Textile Science & Technology- Fiber to

Fiber (2103)

Report Writing : Study

Date: 17 on Sizing Process.
th
Submission April 2021

Submitted To : Submitted By :
Name : Name :

Study on Sizing Process:

Introduction: Sizing is the process of applying an adhesive coating on the surface of the yarn.
Sizing is applied into the yarn mainly to improve the weave ability of warp yarn by making it more
resistant to action of weaving i.e. absorption, friction, tension & flexing. It also maintains good fabric
quality by reducing hairiness, weakness & by increasing smoothness, absorbency of yarn. The most
other features of the sizing is change of various physical properties. Sizing is applied on to the fibre
surface by various process and various recipes according to the requirements. The most commonly
used sizing machine is Slasher sizing machine.

Defination: Sizing is the process of giving a protective coating on the warp yarn to minimize yarn
breakage during weaving.

Sizing is the most important operation in preparing warp yarn for weaving especially with cotton
yarn. The smallest error in sizing process may be very harmful. This may increase warp breakage
rate on the looms and consequently reduce weaving production and quality.Therefore sizing is
termed as the “Heart of Weaving”

Purpose of Textile Sizing: The purpose of sizing is to apply size solution on to the warp yarn
surface during weaving warp yarns under high tension and vigorous abrasion. So that we can get the
following benefits:

 Sizing particularly on cotton yarn will increase the yarn strength and reduce the yarn
breakage.
 Sizing helps to reduce the yarn hairiness
 Sodium Phosphate is used to Increase the overall weight of cotton yarn.
 Because of using softener, the yarn softness will increase.nge of v

Objectives:
1. To increase the smoothness of the warp yarn.

2. To reduce hairiness of warp yarn.

3. To increase the strength of warp yarn.

4. In some cases sizing is now done to modify the character of the warp yarn.Example, to have an
effect on fabric weight on fabric weight, stiffness, handle properties etc.

5. To improve the weave ability of warp yarn.

6. To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness,
strength of yarn.

7. To increase the tensile or breaking strength for cellulose yarn.

8. To increase the elasticity.

9. To remove the projecting fibers.

10. To reduce electrostatic formation for synthetic or blended yarn.

Process of Textile Sizing: A sizing machine is used to size the yarn before using it for
weaving. Sizing machine is generally composed of four sections; the beam creel, size box drying,
chamber, and winding head.  The process of textile sizing is given below:

1.

1. Warp beams are attached on a beam basket pneumatic warping brakes are fitted on the beam
stands. It is used to reduce the warp let-off speed by applying a suitable pressure so to adjust
the warp tension.
2. The brake system can also stop the beam instantly to avoid further rotation due to inertia.
3.  Cooked size solution is pumped into the size box and the size solution is applied to the yarn
by application rollers. It is important to control the size box temperature and yarn tension
during size application.
4. Sized yarns are then passing through a series of steamrolls in the drying chamber. Yarn
should have good contact with the steamroll surface for a good drying result.
 5. At the front end of the sizing machine, the yarn separation rolls separate the warp sheet into
individual yarns. In order to give a uniform yarn layout for winding onto the beam.
6. The adjustable Reed controls the width of the warped being wound onto the beam while the
press rolls control the warp density of the beam, hence more yarn can be wound onto it. Warp
length is marked by a stamping device. This mark assists the operator to cut the continuous
fabric into rolls according to the required length during weaving.
7. Process parameters such as; winding speed, and tension, moisture content, Creole tension,
drying temperature, and size can be controlled by the control panel located at the front end of
the machine.

Types of sizing: Sizing may be classified into Four types on the basis of size% on the yarn.

1. Light Sizing :10% to 15%.

2. Pure Sizing :16% to 25%.

3. Medium Sizing :26% to 50%.

4. Heavy Sizing :50% to 100%.

Differnt technique of Sizing:

1) Hot Melt Sizing.

2) Solvent Sizing(Organic sizing).
3) Foam sizing Sizing.
4) High pressure Sizing.
5) Electrostatic Sizing.
6) Emulsion Sizing.

The Important Features to be remembered During Sizing:

1. If the hairiness of the yarn is high then the concentration of the size would be high.

2. If the twist is high in the yarn then the concentration of the size would be high.

3. If the yarn (finer) count is high then the concentration of the size would be high.

4. If the yarn (coarser) count is high then the concentration of the size would be low.

5. If the temperature of the bath is high then the viscosity of the size would be less and
vice versa.
6. If the cooking time is more than the viscosity would be less.

Effects of Sizing on Yarn: The amount of size add-on depends on yarn structure, sizing recipe,
squeezing roller pressure, m/c speed.As the size add-on is increased—

 The yarn becomes stiffer.

  The yarn becomes less extensible.

 The yarn becomes

more difficult to weave. If a low add-on—

 The yarn becomes hairy.

 The yarn suffers from lack of strength.

 The yarn becomes more difficult to weave.

GRAPH: If Sizing increase, Efficiency also increase up to optimum level.

SIZE % EFFICIENCY%

Low 40

Good 75

Standard 85

Optimum 95

High 85

Very high 75

Extreme 40

Sizing Ingredients-

1) Starch.

2) Binder.

3) Softener.

4) Anti-septic agent.

5) Anti-static agent.
6) Weighting agent.

Starch:
Starch is the main sizing ingredients. They coat the warp yarn with a film & impart
smoothness by binding the projecting fibres to the yarn surface. The viscosity of the size
solution is controlled by the amount of starch, the recipe, degree of mechanical mixing,
temperature & time of boiling. For Example: Potato, CMS(Carboxy Methylated
Starch),PVA (Polyvinyl Alcohol)
Binder:
These materials penetrate into the yarn & contribute in increasing yarn strength. These
materials can be used as an independent gum & substitute of starch products. For Example:
Polyacrylamide, Polyacrylonetrile etc.
Softener:
The hard fragile film is softened by addition of softener. They increase flexibility of yarn
after sizing. For Example : Tallow, Soap, Japanese wax, Modified wax, Artificial wax.

Anti-septic agent:
The size recipe consist starch which the protein substances in the favorable medium for
the development of the micro-organism (Fungi, Mouldetc). The sized warp or grey cloth is
stored for long time; the anti-septic agent is used to prevent the growth of micro- organism
in the grey cloth.

Weighting agent:
These agents are used to increase the weight of the fabric. The fabrics are to be sold at
grey stage or require the special type of finishing to get fuller appearance are sized with
the weighting agent.

The Factors in choosing size ingrediants are:-

1) The recipe should be that which gives fewer end breaks.

2) It should be that which gives the least exfoliation.

3) It should be that which permits easy de-sizing.

4) It should give good fabric characteristics.

5) It should be compatible with machinery (For Ex: it should not cause size build-ups
during weaving or blockages during slashing).

6) It should not cause any degradation of the textile material.

7) The cost of sizing plus the cost of weaving and finishing should be minimum.

Sizing Recipe: Sizing recipe depends on yarn type, total ends.Typical sizing recipe- In 500 Liter
Water:-

• Starch : 10-20% of water.

• Binder : 2-4% of water.

 • Softener : 0.5-1% of water.

Key Accessories:
1. REFRACTOMETER.
2. VISCOSITY CUP.

Equipment: 1. BENINGER ZELL SIZING M/C (SINGLE SIZE BOX).

2.BEN SIZEMIX (COOKER). These sizing machines are equipped with BEN SIZEMIX size cooking
& storage apparatus. A total of 12 (maxm) direct warped beams can be combined & sized to make
weaver’s beam. Moreover an additional unwinding frame provides the facilities to size sectional
warped beam.

FIG
: SIZE NG M/C
Main Parts of the Machine:

Fig. Moisture Roller Fig. Drying Cylinder

Fig:Creel Fig: Sizing Chemical

Process Description:
Back beam unit:
In single end sizing yarns are taken from a creel rather than from a beam. This unit
contains 12 carriers from where yarn is supplied. Indirect & direct process of yarn supply
is frequently used for spun yarns. In case of indirect method beam creel is used. This
beam creel can be arranged in various ways.
Sizing unit:
In this unit a size box is used to apply size to the yarn. The warp sheet is guided through the
solution means of the immersion roller & then through the squeeze roller where the yarns
are pressed to maintain the required size to up percentage by the yarn. The size box
temperature is controlled by flowing steam through pipe.

Drying unit:
14 heated cylinders consist of drying unit. This unit is required to dry the wet sized yarn rapidly,
thoroughly & uniformly. A two cylinder dryer is too slow & it is difficult to maintain by it. But
a multi-cylinder dryer is a good one to main in such a way that after drying. Yarn contains 6%
water.

Cooling unit:
In this unit there is cooling fan & a guide roller. The cooling fan supplies cool air which
extinguish the yarn temperature & also remove the moisture.
Dividing unit:
In order to prevent adhesion between the yarns, it is necessary to separate each sized end
from the others. For this lease rod or breaker rods are used to divide the main warp sheet
into single end.
Measuring & marketing unit:
This unit consists of colouring bowl which contains easily removable colour. This colour is
used for making on sized yarn. Also there is a measuring roller which measures the length
of sized warp yarn.

Beaming unit: Finally the sized warp is wound on weavers beam.

Disadvantages of Sizing:

1) Cost of land and machine is high.

2) Requires lot of labors.
3) Requires utility like gas, electricity etc and their cost is high.
4) Cost of ingredients.
5) The process is long and it takes time.
6) There is a risk of degradation of yarn.
7) The yarn diameter is increased.
8) Requires robust loom.
9) It increases yarn stiffness.
10) The fabric needs to be desized before use.
11) Need knowledge and information about the size ingredients.
12) There is a risk of pollution.
13) Sizing changes the shade of colored yarn 14.100% size material cannot be removed
15.Size material presence leads to uneven dying.