Lesson 1Basic loom settings and parameters: recommended speeds for medium-sized factory looms, warp and weft tensions, pick density, take-up and let-off settingsWe cover basic loom setups for calada, like speed, warp and weft pull, pick spacing, fabric take-up, and beam release. Learn to set, check, and tweak for smooth runs and right 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 covers winding cones, sectional vs straight warping, and sizing for lasting calada warps. Details mix recipes, add-on amounts, stretch control, drying, and how settings boost strength and rub protection.
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 checksWe explain planning warps for calada, figuring ends needed, length, waste, and beam numbers. Covers building good beams, creel setup, even tension, and checks before loom mounting.
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: fiber choice, yarn count ranges, ply, and pairing warp/weft for balanced performanceHere we pick yarns for woven calada, covering fibre type, count ranges, folds, and matching warp to weft. Links yarn traits to strength, rub resistance, size hold, 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 tensionCovers tying or knocking methods for beam swaps, knot types, and starting the loom. Details first runs, shed checks, and setting initial tensions for 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 considerationsFocuses on safe loom setup and running. Includes lockout steps, guards, safe tools, cleaning when stopped, tidy areas, and body-smart ways to cut strain in warp work and tweaks.
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 densityDescribes threading, lease handling, and denting for calada. Covers draft plans, lease order, reed picks, dent plans, and how they shape fabric closeness, cover, and loom run.
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 resistanceExplains picking plain, twill, and strong twill weaves for calada. Balances toughness, rub resistance, cover, feel, and speed using weave charts and performance matches.
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 methodsDetails loom checks like broken ends, weft closeness, edge hold, width, and weight. Explains measure ways, record sheets, and quick fixes for off-specs.
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 actionsReviews calada weave faults like breaks, bars, extra picks, reed lines. Explains yarn, warp, loom causes and step-by-step fixes and prevention.
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
