Fabric Manufacturing I (TE - 213)

Sizing

Size: A gelatinous film forming substance in solution

or dispersion applied normally to warp but sometimes
to weft, generally before weaving is called size

Sizing:The process of applying a protective adhesive coating

the yarns surface is called sizing. This is the most important
operation to attain maximum weaving efficiency specially for
blended and filament yarns.

Objects of sizing:
1. To improve the weave ability of warp yarn.
2. To maintain the good fabric quality by reducing hairiness,
weakness and by increasing smoothness, strength of yarn.
3. To increase the tensile or breaking strength for cellulose
yarn.
4. To increase the elastic property.
5. To remove the projecting fibers.
6. To reduce electrostatic formation for synthetic or blended
yarn.
Causes of warp yarn sizing:
1. To strengthen the yarn by causing the fibres to adhere
together.
2. To make outer surface of yarn smooth so that hairs
protruding from one yarn in the warp should not entangled
with hairs protruding from a neighboring yarn.
3. To lubricate the yarns so that there is less friction when they
rub together in the weaving process. Lubrication also reduces
the friction between the yarns & loom parts. The reduction of
friction reduces the forces acting on the yarn during weaving

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 Fabric Manufacturing I (TE - 213)

Requirement of sizing:
1. Sized warp must be sufficiently strong, smooth & elastic.
2. The sizing process must ensure the application of the required
amount of size on the yarn or the required size regain.
3. The tensions of warp yarn at sizing must be regular & constant
during all the warp unwinding from the warping beams.
4. Yarn strength & loss in elongation should be a within admitted
limits.
5. The package i.e, the weavers beams produced, must be have a
cylindrical shape, the necessary winding density & yarn strength.
6. The sizing process must be efficient, economical & must
ensure the production of high quality sized warps.

Properties of yarn after sizing or sized yarn properties or

technological changes due to sizing:
1. Increase in breaking strength: During sizing, adhesive
material creates bonds between fibers to fibers, which increase
the strength of yarn. It increases 20-40% breaking strength of
the fiber.

2. Increase abrasion resistance:

After sizing he gap between fibers are filled with size and
coating on the outer surface of the yarn takes place.

3. Increase in stiffness:

After sizing, flexibility or pliability of yarn is decreased and

stiffness is increased.

4. Increase in elasticity:

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As extensibility of he sized yarn decrease more force has to be

applied to extent he yarn hence elasticity increases.

5. Increase frictional resistance:

Application of size materials makes outer surface of the yarn

smooth and hence occurs less friction.

6. Increase yarn diameter:

Sizing means coating adhesive on the outer surface of the

yarn. Hence sizing causes increase of diameter of yarn.

7. Decrease in extension: After sizing he gap between the

fibers are filled with size materials. So the slippage between
the fibers does not occur easily. So the extension decreased.

8. Decrease in electrostatic charge:

Electrostatic charge is formed due to the friction between

yarns and size materials contain moisture, which reduces static
friction

9. Decrease hairiness: During sizing protruding hairs of fix

with yarn end. So yarn hairiness decreases.

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 Fabric Manufacturing I (TE - 213)

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 Fabric Manufacturing I (TE - 213)

The picture on the right side shows the appearance of a

properly sized spun yarn used as warp in weaving
process.

The protruding hairs are bound to the yarn body with a

thin coating of adhesive material applied to the yarn in
the sizing process

Size ingredients:

Adhesive: It is the main ingredient of solution preparation. It is

two types.

a) Natural , b) Synthetic
Natural Size: Generally starch of maize, corn potato, sago,

Synthetic Size; Carboxyl methyl cellulose (CMC), PVC, PVA,

Poly Acrylate etc.

Used for:

To make coating on the yarn

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To improve strength.

To increase smoothness.

To improve elasticity and stiffness.

Lubricant or softener: It is the second main ingredients of
size solution preparation,
e.g. Japan wax, tallow, linseed oil, coconut oil, animal fat,
mineral oils.
Used for:
To make the yarn soft and slippery.
To increase the smoothness of yarn.
To reduce stiffness.
Antiseptic or anti mildew agent: Carboxylic acid, salicylic
acid, ZnCl2, Phenol.
Used for:
To prevent mildew formation.
To preserve size material for a long time.
To help to store the sized yarn.
To protect yarn from bacteria or fungus.
Hygroscopic agent: Magnesium chloride, glycerin, and calcium
chloride.
Used for:
To moisture the yarn.
To prevent excessive drying of yarn.

Weighting agent: China clay, sodium sulphate, french chalk.

Used for:
To increase the weight of yarn.
Anti foaming agent: Silicon based deformer, water insoluble
esters, ketones, ethers, pyridine etc.

Used for:

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 Fabric Manufacturing I (TE - 213)

Due to high speed circulation of size ingredients during

cooking foam is formed. Foaming is highly undesirable
during sizing as the foam obstruct the uniform application of
size. For this reason antifoaming agent is used to prevent
the formation of foam in size solution during cooking.

Wetting agent: sulphanol, soap, avirol, alizarine oil etc.

Used for:
To penetrate she sizing solutions in the yarn surface.
To reduce the surface tension.
Choice of Size ingredient:
1.It should give least amount of dust produce.
2. It should permits easy size removal in latter operation.
3. It should give good fabric characteristics.
4. The recipe should be compatible with the machinery.
5. The recipe should not cause any health hazard.
6. The recipe should not cause any degradation of textile
material.
7. It should be cheap.
8. PH should be lies between 7-7.4(neutral condition

Types of Sizing:

1. Pure Sizing:
Pure Sizing means pick-up percentage = 7%.
Minimum percentage of size to be required to facilitate the
weaving smoothly is known as pure sizing. Pure sizing is applied
on finished fabric.

2. Light Sizing:
Light sizing means pick-up percentage = 8-11%. The
additional objects of light sizing are to impart some special feel or
handle properties.

3. Medium Sizing:
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Medium sizing means pick-up percentage = 12-15%.

In addition to be facilitation of weaving increase the weight of the
fabric.

4. Heavy Sizing:
Heavy sizing means pick-up percentage = 16-40%.
Heavy sizing used to increase weight & stiffness of fabric.

Size take up percentage:

The amount of size material added on the yarn
surface is called size take up .

Size take up percentage depends on:

1. Higher twist: lower take up percentage.
2. Finer count: Lower take up percentage.
3. Higher concentration: Higher take up percentage.
4. Higher viscosity: Higher take up percentage.
5. Lower flexibility: Higher take up percentage.
6. Higher immersion length: Higher take up percentage.
7. Higher squeeze roller pressure: Lower take up
percentage.
8. Higher yarn speed: Lower take up percentage.
9. Higher staple length: Lower take up percentage.
10. Crystalline fibre: Lower take up percentage.
11. Amorphous fibre: Higher take up percentage
Techniques of Sizing:

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1. SizingWeaving Curve

A typical sizingweaving curve is as shown in figure.

The weaving efficiency, which is inversely proportional to warp

yarn end breakage rate, reaches its peak when the warp
breakage rate is at its minimum. Initially the warp breaks
decrease with the increase in size add-on level. This is due to the
associated increase in yarn strength and reduction in yarn
hairiness.
The optimal range of size add-on is usually between points A and
B as shown in the typical curve in Fig. Increasing the size add-on
beyond the optimum, leads to an increased penetration of the
size, this makes the yarn inflexible. Such a thick coating of size
film may have a lower extensibility compared to the extensibility
of the warp yarn itself. Inflexibility of the yarn and a size film not
bound securely making the yarn vulnerable to intensive abrasion
action and leading to a higher warp breakage rate.
2. Mechanism of size take-up:
Size take-up is affected by:
1. Viscosity of size mixture: It depends on nature of adhesive,
time of boiling, temperature
and concentration.
2. Squeeze roller pressure: It depends of weight of rollers and
added force.

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3. Roller covering: It depends on hardness and absorbency of

roller surface.
4. Nature and geometry of yarn: It depends on twist in yarn,
fiber fineness and nature of fibers.
5. Speed: It affects the drying and manipulation of warp.
3. Typical size recipe:
Water--------------------80%
Size ingredients------20%
For light sizing:
Type -1: Wheat flour-----280 lbs
Tallow-----------16 lbs

Type-2: Sago--------------100 lbs

Farina------------100 lbs
Tallow-----------10 lbs
Soap--------------4 lbs
For finer count: Farina---100 lbs
Wax------5 lbs
Tallow---4 lbs
For medium sizing:
Flour-------------100 lbs
Clay--------------30-40lbs
Tallow----------15 lbs
MgCl2------------1 gallon
ZnCl2-------------1/2 gallon
For heavy sizing:
Flour-------------100 lbs
Clay--------------130 lbs
Tallow-----------14 lbs
MgCl2 ----------5 gallon
ZnCl2-------------2 gallon
The techniques of sizing are:

1. Conventional / Slasher Sizing.

2. Hot melt sizing.
3. High pressure sizing.
4. Foam Sizing
5. Electrostatic sizing.
6. Combined Sizing.

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 Fabric Manufacturing I (TE - 213)

The slasher sizing machine is consists of the following

seven units:
1. Back Beam Unit
2. Sizing Unit.
3. Drying Unit
4. Cooling Unit.
5. Dividing Unit
6. Measuring & Marking Unit.
7. Beaming Unit

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 Fabric Manufacturing I (TE - 213)

Back beam unit:

The unit contains frame which carries 8-20 beams to get
wound, which may be arranged in various ways.
Sizing unit:
This unit contains guide roller, tension roller, size box,
immersion roller, sizing roller, squeezing roller.
Size recipe is reserved in reserved box & apply it on the yarn.
Guide roller guides the yarn & tension roller maintains the
uniform tension on yarn. The size box is used to apply the size
liquor to the yarn. The size liquor is kept in size box. The warp
sheet is guided through the solution by means of immersion
roller. The squeeze roller removes excess size from the yarn.

Drying unit: It contains of heated cylinder over which warp

sheet passes. There may be two or multi cylinder. Heated cylinder
dries the yarn.
Cooling unit: This unit has cooling fan & guide roller. Cooling fan
supplies cool air to dried warp sheet to cool it.
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Dividing unit: In order to prevent adhesion between yarns, it is

necessary to separate each sized ends from the others. For this
purpose lease rod is used.
Measuring & Marking device: In this unit the length which is sized
is measured by measuring roller & marked at a given distance.
Beaming unit: Finally sized warp is wound on a weavers beam.

Methods of Drying:

The methods of drying are:

1. Cylinder drying:
a. Two Cylinders: Conventional drying. One large cylinder,
one small cylinder.
b. Multiple Cylinders: (Odd number or even number cylinder)
1st two or four cylinders is Teflon coated and steam
pressure is high.
2. Hot air drying.
3. Infra-red drying.
4. Combined drying (Cylinder hot air)

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 Fabric Manufacturing I (TE - 213)

Faults in sizing:
1. Sticky warp.
2. Gum spot.
3. Under slashed yarn.
4. Over slashed yarn.
5. Over dried yarn.
6. Non uniform sizing.
7. Cross or lost ends.
8. Improper boiled of yarn.
9. Incorrect warp length.
10. Dirty warp.

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 Fabric Manufacturing I (TE - 213)

3) A warp beam contains 12950 yds of warp sheet on it. The no. of ends in the
warp sheet is 430 and wt. of full beam is 365 lbs. if the weight of empty beam
is 52 lbs, calculate the count (Ne) of warp yarn.
Solution:
Wt. of yarn = wt. of full beam wt. of empty beam = 365
lbs 52 lbs = 313 lbs
Count of yarn=x

Wt of single warp = 12950/(840 X x)=15.42/x

No of warp = (313/{15.42/x}]=430
Or, 313 X x =430 X 15.42

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Or, x =21.18

Wt of single warp = 15000/(840x32)

=0.5580 lbs
No of warp = (250/.5580)
=448

5) Calculated production is 100 yds/min & eff is 75%

a) Calculate actual production/shift
b) Total length of yarn if total ends is 3250
c) Wt. of sized yarn if count is 40 & take up is 10%

Solution:
a) Actual production /shift = calculate production efficiency
=100x60x8x.75
=36000 yds/shift

b) Total length = Total production No. of ends =36000 x

3250=117000000 yds

c) Wt. of unsized yarn = 117000000/(840 x40)

=3482.142 lbs
Total wt. of sized warp yarn with 10% take up
= (wt. of sized yarn) + (wt. of size yarn take up)

=3482.142+3482.142x (10/100)

= 3830.356 lbs.

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6) Wt. of sized beam is 82.5 lbs. Beam have 1050 yds yarn
whose yarn count
before sizing was 50 Ne, if no. of ends is 3000. Then
a) The wt. of size on the yarn
b) %of size material
c) Count of sized yarn

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