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 explain basic loom setups for calada, covering speed, warp and weft tension, pick density, take-up, and let-off. Learn to set, measure, and tweak for smooth 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 covers cone winding, sectional vs direct warping, and sizing for tough calada warps. We detail sizing mixes, add-on control, stretch, drying, and how settings boost strength, rub resistance, and loom output.
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 go through warp planning for calada, with ends calc, length, wastage, and beam numbers. Plus 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 bit on yarn picking for woven calada covers fibre type, count, twist, ply, and warp-weft matching. Links yarn traits to strength, rub 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 tensionCovers tying-in and knocking-in for beam swaps, knot methods, and loom start-up. Details first trials, shed checks, and setting start tensions 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 on safe loom setup and running. Includes lockout-tagout, guarding, safe tools, cleaning when stopped, tidy-up, and ergo tips 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 drawing-in, lease handling, denting for calada. Covers draft plans, lease order, reed pick, denting schemes, and how they shape density, cover, and run smoothness.
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, reinforced twill for calada. Balances strength, rub resistance, cover, feel, and output with weave diagrams and performance match-ups.
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-side checks like broken ends, weft density, selvedge, width, GSM. Covers measure methods, record sheets, and quick fixes for off-spec.
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 broken ends, barring, double picks, reed marks. Links causes in yarn, warp, loom to fixes 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
