O o d h e a d p u b L i s h I n g L i m I t e d

5.3
Warp preparation
High-quality warp preparation prevents problems from arising not only during
the weaving stage, but also later on during the downstream processing of the
fabric (i.e. during dyeing, finishing and making up). Over the years, warping
technology has had to evolve considerably in order to adapt to the rapid
technological evolution and growing production flexibility of weaving devices
and weaving machines, as the latter strive to win over new markets and new
consumers to more sophisticated, higher added value textiles. Nearly all the
manufacturers have developed (to varying degrees) their preparation machines,
which not only match the exacting demands of the new generation weaving
machines but also help to bring down running costs. A number of
technologically advanced machines have emerged that have solved the problems
of the past and, at the same time, introduced certain innovations for specific
processes.
© 2009 Woodhead Publishing Limited

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Advances in wool technology
108
Ever-increasing production capacities of the weaving machines imply
that the warps have to be changed at ever shorter intervals and that even
mills producing only a few different articles will be forced to make frequent
warp changes. Even with the use of larger warp beam flanges and increased
warp lengths, warp change frequencies cannot be reduced further. Conditions
in mills with a very wide range of articles are even more extreme. A wide
range of articles often means that a different fabric is being produced on
each individual weaving machine, and also that the piece lengths are becoming
shorter and shorter. Add to this the increased weft insertion rates and the
result is an increasing number of warps that have to be made ready for
laying-in in the weaving room at ever shorter intervals.
It is no longer acceptable practice to use the expensive weaving machine
as a knotting machine stand, and in consequence lose up to 10% absolute
efficiency as a result of last pick/first pick downtime of 8 hours. A dramatic
reduction in down-time is achieved with the introduction of ‘divided frame’
looms and the quick style change (QSC) systems. The style change is
accomplished by splitting off the warp beam and associated components
(such as warp-stop motion, warp tension sensor, harness frames and the
reed) and replacing them with a pre-prepared new warp beam with its ends
drawn in and heat sealed to a plastic sheet for quick and simple insertion into
the loom take-up rollers, without causing tension problems. The removed
warp beam is taken to the warp preparatory room on a special mobile module
carrier and reloaded. From the moment the machine stops until the new style
begins to weave takes less than 30 minutes.
5.3.1
Sectional warping
The latest generation of automatic sectional warping machines brings together
solutions to all the most urgent demands of the modern weaving mill,