Sizing

Sizing ' is the process of applying a protective coating on the yarn surface to improve
weave ability.

This is the most important operation to attain maximum weaving [Link], It is

called the heart of weaving.

The process of jute yarn sizing is called dressing.

Objectives of Sizing :

1) To improve the weave ability of yarns by applying a uniform coating on the yarn
surface so that protruding hairs are laid on the yarn surface.
2) To improve abrasion resistance.
3) To increase resiliency.
4) To reduce yarn breakage rate in the loom.
5) To increase smoothness of yarn.
6) To increase yarn strength.

Requirement of Sizing :

1) Sized warp must be sufficiently strong, smooth & elastic.

2) The tension of the warp yarns at sizing must be regular & constant during all the
time of warp unwinding from the warping beams.
3) Yarn stretch & loss in elongation should be within admitted limits.
4) The package, i.e the weavers beam produced must have a cylindrical shape, the
necessary winding density & the yarn length.
5) The sizing process must be efficient, economical & must ensure the production of
high quality sized warp.

Benefits of Sizing :

1) It prevents the warp yarn breakage due to abrasion with neighbouring yarns or
with back rest, heald eye and reed.
2) It improves the yarn strength by 10 to 20%, although it is not the primary objective
of sizing process.
Characteristics of Sized Yarn : Technical changes due to sizing :
• Breaking strength-increase
• Abrasion resistance- increase
1) Higher strength. • Yarn diameter- increase
2) Higher abrasion resistance. • Stiffness-increase
3) Higher bending rigidity. • Flexibility-increase
4) Lower elongation. • Electrostatic property-decrease
5) Lower hairiness. • Hairiness-decrease
• Absorbency-decrease
6) Lower frictional resistance.

The amount of size material added on the yarn surface is called Size add on(%) .

Sizing-weaving Curve :

For the sizing process, depending on the size materials used, there is a target add-
on for the optimum performance of the warp yarns in the weaving process. This can
be understood from the sizing-weaving curve .
The solid line represents the warp breakage rate whereas the broken line indicates
loom efficiency.

Warp breakage rate is generally high at very low level of size add-on. The
performance of the yarn in weaving improves as the size add-on increases. At the
optimum add-on level, warp breakage rate is very low and loom efficiency is high.
However, if the size add-on is higher than the optimum level then warp breakage rate
increases again largely due to the loss of elongation and increase in bending rigidity
of the yarns.
Although add-on primarily influences the weaving performance, it is possible to have
different weaving performances even at the same level of size add-on. This can
happen due to differences in-
(a) Size penetration
(b) Size coating or encapsulation.

Size coating Size penetration Optimum coating & penetration

In the first case, the size material has formed a uniform coating on the yarn surface.
But the penetration of the size material is inadequate. This may tackle the hairiness
[Link] during the abrasion with various machine parts and neighbouring
yarns, the size will fall and thus the weaving performance will be poor.

In the second case, the coating on the yarn surface is inadequate. Therefore, the
yarn will not get adequate protection against the abrasion. Besides, the size
materials have penetrated too much inside the yarn which is not desirable.

The third case is the optimum one where there is a thin but uniform coating
formation on the yarn surface by the size materials. Moreover, the size materials
have also penetrated to some extent in the yarn structure which ensures good
adhesion between the yarn and the size coating. For optimum weaving
performance, size should penetrate to a distance equal to 15-25% of yarn radius.

The sizing material must fulfil some essential properties and at the same time it is
expected that it will have some additional desirable properties. The sizing material
must form a smooth and uniform coating the yarn surface. This is known as film
forming property.

Essential and desirable properties of sizing materials :

1. Film forming. 8. Bacterial resistance.

2. Adhesion. 9. Controllable viscosity.
3. Optimum penetration. 10. Easy removal and recyclability.
4. Film flexibility and elasticity. 11. Cheap.
5. Lubrication. 12. Uniformity.
6. Transparency. 13. Neutral pH.
7. Low BOD.
 ↑
Factors affecting the size take up or size add on percentage :

1. Fibre characteristics: For immature cotton fibre, size take-up percentage higher
- .

due to big lumen and for mature fibre, size pick up lower due to small lumen.

2. Yarn characteristics: For higher yarn hairiness, size pick-up higher and for rough
surface size pick-up increase.
. .

3. Wet ability: For higher wet ability, size pick up is higher due to absorption.

4. Linear density or Yarn count: For Coarser yarn, size take-up higher and for finer
yarn, size take-up lower.

5. EPI: For higher EPI, size take-up higher due to the density of yarn in warp sheet.

6. Uniformity of warp yarn: Uniform Yarn → Lower size take up%

Un-uniform Yarn → Higher size take-up%

7. Warp tension: Higher tension of yarn → Lower size pick up%

8. Temperature: 60°C.

9. Roller weight: Higher squeezing roller wt → low Size pick up % due to

penetration.

10. Roller diameter: Higher Squeezing roller dia→ Size pick up% higher
lower Squeezing roller dia → Size pick up%lower

11. Contact length in size: Yarn contact in size size take-up % →higher

12. Running speed: Running speed higher size pick up lower , due to short time for
penetration of yarn.

13. Size concentration: Size concentration higher → pick up %higher

14. Ingredients: For different ingredient, size pick up percentage vary due to
adhesive power.

15. Preparation condition: Shape of sizing materials should be finer.

Size ingredients & functions :

• Adhesive - Adhesive part is responsible for forming the film and adhering with the
fibers . Ex: Starch, CMC ,PVA ,PVC. ( PVA= Polyvinyl alcohol, PVC= Polyvinyl
chloride ,CMC= Carboxymethyl cellulose)
Function:
a) To improve strength.
b) To improve abrasion resistance.
c) To increase extensibility.

• Lubricant or Softener - Softening agent makes the film flexible so that the film
can bend easily without forming cracks. Ex: Animal fat ,mineral fat, Japan wax ,
Tallow.
Function:
a) To make the yarn soft & slippery.
b) To reduce stiffness.

• Antiseptic or mildew - Antimicrobial agents are added to protect the mildew to

grow on the size film. Ex: ZnCl2, Phenol etc.
Function:
a) It helps to store the yarn without damage.
b) Protect yarn from bacteria or fungus formation.

• Wetting or Hygroscopic agent - glycerin , MgCl2 , CaCl2 etc

Function:
a) Prevent brittleness of size.
b) Helps to keep standard moisture regain.

• Weighting agent - sodium sulphate, china clay

Function:
a) Increase weight of yarn.

• Antifoaming agent - Benzene, pyridine etc

Function:
a)To prevent foam formation.
Size ingredients used in a modern factory :
➢ KOLLO TEX (STARCH MATERIALS)
➢ QUICK SOLON SPR (MODIFIED STARCH)
➢ BINDER (TO BIND SIZE AND YARN TOGETHER)
➢ WAX (LUBRICATING AGENT)
➢WATER

Types of sizing :

1. Pure sizing: This types of sizing is done for unbleached fabric. 7-10% size
ingredients are used on the weight of fabric.

2. Light sizing: This types of sizing is used for Dyeing & Printing of woven fabric.
11-15% size ingredients are used on the weight of fabric.

3. Medium sizing: This types of sizing is used for increase of strength & weight of
fabric. 16-40% size ingredients are used on the weight of fabric.

4. Heavy sizing: This types of sizing is used for increase the weight twisted & lower
count yarn. Above 40% size ingredients are used on the weight of fabric.

Why sizing of filament yarn is necessary?

Multifilament yarns are continuous with no hairiness but contain occasionally some
broken filaments which may cause problems during weaving. Such filaments may
have broken during spinning and winding or during the preparatory weaving
processes of the mills. The broken filaments create problems during weaving by
entangling in loom parts, causing them to ‘‘peel back’’ until a ball is formed, which
ultimately results in a break in the yarn and resultant loom stoppages. The size add-
on required for filament sizing typically varies from 4 to 6% as opposed to 10 to 15%
in the case of spun yarns.
What is the reason behind the popularity of starch for cotton yarn sizing?
• Starch is chemically same with cotton and rayon and thus the adhesion is very
good.
• Desizing is easy
• Relatively cheap
• Properties can be tuned to cope with the need

Chemical Structure of Starch :

For α -D-glucose, which is the building block of starch, both the OH groups of C1
and C4 are down with respect to the next glucose molecule. Therefore no change in
orientation is needed for condensation.

Chemical Structure of cellulose :

On the other hand, in β glucose, the OH group is up at C1 and down at C4. As a

result, every other glucose unit must flip over before the 1,4 hydroxyls can come
closer for condensation.
Starches are having two components. The straight chain component is called
amylose. The branched chain component is called amylopectin.

Amylose Amylopectin

Provides strength. Prevents rapid gelling.

Water soluble. Water insoluble.
Low molecular weight. Relatively high molecular weight.
20-30% . 70-80% .

The proportion of amylose and amylopection differs depending on source. For

example, in potato starch the ratio is 20:80 whereas in wheat starch the ratio is 25:
75.

Size cooking :

Size ingredients are mixed with the help of agitator in mixing tank. In the figure,
➢ A is a motor;
➢ B is agitator getting direct motion from motor.
➢ C is mixing tank.
➢ Size ingredients are added in mixing tank by the help of inclined lid (H) and steam
supply from steam pipe.
➢ After mixing size- ingredients passed through the valve (D) and
➢ Then pumped by pump (E) into
➢ Storing tank (G).
➢ In the storing tank, steam is passed to maintain viscosity of size. Viscosities of
size depend upon concentration and temperature of storing tank (G).
Size cooking : 2 types

1. Ordinary Size Mixing or Conventional Method.

2. Pressure Cooker Mixing or Modern Method.

Ordinary Size Mixing or Conventional Method :

• Procedure:

I. Add required amount of water into the mixing tank making an allowance for
evaporation and condensation.
II. Stirring start and continue until the end of the process.
III. Add antiseptic and stir for 10 mins.
IV. Gradually add starch materials and stir for 30-45 mins.
V. Pass steam and bring temperature to boiling.
VI. Add softener and boil for 15-20 mins.
VII. Continue steaming the correct viscosity is obtained.
VIII. Test and adjust PH 6 to 8 by adding soda ash, alkali or acid.
IX. Total time of cooking is 120-150 mins.
X. Transfer the size material to storage tank. XI. Finally maintain temperature at 60
°C.

Pressure Cooker Mixing or Modern Method :

• Procedure:

I. Add required quantity of water into the mixing tank.

II. Stirring start and continue until end of the process.
III. Add antiseptic and stir for 10 mins.
IV. Gradually add starch and stir for 20- 30 mins.
V. Air plug valve is tied.
VI. Steaming started, temperature automatically raised up to 90°C.
VII. Automatic timer for steaming started and the temperature and pressure raised
up.
VIII. After the temperature rises to 130°C. It is maintained by an automatic controller.
IX. Add softener.
X. Continue steaming at 30°C until the required viscosity is obtained.
XI. Adjust PH is kept 6 to 8 by adding acid or alkali.
XII. Transfer the size materials to storage box.
XIII. Finally maintained temperature at 60°C.
Cooking of Starch :

Starch remains tightly bound in granules and therefore it does not act as adhesive in
cold water. Cooking of starch is required to make it soluble in water. The change in
viscosity of starch solution during cooking is shown in the figure.

• The temperature at which the thermal energy becomes sufficient to overcome

hydrogen bonding within the structure is called ‘gelatinisation’ temperature (P).
• The chain molecules are pushed away from each other causing swelling of the
starch granule. This is marked by increased in viscosity of the solution (Q).
• Due to stirring, the starch granules finally break. The chain molecules of amylose
and amylopection come out within the solution causing reduction in viscosity (T)

starch 2 chain
length of a solid content for art solid contentive
jot viscosity ear, fluidity or, Acid treatment of 25m starch 5
chain
length IEEE Main solid content T22. solid content i
ejon viscosity or on seat fluidity to on
Acid Treatment of Starch :

The viscosity of the sizing paste influences the wet pick-up and resultant add-on %.
The viscosity is influenced by the solid content of starch and molecular chain length of
starch. Aqueous solution of starch is treated with hydrochloric acids at specified
temperature and duration. The acid cleaves the polymer at the glycoside linkage and
thus the length of the polymer chain is reduced. Hence, the viscosity is reduced and
the fluidity, which is the reciprocal of viscosity, increases. The acid treated starch is
often termed as ‘thin boiling starch’ as it results lower viscosity than the normal starch
at a given concentration.

Figure : Acid treatment of starch to reduce the molecular chain length

# Yarn path diagram of Sizing Machine :

A Sizing Machine has Various units

[Link] Beam unit
[Link] Unit
[Link] Unit
[Link] Unit
[Link] Unit
[Link] & marking unit
[Link] or Take up unit
Sizing Machine:

Sizing machine can be divided into four main zones as shown in the following figure:

1. Creel zone
2. Size box zone
3. Drying zone
4. Headstock zone

[Link] Zone :

The creel zone of a sizing machine can have following types of design:

✓Over and under creel

✓Equi-tension creel

✓Vertical creel

Uniform Tension in Warp Sheet :

➢It is very important to maintain adequate and uniform tension in the warp sheet
during the entire sizing process.
➢However, as the sizing process continues, the radius of the warper’s beam
reduces.

Stretching of Warp Yarn:

• In sizing process, the allowable stretch is 1.0-1.5% for cotton and polyester yarns.
The stretch can be higher (3-5%) for viscose and acrylic yarns.
2. Size box zone :

• This is the zone where the warp sheet is immersed into the size paste and then
squeezed under high pressure so that uniform coating of size film forms over the
yarn surface.
• The process of immersion is called ‘dip’ and the process of squeezing by means of
a pair of squeezing rollers is called ‘nip’.
• The size box can have different number combinations of ‘dip’ and ‘nip’ to meet the
requirement of various yarns. For filament yarns ‘one dip and one nip’ is preferred
where as for spun yarns made from staple fibres ‘two dip and two nip’ is advisable.

Fig: One dip and one nip

Fig: Two dip and two nip

 3. Drying zone :

• Methods of drying :
/
1. Cylinder Drying.
2. Hot Air Drying.
3. Infrared Drying.
4. Combined Drying.

1. Cylinder drying:

here, drying is done by passing over hot cylinders.

A. Two cylinder drying:

I. In this drying process, two copper cylinder are used in which one cylinder is large
diameter and other is small comparatively.
II. Firstly warp sheet is passed below the small cylinder and then over the bigger
one.
III. The yarn is dried while traveling through the circumstances of the cylinder.

B. Multi cylinder drying:

I. In this type of machine the drying unit consists of 5 to 7 or 11 cylinders having
same diameter are used.
II. All cylinders may be steel cylinders or first two cylinders are Teflon coated and rest
of are steel cylinder.
III. The cylinders are heated by passing steam.
IV. Heat in initial cylinder is low and gradually increases when moved towards final
cylinder.
V. If large amount of heat is given to the initial, the sized may be backed.
 Advantages:

• High speed process.

• Uniform drying.
• Non-sticky so smooth drying.
• Drying efficiency high.
• Less time required

Disadvantages:

• For high viscosity stick property may observed.

• For friction, yarn hairiness.
• Shinning effect.
• Yarn shape may hamper.

2. Hot Air Drying :

• In this machine, the drying unit is a closed chamber containing a number of guide
rollers through which warp yarn passes.
• Hot air blown into the chamber, causing the moisture in the yarn to evaporate.
• Exhaustion should be used to throw away the moisture.
• If moisture remains inside the chamber it may condense and again fall on the yarn.
• Hot air should be continuously passed through the chamber so the process
becomes somewhat costly.

Advantages:

• Regular drying.
• Not shinning effect.
• Non Sticky property.
• High speed drying.

Disadvantages:

• Costly process
• For closed chamber, required more time. • Less suitable for fine yarn.
• Difficult to maintain temperature
3. Infra-red Drying :

• In this chamber the heating chamber consists of a plate which is constantly heated
by gas flame.
• The warp sheet is passed over the plate and dried in the process.
• When gas flames are not used then electronic plate may be used.
• Arrangement should be made to through out the moisture removed from the yarn.
This machine is not used alone.

Advantages:

• No shinning effect.
• Drying efficiency high.

Disadvantages:

• Yarn may burn.

• Higher cost.
• Difficult to maintain uniform heating.
• Risk of accident.

4. Combined Drying :

• In this type of machine preheating is done by cylinder drying method

• and final drying is done by hot air drying method or infrared drying method.

Advantages:

• Regular drying.
• Drying efficiency is high.
• Speedy process.

Disadvantages:

• Shinning effect.
• High cost.
Factors to be considered while drying :

• EPI: If EPI is more warp sheet density increase and drying time required more.

• Count of warp yarn: Higher count, drying [Link] yarn is coarser, more time
required to dry.

• Twist of warp yarn: Higher twist, lower dry ability.

• Concentration of liquor: Higher concentration lower dry ability.

• Size pick-up%: Higher pick-up% dry ability lower.

• Speed of running: More speed, lower ability because of cylinder and yarn contact
for the time.

• System of drying: Hot air drying < cylinder drying.

Two cylinders drying < Multi cylinder drying

Why Teflon coated cylinder used in drying ?

• The Following are the special features of Teflon Coating:

➢Good Quality
➢Long Durability
➢Very High Efficiency
➢Improved Service

r
Techniques of Sizing :

• Hot melt Sizing

• Solvent Sizing
• Foam Sizing
• High Pressure Sizing
• Electrostatic Sizing
• Emulsion Sizing
• Combined Sizing
r
The wet pick-up by the warp sheet is influenced by the following parameters:

i) Viscosity of Size Paste-

✓ Viscosity of a fluid indicates its resistance against the flow.

✓ Higher concentration(solid materials) implies higher viscosity.
✓ Viscosity of size paste reduces with the increase of temperature.
✓ If more penetration is desired then viscosity should be lowered and vise versa.

Viscosity of size paste can be measured by Zahn cup. It is a stainless steel cup with
a small hole at the centre of the bottom of the cup.

ii. Squeezing Pressure-

✓ The squeeze pressure forces out the excess paste picked up by the warp sheet.
✓ Besides, the pressure distributes the paste uniformly over the yarn surface and
causes size penetration within the yarn structure.
✓ Higher squeeze pressure reduces the wet pick-up and add-on%

Comparison between high and low pressure squeezing:

Pressure Size coating (film thickness) Size penetration

High. Low. High.

Low. High. Low.

iii. Hardness of Top Squeeze Roller-

✓ The bottom squeezing roller is made up of stainless steel.

✓ The top squeezing roller is having a metallic core part which is covered with
synthetic material.
✓ If the hardness of the top roller is low, then there will be flattening of the roller. Thus
the contact area increases which effectively reduces the pressure acting at the nip
zone. Therefore, the size pick-up increases.
iv. Thickness of Synthetic Rubber on the Top Roller-

If the thickness of synthetic rubber cover on the top roller is greater, then the extent
of flattening is more. This will reduce the nip pressure and thus the wet pick-up will
increase.

v. Position of Immersion Roller-

✓The position of the immersion roller within the size box is adjustable.
✓If the height of immersion roller is lowered then the residence time of the warp
sheet within the size paste increases. This will lead to the increase in wet pick-up if
other factors are constant.

vi. Speed of Sizing-

Speed of sizing also influences the wet pick-up by the warp sheet.
✓Higher speed reduces the residence time of the yarn within the paste which should
reduce the wet pick-up.
✓Higher speed reduces the time of squeezing which should increase the wet pick-
up.
✓ In modern sizing machine, the practical speed can be around 100 m/min or less.
Though machine manufactures claim that the speed can be as high as 150 m/min.

Sizing Faults :

r
Hard sizing:
If the size materials are applied too much, the size becomes hard which causes hard
sizing.

Shinnery:
This defect happened due to the friction between the yarn and drying cylinder.

Sandy warp :
Due to not crushed or grind the size material properly.

Ridge Beam:
This fault occurs due to uneven distribution of yarn in wraith.

Improper drying:
Under drying→Bacteria form→Yarn breakage.
Over drying→Hard sizing

Size dropping:
This defect due to not optimum the viscosity of the size solution.
Gelatinization : Gelatinization means breaking down of inter molecular bonds
between the starch molecules and allowing the hydrogen bonding sites to engage
with more water molecules.

Retrogradation : It is chemical reaction that takes place when amylose and

amylopectin chains, in cooked gelatinized starch, re-align themselves to form a
crystalline structure.

Chemistry of PVA manufacturing :

Polyvinyl alcohol is manufactured by the process of addition polymerization of vinyl

acetate. The resulting vinyl acetate polymer is hydrolyzed under varying conditions of
catalyst, time, and temperature to remove varying amounts of the acetate and replace
them with the hydroxyl groups (—OH). The properties of the PVA are largely governed
by the degree of substitution.

If the PVA is hydrolyzed to the maximum possible extent , then the formation of
hydrogen bonding becomes very intense and thus the strength of the PVA film
becomes very high. Besides, its solubility in water is lower as compared to partially
hydrolyzed PVA. Thus the desizing becomes difficult and higher temperature is
required for desizing. Therefore, this grade (super hydrolyzed) is generally not
preferred for sizing.

Partially hydrolyzed PVA exhibits lower film strength. The presence of a big functional
group in the side chain reduces the strength of the partially hydrolyzed PVA film.
Solubility in water is better for the partially hydrolyzed PVA. In partially hydrolyzed
PVA, the acetate group, due to its bigger size, acts as an obstacle against the close
packing of molecular chain. Therefore, the penetration of water molecule is rather
easy in case of partially hydrolyzed PVA and making the desizing operation easier.
Typical Steps Followed in the Industry to Prepare the Size Paste :

1. Take standard volume (700 litres) of water (normal temperature) into the pre-
mixture through water flow meter, start the stirrer.
2. Properly weigh all the chemicals required.
3. Add modified starch, PVA and then Acrylic binder slowly into the pre-mixture
vessel.
4. Stir the mixture for 15 minutes.
5. Start the stirrer of the cooker, transfer the mixture to the closed cooker from pre-
mixture vessel. Close all the open valves of the cooker.
6. Heat the cooker mixture with the injection of direct steam, steam will auto cut
when the cooker temperature reaches the preset limit (110° C). It takes around 30 to
35 minutes.
7. Cook the mixture for another 40 minutes, the temperature of the cooker will reach
to around 120 to 125° C depending on the size recipe.
8. Start the stirrer of the storage vessel and then transfer the cooked size paste to
the respective storage vessels.
9. Add lubricant with the size paste at storage.
10. Maintain storage temperature at around 80-90° C.
11. Paste is ready to transfer to the sow box of sizing machine.

Prime factors that influences the performance of warp yarn during weaving:

1. Yarn strength
2. Elongation
3. Elastic recovery
4. Abrasion resistance
5. Moisture absorption

#Short note on CMC :

Carboxymethyl cellulose (CMC) sizing has very good adhesion to cellulosic fibers,
but due to the high viscosity, the concentrations used in the industry are limited to
low levels. CMC sizes are combined with PVA or acrylic sizing agents to improve
their performance and desizing characteristics. However, the sizes containing CMC
are very difficult to recycle.
#Short note on Lubricants :

The lubricants help to reduce the friction and abrasion between the adjacent yarns
and between yarns and heddles, dropwires, shuttles, rapiers, or projectiles. The
lubricants also enhance the flexibility of the size film. The lubricants are generally
fats, oils, or waxes.

#Short note on Binder :

A binder is used either to enhance or suppress certain interactions between the size
film and the fiber. The binder materials usually tend to reduce ‘‘skinning’’ in the size
box. Acrylics and polyesters are generally used as binders. Some of these binder
materials, especially acrylics, increase the viscosity of the size bath allowing better
encapsulation of the yarn, which prevents hairiness of yarns from interfering in the
weaving operation.

#Why starch is a useful sizing materials?

Though starch has a high biological oxygen demand, lacks bacterial resistance,
sensitive to over drying and can’t be recovered , it is a useful sizing material.
Because, it is inexpensive, is easily desized, is a renewable resource, has good
adhesion to cellulosic fibers, and can be modified to yield a wide range of size film
properties.

#Uses of Starch except sizing.

- used in paper and food processing industries,

- used in medicinal and adhesive applications,
- used in fermentation of alcoholic beverages,
- used as explosive.

#Benifits of acid modification.

- High solid content

- High weaving efficiency
- Low viscosity
- Controlled penetration
- Easy separation of yarn during leasing