Warping machine for plastic mats: preparing the warp beam for the loom
What a warping machine does in a plastic beach mat line, the ZJ-2000's 440 yarns and 900–2000 mm beam, and how to match the warp to your jacquard loom.
A warping machine prepares the warp for a plastic beach mat loom: it takes many warp yarns and winds them side by side, under even tension, onto a single warp beam, which is then mounted at the back of the loom. Without a well-wound beam, the loom cannot weave an even mat, however good its jacquard is. The ZJ-2000 warping machine from Wenzhou Xiangyi Machinery takes up to 440 warp yarns and winds them onto a beam 900 to 2000 mm wide; it stops automatically when a yarn breaks and has a tension adjusting device. This guide explains the job, gives the ZJ-2000's figures, and shows how to match the warp to the loom you run.
Key definitions
- Warp yarn. The yarn that runs along the length of the mat. In a beach mat it holds the hollow PP straws that form the weft. For beach mat warp yarn you can buy yarn in or make round monofilament yourself.
- Warp beam. The roller that carries the full set of warp yarns, wound side by side. One beam is mounted on the loom and feeds the warp as the mat is woven.
- Warping. The step that winds the warp from many separate yarn packages onto that one beam, in the right order and under even tension.
- Warp ends. The number of individual warp yarns across the loom; a jacquard loom lists the maximum it can take.
- Tension. How tightly each yarn is pulled while it is wound. Yarns wound at different tensions behave differently on the loom, which is why the ZJ-2000 has a tension adjusting device.
What the warping machine does in the line
A plastic beach mat production line has two supply streams that meet at the loom. One is the weft: PP raw material is extruded into hollow straws. The other is the warp: yarn is wound onto a beam on the warping machine. Warping happens before a run starts and again whenever a beam is used up.
The ZJ-2000 draws its yarns from the yarn packages loaded behind it, guides them side by side and winds them onto the beam. Two features protect the beam it produces. The automatic stop halts the machine when a warp yarn breaks, so a broken yarn is caught at warping instead of being discovered on the loom. The tension adjusting device keeps the yarns under even tension as they are wound.
ZJ-2000 technical parameters
The figures below are copied from our catalogue.
| Parameter | ZJ-2000 |
|---|---|
| Max. warp yarns | 440 |
| Warp beam width | 900–2000 mm |
| Main motor | 4 kW |
| Weight | 1365 kg |
| Installed size | 2800 × 2100 × 1000 mm |
| Protection | Automatic stop on yarn break, tension adjusting device |
Matching the warp to your loom
The loom you choose decides how many warp ends the beam must carry and how wide it must be. The XY-KTC computerized jacquard looms take between 184 and 632 warp ends, depending on width:
| Loom | Max. weaving width (mm) | Max. warp ends |
|---|---|---|
| XY-KTC900 | 900 | 184 |
| XY-KTC1200 | 1200 | 248 |
| XY-KTC1500 | 1500 | 312 |
| XY-KTC1800 | 1800 | 376 |
| XY-KTC2000 | 2000 | 408 |
| XY-KTC2200 | 2200 | 456 |
| XY-KTC2700 | 2700 | 568 |
| XY-KTC3000 | 3000 | 632 |
Send us the loom models you plan to run and the warp yarn you will use, and we will confirm the warping set-up for each loom width.
Steps to plan warping for a new line
- Fix the loom widths first. List the XY-KTC models you will run; their warp ends and widths set the warping requirement (see the beach mat weaving machine page).
- Decide where the warp yarn comes from. Buy it in, or make round HDPE or PP monofilament on an SJ-YS line (see the monofilament yarn extruder page).
- Confirm the warping set-up. Send us each loom's model and the warp yarn, and we will confirm how the warp beams are prepared for it.
- Plan floor space and power. The ZJ-2000 needs about 2800 × 2100 × 1000 mm and a 4 kW main motor, plus room for the yarn packages it draws from.
- Train for breaks and tension. Operators should know how to restart after an automatic stop and how to set the tension device for the yarn in use.
Ask about warping for your line
The full specification is on the warping machine page. If you are matching warping to looms of different widths, or to a warp yarn you already buy, send us an enquiry with the loom models and yarn details.
Frequently asked questions
- What does a warping machine do in a beach mat line?
- It winds the warp yarns side by side onto a beam that is then mounted on the beach mat loom. The ZJ-2000 takes up to 440 warp yarns and winds them onto a beam 900 to 2000 mm wide, so the loom receives a ready, evenly wound warp.
- What happens if a warp yarn breaks during warping?
- The ZJ-2000 stops automatically when a warp yarn breaks, so the break can be fixed before winding continues. It also has a tension adjusting device to keep the yarns under even tension.
- Where does the warp yarn come from?
- It can be bought in, or made on a monofilament line. Our SJ-YS monofilament extruder makes round yarn from HDPE or PP, and the catalogue lists beach mat warp among its uses.
- What are the ZJ-2000's power and size?
- The catalogue lists a 4 kW main motor, a weight of 1365 kg and an installed size of 2800 × 2100 × 1000 mm.