Process control parameters of weaving

Introduction
Weaving is the action of producing fabric by the interlacing of warp and weft
thread. The warp threads are placed along the length of the fabric and the weft
threads are placed along the width of the fabric.

FLOW CHART OF WEAVING

Yarn
(In the form of spinners package)

Warp Preparation

Weft Preparation

Winding (cone, cheese)

Winding (Cop, Pirn,

Cone, Cheese)

Warping (Pre beam/ Warpers

beam/ back beam)
Sizing (weavers beam)

Drafting, Drawing, Pinning

Denting, Looming
Weaving (Fabric)

Weaving (Fabric)

 Parameters of Yarn preparation

To remove yarn faults ( there are 23 types of yarn faults)
To transfer the yarn from spinners package to a convenient form of package which
will facilitate weaving.
To have desired length of yarn on a package.
To clean the yarn for better appearance and performance.
To make good quality fabric.
To reduce labour cost.
Parameters of Winding
Parameters of Precision Winding
Packages are wound with reciprocating traverse.
Package contains more yarn.
Low stability of package.
Hard and more compact package.
Low unwinding rate.
The wound coils are arranged parallely or near parallely.
Parameters of Non precision Winding
Coils are cross wound.
Package is of low density.
Less amount of yarn is stored in package.
High stability of package can be obtained.
Flange is not necessary.
Unwinding rate is very high.

Parameters of Warping
To prepare a beam to make a fabric.
To increase the wave ability of fabric.
To make a convenient yarn sheet for sizing.
To wound up required length of yarn onto a warp beam.
To facilate the weaving of complex color pattern.
To make reusable small packages

Mainly there are two types of warping

a) Direct/ high speed warping
b) Sectional warping.

Parameters of Sectional Warping

Sectional warping is suitable for producing color fabrics with different pattern.
Production is less in sectional warping. So it is a costly process.
In sectional warping, tension cannot be kept uniform.
Here tapered drum is used as drum.
Hand weaving is necessary to produce sample fabric for bulk production.
Parameters of High speed Warping
High speed warping is suitable for producing fabric with same count and same color
yarn.
Higher amount of yarn is required here.
The speed and production of a high speed warping is very high.
Here simple flanged bobbin is used as beam.
Parameters of Sizing
To protect the yarn from abrasion with heald eye, back rest, reed etc.
during weaving.
To improve breaking strength of cellulosic yarn.
To increase yarn smoothness.
To reduce yarn hairness.
To increase yarn elasticity and stiffness.
To decrease yarn extensibility.
To hinder generation of static electricity for synthetic and blended yarn.
To increase yarn weight.
Loom
The loom is the contact point of the whole process of cloth production, ginning, opening,
carding, spinning, winding, warping, sizing and beaming are done before weaving.

Primary Motion
Shedding: It is the process of separating the warp thread into two layers to form a
tunnel called shed (through which shuttle carrying weft passes) is known as
shedding. During shedding some yarns are raised up and some are depressed down
create a tunnel.

 Picking: The method of passing the weft threads which traverse across the fabric
through shed is called picking. The inserted weft is called a pick.
Beating: It is the process of pushing the pick into the already woven fabric at a
point known as fell of the cloth .By pressure of wraith to jointed feed side of the
cloth is called beating.
Secondary Motion
Take up motion: The motion which with draw (wound up) fabric from the
weaving area at a constant rate and thus give required pick spacing and winds the
fabric on to a roller is called cloth control or Take up motion.
Let off motion: The motion which deliver warp to the weaving at the required rate
and at a suitable constant tension by unwinding it from a flanged known as
weavers beam is called let off motion.
Tertiary Motion
Warp Stop Motion: Machine will be stopped electrically or mechanically.
Weft stop motion: It may be two types(a) Side weft motion & (b) Centre weft motion.
Reed stop motion: Two types(a) Fast reed motion.(b) Loose reed motion.
Drafting: The process of passing yarn through the drop wire is called drafting.
Drawing: The process of passing yarn through the heald eye is called drawing.
Denting: The process of passing yarn through the reed is called denting.

Conclusion:
During fabric manufacturing process, in each step of production should be control.
For better and smooth production with efficiency this controlling parameter are
more helpful .Depending on the context, clothing manufacturing can chart different
courses. High-end designers have different fabric manufacture processes than do
national and international chain stores. Despite their differences, though, the
concept of fabric manufacturing remains constant.

Reference
1.http://textilelearner.blogspot.com/2012/02/process-flow-chart-of-garments.html
2.http://www.onlineclothingstudy.com/2013/05/garment-manufacturing-processflow-chart.html
3. http://www.slideshare.net/karthikamdev/garment-manufacturing-process-fromfabric-to-poduct
4.http://www.slideshare.net/PriyambadaKhushboo/apparel-manufacturing-process
5. http://www.apparelsearch.com/terms/b/bulk_production.htm
6. http://www.apparelsearch.com/terms/p/pre-production_submissions_apparel.htm