2.Winding part- 1 The yarn from the spinning is not adequate in quantity and quality for weaving..pdf

It contains a number of imperfections in the form of thick places, thin
places and slubs. These will pose problems in the subsequent process and ultimate
hinder the cloth quality. Also, the ring cop is small in size and needs to be converted
into a bigger package

1. Winding

2. Winding
The yarn from the spinning is not adequate in quantity and quality for
weaving. It contains a number of imperfections in the form of thick places, thin
places and slubs. These will pose problems in the subsequent process and ultimate
hinder the cloth quality. Also, the ring cop is small in size and needs to be converted
into a bigger package.
The winding process achieves the twin objectives of reducing the imperfections in
the ring yarn as well as converting it into bibber package in the form of cone/cheese.
Fig. Winding process.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 2

3. Winding
Thus, the ring cop which weighs about 60-80 grams is converted into a
package of 1.5 to 2 kgs. Heavier packages of about 5 kgs is used for synthetic
textured yarns.
The winding is the process of transferring yarns from a number of small yarn
packages (ring bobbin, hanks, ring cops) to large yarn packages (cone, cheese,
pirn) in order to make use of yarn in subsequent machinery.
The Winding process not only make bigger yarn packeges, but it also corrects
spinning faults like neps, hairiness, and waxes. It may be electrical or mechanical.
▪Warp: cone, cheese, flanged bobbin
▪Weft: pirn, cop
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 3

4. Winding
Objects of winding
▪To transfer yarn from small packages to large packages, this can be conveniently
used for the weaving purposes.
▪To make a continuous supply of yarn in the subsequent process.
▪To remove yarn faults like hairiness, neps, slubs, and foreign matters.
▪To produce long length of yarn by serially joining one yarn package with another.
▪To clean the yarn.
▪To improve the quality of yarn.
▪To improve the efficiency of yarn for next process.
▪To get a suitable package.
▪To remove thick & thin place of yarns.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 4

5. Winding
▪Improvement of cops building for uniform dyeing with package dyeing.
▪Paraffin waxing of the yarn during the winding process.
▪Introduction into the yarn of a minimum number of knots.
▪Achievement of high machine efficiency i.e., high production level.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 5

6. Winding
Requirements of winding
▪Minimize the yarn fault e.g., slubs, neps, thick & thin places.
▪During winding the mechanical and physical properties of yarn should not be
impaired.
▪The yarn must be wound in such a way as to permit unwinding in the following
process with a minimum of difficulty at the required speeds.
▪The package should contain a yarn of maximum length.
▪To maintain the size and shape of the package for end use.
▪The package size should be controlled for the particular economic requirements.
▪The amount of yarn wastes must be small.
▪Avoid excess looseness and tightness, the package should be standard.
▪Winding speed should be uniform.
▪The package should be cheaper; above all the process must be profitable.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 6

7. Winding
Schematic diagram of Winding
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 7

8. Winding
Schematic diagram of Winding
It has three sections
1.The unwinding zone,
2.The tension and clearing zone, and
3.The winding zone.
The unwinding zone:
To rewind the yarn on a new package, it must first be removed from the old
package. This is accomplished in the unwinding zone. This zone merely consists of a
creel, which holds the old package in an optimum position for unwinding. The
common yarn withdrawal methods, side withdrawal and over-end withdrawal.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 8

9. Winding
The tension and clearing zone:
The next zone is the tension and clearing zone. In this zone, tensions are
applied on the yarns by using tensioners so that yarns are wound on the package with
proper compactness. The objectionable yarn faults (thick & thin spots, slubs) as well
as other contaminants (colored and foreign fibers) are also removed by using optical
or capacitance-based yarn clearer.
This zone consists of a stop motion which causes the winding to stop in the case of a
yarn break or the depletion of a supply package. The yarn is directed into this zone by
a guide.
The winding zone:
In the third and final zone, yarns are wound on the package by means of
rotational motion of the package and traverse motion of the yarn guide. Based on the
operating systems employed in the winding zone, two major winding principles have
evolved.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 9

10. Winding
Yarn Withdrawal
Removal or unwinding of yarn from package during weaving is called
withdrawal of yarn.
There are two types of yarn withdrawal:
1.Side-withdrawal
2.Over end withdrawal
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 10

11. Winding
Side withdrawal
In side-withdrawal, the bobbin must rotate for the yarn to be removed. Typical
uses of side-withdrawal are to be found in the various operations on a warp. In view of
the multiplicity of ends in a warp it is virtually impossible to use anything but side
withdrawal.
Features:
▪Package will rotate in side-withdrawal.
▪Yarn twist will be unchanged.
▪No balloon formation.
▪It is applied to flanged bobbin.
▪The rate and speed of unwinding is slow.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 11

12. Winding
Advantages:
▪The yarn does not rotate upon withdrawal.
▪The yarn twist remains constant.
▪No balloon formation.
Disadvantages:
▪At high winding speeds, due to inertia, the rotation of the bobbin may lead to tension
variations in the yarn.
▪This process is costlier for practical use.
▪High speed impairs the stability of the package.
▪Flanged bobbin required.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 12

13. Winding
Over end Withdrawal
This method is the simplest and most common method of yarn withdrawal. The
yarn is to take away along a line which roughly coincides with the axis of the package.
Using this technique, it is not necessary to rotate the package.
It is used in circumstances where high unwinding speeds are required, such as in high-
speed beaming and the removal of yarn from weft packages.
Features:
▪Package remain stationary during unwinding.
▪Formation of balloon occurs.
▪Twist/inch of yarn changed.
▪Generally, cop, pirn, cone, cheese are packages used for over end withdrawal.
▪The rate of unwinding is high.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 13

14. Winding
Advantages:
▪Very high rates of yarn withdrawal.
▪Not so expensive.
▪Not necessary to rotate the package.
▪Flanged bobbin is not required.
Disadvantages:
▪Balloon formation.
▪There is a chance of one turn twist in the yarn.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 14

15. Winding
Difference Between Side Withdrawal and Over End Withdrawal
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 15
Side Withdrawal Over End Withdrawal
1.Packagemustrotate 1.Packageisstationary
2.Noballoonformation 2.Balloonformation
3.Yarntwistisnotchanged 3.Yarntwistischanged
4.Theprocessiscostlierforpracticaluses4.Theprocessischeap
5.Highspeeddecreasesthestabilityof
packages
5.Morestablepackages
6.Needsflangedbobbin 6.Noneedofflangedbobbin
7.Unwindingisnotfast 7.Unwindingisfast
8.Possibilityofyarntensionvariation 8.Nopossibilityofyarntension
variation

16. Winding
Ballooning/Balloon Theory
▪The rotation applied to departing yarn drawing at high speed of the yarn unwinding
from a stationary spinning cop, the yarn is thrown by centrifugal force away from the
cop axis and circumscribes in space of plane is called balloon. The theory is called
balloon theory.
▪In the process of yarn unwinding from the cop every element of the yarn in the
balloon performs a complicate movement along the yarn axis and a rotational
movement around the cop axis.
▪The shape of the balloon depends on the tension of the yarn at unwinding from the
cop. The balloon is more salient when the tension is reduced and in this case the
conditions of yarn unwinding from the cop are better. When the tension is increased
the balloon becomes gently sloping.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 16

17. Winding
Ballooning/Balloon Theory
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 17

18. Winding
Balloon size depends on
▪Yarn count: Higher the yarn count, lighter the yarn and higher the balloon size.
▪Yarn winding/unwinding rate: Higher the speed of winding/unwinding higher
the centrifugal force is produced; hence larger balloon is formed.
▪Size of the package: If the package is larger, then the height of the balloon will be
higher.
▪Lift of the package: Higher the lift of the package then the larger balloon is
formed.
▪Position of the guide: If the yarn guide is placed at larger distance from the yarn
package, then larger balloon is formed.
▪Air resistance: If the air resistance is more, then smaller balloon is formed.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 18

19. Winding
TypesofWindingPackages
Therearethreetypesofwindingpackages,which
arepointedoutinthebelow:
1.Parallelwindingorparallelwoundpackage
2.Nearparallelwindingornearparallelwoundpackage
3.Crosswindingorcrosswoundpackage
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 19

20. Winding
Parallel winding or parallel wound package
In this type of winding package, yarn is wound parallel to each other on the
package containing flanges on both sides of package.
In case of parallel winding package, traversing guide does not require. It is
necessary to have a flanged package.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 20

21. Winding
Advantages of Parallel winding or parallel wound package
▪In this package, so many yarns can be woundat a time.
▪No change of twist during winding.
▪The package is stable here.
▪There is a possibility of side withdrawal here.
▪Yarn density is more.
▪Traversing mechanism is not needed.
Disadvantages of Parallel winding or parallel wound package
▪Here, two sides of the windingpackage has needed flanged.
▪Over end withdrawal is not possible here.
▪Needed separate mechanism for yarn unwinding.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 21

22. Winding
Near parallel winding or near parallel wound package
Incaseofnearparallelwindingornearparallelwoundpackage,the
packagecontainsoneormoreyarnwhicharelaidverynearlyparalleltothelayers,
andwhicharealreadyexistingonthewindingpackage.
For instance, Pirn, Cop.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 22

23. Winding
Advantages:
▪Flanged is not necessary here.
▪During winding, no change of number of yarn turns per inch or twist.
▪The package is comparatively stable.
▪Over end withdrawal is possible here.
Disadvantages:
▪Side withdrawal is not possible here.
▪Traversing mechanism is required here.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 23

24. Winding
Cross winding or cross wound package
Incaseofcrosswindingorcrosswoundpackage,thewindingpackage
containsasingleyarnwhichislaidonthepackageatanappreciablehelixangleso
thatthelayerscrossingoneanothertoprovidestability.
For example, Cone, Cheese, Spool etc.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 24

25. Winding
Advantages:
▪Overendwithdrawalispossiblehere.
▪Stabilityofyarnpackage.
▪Flangedisnotneededhere.
Disadvantages:
▪Yarnqualityislesshere.
▪Yarntwistischangedduringwinding.
▪Traversingmechanismisrequiredhere.
▪Balloonformationoccurs.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 25

26. Winding
Types of Winding
According to density:
▪Precision winding (cones & chesses)
▪Non-precision winding
According to type of package:
▪Cone winding package
▪Pirn winding package
▪Flange winding package
▪Cheese winding package
▪Cop winding package
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 26
According to the build of the package:
▪Parallel winding package
▪Near parallel winding package
▪Cross parallel winding package
According to methods of drive:
▪Positive or direct drive
▪Negative or indirect drive
According to the future of automation:
▪Conventional winding
▪Modern winding

27. Winding
PrecisionWinding
Byprecisionwindingsuccessivecoilsofyarnarelaidclosetogetherina
parallelornearparallelmanner.Bythisprocessitispossibletoproduceverydense
packagewithmaximumamountofyarnstoredinagivenvolume.
FeaturesofPrecisionWinding
▪Packagesarewoundwithareciprocatingtraverse
▪Patterningandrubbingcausesdamageofpackages
▪Packagecontainsmoreyarn
▪Packageislessstable
▪Thepackageishardandcompact
▪Thepackageisdense
▪Rateofunwindingofpackageislowandtheprocessofunwindingishard
▪Thewoundcoilisarrangedinaparallelornearparallelmanner
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 27

28. Winding
Non-PrecisionWinding
Bythistypeofwindingthepackageisformedbyasinglethreadwhichis
laidonthepackageatappreciablehelixanglesothatthelayerscrossoneanother
andgivestabilitytothepackage.Thepackagesformedbythistypeofwindingare
lessdensebutismorestable.
Features
▪Onlyonecoilisusedtomakethispackages
▪Crosswindingtechniqueisused
▪Thepackagedensityislow
▪Minimumnumberofyarniswound
▪Thepackageformedissoftandlesscompact
▪Thestabilityishigh
▪Flangesarenotrequired
▪Therateofunwindingishigh,andtheprocessiseasy
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 28

29. Winding
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 29
Difference between precision and non-precision winding
Precision Winding Non-Precision Winding
Thewoundcoilarrangedparallelornearparallel.Thecoiliscrosswise-wound.
Theyarndensityofthepackageishigh. Theyarndensityofthepackageislow.
Flangedbobbinmaybeused. Notuseofflanged.
Theyarnpackageishardandmorecompact. Theyampackageissoftandlesscompact.
Lowstabilityofthepackage. Highstabilityofthepackage.
Windingangleis90ᵒ or near 90ᵒ Windingangleislessthan80ᵒ
Thebobbiniswoundwithoneormorethreads.Thebobbiniswoundwithonethread.
Yarntensioniscomparativelyhigh. Yarntensioniscomparativelyless.
Unwindingrateislow. Unwindingrateishigh.

30. Winding
AuxiliaryFunctionsofWinding
Creeling:
Creelingistheplacementoffullpackagesinpositionreadytobeunwound
aspartofthetransferoperations.Analternativemeaningistheremovalofthe
exhaustedpackages&theirreplacementwithfullones.
Piecing:
Piecingisthefinding&connectingoftheendsonthepackages.The
connectionbetweentheendscanbemadebyknottingadhesionorweldingbutthe
formerisbyfarthemostcommon.Suchconnectionsarerequiredwheneveranend
breaksorwhenacreelingoperationhasbeencompleted.
Doffing:
Doffingistheremovalofnewlywoundpackages&thereplacementofthese
byemptypackageswhichwillreceiveyarnduringthetransferprocess.Itwillbe
notedthatcreelpackagesareemptiedasthepackagestobedoffedarefilled.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 30

31. Winding
Windingefficiency
Theratiobetweentheactualproductionandthecalculatedproductionis
calledwindingefficiency.Itisexpressedbyinpercentage:
Windingefficiencyη={(Actualproduction)/(Calculatedproduction)}×100%
Factors:
Windingefficiencydependsonthefollowingfactors
▪Spindleordrumspeed:Thehigherthespeedthemoreisthewindingefficiency
▪YarnCount:Yarncountisproportionaltowindingefficiency
▪Yarnquality:Ifyarnqualityincreases,thenwindingefficiencyincreases
▪Workerefficiency:Themoreefficienttheworkeristhemoreefficientthe
windingwillbe.
▪Humidity:Humidityisreciprocalorinverselyproportionaltowindingefficiency.
▪Workloadperworker:Iftheworkloadoneachworkerisless,efficiencyof
windingwillbemore.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 31

32. Winding
▪Maintenance and over hauling:If the maintenance and overhauling of the
machine is not correct then efficiency of winding will decrease.
▪Powerfailure:Ifpowerfailurerateincreasesthewindingefficiencywill
decrease.
▪Creelingtime:Themorethecreelingtimethelessistheefficiency.
▪Doffingtime:Themorethedoffingtimethelessistheefficiency.
▪Capacityutilization:Whencapacityutilizationdecreasesthenefficiency
increases.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 32

33. Winding
Reasons for lower efficiency
▪Power failure
▪Improper maintenance and over hauling
▪Natural disasters
▪Less skilledlabor
▪Labor unrest
▪Shortage of machine parts and raw materials
▪Strike
▪Maintenance problems
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 33

34. Winding
Faults in Winding
1. Slack knots or knots with long tails:
Causes: Slack knots get untied, while long tail cause breakage of an adjacent ends
in weaving and pass with difficulty through the healds and reed.
Remedies: Knots should be given in a proper way.
2. Piecing up:
Causes: Not having found the tail from the package the operator ties the yarn end
from the bobbin to one of the broken yarn coils on the winding package, which
causes breakage in warping.
Remedies: Operator should be careful during knotting.
3. Overlapping:
Causes: The operator does not tie-in the ends, but merely winds them around the
package without knotting, which results in warper stoppage.
Remedies: Double check during knotting.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 34

35. Winding
4.Faultyshapeofpackage:
Causes:
▪Faultyyarnguide,
▪Faultybuildingdevice,
▪Faulty traverse motion,
▪Faulty drum guide.
Remedies:
▪Correctyarnguideshouldbeused,
▪Accuratebuildingdeviceshouldbeset,
▪Perfecttraversingmotionshoulduse,
▪Correctdrumguide.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 35

36. Winding
5. Sloughing off: Thickbunchesofyarnarewovenintothefabricintheweft
directionduetoslippingoffofcoilsofyarnfromthepirnduringweaving.
Causes:
▪Improperpackagecharacteristics.
▪Softlywoundpirns.
▪Harshpickingand/orpoorshuttlechecking.
▪Poorhumidityconditionsduringthestorageofpirns
Remedies:
▪Employcorrectpackagecharacteristicsinpirnwinding.
▪Ensureproperyarntensionduringpirnwindinginthecaseofrewoundweftandin
spinninginthecaseofdirectweft.
▪Checkthepickingandcheckingmechanisms.
▪Conditiontheweftbeforeputtingitonloom.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 36

37. Winding
6.Jailformationorstitching:
Causes:Improperset-upofconeholder.
Remedies:Accurateset-upofconeholder.
7.Formationofribbon:
Causes:Improperset-upofcamswitch.
Remedies:Perfectset-upofcamswitch.
8.Bellshapedcone:
Causes:Faultyset-upofconeholderswithwindingdrum.
Remedies:Set-upshouldbeperfect.
9.Ringshapedcone:
Causes:Faultysettingofconeholder.
Remedies:Accurateset-upofconeholderisnecessary.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 37

38. Winding
10.Softpackage:
Causes:Imperfecttensionduringwinding.
Remedies:Tensionshouldbeperfect.
11.Tightbobbin:
Causes:Highertensionduringwinding.
Remedies:Tensionshouldbefixed.
12.Mixingofyarnsofdifferentlineardensity:
Remedies:Lineardensityofmixedyarnshouldbesame.
13. Excessive full bobbin:
Remedies: Yarn should be wound at a definite length.
14. Variation of tension:
Remedies: Tension must same throughout the totalwinding process.
Md. Abdul Alim, Asst. Prof., Dept. of Textile Engineering, KUET. 38