SIZING

Size:
A gelatinous film forming substance in solution or
weaving is called size.
Sizing:
Sizing is the process of applying a protective
adhesive coating on the surface of the yarn, so that
the warp yarn can withstand against the weaving
forces. This is the most important operation to attain
maximum weaving efficiency especially for blended
and filaments yarn.
Dressing:
The process of jute yarn sizing is called dressing.
 Objective of sizing
1. To improve the weave ability of warp yarn by
making it more resistant in action of weaving.
2. To maintain good fabric quality by reducing
hairiness, weakness & by increasing smoothness of
yarn.
3. To improve the tensile or breaking strength of
cellulosic yarns.
4. To increase the stiffness.
5. To increase the weight of yarn.
 Types of sizing
1. Pure sizing: This types of sizing is done for unbleached
fabric. 3-10% 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.
 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 implies loom efficiency.
 Sizing weaving curve
At very low level of size add-on, the yarn is not
adequately covered by the size film and therefore the
yarn is not protected from the abrasion with various
loom parts. So, 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.
The optimum add-on level is marked by very low level
of warp breakage rate. 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.
 Sizing and weaving performance
Weaving performance primarily depends on optimum level of
size add on.The optimum level of size add-on will depend on the
following factors:
· Type of fibre
· Type of size materials
· Yarn spinning technology
· Yarn count and twist
· Level of hairiness in the yarn
· Loom type and loom speed
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 and (b) Size coating or encapsulation. This
can be explained from the Figure
 Sizing and weaving performance

Figure: Size coating or encapsulation, size penetration and optimum coating and
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 in adequate. This may tackle the hairiness
problem. However, the adhesion of the size film with the yarn will be lower. The
size coating will also be very stiff. Therefore, during the abrasion with various
machine parts and neighboring yarns, the size will fall (shed) and thus the weaving
performance will be poor. In the second case, the coating or encapsulation 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.
Size ingredients & their function
1. Adhesive: Generally starch of maize, corn, rice,
potato & CMC, PVA, PVC are used as adhesive.
Function:
a) To improve strength.
b) To improve abrasion resistance.
c) To increase extensibility.
2. Lubricant or Softener: Mineral oil, linseed oil,
coconut oil, vegetable oil, tallow, japan wax,
vegetable wax are used as a lubricant.
Function:
a) To make the yarn soft & slippery.
b) To reduce stiffness.
3. Antiseptic or Anti mildew agent: Salicylic acid, Zinc
chloride, phenol carboxylic acid are used as antiseptic
agent.
Function:
a) It helps to store the yarn without damage.
b) Protect yarn from bacteria or fungus
formation.
4. Deliquescent or Hygroscopic Agent: Glycerin, calcium
chloride, are used as deliquescent agent.
Function:
a) Prevent brittleness of size.
b) Helps to keep standard moisture regain.
5. Weighting agent: China clay, French chalk, sodium
phosphate are used as weighting agent.
Function:
a) Increase weight of yarn.
6. Wetting agent: Magnesium chloride, avirol,
sulphanol A are used as wetting agent.
Function:
a) Helps to wet yarn instantly.
7. Tinting agent: Blue, Ultra-marine blue is used as
tinting agent.
Function:
a)To increase lusture or brightness.

8. Antifoaming agent: Benzene, pyridine are used as

antifoaming agent.
Function:
a)To prevent foam formation.
 Technological change due to Sizing:
• Breaking strength-increase
• Abrasion resistance- improve
• Stiffness-increase
• Elongation-decrease
• Electrostatic property-decrease
• Hairiness-decrease
• Yarn diameter-increase
• Absorbency-decrease
• Flexibility-decrease
 TYPICAL RECIPE OF SIZING
Carded cotton yarn
• Modified Starch : 10.5 % on the weight of water
• PVA : 2.86 %
• Acrylic binder (liquid) : 6.6 %
• Lubricant : 0.7 %.
• Paste viscosity: 6.5±0.2 second, Solid content: 12-13%
•
Combed cotton yarn
• Modified Starch : 12.5 % on the weight of water
• PVA : 3.0 %
• Acrylic binder (liquid) : 6.91 %
• Lubricant : 0.87 %.
• Paste viscosity: 6.4±0.2 second, Solid: 12%
•
Polyester-cotton blended yarn
• Modified Starch : 13 % on the weight of water
• PVA : 3.6 %
• Acrylic binder (liquid) : 8.4 %
• Lubricant : 0.87 %.
• Antistatic : 0.5 kg
• Paste viscosity: 7±0.2 second, Solid:
•
 Choice of Size ingredient
1.It should give least amount of exfoliation.
2. It should permits easy desizing when required.
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).
9. It should give fewest end breakage in weaving.
Size cooking equipment's:
1. Motor.
2. Agitator: Size ingredients are mixed with the help of
agitator in mixing tank.
3. Mixing tank: here size ingredients are mixed.
4. Pump: After mixing, size mixer transfer to the
storage tank by pump.
5. Storage tank: Size mixer are store in storage tank.
Size Cooking:
1. Ordinary cooking.
2. Pressure cooking.
Ordinary cooking: Pressure Cooking:
▪ Add required amount of • Add required amount of
water.
water. • Add required antiseptic
▪ Add required antiseptic with stirring.
with stirring. • Gradually add starch and
▪ Gradually add starch and stir for 30-45 min.
• Start steaming and raise
stir for 30-45 min. temperature up to 130⁰C.
▪ Continue steaming until • Add softener.
correct viscosity is • Continue steaming until
obtained. correct viscosity is obtain.
• Stop steaming.
▪ Stop steaming. • Adjust PH between 6-8
▪ Adjust PH between 6-8 by adding acid or alkali.
adding acid or alkali. • Transfer the size solution
▪ Transfer the size solution to the reserve tank and
maintain temperature at
to the reserve tank and 60⁰C.
maintain temperature at
60⁰C.
 Techniques of Sizing
* Conventional Slasher sizing
* Hot melt sizing
* High pressure sizing
* Foam sizing
* Solvent sizing
* Electrostatic sizing
* Polymer emulsion sizing
* Combined sizing
 Conventional slasher sizing
This is the most used sizing machine for large scale
production. The first sizing machine was built in 1803
in England. The major parts of the slasher are the
creel, size box, drying units, beaming and various
control devices. About all types of yarns can be sized
by slazer sizing machine. In this sizing machine the
warp is passed through a size liquor bath then through
a separating unit and cooling unit.
A typical evaporation rate in a modern slasher sizing
machine is around 13 kg/hr/m2. The maximum
recommended machine speed is 120 m/min (400
ft/min).
 Slasher sizing process
• Slasher sizing:
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.
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.
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.
 Hot melt sizing
Suitable for high speed weaving e.g. shuttle fewer
looms where there is risk of yarn hairiness. Sizing is
done in the warping machine by having a special
arrangement called size applicator. The size is kept in
cake form where the warp is kept pressed.
 High pressure sizing
During high pressure sizing, a significant amount of
pressure is applied to the warp yarn to facilitate the
penetration of the size solution. As a result of high
pressure sizing, you may notice that it is more
expensive than other sizing techniques. Despite its
faster drying times, high pressure sizing has a smaller
size take up percentage than other sizing techniques.
 Foam sizing
In foam sizing, a foaming agent is added to the size
solution as part of a specialized sizing process. Foam
sizing is used to achieve light shades and enhance the
yarn’s overall quality by securing a rich and stable foam
which is then applied to the warp yarn during the sizing
process. 70% energy is saved and production is
increased.
 Solvent sizing
Textile industries use solvent sizing to strengthen yarns
without using water in an innovative and cost-effective
way. The process utilizes organic solvents instead of
traditional aqueous solutions. This machine has a hood
that protects solvents from evaporating, so there is
little solvent loss here, and solvent can still be used.
Solvent sizing is not just about cost savings, it also has
many other benefits. Eliminating water from the sizing
process reduces moisture content, resulting in
quicker yarn drying times, resulting in more efficient
manufacturing practices
 Electrostatic sizing
An electrostatic sizing technique is an advanced and
costly method of sizing yarn. In this method, the size
solution is applied to the yarn using electrostatic
attraction. Although this innovative approach offers
unique advantages, its implementation requires
specialized equipment and precise control systems,
which increases its cost.
 Polymer emulsion sizing
In the case of emulsion sizing, the size ingredients have
been passed through an emulsion. In this case, the
emulsion is formed by the mixing of oil polymer and
soap to make an emulsion.
Combined sizing
Combined sizing is a specialized technique primarily
employed for sizing denim fabrics. It involves two
distinct steps to achieve the desired fabric properties. A
dyeing process first imparts color to the warp yarn, and
second, a sizing process enhances the strength and
performance of the yarn.
 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: ↓
2. Finer count: ↓
3. Higher concentration:↑
4. Higher viscosity:Down
5. Lower flexibility:Down
6. Higher immersion length: ↑
7. Higher squeeze roller pressure: ↓
8. Higher yarn speed: ↓
9. Higher staple length: ↓
10. Crystalline fibre: ↓
11. Amorphous fibre: ↑
 Drying system
• Cylinder drying:
i)Two cylinder drying.
ii)Multi cylinder drying.
• Hot air drying.
• Infrared drying.
• Combined drying.
 Two Cylinder Drying:
• In this drying process, two copper cylinder are used
in which one cylinder is large diameter and other is
small comparatively.
• Firstly warp sheet is passed below the small cylinder
and then over the bigger one.
• The yarn is dried while traveling through the
circumference of the cylinder.
• Advantages:
• Simple process and cheap.
• Less risky.
• Disadvantages:
• Slow process.
• Drying efficiency is low.
• Irregular drying.
• Due to sticky property of cylinder uneven
drying.
 Multi Cylinder Drying
• In this type of machine the drying unit
consists of 5 to 7 or 11 cylinders having
same diameter are used.
• All cylinders may be steel cylinders or
first two cylinders are Teflon coated
and rest of are steel cylinder
• The cylinders are heated by passing
steam.
• Heat in initial cylinder is low and
gradually increases when moved
towards final cylinder.
• 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.
 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
 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 singally.
• Advantages:
• No shinning effect.
• Drying efficiency high.
• Disadvantages:
• Yarn may burn.
• Higher cost.
• Difficult to maintain uniform heating.
• Risk of accident.
 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
1. EPI: If EPI is more warp sheet density increase and
drying time required more.
2. Count of warp yarn: Higher count, drying quickly.
3. If yarn is coarser, more time required to dry.
4. Twist of warp yarn: Higher twist, lower dry ability.
5. Concentration of liquor: Higher concentration
lower dry ability.
6. Size pick-up%: Higher pick-up% dry ability lower.
7. Speed of running: More speed, lower ability
because of cylinder and yarn contact for the time.
8. System of drying: Hot air drying < cylinder drying.
9. Two cylinders drying < Multi cylinder drying
 Dressing of jute yarn
• Beaming process follows after spool winding. In
beaming operation yarn from spool is wounded over a
beam of proper width and correct number of end to
weave jute cloth.
• To increase the quality of woven cloth and weaving
efficiency, the warp yarns are coated with starch
paste. Adequate moisture is essential in this process.
• Quality characteristic of a beam is width of
beam-number of ends and weight of stand and there
is a continuous passage of yarn through starch
solution from spools to the beam.
• Starch solution in water contains tamerine kernel
powder (TKP), antiseptic-sodium silica fluoride and its
concentration varies with the quality of yarn.
 Sizing of filament yarn
1. In staple yarn, discrete Size ingredients:
fibres are brought together i) Synthetic adhesives – eg.
by the help of twisting. The PVC, PVA, CMC etc.
yarn surface is rough and ii) Plasticizers – are not
uneven. absorbed by the fibres, form
2. In multi filament yarn the film, prevent cracking and
breaking of the film and
component filaments are provide adherence.
arranged in parallel position iii) Others – eg. Antistatics.
except when they are
Cautions in synthetic sizing:
twisted. The yarn surface is
i) Heating for drying.
smooth and even in cross
ii) Splitting for separation.
section. (Individualization of the yarn)
3. The difference in yarn iii) Tension not to stretch.
characteristics necessitate
different approach to sizing.
 Disadvantages of Sizing
• Additional capital investment for the unit.
• Longer process.
• Extra cost of ingredients.
• Extra cost for utilities.
• Extra labour cost.
• Possibility of some sort of deterioration of yarn quality
arising from process handling
• Increase in diameter precludes the accumulation of
more ends/inch.
• Some rough yarn surface.
• Reduction in extension.
• Increase in stiffness.
• Generation of fluff
• More robust loom.
• More power required to run into steam.
• Problem of size removal.
• Risk of uneven shed.
• Extra cost for sizing.
• Additional information about ingredients
before desizing.
• Pollution of environment.
• Possibility of color fading of dyed warp.
• Possibility of chemical changes.
 Attempts which have been tried to substitute sizing
• Use of high quality warp yarn:
The yarn which is made from longer staple & uniform staple
length may used for weaving at low speed. We may use
combed yarn.
• Use of wrapped yarn:
It is as like as core spun yarn. By using this type of yarn
weaving is possible without sizing
• Use of twisted yarn:
Twist gives certain strength to the yarn. By using this yarn
weaving may done at high speed without sizing. It is one
kind of ply yarn.
• Use of singed yarn:
Singeing may done during warping and it must be dyed
yarn. After dyeing singeing is performed. By this process
hairiness of yarn is removed which is suitable for weaving.
Use of heat setted yarn:
It is performed synthetic and synthetic
natural blended yarn.
Modification of loom mechanism:
By reducing the length of shed weaving
is done without sizing. Suppose the
length of weaving zone is 40" and PPI =
60 the no of sheds to be formed to
produce 1 pick fabric = 60 × 40 = 2400
times. So a high stretch is acted on the
warp of the weaving zone. So if we
reduce this shedding length then this
high strength is reduced and weaving
may done without sizing.
If Weaving length= 30” & PPI= 60 then
the no of sheds to be formed to
produce 1 pick fabric = 60 × 30 = 1800
times.
The approximate modification of looms
is given below:
 Faults of sizing
A Broken, Missing, Crossed and Sticky Ends:
Among the most frequent causes of all these faults of sizing are breaks during sizing,
accumulating layers of yarn on the warper’s beams, and missing ends, such as the total number
of ends in the back beams and some that are missed during the actual warping process. During
sizing, crossed ends are formed, which means the warp ends are not present in their proper
place on the beam. Therefore, knotting one end to the other end is possible. When size
ingredients are improperly cooked, sticky ends form.
Remedy:
• Missing ends should be reconnected to the back beams.
• Make sure the warp ends are positioned properly, minimizing the need for knots.
• Using revolving lease rods, reduce stickiness after drying.

Defective Selvedge:
• The selvage ends in a weaver’s beam can cause difficulty when it comes to undoing the ends
during the weaving process due to their unevenness. The selvedges of the sized beams that
have bulged and sunken edges are defective selvedges.
Remedy:
• To control sunken selvedges, set the expandable comb at the headstock correctly.
• Maintain uniform tension by properly adjusting the expandable comb.
• For bulged beams, adjust the beam pressing roller in such a way that it reaches both flanges.
• Contact the flanges with the pressing roller and ensure proper alignment.
 Faults of sizing
Ridges on the Beam:
• The ridges on a beam form when the ends of the beam that fit in one dent of the comb are
not allowed to spread out.
Remedy:
• This defect can be minimized by properly adjusting the dancing roller at the headstock.
• Make sure the dancing roller is aligned and in good condition.

Size Spot:
• In the process of sizing a garment, this fault of sizing can occur as a result of an inadequate
or incorrect addition of the size ingredients into a chemical mixing tank during the sizing
process, resulting in the warp yarn not mixing correctly with the chemicals.
Remedy:
• The chemical mixing tank needs to be filled with the correct amount of size ingredients
gradually and in the correct proportions.
• To ensure the proper mixing of the size chemicals with the warp yarn, you will need to use
appropriate mixing techniques.
• Make sure the mixture is continuously stirred to guarantee a uniform distribution of the
ingredients of different sizes.
.
 Faults of sizing
Shinnery:
• Due to friction between the drying cylinder and the warp yarn during the drying
process, defects are usually produced as a result of the friction.
Remedy:
• To prevent excessive friction between the warp yarn and the cylinder, adjust the
drying temperature.
• To reduce friction and avoid overheating, let the warp yarn dry on the drying
cylinder for an adequate period of time.

Improper Drying:
• This types of faults of sizing may occurs when the warp yarn is subjected to drying
conditions which are either excessive (over-drying) or insufficient (under-drying),
which can lead to two distinct issues: over-drying and under-drying. When yarn is
over dried, it becomes too rigid. If the yarn is under dried, bacteria can grow on it,
potentially resulting in yarn breakage.
Remedy:
• Avoid both over-drying and under-drying by setting the drying parameters to the
recommended levels.
• Ensure that the warp yarn is not exposed to excessive or insufficient drying
temperatures and times.
 Faults of sizing
Size Stitching:
• This type of faults of sizing occurs when the drying process is not perfect after
the sizing process is completed.
Remedy:
• Ensure that the drying parameters (temperature, time, and humidity) are set
correctly for the specific sizing material and yarn type.
• Ensure that the warp yarn receives sufficient time and heat for complete
drying.

Sandy Warp:
• The possibility of this type of fault of sizing occurs when the material being
used for sizing is not properly ground or crushed in order to achieve the
desired consistency in the sizing process.
Remedy:
• Make sure the size material used is high quality and meets the required
standards. Use reputable suppliers.
• To process the material, use well-maintained and suitable grinding and
crushing equipment.
 Faults of sizing
Hard Sizing:
• This fault occurs when too much sizing material is applied to the warp yarn during the
sizing process, resulting in an excessive buildup of size on the yarn fibers during the sizing
process. A sizing recipe with incorrect proportions of sizing ingredients may result in a
large amount of size being applied to the yarn as another cause of this fault.
Remedy:
• Make sure the sizing recipe contains the appropriate amounts of sizing ingredients for the
specific yarn and weaving requirements. Conduct trials and adjustments if necessary.
• Ensure that sizing material is not overapplied and that precise and consistent sizing
techniques are used to achieve the desired sizing level.

Uneven Sizing:
• This Sizing fault can occur when the process of sizing is not performed correctly. Among
these errors are errors in applying size material or inadequate control of drying conditions.
A size liquor’s concentration, which contains sizing ingredients, can affect the process of
sizing. Under-concentration and over-concentration can both cause problems.
Remedy:
• Standardize sizing procedures to ensure consistency and accuracy.
• Size liquor concentration must be adjusted accurately based on the yarn and fabric
specifications.
 Properties of a Good Sizing Material
• Environmentally safe. • Reasonable extensibility.
• Good film former. • Recoverable and reusable
• Reasonable use economics. • Low static propensity.
• Easily removed.
• Penetration of yarn bundle.
• Easily prepared.
• Elasticity.
• Lack of odor.
• Good film flexibility. • No beam blocking.
• Good specific adhesion. • Compatible with other ingredients.
• Good frictional properties. • Good abrasion resistance.
• Transparency. • Neutral pH.
• Bacterial resistance. • Insensitive to high heat.
• Reasonable strength. • Low BOD (Biological oxygen demand).
• Rapid drying.
• Controllable viscosity.
• No re-deposition of size
• Water soluble or water dispersible.
• No effect on drying.
• Good hygroscopic characteristics.
• Uniformity.
• Improves weaving efficiencies.
 Math
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