of the warp yarn requirement= 129780000 m x 1.083
yds/m
= 140,594,957 yards
Total weight of warp yarn requirement= 140594957 lbs (pounds)
45 x 840
= 3719.44 lbs
Total weight to be ordered (consider waste) = 3719.44 x 1.02 lbs
= 3793.88 lbs

The weight in of yarn in one package = 3793.88 / 707

= 5.37 lbs
The weaver has to order 707 yarn packages each
containing 5.37 lbs from the winding factory so that he can
prepare the beam on his warping machine.

Beam warping calculation 2

An order for 24200 m of the following finished fabric has been
received.
Cotton 15 tex X Cotton 15 tex X 1.2 m
38 1/cm X 35 1/cm
Warp Crimp, C1 = 9%, Weft Crimp, C2 = 8%, Warp and weft waste
= each 2.5%
A beam warper with a creel capacity of 600 is available. Calculate,
a) The number of back beams to be prepared and the width of the
beams.
b) Total requirement of warp and weft yarn.
c) Number of yarn packages required for warping and the weight
of yarn to be wound on to each package.

Sectional Warping Calculation

In sectional warping also we have two stages.
In the first stage we wind a certain number of warp
ends, which depends on the creel capacity, on to a
warping drum. The density of the warp ends wound on
to the drum is similar to the warp density on the
weavers beam. Therefore the number of warp ends
wound on to the drum represents only a section of the
complete warp beam.
To complete the total number of ends required on the
weavers beam we have to wind several sections on to
the drum.
Once all the sections are wound on to the drum we have
to transfer the whole set of ends to the weavers beam.
This is the second stage of sectional warping. This step
is known as Beaming.

Sectional Warping Calculation

Example
A weaver receives an order to weave 2500 m of a fabric
having following specifications:

Nylon 75d/24f X Nylon 75d/24f

X 48 inches
102 1/inches X

83 1/inches

The above details are of the finished fabric. The finished

fabric has following crimps: Warp crimp, C 1 = 6%, Weft
crimo, C2 = 5%, assume a warp waste of 3%. The fabric has
warp way strips in white and red colours of 0.5 inch width.

Now the weaver has to determine the warping details and

yarn requirements.

Why Sectional warping?

The fabric quantity ordered is small
(2500 m), and it has warp way
stripes. Therefore the most suitable
method of warping is sectional
warping.
The sectional warping machine
available in the factory has a creel
capacity of 600.
First of all let us calculate the total
number of warp ends in the fabric.

Total number of ends in the

beam

Total number of warp ends in the fabric= 102 1/inch x

48 inches
= 4896
The warp and weft crimps of the finished fabric are
given.
When we consider the weft, the un-crimped length of
the weft is equal to the width of the warp sheet at the
reed. The width of the warp sheet at reed (reed-in
width) is approximately equal to the width of the warp
on the beam.
Width of the Finished fabric = 48 inches

Calculation of the width of the warp sheet

If the width of the warp sheet at reed is W,
The crimp of the weft of finished fabric is defined as
follows:

Length of the un-crimped weft Width of the fabric

Weft Crimp, % = C2 =
_________________________________________x 100
Width of the fabric

Therefore, C2, % = (W 48) 100/ 48

W = (48 x 5/100) x + 48
= 50.4 inches

Reed-in width and beam width

In this calculation we assume that any permanent
change of the length of the weft takes place due
to finishing or weaving processes.
Width of the warp sheet at the reed = 50.4 inches
Therefore width of the warp to be wound on to
the drum = 50.4 inches {This can be little larger
than 50.4 (reed-in width) for practical reasons}
Number of sections to be wound onto the drum
= 4896 / 600
= 8.16 Sections

Number of sections to be
wound

In this case,
We can either wind 8 sections with 600
ends and then a 9th section with a
reduced number of ends (600 x 0.16
= 96) or
We can wind 9 sections with 4896/9 (=
544) ends per section or
we can select the width of a section
depending on the numbers of threads
in the colour repeat of the warp.

Which method is better?

The second method is better than method
1because
1. We have to creel a lesser number of yarn packages at the
beginning and we do not have to remove some packages
after 8 sections.
2. Further we can use 544 packages with the same amount
of yarn in each package.
However we must be careful to maintain the number of
threads in the colour repeat. If the number of threads in one
section (544) is not equal to a multiple of the threads in the
colour repeat we will have to change the packages in the
creel during change overs from one section to the other.

Consider the method 2

If we are going to wind 9 equal sections on to the drum,
The width of one section on the drum = 50.4 / 9 = 5.6 inches

So we have to wind 9 sections each having 544 ends amounting to

4896 ends per beam. We do not use the available creel capacity of
600 spindles.
This fabric has two colours, white and red in the warp. In the case
fabrics with coloured stripes we have to consider colour repeat also
when we decide for the width of one section.
Number of yarns in one 0.5 inch wide strip = 102 /2 = 51
Therefore we have to arrange warp yarns in the following order for
warping:
51 Black, 51 White, 51 Black , 51 White so on (48 white strips and 48
black strips)
The number of threads in one section (544) is not a multiple
of 51. Hence it is better to change the number of threads per
one section to 510 and wind 9 sections with 510 threads (9 x
510 = 4590) and to have 4896 4590 (= 306=51 x6) ends for
the last section.

Now Consider the method 3

If we want to select a section width depending on the colour repeat
we have to follow the following method.
Total number of coloured strips in the fabric = 4896 /51 = 96
Maximum number of colour strips in one section = 600 / 51 = 11.7

The number of cololur strips in one section must be less than 11. It
is better if this number is equal to a multiple of 2 as we have two
colours of same width. Further is advisable to select a number
which is a fraction of 96. The largest number which fulfils both the
conditions is 8.
Therefore the number of colour strips per section = 8
Number of threads per section = 8 x 51 = 408
(We use only 408 positions of the creel which has 600 capacity.)
Number of sections to be wound = 96 / 8 = 12
This method is the best method as we do not have to
change the creeling during the process of warping.

Requirement of warp yarn

The requirement of warp has to be calculated separately for white
and red threads.
Total length of the fabric= 2500 m
Total length of the warp yarn = 2500 x 1.06 x 4896 = 12,974,400
m
Length of the warp yarn with waste = 12974400 x 1.03 m
= 13,363,632 m
Total weight = 13363632 x 75 g
9000
= 111363.6 = 111.36 kg
Amount of white yarn = amount of red yarn = 111.36/2 = 55.68 kg

Now we must calculate the amount of yarn to be wound onto

individual packages. It depends on the which of the above
mentioned methods we want to use

Yarn amount per package

If we use the method 2 above
Each of 204 (510 -306) packages must have a length of
2500 x 9 x 1.03 x 1.06 m of yarn.
Each of 204 packages must have 24566 m of yarn from
which 102 must be wound with white yarn and other 102
with red yarn.
Each of 306 packages must have a length of 2500 x 10 x
1.06 x1.03 m (=25750 m) of yarn from which 153 must be
wound with
and other
withWeight
red yarn.
1. Yarn
No.white
of packages
Length153
/
/
Total /kg
Yarn requirement is as follows:
package
package
2. White

3. Red

4. Total

102

24566 m

204.71 g

20.88

153

27295 m

227.5 g

34.80

102

24566 m

204.71 g

20.88

153

27295 m

227.5 g

34.80

510

111.36

Yarn amount per package

If

we use the method 3 above

Total number of packages
= 408
Total number of white packages
= 204
Total number of red packages
= 204
Number of sections
= 12
The length of yarn to be wound
to each package
= 2500 x 12 x 1.03 x 1.06 m
The mass of yarn to be wound
to each package
= 2500 x 12 x 1.03 x 1.06 x
75/9000 g
= 275.95 g

Yarn amount per package

Yarn requirement is as follows:
Yarn

No. of
packages

Length /
Weight /
Total /kg
package
package

White

204

32754 m

272.95 g

55.68

Red

204

32754 m

272.95 g

55.68

Total

408

32754 m

272.95 g

111.36

Even though we use a higher creel capacity

in the case 2, it appears to be difficult to
carry out. We have to take more care in
winding of packages and creeling has to be
changed after winding of 9 sections.

Exercise Sectional Warping

A warper has to prepare a beam to weave 3000 m of the following
polyester gabardine fabric using his sectional warping machine.
PE, 150 dTex/36f x PE, 150 dTex/36f
x 130 cm
25 1/cm X
24 1/cm
The finished fabric has warp way stripes of 1 cm width of grey and
white colours.
C1 = 6%, C2 = 5 %, Warp waste = 3%
Calculate,
a. Number of sections to be wound on to the warping drum and
width of each section.
b. Number of yarn packages required from each colour and
c. The quantity of yarn to be wound on to each package so that
winding of yarn packages as well as warping is carried out
efficiently.

END