Lesson 1Basic loom settings and parameters: recommended speeds for medium-sized factory looms, warp and weft tensions, pick density, take-up and let-off settingsThis section explains basic loom settings for calada, including speed, warp and weft tension, pick density, take-up, and let-off. It shows how to set, measure, and fine-tune parameters for stable running and target fabric quality.
Setting loom speed for fabric and yarn typeWarp tension setting and monitoringWeft insertion and tension adjustmentPick density, take-up, and let-off tuningRecording standard setting recipesLesson 2Warp winding, warping, and sizing: breaking down sectional warping vs direct warping, sizing chemistry and process parameters for strength and abrasion protectionThis section covers cone winding, sectional and direct warping, and sizing for durable calada warps. It details sizing recipes, add-on control, stretch, drying, and how parameters affect strength, abrasion resistance, and loom efficiency.
Cone winding quality and package buildDirect versus sectional warping selectionSizing chemicals for strength and abrasionSizing add-on, viscosity, and drying controlWarp stretch, hairiness, and abrasion behaviorLesson 3Warp planning and beam preparation: calculating warp length, required ends, wastage, beam creel layout and quality checksThis section explains warp planning for calada, including ends calculation, warp length, wastage, and beam count. It also covers beam build quality, creel layout, tension balance, and inspection before mounting on the loom.
Calculating required ends and set widthWarp length, allowances, and wastageBeam density, hardness, and build qualityCreel layout for balanced tensionBeam inspection and identification tagsLesson 4Yarn selection for woven calada: fibre choice, yarn count ranges, ply, and pairing warp/weft for balanced performanceThis section covers yarn selection for woven calada, including fibre type, yarn count, twist, ply, and pairing warp and weft. It links yarn properties to strength, abrasion resistance, dimensional stability, and fabric comfort.
Fiber choice for strength and durabilityYarn count ranges for calada fabricsTwist, ply, and hairiness controlMatching warp and weft performanceTesting yarn strength and evennessLesson 5Tying-in/knocking-in and loom commissioning: methods for replacing beams, knotting techniques, initial trial runs and setting starting tensionThis section covers tying-in and knocking-in methods when changing beams, knotting techniques, and loom commissioning. It details initial trials, checking sheds, and setting starting tensions before full production.
Hand tying-in and knotting techniquesUsing automatic tying-in machinesKnocking-in new warps on existing loomsTrial runs, shed checks, and first metersAdjusting starting tensions and settingsLesson 6Safety and maintenance during loom setup and operation: lockout-tagout, guarding, tool use, cleaning while stopped, ergonomic considerationsThis section focuses on safe loom setup and operation. Topics include lockout-tagout, guarding, safe tool handling, cleaning while stopped, housekeeping, and ergonomic practices to reduce strain during warp handling and adjustments.
Lockout-tagout during setup and repairsMachine guarding and pinch-point risksSafe tool use and cleaning proceduresErgonomic handling of beams and reedsRoutine checks and minor maintenanceLesson 7Drawing-in, denting, and lease arrangement: step-by-step drawing-in methods, reed selection, denting plans and importance for fabric densityThis section describes drawing-in, lease handling, and denting for calada fabrics. It covers drafting plans, lease order, reed selection, denting plans, and how these choices influence fabric density, cover, and running performance.
Reading and applying drafting plansLease rods, cross order, and mix-upsReed selection by count and widthDenting plans for density and coverChecking ends order before loom startLesson 8Weave selection and rationale: plain, twill, and reinforced twill structures; choosing weave for strength and abrasion resistanceThis section explains how to select plain, twill, and reinforced twill weaves for calada fabrics. Emphasis is on balancing strength, abrasion resistance, cover, handle, and productivity using weave diagrams and performance comparisons.
Plain weave structure and performance limitsTwill and reinforced twill for heavy-duty fabricsWeave factor, cover, and yarn stress analysisSelecting weaves for abrasion and tear strengthLesson 9In-process quality checks for woven production: monitoring broken ends, weft density, selvedge control, fabric width and GSM measurement methodsThis section details routine in-process checks on the loom, including broken ends, weft density, selvedge quality, width, and GSM. It explains measurement methods, recording formats, and how to react quickly to deviations.
Broken end monitoring and stop motionsWeft density and pick variation checksSelvedge appearance and edge controlFabric width and GSM measurement methodsQuality data logging and response actionsLesson 10Common defects, root causes, and corrections: handling broken ends, barring, double picks, reed marks and corrective actionsThis section reviews common woven defects in calada, such as broken ends, barring, double picks, and reed marks. It explains root causes in yarn, warp, and loom settings, and outlines systematic corrective and preventive actions.
Broken ends, slack ends, and streaksBarring from count or tension variationDouble picks, missing picks, and floatsReed marks, temple marks, and stainsRoot cause analysis and corrective plans
