ball warping process

Ball Warping

Process

Ball Warping The main object of ball warping is to prepare log for the rope

dyeing machine. Here magazine type of creels is used for the creeling of yarns in the form of cheese. The no. of ends taken one as per requirement of further processes that is for preparing the weavers beam .According to no. of ends in each group, the respective creeling is done to make the required no. of logs to be used at the creeling zone of rope dyeing machine.

Length of rope on log is generally 12830 m, the sheet of yarns passes through the lese reed where lease are inserted, these facilities denting the long the chain beaming. Lease are inserted at regular intervals which can set automatically on the machine .generally after every 100mts, lease is inserted .lease also help in yarn separation after sizing.

Flow Chart of Denim Production:

Spinning

↓Ball Warping

↓Rope Dyeing

↓Long Chain Beaming

↓Sizing

↓Weaving

Process Machine

Ball Warping

Karl Mayer - Germany

Morrison - U.S.A

Griffin - U.S.A

DyeingMorrison - U.S.A

Smartec - China

Long Chain Beam

Karl Mayer - Germany

Morrison - U.S.A

Griffin - U.S.A

SizingGriffin - U.S.A

UK IL Machinery - Korea

WeavingTsudakoma - Japan

Picanol Summum - Belgium

Finishing

Monforts Finishing Range - Germany

Osthoff Singeing Machine - Germany

Kyoto Flat Finishing Range - Japan

Morrison Finishing Range - U.S.A

Sheentech Stenter Machine - Taiwan

Harish Stenter Machine - India

Smartec Mercerizing Range - China

Redflag Desizing and Overdyeing Machine - China

KEY MACHINERIES

NAME : MORRISON BALL WARPING MACHINE

Origin :USA

Creel capacity : 456

Winding Speed : 250-300m/min

Maximum Beam Diameter : 1200mm

Maximum Length of Yarn : Around 12000m

Yarn type : Both Ring & Open End yarn

Machine Specification

NAME : KARL MAYER WARPING MACHINE

Origin : Germany

Creel capacity : 720

Winding Speed : 400m/min

M/c Speed r.p.m : 450 m/mim

Maximum Beam Diameter : 1200mm

Maximum Length of Yarn : Around 12000m

Yarn type : Both Ring & Open End yarn

Machine Specification

Required yarn

These yarns may range in count from Ne 7.5 to Ne 30.0

Ball Warping:

It involves creeling of multiple ends of yarn

( Between 350-500 ends) and collecting them into an untwisted rope for dyeing.

The rope is wound onto a long cylinder called a log on a machine called as a ball warper.

Indigo dyeing will take place at rope form.

Then long Chain Beaming is done.

After sizing, it is ready for weaving.

Machine Main Parts :

Creel Section :

Bobbin Stand/ Package Holder

Post

Sensor

Ceramic Guide

Head Stock :

Motor

Counter Roller

Traverse

Hook

Pressure Roller

Reed

Control Panel

Ball Warper

Magazine creel

Ball Warping process:

In ball warping, 350 to 500 yarn ends are pulled

from the creel. The yarns then pass through a

comb-like device (reed), which keeps each warp

yarn separate and parallel to its neighboring

ends.

At intervals of every 1000 or 2000 yards, a

lease string is placed across the sheet of warp

yarns to aid yarn separation.

The yarns then go through a funnel-shaped

device called a trumpet or condenser, which

collapses and condenses the sheet of yarn into

rope form.

The rope is wound onto a long cylinder called a

log on a machine called as a ball warper.

Indigo dyeing will take place at rope form.

Yarn path diagram

of Ball Warping

Rope Dyeing :

Generally two types of dye stuff are used to produce the desired shades. They are -

Indigo dyes

Sulphur dyes

Indigo Dye :

Indigo blue dye (vat dye) is not soluble in water in normal condition. To make water

soluble, reduction is done by using reducing agent. Reducing agent: sodium hydro

sulphite (Na 2S 2O4) (trade name - Hydrose) .

Sulphur Dye :

It is cheap in price.

Wet fastness is good but light fastness is not so good.

It is insoluble in water. But reacting with Na 2S (reducing agent) it produces Thiol

which is water soluble.

Chemical name Amount (kg)

Indigo 350 kg

Caustic 250 kg

Sodium Hydrosulphite 350 kg

Sequestering agent 5 kg

Dispersing agent 14 kg

Wetting agent 17 kg

Total volume 3500 Litre

Chemical Name Amount (kg)

Caustic Soda 90 kg

Sequestering Agent 6 kg

Wetting Agent 20 kg


Indigo Preparation :

Mercerization Bath Liquor :

Chemical Preparation Procedure :

Fig: Mercerization Bath

Fig: Chemical Preparation Tank

Chemical Preparation Procedure :


Sodium Hydrosulphite 30 kg

Caustic Depends on required PH


Hydrosulphite :

Concentration Amount Volume

Double 150 kg 600 Litre

Single 75 kg 600 Litre

Caustic Soda Solution:


Softener 70 kg

Carboxylic acid 10 kg


Softener

Fig: Wash Bath

Fig: Dye Bath

Chemical Name & Function:

No. Chemical Name Function

1 Caustic Soda Removes fat and wax by the action of saponification. Mercerizes the cotton fiber as a result the amorphous

region is converted to crystalline region , so the luster and absorbency of cotton is increased .

2 Wetting Agent It emulsify the waxes in the grey cotton and to ensure the

satisfactory penetration of dye liquor into the substrate.

3 Sequestering Agent Used to remove the hardness of water ,makes the water

soft.

4 Reducing Agents Indigo dyes are not soluble in water . Sodium

Hydrosulphiteis used to reduce the indigo converted at

leucoform .

5 Dispersing Agent Used to resist the aggregation of Indigo dyes .

6 Softener It helps to open the yarn from during long chain beamer

section.

7 Carboxylic acid During mercerization and dyeing process the PH of yarn

increased , carboxylic acid decreases the PH (6.5-7.5)

8 Fixing agent Helps to the fixation of sulphur black dyes

9 Glucose (dextrose

monohydrate)

Used to make the sulphur black dyes soluble in water.

Process sequence in Indigo rope dyeing in denim :

In rope dyeing, 12-36 ball warping ropes of yarn are fed side-by-

side simultaneously into the rope dyeing range for application of

the indigo dyeing.

The passage of yarn in rope dyeing is as below:

Pre Scouring

↓

Hot Wash

↓

Cold Wash

↓Dye baths

↓Hot Wash

↓

Cold Wash

↓Softener Application

Rope Dyeing

Figure: Rope Dyeing Process Flowchart (Morrison)

a) Pre-scouring

In the rope dyeing range the ropes are first passed through one or

more scouring baths. It consist of wetting agents, detergents and

caustic. The objectives of pre-scouring is to remove the wax

content from cotton, naturally occurring impurities in cotton fiber

yarn such as dirt, minerals, ash, pectin, and naturally occurring

waxes, removal of trapped air from cotton yarns through wetting

the yarn .

The following agents are normally used in pre-scouring.

Caustic Soda: In pre-scouring, 3–5% sodium hydroxide is used,

which removes the wax by the action of saponification.

Wetting agent: Anionic wetting agents are normally used.

Sequestering agent: It is used to make the water soft, as it is

very difficult to find the desired softness in water.

b) Hot wash

The ropes are hot washed at 80 – 90ºC

to remove the sodium hydroxide left in

the yarn after pre-scouring, otherwise it

will change the pH values of dye – bath.

c) Cold wash

After hot wash, the yarn ropes are fed

through a cold wash bath to bring back

to its room temperature.

d) Dyeing

The ropes of yarn are then fed into the

indigo dye baths .

The pH of the indigo dye bath should

be maintained between 10.5 to 11.5, as

at this level, the dye affinity is very

high. pH is maintained by the addition

of caustic soda.

Fig: Wash Bath

Fig: Dye Bath

A.Brand Name : Metrohm

Model : 877 Titrino Plus

Origin : Switzerland

Use : Test GPL of Indigo & Hydro& measure Redox Potential for

Reducing agent .

B.Brand Name : Metrohm

Model : 794 Basic Titrino

Origin : Switzerland

Use : Used to check PH

C.Brand Name : HACH LANG

Model : LICO 500

Origin : Germany

Use : Used to check GPL for Black dye bath

Quality Assurance Equipments/ Laboratory Equipments

Metrohm

Squeeze Pressure :

High pressure will lead to lower wet pick up and result in lesser color

and better penetration. At rope dyeing, squeeze pressure is 5-10 tones,

i.e. Wet pick up is as low as 60%. If squeeze rolls are too hard then

there are chances of slippage and uneven yarn tension. If squeeze

rollers are too soft then shading will occur. Surface of the squeeze rolls

should be ground twice a year.

e) Washing

After the dyeing process, the ropes of yarn are rinsed in several water

baths to remove any unfixed dye. Rubbing fastness of indigo, which is a

very important parameter, can be improved through washing.

f) Drying and Coiling

After the washing, the ropes are dried by hot cylinder and coiled in can.

Re-beaming process (Long Chain Beaming )

Once the warp yarns are rope dyed, it is then necessary to change the

yarn alignment from a rope form to a sheet form before entering the

next process, sizing. Re-beaming involves pulling the ropes of yarn out

of storage tubs and moving them upward to a guiding device (sometimes

called a satellite). This upward travel allows the ropes to untangle.

Once the ropes come down from the guiding device, they go through

tensioning rollers to help further the separation of the ropes before

going through a comb at the warper

Warper separates individual yarn ends and keeps them parallel to one

another. From the comb, the warp yarns are guided onto a flanged

section beam.

After sizing, it is ready for weaving.

Different parts of long chain beamer

Can

Accumulator

Tension Stand

Reed

Counting Roller

Beam

Brief Description of Different Parts :

Accumulator

An accumulator is a device which allows the rope to be accumulated in

a controlled manner at the time of unwinding in order to find out and to

repair a broken end. The accumulator is an important component on a

Long Chain Beamer, as there is no stop motion device in the re-beamer

and the operator observes the yarn sheet whether there is any broken

end.

Beater Bar and Comb

After the Accumulator the rope returns to the Tension Stand. The

function of the Beater Bar is to apply sufficient tension, friction to the

rope, assisting in the opening or spreading the yarn and to separate the

ends without any damage. After the Beater Bar the rope passes through

a comb located on the Long Chain Beamer, which separates individual

yarn ends and keeps them parallel to each other. From the comb, the

warp yarns are guided onto a flanged beam.

L C B Floor

Tension Stand

When the ropes come down from the guiding device, it passes through

tensioning Stand rollers (Fig.). The purpose of the Tension rollers is to

established necessary warp tension to the rope and help in further

separation of the ropes before going through a comb. If no tension is

applied to the rope, then the rope have a tendency to resist opening up

into the sheet form. This may lead to rope damage.

The Tension Stand is approximately 4-feet high and consists of two

tension drums, each approximately 14-inches in diameter. These rolls

are fitted one over another.

Fig. : Tension Stand

ball warping process

Engineering