Sizing and details

sizing

1. SIZING
1
MD MAHBUBAY RABBANI MIM
DHAKA UNIVERSITY OF ENGINEERING AND
TECHNOLOGY(DUET),GAZIPUR
Contact number:-01767281858

2. CONTENTS AT A GLANCE
What is sizing.
Objectives.
Requirement of sizing.
Process flow chart.
Types and techniques
of sizing.
Technological
changes.
Features of sizing.
Factors affecting size
take up%.
Graphically represent.
Faults and effect of sizing.
Size ingredients and their functions.
Properties of size ingredients.
Factors in choosing size materials.
Filament sizing and requirements.
Machine parts and descriptions.
Disadvantages of sizing.
Calculations.
2

3. WHAT IS SIZING
Sizing is a process of applying an adhesive coating
on the surface of the yarn.
Sizing is the most important operation in preparing
warp yarn in weaving especially with cotton.The
smallest error in sizing process may be
harmfull.Thoughsizing is termed as heart of weaving.
3

4. SIZING MACHINE 4

5. OBJECTIVES OF SIZING
1.Toincreasesmoothnessofwarpyarn.
2.Toreducehairinessofwarpyarn.
3.Toincreasethestrengthofwarpyarn.
4.Toincreasetheabrasionresistanceof
theyarn.
5.To improve the weave ability of warp
yarn.
5

6. OBJECTIVES OF SIZING
6.To maintain good fabric quality.
7.To increase the tensile strength 0f
warp yarn.
8.To increase the elasticity.
9.To remove the projecting fibers.
10.To reduce electrostatic formation
for synthetic or blended yarn.
6

7. REQUIREMENTS OF
SIZING
1.Sizedwarpmustbestrongandelastic.
2.Yarnstrengthandelongationshouldbewithinadmitted
limits.
3.Theprocessmustensureofrequiredamountofsizeonthe
yarn.
4.Thetensionofwarpyarnmustbeconstantallthetime.
5.Theweaversbeammusthaveacylindricalshape,
necessarywindingdensityandtheyarnlength.
6.Thesizingprocessmustbeefficient,economicalandmust
ensuretheproductionofhighqualitysizewarps.
7

8. SIZING PROCESS FLOW
CHART
8

9. TYPES OF SIZING
Pure sizing: when the size pick up % is
about 3-10 % it is called pure sizing.
Light sizing: when the pick up% is
about 11-16% it is called light sizing.
Medium sizing: when the size pick up%
is about
17-40% it is called medium sizing.
Heavy sizing: when the size pic up% is
above 40% then it is called heavy
sizing.
9

10. DIFFERENT TECHNIQUE OF
SIZING
Hot melt sizing.
Solvent sizing( organic
sizing).
Foam sizing.
High pressure sizing.
Electrostatic sizing.
Emulsion sizing.
10

11. TECHNOLOGICAL
CHANGES(INCREASED) DUE TO SIZING
Increase in breaking strength:
Duringsizing,adhesivematerialcreatesbonds
betweenfiberstofiberswhichincreasethe
strengthofyarn.Itincreases20-40%breaking
strengthofthefiber.
Increase abrasion resistance:
Aftersizingthegapbetweenfibersarefilledwith
sizeandcoatingontheoutersurfaceoftheyarn
takeplace.
Increase in elasticity:
Asextensibilityofthesizedyarndecrease,more
forcehastobeappliedtoextenttheyarn.Hence
elasticityincreases.
11

12. TECHNOLOGICAL
CHANGES(INCREASE) DUE TO SIZING
Increasefrictionalresistance:
Applicationofsizematerialsmakesouter
surfaceoftheyarnsmoothandhence
occurslessfriction.
Increaseyarndiameter:
Sizingmeanscoatingadhesiveonthe
outersurfaceoftheyarn.Hencesizing
causesincreaseofdiameterofyarn.
12

13. TECHNOLOGICAL
CHANGES(DECREASE) DUE TO
SIZING
Decreaseinelectrostaticcharge:
Electrostaticchargeisformeddueto
thefrictionbetweenyarnsandroller.
Sizematerialscontainmoisturewhich
reducesstaticfriction.
Decreasehairiness:
Duringsizingprotrudinghairsofyarnfix
withyarnendsoyarnhairiness
decreases.
13

14. THE IMPORTANT FEATURES TO
BE REMEMBERED DURING
SIZING
1.Ifthehairinessoftheyarnishigh
thentheconcentrationofthesize
wouldbehigh.
2.Ifthetwistishighintheyarnthen
theconcentrationofthesizewould
behigh.
3.Iftheyarn(finer)countishighthen
theconcentrationofthesizewould
14

15. THE IMPORTANT FEATURES TO BE
REMEMBERED DURING SIZING
4.Iftheyarn(coarser)countishighthenthe
concentrationofthesizewouldbelow.
5.Ifthetemperatureofthebathishighthen
theviscosityofthesizewouldbelessand
viceversa.
6.Ifthecookingtimeismorethanthe
viscositywouldbeless.
15

16. FACTORS AFFECTING THE SIZE TAKE
UP%
Viscosityofthesizerecipe:Ifviscosityofthesize
liquorisnotproper,itisdifficulttopenetratefor
thesizematerialtothecoreoftheyarn.
Lubrication:Lubricantcanexistatthesurfaceor
existinsidethestructureandlaterworkitselfto
thesurfaceastheyarnrubsoverafriction
surface.
Degreeofsizepenetration:Itdeterminesthe
stiffnessforagivenyarnbearingagivensize.So
ifDegreeofpenetrationisnotproper,sizetake
up%willbeun-uniform.
16

17. FACTORS AFFECTING THE SIZE
TAKE UP%
Squeezerollerpressure:Ifthe
pressureofsqueezerollerisnot
sufficient,sizeadd-onmaybe
increasedordecreased.
M/CSpeed:Ifm/cspeedishighor
lowconsequentlysizetake-up%
maybelessorhighcorrespondingly
thantherequiredtake-up%.
17

18. TYPICAL SIZE RECIPE
Sizing recipe depends on yarn type, total
ends.
In500LiterWater
•Starch:10-20%ofwater.
•Binder:2-4%ofwater.
•Softener:0.5-1%ofwater.
18

19. FAULTS OF SIZING
1.Sizingspots:
Sizematerialshouldbeaddedgraduallytothe
mixingtankforgoodmixing.Ifitisaddedatonce,
spotsareappearedontheyarn.
2.Repeatingwarpstreaks:
Thisdefectisduetouneventensioninthepre
beam.
3.Shinnery:
Thisdefectduetothefrictionbetweentheyarn
anddryingcylinder.
4.Sandywarp:
Duetonotcrushedorgrindthesizematerial
properly.
5.Ridgebeam:
Thisfaultoccursduetounevendistributionofyarn
inwraith.
19

20. FAULTS OF SIZING
6.Hardsizing:
Ifthesizematerialsareappliedtoomuch,thesize
becomeshardwhichcausehardsizing.
7.Improperdrying:
Underdrying-Bacteriaform-Yarnbreakage-over
drying-Hardsizing.
8.Sizedropping:
Thisdefectduetonotoptimumtheviscosityof
thesizesolution.
9.Sizestitching:
Duetoimproperdryingaftersizing.
10.Unevensizing:
Duetooverorundersizing.
Duetooverorunderconcentrationofsize
liquor
20

21. EFFECTS OF YARN ON SIZING
Asthesizeadd-onisincreased—
Theyarnbecomesstiffer.
Theyarnbecomeslessextensible.
Theyarnbecomes moredifficultto
weave.
Ifalowadd-on—
Theyarnbecomeshairy.
Theyarnsuffersfromlackofstrength.
Theyarnbecomes moredifficultto
weave.
21

22. PRIMARY SIZE MATERIAL
Starch (modified and
unmodified).
Polyvinyl alcohol(PVA).
Carboxymethylcellulose
(CMC).
Acrylic (various addition
polymers).
22

23. DIFFERENT SIZE
INGREDIENTS
1.Gums (natural & synthetic).
2.Lubricants or softeners.
3.Antiseptic or anti mildew agent.
4.Wetting agent.
5.Anti foaming agent.
6.Tinting agent.
7.Weighting agent.
23

24. DIFFERENT SIZE INGREDIENTS AND FUNCTIONS
1.Gums: This material is the base off size. It is two types such as
natural or synthetic . Examples
Natural: starch, corn flour potato wheat flour etc.
Synthetic: Polyvinyl alcohol,carboxymethylcellulose
polyacryloamide.
Functions:
To coat the warp yarn with the film.
Impart smoothness.
To reduce hairiness.
Increase elasticity.
24

25. DIFFERENT SIZE INGREDIENTS AND FUNCTIONS
2.Lubricants or softeners:
vegetable & animal fats, japan wax ,tallow
cotton seed soap TRO etc.
Functions:
To give a softer feel to sized yarn.
To smoothen the yarn.
To reduce stickiness of yarn.
3.Antiseptic Agent.
Phenol , boric acid , carboxylic acid etc.
25

26. DIFFERENT SIZE INGREDIENTS AND FUNCTIONS
Function.
Prevent mildew growth.
Prevent spoiling of size mixture while storing.
4.Wetting Agent.
Soap ,aviroletc.
Functions.
Toincrease wet ability.
To improve penetration.
Sizing distribution uniformly.
26

27. DIFFERENT SIZE INGREDIENTS AND FUNCTIONS
5.Anti Foaming Agent.
Silicones , benzene , pyridine etc.
Function.
Prevent foam formation.
6.Tinting Agent.
Blue is used as tinting agent.
Functions.
Increase brightness.
Prevent dusting off.
27

28. PROPEERTIES OF SIZE INGREDIENTS
It should be easily removed during wet
processing.
It should not do any harm to the fiber or yarn.
Adhesive substances should be more adhesive.
It should give good fabric characteristics.
It should have the ability to dry instantly after
sizing.
It should not cause any degradation.
It should not change the color of the yarn.
It should be cheep & available.
28

29. THE FACTORS IN CHOOSING SIZE MATERIALS
ARE
The recipe should be that which gives
fewer end breaks.
It should be that which permits easy
de-sizing.
It should give good fabric
characteristics.
It should not cause any degradation.
The cost should be minimum.
It should be compatible with
machinery.
29

30. FILAMENT SIZING
The process of applying size on
filament yarn is called filament
sizing .Twisted and zero twisted
filament yarns can be sized . Low
twisted multifilament should be
sized because if a single filament
breaks it can develop a fuzz ball
float that will ultimately cause a
loom stop.
30

31. REQUIREMENT OF FILAMENT
SIZING
1.Size solution must sufficiently penetrate the
filament bundle.
2.The adhesion between the filament and size
must be good.
3.The sizing agent must dry quickly.
4.The size should not cause static build-up.
5.Size film should not affected by humidity.
6.The size should be easily removable during de-
sizing.
31

32. GRAPH
If sizing increase then efficiency% will also increase up to
optimum level.
32
SIZE% EFFICIENCY%
Low 40
Good 75
Standard 85
Optimum 95
High 85
Very High 75
Extreme 40

33. GRAPHICALLY REPRESENT
33

34. SIZING VARIABLES
Viscosity of the size solution.
Sizing machine speed.
Size add-on levels.
Concentrati0n of the size mixture.
Volume of the size box.
Condition of squeeze rolls.
Squeeze pressure.
Hardness of squeeze rolls.
Diameter of squeeze rolls.
Yarn count & number of size box.
34

35. SECTIONS OF SIZING MACHINE
i.Creels-(unwinding zone).
ii.Sizing boxes-(Sizing zone).
iii.Drying cylinder-(drying zone).
iv.Bust rods-(splitting zone).
v.Head stock-(weaver’s beam
preparation zone).
vi.Controls & instrumentations.
35

36. MACHINE DESCRPTION OF SLASHER SIZING
MACHINE
Machine Description:
Slashersizing machine is a continuous sizing machine.
Section of slashersizing machine are
1.Back beam unit
2.Sizing unit
3.Drying unit
4.cooling unit
5.Dividing unit
6.Measuring and marking unit
7.Beaming unit.
36

37. SLASHER SIZING
MACHINE
37

38. CREELS
There are four major types of creel
such as,
1.Over/under creel.
2.Equitensioncreel.
3.Inclined creel.
4.Vertical stack creel.
38

39. 39

40. 40

41. MAIN PART’S AND FIGURE 41

42. 42

43. MAIN PART’S FIGURE 43

44. SOME DISADVANTAGES OF
SIZING
1.Cost of land and machine is high
2.Requires lot of labors
3.Requires gas, electricity etc.
4.Cost of size materials.
5.The process is very long .
6.Risk of degradation of yarn.
7.Diameter of yarn is increased
8.Changes of shade of colored yarn.
9.It increases yarn stiffness.
10.De-sizing is required before use.
44

45. CALCULATIONS
1.Size take up%=
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2.Solide add on%=
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4.Wt of total length=
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45

46. CALCULATIONS
5.Required starch%
=
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×
100
6.Waste%=
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kg
46