1. 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 .

2. 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.

3. Warping Breakage Study
NO.OF ENDS
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

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

5. Warping Breakage Study
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.

6. Warping Breakage Study
CONDITION OF MACHINE
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.
ECCENTRIC GUIDE ROLLERS THE GUIDE ROLLERS AT WARPING SHOULD BE CHECKED FOR EVERY SIX MONTHS TO AVOID TENSION VARIATION.
THREAD GUIDE DEEP CUTS IN THREAD GUIDES CAN INCREASE YARN TENSION .
DIRTY GIUDES SHOULD BE CLEANED WITH CARBON TETRA CHLORIDE.