Warping Mathematical Problems

Wt in lbs
1. The length of warp =
No of ends

Wt of warp in lb  Count  840

= (yds)
No of ends
Wt of warp in lb  Count
= (Hank)
No of ends
2. The total length of yarn in the warp
Length of warp  No of ends
=
840
or Actual length of in yds/hr=
Length of warp in yds  No of ends
3. Wt of warp in lbs =
840  Count
Length of warp in yds  No of ends
=
Count

Count  wt in lbs  840

4. No of ends in the warp =
Length of warp in yds
Count  wt in lbs
=
Length of warp in hanks

5. Count of warp or
Length of warp in yds  No of ends
Beam count =
840  Wt in lbs
Total length of yarn on the beam in yds
=
840  Wt in lbs

Total length of warp to be produced in yds

6. Time required = hr
Actual production in yds per hr  No of m/cs

Total length of warp to be produced in yds = Length of warp in yds required per beam
 No of beams per set  No of sets

7. Production = Surface speed of drum × π × Dia. of drum × Creel Capacity

1. A super speed beam warpers with a warping speed of 880 yds per min is preparing a
standard warp of 525 ends. If the yarns count 30’S and overall efficiency is 84%. Calculate the
following; the length of warp on each beam is required to be 44352 yds. Ignore waste.
I) Total length of warp produced per day of 8 hrs.
II) No of beam produced per day of 8 hrs.
III) Total weight of yarn in lbs warped per drum
IV) Weight of yarn on a beam.
 I) Total length of warp produced per day of 8 hrs = Calculated production ×
Efficiency × 60.
84
= 880  60   8 yds.
100

= 354816 yds

II) No of beam produced per day of 8 hrs

Total length of warp produced per day of 8 hrs in yds
=
Length of warp on a beam in yds
354816
= = 8 beams.
44352
III) Total weight of yarn in lbs warped per drum
Total length of warp yarn in yds  No of ends
=
840  yarn count
354816  525
= = 7392 lbs.
840  30
Total wt of yarn in lb
IV) Weight of yarn on a beam =
No of beam produced
7342
= = 924 lbs
8
2. Calculate the length of warp that can be produced per day of 8 hrs on a improved high
speed beam warper if the warping speed is 610 yds per min. The efficiency is 75%.

Actual production or Actual length of warp

75
produced per hr = 610  60  yds = 27450 yds.
100

Total or Actual length warp produced per day of 8 hr

= 27450 × 8
= 219,600 yds

3. Calculate the total no of ends on back beam which weights 242 lbs. The weight of the
empty beam as indicated from the marking on its flanges is 62 lbs. The count of the yarn is
40’S cotton and the length of warp on the beam is 14000 yds.

Weight of yarn = 242 – 62 = 180 lbs

Count  wt in lbs  840

No of ends in the warp =
Length of warp in yds
40  180  840
= = 432
14000

4. Calculate the count of yarn on a back beam which weights 303 lbs and has 12000 yds
on it. The total no of ends in the warp is 420 and the wt of empty beam 63 lbs.
 Weight of yarn = 303-63 = 240 lbs.

Count of warp yarn =

length of warp in yds  No of ends
=
840  240
12000  420
= = 25' s
840  240
5. You are required to prepare a warp of 12,000 yds from 1000 lbs of 30’s twist. Calculate
the no of ends yarn can have in the warp allowing 5% for waste and off on the bobbin.

wt in lbs  840  Count

No ends in the warp =
Length of warp in yds
Wt of yarn in lb = 1000 – 5% = 950 lbs.

950  840  30
No ends in the warp = = 1995.
12000

6. A beam made on a high-speed warping machine weights 369lb with the warp, the wt
of the empty beam 69 lbs. The no ends on the beam are 420 and count 20’S. Find out-

(a) The length of warp

(b) The total length of yarn in the warp.
(c) Amount the warper is to be paid if the rate of warping is 7 praises per 1000 yds of
warp.

Wt of warp in lb  Count  840

(a) The length of warp =
No of ends
Wt of warp on the beam = 369-69 = 300.
300  20  840
Length of warp = = 12000yds.
420

(b) The total length of yarn in the warp

= Length of warp  No of ends
= 12000  420 yds
12000  420
= hanks = 6000 hanks.
840

7. Calculate the wt of warp on a set of back beams which contains 2940 ends. The length
of warp on each beam being 16,000 yds & count of 50’s.

Length of warp in yds  No of ends

Wt of warp in lbs =
840  Count
16000  2940
= = 1120 lbs.
840  50
8. Calculate the beam count of the yarn on a set of 6 slasher beams, each of which contains
525 ends of 12,000 ends of 12,000 yds, at wt of warp on back beams is 12,000 lbs.

Total ends = 525 × 6 = 3150

Length of warp in yds  No of ends
Beam count =
840  Wt in lbs
12000  3150
= = 37.5’S.
840  12000

9. Calculate the no. of warper beams and the length of warp that can be made from 440
bobbins, each of which contains ½ lb of 60’S cotton. The no of ends of warp required is 2200.
Allow 5% waste and yarn left on the bobbins.

Total wt of yarn in lb = 440 × ½ - 5%. = 209 lbs.

Wt of warp in lb  Count  840
Length of warp in yds =
No of ends
209  60  840
= = 4788 yds.
2200

Total no of ends
No of beams =
No of bobbins
2200
= =5
440

10. A warpers beam produced on an improved modern high speed beam warping
machine contains 39780 yds of warp with 420 ends. If net wt of the warp on the beam is 663
lbs. Calculate beam count.

Length of warp in yds  No of ends

Beam count =
Wt in lbs  840
39780  420
= = 30’S
663  840

11. Calculate the quantity of yarn in lbs which will be required for a set of 6 back beams
to be produced on a modern high speed beam warper. The length of warp on each back beam
is 24000 yds and there are 462 ends on each beam count 36’S. Allow 1 1 % or 1.5% for waste
2
during warping.
Length of warp required per beam = 24000 + 1 1 %
2
= 24360 yds.
Total length of yarn in yds
Wt of yarn in lbs required for the set =
Count  840
Total length of yarn for
the set = Length of warp in yds required per beam
 No of ends per beam  No of beams
 = 24360  462  6 = 67525920 yds
67525920
Wt of yarn in lbs required for the set = = 2233 lbs
36  840

12. 8 sets of 6 warpers beams each is to be produced on 4 warping machines. The length
of warp on each beam is required to be 14,000 yds. If the production (actual) of each machine
is 2800yds per hr. How long will it take to complete the sets?

Total length of warp in yds = Length of warp in yds required per beam
 No of ends per set  No of beams
= 14,000  6 8
= 672000 yds.
Total length of warp in yds
Time required =
Actual production in yds per hr  No of m/cs
6,72,000
= = 60 hrs.
2800  4

13. A warper beam contains 12,600 yds of warp wound on it. The no of ends in the warp
is 420 and wt of the full beam is 361 lbs. If the wt of the empty beam is 51 lbs. calculate the
beam count.

Length of warp in yds  No of ends

Beam count =
Wt in lbs  840
12600  420
=
840  (361 − 51)
= 20.3’S

14. Calculate the time required to prepare of 8 warpers beam on 2 improved modern high
speed beam warpers with warping speed of 560 yds (calculated) per min. The length of warp
on each beam is required to be 36,000 yds. Efficiency 80%.

Actual production in yds per machine per hr

= Calculated production in yds / mcs / hr  60  Efficiency
80
= 36,000  60  = 26880 yds.
100

Total length of warp in yds  No of beams

Time required =
Actual production in yds per mcs per hr  No of m/cs
36000  8
= = 5.36 hrs.
26880  2

15. A modern high speed beam warping machine produces 8 beams each containing
222,720 yds of warp per day of 8 hrs. If the calculated warping speed of the warper is 580 yds
per min. Calculate efficiency.
 222, 720
= 27840 yds.
Actual production in yds per hr = 8

Calculated production in yds per hr = 580  60 = 34800 yds.

Actual production
Efficiency =  100%
Calculated production
27840
=  100% = 80%
34800

16. A full beam produced on a direct warping system is having 1.4 m width and contains 500 ends
of 30 tex yarn. The empty and full beam diameters are 30 and 75 cm, respectively. If the beam
density is 0.4 g/cm 3, then calculate the length of warp and its mass in kg.
Solution:
Beam width (L) = 1.4 m =140 cm

Number of ends = 500

Count = 30 tex

Empty beam diameter (d)= 30 cm

Full beam diameter (D) = 75 cm

So, the total mass of yarn on the beam is 207.82 kg and length of warp sheet is 13.85 km.
17. A Typical Calculation for Sectional Warping:

Available Creel capacity = 560

Total no. of ends per pattern = 42
Total width of warp = 56”
Dia. of drum= 30”

So, no. of pattern per section = Creel Capacity / Total ends in pattern
= 560 / 42
= 13.33
≈12 pattern (As required)

Creel to be used = Total pattern x Total ends in pattern

= 12 x 42
= 504

Total section = Total Ends / Creel used

= 7000 / 504
= 14 sections

Width of each section = Width of warp on drum or beam / Total sections

=56/14
=4 inch

Production = Surface speed of drum × π × Dia. of drum × Creel Capacity

= 20.65 × 3.1416 × 30” × 504
= 980895.48 inch/ min
= (980895.48/39.37) × 60 m/hr
= 1494887.7 m/hr
 • Relationship of section height and traverse in sectional warping.

Figure: Schematic representation of sectional warping principle

As the winding of one layer is completed on the drum, the section of ends is given a
requisite traverse so that the end at one extreme corner touches the inclined surface.
Thus, it gets support from the inclined surface. As the process continues, the thickness
(or height) of the section gradually increases. When requisite length has been wound
in a section, next section is started by shifting the expandable reed assembly by
suitable distance (distance s of following Figure)

Figure: Traverse in sectional warping

If α is the angle of inclination, x is the traverse given to the section and h is the height
of the section then

For drum with fixed angle, if the yarn is coarser then one layer of the warp ribbon will
result in higher increase in thickness (Δh) and thus to match the inclination, the
traverse speed (Δx) should be higher. The machines are designed with provisions to
change the traverse speed so that a wide range of yarn counts can be managed. For
fixed angle drums, only one variable i.e. traverse speed is to be adjusted while with
variable angle drums both traverse and the angle of inclination can be varied. For
drums with variable angle, the angle is changed by changing the inclination of metal
plates which are supported at the end of the drum. When the angle is increased, larger
gaps are created between the neighboring metal plates. Therefore, the yarn will
remain unsupported at the gaps between two metal plates.