Table Tag: process

Complete Weaving Mill Process

Introduction: Introduction to Fabric Manufacture and the Process of Weaving

In this article, we will take a look at the warp sizing process.

The weaving process is one of the most important processes in textile production. It is a complicated process and requires a lot of expertise to get it done right. The different parts of the process are warp sizing, warping, weaving, and taking up.

The weaving process is a complex process, and it can be confusing to understand all the steps of the process. With this guide, we will break down each step of the process so that you can better understand how weaving works.

The weaving process starts with yarns. Yarns are made up of two strands: one strand is called the warp and the other is called the weft. The warp is set up on a loom in order to create a pattern, while the weft is woven through it.

In order for there to be a pattern created by this method, there needs to be two sets of yarns: one set called “warp” and another set called “weft.”

What is warping section or department in a weaving mill.

The term “warp” derives from its first use as a verb meaning “to weave”. Warp threads are longitudinal threads that run parallel to each other and are stretched in one direction across a loom. A weaver who prepares the warp is called a warper; one who prepares it after it comes from the mill is sometimes called an overseer or dresser. Warping is a process of preparing the loom to weave. It is the process of winding yarn or thread onto a long, narrow, continuous piece of wood called a warp beam. The yarns are held taut and parallel to each other. Once the warp has been wound on the beam, it can be secured in place with ties or clips.

What is sizing in a weaving mill or fabric manufacturing

Sizing is a process conducted after the warping function. Here the yarn lapped on beam is coated with some material which increases in strength of yarn so that it may run smoothly during the next step of fabric manufacturing.

Weaving Section

Here starts the final stage of Raw Fabric manufacturing. The Machines used in this process are called looms. There are several types of looms being used to produce fabric. We will introduce you to some mainly used weaving machines or looms in this article.

  1. What is Auto Loom or how an Auto Loom works:

    The auto loom function was invented by Charles Weldon in 1814. It was an improvement on a previous invention called the flying shuttle, which required a person to move it back and forth manually. The machine consists of two sets of threads, one set for each warp, that are stretched over and through a series of heddles and then attached to a shuttle that moves back and forth across the width of the fabric. The shuttle is controlled by cams on a rotating shaft with different patterns for each type of weave.
  2. What is Shuttle Less Loom or how a Shuttle Less Loom works:

    A shuttle is a device that holds the weft yarn, which is threaded through the warp yarns. A shuttle less loom function is a type of loom that does not require a shuttle to carry weft yarn. The first loom was invented around 4000 BC and it consisted of two sticks with threads stretched between them. It was used for weaving cloth by hand. The process of weaving cloth on these looms was slow, tedious, and required much skill. The invention of the shuttle less loom function in 1738 significantly changed this process and made it much quicker and easier.
  3. What is Air Jet Loom or how an Air Jet Loom works:

    The air jet loom is a type of loom that is more advanced than the conventional loom. It is used for weaving fabrics that are usually made from synthetic fibers. The air jet loom functions by blowing compressed air through a nozzle to create loops of yarn on the surface of the fabric. This process is known as looping and it resembles sewing in many ways. It creates loops by pressing the needle against the fabric’s surface and then releasing it to pull up a loop of yarn before repeating this process.

    Air jet looms are used to weave fabric. They use air jets instead of typical brushes or rollers. Air jet looms are also faster than most other looms, allowing production times to be much shorter.
  4. What is Water Jet Loom or How a water Jet Loom works:

    The water jet loom is a type of loom that is used in the textile industry for weaving fabrics. It was invented by the Swedish engineer, Bengt A. Malmqvist in the 1950s and has been improved on since then. The water jet loom functions by using a high-pressure water jet to produce its weft yarns.

    The water jet loom is a unique tool in the world of weaving. It uses the power of high-pressure water to create an intricate and diverse range of designs. Fabric woven on an air jet loom is stronger, more flexible and has better textural properties than traditional weaving.
  5. What is Rapier Loom or How a Rapier Loom works:

    Rapier looms are a type of power loom and they can be used to weave products such as tablecloths, rugs, and clothing. An ideal laptop for craft weaving is the HP w19i rapier loom. It offers maneuverability, flexibility and a sturdy design to ensure optimal performance while weaving on the go. Power looms use a series of wires that power your material through the weaving process; shuttle looms utilize this same concept but use shuttles that slide across the fabric rather than a series of wires.

    Rapier loom is a special type of power loom, with a slanted blade. It was used to propel the shuttle through between two sets of heddles, or to make the textile threads stretch out over one row of wood batten and then onto another row of batten at the other end of the loom. The term “rapier-loom” (or “rapier”) acquired its name from these blades that were designed so that the threads would be caught, or perhaps not caught at all, by these lower blades and then propelled into the shedder called “heddle bar”.

    The rapier loom is a hand-woven textile that uses a shuttle to weave individual threads. The rapier loom is most commonly used in the making of rugs, but it can also be used to make decorative fabrics, wall coverings and area carpets

Author: Afzaal Khadim Khan
Owner: Textiles Bar
Lahore Pakistan

If you are interested in learning about the yarn manufacturing process of spinning process Please Click Here

How a Spinning Mill Works (Complete spinning mill process)

This is a process of converting raw cotton into a more usable form.

In the first stage, raw cotton is mixed with water in order to remove dirt and impurities. The mixture is then sent through a series of machines called ‘blow room’ and ‘carding’. In the blow room, air is blown to make the cotton fluffy. This process makes it easier for the carding machine to separate out fibers of different lengths. The carded fiber is then compressed into slivers which are spun together to form yarns.
Spinning is a process that converts raw materials, such as cotton, wool, or flax, into a continuous strand of yarn. The process is carried out in four steps: carding, drawing out, spinning and twisting.

Below are the details of some major sections or departments used in a spinning mill to convert the fiber into yarn.

In the carding process the raw material is first broken down into small pieces and then it is cleaned from the impurities like trash, dead fiber, dust and dirt. After this cleaning process the cleaned cotton is converted into sliver form. This sliver is stored and carried forward to the next section in canes.

The carding machines separate the raw material into a web of long fibers called sliver. The process starts by drawing slivers from the carding machine. The slivers are then taken to the drawing machines where this sliver is reprocessed to make it softer, straight and variation is decreased by using several canes of sliver into one row.

It is a process in which the fibers are passed through a series of rotating brushes. The brushes pull out the shorter fibers and leave behind the longer ones, which are then wound onto bobbins in the forms of laps.
The most common type of machine used for combing is called a comber.

The simplex frames pull the slivers out to make them thinner and longer, while being twisted together to form roving.

The roving is then taken to the spinning frames where it is stretched out and twisted together even more tightly to produce yarn. In the spinning mill process, yarn is spun into thread by a spinning machine. The spinning machine is called a ring frame and it includes four parts: the spindle, the flyer, the bobbin and the doffer.
The spindle is attached to a rotating drive shaft that is powered by an electric motor. The flyer is a large rotating cylinder with many slots in it that catches thread as it comes off of the spindle. The bobbin holds all of the thread coming off of the flyer and stores it until it can be wound onto a small container called bobbin

Then the yarn bobbins are converted into big yarn cones to their final shape.

Then these cones are brought to the packing department. Packing is being done in both mechanical and manual form. most common packing are carton packing, PP bag packing and pallets.

Author: Afzaal Khadim Khan
Owner: Textiles Bar
Lahore Pakistan