Calculation of Warping Plan in The Weaving Mill Production
Yarns are threaded onto a beam to generate the warp, which forms the fabric’s lengthwise structure, during the vital phase of warping in the weaving process. As part of the warping plan, the yarns are arranged and laid out on the warp beam in accordance with the intended fabric characteristics, including weave pattern, width, and density. To obtain the required fabric properties and weaving efficiency, it usually takes into account variables like yarn count, tension, and the number of ends per inch. In this article, we explain the Calculation of the Warping Plan in The Weaving Mill Production process.
In the weaving mill, The warper gets the required no of ends and the number of beams from the R&D department, and then he makes a plan on how to complete that task whether on one creel or on more no. of creels.
Some examples are given below to show the concept of a Calculation of a warping plan.
Problem: 01
If Weight of Bag: 50 Kg, Total Number of Cone: 24, Count: 7 OE. Then find out the length of yarn in one cone.
Solution:
Per cone weight = total weight of cone /total no of cone
= 50/24
=2.08333
Length of yarn in one cone = weight × count
=2.08333×2.20462×840 × 7/1.0936 M
=24695.1307 M
Answer: Length of 7 OE = 24695 M
Problem: 02
If Set length: 21000 m, Count: 7 9 12 Ratios: 4:4:4, Find out average count.
Solution:
Average Yarn Count= 12 × 7 × 9 × 12 /4 × 9 × 12 + 4 × 7 × 12 + 4 × 7 × 9
=9072/432+336+252
=9072/1020
=8.894
Answer: Average Count = 8.89
Problem: 03
If, Set length: 24695 m, Total ends: 4464, Ends/beam: 446, Total beam: 10, Count: 7 OE, Find out the weight of yarn required.
Solution:
Weight of yarn in one beam =Set Length × Total Ends × 1.0936/840 × 2.2046 × count
= 24695 × 446 × 1.0936/840 × 2.20462 × 7
= 12044877.592/12963.1656
=929.16 Kg
Total yarn required = Weight of yarn in one beam× Total beam
=929.16×10
=9291.61 Kg
Answer: Total Yarn Required = 9291.61 Kg
Problem: 04
Given here, Set length=13650 met Total ends= 466, Count= 16, Empty beam weight=300 kg, find out the total weight of the 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: The beam weight is 534 kg