Denim Manufacturing - Yarn Process Warping

 

The production process of denim given in the following link gives the general idea of the process, the series of blogs like this give the brief explanation of the process and machines. Here in this blog we will go forward to next and important step, which is Warping Process:

https://bindaprocess.blogspot.com/2022/02/denim-production-process.html 

Warping 

It is the process of transferring  multiple yarns, each on a separate yarn  package into a single collecting package.

Ball Warping

In rope dyeing as explained in https://bindaprocess.blogspot.com/2022/03/denim-yarn-dyeing.html

This package of yarns is  referred to as a ball warp. The  individual yarns are brought together  and formed into a rope. The rope is then  wound onto a cylindrical barrel  sometimes called the log, it got its name  from when they were originally made from  solid pieces of wood. Today logs are made  from metal and covered with rubber. The  log does not have any flanges, the yarn collecting package is referred to as a  beam.

When the yarns are laid in sheet  form onto a cylindrical barrel with side  flanges and yarn ends lying parallel to  one another in either case, the supply  yarn packages are placed on spindles  which are located in a framework called  a creel. Traveling package creels are:

V- Shaped Creels

With the current  packages of yarn that are being used to  make the beam or log, placed on the  outside of the V. The replacement yarn  packages for the next warper set are  placed on the inside of the V. When the  running packages are depleted the empty  yarn packages on the creel are rotated, so that the spent packages then move to  the inside of the V and the previously  stored full packages moved to the  outside of the V, ready to be processed  into the next warp.This system  eliminates time lost in creeling up new  yarn packages.

Continuous Magazine Creels

These are straight-line creels with  enough package holders. So that each end  running has a reserve yarn package place  beside it. The tail end of the running  package is tied to the beginning end of  the reserve package. Once the running  package is depleted the yarn transfers  over to the reserve package and the  warper continues to run. This is a random  method of creeling yarn packages and is  most effective by Mills running beams  and balls.With a standardized number of  ends yarn types or yarn counts on them.

Truck Creels

It describe a system where  one creel is running yarn packages while  a second creel  being loaded. Once the current set of  packages is exhausted, the creel is moved  out of the way and the second creel is  moved into the running position.The yarn  hands from the second creel must be  pulled forward and threaded through the  appropriate guides in ball warping  anywhere from 250 to 400 yarns or ends  are pulled from the creel.

These yarns  then pass through a comb like device  sometimes called a hack or Reid which  keeps each warp yarn separate and  parallel to its neighboring ends. Every  one to two thousand yards a least string  is interlaced through the warp yarns at  the hack the string aids the yarn  separation into sheet form during the  subsequent redeeming operation.

After  dyeing the yarns then go through a  funnel shaped device called a trumpet  which condenses the sheets of yarns , interrupts form the trumpet is located  at the base of the warper head and moves  back and forth guiding the rope of yarns  onto the log.

Once the yarns have been  wound under the log this package is  known as a ball warp and is ready to be  delivered to the indigo rope dye range.

Beam Warping

During beam warping, yarns from the creel  are in a sheet form and are wound  parallel to each other onto a flanged  beam. These yarns will not go through the  indigo rope tie range but can be either  slasher died or left natural.

If left  natural the resulting fabric could then  be piece dyed or used as a natural denim  which could even later be garment dyed. If desired another option could be to  beam dye the yarns using something other  than indigo dye.

The complete warping process describe in this blog can be viewed here:

https://youtu.be/425GgktN5I0