Century Enka Ltd. - Pune, Konkan Synthetic Fibres - Mahad in Maharashtra & Rajashree Polyfil - Bharuch in Gujrat producing Nylon & Polyester Filament Yarns, Tyre Cord Fabrics & Engineering Plastics.

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Redefining Nylon Yarn Quality

After completing the first phase of modernization, we have now launched Draw Warper Jumbo Beams for the first time In India. The product is focused for manufacturing of premium fabrics made from Zero Twist Sized Warp Yarn. These products are being produced on world class superior Hi-Tech German Make Draw Warping Machines. This modern technology, which has been available only in the international market, has now been made available to the domestic consumers. It will open up new opportunities for growth in nylon yarn industry, in terms of volumes as well as new quality fabric creations.

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Nylon Sizing - Why

Bringing International Technology To The Door Steps

BENEFITS TO THE WEAVER

1. Superior & Defect Free Fabrics

Internationally, Nylon yarn warp is invariably used after sizing. However, in India due to lack of availability of proper sized warp, the fabrics are produced with low twist yarn.
With the availability of sized warp, fabric defects are practically eliminated. Due to binding of fiber by suitable chemicals, superior & fault free fabric is now a reality especially with higher warp ends.

2. Unmatched Dyeing Evenness

Dyeing evenness achieved in the low twist fabrics is never good, mainly due to imperfect system of sectional warping & twist variations caused at up twister machines.
During sizing process (especially with Draw-warped Beams), there is no need of any sections & weaving beams are produced eliminating tension variations along the warp sheet.

3. Convenient & Economical Way To Weaving

High inventories are required by weaver to make warp, due to lengthy processing period of twisting and sectional warping. With the left over bottoms, fear of different merge mix up adds to weaver's woes.
Ready to use sized beam is the most economical & convenient solution to warp preparation. With no possibility of mix-up in warp size beams, it opens up the opportunity to try out multiple varieties under one roof.

4. Expansion Of Weaving Capacity Made Easy

In India, weaving is mainly a small scale industry. The twisting machinery installation involves extra finance & space.
With ready to weave sized beams, expansion of weaving capacity becomes much more easier.

5. Growth Avenues & Flexibility for New Fabric Creation.

Excellent warp shall open new frontiers for fabric varieties in heavy ends which otherwise was not possible with existing low twist route. Instant warp makes the trials to be done faster & at low cost.

6. Increased Productivity On Looms

Efficiency of loom is increased by around 5-10% using sized beam as compared to low twist warp beam due to minimum stoppages on loom.

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NYLON SIZING - MYTHS AND REALITY

MYTHS		REALITY
1.	Nylon can not be sized similar to Polyester	Nylon yarn size beams run as efficiently as polyester yarn, in fact better due to inherent superior strength of Nylon yarn.
2.	Proper desizing can not be done in case of Nylon, since desizing requires high temperature.	For sizing of Nylon yarns, care has to be taken while selecting the size chemical, so that desizing can be done at low temperature (upto 70 degC). New sizing chemicals have been identified which can be successfully desized at low temprature. There has been no complaint from any of our weavers.
3.	Zari yan cannot be used with sized beams	Low temperature de-sizing ensures no damage to Zari. At present all CEL base size beams are successfully running for various fabric qualities with Zari yarn, without any problem.
4.	Confidentiality of quality is lost	Wherever requested by weaver the confidentiality of product is maintained at our/sizer end.
5.	Nylon Yarn is stretched by sizers during sizing.	This was the concept, adopted by sizers years back. After introduction of Jumbo beams in sizing sector, most of the sizers realised importance of quality. Today, almost all the sizers (at least who are running jumbo beams) do not stretch the yarn; thus maintaining yarn quality.
6.	Sizer does not give the length as mentioned on the sized beams.	Sizers are supplying the same length as mentioned on the beams. The shortage on looms is due to the warp crimp (weave effect) in the fabric. Moreover, the shortage in sized beams appears to be more than sectioned warped beams, since sectional warped beams are of twisted yarns, which contracts during warping and again streches on loom. Hence, it appears that less shortage is there. Example: Twisted yarn (1000 Mts.) --> Sectional Warping (975 Mts.)--> Loom (960 Mts.) Sized beam(1000 Mts) --> (960 Mts.) For a plain weave 8-9% of warp shortage on loom is there for all types of yarns.
7.	Sizer can change the base yarn, Affecting the fabric quality.	Weaver can request the Sizer to mention the Lot No. of base yarn on sized beam, and can cross check it with us. We will also request the sizers to put our Lot No. on sized beams.
8.	Sizer takes very high Denier Gain in sized beams.	The chemical applied by the sizers is around 6-7% of yarn weight. Sizer will do similar addition in the Denier, Weavers can always cross check the actual Denier of base yarn with us.

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DRAW WARP BEAMS-THE MOST EFFECTIVE WAY TO SIZE WARP YARN

Beam sizing Implies Unmatched Quality of Warp

1.Most Modern & Exclusive Technology To Produce Warpsheet

During Draw-warping process POY is converted directly into ready for sizing warp sheet whereas in case of DT/FDY packages, individual ends are drawn, and then warp sheet is made on separate warping machine. Draw warping is specialized technology to produce high-class warp sheet. CEL produces Draw Warping products on German machines, which are considered as best in this field.

2.Precise Tension Control And Unmatched Dyeing Uniformity

During Draw-warping, All the POY are drawn in sheet form together, under precise tension control and wound on beam for sizing. Whereas in DT/FDY, all the packages are drawn on different positions at different times and all the packages are then combined on warping machine to prepare warp sheet.
The tension and dyeing uniformity achieved in Draw-warper is far superior than DT/FDY-warping route.

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