The main possible reasons for warp floats are given below:
The warp tension has great importance during weaving. If the technician doesn't select proper warp tension, or keeps low warp tension to reduce warp breakage, the chances of warp floats gets increased. The warp ends fail to raise completely and weft yarn passes over the warp ends. Thus the warp tension plays very important role in warp floats. The technician should choose an amount of warp tension in such a way that there is lowest warp breakage rate and there is not a warp floats problem in the fabric.
The quantity of warp beam directly influences the frequency of warp floats. If the beam winding density near the flanges is lower then the middle ends, then weaving technician comes into big trouble. When he applies required warp tension, he fails to achieve uniform warp tension on the loom. The warp tension gets lowered at both the selvedge. This warp tension variation causes warp floats near the selvedge in the fabric. A high degree of care should be taken to avoid the variation in beam winding density.
The yarn quality is always a very big issue in weaving. It is directly associated with warp floats problem in the woven fabric. Big knot always results in the form of warp floats in weaving. A big knot prevents the up and down movement of adjacent end. In this way the big knot creates warp floats in weaving. A Weaver should always use auto spliced yarn to avoid these warp floats. We should always use Weaver's knot during warping and weaving.
it is very important aspect. The environment of spinning department should be as clean as possible. If fibers are flying in the department, they get spun with yarn to be spun on machine. When this yarn goes to weaving, the wrapped flying fibers with the yarn fail to pass through the dent of the reed. These flying fibers converted into ball form behind the reed. These flying fibers balls interrupt the raising and lowering movement of adjacent end. Thus these balls results in the form of warp floats in the fabric.
If the sizing of warp yarn is not proper, it may be the reason of warp floats in the fabric . Since we know that warp ends are rubbed to each other during shed crossing during weaving. If the beam is not sized properly or size percentage is not sufficient, then fiber fraying gets started in the yarn. This fraying of fibers helps into yarn fusion and generates warp floats in the fabric.
if the all above stated terms are ok, then the role of loom settings comes into play.