Thread Breakage in Modern Loom and Efficiency

The study is to find out the relation of thread breakage rate on modern loom to the relative humidity and fabric specifications. This result supports thread breakage rate increased with the choice of rapier loom instead of air jet loom. It also shows that loom width has negative relation towards thread breakage and in the production floor relative humidity has insignificant relation with thread breakage rate. Key part of the study shows that warp and weft breakage rate has interrelation. In the production floor loom types and fabric constructions are studied for thread breakage at floor temperature and found no relation to the relative humidity. But, significant relation of warp and weft thread breakage rate to EPI, loom categories, loom width, fabric length produced, weft count and interrelation between warp and weft breakage rate.


INTRODUCTION
Thread breakage is the certain actions in the different sections of weaving.It increases the stoppage time of the loom and thus reduce the efficiency of the weaving.Modern loom has been developed to increase the productivity and efficiency in weaving.Different types of picking like-water jet, air jet, multiphase and rapier picking has been developed with the parts like reed, heald wires, shedding mechanism etc.This study focuses on the thread breakage rate in modern loom specially three different models air jet, rapier (optimax) and rapier (gamma) for different fabric construction at the room temperature in the production floor.Using correlation and regression analysis, the breakage rate for warp and weft are analyzed for 24 days in 15 looms of which five are air jet, five are rapier (optimax) and five are (gamma) loom.Finally, average and total thread breakage rate also calculated to analyze the correlation among the parameters.This study found interrelation between warp and weft breakage rate but, found no relation to the relative humidity.Again, significant relation of warp and weft thread breakage rate to EPI, loom categories, loom width, fabric length produced, weft count and interrelation between warp and weft breakage rate have been observed by the correlation and regression analysis.

LITERATURE REVIEW
The weaving machines used in many old textile industries, jute industries, and power loom factories for weaving conventional fabrics are of primitive type and hardly have undergone any modification.While designing any modification of such weaving machines needs attention for improvement of weaving efficiency for weaving such yarn having low extensibility as in case of jute.In the conventional weaving machines there are inadequate arrangements for controlling the strain on the warp yarn during weaving.After conducting some studies in jute mills, it has come to light that the efficiency of hessian loom varies within a range of 48-60% in which the loss in efficiency is 12-14% for warp breakages and 4-5% for manual weft replenishment.Thus, it was felt necessary to overcome this problem by simple machine modifications to improve the weaving efficiency.In the conventional jute loom the free length of the warp yarn provided is comparatively much less than all other modern looms used in the textile industry, in spite of jute yarn having very low extensibility.There are inadequate arrangements for controlling the strain of warp yarn during weaving.There is no automation in the system.These factors influence the warp breakage rate, which lowers the weaving efficiency to some extent.Early works shows that the tension peak at beat-up is proportional to the maximum fell displacement and is independent to basic warp tension.The warp breakage rate can be minimized by controlling the strain on the yarn during a loom cycle (Marks & Robinson, 1976).The height of tension peak during shedding may be controlled either by controlling the size of the warp shed or by controlling the free length of the warp (Greenwood, Weaving: Control of Fabric Structure, 1975).Other found in their study the study of warp tension variations and felt that it is necessary to measure the warp tension upon a single thread rather than upon the whole warp, as the latter would give average effects in which significant features might be concealed.He opined that the tension is much greater at the bottom than at the top shed, and the beat-up with the falling 25 thread is stronger than with the rising thread, and consequence of the common practice of depressing the closer shed.The inertia, or weight and size of the beam influence the form of tension cycle, which therefore varies as a beam empties.He also stated that throughout one turn of the beam, the tension in the single thread commonly varied by 40-50% of its mean value.He also studied the effect of vibrating backrest, which increases the tension in the lower parts of the cycle and reduces it at the bottom shed (Owen, 1928).Again study shows that the effect of cloth fell position on pick spacing on power loom and established the relation between the cloth fell and the intensity of the beat-up force.The relation between beat-up force and pick spacing is also established (Greenwood & Cowhig, J Text Inst, 1956).Warp tension has measured under static condition.The behavior of such mechanism when running at weaving speed is often very different from what would be anticipated from the study of the mechanism at rest or in slow movement (Snowden & Chamberlain, 1956).Peak tension on warp during weaving is high particularly during the position of beat-up and open shed.The generation of high peak tension in the yarn is one of the main reasons for warp breakages.To reduce peak tension the attachments of oscillating backrest and front rest was developed, which not only improved the fabric cover but also eliminated the reed mark (Neogy, 1976).
In this study influence of loom types, fabric specification and relative humidity on thread breakage are analyzed by correlation and regression models.

RESULTS AND DISCUSSION
Warp and weft break at different fabric constructions are listed in the A1: Air jet loom, A2: Rapier (Optimax) loom and A3: Rapier (Gamma) Loom.Then, the breakage rate is tabulated in table A4-A6 respectively for the three modern looms.The comparative results are shown in A7 and A8.From table 4, correlation coefficient shows no significant relation of thread breakage rate either in warp way or in weft way direction which is same as results from table 1 and 2. Thus, there is no significant relation of relative humidity and thread breakage rate which fails the hypothesis H4.The average value for specific fabric construction and choice of yarn the following A8 is prepared to analyze the relation of thread breakage rate in warp and weft direction for the three different modern looms.From table-9 correlation coefficient shows no significant relationship of average relative humidity to the either warp or weft thread breakage rate for specific fabric construction.This opposes the results found by Vicky Ashok Patilat.el., in their productivity experiments.But, it also gives us further scope of study in this respect ( Patil, Gulhane, Turukmane, & Patil, 2017).The result might have been vary due to the production floor temperature variation in uncontrolled manner.From time study of the repairing thread breakage in the industry, we see the efficiency of Air jet and Rapier (Optimax) lose 0.65-0.69%due to thread breakage on the other hand Rapier (Gamma) loses 1.1% efficiency.Thus, loom categories influence the productivity of the industry in a great deal throughout the annual production amount.

CONCLUSIONS
In this study the thread breakage rate are found to be related to the types of looms.In air jet loom the thread breakage rate are less than other models of Rapier looms.Fabric width, epi, fabric length produced and production per day have influence on the thread breakage rate.But, the effect of relative humidity on the thread breakage rate was insignificant in this study which leads to the requirement of further study in this field.This concludes that the fabric and loom parameters influences the thread breakage rate in different way.It is also found that the interrelation of the warp and weft thread breakage is significant.So, by choosing the right setting of the loom and fabric construction to reduce the thread breakage up to the minimum.It is recommended that similar studies should be conducted to find out correct level of relative humidity and achieve maximum production and quality fabric production.The effectiveness control on the loom shed efficiency leads to control on warp breakage rate.As the whole experiment is completed in a particular time bound.The result may vary in environmental change of the production floor.If the limitations of the research can be reduced and the experiment can be performed in versatile experimental conditions the result would be more precise to draw the conclusion.

2581-8341 Volume 02 Issue 04 June 2019 DOI: DOI: 10.47191/ijcsrr/V2-i4-01 IJCSRR @ 2019 Volume 02 Issue 04 June 2019 Available at: ijcsrr.org Page No.-24-35 26
1. To analyze the correlation of thread breakage rate with fabric specifications 2. To analyze the correlation of thread breakage rate with modern looms (Air jet and Rapier) 3. To analyze the effect of Relative Humidity% on thread breakage rate in the production floor.4. To find a new scope of research in this area of interest. ISSN:

Table 3 : Regression model summary for thread breakage rate Independent variables Warp Breakage Rate (a) (2)Weft Breakage Rate
**. Correlation is significant at the 0.01 level(2-tailed).From the table 1 and table 2, warp breakage rate is significantly influenced by loom category, weft count, EPI, loom width and fabric length table 2 (a) at 1% level of significance (p<0.01).The goodness of fit for the model of warp breakage rate is 65.1%.On the other hand, weft breakage rate is significantly influenced by loom width, loom width and production per day of the fabrics ISSN:

2581-8341 Volume 02 Issue 04 June 2019 DOI: DOI: 10.47191/ijcsrr/V2-i4-01 IJCSRR @ 2019 Volume 02 Issue 04 June 2019 Available
of significance (p<0.01) and goodness of fit for the model is 39.6%.Here, EPI and loom width have negative influences on breakage rate and other parameters shows positive influences on breakage rate of respective type of thread.To find out the relation of the thread breakage rate and relative humidity in the production floor excluding the types of loom, table-A4-A6 are prepared to analyze the correlation with the relative humidity percentage.

Table 4 : Correlation Coefficient for Relative Humidity and Thread Breakage Rate
**. Correlation is significant at the 0.01 level (2-tailed).

Table 6 : Regression co-efficient of warp and weft breakage rate in air jet and rapier loom Air jet Warp Breakage Rate Rapier (Gamma) Warp Breakage Rate
From table 5 and 6, warp breakage rate is decreased 4.023 times for air jet loom and in Rapier (Gamma) it increases 3.792 times respectively with the unit increase of weft breakage rate at 1% level of significance (p<0.01).ISSN:

Table 7 : Comparative Breakage Rate for Air jet and Rapier Loom
Figure 1: Bar Chart for Breakage Rate From the above figure 1 based on table7, it is clear that, thread breakage rate are more in rapier looms than air jet loom (prominent in warp than weft breakage).But, difference is also clearly observed in two different models of Rapier looms (Optimax and Gamma).Again, considering average relative humidity for specific construction of fabrics, table 8 is as follow-