**4.1.2 Production of terry fabrics**

The production of terry fabrics is a complex process and can only be realized on special designed weaving machines. Two warps are processed simultaneously in the production of terry fabrics which one of them is the ground warp that are highly tensioned and the other is the pile warp that is lightly tensioned. A special weaving method enables loops to be formed with lightly tensioned ends on either one surface or two surfaces (Adanur, 2001). Two specialized mechanisms are used in terry weaving machines such as reed control and fabric control.

Two picks are inserted at a variable distance –the loose pick distance- from the cloth fell. The loose pick distance is varied according to the desired loop height. When the third pick is beaten up, the reed pushes the pick group, on the tightly tensioned ground warps, towards the fell and loose pile warp ends woven into the pick group are uprighted and form loops. Depending on the weave, loops are thus formed on one or both sides of the fabric. In general, the reed has two beat up positions which do not impose alternative movements to the warp, fabric and various components of the weaving machine. The sley has a special mechanism built in which allows different beat-up positions for pile formation (Adanur, 2001).

Fig. 8. Structure of a three-pick terry fabric (Adanur, 2001).

In the second system, the sley motion is constant on the other hand cloth fell is moving. Using this principle the fabric is shifted towards the reed by means of a positively controlled movement of the whip roll 6 and a terry bar together with the temples on the beat-up of the fast pick. The sturdy reed drive is free of play. It provides the necessary precision for the beat-up of the group of picks. A compact, simplified whip roll system 6 with the warp stop motions arranged on two separate levels improves handling and has a decisive influence on reducing broken ends. With the help of electronics the precision of measuring the length of pile yarn is improved. The tensions of the ground and pile warps 1 and 2 are detected by force sensors 3 and 9 and electronically regulated. In this way warp tension is kept uniform from full to the empty warp beam. To prevent starting marks or pulling back of the pile loops the pile warp tension can be reduced during machine standstill (Badawi, 2007).

The production of terry fabrics is a complex process and can only be realized on special designed weaving machines. Two warps are processed simultaneously in the production of terry fabrics which one of them is the ground warp that are highly tensioned and the other is the pile warp that is lightly tensioned. A special weaving method enables loops to be formed with lightly tensioned ends on either one surface or two surfaces (Adanur, 2001). Two specialized mechanisms are used in terry weaving machines such as reed control and

Two picks are inserted at a variable distance –the loose pick distance- from the cloth fell. The loose pick distance is varied according to the desired loop height. When the third pick is beaten up, the reed pushes the pick group, on the tightly tensioned ground warps, towards the fell and loose pile warp ends woven into the pick group are uprighted and form loops. Depending on the weave, loops are thus formed on one or both sides of the fabric. In general, the reed has two beat up positions which do not impose alternative movements to the warp, fabric and various components of the weaving machine. The sley has a special mechanism built in which allows different beat-up positions for pile formation (Adanur,

In the second system, the sley motion is constant on the other hand cloth fell is moving. Using this principle the fabric is shifted towards the reed by means of a positively controlled movement of the whip roll 6 and a terry bar together with the temples on the beat-up of the fast pick. The sturdy reed drive is free of play. It provides the necessary precision for the beat-up of the group of picks. A compact, simplified whip roll system 6 with the warp stop motions arranged on two separate levels improves handling and has a decisive influence on reducing broken ends. With the help of electronics the precision of measuring the length of pile yarn is improved. The tensions of the ground and pile warps 1 and 2 are detected by force sensors 3 and 9 and electronically regulated. In this way warp tension is kept uniform from full to the empty warp beam. To prevent starting marks or pulling back of the pile

loops the pile warp tension can be reduced during machine standstill (Badawi, 2007).

Fig. 8. Structure of a three-pick terry fabric (Adanur, 2001).

**4.1.2 Production of terry fabrics** 

fabric control.

2001).

Fig. 9. Fabric control mechanism (Dornier, 2007).
