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 weft pull, pick closeness, take-up, let-off. Learn to set, measure, tweak 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 covers cone winding, section direct warping, sizing for tough calada warps. Details mix recipes, add amount, stretch, drying, how they boost power, rub guard, 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 checksWe explain warp planning for calada, ends count, length, waste, beam numbers. Covers beam build, creel setup, pull balance, checks before loom fit.
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 performanceCovers yarn pick for woven calada, fibre type, count, twist, ply, warp weft match. Links yarn traits to power, rub hold, size steady, cloth ease.
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 knocking when swap beams, knot ways, loom start-up. Details first runs, shed checks, start pulls before full go.
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 safe loom setup run. Covers lockout-tagout, guards, safe tools, clean when stopped, tidy up, body-smart ways to cut strain in warp work 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 drawing-in, lease hold, denting for calada. Covers draft plans, lease order, reed pick, dent plans, how they shape closeness, cover, run ease.
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, strong twill for calada. Balances power, rub hold, cover, feel, speed with weave maps compares.
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, broken ends, weft closeness, edge hold, width, gsm. Explains measure ways, record forms, 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 actionsReviews calada woven faults like broken ends, bars, double wefts, reed lines. Root in yarn warp loom set, fix prevent steps.
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
