study on sizing practices in bangladeshi weaving mills

8/9/2019 Study on Sizing Practices in Bangladeshi Weaving Mills

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STUDY ON SIZING PRACTICES IN BANGLADESHI WEAVING MILLS

BY

Subrata Majumder ID: 092-23-1466

Sajib Kumar Das ID: 092-23-1485

This Report Presented in Partial Fulfillment of the Requirements for the Degree of

Bachelor of Science in Textile Engineering.

Supervised By:

Prof. Dr. Mahbubul Haque

Professor & Head

Department of Textile Engineering

Daffodil International University

DAFFODIL INTERNATIONAL UNIVERSITY

DHAKA, BANGLADESH

APRIL, 2013


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DECLARATION

We hereby declare that, this project/thesis has been done by us under the supervision of Prof.

Dr. Mahbubul Haque, Prof. & Head, Department of Textile Engineering, Daffodil

International University.We also declare that neither this project nor any part of this projecthas been submitted elsewhere for award of any degree or diploma.

Submitted By:

Subrata Majumder ID: 092-23-1466

Sajib Kumar Das ID: 092-23-1485



Supervised By:


Professor & Head,



Approved By:


Professor & Head,




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ACKNOWLEDGEMENT

First we express our heartiest thanks and gratefulness to almighty Allah for his divine blessing,

which makes us possible to complete this project successfully.

We fell grateful to and wish our profound indebtedness to our honorable SupervisorProf. Dr.

Mahbubul Haque, Prof. & Head, Department of Textile Engineering, Daffodil International

University, Dhaka. Deep Knowledge & keen interest of our supervisor in the field of weaving

influenced us 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.

We would like to express our heartiest gratitude to other faculty members and the staffs of TE,

for their kind help to finish our project.

We would like to thank our entire course mate in Daffodil International University, who took

part in this discuss while completing the course work.

We are also grateful to all the members of TALHA FABRICS Ltd. & SIM FABRICS Ltd.

who helped us to complete our project.


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ABSTRACT

This project work mainly focuses on the overall overview of the scenario of sizing practices

conducted in the Bangladeshi weaving Mills. 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, its 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.


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CONTENT

I. DECLARATION

II. ACKNOWLEDGEMENT

III. ABSTRACT

Chapters Page no.1. Introduction...01

1.1 Background of the Study.....02

1.2Objectives of the Study ...02

1.3 Application aspects of this project......03

1.4 Further Scope of the Project....03

1.5 Limitation of the project..04

2. Theoretical foundation ..05

2.1 Sizing...05

2.2 Objectives of sizing.05

2.3 Description of sizing Process..06

2.3.1 Flow Chart of sizing.06

2.3.2 Process description...06

2.3.3 Sizing Machine.07

2.3.4 Machine parts...07

2.4 Sizing Techniques...07

2.4.1 Conventional aqueous sizing....07

2.4.2 Non-Conventional Sizing.....08

2.5 Sizing calculation....082.5.1 Size beam width...08

2.5.2 Pick up% .08

2.5.2.1 Direct method...09

2.5.2.2 Indirect method.09

2.5.3 Measurement of viscosity....09

2.5.3.1 Cup method...09

2.5.3.2 Refractometer....10

2.6 Some important parameters for the process control of sizing....10

2.6.1 Process control in sizing..10

2.6.2 Effects of sizing on yarn properties.102.6.3 Factors on which recipe depends.11

2.6.4 Factors influencing size pick up% ..11

2.7 Drying.11

2.7.1 Different methods of drying12

2.7.1.1 Cylinder Drying12

2.7.1.2 Hot Air Drying..13


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2.7.1.3 Infrared Drying.14

2.7.1.4 Combined Drying.14

2.7.2 Factors influencing drying efficiency..15

2.8 Behavior of yarn due to sizing16

3. Materials and Methods..173.1 Materials Used.17

3.1.1 Size Materials17

3.1.2 Yarn Used.18

3.1.3 Water Used19

3.2 Methodology19

3.2.1 Establishment of ideal pick up% ..19

3.2.2 Size cooking procedure.20

3.2.3 Determination of pick up% by refractometer20

3.2.4 Determination of viscosity by viscosity cup.20

4. Experimental Work ......21

4.1 Experimental Machine Details21

4.2 Frequently used size recipe.22

4.3 Some other recipe according to their construction.27

4.4 Machine settings data according to construction28

4.5 Comparative analysis of breakage and elongation.29

4.5.1 Breakage Study29

4.5.2 Elongation reduction due to sizing..30

4.6 Sizing Faults and their remedies.30

5. Result and discussion.....31

5.1 Analysis of size material..31

5.2 Analysis of yarn used...31

5.3 Analysis of water used.31

5.4 Pick up% analysis31

5.5 Machine settings analysis31

5.6 Breakage analysis32

5.7 Elongation Reduction Analysis...32

5.8 Analysis of sizing faults..32

6. Conclusion....33

REFERENCE...34

APPENDIX....35

List of figure.....35

List of table...35


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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 todays 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

sizingtype 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.

Bangladesh is one of the leading exporters of ready-made garments in the world. Our ready-

made garments are mainly produced from two types of fabrics e.g. (i) woven fabric and (ii)

Knitted fabrics. Nearly 98% of the export oriented knitted fabrics are manufactured in

Bangladesh while only 35% export oriented woven fabrics are produced in Bangladesh and the

rest of the fabrics are imported. Various factors are thought to be responsible for poorperformance of the woven manufacturing sector. Surprisingly in many cases the cost of local

fabric is not very attractive to the garment manufacturers and they prefer to import fabric from

countries like china, South Korea, Taiwan, India and Pakistan. Though our production skill is no

doubt up to a good level but it does not mean that there is no possibility of further improvement.

The project is fully emphasized on the development of weaving sector by means of the

development of the sizing section as the sizing is called the heart of weaving.

We are very glad to found ourselves as the personnel to be a part of such an interesting project

work entitled Sizing Practices in Bangladeshi Weaving Mills.This project is emphasized on

the most commonly used sizing process practiced in the weaving mills of our country. The

project is also emphasized on the detailed information about the sizing methods, size ingredients,

raw materials and machines used in sizing. We consider this project as the primary paperwork

for the further deep line research on sizing. We are very hopeful about this project and wish to

introduce this project as the key work paper for further research and development in sizing and

weaving sector.


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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.


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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 ofweaving. 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 furtherresearch 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 developingeither a loom or a cotton yarn which will give the same weaving performance without

sizing.


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1.5 Limitation of the Project:

During the project work we have faced a lot of problems. In absence of those problems this

would be a great paper work. We found problems in gathering the sufficient information about

the relation between the sizing and weaving performance. We also found the sizing technicians

very helpful and experienced, but they were not well conversant with the academic or theoreticalknowledge. As a result we failed to get full access to the sizing and weaving related information

in some extent.


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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.


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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 wateralong with other size ingredients. Then mixture is boiled at 90c temperature for 5 min.

After 5 min native starch is added to the solution and again boiled the solution for 5 min.

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 weavers beam.


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2.3.3 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 - 1: Typical Sizing Machine

Fig - 2: Conventional Sizing Machine


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2.4.2 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 warp yarn due to electrostatic force of attraction.

This process ensures the reduction of cost of raw material and reduction of pollution.

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 th of energy is required to evaporate solvent.

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.

Foam Sizing: Here the solvent is replaced by water. Foam of size is used which must

possess liquor, a gas, mechanical energy and thermal energy. Thus 70% energy is saved

and production is increased.

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 wellblend sizing needs both machinery as well as operational requirements.

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.

=

/

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:

Fig - 3: Non-Conventional Sizing Machine


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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:

Size pick-up in % =

100

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 willlead 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 droppingthrough 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.


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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.


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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.


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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.

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 - 4: Diagram of Two Cylinder Drying

Fig - 5: Diagram of Multi Cylinder Drying


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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 rollersthrough 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.

Advantages:

1. Regular drying.

2. Not shinning effect.

3. Non-sticky property.

4. High speed drying.

Fig 6: Diagram of Hot Air Drying


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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.

Advantages:

1. No shining effect.


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.

Fig - 7: Diagram of Infrared Drying


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Advantages:

1. Regular drying.


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 caseof 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.


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2.8 BEHAVIOR OF YARN DUE TO 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

Fig - 8: Appearance of yarn before and after Sizing


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3. MATERIALS AND METHODS

3.1 MATERIALS USED:

To complete the project work we 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.

Good film former.

Reasonable use economics.

Penetration of yarn bundle.

Elasticity. Good film flexibility.

Good specific adhesion.

Good frictional properties.

Transparency.

Bacterial resistance.

Reasonable strength.

Controllable viscosity.

Water soluble or water dispersible.

Good hygroscopicity characteristics. Uniformity.

Clean split at bust rods.

Improves weaving efficiencies.

No effect on drying.

Reasonable extensibility.

Recoverable and reusable

Low static propensity.

No skimming tendency.

Easily removed.

Easily prepared. Lack of odor.

No beam blocking.

Compatible with other ingredients.

Good abrasion resistance.

Neutral pH.

High fold endurance.

Insensitive to high heat.

Low BOD.

No build up on dry cans. Reduced shedding.

Rapid drying.

No re-deposition of size

Insensitive to changes in relative

humidity.


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Some size materials and auxiliaries used in weaving mills are mentioned below along with their

respective category and function:

Materials Chemicals Function

Adhesive materials:

Like modified starch,

synthetic chemicals.

Kottotex T5N

Topioca

Penetrose

Amisol

-To increase strength.

-To impart adhesion making the yarn less hairy.

-To increase abrasion resistance.-To increase smoothness.

-To increase elasticity a stiffness.

Wetting agent

Perfectly ASP

PVA

Gohsenol

-It increases size exhaust.

-To obtain a uniform distribution of sizing

solution on yarn surface.

-It helps to wet yarn instantly.

Acrylic sizing agent

Acrysize

Trisize SY

Sizetex

Ideal sizer for 100% polyester filament/spun

and blended yarn. Will give better performance

on fully automatic machines.

Lubricants softener

Sizewax

Piniwax

Pinitex

-It makes the yarn soft and slippery.

-It reduces stiffness.

-It increases yarn smoothness.

-It increases elasticity.

Antifoaming agent Resplimite -To prevent foam formation.

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 CSPValue (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

Cotton

7, 10, 12, 13, 16, 20, 30 Carded

16, 20, 30, 40, 50, 60, 80, 100/2,

80/2, 20/2, 30/2, 40/2, 50/2, 60/2Combed

PC 16, 20, 30, 45 Carded or Combed

CVC 12.5, 20, 30, 38, 40, 45, 26/2 Combed

Fancy yarn Slub yarn 10, 12, 13, 16, 20, 30, 40 Carded or Combed

Mlange yarn 20, 30, 40 Combed or Carded

Polyester (Core spun) (40+45D) Combed

Polyester filament 70D, 75D, 100D, 120D, 150D

Table 1: Size Materials and Auxiliaries

Table 2: Yarn usually used in Sizing


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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 < 5dH

Dissolved solids < 1 ml/L

Solid deposits


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3.2.2 Size cooking procedure:

Water

PVA (10 minute steamed 700c)

Starch (30 minute steamed 900c)

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


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4. EXPERIMENTAL WORK

4.1 EXPERIMENTAL MACHINE DETAILS:

The project work is done on the sizing machines having the double immersion, double squeezing

and multi cylinder drying arrangement. All the sizing machines are equipped with weavers

beam arrangement at the front and warp beam arrangement at the tail of each machine. The

detailed machine description is given below.

Machine No. 1

M/C Name: West Point Sizing Machine

Head Length: 2.4 meter

Size Box r/r Length: 1530mm, 1330 mm

Steam Cylinder: 14 Pcs

Creel Capacity: 24 Beams

Machine No. 2

M/C Name: West Point Sizing MachineHead Length: 2.4 meter

Size Box Padder Roller Length: 1330 mm



Machine No. 3



Size Box r/r Length: 1980mm, 1800mm



Machine No. 4



Size Box Padder Roller Length: 1980mm



Machine No. 5

M/C Name: SUCKER MULLER Sizing M/C





Machine No. 6, 7M/C Name: I. R. GRIFFIN Sizing Machine


Size Box r/r Length: 2000, 1800 mm



Machine No. 8

M/C Name: SUCKER MULLER Sizing M/C





Machine No. 9

M/C Name: BENNINGER ZELL Sizing M/C






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4.2 FREQUENTLY USED SIZE RECIPE:

Case 1: Construction:

"

Fiber composition: PCWeave: Plain

Total ends: 4580

Warp length: 12000 yds

Size: 18.6%

Squeezing pressure: 8 KN

Pick up: 9%

Dry temperature: 150C

Moisture: 6.5%

Modified Starch (Penetrose): (60 + 48) kg

Tapioca Starch: (10 + 8) kg

Wetting agent (PVA): (8 + 6) kg

Size wax (Pinitex): (3 + 2) kg

Binder (Acrysize): (12 + 9) kg

Water: (500 + 40) ltr.


"

Fiber composition: 100% Cotton

Weave: Plain

Total ends: 4150


Beam space: 65

Size: 16.7%


Pick up: 8%


Moisture: 6.5%

Modified Starch (Penetrose): 38 kgTapioca Starch: 7 kg

Wetting agent (PVA): 4 kg

Size wax (Pinitex): 2.5 kg

Binder (Acrysize): 7 kg

Water: 350 ltr.


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"


Weave: Shemrey (4/1 Satin)

Total ends: 6280

Warp length: 11800 ydsBeam space: 65

Size: 21.2%


Pick up: 13%


Moisture: 6.5%


Wetting agent (PVA): (12 + 10) kg

Size wax (Pinitex): (5 + 4) kg


Water: (500 + 400) ltr.


"


Weave: Canvas

Total ends: 8500


Beam space: 65

Size: 24.6%


Pick up: 12%


Moisture: 6.5%


Wetting agent (PVA): (14 + 12) kgSize wax (Pinitex): (6 + 4.5) kg


Water: (500 + 400) ltr.


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30


"


Weave: 4/1 Satin

Total ends: 8500


Size: 18.6%


Pick up: 14%


Moisture: 6.5%

Modified Starch (Penetrose): (85 + 68) Kg

Wetting agent (PVA): (14 + 11.5) Kg

Size wax (Pinitex): (5 + 4) Kg

Binder (Acrysize): (16 + 13) Kg

Water: (500 + 400) ltr.


"


Weave: Poplin

Total ends: 9000


Beam space: 65

Size: 24%


Pick up: 14%

Dry temperature: 1500 C

Moisture: 6.5%

Modified Starch (Penetrose): 85 Kg

Wetting agent (PVA): 14 Kg

Size wax (Pinitex): 5 KgBinder (Acrysize): 16 Kg

Water: 500 ltr.


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31


"


Weave: 3/1 Twill

Total ends: 6120


Size: 14%


Pick up: 10%


Moisture: 6.5%


Tapioca Starch: 7 Kg

Size wax (Pinitex): 4 Kg

Binder (Acrysize): 9 Kg

Water: 500 ltr.


"


Weave: Canvas

Total ends: 7450


Beam space: 65

Size: 23.8%


Pick up: 10%


Moisture: 6.5%


Wetting agent (PVA): 42 KgSize wax (Pinitex): 15 Kg

Binder (Acrysize): 45 Kg

Water: 1500 ltr.


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32


"


Weave: 2/2 Matt

Total ends: 5130


Beam space: 90

Size: 14.2%


Pick up: 9%


Moisture: 6.5%


Size wax (Pinitex): 4 Kg

Binder (Acrysize): 7 KgWater: 500 ltr.


"


Weave: Canvas

Total ends: 7320


Beam space: 67

Size: 15.1%


Pick up: 10%

Dry temperature: 1500 C

Moisture: 6.5%


Tapioca Starch: 37 Kg

Size wax (Pinitex): 18.5 KgBinder (Acrysize): 59 Kg

Water: 2600 ltr.


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4.3 SOME OTHER RECIPE ACCORDING TO THEIR CONSTRUCTION1

Construction Kollotex Parfectamyl PVA Multitex Sol-wax Water

() 56 3 20 13 4 545

() 56 12 17 12 4 540

() 55 14 17 13 4 540

() 56 14 18 16 5 540

() 61 8 26 12 4 525

()

61 12 26 12 4 510

() 61 8 27 12 3 520

By analyzing the data on size recipe, we found that size recipe totally depends on the

construction of the desired fabric. The amount of size materials varies corresponding to the

construction of the desired fabric as well as the weight of warp yarn used for sizing.

1Data Source: Sizing unit of BEXIMCO TEXTILES LTD.

Table 4: Some practiced recipe according to the Fabric Construction


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4.4 MACHINE SETTING DATA ACCORDING TO FABRIC CONSTRUCTION2

ConstructionTotal

ends

Count

(Ne)

Creel

tension

Winding

tension

Press

tension

Dry

tension

Squeeze

pressure

Moisture

(%)

" 9840 20/1 450 N 1800 N 1650 N 1600 N 6 KN 6.5

" 6840 20/1 500 1800 1700 1650 5.5 6.5

" 6600 40/1 450 1800 1650 1600 6 6.5

" 7980 40/1 550 1900 1800 1700 8 6.0

/

12000 100/1 500 1800 1650 1600 5 6.5

/

" 9840 80/2 700 2400 2200 2000 8 6.5

" 5400 30/1 500 1800 1650 1600 5.5 6.0

" 8640 50/1 600 2000 1800 1700 7 6.5

/

" 6600

45/1

(CVC)500 1800 1650 1600 5.5 6.5

" 7200

45/1

(CVC)500 2000 1800 1680 5.5 6.5

"

5400 30/1 450 1800 1650 1600 5.5 5.5

2Data Source: Sizing Unit of TALHA FABRICS LTD.

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


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4.5COMPARATIVE 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.

4.5.1Breakage 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 1330 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

Relation between Warp Breakage in Weaving & Pickup%

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

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


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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 60Original Yarn

Elongation (%)

5.16 4.73 4.66 4.56 4.54 4.40 4.16

Sized Yarn

Elongation (%)

3.51 3.40 3.36 3.25 3.20 3.0 2.75

Total Reduction in

Yarn Elongation (%)

31.97 28.11 27.89 28.73 29.52 31.81 33.89

4.6 SIZING FAULTS AND THEIR REMEDIES:

Fault name Causes Remedies

Uneven sizing

Worn out pressure roller.

Incorrect size level in size box.

Higher viscosity.

Change of grinding pressure

roller.

Proper level of size in box.

End missingWeak yarn.

Excessive speed.

Tension and speed according to

quality.

Joint endImproper leasing.

Improper combing.

Proper leasing.

Proper combing

Excessive dried Low drying speedProper speed should be

maintained.

Wet warp High drying speedProper speed should be

maintained

Pattern breakingEnd missing.

Improper leasing.

Proper leasing should be

controlled

Conical beam Mechanical fault in winding Repair mechanical fault.

Excessive hard

or loose beam

PVI (Pressure Variable Index)

not work properly. Maintenance of the PVI box.

Table 7: Reduction of yarn elongation due to sizing

Table 8: Some Important Sizing Faults and Their Remedies


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5. 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 typeof 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 weavers 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 accordingto 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.


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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.


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6. CONCLUSION

This project might be seemed as a simple paper work on sizing. We are not clamming that this

paper delivers the overall details of entire sizing process. But we 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 we hope. In thisproject we tried to provide the information as accurate as possible. But as we know, nothing is

perfect in this universe. So, there might be some mistakes regarding this project. We hope,

everyone will consider them as the mistakes of dark horse.


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REFERENCES:

1. B. C. Goswami; R. D. Anandjiwala; D. M. Hall. Textile Sizing. ISBN: 0-8247-5053-5.

Copyright 2004 Marcel Dekker, Inc.

2. M. Sonawane; P. P. Raichurkar; L. C. Patil; Sachin Kulkarni; T. C. Patil. Sizing Impact

Of Process Parameter On Beam Quality And Similarly On Loom Performance. Centre forTextile Functions (CTF), NMIMS MPSTME, Maharashtra.

3. E. Abrams; C.W. Rougeux; J.N. Coker. Polyvinyl Alcohol as a Warp Size for Various

Staple Yarns. Textile Research Journal. 1956, 26, 875880. In English.

4. S. Gordon; Y.L. Hsies. Cotton: Science and technology (2007). Woodhead Publishing

Ltd, 3-5.

5. M. Lewin; S.B. Sello. Handbook of Fiber Science and Technology. Vol I; Part B (1993).

CRC Press. 10-11.

6. Warner; B. Steven. Fiber Science (1995). Prentice-hall. 217.

7. Md. Ashraful Islam. Quality Control in Cotton spinning (2000). Books Fair Publications.

32-33.

8. Md. Ashraful Islam. Science of Textile Raw Materials (1998). 3-8.

9. A. Brent Strong. Sizing and Coupling Agents- The Magic Of Composite Performance.Brigham Young University. 1-12.

Web Resources:

http://en.wikipedia.org/wiki/Sizing

http://textilelearner.blogspot.com/2012/05/drying-drying-systems-used-in-sizing.html

http://textilelearner.blogspot.com/2011/06/properties-of-good-sizing-material_7653.html http://www.modifiedstarchproducts.com/textile-starch.html

http://textilelearner.blogspot.com/2012/07/process-flow-chart-of-sizing.html

http://textilefashionstudy.com/requirements-of-sizing-choice-of-size-ingredients/

http://textilefashionstudy.com/types-of-sizing-application-methods-technical-changes-

due-to-sizing/


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APPENDIX

List of Figures

Fig 1: ..Typical Sizing Machine

Fig 2: Conventional Sizing Machine

Fig 3: Non Conventional Sizing Machine

Fig 4: ..Diagram of Two Cylinder DryingFig 5: Diagram of Multi Cylinder Drying

Fig 6: ...Diagram of Hot Air Drying

Fig 7: ...Diagram Infrared Drying

Fig 8: Schematic Diagram Of Size Spun Yarn Before And After Sizing

Fig 9: .Appearance Of Size Spun Yarn Before And After Sizing

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

List of Tables

Table 1: Size Materials and Auxiliaries

Table 2: Yarn usually used in Sizing

Table 3: ..Standard of Water Used in Sizing

Table 4: .Some practiced recipe according to the Fabric Construction

Table 5: ...M/C Settings According to Construction

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

Table 7: Reduction of yarn elongation due to sizing

Table 8: ...Some Important Sizing Faults and Their Remedies

study on sizing practices in bangladeshi weaving mills

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