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 lesson covers basic loom settings for calada, like speed, warp and weft tension, pick density, take-up, and let-off. It shows how to set, measure, and adjust for steady running 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 lesson handles cone winding, sectional and direct warping, and sizing for tough calada warps. It covers sizing mixes, add-on control, stretch, drying, and how settings 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 lesson explains warp planning for calada, covering ends calculation, warp length, wastage, and beam numbers. It also includes beam build 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 lesson covers yarn choice for woven calada, including fibre type, yarn count, twist, ply, and matching warp and weft. It connects yarn properties to strength, abrasion resistance, 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 lesson covers tying-in and knocking-in when changing beams, knotting methods, and loom start-up. It details first trials, shed checks, 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 lesson stresses safe loom setup and running. It includes lockout-tagout, guarding, safe tool use, cleaning when stopped, housekeeping, and ergonomic tips to cut strain during 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 lesson describes drawing-in, lease handling, and denting for calada fabrics. It covers drafting plans, lease order, reed choice, denting plans, and how they affect fabric density, cover, and running.
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 lesson explains picking plain, twill, and reinforced twill weaves for calada fabrics. It balances strength, abrasion resistance, cover, handle, and output 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 lesson details regular checks on the loom, like broken ends, weft density, selvedge quality, width, and GSM. It explains measurement methods, 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 lesson reviews common woven faults in calada, like broken ends, barring, double picks, and reed marks. It explains causes in yarn, warp, and loom settings, with 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
