TET-203 Weaving & Knitting

Preparatory Processes and

Mechanisms

Sizing Materials
 Cooking Section

Cooking section includes:

Size cooker
Size storage tank
Limit switches on storage

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Temperature sensor
Agitator (stirrer)

The maximum capacity of a typical size cooker is 1250 liters.

The agitator ensures homogeneous liquor. It also helps to
break the starch granules.
 Sizing
Ingredients

Adhesives / Solvent
Lubricants/ Additives/
Film
Softeners Auxiliaries (Water)
Formers

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 ADHESIVES
The main function of sizing is to improve the weavability
of the warp, so the essential part of size recipe is the film
former/adhesive.
The adhesives bind the constituent fibers of the yarn
together and hence increase its strength.
The adhesives also perform the film forming task, i.e.

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Cover the yarn surface to decrease the un-evenness of
yarn (thick, thin & neps) and to lay down the protruding
fibers.
Natural starches performed a useful function, and they
still do in the cotton industry.
Because natural starches and cotton have similar
chemical nature, the starches adhere very well to cotton
as well as to rayon.
 Properties:
A good adhesive should have the following properties:
Film strength
Adhesion
Penetration

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Viscosity
Elasticity
Solubility
Anti mild growth
Stability in storage
 Adhesives & Film Formers
The primary size materials that act as film formers are
Starch (modified and unmodified)
Polyvinyl alcohol
Carboxy methyl cellulose (CMC)

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Acrylic (various addition polymers)

Other sizing agents are utilized as binders to improve the

adhesion aspects of the film-forming sizing agents.
 Classification:
Adhesives can be classified on the basis of origin:

Adhesives /
Film Former

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Natural Modified Synthetic
Adhesives Adhesives Adhesives

Plant Based Animal Based

Adhesives Adhesives
 NATURAL ADHESIVES
Cellulose and starch have identical chemical constitution.
They are both polymers of glucose, a sugar found in its pure
form in grapes and often referred to as grape sugar.
Plant based adhesives : Starch occurs widely in plants but is
found in its purest form in the seeds (such as in wheat, corn,
rice, and sorghum).
In the roots and tubers (such as in potato, tapioca, and

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arrowroot).
In the stem pith of plants (such as in sago).
These are the adhesives, obtained from seeds of different
plants, e.g., maize, potato, wheat, rice, banana, guar gum etc.
Raw, unmodified starch is designated as pearl starch and can
be marketed as fine or coarse, dustless powders.
Unmodified (pearl) starch has high water bonding or
thickening power when cooked.
 Maize Starch
Maize Starch:
Maize starch, obtained from the corn kernel, is most
commonly used starch for sizing purposes in the United
States. It is used both in its natural form and modified form.

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Characteristics:
It has high viscosity in solution, shows high stickiness and gels
upon cooling.
The film flexibility, strength and elongation are low.
It gives a harsh and rough feel on drying.
Its film cracks and splinters under bending.
It requires an enzyme to de-size.
 Potato Starch:
Potato starch is obtained from white potatoes, which contain
about 18% starch. It is the second best starch after corn
starch. It is most popular starch in Europe.

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Characteristics:

It gives a smoother feel and more transparent film.

It is used for fine goods and colored goods, despite its higher
price.
Its viscosity is not stable and falls off rapidly under strong
agitation.
 Sago Starch:
Granules of sago starch have a characteristic egg-shaped
appearance. It is obtained from various palm trees. It is not as
uniform in qualities as corn or potato starch. It is very difficult
to obtain in a clean, pure condition.

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Characteristics:
It is a good adhesive, owing to its strong sticking power and
softness of sized yarn.
It has intermediate values of viscosity, less than corn starch.
It gives a harsh feel, causing excessive wear and tear.
It takes 4 6 hours to cook its sizing paste perfectly.
The demerits include the variation of quality due to its
material and expensiveness.
Parameters Maize Starch Modified Potato Starch Wheat Starch
Starch

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Penetration Medium Good Good Weak

Low &
Viscosity High & Stable Low & Stable Low & stable
unstable

Moisture 14~16% 14~16% 20~24% 20~24%

 Disadvantages of Natural
Adhesives
Difficult to make paste
Deterioration of paste
Attacked by micro organisms

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Change in viscosity
Difficult to de-size

Therefore pure starches are not used, so derivatives are used.

 MODIFIED ADHESIVES
Treating the natural adhesives with some chemicals produces
modified adhesives.
The property of natural starches to produce high viscosities
can be reduced or eliminated by modifying the starch.
Modified starch

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Carboxy Methyl Cellulose (C.M.C)
 Modified Starch:
The commercially available grades of maize starch are
Penetrose 50500, Penetrose 50100 and Amisol.

It is hydrolyzed starch.

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Easily soluble in water at 600C.
Penetration is strong.
Low & stable viscosity.
Give higher conc. with low viscosity.
Adhesiveness is not very good so used with PVA
 Carboxy Methyl Cellulose
(CMC):
It is generally sold as the sodium salt and is called sodium
carboxy methyl cellulose (SCMC).

Preparation:

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The manufacturing process of CMC consists of impregnating
cellulose (derived from wood pulp) with sodium hydroxide to
form alkali cellulose. It is then treated with mono-chloro acetic
acid (sodium mono-chloro acetate) to produce sodium
Carboxy Methyl Cellulose. Sodium chloride is obtained as a
bye product, which is obtained after neutralizing and drying
the reaction mass.

Wood pulp + NaOH + Mono-chloro Acetic acid Sodium CMC

 Carboxy Methyl Cellulose
(CMC):
Properties:

The CMC has medium and stable viscosity.

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It gives a clear film which is quite strong and fairly flexible.
It has the tendency to absorb and hold moisture.
It is more resistant to biological attack.
CMC is easily de-sized, since it has high water solubility.
Suitable for synthetic & blended yarns.
Cost is higher than maize starch.
 SYNTHETIC ADHESIVES:
These are synthesized polymers and are used for natural &
synthetic yarns.
Synthetic adhesives are derived from petroleum.

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Poly Vinyl Alcohol
Acrylic polymers
 Poly Vinyl Alcohol (PVA):
It is the second largest adhesive used in sizing, produced by
a multi-step process.
It is produced from addition polymerization of vinyl acetate.
First vinyl acetate is made from acetic acid and acetylene
and then polymerized to poly vinyl acetate.

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It is then dissolved in a solvent and hydrolyzed by use of
either an acid or alkaline catalyst.
Poly vinyl alcohol being insoluble in methanol precipitates
out. It is then filtered, washed, dried and packed.
Polymerization degree of PVA used for sizing is 1000~2000,
PVA with polymerization degree of 1700 is used for cotton &
Poly cotton yarns.
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 Poly Vinyl Alcohol (PVA)
The versatility of PVA is because, it can be manufactured into a
variety of modified forms and can be utilized alone or in
combination with other size materials, e.g., starch, and CMC.
Also as a binder with numerous fiber substrates, e.g., glass,
acrylic, polyester, cellulose acetate, nylon.

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PVA with fully or intermediate hydrolysis are used in cotton or
blend yarn sizing because of more hydroxyl groups.
PVA has better adhesion properties due to presence of more
hydroxyl groups.
More hydroxyl group, more hydrogen bonding at fiber-size
interface.
So greater bonding will result into better adhesion.
For hydrophobic/ polyester fibers partially hydrolyzed PVA is
used as it has better adhesion to it because of ester group.
 PVA properties
Available in powder form, moisture regain is 2~6 % & Cost/kg
is 135~140 Rs.
Used for large range of textiles (cotton, polyester etc.)
Size recovery by ultrafiltration is unique quality of PVA.
Soluble in water at room temperature.

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It has high abrasion resistance, can be easily desized in hot
water.
Available in different viscosities i.e., low, medium & high.
High stickiness & high strength.
Good film flexibility, abrasion resistance moisture absorption.
Give less breakage with low size % age.
Due to high adhesion and strength properties, separation at
leasing causes hairiness on yarns.
 Acrylic Polymers
It is a polymer of acrylic acid or acryl amide.
Available in powder form (pure) & in liquid form (modified
form).
Sensitive to heat & easily de-sized.

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Less adhesiveness film strength & elasticity than PVA.
Improves bending strength of sized yarn.
Most commonly used acrylics are size CB, Size CT, Polysize &
AR-100.
Moisture in acrylics ranges from 70~75%.
Acrylic sizes do not require cooking but can be heated up to
100C for dispersing wax or lubricants as well as with other
sizes, e.g., starch.
 Acrylic Polymers
its greatest advantage is the high binding strength to a
number of manmade fibers under weave room conditions.
It has low dry bonding strength on the slasher, facilitating easy
splitting at the bust rods.
It has two types i.e. water soluble and insoluble.

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The water-soluble size consists primarily of the sodium and
ammonium salts of acrylic acid.
Due to presence of particularly ammonium salts, nylon
filament yarns has stronger adhesion to acrylic adhesives.
It imparts good elongation properties to yarn.
Water soluble acrylics have high solution viscosity, therefore it
is used as viscosity builder in low concentration size solutions.
 Acrylic Polymer & Nylon

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They are more readily and easily soluble in water at low
temp.
It is not suitable for low RH environment.
Comparison of different
Adhesives

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 Binders
Binders are true film formers but are generally not used alone
for sizing.
Binders are used to increase weaveability by promoting the
adhesion of the primary film-forming size (starch, PVA,
CMC, acrylic) to a specific fiber yarn.
Acrylics is the only primary film forming material which is also

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used as binder.
Most commonly used binders are
Acrylic
Poly Vinyl Acetate (PVAc)
PVAc is the least expensive polymer, in all polymers in sizing.
PVAc is used as sizing agents on acetate and polyester
filament yarns and as binders for fiberglass, polyester, and
blended spun yarns due to its weak film strength.
 Properties of Binders
Splitting more easily at the bust or lease rods reduced
cohesion
Easier application and removal of size
Reduced hairiness

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Improved size film/solution viscosity properties, e.g., strength
and elongation
Desizeability, etc.
No blocking or sticking on the dry cans
No downstream processing problems (preparation, dyeing and
finishing)
Reduced costs while improving compatibility with other size
box ingredients
LUBRICANTS & SOFTENERS
The purpose of lubricants and softeners is to reduce friction
and abrasion between adjacent yarns as well as between
yarns and machine parts.
They also give a soft handle to the warp and the size film and
to decrease the brittleness of the film through lubrication.

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Some important properties include:
To make the yarn soft.
To make the yarn surface smooth & uniform.
To increase the penetration of size liquor in to yarn.
To increase the moisture absorption in the yarn.
It is used 5~10% on the basis of adhesives.
 Classification of Softeners:
Wax Group
The term wax includes about any lubricant of a solid nature. They
may be animal, vegetable, mineral or synthetic products.
Cetyl alcohol is an animal derived wax and paraffin wax represents
synthetic wax which is used to harden the wax for better lubrication.
Emulsifiers are added to wax to increase desizability.

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Oil Group
Oil group is further classified into vegetable, animal and mineral oils.
Vegetable Oils
Vegetable oils used for textile are obtained from corn, cotton seed,
peanuts, soybeans and coconuts.
Animal Oils
The animal oils are primarily obtained from fish, cattle, chickens, etc.
Synthetic Oils
Synthetic lubricants are mostly used in international markets,
including Olinor R, Vinarol and elvanol.
 AUXILIARY AGENTS
Antiseptic Agent
Protect the warp from bacteria & mild growth.
It is used 0.3~0.5 % of starch.
Copper sulphate (CuSO4) & Zinc chloride (ZnCl2).
Weightening Agent

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Used for finer counts (silk) to increase the weight of yarn.
China clay, Chalk powder, MgSO4 etc.,
Antistatic Agent
Used to reduce the electrostatic charge in synthetic yarn.
Urea, Glycerol, Ethylene glycol etc.,
Urea and sugar are also used as humectants.
They are used to retain moisture in size products.
Starch Swelling Agent
Cause swelling of starch.
Cause even viscosity & good size paste.
Reduce liquor preparation time.
NaOH is most common swelling agent.
It is used 0.2~0.5 % on starch weight.
Hygrocsopic Agent

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Glycerin is popular hygroscopic agent (moisture absorbent).
It is used also used as antiseptic as well as softener.
Neutralizing Agent
Soda ash is used to adjust the PH value of liquor as 7.
Defoamer
Foam may be formed due to poor water quality, PVA. & starch.
Most commonly used defamers are kerosene oil & vinyl emulsifier.
WATER
It should be soft, free from impurities like salts. It should have neutral PH
value.
 TYPES OF SIZNG

Surface Sizing:
Size is applied mainly on surface of yarn. Size material doesnt
penetrate into the core of the yarn.

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Properties:
High abrasion resistance
Poor working performance
Low hairiness factor
 Core Sizing:
Size material is mainly penetrated into the core of the yarn.

Properties:
Poor abrasion resistance
High working performance
High hairiness factor

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Optimal Sizing:
Material is applied on both the surface and penetrated into
the core.

Properties:
Good abrasion resistance
High working performance
Low hairiness factor
 Cold Sizing
Cold sizing is a technique in which adhesive is applied at room
temperature.
C.S agents are a blend of PVA with antistatic agents in water.
Cold sizing is done with a waxing system located between

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warping drum and beam of sectional warping machine.
Size is applied through rotation of rolls.
Size pick up can be adjusted by controlling the difference
between warp sheet speed & applicator roll.
Infra red radiations dry the warp sheet without contact.
C.S. is accurate and controlled liquor application.
No size cooking is required, no labor and less expenditure.
Gentle sizing of warp without loss in elongation.
 Cold Sizing

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 Factors Influencing Sizing
Recipe Parameters
Type of yarn, spun or filament.
Spun yarn parameters such as twist, count, hairiness etc.
Spinning system, i.e., ring, rotor, air-jet, compact, etc.

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Type of weaving machine, i.e. shuttle, projectile, rapier, air-jet,
water-jet, multiphase, etc.
Size add on% requirement.
Number of size boxes on size machines.
Construction and weave of fabric.
Environmental laws.
 Selection of Size Materials
For high twist yarns, highly penetrating material should be
used or a penetrating agent must be added in recipe.
For open end and low twist yarn highly viscous size liquor is
required to avoid excessive penetration of size material.
PVA film has an adhesive strength that is more than three

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times that of starch to polyester fibers.
Highly twisted filament yarns dont require sizing, as they have
smooth and finished surface which is more than enough.
For plain weaves more size concentration is required as
compared to other weaves.
For yarns having high hairiness ratios, more viscous solutions
should be made to encapsulate yarn in better way.
For this purpose binders are added.
 Selection of Size Materials
For coarser counts & higher number of ends, those materials
must be in size liquor which have low dry bound forces.
For coarser yarns more viscous size recipe is required and for
finer counts more penetrating sizing materials are required.
Warps for high speed looms must have high strength as

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compared for low speed looms.
Following table shows preferred sizing w.r.t loom type.
 Sequence of size preparation
-Mixing the adhesive component of size with cold water.
-Addition of wetting agent to the adhesive component.

-Mixing the lubricating agent with boiling water and then

adding it to the mixture of sizing and adhesive component.
-Addition of auxiliaries (antistatic) agent to the above.

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-Boiling all the mixed ingredients on slow fire with continuous
stirring.
-Continuation of boiling till the sizing paste becomes
transparent and of constant viscosity. It is checked by lifting
the liquor with the help of a stick.
-The paste is then cooled with continuous stir.
-It is then filtered through fine fabric.
-The boiled and filtered paste is diluted with cold water to the
required volume as per the liquor to material ratio (e.g 10:1).
 How to check the size paste
Lift the size paste between the thumb and the forefinger
and smudge it for some time.
Separate out the two fingers.
Tackiness should be felt while separating the fingers.

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Spread small amount of size on a glass plate.
Allow it to dry. A formation of thin film on drying indicates
the good preparation of the size paste.

The absence of tackiness and film formation indicates that

the size paste is not properly prepared.
Compatibility between fiber
and size becomes important
With nylon, polyacrylic acid is frequently preferred because of
the adhesion properties,
Where as with polyester, acrylate sizes are usual.
Sizing materials must have high adhesive power and, in

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general, the requirements of man-made fibers are different
from those of natural fibers.
Nevertheless, some sizing materials are suitable for both types
of fiber.
For example, PVA and CMC is suitable for many synthetic
fibers and can also be used for cotton, wool and cellulosic
fibers.
 Single End Sizing
It is used for small sample manufacturing.
Yarn from package is supplied to size box with the help of
thread guide.
Yarn is dipped in size paste by a clamp with roller in size box,

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and positively driven squeezing rollers remove excess.
Hot air drying chamber is used for drying, which is equipped
with epicycle gearing to push forward yarn continuously.
Disc type tensioners are used to separate yarns from drum.
A grooved roller driven winding system is used for winding.
Sizing speed and hot air temperature is controlled digitally.
 Single End Sizing
Rotation of winding drum provides rotary traverse.
It does not have size cooking facility, so separately prepared
size is filled in size box.
A continuous stirrer and hot plate is attached with size box to

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maintain viscosity of size paste.
 Single End Sizing

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