UNIT = I

Comparison Between Combed Yarn and Carded yarn

15Key Difference Between Carded Yarn and Combed Yarn:

The main differences between combed yarn and carded yarn have explained in the below:
1. The finished knit fabrics made by combed yarn and carded yarn have no important change because of
color fastness to light and color fastness to wash.
(In case of color fastness to rubbing, a little effect is found on finished knit fabric made by a same count
combed yarn and carded yarn. In some other cases, combed yarn shows better result than carded yarn.)

2. Same count of combed and carded yarns has many different characteristics which is totally influence in
the quality of fabric.
3. Combed yarn and carded yarn have great effect on gram per square meter (GSM). Carded yarn produces
lower GSM (gram per square meter) fabric than combed yarn, while using the same count for both types
of yarn.
4. Normally, combed yarns are more uniform than carded yarns.
5. Combed yarn TPI is lower than carded yarn.
6. While the yarn count is same then shrinkage of all types of fabric produced from carded yarn is more
than that produced from combed yarn.
7. Normally, carded yarn strength is lower than combed yarn of the same count.
8. Carded yarn is more hairy than combed yarn.
9. Combed yarns are more lustrous than carded yarns.
10. Fabric made of Combed yarn is gentle against the skin.
11. Combed yarn production process is not easier than carded yarn production process.
12. Carded yarn is cheaper than combed yarn.
13. The resistance of pilling effect on fabric surface produced by combed yarn provides better result than
same count of carded yarn.
14. Less amount of loose hairy fibers are removed from combed yarn by knitting process and pretreatment
process than carded yarn. As a result fabric produced from combed yarn shows less GSM (gram per
square meter) than fabric produced from carded yarn after finishing.
From the above discussion, it can be said that in case of producing fabric from combed yarn should maintain
lower gram per square meter (GSM) than carded yarn fabric for achieving same finished gram per square
meter (GSM).
DEFINITION:
Carded Yarn:
Carded yarn is a cotton yarn which has been carded but not combed. This type of yarn contains a wide range of
fibre length. As a result, carded yarn is not as uniform as combed yarns. It should be noted here that, carded
yarns are considerably cheaper and are used in coarse and medium counts.

Properties of Carded Yarn:

Some important characteristics of combed yarn have mentioned in the following:
1. Carded yarn is comparatively less regular yarn.
2. It is comparatively lower strength of yarn.
3. This type of contains neps.
4. It has less lusture than combed yarn.
5. This type of yarns is produced including short fibres.
6. Carded yarn is more hairy than combed yarn.
7. Combed yarn is cheaper than combed yarn.
8. It is one of the lower quality of yarn.
9. It has harder hand feelings.
10. It has comparatively lower strength than combed yarn.
11. Normally, low quality fabrics are produced by using this type of yarn.
12. Dyeing and knitting wastage is very high for carded yarn than combed yarn.
Combed Yarn:
Combed yarn is a yarn that has undergone a time consuming combing process. Combing process makes its fibers
straight and also ensures that the fibers run parallel to each other. Combing process makes the combed yarn more
compact and strong. It should be noted here that, combed yarn needs higher cost than carded yarn. On the other
word, the yarn which is produced by using longest and fibre is termed as combed yarn.

Key Properties of Combed Yarn:

The main properties of combed yarn are in the below:
1. Combed yarn is extremely soft version of cotton.
2. It is more strong than others yarn such like carded yarn.
3. Combed yarn is slightly more expensive in manufacturing than conventional yarn.
4. It is very fine yarn.
5. Combed yarn is perfect for producing linen fabric.
6. It is also used perfect for producing those fabrics which are worn against the skin.
7. This type of yarn is produced by using fine and longest fibre.
SPINNING:
Spinning is the first steps of textile product processing. The process of making yarns from the textile
fiber is called spinning.
Spinning is the twisting together of drawn out strands of fibers to form yarn, though it is colloquially used
to describe the process of drawing out, inserting the twist, and winding onto bobbins.
There are different types of spinning, the most commonly forms of spinning are: Ring,Rotor spinning,
Air Jet, Friction.

Blow Room Section:

It is that kinds of section where the supplied compressed bales are opened, cleaned and mixing or blending for
making uniform lap of definite length. The range of blow room cleaning efficiency is 60-65%. It should be noted
here that, blow room is the first section of spinning line for producing cotton yarn.

Basic Operation in Blow Room:

The below operation has don main blow room section of a spinning line:
1. Opening,
2. Cleaning,
3. Mixing or blending,
4. Lap forming.
All the above operations have explained in the following:
1. Opening:
Here, the compressed bales of fibres are opened for making the cotton tuft in a small size (as much as possible).

2. Cleaning:
This operation is used to remove dust, dirt, broken leafs, broken seeds, stalks and other foreign materials from
the fibres.

3. Mixing or blending:
Mixing or blending process has performed for producing higher quality yarn by reducing production costing
which is only possible by mixing different grade of fibres.

4. Lap forming:
This operation has done due to the below reasons:

 It is done to transfer the opened and cleaned fibres into a sheet form of specific width and uniform unit
length which is termed as lap.
 It is also used to roll the lap of predetermined length into a cylindrical shape around a lap pin.
 It is also used to transfer the lap from the lap pin int a rod to suitable handle and feed it to subsequent
processing carding machine.

CARDING
Carding is one of the most important operations in the spinning process as it directly determines the final
features of the yarn, above all as far as the content of neps and husks are concerned. There are many
objectives of the carding process and these can be summarised as:

Object or task of the card:

Opening to individual fibres:
The blow room only opens the raw material to flocks where as the card opens it to the stage of individual
fibres. This enables the eliminations of impurities and good performance of the other operation.
Elimination of impurities:
Impurities are mostly eliminated in taker in and a small portion of it is eliminated by flat stripping.
Modern card removes 80 – 90% impurities from lap and sliver contain only 0.05 – 0.3% foreign matter.
Elimination of dust:
Card is good dust removing machine. I t removes free dust as well micro particles by significant friction.
Disentangling of neps:
Blow room increase neps from machine to machine, but card reduce it to a small friction. The card does
not remove neps but disentangles it by opening them. Closer spacing between the clothing, sharper
clothings optional speed of taker in, low doffer speed etc. Can improre the disentangling process of neps.
Fibre blending:
The card scarcely improve long term blending as the residence time of the material in the machine is to
short. The card improves traverse blending and fibre with fibre mixing.

Action in Carding Machine:

The following 4 actions take place in a carding machine:
1. Combing action;
2. Carding action;
3. Stripping action;
4. Doffing action.

1. Combing action:
Combing action takes place feed roller and taker in. Here the pin direction of the two surfaces are the
same. Combing is the straightening and paralleling of fibre and the removal of short fibres and impurities
by using a comb or combs which is assisted by roller and brushed.

2. Carding action:
Carding action takes place between flat and cylinder.
In carding action:
 Direction of wire in two surfaces are opposite.
 The moving direction of roller are also opposite.
 One roller is slower and other is fast.
So carding action is known as point against point action.
3. Stripping action:
Stripping action takes place between a. Taker in & Cylinder and b. Doffer & Stripper.
In stripping action:
 Wire direction will be the same.
 Roller moving direction will be the same.
 One roller will be faster than another.
So stripping action is known as “Point back point” action.

4. Doffing action:
This action take place between cylinder and doffer. In this place fibre is transferred from cylinder to
doffer. Low speed doffer is called fibre from high speed cylinder and make a condensed web for
formation of sliver.

Draw Frame: -
Draw frame is a machine for combining and drawing slivers of a textile fiber (as of hemp for rope
manufacture or cotton for spinning). Drawing is the operation by which slivers are blended, doubled and
leveled. In short staple spinning the term is only applied to the process at a draw frame.

In drawing slivers are elongated when passing through a group of pair rollers, each pair is moving faster
than previous one.

Actions Involved in Draw Frame :-

Drafting: It is the process of increasing length per unit weight of sliver. It is mainly due to peripheral
speed of the rollers.

Doubling: The process of combing two or more carded sliver into a single form is called doubling. In
draw frame m/c generally six slivers are fed to convert into one i.e. six doubling.

Drawing: In the cotton industry the term is applied exclusively to processing on the draw frame, where
the operation is one of doubling and drafting. Drawing= Drafting + Doubling.
Tasks of Draw frame
1. Equalizing
2. Parallelizing
3. Blending
4. Dust removal
Equalizing: One of the main tasks of draw frame is improving evenness over short, medium and
especially long terms. Carded slivers are fed to the draw frame have degree on unevenness that cannot be
tolerated in practice and slivers from the comber contain the “infamous” piecing. It is obscured by draw
frame.
Equalizing is always performed by a first process, namely doubling and can optionally also be performed
by a second process, namely auto leveling. The draft and the doubling have the same value and lie in the
range of 6 to 8.

Parallelizing: To obtain an optional value for strength in the yarn characteristics, the fibers must be
arranged parallel in the fiber strand. The draw frame has the tasks of creating this parallel arrangement. It
fulfills the task by way of the draft, since every drafting step leads to straightening the fibers.

Blending: In addition to the equalizing effect, doubling also provides a degree of compensation of raw
material variation by blending. Their results are exploited in particular way in the production of blended
yarns comprising cotton or synthetic blends. At the draw frame metering of the individual components
can be carried out very simply be selection of the number of slivers entering the machines.

Dust Removal: Dust is steadily becoming a greater problem both in processing and for the personnel
involved. It is therefore important to remove dust to the greatest practical extent at every possible point
within the overall process.
Dust removal can only be carried out to a significant when there are high levels of fiber. Since a large
function the smallest particles adhere relatively strong to the fibers. High performance draw frame is
equipped with appropriate suction removal systems; more than 80% of the incoming dust is extracted.

Speed Frame and function of speed frame

Speed Frame/Roving Frame/Simplex machine
The output from the draw frame is fed into the roving frame (also called ‘speed frame or
simplex machine or flyer frame‘) where the linear density of sliver is reduced by drafting and
the resultant product is called the roving. After the drafting operation, the roving is wound on the
bobbin. During winding, a little amount of twist is imparted to the roving.
Objects:
 To draft the drawframe sliver to reduce weight per unit length.
 To insert small amount of twist into the roving.
 To wind twisted roving onto the bobbin.
Significant of Roving Frame/Why the Draw Sliver is not Direct Used in Ring
Machine?
There are two principle region:
 The first reason is related to the required draft. The draw sliver is to thick, untwist strand
that tends to be hairy and to create fly. The draft needed to convert this to a yarn is in the
resign of 300-500.The speed frame process minimizes the sliver weight to a suitable size
for spinning into yarn and inserting twist, which maintains the integrity I the draft
strands. It is impossible to feed the sliver to ring frame for yarn production due to
limitation in draft in ring frame. So the fine twisted roving is better to this purpose.
 The second reason is related with transportation and space limitation on ring frame. The
draw frame can represent the worst conceivable mode of transport and presentation of
feed material to the ring spinning frame.

Tasks of Speed Frame/Functions of Speed Frame:-

The major tasks of the speed frame process are listed as follow
Creeling: To feed the sliver by the help of several rows of driven rollers to the machine.
Drafting: to reduce the size of the strand
Twisting: to impart necessary strength
Laying: to put the coils on the bobbins
Winding: to wind successive layers on the bobbin at the proper rate of speed
Building: to shorten successive layers to make conical ends on the package of roving
Doffing: To replace an empty bobbin at the place of full bobbin.
 Creeling: Creel is the place situated at the back of the machine where the raw material is
placed to be fed to the drafting zone.
Optimum creel tension draft should be selected to control sagging or stretch in drawing sliver.

Drafting:
Drafting is normally carried out by a draft system with double apron capable of working with
entering sliver counts of 0.12-024 Ne and counts of the delivered roving of 0.27—3 Ne.
The draft given in the roving process will be in the range between 4 and 20 and can work fibers
of a length of up to 60 mm.

Twisting:
It is very important factor which produces strength in the roving and twist is inserted with the
help of flyer.
When flyer rotates, the twist is produce in the sliver.
Twist level depends upon flyer speed and delivery speed.

Laying:
Lay refers to the arrangement of the roving coils wound around the bobbin in any given layer.
The closeness of the lay is measured in “coils per inch,” which means the number of roving coils
wound around the bobbin per inch parallel to the axis of the bobbin.
The purpose of the laying operation is to put the successive coils of roving side by side in a
uniformly spaced arrangement.
This regular, uniform arrangement is achieved by making the bobbins move up and down at a
uniform rate of speed for each layer.

Winding:
Winding is the process by means of which the roving is drawn from the front roll through the
flyer and onto the bobbin.
The rate of winding compared to the rate of delivery at the front roll controls the winding
tension.

Building:
The building motion is controlled by the steady upward and downward movements of the
bobbin rail containing the bobbins and spindles.
Doffing:
It is the optional function of speed frame. Doffing could be done manually or automatically.
 RING FRAME

Object:
1. To produce required count of yarn from the supplied roving by the drafting.
2. To insert sufficient amount of twist to the yarn.
3. To wind the yarn onto the bobbin.
4. To build the yarn package properly.

Main Parts Ring Frame:

1. Creel
2. Guide roller
3. Trumpet
4. Drafting rollers
5. Yarn guide
6. Lappet
7. Balloon controlling ring
8. Traveler
9. Ring
10. Spindle

Passage diagram:

Fig: Passage Diagram of Ring frame

Description:
The feed material come from speed frame i.e. roving bobbin is placed on the creel. The creel which
is attached to the machine is umbrella type. Then feed material is passed under the guide rollers and through
the trumpet in to the drafting zone. Here some draft is inserted in to the roving. The draft system is 3 over
3 drafting system with apron. The delivery material that is delivered from the front roller is reached to the
traveler over pneumatic waste collector, lappet and through balloon controlling ring. Lappet is used to
control the material path and balloon controlling ring is used to control the balloon formation and spinning
tension. Here roving is twisted by the movement of the traveler around the ring. The yarn is then wound on
the ring cop.

Winding:
Winding is one of the most important operation, which is mainly occurred in spinning section. Besides, it
is also important in fabric manufacturing. In fabric manufacturing, directly winding is not so much
important, but rewinding is so important.
The creation of large yarn packages that can be easily unwound, is called winding.
This makes using the yarn on subsequent machines both easier and more economical.
After warping, some packages contain just a few grams of yarn which is unsuitable for the efficiency of
further processing, such as warping, twisting, and quelling. This necessitates the preparation of a dense
and uniform yarn package of sufficiently large size from unsuitable packages which can unwind in the
subsequent operations without interruptions, is called rewinding.The yarn unwound from the package
passes through yarn tensioned and control systems, and with the help of a grooved cylinder, is wound
evenly around the package; the yarn enters the recess in the cylinder, thus the rotary movement of the
cylinder corresponds to the translation of the yarn.Winding machines currently have independent heads
with individually adjustable motors. A modern winding machine can process yarns ranging from a count
of Ne 2 to finer ones, at a winding speed of 400 to 2000 m/min.

Winding is more than just transferring yarn from one package to another. Further functions of winding are
to check the yarn and to eliminate any faults found.

Materials Processed:
Input - Yam (spinning bobbins)
Output - Yarn (large cones, tubes, etc.)

Objectives of the Process:

 Inspect the yarn
 Clearing of defects
 Lubricate the yarn
 Package the yarn
A basic diagram of winding m/c:

A basic diagram of winding m/c

Auxiliary functions of a winding machine

1. Creeling: Creeling is the removing of empty package and placement of the full package, in the feed
region of the machine, ready to be unwound as part of the transfer process.

2. Piecing: Piecing is the process of finding the ends of the packages and connecting them

3. Doffing: Doffing is the process of removing the full package and placement of the empty package, in
the delivery region of the machine, ready to receive yarn as part of the transfer process.
Importance of winding:
Unevenness in traditionally spun staple yarns is a natural phenomenon usually induced by the process of
manufacturing (spinning). Although with modern process controls and machines many imperfections in
the spun yarns can be controlled, some still remain in the final yarns. Most common of all imperfections
are thin or weak places, thick places, slubs, neps, and wild fibers, as shown schematically.

During the subsequent processes of winding, warping, and slashing, not all but some of these
imperfections create obstacles to steady and smooth working. Therefore, it is important to classify,
quantify, and remove those imperfections which may cause the interruption of the operation. In other
words, only ‘‘objectionable’’ faults need to be removed for trouble-free processing of the yarns. The ring-
spinning operation produces a ring bobbin containing just a few grams of yarn which is unsuitable for the
efficiency of further processing, such as warping, twisting, and quelling. This necessitates the preparation
of a dense and uniform yarn package of sufficiently large size which can unwind in the subsequent
operations without interruptions.

The packages prepared for warping are normally cross-wound, containing several kilograms of yarns.This
implies that a number of knots or splices are introduced within each final package. Bear in mind, each
knot or splice itself is an artificially introduced imperfection; therefore, the size of this knot or splice must
be precisely controlled to avoid an unacceptable fault in the final fabric.

In modern winding machines, knots and splices are tested photoelectrically for size, and only acceptable
knots and splices are allowed to pass on to the winding package. In modern spinning processes, such as
open end, friction and air jet, the spinning process itself produces a large cross-wound package, thus
eliminating the winding operation.

Functions of the Winding Operation:

Important functions of the winding operation are
1. Clearing of yarn faults OR remove objectionable falts
2. Making larger wound packages
3. Preparing soft packages for dyeing
 WARPING
What is Warping?
In textile sector, weaving is the first process of fabric manufacturing.
Here, warping is defined as the parallel winding of warp yarn or warp ends from cone, cheese winding
packages on to a warp beam.
According to required quality of fabric, warping should be done by using required quality of yarnpackages.
Otherwise, fabric quality will be hampered. In weaving section of textile factory, low quality warp beam is
one of the main reasons of fabric wastage.

Objects of Warping:
The main objects of warping have pointed out in the below:
1. It helps to make progressive next step of fabric manufacturing.
2. It also used to make reusable small winding packages.
3. It is used to expand the required quality of warp yarn.
4. It is used to expand the weave-ability of warp yarn during fabric manufacturing.
5. It is used to make suitable warp yarn sheet for the next process named sizing.
6. It is used to wind definite length of warp yarn in the warp beam.
7. It helps to increase fabric manufacturing production.

Importance of Warping:
Some important key points of warping have presented in the following:
1. It helps to buildup of parallel yarn sheet.
2. Warping is the total combination of various small winding packages.
3. It helps to modify various faults of warp yarn such as large knots, thin place and thick place etc.
4. It helps to buildup of warp beam by using required quality warp yarn.
5. It also helps to wind the predetermined length of warp yarn in the warp beam.
6. It helps to achieve long length of warp yarn which is too much helpful for excessive fabric
production.
7. It also helps to accelerate the next process for woven fabric production.

Important requirements of Warping:

1. The tension of all wound ends must be uniform and possibly constant during all the time of
with drawl from the supply package.
 2. Warping should not impair the physical and mechanical properties of yarn.
3. The tension should be moderate to allow the yarn complete retain its elastic properties.
4. Predetermined length should be observed.
5. Production rate should be high as possible.
6. The surface of warping package must be cylindrical.

Types of Warping:
1. Sectional or Pattern Warping(conical drum or dresser warping).
2. High speed/ Beam/ Direct Warping(preparatory beam warping).

Sectional or Pattern 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.Features of sectional
warping:To produce Fancy fabric (stripe/Check)To produce weavers beam from yarns which does not
required any sizing material to be applied before weaving.To produce weavers beam of small amount of
warp yarn.At first wound section by selection and final weavers beam produce immediately
after sectional warping.Production is less, so costly process.A tapered beam or drum is used.

Fig: Sectional or Pattern warping

High speed/ Beam/ 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.

Fig: Direct warping

 Differences Between Sectional and High Speed Warping

High Speed Warping Sectional Warping

1. Beam warping is used for long 1. Sectional warping is used for
runs of grey fabrics & simple short runs especially for fancy
pattern. pattern fabrics.
2. The amount of colored yarn is 2. Greater amount of colored yarn
less than 15% of the total. is used.
3. High production. 3. Low production.
4. Large amount of yarn required. 4. Small amount of yarn required.
5. Single yarn is used. 5. Twisted yarn is used.
6. Less expensive. 6. More expensive.
7. It is most widely used for cotton, 7. It is most widely used for silk
linen, woolen & worsted yarn. & synthetic yarn.
8. Uniform tension of yarn. 8. Less uniform tension of yarn.
9. Weavers beam is produced after 9. Weavers beam is produced
sizing. after warping.
10. Creel capacity is more. 10. Creel capacity is less.
11. Beam warping is more widely 11. Sectional warping is not
used. widely used.

SIZING:
Size is a gelatinous film forming substance in solution or dispersion form, applied normally to warp yarns.
It can sometimes be applied to weft yarns.
Sizing is the process of applying the size material on yarn. A generic term for compounds that are applied
to warp yarn to bind the fiber together and stiffen the yarn to provide abrasion resistance during weaving.
Starch, gelatin, oil, wax, and manufactured polymers such as polyvinyl alcohol, polystyrene, polyacrylic
acid, and polyacetates are employed.
The process of applying sizing compounds. The process of weighing sample lengths of yarn to determine
the count. Now automation is used in sizing operation.
 Fig: Yarn sizing

Objects of Sizing:

1. To protect the yarn from abrasion

2. To improve the breaking strength of the yarn
3. To increase smoothness of yarn
4. To increase the weaviability
5. To decrease hairiness
6. To decrease the generation of static electricity

Types of Sizing:
1. Pure sizing: when the size pick up % is about 3 – 10 % it is called pure sizing.
2. Light sizing: when the size pick up % is about 11 -16% it is called light sizing.
3. Medium sizing: when the size pick up % is about 17 – 40 % it is called medium sizing.
4. Heavy sizing: when the size pick up % is above 40 % then it is called heavy sizing.
Size Ingredients and Their Functions:
Various sizing ingredients have pointed out in the below:
1. Adhesive,
2. Wetting agent,
3. Weighting agent,
4. Softener or lubricant,
5. Hygroscopic agent,
6. Tinting agent,
7. Anti-mildew or antiseptic agent,
8. Antifoaming agent.
All the above sizing ingredients have explained in the following with their functions:

1. Adhesive:
Generally adhesives are potato, Carboxy Methyl Cellulose (CMC), startcg of maize, sag, corn, PVA and
PVC.
Functions of Adhesive in Sizing:
 It is used to impart adhesion,
 It is used to increase stiffness and elasticity of warp yarn,
 It is used to increase strength of warp yarn,
 It is used to reduce extension percentage,
 It is used to increase smoothness of warp yarn.

2. Wetting agent:
Wetting agent which are used in sizing are Magnesium Chloride, soap and sulphanol.
Functions of Wetting agent in Sizing:
 It is used to achieve uniform distribution of sizing solution,
 It is used to increase size exhaust.

3. Weighting agent:
Weighting agents which are used during sizing warp yarn are French chalk, sodium sulphate and china clay.
Functions of Weighting agent in Sizing:
 It is used to prevent opening of cloth,
 It is used to provide fullness and feel to the woven fabric,
 It is also used to increase the weight of warp yarn during finishing.

4. Softener or lubricant:
Softener or lubricants which are used diring sizing warp yarn are soap, mineral oils, coconut oil, tallow,
TRO, animal fats and japan wax.
Functions of Softener or lubricant in sizing:
 It is used to decrease stiffness,
 It is used to increase the smooth of warp yarn,
 It is used to decrease friction and flexibility,
 It is also used to make the warp yarn soft and slippery.

5. Hygroscopic agent:
Hygroscopic agents used in sizing are calcium chloride, magnesium chloride and glycerin.
Functions of Hygroscopic agent in Sizing:
 It is used to prevent excesive drying of warp yarn.
 It is used to increase the moisture of yarn,

6. Tinting agent:
Blue is used in sizing as tinting agent.
Functions of Tinting agent:
 It is used to prevent dusting off,
 It is used to increase the brightness of warp yarn,
 It is used to remove the yellowish color of warp yarn,
 It is also used to form a particular shade.

7. Anti-mildew or antiseptic agent:

Anti-mildew or antiseptic agents are Phenol, Carboxylic acid, salicylic acid.
Functions of Anti-mildew or Antiseptic Agent in Sizing:
 It is used to protect yarn from fungus or bacteria.
 It is used to prevent mildew formation,
 It is also used to help to store the sized warp yarn.

8. Antifoaming agent:
Antifoaming agents which are used in sizing are benzene, pyridine.
Functions of Antifoaming Agent in Sizing:
 It is used to prevent foam formation.
The sizing machine can be divided into four main zones as shown in below figure. The zones are
 Creel zone
 Size box zone
 Drying zone
 Headstock zone

The creel zone contains large number of warper’s beam which can be arranged in different fashion
depending on the design of the creel. Individual warp sheet emerging from warper’s beam are merged
together to form the final warp sheet which passes through the size box. During the passage through the
size box, the warp sheet picks up size paste and holds a part of the paste after squeezing. Then the wet
warp sheet passes through the drying zone and wound on the weavers beam.

Zones of a sizing machine

DRAWING – IN:

After sizing, the sized warp beam is prepared to be placed on the weaving machine. High fashion fabrics
generally have high density which increases the demand on the quality of shed opening. As a result, warp
leasing is becoming more popular. Different lease combinations can be selected with the automated leasing
machines.

Drawing-in is the entering of yarns from a new warp into the weaving elements of a weaving machine,
namely drop wires, heddles and reed, when starting up a new fabric style. Tying-in-the new warp ends to
the depleted warp is done when a pattern is not required.

A drop wire is a narrow metal sheet that that is hung in the air by the tensioned warp yarn. If the warp yarn
is broken or slacken(loose), then the drop wire drops and touches a metal bar that extend along the width
of the machine. This contact between the drop wire and metal bar closes an electrical circuit and shuts down
the machine immediately. There is drop wire for each warp yarn.

Pinning machines are used to pin open drop wires on warps. Since the pinning speed is high (up to 200
wires per minute), these machines are economical for more than 3000 warp ends.
After drop wire, the warp yarn goes through the heddle eye (there is only one warp yarn per heddle eye).
This is done according to a plan called drawing-in-draft. Then the yarn is threaded through the reed spaces.
A reed space is the opening between two dents (metal) in a reed. In general, one, two or three warp yarns
are passed one reed space. The reed plan specifies the number of yarns per reed spaces. The number of
yarns depends on the diameter of the yarns and the dent opening; each yarn should be able to move freely
up and down in the reed space independent of the other yarns.

Schematic of Drawing-in

Warp drawing-in system

In the manual mode of drawing-in, one person sorts the warp and the other draws it through from the other
side. The sorting step can be automated by a reaching machine.

Today, the drawing-in and tying-in processes are fully automated. Drawing-in is done using robot-like
machines. A special type of heddle is needed for automated drawing-in. The warp ends, taken from the
warp sheet, are fed individually to the drawing in element; heddles are separated from the stack and brought
to the drawing-in position; a plastic knife opens a gap in the reed and a hook draws-in the warp end through
the heddle and reed in one step.
 Fully automated Drawing-in machine

Automatic drawing-in increases speed, flexibility and quality in weaving preparation compared to manual
drawing-in. A drawing-in rate of 50,000 warp ends per 8 hours (200 ends per minute) is possible.

Changing style means producing a new fabric style, weaver’s beam changing means going on weaving the
same fabric style just replacing the empty beam with a full beam of same type.

Drawing in consists of threading the warp yarns through the drop wires, the healds and the reed. Depending
on the styles of the produced fabrics and on the company’s size, this operation can be carried out manually,
by drawing-in male or female works.

TYING-IN:
After the depletion of a warp beam on the weaving machine, if there will be no change in design,
then the drawing-in process needs not be repeated. The ends old warp beam (now a fabric beam) are cut
and the ends of the of the new warp beam are tied to the corresponding ends of the beam which is called
tying-in process. Then, the warp ends are pulled through the heddle eyes and reed until the knots are
cleared.

A small portable robot is used on or off the weaving machine for tying-in. A typical warp typing machine
can knot single or ply yarns from 1.7 to 80 Ne (340-7 tex.). They knot cotton, wool, synthetic and blend
warp yarns as well as yarns of different thickness. Typical knotting of a knotter is from 60-600 knots per
minute.

With a continuous filaments and bulky yarns, a non-slip double knot is recommended which can handled
by knotting machine. Some automatic tying machine can knot extremely short tails of yarns (5mm). Tape
yarns and monofilaments requires a slightly different typing machine. Tape yarns up to 8mm width can be
tied. The knotting speed is typically 60 to 450 knots per minute. The number of warp ends to be tied together
can be preprogrammed; once this number is reached, the knotter stops automatically. A dual knotting
system is used on a double beam weaving machine; the knitters work from left to right and from right to
left simultaneously.

The warp welding machine is used to weld the warp end layer with a plastic foil after drawing-in which
provides simple insertion through the weaving machine. This results in time saving at the

machine startup. After drawing-in with a brush beam the ends protruding from the reed are aligned parallel
and stretched evenly. An approximately 5cm wide plastic foil is placed on top of the lower welding bar and
a longer piece of plastic foil is placed on the warp yarns above the lower piece of plastic foil. By moving
the upper welding bar down, the plastic foils are welded together with the warp yarns in between.

Several points should be considered during drawing-in typing-in. Improper splicing and / or knotting can
become critical to good weaving performance. The straightness of individual warp yarns and their freedom
to act independently as they pass through a weaving machine are important for quality weaving. Yarns that
are crossed and tangled cannot proceed without excessive stress and yarns that r restricted or influenced by
drop-wire activity, heddle spacing, harness interference or reed spacing will not weave at top performance.