Warping Breakage Study
FOR A GIVEN QUALITY OF YARN ,THE END
BREAKAGE RATE AT WARPING REFLECTS
THE CONDITION OF THE WARPING
MACHINE AND THE QUALITY OF WINDING
IN TERMS OF PACKAGE FAULTS.
PROPER RECORDING OF CAUSE-WISE
END BREAKS AT WARPING WILL HELP IN
IDENTIFYING THE NECESSARY
CORRECTIVE ACTION TO BE TAKEN TO
REDUCE THE END BREAKAGE RATE .

Warping Breakage Study
FOR A RELIABLE ESTIMATE BREAKAGE
RATE PER 400 ENDS AND 1000 METERS
CALCULATED FROM THE DATA.
COMPARE THE DATA WITH NORMS
FOR GOOD WARPING PERFORMANCE THE
BREAKAGE RATE TOLERATED IS AROUND
1 TO 1.2 BREAKS.

NO.OF ENDS
Warping Breakage Study
TOTAL BREAKS/400
ENDS/1000METERS
END BREAKS DUE TO
SOFT YARN
THICK PLACE
FOREIGN MATTER
SLUB
BAD PIECING
FLUFF
BUNCH YARN
BAD KNOT
STITCH
CUT PACKAGE
TOTAL BREAKS

Warping Breakage Study
MINIMISING END BREAKS AT WARPING INVOLVES FOUR
STEPS
I) CONTROL OF TENSION IN THE YARN
II) SATISFACTORY MAINTENANCE OF THOSE MACHINE
SETTING AND MECHANICAL CONDITION OF THE
MACHINE THAT AFFECT YARN TENSION.
III) MINIMISING THE DEFECTS ON PACKAGE
PRODUCED AT WINDING.
IV) A REGULAR CHECK ON THE END BREAKAGE RATE
FOR COMPARISION WITH THE NORMS.

Warping Breakage Study
I) CONTROL OF TENSION IN THE YARN
AVERAGE YARN TENSION SHOULD BE ADJUSTED
ACCORDING TO YARN COUNT AND SHOULD NOT
EXCEEDS 5 5 OF THE SINGLE THREAD STRENGTH.
THE TENSION LEVEL ON HIGH SPEED WARPING
MACHINES CAN BE ADJUSTED BY A SUITABLE
COMBINATION OF TENSION WEIGHT ,WARPING
SPEED.
THE ACTUAL TENSION LEVELS SHOULD BE
CHECKED AT LESAT ONCE A MONTH ON EACH
MACHINE WITH HELP OF A TENSION METER.

Warping Breakage Study
CONDITION OF MACHINE
1.
ALIGNMENT OF THE PACKAGE AT THE CREEL.
NON-ALIGNMENT OF THE CREEL PACKAGE WITH
RESPECT TO THE FIRST GUIDE IS OFTEN CAUSE OF
HIGH END BREAKAGE RATE AT WARPING.
2.
ECCENTRIC GUIDE ROLLERS
THE GUIDE ROLLERS AT WARPING SHOULD BE
CHECKED FOR EVERY SIX MONTHS TO AVOID
TENSION VARIATION.
3.
THREAD GUIDE
DEEP CUTS IN THREAD GUIDES CAN INCREASE
YARN TENSION .
DIRTY GIUDES SHOULD BE CLEANED WITH
CARBON TETRA CHLORIDE.