The document provides information about the ball warping process used to prepare yarn for denim production. It discusses: 1) Ball warping involves creeling multiple ends of yarn and collecting them into an untwisted rope for dyeing. The rope is wound onto a long cylinder called a log. 2) Key steps include passing yarn through a reed to separate ends, inserting lease strings, and condensing the yarn into a rope using a trumpet. 3) After indigo dyeing the rope, it undergoes long chain beaming to change the alignment from rope to sheet form before sizing and weaving. Tension rollers help further separate the yarns.

1. Ball Warping
Process

2.  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.

4. Flow Chart of Denim Production:
Spinning
↓
Ball Warping
↓
Rope Dyeing
↓
Long Chain Beaming
↓
Sizing
↓
Weaving

5. Process Machine
Ball Warping
Karl Mayer - Germany
Morrison - U.S.A
Griffin - U.S.A
Dyeing
Morrison - U.S.A
Smartec - China
Long Chain Beam
Karl Mayer - Germany
Morrison - U.S.A
Griffin - U.S.A
Sizing
Griffin - U.S.A
UK IL Machinery - Korea
Weaving
Tsudakoma - 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

6. 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

7. 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

8. 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.

9. 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

10. 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

11. 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.

12. 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
Total volume 3000 Litre
Indigo Preparation :
Mercerization Bath Liquor :
Chemical Preparation Procedure :
Fig: Mercerization Bath
Fig: Chemical Preparation Tank

13. Chemical Preparation Procedure :
Chemical Name Amount (kg)
Sodium Hydrosulphite 30 kg
Caustic Depends on required PH
Total volume 200 Litre
Hydrosulphite :
Concentration Amount Volume
Double 150 kg 600 Litre
Single 75 kg 600 Litre
Caustic Soda Solution:
Chemical Name Amount (kg)
Softener 70 kg
Carboxylic acid 10 kg
Total volume 1000 Litre
Softener
Fig: Wash Bath
Fig: Dye Bath

14. 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.

15. 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)

16. 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.

17. 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

18. 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

19. 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.

20. 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.

21. Different parts of long chain beamer
Can
Accumulator
Tension Stand
Reed
Counting Roller
Beam

22. 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.

23. L C B Floor

24. 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