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How to Calculate Warping Plan in Weaving

How to Calculate Warping Plan in Weaving
Rofiquzzaman Raju
Fabric Technologist,
B.J.Group, Mawna, Gazipur
Email: rtextile.finance@gmail.com



Warping Plan
The warping plan is fed in the panel as per warping sequence. The yarns from cones are passed through accumulators, thread guides and arms which winds up a preset numbers of meters on the drum. The warper gets the required no of ends and the number of beams from the weaving department and then he made the warping plan that how to complete that task whether on one creel or on more no. of creels.
Warping
Some examples are given below to show the concept of warping plans using one creel and two creels.

Example-1:

If,

No. of ends = 1080
No. of beam = 4
Count = 10/s
No. of cones in one bag = 16
No. of warper's beams with no. of ends on each = ?
Length per beam = ?
No. of Bags of 100 lbs = ?

Plan for one Creel

Then,
The total no. of ends on the weavers beam = 1080 x 4 = 4320 ends

Cone wt. = bag wt. / no. of cones in bag
= 100 / 16 = 6.25 lbs

Length of yarn on one cone = cone wt. In lbs x count x 768.1
= 6.25 x 10 x 768.1 = 48006 m

Lessen the length up to 1 % because of variation in yarn length among different cones length of yarn on one cone = 47600 m

No. of ends x no. of beams = total no. of ends
617 x 6 = 3702
618 x 1 = 618
………………………..
Total = 4320 ends

So, 7 warper's beams

i.e. 6 beams of 617 ends and 1 beam of 618 ends

Length / Beam = length of yarn on one cone / no. of beams
= 47600 / 7 = 6800 m / beam

Bags required = No. of ends on warper beam / no. of cones in one bag
= 618 / 16 = 39 bags approx.

Example-2:

If,

No. of ends = 1140
No. of beams = 4
Count = 10/s
No. of cones in one bag = 24
No. of warper's beams with no. of ends on each = ?
Length per beam = ?
No. of Bags of 100 lbs = ?

Plan for two Creel

The total no. of ends on the weavers beam = 1140 x 4 = 4560 ends

Cone wt. = bag wt. / no. of cones in bag
= 100 / 24 = 4.16 lbs

Length of yarn on one cone = cone wt. In lbs x count x 768.1
= 4.16x 10 x 768.1 = 31952 m

Lessen the length up to 1 % because of variation in yarn length among different cones

Length of yarn on one cone = 51600 m

No. of ends x no. of beams = total no. of ends
= 570 x 8 = 4560 ends

So, 8 warper’s beams of 570 ends each

No. of beams per creel = no. of warper’s beam / no. of creels
= 8 / 2 = 4

Length / Beam = length of yarn on one cone / no. of beams per creel
= 31600 / 4 = 7950 m / beam

Bags required = No. of ends on warper beam X no. of creels / no. of cones in one bag
= 570 X 2 / 24 = 48 bags approx.

Example-3:

Given here, Set length=13650 m, Total ends= 466, Yarn Count = 16, Empty beam weight=300 kg, find out total weight of beam?

Solution:
Weight of yarn in one beam = set length ×total ends×1.0936÷840×2.2046×count
= 13650×466×1.0936÷840×2.2046×16
= 6956280.24÷29629.824

Total weight = yarn weight+ Empty bobbin weight
= 234 +300
=534 kg

Answer: Beam weight = 534 kg

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