CREATIVES

1. Sizing
SAYED ARIFUZZAMAN

2. Content
 1.What is size & sizing?
 2.Objects
 3.Technological change due to sizing
 4.Requirement of sizing
 5.Types of sizing
 6.Sizing process
 7.Sizing Ingredients
 8.Faults of Sizing
9. Disadvantages of Sizing
 10.Technique Of Sizing
 11.Different Machine of sizing
 12. Main Parts of sizing machine

3. Size:
 A gelatinous film forming substance in applied
normally to warp but sometimes to weft, generally
before weaving.
Sizing:
A method of applying a gelatinous film forming
substance on warp is called sizing.

4. Objects
 1.To increase the breaking strength of yarn.
 2.To increase smoothness of yarn.
 3.To protect the yarn from abrasion resistance.
 4.To increase elasticity of yarn.
 5.To decrease hairiness.
 6.To decrease generation of static electricity.
 7. To improve the weave ability of yarn.

5. Technological change due to sizing
 Increase in breaking strength: During sizing, adhesive material
creates bonds between fibers to fibers which increase the strength of
yarn. It increases 20-40% breaking strength of the fiber.
 Increase abrasion resistance: After sizing the gap between fibers are
filled with size and coating on the outer surface of the yarn take place.
 Increase in stiffness: After sizing, flexibility or pliability of yarn is
decrease and stiffness is increased.
 Increase in elasticity: As extensibility of the sized yarn decrease, more
force has to be applied to extent the yarn. Hence elasticity increases

6. Technological change due to sizing
 Increase frictional resistance: Application of size materials
makes outer surface of the yarn smooth and hence occurs
less friction.
 Increase yarn diameter: Sizing means coating adhesive on
the outer surface of the yarn. Hence sizing causes increase of
diameter of yarn.
 Decrease in extension: After sizing the gap between the
fiber does not occur easily. So the extension decreased.
 Decrease in electrostatic charge: Electrostatic charge is
formed due to the friction between yarns and roller. Size
materials contain moisture which reduces static friction.
 Decrease hairiness: During sizing protruding hairs of yarn fix
with yarn end so yarn hairiness decreases

7. Requirement of sizing
 1. Sized warp must be strong and elastic.
 2. Yarn strength and loss in elongation should be within admitted
limits.
 3. The process must ensure the applications of required amount of
size on the yarn.
 4. The tension of warp yarn must be constant all the time.
 5. The weavers beam must have a cylindrical shape, necessary
winding density and the yarn length.
 6. The sizing process must be efficient, economical and must ensure
the production of high quality size warps.

8. Types of sizing
There are four types of sizing. These are:
1. Pure Sizing.
2. Light Sizing.
3. Medium Sizing.
4. Heavy Sizing.
 Pure Sizing: To produce unbleached fabric when sizing is done on
yarn is called pure sizing. On the weight of yarn 3 -10% the size
ingredients are used.

9. Types of Sizing
 Light Sizing: In case of printing and dyeing the sized are used is
called light sizing. About 11-16% sizing ingredients are used on
the weight of yarn.
 Medium Sizing: To increase the weight of yarn and strength the
medium sizing are used. About 17-40% sizing ingredients are
used on the weight of yarn.
 Heavy Sizing: Heavy Sizing is known as when sizing is done on
lower count and twisted yarn. Above 40% sizing ingredients are
used on the weight of yarn.

10. Sizing process
Warping Beam Sizing Drying
LeasingWeavers’ Beam

11. Sizing Ingredients
Adhesive:
 1.To increase yarns strength
 2.To increase yarn abrasion resistance
 Exp: Maize corn, wheat flower, Potato,Sago,PVC etc.
Lubricant:
 1.To increase yarn smoothness.
 2.To increase yarn elastic
 Exp: Mineral oil, Linseed oil, Japan wax, coconut oil.

12. Sizing Ingredients
Antiseptic agent:
 1.It help to store the yarn without damage.
 2.Protect yarn from bacteria or fungus formation
 Exp: Zncl2,Phenol,Carboxylic acid etc.
Deliquescent agent:
 1.To prevent brittleness of size
 2.Helps to keep standard moisture regnant
 Exp: Mgcl2, Glycerine

13. Sizing Ingredients
 Wetting agent: Helps to wet yarn instantly.Exp: Mgcl2
 Weighting agent: To increase yarn weight.Exp: china clay,
French chalk.
 Tin Ting agent: To increase yarn brightness. Exp: Blue
 Antifoaming agent: To prevent foam formation. Exp: Benzene,
Pyridine.

14. Faults of Sizing
 Sizing spots
 Repeating warp streaks
 Shinnery
 Sandy warp
 Ridge beam
 Hard sizing
 Improper drying
 Size dropping
 Size stitching
 Uneven sizing

15. Faults of Sizing
 1. Sizing spots: Size material should be added gradually to the
mixing tank for good mixing. If it is added at once, spots are
appeared on the yarn.
 2. Repeating warp streaks: This defect is due to uneven tension
in the pre beam.
 3. Shinnery: This defect due to the friction between the yarn and
drying cylinder.
 4. Sandy warp: Due to not crushed or grind the size material
properly.
 5. Ridge beam: This fault occurs due to uneven distribution of
yarn in wraith.

16. Faults of Sizing
 6. Hard sizing: If the size materials are applied too much, the
size becomes hard which cause hard sizing.
 7. Improper drying: Under drying-Bacteria form-Yarn breakage-
over drying-Hard sizing.
 8. Size dropping: This defect due to not optimum the viscosity
of the size solution.
 9. Size stitching: Due to improper drying after sizing.
 10. Uneven sizing: Due to over or under sizing. Due to over or
under concentration of size liquor.

17. Disadvantages of Sizing
 1. Cost of land and machine is high
 2. Requires lot of labors
 3. Requires utility like gas, electricity etc and their cost is high
 4. Cost of ingredients
 5. The process is long and it takes time
 6. Risk of pollution
 7. The yarn diameter is increased
 8. Cost of desizing
 9. It increases yarn stiffness
 10.Need knowledge and information about the size ingredients
 11.Chance of uneven colour
 12.Less warp length on beam
 13.100% size material cannot be removed

18. Technique Of Sizing
1. Hot melting sizing:
 The size is preferably applied by urging a block of solid size against
the grooves of the hot cylinder. From the point of application the
molten size is carried by the rotation of the cylinder to a zone where
each moving yarn strand passes briefly through a corresponding
size-filled groove, essentially tangentially to the cylinder, and then
moves away coated with an optimum amount of size. The method of
application is unique in its capacity for placing a quick-setting, high
molecular weight, film-forming melt size on yarn at high speed

19. Technique Of Sizing
2. Solvent sizing: Sizing is accomplished by using a non-
aqueous organic solvent as the treatment media instead of water.
Chlorinated hydrogen is mostly used as solvent and 1/10 the of
energy is required to evaporate solvent.

 3. Foam sizing: In foam sizing, a concentrated size
composition is mechanically foamed at room temperature and is
applied to the warp yarns by the Reed-Chat wood applicator. The
main feature of the applicator is a horizontal padder. The foam
collapses at the nip of the padder, applying the size uniformly to
the warp yarn at a lower wet pickup.

20. Technique Of Sizing
 4. High pressure sizing: In high pressure sizing
techniques, heavy pressure is used for penetrating
concentrated size solution in the warp yarn.
5. Electrostatic sizing: This type of sizing is applied by
producing electric charge between the size material. When
yarn is passed through the electrolyte solution, like NaCl,
oppositely charged sized materials and particle are sprayed,
by which the neutralization of charge is happen and size got
fixed on the yarn.

21. Technique Of Sizing
 6. Emulsion sizing : It has been found advantageous to have
the size ingredients in emulsion and well-dispersed
throughout the size bath; and to this end, colloid mills and
homogenizers are now in Widespread use. a Heretofore,
various dispersions and emulsions have been employed for
distributing the insoluble content of size baths. In some cases,
the ingredients for addition to starch solution are simple
mixtures which are mechanically dispersed in the size bath.
Emulsion is the dispersed form of soap and oil.
 7. Combined sizing: This techniques consists of two process,
dyeing is done at first and then sizing is applied
simultaneously. Denims required this type of sizing

22. Technique Of Sizing
8. Slasher sizing: In the slasher sizing method, several ends
of yarn(frequently several thousand ends of yarn) are led
through a sizing bath, then through squeeze rolls, around
drying cans to splitting rods, and then to a. take-up device. The
yarns run very close to each other in the conventional
equipment and they tend to touch, even to intertwine. It is
common to see two or three ends go over the drying cans as a
superficially adhered bundle and, when this bundle reaches the
splitting rods, the yarns become separated and they are wound
onto beams as an orderly fleece of ends

23. Different Machine of sizing
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.

24. Non-Conventional Sizing:

 Dry Sizing: This is carried out by spraying dry size powder on the
warp sheet and the size powder is thought to be fixed in the
yarn due to electrostatic force of attraction. This process ensures
the reduction of cost of raw material and reduction of pollution.

 Blend Sizing: Manmade fibers are more sensitive to heat and
tension. However successful size will result better performance
than 100% cotton. In order to perform well blend sizing needs
both machinery as well as operational requirements

25. Shirley Automatic Size Box
 Shirley automatic size box
maintain constant level of size
solution
 It also maintains constant
concentration per volume.
 There is a immersion roller to
immerse warp yarn into liquor
and a squeezing roller to
control size take-up%.
 There are two separate pipes
named a water pipe which
control size liquor volume in
box and a size solution pipe
which control concentration.

26. Principle of Shirley Automatic Size Box
 Some basic principles of a Shirley automatic size-box have pointed
out in the following:
 1.The necessary quantity of water through a water pipe and size
liquor solution through a pipe are added in a size box.
 2.The main principle is that when concentration of size solution
becomes more. Water comes automatically from water pipe to
maintain its concentration.
 3.When concentration becomes less, size is automatically from water
pipe to maintain its concentration.
 4.When concentration becomes less, size is automatically supplied size
ingredient pipe and maintains its concentration and volume.
 5.Yarn is feed to the immersion roller via guide roller and finally comes
out from in between the squeezing and sizing roller.
 6.Yarn size take-up% is controlled by the pressure of squeezing roller.

27.  Machine Description: Slasher sizing machine is a continuous sizing
machine. This machine has a number of units. For an ideal sizing
machine following units are most common, 1. Back beam unit
 2. Sizing unit
 3. Drying unit
 4. Cooling unit
 5. Dividing unit
 6. Measuring & marking unit
 7. Beaming unit The machine in our lab is a semi automatic
machine which is electrically driven by a heavy motor.

28.  Back beam unit: In single end sizing yarns are taken from a creel
rather than from a beam. This unit contains 12 carriers from where
yarn is supplied. Indirect & direct process of yarn supply is frequently
used for spun yarns. In case of indirect method beam creel is used.
This beam creel can be arranged in various ways.
 Sizing unit: In this unit a size box is used to apply size to the yarn.
The warp sheet is guided through the solution means of the
immersion roller & then through the squeeze roller where the yarns
are pressed to maintain the required size to up percentage by the
yarn. The size box temperature is controlled by flowing steam
pipe.
 Drying unit: 14 heated cylinders consist of drying unit. This unit is
required to dry the wet sized yarn rapidly, thoroughly & uniformly. A
two cylinder dryer is too slow & it is difficult to maintain by it. But a
multi-cylinder dryer is a good one to main in such a way that after
drying. Yarn contains 6% water.

29.  Cooling unit: In this unit there is cooling fan & a guide roller. The
cooling fan supplies cool air which extinguish the yarn
& also remove the moisture.
 Dividing unit: In order to prevent adhesion between the yarns, it is
necessary to separate each sized end from the others. For this
rod or breaker rods are used to divide the main warp sheet into
single end.
 Measuring & marketing unit: This unit consists of colouring bowl
which contains easily removable colour. This colour is used for
making on sized yarn. Also there is a measuring roller which
measures the length of sized warp yarn.
 Beaming unit: Finally the sized warp is wound on weavers beam

31. Main parts of sizing machine
1.Creel 11.Cooking Box
2.Pre-Beam 12.Stream pipe
3.Feeding r/r 13.Drying cylinder
4.Tensioner r/r 14.Guide r/r
5.Guide r/r 15.Lease Rod
6.Sizing Box 16.V-Reed
7.Emersion r/r 17.Nipper r/r
8.Sizing r/r 18.Warp Beam
9.Squeezing r/r 19.Pressure r/r
10.Reverse Box