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 covers basic loom settings for calada, like speed, warp and weft tension, pick density, take-up, and let-off. It demonstrates setting, measuring, and tweaking for smooth runs and quality fabric in factory conditions.
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 handles cone winding, sectional and direct warping, and sizing for sturdy calada warps. It details sizing mixes, add-on control, stretch, drying, and how settings boost 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, covering ends calculation, length, wastage, and beam numbers. It includes beam quality, creel setup, tension balance, 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 performanceThis section discusses yarn picks for woven calada, including fibre type, count, twist, ply, and warp-weft matching. It connects yarn traits to strength, abrasion resistance, stability, and 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 for beam changes, knotting methods, and loom start-up. It details trials, shed checks, and 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 stresses safe loom setup and running. It covers lockout-tagout, guarding, tool safety, cleaning when stopped, housekeeping, and ergonomics to cut strain in warp work 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. It covers drafting, lease order, reed choice, denting plans, and their role in density, cover, and loom 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 picking plain, twill, and reinforced twill for calada. It balances strength, abrasion resistance, cover, feel, and output using weave diagrams and 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 outlines loom checks like broken ends, weft density, selvedge, width, and GSM. It covers measurement, recording, and quick fixes for issues.
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 calada defects like broken ends, barring, double picks, reed marks. It links causes to yarn, warp, settings, and gives fix and prevention 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
