WARPING

Warp beams can be produced either through the normal warp then size method, or can be produced via single-end sizing and then warping.

Using either process requires the creation of a warp order. A warp order describes the type of section beam to produce and the yarns that must be placed on the beam.

Under normal warp beam creation, warping occurs first onto smaller section beams. The number of ends on a section beam is a function of the number of ends (yarn cones) that the warping frames can hold. These section beams are then joined together through a sizing (or slashing) range to create the final warp beam.

Should the yarn on the section beam need to be dyed before being being sized then the section beams for a warp order can be processed through the dyehouse.

If the warp beam is produced using single end sizing, the warp order is created in the normal manner, but it is flagged as being a “direct warp” process. This indicates to the system that no section beams will be created and that there will be no requirement to use a sizing range later in production.

All section beams and warp beams produced during the warping and sizing processes are numbered and ticketed for full factory floor control. Beams can also record the physical beam core (the metal beam the yarn is placed on) for extra tracking and control. This is very important in the dyeing process, since beam identification tags cannot usually be process in the dyeing vessels.