For excellent results, it is essential to have high quality sized beams. In order to ensure the best possible outcomes in our woven creations, it’s imperative to address any issues that may arise when weaving with sized beams. We’ll discuss the most common faults of sizing and their underlying causes in this article. But don’t worry, we won’t leave you hanging. We will also discover effective methods for correcting these faults and ensuring high quality standards for weaver’s beams. Let’s get started on this journey together and discover how to deal with sizing challenges for a more smooth weaving experience.
Faults of Sizing:
Following is a list of some of the most important faults of sizing.
- A broken, missing, crossed and sticky ends.
- Defective selvedge.
- Ridges on the beam.
- Size spot.
- Shinnery.
- Improper drying.
- Size stitching
- Sandy warp
- Hard sizing
- Uneven sizing.
1. A Broken, Missing, Crossed and Sticky Ends:
Among the most frequent causes of all these faults of sizing are breaks during sizing, accumulating layers of yarn on the warper’s beams, and missing ends, such as the total number of ends in the back beams and some that are missed during the actual warping process. During sizing, crossed ends are formed, which means the warp ends are not present in their proper place on the beam. Therefore, knotting one end to the other end is possible. When size ingredients are improperly cooked, sticky ends form.
Remedy:
- Missing ends should be reconnected to the back beams.
- Make sure the warp ends are positioned properly, minimizing the need for knots.
- Using revolving lease rods, reduce stickiness after drying.
2. Defective Selvedge:
The selvage ends in a weaver’s beam can cause difficulty when it comes to undoing the ends during the weaving process due to their unevenness. The selvedges of the sized beams that have bulged and sunken edges are defective selvedges.
Remedy:
- To control sunken selvedges, set the expandable comb at the headstock correctly.
- Maintain uniform tension by properly adjusting the expandable comb.
- For bulged beams, adjust the beam pressing roller in such a way that it reaches both flanges.
- Contact the flanges with the pressing roller and ensure proper alignment.
3. Ridges on the Beam:
The ridges on a beam form when the ends of the beam that fit in one dent of the comb are not allowed to spread out.
Remedy:
- This defect can be minimized by properly adjusting the dancing roller at the headstock.
- Make sure the dancing roller is aligned and in good condition.
4. Size Spot:
In the process of sizing a garment, this fault of sizing can occur as a result of an inadequate or incorrect addition of the size ingredients into a chemical mixing tank during the sizing process, resulting in the warp yarn not mixing correctly with the chemicals.
Remedy:
- The chemical mixing tank needs to be filled with the correct amount of size ingredients gradually and in the correct proportions.
- To ensure the proper mixing of the size chemicals with the warp yarn, you will need to use appropriate mixing techniques.
- Make sure the mixture is continuously stirred to guarantee a uniform distribution of the ingredients of different sizes.
5. Shinnery:
Due to friction between the drying cylinder and the warp yarn during the drying process, defects are usually produced as a result of the friction.
Remedy:
- To prevent excessive friction between the warp yarn and the cylinder, adjust the drying temperature.
- To reduce friction and avoid overheating, let the warp yarn dry on the drying cylinder for an adequate period of time.
6. Improper Drying:
This types of faults of sizing may occurs when the warp yarn is subjected to drying conditions which are either excessive (over-drying) or insufficient (under-drying), which can lead to two distinct issues: over-drying and under-drying. When yarn is over dried, it becomes too rigid. If the yarn is under dried, bacteria can grow on it, potentially resulting in yarn breakage.
Remedy:
- Avoid both over-drying and under-drying by setting the drying parameters to the recommended levels.
- Ensure that the warp yarn is not exposed to excessive or insufficient drying temperatures and times.
7. Size Stitching:
This type of faults of sizing occurs when the drying process is not perfect after the sizing process is completed.
Remedy:
- Ensure that the drying parameters (temperature, time, and humidity) are set correctly for the specific sizing material and yarn type.
- Ensure that the warp yarn receives sufficient time and heat for complete drying.
8. Sandy Warp:
The possibility of this type of fault of sizing occurs when the material being used for sizing is not properly ground or crushed in order to achieve the desired consistency in the sizing process.
Remedy:
- Make sure the size material used is high quality and meets the required standards. Use reputable suppliers.
- To process the material, use well-maintained and suitable grinding and crushing equipment.
9. Hard Sizing:
This fault occurs when too much sizing material is applied to the warp yarn during the sizing process, resulting in an excessive buildup of size on the yarn fibers during the sizing process. A sizing recipe with incorrect proportions of sizing ingredients may result in a large amount of size being applied to the yarn as another cause of this fault.
Remedy:
- Make sure the sizing recipe contains the appropriate amounts of sizing ingredients for the specific yarn and weaving requirements. Conduct trials and adjustments if necessary.
- Ensure that sizing material is not overapplied and that precise and consistent sizing techniques are used to achieve the desired sizing level.
10. Uneven Sizing:
This Sizing fault can occur when the process of sizing is not performed correctly. Among these errors are errors in applying size material or inadequate control of drying conditions. A size liquor’s concentration, which contains sizing ingredients, can affect the process of sizing. Under-concentration and over-concentration can both cause problems.
Remedy:
- Standardize sizing procedures to ensure consistency and accuracy.
- Size liquor concentration must be adjusted accurately based on the yarn and fabric specifications.
You may read:
- Definitions of sizing, objectives and impact on warp yarn.
- Why sizing is called heart of weaving.
- Primary and Secondary Size Ingredients.
- Characteristics of Good Size Ingredients.
- Types and Techniques of sizing.
- Working Principle of Slasher Sizing Machine.
- Size Cooking Equipment.
- Drying Methods in Sizing Process.
- Modern Control System of Sizing Machine.
- Size Recipe for Synthetic Yarn
