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 part explains basic loom settings for calada, covering speed, warp and weft tension, pick density, take-up, and let-off. It shows how to set, measure, and adjust fine for smooth run and right cloth 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 part covers cone winding, sectional and direct warping, and sizing for tough calada warps. It details sizing mixes, add-on control, stretch, drying, and how settings shape strength, rub resistance, and loom work.
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 part explains warp planning for calada, with ends count, warp length, waste, and beam numbers. It covers beam build quality, creel setup, tension balance, and checks before loom mount.
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 performanceThis part covers yarn pick for woven calada, with fibre type, yarn count, twist, ply, and warp-weft match. It links yarn traits to strength, rub resistance, size stability, and cloth 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 part covers tying-in and knocking-in when changing beams, knot ways, and loom start-up. It details first trials, shed checks, and setting start tensions before full run.
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 part stresses safe loom setup and run. Topics cover lockout-tagout, guarding, safe tool use, cleaning when stopped, tidy-up, and body-friendly ways to cut strain in warp handling 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 densityThis part describes drawing-in, lease handling, and denting for calada cloths. It covers draft plans, lease order, reed pick, denting plans, and how choices shape cloth density, cover, and 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 resistanceThis part explains picking plain, twill, and strong twill weaves for calada cloths. Focus on balancing strength, rub resistance, cover, feel, and output using weave drawings and performance match.
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 part details regular checks on the loom, like broken ends, weft density, edge control, width, and gsm. It explains measure ways, record forms, and quick fix for off marks.
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 part reviews common woven faults in calada, like broken ends, barring, double picks, reed marks. It explains root causes in yarn, warp, loom settings, and step-by-step fixes and prevents.
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
