Pradeep Kulshrestha explains the benefits of direct creel in weaving.

Conventional weaving was carried out by warp packages, beginning with warping-direct and sectional, then sizing, if required, and then on looms. But the process now has been modified, especially in technical textiles. It is simple and cost effective. Due to continuity of longer warp length through drum in running loom, loss of time in beam gaiting is fully avoided. Less contribution of skilled manpower also reduces the weaving cost with satisfactory production and product quality.

The floor space depends on sorts to run on loom. Provisions for more than one type of warp packages to hold yarn or fibre can be made. This is very effective in saving costs and maintaining consistency in woven fabric productivity if the same product is running for longer time.

Conventional warping process: For weaving, warp ends earlier came from direct creel or V-creel to wind on wrappers beam in direct warping and on weavers beam in sectional warping. These beams require beam gaiting on loom. Warping needed minimum one operator and a helper; beam gaiting required minimum three-beam gaiter, assistant and fitter. Six to eight looms were allocated to a team of weaver and helper. These seven skilled workers can now be replaced by a weaver and one or two helpers on loom if direct creel and drum weaving is carried out.

Waste control: Due to continuity in weaving, much lesser quantity of warp waste is generated compared to weaving with weavers beam. In rapier looms, selvedge waste remains under norm (less than 3 per cent).

Saving in time: Beam gaiting is not required, and therefore, a lot of time is saved, as there is no need to frequently reset loom and troubleshoot to repeatedly produce fabric without defects as per sample. Exhausted warp packages can be replaced during weaving by just applying knots at both ends.

Scheduled maintenance: For exclusive cleaning and lubrication of loom, total packages on creel need to be changed, or else the warp packages can be changed intermittently without affecting loom functioning.

Safety of creel:

Creel is balanced by its own weight and the total weight of warp material kept on it. It is advisable to put foundation bolts as well as support from wall and pillars so that it may not fall down or vibrate with working loom. Even detachable racks should be joined together and can be separated, if required.