SIZING

1 .PRINCIPLES OF SIZING.

A Sizer cannot change the basic properties of a bad yarn to good sized yarn.
For good weaving efficiency and defect free fabric, basically the yarn has to be good.
But bad sizing can spoil a good yarn

2. BASICS OF SIZING.
Studies have proved that under normal conditions, weaving performance is influenced to the
extend of
60% to 65% by yarn quality, 20% to 25% by preparatory techniques and only 10% to 20 % by
weaving operations.
Ring Spinning has always remained at the forefront both as the most popular spinning process
and as the quality bench mark.
Compact spinning represents a new process using the basic component of ring spinning but
producing a better yarn quality through the compacting of the yarn structure. This is produced
by introducing an intermediate condensing or compacting zone between drafting and yarn for-
mation.
Advantages claimed are
-Tenacity increase by 25%.
.-Hairiness reduction by 30% ( one important feature we achieve in sizing).
.-Elongation increase by 15% to 20%
-Improvement in yarn irregularity.

3. PURPOSE OF SIZING.
To improve the weavebility of yarn by forming a thin size film around the yarn and impart
abrasion resistance to the yarn.
Individual fibres are very delicate and are susceptible to breaks due to friction (fibre to
fibre or fibre to metal} There are also protruding fibres by virtue of being staple fibre and
hampers the weaving by way of ball formation and entanglement. Size coating helps in
safeguarding the fibres being exposed to the onslaught of weaving and helps in cementing
the protruding fibres.
Strength of the yarn is increased in most of the instances by size penetration and absorp-
tion into the yarn. Penetration binds the fibres with each other and absorption makes the
fibres to swell and in turn helps to hold them together.
4. OTHER YARNS.
Open end yarns being bulky has more penetration than ring yarn and hence requires less
pick up for similar construction. At the same time coating on the outside layer has to be
complete as OE contains more protruding fibres due to wrap yarn principle.
Polyester cotton, polyester viscose and 100% polyester spun yarn being more hairy and
bulky requires more outer coating and less penetration. Polyester and polyamide fibres
donot have good affinity to starch and hence calls for the use of exclusive binders.
While using Viscose yarn which by itself has a moisture regain of 14% use of acrylic bind-
ers has to be done with discreet as the later also has high deliquescent properties and
can make the yarn mashy.
Monofilament yarns do not require any size. Problems of static electricity, if persists, can
be overcome by using spin oil.
Starch and gum are not suitable for multi filament yarn. Synthetic sizes such as PVA, Poly
acrylics, partially hydrolysed acetylates are used.
Nylon fibres have very poor moisture regain and also not compatible with starch. Hence,
acrylic copolymer sizes along witn PVA and little softeners are used.

5. REQUIREMENTS OF SIZED YARNS.

Optimum size pick up for the given style.
Optimum size pick up for the given weaving machine.
Uniform size pick up for ends and yarns end to end.
High degree of size encapsulation, a minimum of 80%.
Retention of basic yarn properties to a maximum extent like bulkiness, elongation, flexibil-
ity etc.
Tough, thin and flexible film to withstand weaving stress, minimum shredding of fibres
and size particles.
Uniform moisture content.
No degradation of film during reasonable storage.
Smooth surface and no sticky ends.
No migration of ends.
Uniform tension between yarns.
Increase in tensile strength as an added advantage.
Easy desizing at chemical processing.
Reproducible beam quality.
6. SIZING INGREDIANTS.
6.1 Essential properties.
Uniform viscosity (all ingredients must dissolve and should become homogenous.
Ease of preparation.
Thin film forming property.
 Stability to decomposition.
Adhesiveness to the yarn.
Absence of prolonged tackiness during entire sizing.
Absence of foaming properties.
Absence of prolonged congealing and skimming at application temperature.
Flexibility and fold endurance.
Good tensile strength.
Resistance to abrasion.
Insensibility to over drying.
Ease of desizing.
Compatability with elongation properties with the parent yarn.
6.2 SIZING INGREDIANTS.
6.2.1 Primary ingredients.
Adhesives. Maize starch, Tapioca, corn, TKP, dextrin etc.
Softners Animal tallow, vegetable tallow, ester oil, paraffin
( lubricants ) wax, synthetic tallows, linseed oil etc.
Binders Gum, Gelatine, PVA, CMC, Poly acrylates, resins etc.
6.3.2 Secondary Ingrediants.
Antisceptic Zinc chloride, Phenol, ( to reduce mildew )
Agents.
Anti static agents, To avoid static electricity such as
Weighting French chalk, China clay.
Agents.
Tinting agents. Water soluble colours.
Anti-foaming to subside foaming such as
Agents.

6.3 PROPERTIES OF NATIVE STARCH.

Sr.no. Details Maize Po- Tapi-
tato oca
1. Appearance White White White
pow- pow- pow-
der der der
2. Moisture Content 13% 9.5% 13%
3. PH value of 15% aqueous solu- 4.5- 5.0- 5.0-
tion 7.0 8.0 6.0
4. Starch (on dry basis) 98.0% 98.6% 99.0%
 5. Viscosity in Redwood viscome- 40.0 38.0 50.0
ter in seconds
6. Total ash content 0.50% 0.40% 0.15%
7. Viscosity of 5% solution at 50 500- na na
in cps ( Brookfield viscosity 700

6.4 Types of Starches.

Starch is composed of a mixture of two polymers called amylose and amylopectin of wide mo-
lecular configuration and degree of polymerisation.
In addition to being a major food item, they are extensively used in pharmaceutical industry, in
coating, paper and textile industry.
However, native starch exhibits limited applications due to low shear stress resistance, and low
thermal decomposition, high retrogradation and synarises poor process ability and solubility to
common organic solvents.
Starch modification is aimed at correcting one or more of the above shortcomings which will
enhance its versatility and satisfy consumers demand.
6.5 Modification methods.
Modification of native starches are done by various methods which will be described below in
brief, but are relevant to particular industry and particular application. Popularly known as thin
boiling starches are a part of these modified starches and the modification used to be done by
chemical method.
1. Physical modification.
Heat moisture treatment which is used for pulses starch, is done at restricted mois-
ture level and temperature.
Annealing treatment is a treatment of starch at a temperature below the gelatinisa-
tion temperature.
Retrogradation. When native starch is heated and dissolved in water, the crystalline
structure of amylose and amylopectin molecules is lost and they hydrate to form a
viscous solution. This solution when kept for a long time at a lower temperature, the
molecules of amylose and amylopectin retrograde and rearrange themselves again
to a more crystalline structure to form a more viscous composition. Retrogradation
can expel water from the polymer and this is a process known as syneresis.
Glow discharge plasma treatment .Native starch is highly cross linked by glow dis-
charge plasma without the assistance of conventional chemical agents, thus avoiding
environmental concern.An energy change transfer mechanism is suggested for the
function of plasma Such modified starches find most application in medical field.
Osmotic pressure treatment.
Gelatinisation.
2. Chemical method.
 Etherification or Esterification method. The method primarily includes substitution of
hydrophilic hydroxyl group of starch by hydrophilic functional groups.
This makes the starch cold water soluble, prevents starch gelatinisation. The sodium
salt of the carboxyl methyl starch is used in pharmaceutical industry and also in sizing
and printing industry.
Acid treatment method.
The method for the manufacture of acid thinned starch entails treatment with min-
eral acid at a temperature below gelatinisation for specific period to get desired vis-
cosity.
Oxidation method.
The process involves reacting starch with a specified amount of oxidising reagent un-
der controlled temperature and PH. Oxidation causes depolymerisation which results
in a lower dispersion viscosity and introduces carbonyl groups which retard recrystal-
isation.

3. Enzymatic modification method

This involves exposure of starch suspensions to a number of enzymes primarily to
produce highly functional derivatives.
The application of such derivatives producing resistant starch with reduced glycemic
index and can be used in diabetes and cardio vascular diseases.
Such enzymatically treated starch find abundant use in the pharmaceutical industry.

4. Genetic Modification.
These set of techniques involves transgenic technology that targets the enzymes in-
volved in starch bio synthesis.
Generic modifications can be carried out by the traditional plant breeding techniques
or through bio technology.
6.5 Types of Adhesives.
Adhesives can be divided into 3 broad categories.
Natural starches such as sago, corn, Maize, tapioca, wheat etc. also known as native
starches.
Modified or esterified starches which have been modified to produce lower viscosity
that requires reduced penetration time.
Synthetic sizes (also known as binders) such as polyvinyl alchohal (PVA), acrylic co-
polymers and sodium salt of carboxyl methyl cellulose.
7.0 One shot size.
It is a hybrid, commonly being a combination of a modified or an esterified starch with
PVA, specific type of lubricants, acrylates and few other ingredients The objective is to
avoid mixing errors, reduce preparation time, reduce storage area and period of storage.
However, it is very essential to know the ingredients in greater detail. No single standard
 formula is suitable for different counts. Consistency of the product with respect to the
parameters of the ingredients in the mixings should be quality assured by the supplier
and hence it is better to go with branded suppliers.
8.0. SIZE PREPARATION EQUIPMENT
There are two broad based systems.
8.1 Conventional Batch process
- open cooking kettle. (still in use).
- pressure cookers.( widely used )
- homogeniser ( not in use ).
8.2. Modern continuous preparation.
- dry freed system ( not in use )
- injection cookers. (used for sophisticated process )
A hot melt warp yarn size composition. It is a method of applying,
desizing and disposing of it which essentially eliminates
Atmospheric and water pollution at all stages of the process. The
Size is a blend of ethylene / vinyl acetate co polymer with micro
Crystalline paraffin hydro generated tallow wax. It is applied as a
melt to warp yarn, desized with hot petroleum solvent and the
extracted size and unremoved solvent burnt non-polluting carbon
di -oxide and water.

9.0 HIGH PRESSURE SIZE COOKER.

As per Charles law
P T or P / T is constant.
Where, P is pressure in lbs. per sq. inch and T the temperature in
absolute scale.(-273C).
Thus, as we raise the pressure inside the cooker above the atmospheric
pressure, the temperature increases on a pro rata .This shortens the
cooking time and takes place under controlled condition. However, tempe
-rature beyond 130C is not recommended as the starchy materials tend to get charred and
loose swelling properties. The native starches are also known as Natural co-polymers. Continu-
ing the injection of steam but maintaining the pressure around 22n to 24 lbs. per aq. Inch,
starch molecules explode, absorb moisture and swells and results in the formation of a viscous
solution. As steaming continues, the viscosity keeps increasing after a stage, viscosity becomes
steady and again the viscosity starts dropping and a thinning down takes place.
It is found that optimum cooking is reached when the viscosity raise is stopped and is steady
for a while.
This can be checked by random samples from the sampling cock that is provided for the same.
This procedure may be repeated for different types of size mixings and standard cooking times
for various mixings may be recorded and reproduced whenever needed.
Size viscosity is mentioned in terms of Centipoise. (CP).
Water recommended for size preparation should be treated and having a hardness of not more
than 50 ppm and a neutral PH value.
The graph below illustrates the pattern of viscosity behaviour with continuous supply of steam.

9.1. PIPING LAYOUT

Piping layout should be so designed so that it must be possible to pump from every cooker and
it must also be possible to pump to every sow box and to every storage kettle so that residual
size can be effectively used and minimise effluent losses.
A so called cock-tail kettle which will have admixture of all residual stock can be used for less
critical applications such as the pile beam of a Terry fabrics.
Weekly reconciliation of all starch materials used is a good practice.

10.0 CLASSIFICATION OF SIZING MACHINES.

10.1. Direct Sizing

It is a one step process. It can be beam to beam sizing where number of threads is not a
constraint. For cases where warp density is very high, the warp sheet is separated into 2 or 3
sheets with provision for equal number of sow boxes and dry them separately and beamed. (
as is present now ).
It is a 2 step process involving sizing and assembling. It is also referred to single end sizing.It
can be a 2 stage or 3 stage system (Popularly known as the Tsudokoma and Kawamoto sys-
tems respectively.This system is mostly used for filament yarn sizing.
10.2. Hot Melt Sizing.
There are no sow boxes or drying systems. A rotating heated application roll, located between
the warper creel and the warper applies the molten, 100% active size to the yarn. This is drawn
over grooves on the roll which separates the ends during the size application, has time to pick
up molten size and which then cools off around the yarn before the yarn is wound onto the
warper.
The size in the form of a solid block touching the surface of the roll begins to melt into the
grooves as the heated roll turns and the yarn passes through.
10.3. Winder Sizer.
This is a process in which unsized wound packages are converted into sized wound packages.
This process is the real single end sizing. Yarn from each package goes through a small trough
fitted with immersion roll and squeezing rollers ( in short a mini sowbox) and goes into a hot air
drying chambers where the yarn is dried and wound on to individual package.
Direct Sizing Machine. ( Popular sizing machine )

Various segments of a conventional sizing machine are

Creel section.
Sowbox ( size box ).
Drying section.
Dry splitting section.
Beam winding section.
10.3.1 Creel Section.
Broadly classified into 3 types and they are
Zig Zag creel.
Horizontal creel with individual guide rollers.
Vertical creel with common guide rollers
Magazine creels are spare creels on wheels (anyone of the types mentioned above) and can
be moved into position by the arrangement of the rails. This saves time of creeling fresh set
and improves utilisation particularly for short runs.
The challenge of operating the beams in any type of creel lies in the acceptable solution for
ease of unwimding and at the same time avoid over running of beams. For this, the beam
shafts are run on
-oil lubricated plummer blocks
- Heavy duty double row ball bearings.
- Polyethylene bearings.
The braking systems employed are
- Dead weight slung from ropes or above with springs in place of dead weights.
- Steel clamps with provision for loosening on the shafts on both sides.
- More sophisticated system is the centralized beam tensioning arrangement by pneumatic
system and individual brakes to synchronize with the stopping of the machine. All actions like
machine starting, beam brake releasing and applying uniform minimum tension are all synchro-
nized. The modulation for tension application and braking are inbuilt.
This arrangement no doubt is accurate and effective, but cumbersome and difficult to han-
dle very large beams and high running speeds.
An addition of a compensating roller of just adequate diameter and weight helps taking
away the slackness and this placed just before the entry guide roll in the sow box.
10.3.2. Positive Feed System.
Prior to the introduction of this system, yarn sheets from back beams were used to be
drawn by the size roller and squeeze roller through a nip contact which is prone to high slip-
page .Positive feed device consists of a large rubberised roll of 12 diameter in conjunction
with a nip roller of 3 diameter (chromium plated ) which helps in atleast 80% of yarn overlap
on rubber roll and are driven by a stretch control device. The above mechanism helps in a slip-
page free feeding of yarn sheet to sizing rollers.
10.3.3. Size box or Sow box
Modern Sow boxes are fabricated from high quality stainless steel (grade 314)
Provisions are made for both direct and indirect heating.
There are sow boxes with
- single dip-single nip.
- single dip-double nip
- double-double nip.
Care of rollers is very important
-The s.s.size rolls should be smooth with no burrs or cuts.
-the squeeze rolls with rubber coating should have shore hardness of about 80A, uniform
throughout and without burrs or cuts. It is recommended to periodically grind, polish and
buff the roller.

It has been demonstrated that by a 6 fold increase in squeezing intensity and a 75% higher
size concentration, the wet pick up can be almost halved, ensure identical size pick up and
result in economy of thermal energy and other associated costs.
For the above
- The cooking storage kettle and the sow box must be able to handle the high viscosity
( 200 to 240cp ).
- Homogenuity of the size must be maintained throughout.
 - Sow box has to be of robust construction to withstand higher loading of rollers.
- Squeeze rollers are loaded up to 8000 kgs. on a 190 cms face width meaning, a 42
kgs. linear loading per cm. They are coated with nitrile rubber on a specially designed
steel roller called The undeflatable roller that are heavy duty to withstand such
pressure

Diagram

10.3.4 DRYING Section.

The thermal performance of a drying system is the ratio between

100.

The thermal performance will vary with the drying parameters of the warp ends / unit width,
yarn dernsity, size wet pickup and concentration.
1. Drying system. ,
a. The earliest was the Slasher sizing machine with 2 cylinders of 9ft. and 6ft. The heat trans-
fer was very low due to
- Limitation on steam inlet pressure. The rapturing load on the cylinder material per
unit width is represented by the formula Pa / 2t, where, P is pressure, d is the diame-
ter of the cylinder and t is the thickness of cylinder. Thus,to inject a pressure of 5.5
kgs. Per sq.in. which is possible in smaller cylinders of 30 or 32 , needs atleast 3
times the present thickness which makes the proposal unworkable due to
Very high cost,
More power requirement to run
Higher movement of inertia and hence higher initial torque and higher retarding
While stopping.
Removal of cylinders becomes a very difficult and cumbersome process.
Additional evacuation system required for cleaning the trapped vapour around
The cylinders
Removal of water condensate is difficult and may lead to malfunction.
b. Hot air chamber drying system.
It was introduced later on the principle of stenter, but had many short comings such as
- The heat transfer factor is very low at around 45 % compared to cylinder heating
wfere we can achieve up to 70%. -
- Maintaining optimum vapour ( optimising between heat and the moisture in the va-
pour) requires a very costly and sophisticated moisture monitor and controller unit
to be installed and this will automatically operate the opening and closing of the
damper.
 - Many guide rollers inside the chamber will have to be precisely fixed to be all parallel
both horizontally and vertically.
- Due to air passage, the sheet of yarn tend to get fluttered and sometime rolling and
crossing of ends take place.
c. Modern multi cylinder drying system.
They have now comr to stay. Lots of improvements have taken place which are dealt in
greater detail later.

v- is drying speed,
E- total warp ends.
S- size % age applied.
Ne- Warp linear density.
C- Sow box concentration %age.
Rc Moisture regain.
Rw- moisture content of the yarn in weavers beam
P- Drying performance in kgs. Of water evaporation per minute.
L- Length in meters of 100 kgs. Of over dry unsized yarn.
Weight of wet yarn corresponding to100 lbs.
of oven dry yarn. _ 100+Rc+100xS/C _ kgs.
Weight of dried size warp. _ ( 100 + C )x ( 1+Rw)/100. _ kgs
P = V/L ( 100+Rc+100S/C) ( 100+S ) x 1+Rw/100) _kgs.
Weight of 1 yard of warp sheet. _ E/840xNe _lbs.
Length of 100 lbs. in yds. _ ( 840 x 100 x Ne)E. yds.
100
Therefore P = 84103 (100 + + ) (100 + )(1 + 100) _kgs

If the moisture regain in the sized warp is the same as that in the back beam then,
100
P = 84103 ( - 1.08)

Example.
E= 6000; Ne = 12s; size% = 12.5%; box conc.= 10%; V = 55meters / mt. then

55 6000 12.5 10 0
P =( )( 1.08) = 36.5 lbs.
84 1000 12 10
This is the evaporation rate at 100% machine efficiency. i.e. 36.5 x 60 or 2190 lbs.
This with a specific steam requirement of 1.6 lbs. to 1lb. would require 3500 lbs.of steam
per hour.
Cylinder of the type and design have evaporation rate of 200lbs./ can /petr hour.
Thus a 11 can set would be required for the high drying load.
 For filament yarn warp sizing, normally, an air injection is provided to purge the excess
steam from the cylinders.

Heat Energy Economy systems.

Exhaust air from boiler and radiated heat from cylinders are trapped, guided into a heat
exchanger. This resultant fresh hot air is circulated between the cylinders.
Foam sizing technique can reduce the wet pick up by half or more. However, commercial
viability is in ultra filteration technique which enable the expensive foaming agents to be
recycled.
Hot melt systems such as wax application have been found very successful in totally avoid-
ing the drying process and also ensure freedom from hairiness. But it has very few areas
of application.
Carefully designed exhaust hoods or canopy for sizing machine ie sow box and drying cyl-
inders is very essential and can further add to the thermal economy. Apart from this,
steam vapour from the drying cylinders will rise to the roof and can cause corrosion to the
steel structures-beams and purlins.
Hot air drying chambers are covered and the vapour passes through a pipe open to at-
mosphere fitted in every chamber. However, the heaet transfer efficiency is only about
45% in hot air drying systems compared to about 70% in cylinder drying. Drying of one
side of the yarn is overcome by yarn both sides coming in contact with the hot surfaces of
multiple cylinders employed. The design of the hood requires care such as
The extracted volume by the extractor fan should be such as to maintain a certain mini-
mum air of the hood velocity at the edges , as, otherwise, vapour will escape into the
room.
Side extraction is preferable to axial extraction.
Angle of repose of the hood is normally maintained around 35 to avoid water droplets
and vapour condensate to run down the sides.
Hood gutters must be correctly graded.
Hood can be erected on rails so as to facilitate lifting the cylinders when needed by push-
ing the hood to the creel section.
It is preferable to use positive exhaust system extended for the sow box also instead of a
natural extract system.

10A.3.5 The Splitting Table

 First splitting rod is the bursting rod that individualizes the yarn sheet.
It is the kocation where the correct crackling temperature required can be assessed.
The length of the table is based on the warper working width and the minimum and
maximum width between flanges of the weavers beams to be produced. The conver-
gence or the divergence of the extreme selvedge yarn from either of the edges of the
warp sheet to the corresponding weaver beam flanges should not be more than 7 or
0.123 radians and this aspect becomes the design factor of the length of the splitting
table.

diagram

10.3.6 The Head Stock

It is similar to a warping machine head stock. It has additional provisions such as

-A facility to apply a predetermined tension.
-Provision of a draw roller to pull the yarn sheet and deliver to weavers beam.
-An expanding wrath or a swing reed that position the yarn between flange to flange.
10.3.4. Stretch Control
During sizing, the yarn remains under tension. The tension makes the yarn to loose some elon-
gation properties. We call this tension as Stretch on the sizing machibe. The latest concept is
to have Zero stretch. Following are the five stretch zone.
Creel Zone. Warping beams.
Wet Zone. Sow box.
Drying Zone. Drying cylinders.
Splitting Zone. Lease rods.
Head Stock Zone. Drag roller and sized beam.

10.3.5 Drive systems.

This system has also achieved lot of improvement and sophistication.
Two zone D.C. drive system where one motor drives the weavers beam while the other
which is the main motor and which drives all other units through proper tappings on a
side shaft.
A single drive system which uses power converter to convert A .C. to D.C. current and this
drives the entire slasher through mechanical transmission.
 Muti motor drives which reduces the load on stretch control devices as a media for me-
chanical transmission directly through motors and synchronized by means of dimmerstat.
Digital drive or a micro processor controlled system for various components of the ma-
chine.
To achieve a constant tension of the weavers beam, a constant power input is necessary.
When the machine stops, there is a tendancy for counter rotate. To prevent this a small
trickle current is allows to reach the motor winding, which is enough to prevent counter
rotation.

10,3.6 Machine Controls.

Size box controls.

-Size level control.
-Sow box temperature control.
-Squeeze roll pressure control.
-Size viscosity control.

Moisture Control
The moisture content in the sized and dried yarn sheets passing over the sensor rollers
placed after the drying zone is being monitored at many places across the width. The
weighted average of these readings which are quickly computed is compared with the set
data. The difference in the readings if any trigger the machine to run slower or faster as
required through the assistance of a Tacho Generator.

Stretch Control
Types of stretch control devices ( their merits and demerits ).
a. P.I.V. Variator.
PIV variators are 100% slippage free variators but failure rates are high as the plates in
the linking system can get elongated quickly even though they are immersed in oil bath
all the time. Hence, they are not commonly used.
b. Reeves Variator.
Reeves variators uses wooden blocks with leather contacts surface. This leads to slip-
page and constant wear leading to less or no control on tension variations over a period
of time.
c. Tension Regulator.
Tension Regulators employ differential motion principle and a pair of driver / driven
cones to make infinitely minute variations. Here, again, the belt slippage on the cones
results in not a totally foolproof system of a stretch control device/
d. Micro-step Variator.
 The micro step variator is also a positive driver / driven speed variators but with a dif-
ference that it is not stepless. It is highly human oriented and hence prone to human
errors.
e. Multiple point drive.
Multiple point drive employ multiple motors at the various stretch control zones and
through a microprocessor synchronizes the various speeds as per the predetermined
ratio. This system is no doubt the best but very capital intensive and also consumed lot
of energy.

However, Stretch indicators, monitors and controllers must always consider the elonga-
tion and slippage phenomenon of the yarn sheet and incorporate the above factors af-
ter reasonable assessment before evolving realistic stretch ratios.

Cylinder Temperature Control.

According to the zonal division, the cylinders in each zone are supplied with steam at
varying desired pressure to maintain the corresponding temperature depending on the
skin heat transfer, the wet pick up at back stage and the extend of drying needed
The cylinder temperature control is augumented by a bi-metal thermal system with the
help of pyrometer probe.
11.0 Common defects that may creep in during sizing process.

Higher elongation losses.

Emphasis on stretch control and preserving the elongation properties of the yarn is very
essential.Wet stretch is more sensitive than dry stretch that can leave a permanent loss of
elongation.
Poor sizing or uneven sizing.
This phenomenan can occur along the length and breadth of the yarn sheet due to not
maintaining the sow box level control rigourously and no planned or programmed size
pressure applied on the squeeze rollers at full speed and at crawl speed.
Uneven drying of yarn sheet.
Not to increase the skin heat temperature of 101C for the cylinder.
Use of 3 kgs./sq. cm .steam pressure to allow forcible entry into the cylinder.
Proper and sensitive steam relay valve to maintain uniform temperature of cylinder.
Cylinder temperature indicators may be fixed to help in controlling the cylinder tempera-
tures manually.
Syphon system should work effectively.
Uniform surface properties and uniform Teflon coating of few cylinders are very essential.
Missing ends.
Occurs due to lappers on the warping beam, sow box rollers and sometimes on cylinders.
Migration.
 This occurs in dry splitting area due to improper drying or rolling of ends due to slackness
and tightness .
Crossed ends.
Due to slackness and tightness of the yarn sheet.
Sticky ends.
Due to lumps in size solution.
Patchy size on contact surfaces.
Due to rolling of ends and migration.

12.0 Total Slasher Control.

This is about the computer controlled slasher sizing machine. There are about 5 essential
Elements.
Computer module with a microprocessor card, a memory card and the input/output card.
Trandsducers measure each variable of interest and provide the computer with the appro-
priate electronic signals.
Output tranducers, then convert the electrical output of the computer into a mechanical
movement such as opening or closing a valve or switching a motor.
A keyboard provides the means of inserting the probramme into the computer.
A printer to print out the actual response to the programme for monitoring purpuses.

The computer slasher control automatically fixes

-Pneumatic creel loading for creel tension.
-temperature of size in sow box.
-Size level control.
-Squeeze roll loading.
-Squeeze roll / cylinder draft for stretch control.
-Speed of the drying cylinder in relation to drag roll.
-Temperature of drying cylinders.
-Moisture control of sized yarn.
-Beaming tension. ie tension between beam and drag roll.
-Beam presser roll loading.

The demand made by modern weaving machines cannot be completely satisfied by super-
vision, no matter how skilled and conscious the operative..
The signals to all the above built in mechanism in the computer is given by various sensors
located in the machine.
The non contact type of sensor monitors the wet pick up and size concentration. Thus the
size add on is naturally controlled size add on%
 %
Size add on % = 100
Higher viscosity means more encapsulation and low penetration. Similarly for a given con-
centration encapsulation is more at higher speeds than lower speeds or crawl speed. The
system fully controls the add on at crawl speed as well. It is claimed that there is an effi-
ciency increase of 2-5%.
The sensor after wet splitting automatically regulates squeeze roller pressure, chech hard-
ness and applies uniform squeezing across the width.It is monitored by piezo-electric sen-
sors.
Online yarn hairiness sensors are used for all unsized yarn and after sizing at leasing sec-
tion. The encapsulation has to be maximumat certain size add on only.
Sensors after first drier checks the residual moisture and corrects the cylinder tempera-
ture and also manipulating the speed.
Various parts of the machine are run by servo motors. The speeds are monitored and con-
trolled by programmable micro processor due to ehich of strtch below 1% is possible for
cotton, 1.5% for p/c and p/v yarns.

13. Single End Sizing.

Unless absolutely necessary, it is better not to size the yarn. Sizing in legitimate cases, im-
proves the performance in weaving but while doing so introduces lot of defects besides it
also additional process, additional inventory and additional cost and lastly involves tedi-
ous effluent treatment operations.
Infact, a Japanese manufacturer, when the necessity arose for sizing, developed a ma-
chine with integral number of heads, each head having
-a bobbin/ package holder fitted with tensioning system etc.
-a mono sow box with controls,
-a hot air drying chamber,
-individual yarn winding machine.
While, the attempt was to give fault free sized yarn without having to do anything with
adjacent yarns, he could not take off as the process was very slow and economically unvi-
able.
Single end sizing is a via media between the conventional saizing to the type of process
mentioned above.
Single end sizing as developed by Tsuedakoma of Japan, is a 2 stage approach. The process
involves warping and sizing in one process and assembly of these beams as aseparate pro-
cess.
In Kawamoto type, the processes involved are 3 stages. Warping followed by sizing and
finally assembling are done separately.
These systems were originally drveloped for sizing fine synthetic filament yarn of very fine
denier multi-filament, flat,intermingled filament with low twist as they have to handled
 carefully. Even the size receipe is of synthetic base having compatibility with the filament
yarn.

14. Finer Aspects of Sizing.

At creel tension and brakes should be minimum and stretch applied should between 0.4%
to 0.8%.
Alignment of beams should control crossing.
At sow box, uniformity of viscosity, temperature, concentration and circulation of size
yarn are essential.
2 sow boxes with double squeezing, dry nip feeding, uniform and soft squeezeing, wet
splitting etc. are to be juditiously selected.
Yarn sheet has to be pre-dried so that they do not stick when they join again as one sheet.
Sheet density has considerab;e effect on pick up. Sheet density very often prevent size so-
lution from penetration in the space between 2 adjacent threads and may lead to poor
encapsulation. Hence, it is recommended that conditions are close to those achieved in
single end sizing.Thus, mathematically
-N= 0.5% x W/D for cotton.
-N= 0.4% x W/D for polyester cotton,
-N= 0.25% x W/D for filament yarn
Where N = Number of ends.,
W = Effective of sow box in m.m.
D = Diameter of yarn in m.m.
Having coated the yarn,it is essential to quickly achievethe point of tackiness in the sized
yarn so as to avoid a inter yarn co-hesion.This is achieved by pre-drying and then resort to
final drying. Half the sheet is separated andpassed over one set of pre-drying cylinders
and the other half through another set of pre-drying cylinders before they pass through
finisher dryers.
Some sizers adopt splitting the sheet after the sowbox and before the first cylinder. It is
proved that split drying is more effective than split immersion. Best results are achieved
by adopting both as in the case of Syncro-4.
Comparison of some properties of some native starch film

Sr.no. Size film Tensile strength Elongation

Kgs. / 2 %age
1. Wheat starch 40-50 10-20.
2. Corn 50-60 10-20
3. Cmc 30-40. 10-20.
4. Acrylic size 10-20
5. PVA FULLY 420-450
Hydrolysed
6. PVA partially 370-400
Hydrolysed
Adhesion Strength of cotton and polyester.

Sr.no. Adhesives Adhesion to pol- Adhesion to

yester k.pascal cotton k.pascal
1. PVA 10 4.9
2. Polyacrylate 8 3.6
3. C.M.C 4 3.9
4. Starch 3 3.6

Adhesion Strength ( gms. / m.m )

Sr.no. Yarn C.M.C PV partially

hydrolised
1. Acetate 0.5 10.0
2. Nylon 6 2.0 11.0
3. Acrylic 1.5 9.0
4. Polyester 0.5 7.0

Strength, Elongation and Viscosity of some common modified Starches.

Sr.no. Modified starches. Strength Elongation Viscosity

Kgs. / 2 %age In dl/ g
1. Corn unmodified 4.67 3.20 1.73
2. Acid modified 4.94 2.70 0.88

3. Chlorine modified 4.50 2.30 0.25

4. Hydroxy ethylaate 4.74 2.50 1.66
5. Enzyme activated 4.18 2.60 0.38

Properties at Gelatinisation of native starch.

Sr.no. Name of starch Gelatinisation Strength extension

temp. in C Kgs/ 2
1. Potato 65 -68 414 4.2%
2. Tapioca 70 -74 na Na
3. Sago 72 -74 400 2.6%
4. Maize / corn 75 -77 468 4.0%
 5. Rice 80 -83 na Na
6. Wheat 80 -82 na Na

Steam Pressure and Temperature relations.

Sr.no. Steam pressure Steam pressure Temperature

Kgs. Per 2 Lbs. per sq.inch. C
1. 0.0 0.0 100
2. 0.5 7.0 111
3. 1.0 14.0 120
4. 2.0 28.0 134
5. 3.0 42.0 143
6. 3.5 49.0 147

Steam Pipe Capacity.

Steam pipe diameter in mm.
Sr.no Steam pressure 25 40 50 85 100
Kgs./2 Kgs.hr Kgs./hr Kgs./hr Kgs./hr Kgs./hr
1. 3.0 150 385 605 1545 2415
2. 4.0 185 470 735 1885 2945

SIZING CALCULATIONS.

Sr.no Details Unit Calculations

1. Size add on %age
Sn = x100, where,

( nominal ) Ws = Weight of sized yarn
Wu = Weight of unsized yarn
Sn = Size add on
Correction factors to Wsc = weight of sized yarn minus moisture
be applied. regain of 5%.
Wuc = Weight of unsized yarn minus mois-
ture regain of 7.5 %
2. Size add on %age 0.95 0.925
Snc = x 100
( corrected ) 0.925
3. Stretch %age
Strtetch = 100., where,

 Lf is actual measure of yarn delivered for
sizing.
Ld is actual measure of yarn delivered after
sizing.
4. Invisible or Dead Loss %age
Dead Loss = 100, where

Au is the amount of sizing materials used
minus the moisture content.
Aa is the amount of actual size add-on.
5. Weight of unsized Grams per 0.59 ., where,

warp neter n = total number of ends.
C = count of yarn in Ne.

6. Weight of Sized warp Grams per 0.59 ,where,

meter. N = total number
C = count in Ne
S = size add on %age.
7. .Length of yarn in Meters W = weight of sized yarn in kgs.
sized beam. S = size add on (say 10% )
D = beam outer dia. with yarn.( say 0.8m)
d = beam barrel dia. ( say 0.15m)
h = distance between flanges (say 1.80 m)
n = number of ends in the beam. (say
4000)
C = yarn count in Ne ( say 30s)
8. Volume of sized yarn Cubic T= tightness factor of beam. ( say 0.50)
in the beam neters 22
( 4 )
Weight of yarn in the Kgs. 22
beam 4 hT 1000.
Kgs.
= 393 x( 2 - 2 )
Weight of unsized Kgs.
yarn per meter. 0.00059 /C.
Total cumulative Meters
length in the beam 666 x 103 x ( 2 - 2 )x h x C.

9. Length of warp on Meters

the beam 666 103 ( 2 2)
.

Worked out example Meters 666 1000 0.6175 1.8 30

4000.
 = 5552 meters.
10. Steam Consumption

Sizing machine dur- Kgs.

ing operation. 2.00. Per kg. of yarn sized
Sow box. Kgs. (100% moisture pick up)
Cooker. Kgs. 0.20. per kg. of yarn sized.
0.30. per kg. of yarn sized.
Total average steam Kgs.
consumption.. 2.50. per kg. of yarn sized.

Best spread of yarn in sowbox. ( cotton ).

Sow box width in number of ends
Inches. ( count )
54 750 x
60 840 x
63 880 x
72 1000 x
84 1180 x

Dry dividing field length. 5 x difference in working widths of warper and weavers beam.
( the convergence or divergence from the warping width to the
Weavers beam of the selvedge ends should not be more than
6 to 7 ).

11.22
Machine speed where, S = steam available in kgs. / hour.

Calculation C = count Ne.

N = number of ends.
Time value of detention.( in minutes).
Set change.