FINAL PROJECT REPORT OF PROJECT II

Submitted
In The Partial Fulfillment Of
Bachelor Of Technology
Department Of Textile Technology
Govt. College Of Engineering & Textile Technology
Berhampore, Murshidabad
Submitted to: Submitted by:
Mr.Tarit Guha Md Abdul Hamid
Roll No:11101415017
Dept:Textile Technology
Year:4th year(8th sem)
 DECLARATION

I, hereby declare that, this project has been done by me under the supervision of Mr.Tarit
Guha,Department of Textile Technology,Government College Of Engineering And
Textle Technology,Berhampore . I also declare that neither this project nor any part of this
project has been submitted elsewhere for award of any degree or diploma.

Submitted By:
Md Abdul Hamid

Department of Textile Technology

Government College of Engineering
&
Textile Technology,Berhampore

Approved by
Mr.Tarit Guha
Department of Textile Technology,
Government College of Engineering
And
Textile Technology,Berhampore
 ACKNOWLEDGEMENT

First I express my heartiest thanks and gratefulness to almighty God for his divine blessing,
which makes me possible to complete this project successfully.

I fell grateful to and wish my profound indebtedness to my honorable Supervisor Mr. Tarit
Guha Deep Knowledge & keen interest of my supervisor in the field of dyeing influenced me
to carry out this project. His endless patience, scholarly guidance, continual encouragement,
constant and energetic supervision, constructive criticism, valuable advice, reading many
inferior drafts and correcting them at all stage have made it possible to complete this project.
I would like to express my heartiest gratitude to other faculty members and the staffs of
dyeing, for their kind help to finish my project.
 ABSTRACT

This project work mainly focuses on the overall overview of the scenario of sizing practices
conducted in Government College Of Engineering And Textile Technology,Berhampore

The sizing of yarn is absolutely essential to render it weavable. Without sizing the end
breakage rate of warp, particularly in the case of single yarns, is so high that weaving
becomes impossible. The objective of sizing, however, cannot be looked upon as a process
that improves the basic quality of yarn. The fact is that by endowing the yarn with abrasion
resistance, proper sizing bring out the full potential of a yarn to weave. Trials were conducted
to have knowledge on the basis of sizing, it’s preparatory, control over it, outcomes and
performance of weaving which completely depends on sizing. For this study, trials were
conducted in such a way that, making the beam with variables in terms of yarn quality,
materials, stretch applied, moisture content and beam quality etc and then collecting their
breakage rate at loom shed. These studies were conducted for different count and
constructions then the respective results with respective were collected. The project consists
of the chapters regarding the top to bottom of the overall sizing process, materials and
methods, experimental information and the ingenious discussion of the results. There is also a
chapter in this project containing some proposals, which will help the further researchers to
research on those proposals.
Title of The Project: Correlation Between wet pick
up% And add on% in Sizing Process.

.About the Project:

Wet pick up%: This is defined as the amount of size that carried by the warp yarn during
sizing operation and is expressed as percentage of the original weight of the warp yarn. Pick
up % is also known as take up % or simply size %.

Wet pick up can be calculated by this formula :

Wet pick up=(Size paste in liter/Yarn size in kg)*100

Effects of Add on in sizing of yarn: The amount size Add on depends on yarn
structure,sizing recipe,squeezing roller pressure,machine speed.

As the size Add on is increased:

i. The yarn becomes stiffer\

ii .The yarn becomes less extensible.
iii.The yarn becomes more difficult to Weave.

If low Add on:

i.The yarn becomes hairy.
ii.The yarn suffers from lack of strength.
iii.The yarn becomes much difficult to Weave.

We can calculate Add on by this Formula:

Add on: ( Mass of Sized yarn /Mass of unsized yarn)*100

 content:
I. DECLARATION
II. ACKNOWLEDGEMENT
III. ABSTRACT
Iv. About Project

Chapters
1. Introduction………………………………………………………………...……
1.1 Background of the Study………………….………...………………….
1.2Objectives of the Study ………………………………..……………….
1.3 Application aspects of this project……………………………..……....
1.4 Further Scope of the Project…………………………………………....
1.5 Limitation of the project………………………………………………..

2. Theoretical foundation ……………..……………………………………………

2.1 Sizing…………………………………………………………………...
2.2 Objectives of sizing…………………………………………………….
2.3 Description of sizing Process…………………………………………..
2.3.1 Flow Chart of sizing………………………………………….
2.3.2 Process description…………………………………………...
2.3.3 Sizing Machine……………………………………………….
2.3.4 Machine parts………………………………………………...
2.4 Sizing Techniques……………………………………………………...
2.4.1 Conventional aqueous sizing………………………………....
2.4.2 Non-Conventional Sizing………………………………….....
2.5 Sizing calculation……………………………………………………....
2.5.1 Size beam width……………………………………………...
2.5.2 Pick up% …………………………………………………….
2.5.2.1 Direct method……………………………………...
2.5.2.2 Indirect method…………………………………….
2.5.3 Measurement of viscosity…………………………………....
2.5.3.1 Cup method………………………………………...
2.5.3.2 Refractometer……………………………………....
2.6 Some important parameters for the process control of sizing………....
2.6.1 Process control in sizing……………………………………..
2.6.2 Effects of sizing on yarn properties………………………….
2.6.3 Factors on which recipe depends…………………………….
2.6.4 Factors influencing size pick up% …………………………..
2.7 Drying………………………………………………………………….
2.7.1 Different methods of drying…………………………………
 2.7.1.1 Cylinder Drying……………………………………
2.7.1.2 Hot Air Drying……………………………………..
2.7.1.3 Infrared Drying……………………………………
2.7.1.4 Combined Drying………………………………….
2.7.2 Factors influencing drying efficiency………………………..
2.8 Behavior of yarn due to sizing…………………………………………

3. Materials and Methods…………………………………………………………..

3.1 Materials Used………………………………………………………….
3.1.1 Size Materials…………………………………………………
3.1.2 Yarn Used…………………………………………………….
3.1.3 Water Used……………………………………………………
3.2 Methodology……………………………………………………………
3.2.1 Establishment of ideal pick up% ……………………………..
3.2.2 Size cooking procedure……………………………………….
3.2.3 Determination of pick up% by refractometer…………………
3.2.4 Determination of viscosity by viscosity cup………………….

4. Experimental Work…………………… ………….………………………….....

4.1 Experimental Machine Details…………………………………………
4.2 Frequently used size recipe…………………………………………….
4.3 Some other recipe according to their construction…………………….
4.4 Machine settings data according to construction………………………
4.5 Comparative analysis of breakage and elongation…………………….
4.5.1 Breakage Study………………………………………………
4.5.2 Elongation reduction due to sizing…………………………..
4.6 Sizing Faults and their remedies……………………………………….

5. Result and discussion……………………………………….…………………....

5.1 Analysis of size material………………………………………………..
5.2 Analysis of yarn used…………………………………………………...
5.3 Analysis of water used………………………………………………….
5.4 Pick up% analysis………………………………………………………
5.5 Machine settings analysis………………………………………………
5.6 Breakage analysis………………………………………………………
5.7 Elongation Reduction Analysis………………………………………...
5.8 Analysis of sizing faults………………………………………………..
6. Conclusion……………………………………………………..…..……………
1. INTRODUCTION
Textile processes have experienced radical change due to new inventions and the stringent
demands of high-quality products. The past three decades have seen the development of new
fibers, new spinning methods and new weaving techniques as well as the value addition of
existing products and increased productivity of current processes. Modern looms are
operating at very high speeds, thus imposing stringent requirements on the warp that can be
woven efficiently. In the sequence of textile processes, sizing has continued to retain its
importance in the value chain and has proved necessary even with today’s demanding
requirements. Using innovative techniques, the sizing machine and chemical manufacturers
have tried to keep pace with the increased speed of looms.
The subject of sizing is complicated because of the important roles played by interactions
among fiber type, yarn type, sizing chemicals, preparatory weaving processes,
characterization of the performance of sized yarns that can help in predicting the behavior of
warp during weaving, easy size removability after weaving, and environmental pollution.
Prediction of the efficiency of sizing—type of size, amount of size, penetration of size in
different yarn structures, and the mode of different deformations of the sized yarns, in terms
of weaving efficiency has confounded textile scientists and technologists for a long time.

1.1 Background of the study

Effective application of sizing technique totally depends on the experience of the sizing
experts. Because experience is the combination of self realization on the basis of successful
application of methods. The main goal of this study is to make a bridge between the practical
experience and the academic knowledge. It is also the aim of the study to pick up the
experience of the experts and expose the knowledge to the beginners.
During the theoretical study period of our Bachelor Degree in Textile Engineering we
realized that weaving is totally a technology based field in textile engineering and sizing is
the grey matter of weaving. Total weaving performance depends on the successful
accomplishment of sizing. But we found that the sizing sector has not been advanced along
with other section. As a result we are still facing severe problems in the development of
weaving sector. The present scenario of weaving sector of our country is very
underprivileged. There are many reasons behind this problem. The lack of development in
sizing is one of the important reasons of
underprivileged condition of weaving in our country. Basically, scrutinizing the problem
discussed above, we found ourselves curious to choose this project to be accomplished.
1.2 Objectives of the study
Behind every successful invention there must be one or more simple plan or findings. Even a
very little curiosity can make the finest invention of the world possible just like the falling
apple of Newton.
To make our project successfully completed at first we made some findings or objectives just
depending on our curiosity about the project. These are mentioned below:
 To observe the whole sizing process from top to bottom in order to get advanced with
this precise field of weaving.
 To gather knowledge on sizing machineries and sizing ingredients.
 To have knowledge on the size recipe corresponding to the required fabric
construction.
 To know about the application of sizing materials according to the fiber
characteristics.
 To know about the sizing techniques and methods usually practiced in the weaving
mills of our country.
 To observe the pickup% according to the construction.
 To observe the appearance, quality and other properties before and after sizing.
 To observe the loom performance and breakage% after sizing.
 To observe the faults occurred during sizing and during weaving due to improper
sizing.
 To observe the extensibility of warp yarn due to sizing.
 To observe the tension or stretch applied to the warp yarn during sizing and its impact
on yarn elongation.
 To observe the steam pressure and temperature and its influence on sizing
performance.

1.3 Application aspects of this project

Sizing is the heart of weaving. There have been significant studies on sizing, size materials
and other portion of this process. This project is also an identical one in the field of weaving.
This study combines the knowledge of sizing and makes a bridge between sizing and its
subsequent processes to flourish the field of weaving by finding out some problems, their
solutions and new ideas. Studying the effects of new method of sizing and its consequences
will flourish the field of weaving. This study will be helpful for the size material suppliers,
weaving industries as well as the students and the further researchers, who are intended to
develop this field.

1.4 Further scope of the project:

This project will be very helpful for the students and further researchers to develop further
research and sizing related advanced project work. Taking the project as a guide line,
following further research is possible:
 Proper utilization of raw materials e.g. size ingredients, yarn, water etc. used in sizing
without hampering the performance of weaving.
 Cost and wastage minimization of sizing.
  Development of a modern sizing machine to ensure the optimal weaving performance.
 Time Study and material management in sizing.
 Steam temperature and pressure analysis in sizing and its development to ensure the
optimal utilization.
 Effect of sizing on the fabric construction, weave design and loom performance.
 Effect of sizing on physical and chemical properties of yarn, as well as the desired
fabric.
 Effect of warp preparation on weaving performance.

Beside these chances of possible further researches we found some proposals of further
research work about the development of sizing as well as weaving.
 Development of a sizing machine containing automatic drawing – in and denting
arrangement along with the head of the sizing machine at the front rather than the
unproductive manual procedure, which will ultimately demolish the consumption of
extra time, cost and manpower.
 Sizing is done on warp yarn only to increase the weaving performance, which
ultimately leads to the addition of an extra process called desizing for further
subsequent processes. If sizing operation can be demolished without hampering the
weaving performance, then profitability of the weaving industry will be increased due
to the removal of costly wet processes in weaving. Our proposal in this regard is to
make it happen by developing either a loom or a cotton yarn which will give the same
weaving performance without sizing.

.5 Limitation of the Project:

During the project work I have faced a lot of problems. In absence of those problems this
would be a great paper work. I found problems in gathering the sufficient information about
the relation between the sizing and weaving performance. I also found the sizing technicians
very helpful and experienced, but they were not well conversant with the academic or
theoretical knowledge. As a result I failed to get full access to the sizing and weaving related
information in some extent.
2. THEORETICAL FOUNDATION
2.1 SIZING
Sizing of the warp yarn is essential to reduce breakage of the yarn and thus production stops
on the weaving machine. On the weaving machine, the warp yarns are subjected to several
types of actions i.e. cyclic strain, flexing, abrasion at various loom parts and inter yarn
friction.
With sizing the strength or abrasion resistance of the yarn will improve and the hairiness of
yarn will decrease. The degree of improvement of strength depends on adhesion force
between fiber and size, size penetration as well as encapsulation of yarn. Different types of
water soluble polymers called textile sizing agents/chemicals such as modified starch,
polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC), acrylates are used to protect the
yarn. Also wax is added to reduce the abrasiveness of the warp yarns. The type of yarn
material (e.g. cotton, polyester, linen), the thickness of the yarn, and type of weaving
machinery will determine the sizing recipe.
The sizing liquor is applied on warp yarn with a warp sizing machine. After the weaving
process the fabric is desized (washed).

2.2 OBJECTIVES OF SIZING

Sizing is a process by which films of chemicals are applied over the yarn. The main objective
of sizing is resistance to abrasion and thus to improve the weaving performance. Some
important objectives of sizing are as follows:

 To impart more strength in the yarn.

 To reduce the yarn hairiness that would cause problems in weaving process
 To increase the abrasion resistance of the yarn against other yarns and various
weaving machine elements
 To impart flexibility in the yarn.
 To increase the weaving performance.
 To reduce fluff and fly during the weaving machine process for high speed weaving
machines.

These objectives are achieved by applying a uniform and smooth protective film of suitable
sizing material on the yarn.
We also want that in the sized yarn there should be
- Cyclic warp tension.
- Some increase in tensile strength in the yarn.
- Minimum loss of extensibility in yarn (4.4-4.6% elongation at break is required for cotton).
- Required moisture content (8-10% of cotton).
- Good quality of sized beam (neither too soft nor too firm & free from yarn defects).
- Good productivity and efficiency.
- Reduced Cost.
2.3 DESCRIPTION OF SIZING PROCESS:

2.3.1 Flow chart for sizing:

Size Cooking
↓
Creeling
↓
Yarn Feeding
↓
Sizing (in show box)
↓
Drying
↓
Leasing
↓
Denting
↓
Empty Beam Feeding & M/C Running
↓
Ends Cutting
↓
Doffing

2.3.2 Process Description:

 At first particular amount of water is taken in a tank and add wetting agent to the
water along with other size ingredients. Then mixture is boiled at 120°c temperature
for 45 min. After 20 min native starch is added to the solution and again boiled the
solution .
 After preparing the solution, it is transferred to other tank from which solution passes
to the sizing bath.
 The sizing box is used to apply the size liquor to the yarn. The warp shed is guided
through the solution by means of the immersion roller, and then passed through the
squeeze roller where the yarns are pressed to maintain the desired percentage of size
material on the yarn. The size box temperature is usually maintained by means of
steam pipes and the steam flow is regulated to control the temperature. It is also
necessary to control the level of the solution in the size as well as the concentration of
size.
 From the squeeze roller the yarn moves to the drying cylinder through the guide
roller. There are several drying cylinder. The yarn sheet moves separately being two
parts over these drying cylinders, then the yarn sheet which comes from two separate
beam line meet together and move over rest 4 cylinders. Then lease rods separate the
yarns attachment and finally the yarn wound over weaver’s beam.

2.3.3 Sizing Machine:

Fig - 1: Typical Sizing Machine

 2.3.4 Important Machine Parts

 Warp beam.
 Guide Roller.
 Tension Roller.
 Draw Roller.
 Size box.
 Immersion roller.
 Squeezing roller.
 Small cylinder.
 Big cylinder.
 Ribbed roller.
 Delivery roller.
 Emulsifying unit.
 Lease rod.
 Reed.
 Measuring roller.
 Delivery roller.
 Spreading roller.
 Weavers beam.
 .

2.4 SIZING TECHNIQUES:

Sizing machine can be classified according to the method of drying as follows:
2.4.1 Conventional Aqueous Sizing
 Double Cylinder Sizing: This consists of only two drying cylinder or two sow box
arrangement which leads to more energy consumption.
 Multi Cylinder Sizing: This consists of more than one sow box and several groups of
drying cylinders. This is suitable for densely spaced yarns. Warp yarns are dried
separately by separate drying arrangement. This is also suitable for dyeing and sizing
together resulting in saving of wastes.

Fig - 2: Conventional Sizing Machine

2.5 SIZING CALCULATION

2.5.1 Size beam width:

Size beam width is calculated by the ratio of total ends of the beam to the ends/inch of that order.
𝑇𝑜𝑡𝑎𝑙 𝑒𝑛𝑑𝑠
𝑋= 𝐸𝑛𝑑𝑠/𝑖𝑛𝑐ℎ

2.5.2 Pick up %
This is defined as the amount of size that carried by the warp yarn during sizing operation and is
expressed as percentage of the original weight of the warp yarn. Pick up % is also known as take
up % or simply size %.
There are two methods of calculating pick up% which are described below.
2.5.2.1 Direct Method:
In case of direct method certain amount of sized yarn is taken and then weight and moisture
regain % are recorded. The yarns are then desized using a good desizing method. After that the
yarns are dried to previous moisture regain level and weight is recorded again.

After weighing the size pick-up percentage was calculated by using following formula:

𝐴−𝐵
Size pick-up in % = × 100
𝐵
A = Weight of the sized yarn
B = Weight of the desized yarn
This method of size pick up % calculation is very authentic but needs time and extra arrangement
for desizing and drying where the indirect method does not need anything of these difficulties.

2.5.2.2 Indirect Method

The indirect method of calculating pick up % is very convenient but has the following
drawbacks:
 The weight of empty beam barrel should be correct and should be checked in a regular
basis, wrong information will lead to wrong calculation of the pickup %.
 The moisture regains of the incoming material and outgoing material must be same. If
different then the result must be corrected and must be accounted in the final result.
 Any error in the length measuring motion of the weavers beam will provide wrong
estimation of the pickup %.
 Sometimes extra yarn is wound on the beam at the starting of the new beam; this will
lead to wrong estimation of the pickup %.
 Any stressing of the yarn will also lead to wrong calculation of pickup %.

2.5.3 Measurement of viscosity

2.5.3.1 Cup Method:
There are various types of instruments and methods for measuring viscosity. But in the weaving
mills of our country, they use a viscosity cup, which have a smaller hole at the bottom. Once
filled with the size solution the liquid will drop through the bottom hole. The rate of dropping
through the hole will depend on the viscosity. A high viscous solution will take more time to
drop and vice versa. Anyway the viscosity cup does not provide any numerical values of
viscosity but it only relative increase or decrease of the viscosity. A variation of 15% time
between two reading means that there is signification variation between the two size mixes and
needs to be adjusted or needs to be take actions.
2.5.3.2 Refractometer:
Procedure to testing process-
 1 or 2 drop of sample is put on the prism.
 The daylight plate is closed gently. The sample must spread over the prism surface. Air
bubble should be eliminated.
 The scale is read through the eye-piece. To focus, the eye piece is to be turned in either
direction until it is clear. The reading is taken where the boundary line interacts with the
scale.
 After the reading is read the sample is to be wiped with a wet tissue.
With higher refractor reading lower viscosity of size solution is desired. One disadvantage of
refractor reading is that for colored size paste the reading is less reliable.

2.6 SOME IMPORTANT PARAMETERS FOR THE PROCESS CONTROL OF SIZING:

2.6.1 Process Control in Sizing:

The process control program in sizing should, therefore, comprise of the following aspects:
1. Selecting the correct size recipe and size pick -up level.
2. Ensuring correct ratio of size paste.
3. Control of the followings:
- size pick up
- stretch
-moisture content
-quality of beam
-machine speed
-machine efficiency
-a method to calculate the expected level of productivity

2.6.2 Effects of Sizing on Yarn Properties:

The following properties of yarn are affected by sizing:
 Yarn elasticity decreases.
 Yarn strength increases.
 Hairiness of yarn increases.
 Flexibility of yarn decreases.
 Smoothness of yarn increases.
 Irregularity of yarn decreases.
 Yarn diameter increases.
 Yarn weight increases.
2.6.3 Factor on which recipe depends:
 Composition of yarn
 Yarn count
 Total no. of ends
 Weight of yarn

2.6.4 Factors influencing size pick up%

 Viscosity of size paste in size box: Any variation in the concentration or temperature
alters the viscosity of the paste which in turn affects both the level of size pick up and
extent of penetration. Initially as the viscosity increases, the size pick-up also increases.
But as the viscosity increases beyond a point, the size pick up is reduced.
 Squeezing pressure and condition of squeezing nip: The squeezing pressure determines
the extent of penetration of the size paste between the fibers of the yarn and also of the
removal of excess size paste and hence the level of the size pick up.
 Speed of the sizing machine: Other sizing conditions remaining unchanged, the size pick
up increases with increasing sizing speed and vice versa. This is because the time
available to squeeze the surplus size from the yarn is less at high speeds.
 Depth of immersion roller in size paste: the depth of immersion roller in the paste
determines the duration for which the yarn remains immersed in the paste. This duration
in turn influences both the level of size pick up and the extent of size penetration.
Level of size paste in the size box: Variation in the level of size paste is an important
source of size pick-up variations both within and between beams.
 Density of ends: When the density of ends is high, difficulties are encountered in
obtaining adequate and uniform size penetration. Therefore size pick up may vary at
these fabrics.
 Yarn tension: In case of higher tension during sizing the set of warp yarns encounter a
stretch of comparatively higher tension and thus the set of yarn increases in length. If this
increase is too high then the elongation property of the yarn will be decreased. So the
yarn will face comparatively higher breakage in subsequent processes. On the other hand
lower yarn tension leads to uneven sizing. So the yarn tension must be optimal.
 Yarn twist: In case of high twisted yarn penetration time should be increased in order to
obtain the optimal pick up %.
 Dia. of the yarns: Yarn with greater dia consumes higher size paste. Therefore, the higher
the dia of yarn, the higher the pickup will be added.
2.7 DRYING
Drying is a mass transfer process consisting of the removal of water or another solvent by
evaporation from a solid, semi-solid or liquid. This process is often used as a final production
step before selling or packaging products. In sizing, drying is necessary to bring the sized
material hard.
2.7.1 Different Methods of Drying:

2.7.1.1 Cylinder Drying: In this type of m/c, drying is done by passing over hot cylinders.
a) Two Cylinder Drying:
 In this drying process, two copper cylinder are used in which one cylinder is large
diameter & other is small comparatively.
 Firstly warp sheet is passed below the small cylinder & then over the bigger one.
 The yarn is dried while traveling through the circumstances of the cylinder.

Fig - 4: Diagram of Two Cylinder Drying

Advantages:
1. Simple process & cheap.
2. Less risky.
3. Uniform temperature.
4. Almost uniform drying.

Disadvantages:
1. Slow process.
2. Drying efficiency is low.
3. Irregular drying.
4. Due to sticky property of cylinder uneven drying.

(b) Multi Cylinder Drying:

 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 & rests are of
steel.
 The cylinders are heated by passing steam.
 Heat in initial cylinder is low & gradually increases when moved towards final cylinder.
 If large amount of heat is given to the initial, the sized may be backed.
 If finer yarn is used, then no need to use excess cylinder.
 Fig - 5: Diagram of Multi Cylinder Drying

Advantages:
1. High speed process.
2. Uniform drying.
3. Non- sticky so smooth drying.
4. Drying efficiency high.
5. Less time required.

Disadvantages:
1. For high viscosity, stick properly may observed.
2. For friction, yarn hairiness.
3. Shinning effect.
4. Yarn shape may hamper.
5. Possibility of yarn flatten.

2.7.1.2 Hot Air Drying:

 In this m/c, the drying unit is a closed chamber containing a number of guide rollers
through warp yarn.
 Hot air is 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 & again fall on the yarn.
 Hot air should be continuously passed through the chamber, so the process becomes
somewhat costly.
 Fig – 6: Diagram of Hot Air Drying

Advantages:
1. Regular drying.
2. Not shinning effect.
3. Non-sticky property.
4. High speed drying.

Disadvantages:
1. Costly process.
2. For closed chamber, reqd more time.
3. Less suitable for fine yarn.
4. Difficult to maintain temperature.

2.7.1.3 Infrared Drying:

 In this machine, the heating chamber consists of a plate which is constantly heated by gas
flame.
 The warp sheet is passed over the plate & dried in the process.
 When gas flames are not used, then electronic plate may be used.
 Arrangement should be made to throughout the moisture removed from the yarn. This
m/c is not used signally.

Fig - 7: Diagram of Infrared Drying

Advantages:
1. No shining effect.
2. Drying efficiency high.

Disadvantages:
1. Yarn may burn.
2. Higher cost.
3. Difficult to maintain uniform heating.
4. Risk of accident.

2.7.1.4 Combined Drying:

 In this type of m/c, preheating is done as cylinder drying method.
 And final drying is done by hot air drying method or infrared drying method.

Advantages:
1. Regular drying.
2. Drying efficiency high.
3. Speedy process.

Disadvantages:
1. Shinning effect.
2. High cost.
2.7.2 Factors Influencing Drying Efficiency:
 Speed of the machine: The machine speed or the rotary motion of the drying cylinder
should be precise. Higher or lower speed may lead to improper or excess drying which
will lead to poor performance in the subsequent weaving process.
 No. of ends in warp sheet (Density of warp): Higher drying condition is required in case
of higher no. of warp sheet. The temperature of the drying cylinder should be precisely
higher in case of higher no. of warp yarn.
 Linear Density of warp: In case of finer count drying can be of moderate condition, but in
case of coarser count higher drying condition is required.
 Pick up % to be applied: If higher pick up% is applied then higher drying should be
carried out and vice versa.
 Box Concentration: Higher drying should be carried out in case of higher box
concentration, because higher box concentration leads to higher pick up % which
ultimately leads to greater time, temperature and drying condition.
 Moisture regain of the final beam: If the required moisture regain of the final beam is
lower, lower drying will be applied and vice versa.
 Temperature of the drying cylinder: Optimal temperature of the drying cylinder leads to
precise drying efficiency. In case of lower temperature higher time will be required.
 Area of contact around the cylinder: Higher area of contact around the cylinder ensures
highly efficient drying and also ensures less temperature and time consumption.
2.8 BEHAVIOR OF YARN DUE TO SIZING

Fig - 8: Appearance of yarn before and after Sizing

The picture on the right side shows the appearance of a properly sized spun yarn used as
warp in weaving process.

The protruding hairs are bound to the yarn body with a thin coating of adhesive material
applied to the yarn in the sizing process.

Fig - 9: Appearance of size spun yarn before and after sizing

3. MATERIALS AND METHODS
3.1 MATERIALS USED:
To complete the project work I emphasized on the materials, which are related with the sizing
process. Here are some materials used in sizing. Not only the size ingredients are the raw
materials, but yarn and water are also the raw materials for the project work on sizing. Different
types of water soluble polymers called textile sizing agents/chemicals such as modified starch,
polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC), acrylates are used to protect the yarn.
Also wax is added to reduce the abrasiveness of the warp yarns. The type of yarn material (e.g.
cotton, polyester, linen), the thickness of the yarn, and type of weaving machinery will determine
the sizing recipe.All the materials are discussed below.

3.1.1 Size Materials Used:

Different types of sized ingredients are used for sizing. Different size ingredients have different
characteristics. Followings are the main size ingredients used for sizing. Natural starch and its
derivatives still constitute nearly 75%of the sizing agents used in the textile industry throughout
the world. Up until the development and commercial use of manmade fibers, the sizing materials
employed in the textile industry had to meet the needs of the natural fiber weaving industry. The
sizing material used primarily in the cotton manufacturing industry used natural starches.

Some properties of a good size material are given below:

 Environmentally safe.  Recoverable and reusable
 Good film former.  Low static propensity.
 Reasonable use economics.  No skimming tendency.
 Penetration of yarn bundle.  Easily removed.
 Elasticity.  Easily prepared.
 Good film flexibility.  Lack of odor.
 Good specific adhesion.  No beam blocking.
 Good frictional properties.  Compatible with other ingredients.
 Transparency.  Good abrasion resistance.
 Bacterial resistance.  Neutral pH.
 Reasonable strength.  High fold endurance.
 Controllable viscosity.  Insensitive to high heat.
 Water soluble or water dispersible.  Low BOD.
 Good hygroscopicity characteristics.  No build up on dry cans.
 Uniformity.  Reduced shedding.
 Clean split at bust rods.  Rapid drying.
 Improves weaving efficiencies.  No re-deposition of size
 No effect on drying.  Insensitive to changes in relative
 Reasonable extensibility. humidity.
Some size materials and auxiliaries used in weaving mills are mentioned below along with their
respective category and function:

Materials Chemicals Function

-To increase strength.
Soloact DN
Adhesive materials: -To impart adhesion making the yarn less
Soloact SFR
Like modified starch, hairy.
ECO DN
synthetic chemicals. -To increase abrasion resistance.
Soloact Plus
-To increase smoothness.
-To increase elasticity a stiffness.
-It increases size exhaust.
Seycolube2905
-To obtain a uniform distribution of sizing
Wetting agent PVA
solution on yarn surface.
JEGAWAX
-It helps to wet yarn instantly.
Hemasize-400 These materials penetrate into the yarn and
Zydex 2400 contribute in increasing yarn strength.
Binder
Sunny FIX PLC

SICO12 -It makes the yarn soft and slippery.

(TRAFFIX -It reduces stiffness.
Lubricants softener
MSWI -It increases yarn smoothness.
FLA) -It increases elasticity.
Antifoaming agent Sunny Stat VK -To prevent foam formation.
Table – 1: Size Materials and Auxiliaries

3.1.2 Yarn Used

Yarn quality plays an important role in sizing and the subsequent processes. Mainly the pickup%
strongly depends on the quality of yarn. The amount of size to be applied depends on the CSP
Value (Count Strength Product) of the particular yarn. It is also important in sizing that, whether
the yarn is carded or combed, coarser or finer, ring spun or rotor spun etc.
A chart of different yarn quality is given below on the basis of our practical observation.

Fiber composition Count (Ne) Yarn type

7, 10, 12, 13, 16, 20, 30 Carded
Cotton 16, 20, 30, 40, 50, 60, 80, 100/2,
Combed
80/2, 20/2, 30/2, 40/2, 50/2, 60/2
PC 16, 20, 30, 45 Carded or Combed
CVC 12.5, 20, 30, 38, 40, 45, 26/2 Combed
3.1.3 Water Used
The advantages of water as the carrier rather than using an organic solvent are, of course, less
chance of pollution and fewer problems with the potential hazardous materials which may affect
the people who work with the sizing.
Water quality is very important factor in warp sizing. It is said that water is the life line in the
wet process. From the beginning to the end of warp sizing a huge amount of water is needed.
Standard of water used in sizing is as follows:

Minimum standard Permissible concentration

Color Colorless
Smell Odorless
pH value Neutral (pH= 7)
Water hardness < 50 dH
Dissolved solids < 1 ml/L
Solid deposits <50 mg/L
Organic substances <20 mg/L
Inorganic salt <500 mg/L
Iron (Fe) < 0.1 mg/L
Copper (Cu) < 0.005 mg/L
Nitrate (NO3) < 50 mg/L
Nitrite (NO2) < 5 mg/L
Table – 3: Standard of Water used in Sizing

Quality of water found practically:

PH: 7
Hardness: <1 PPM
Iron: 0-0.25 mg/L

3.2 METHODOLOGY:
3.2.1 Establishment of ideal pick up%
 Generate the approximate or required pick up % from the available chart from
experience.
 Produce three or five weavers beam having different pick up with one having the above
pick up% and one or two beams with lower pick up % with higher pick up%.
 Or have a beam with three or five different length of warp yarns having different pick
up% as above.
 Weave all the beams under the supervision of an expert weaver and get the warp
breakage report of each of the beam.
 Pick up % of the beam length that gives lowest warp breakage is the ideal pick up% for the set of warp yarns.
3.2.2 Size cooking procedure:

Water

Mixture Starch with water for 20 minute

Starch (45 minute steamed 1200c )

Size + Wax

Steam (20 minute at 900c )

Cooked size

3.2.3 Determination of size% by Refractometer:

Took the meter

Cooked size collect

Give on the tip of the matter

Observed the scale inside

Rating find in the scale

3.2.4 Determination of viscosity by viscosity cup:

Take the viscosity cup

Collect the cooked size in the cup

Determination the time required to drop out the liquor from the bottom hole of the cup

If 22-30 second required then the viscosity is O

Case – 1: Construction

Weave: Plain
Total ends: 7923
Warp length: 4000 miter
Size: 18.6%
Squeezing pressure: 8 KN
Pick up: 200 ml
Dry temperature: 1200 C
Moisture: 6.5%
ECO DN: 75 kg
M-5000: 04 kg
SICO 12: 02 kg
R.F: 9.7
Viscosity: 9:7
Water: 825 ltr.

Case – 2: Construction:
Yarn count:10 OE LTM
Fiber composition: 100% Cotton
Weave: Plain
Total ends: 5544
Warp length: 2528 miter
Beam space: 65”
Size: 16.7%
Squeezing pressure: 7 KN
Pick up: 8%
Dry temperature: 1200 C
Moisture: 6.5%
ECO DN: 75 kg
M 5000: 4 kg
SICO 12: 02 kg
R.F: 4.8
Viscosity: 4:69
Water: 825 ltr.
Case – 3: Construction
Yarn count: 10 OE LTM
Fiber composition: 100% Cotton
Weight: 4967.65 kg
Total ends: 5544
Warp length: 2528 miter
Beam space: 65”
Size: 21.2%
Squeezing pressure: 8 KN
Pick up: 13%
Dry temperature: 1200 C
Moisture: 6.5%
S.DN: 100 kg
M-5000: 05 kg
SICO 12: 03 kg
R.F: 8.3
Water: 600 ltr.

Case – 4: Construction:

Yarn count: 16 OE
Fiber composition: 100% Cotton
Weave: Canvas
Total ends: 7870
Warp length: 2611Miter
Beam space: 81.5”
Size: 24.6%
Squeezing pressure: 8 KN
Pick up: 12%
Dry temperature: 1200 C
Moisture: 6.5%
S.DN: 100 kg
ZYDEX 2400: 03 kg
Hemasize-400: 05 kg
Sico 12: 04 kg
Water: 600 ltr.
 Case – 5: Construction:

Yarn count: 30 CWC

Fiber composition: 100% Cotton

Total ends: 7680

Warp length: 3884 miter
Beam space: 80”
Size: 18.6%
Squeezing pressure: 8 KN
Pick up: 14%
Dry temperature: 1200 C
Moisture: 6.5%
S.DN: 100 Kg
Zydex 2400: 03 Kg
Sico 12: 04 Kg
Hemasize 400: 05 Kg
Water: 600 ltr.

4.4 MACHINE SETTING DATA ACCORDING TO FABRIC CONSTRUCTION1

Total Count Creel Winding Press Nip Leasing Moisture

Construction:
ends (Ne) tension tension tension tension pressure (%)

𝒄𝒐𝒏𝒔𝒕𝒓𝒖𝒄𝒕𝒊𝒐𝒏: 𝟏 36
7923 1200N 5300 N 4720 N 1500 N 4050N 6.5
CWC
Construction:2 5544 10OE 1200N 5300N 4720N 2000N 4050N 6.5

Construction:3 5544 10 OE 1200N 5300N 4720N 2000N 4050N 6.5

Construction:4 7870 16OE 800N 1970N 1820N 2000N 1670N 6.0

Construction:5 7680 30CWC 800N 1970N 1820N 2000 1670N 6.5

Table – 5: M/C Setting Data According To Fabric Construction

COMPARATIVE ANALYSIS OF BREAKAGE AND ELONGATION

Sizing is like cementing action. In the optimum zone the yarn possesses maximum elongation
at break, beyond that the cementing action becomes more prominent. So that strength
increases but elongation decreases. For this reason, there are possibilities of more end breaks
in sizing.

4.5.1 Breakage Study:

A comparison of warp breakage per loom per shift with the pickup% in accordance with the
yarn count and construction is given below:

Count (Ne) Construction Pickup% Average Breaks/Shift

10 Light 8 18.5
Medium 10 13.3
16 Medium 9 15.6
Heavy 13 11.4
20 Light 8 9.1
Heavy 12 13
30 Light 9 9.4
Heavy 14 9
40 Light 9 8.8
Medium 12 9.6
60 Light 10 6.4
Heavy 13 8.2

Table – 6: Relation between the end breaks/shift and size%

Relation between Warp Breakage in Weaving & Pickup%

Fig – 10: Relation between Warp Breakage in Weaving & Pickup%

4.5.2 Elongation Reduction Due to Sizing:
A comparative analysis of the total reduction in yarn elongation due to sizing in accordance
with the corresponding yarn count is given below:

Parameters Count
( Ne)
7 12 16 24 30 40 60
Original Yarn 5.16 4.73 4.66 4.56 4.54 4.40 4.16
Elongation (%)
Sized Yarn 3.51 3.40 3.36 3.25 3.20 3.0 2.75
Elongation (%)
Total Reduction in 31.97 28.11 27.89 28.73 29.52 31.81 33.89
Yarn Elongation (%)

Table – 7: Reduction of yarn elongation due to sizing

4.6 SIZING FAULTS AND THEIR REMEDIES:

Fault name Causes Remedies

Worn out pressure roller. Change of grinding pressure
Uneven sizing Incorrect size level in size box. roller.
Higher viscosity. Proper level of size in box.
Weak yarn. Tension and speed according to
End missing
Excessive speed. quality.
Improper leasing. Proper leasing.
Joint end
Improper combing. Proper combing
Proper speed should be
Excessive dried Low drying speed
maintained.
Proper speed should be
Wet warp High drying speed
maintained
Pattern End missing. Proper leasing should be
breaking Improper leasing. controlled
Conical beam Mechanical fault in winding Repair mechanical fault.
Excessive hard PVI (Pressure Variable Index)
Maintenance of the PVI box.
or loose beam not work properly.

Table – 8: Some Important Sizing Faults and Their Remedies

4. RESULTS AND DISCUSSION

From the experimental work we have gathered some results which are shown in this project
paper in the previous chapter. The discussion of these findings or results is discussed below:

5.1 Analysis of Size Material:

The first and foremost job of a sizing expert is to select the right size material for the right
type of yarn in a right quantity. There are various types of size materials found in the market.
Different size materials are used by the weaving industries depending on the function of the
size materials and the type yarn. But the interesting thing is that the selection of size materials
also varies from industry to industry. This is because of the marketing strategy of the size
chemicals supplier. Table – 1 represents the size materials according to the category and
function usually practiced by the weaving industries.

5.2 Analysis of Yarn Used:

Yarn is the main raw material of the sizing process and besides it is the final object or product
of sizing. It is very important to be ensured about the quality, consumption and type of yarn
used in sizing. Table – 2 represents the type and quality of yarn to be sized.

5.3 Analysis of Water Used:

Though sizing is carried out in the weaving industry, it is a wet process. As we know that the
purification of water is very important in any kind of wet processes. Otherwise the process
cannot be run accurately or the perfect product will not be obtained. Purification of water is
also done in case of sizing. Table – 3 shows a standard of water used in sizing. It contains the
parameters and corresponding value of purified water.

5.4 Pick up% Analysis:

As we seen in the previous chapter (Experimental Work), the size recipe and the pick up% is
applied on the warp sheet not only considering the yarn count or quality rather than the yarn
consumption, construction of the fabric, fiber type etc. Table – 4 shows the typical recipe
according to the construction. The table state that the pickup% varies depending on the yarn
quality, count and construction (EPI, PPI, Total Ends and Total Yarn Consumption).

5.5 Machine Settings Analysis:

To have a perfect weaver’s beam obtained by sizing process, it is important to have some
control over the machine settings while running the sizing process. A machine setting varies
according to the quality, count, consumption and condition of desired fabric. The application
of steam pressure and temperature, machine speed, drying speed and temperature, squeezing
pressure depends on the condition of yarn sheet to be sized. Table – 5 shows the
corresponding machine settings data for the particular construction. It also shows that the
pressure, temperature, moisture and other machine settings also depend on the construction of
the desired fabric.

5.6 Breakage Analysis:

Sizing is done only to improve the weaving performance or to reduce the warp breakage
during weaving. But warp ends may still be broken due to improper sizing. Excessive or
insufficient addition of size paste on the warp sheet may also lead to poor weaving
performance. That means end breakage not only occur in absence of sizing, but also occur
due to uneven sizing. Table – 6 represents a comparison of warp breakage per loom per shift
with the change of pickup% in accordance with the yarn count and construction. Sizing is
mainly done to minimize the warp breaks. But it should be done by considering the
construction of the desired fabric. Fig – 10 indicates that end breakage reduces with the
increase of pick up percentage. But beyond a certain level of pick up% insertion the end
breakage increases dramatically.

5.7 Elongation Reduction Analysis:

Sizing leads to better weavability. But due to the application of tension on the warp sheet
during the sizing operation the particular yarn set experienced some extension and thus the
elongation at break property reduces. Thus a great reduction in elongation property of that
particular warp sheet takes place. Table – 7 shows that, due to cementing action of size
materials the elongation property of the particular yarn set decreases. This is because of the
extension of yarn sheet during sizing. This extension takes place due to the effect of tension
carried out on the warp sheet.

5.8 Analysis of sizing Faults:

During the cementing action of size material on warp sheet some problems with the warp set
might be carried out. This might be occurred due to the improper choice of size material or
improper machine settings. Again some problems might be carried out during weaving which
also might be caused due to improper sizing. Table – 8 represents the sizing faults occurred in
the sizing zone and their causes and corresponding remedies are also discussed in the table.
5. CONCLUSION
This project might be seemed as a simple paper work on sizing. I am not clamming that this
paper delivers the overall details of entire sizing process. But I strongly believe that the
information provided in this paper is the critical technical information to accomplish
successful sizing practice. It would be the key to make further research in this field, as I hope.
In this project I tried to provide the information as accurate as possible. But as I know,
nothing is perfect in this universe. So, there might be some mistakes regarding this project. I
hope, everyone will consider them as the mistakes of dark horse.