A woven piece of textile contains two thread systems. The Warp is the lengthwise treads, and the Weft the sideways threads.
The quality of the warp beam (a metal drum where the threads are wound) is imperative to a good woven piece, as it regulates an even tension of all the threads. When Ekelund in 2003 installed its new warp beam from the maker Beninger, a top-of-the-line system, our quality increased impressively and we made less imperfect textiles.
The set-up process of the warp is done by, from a yarn fixture pull a set of 300 threads – a “band”, which through special process, is loaded onto the warp beam. This set-up is repeated until approximately 4,500 of the threads are loaded onto the warp – as is typical for all our weaving. The speed of loading is 500 meter per second (1,600 feet/sec). A normal length of each warp thread is 1,000 meter (3,200 feet).
At the start and at the end of each “band”, every second thread is pulled up and the other down – the interchange. Through this interchange a rope is threaded so it can be separated or opened.
When all the threads are rolled onto the warp beam then the drum is removed. The threads are then installed on the loom from the warp beam and readied for the actual weaving to start.
Traceability is important, so the warp beam is numbered and the number entered in the manufacturing journal. The data includes the yarn traceability numbers and the date.
Yarn – returned to bobbins for re-use
Plastic bobbins – recycled
Paper tubes – burned for heat
Cardboard – recycled
Environmental Impact – By using only twisted yarn in our product lineup we do not need to glue the yarn onto the warp which otherwise is customary. By not using glue we eliminate the need for solvents for cleaning and energy for the cleaning process as well as for controlling of any discharge from the process.