From a consideration of spinning we arrive at a definition of the manufacturing processes.
Unlike the spinning which is carried on in a building five or six storeys high, the manufacture of cotton goods takes place in a “shed,” as much of the work as is possible being carried on on the ground floor. The weft yarn, or that which is laid transversely in the cloth, leaves the mule in the condition in which it is required at the loom, but the twist or warp yarn passes through several “preparatory” processes to fit it for the operation in the weaving:—
1. Winding—to take the yarn from the cop and place it on the warper’s bobbin.
2. Warping or beaming to wind the yarn from 400 or 500 bobbins to one large beam.
3. Sizing—i.e., covering the warp with an adhesive preparation to fit it for standing the strains in weaving.
4. Attaching the healds and reeds to the warp, called looming or drawing-in.
5. Weaving.
Each of these will be described more fully in succeeding chapters, and as in different districts different methods are employed, more especially in the sizing and beaming systems, the one chosen for most minute description will be the one used most commonly, although the other systems will be referred to.
The weaving mill—or, as it is termed, shed—requires description next. The general details of such a building will be more easily understood by referring to the annexed plan.
The most important point to remember in the arrangement of the rooms for the different processes, is to place each so as to require as little transit of material as possible. The engine, a condensing one of 110 indicated H.P., horizontal, is driven by the steam generated in a 30ft. by 7ft. two-flued steel boiler working at 120lb. pressure.
In the flue is fixed a set of economisers heated by the hot air and gases generated in the furnace, and through the pipes of which passes the feed water.
In the winding room are two 200 spindle machines (100 each side), keeping 12 winders employed. There are 3 beaming frames, 504 ends each. In the sizing department are found the usual becks and cisterns for mixing purposes, and one slasher sizing machine. It will be noted that the weaving shop has direct communication with the looming room where the beams are stored, and with the warehouse whence the weavers obtain the yarn, at the same time returning the manufactured material. There is also an outlet into the mill yard without passing through any other department.
In case of a new shed having to be built, many important questions present themselves for consideration. In fixing upon the site, the essentials for a suitable position are a foundation sufficiently damp and of such a nature as not to easily part with moisture, even in hot weather, so as to preserve that humid atmosphere so essential to good weaving, more especially where heavy sizing is resorted to; yet there must be no yielding, for it is of vital importance that vibration be reduced to a minimum, both in weaving, winding and warping, to avoid breakages of yarn.