Sizing g

Faisal Ansari
B.E Textile Manager Technical G.S I d t i (P t ) Ltd G S Industries (Pvt.) Ltd. E/20-A S.I.T.E, Karachi

Sizing
Sizing may b d fi as be define
th process of applying protective coating / the f l i t ti ti size on warp yarns in the production of woven fabrics for improving weaving efficiency.

Size
Size is defined as the co pos o o matter app ed to the warp ya for S e s de ed e composition of a e applied o e a p yarn o weaving protection. Size usually consists of a water soluble, filmforming macromolecule and a lubricant.

Purpose
Sizing is carried on warp yarns in order: To withstand the rigors of weaving To minimize the abrasive stresses on warp yarns To improve the weaving efficiency

Process
Sizing process is carried on slasher In slashing warp yarns to be sized slasher. slashing, are go through the following sequence: 1. The warp yarns are let-off as a flat sheet and then pass through a size applicator consisting of a trough containing the size formulation and squeeze rolls. 2. The yarns pass over heated cans to dry. 3. 3 At the exit end of the slasher is an arrangement of bust bars which separate each warp end from its neighbor. 4. The individual warp ends pass through a reed which guides the yarn onto the take-up beam take up beam.

Sizing Agents
Sizing agents are selected on the basis of type of fabric ,environmental friendliness ease of environmental friendliness, removal, cost considerations ,effluent treatment, etc Natural sizing agents Synthetic sizing agents

Natural sizing agents

Natural sizing agents are based on natural substances and their derivatives:

1. Starch and Starch Derivatives Native Starch

Corn (Maize) Tapioca (Cassava) Wheat Sweet Potato Potato (farina) Sago Rice Yucca

Modified Starch
Thin Boiling Starch Dextrin British Gum Oxidized Starch Starch Ethers

2. Cellulosic derivatives
Carboxymethylcellulose (CMC), Methylcellulose Hydroxyethylcellulose

3. Protein-based starches
Glue Gelatin Albumen

Synthetic sizing agents

1. 2. 3. 4. Polyacrylates, Modified polyesters, Polyvinyl alcohols (PVA), Styrene/maleic acid copolymers

Starch is a complex carbohydrate which is insoluble in water ;

it is used by plants as a way to store excess glucose . Biochemically, starch is a combination of two polymeric carbohydrates
(polysaccharides) called amylose and amylopectin amylopectin.

1. Starch

Carbohydrates
Carbohydrates (Saccharides) are chemical compounds that contain
Oxygen, Hydrogen, and Carbon atoms, and no other elements. They consist of monosaccharide (sugars) of varying chain lengths and that have the general chemical formula Cn(H2O)n or are derivatives of such The smallest such. value for "n" is 3. Carbohydrates are classified by their number of sugar units: Monosaccharides such as glucose and fructose, Disaccharides such as sucrose and lactose, Oligosaccharides Polysaccharides such as starch, glycogen, and cellulose.

Monosaccharides
Monosaccharides may be divided into aldoses, which have an aldehyde group on the first carbon atom, and ketoses, which typically have a ketone group on the second

Non-cyclic forms of carbohydrates

OH O O

Here are the non-cyclic forms of: fructose

(a ketose, i.e. contains a ketone group)

O HO H H H OH OH H H H OH OH OH

H HO H H

OH H OH OH

OH

OH

OH

ribose glucose fructose ribose aldehyde eto e ketone hydroxyl glucose

(both aldoses i e contain an aldoses, i.e. aldehyde group)

Non-cyclic and cyclic forms of glucose

O

There are three other ways of representing the cyclic form

OH H O H H OH H OH

OH H OH OH HO

OH

non-cyclic form of glucose

HO H H

Haworth formula
H HO HO H OH H O H OH OH

OH

cyclisation
HO H OH H OH O

chair representation
O HO OH

cyclic form of glucose

H HO H H

HO CH2OH OH

OH

stereo projection

Structure of Glucose
(Non Cyclic form to cyclic form conversion stages)
O
1

H OH H H HO H H

CHO OH H OH OH CH2OH HOCH2

HO

H CHO

H HO H H
5 3

OH

OH OH
6

OH

OH

OH CH2HO H HOCH2 OH OH H CH2OH H H OH HO H OH OH H H HO H OH - Glucose O OH H HO H CHO OH H CH2OH H OH O H H H OH

4

H H

H CH2OH OH OH H OH CHO H H

HO

H CHO OH

HO

CH2OH
6

H OH
3

O H H
2 1

HO

OH

H OH -Glucose

Disaccharides
Disaccharides are composed of two monosaccharide units bound together by a covalent gy glycosidic bond. The binding between the two sugars results in the loss of a g g hydrogen atom (H) from one molecule and a hydroxyl group (OH) from the other.

Maltose a disaccharide
A maltose molecule is formed from two g glucose molecules
OH H OH HO H OH O H H OH HO H OH H OH OH O H H OH H H

A water molecule splits out this is a condensation reaction

OH

condensation

H O H

and the two glucose units are linked by a glycosidic bond (or link)

H OH HO H

H OH H H HO HO

H O OH H

OH O

Lactose a disaccharide
OH H H OH H OH H OH OH

An -lactose molecule is formed from one f df galactose molecule and one -glucose molecule A water molecule splits out this is a condensation reaction and the two monosaccharide units are h id it linked by a glycosidic bond (or link)

OH HO H H OH H OH O OH H H

HO

condensation
OH OH HO H H OH H OH H OO H H H OH H OH H OH OH

Hydrolysis of sucrose
OH H O H H O H OH HO HO H O H H OH OH H H

A sucrose molecule reacts with a water molecule to form one -glucose molecule and one fructose molecule

OH HO

hydroylsis The glycosidic bond gy is broken in the reaction

H OH H

OH O H H OH H OH HO OH O H H H OH

OH HO

and the two monosaccharide units are formed

HO

Oligosaccharides
Oligosaccharides composed of longer chains of monosaccharide units bound together by l b glycosidic bonds. Oligosaccharides typically contain between three and nine idi b d Oli h id t i ll t i b t th d i monosaccharide units

Polysaccharide
Starch
CH2OH H OH O H OH O O H H H

Polysaccharides are composed of longer chains of monosaccharide units bound together by glycosidic bonds. Polysaccharides contain greater than ten monosaccharide units.

CH2OH H OH O H OH O H H H O H

CH2OH O H OH H H H O OH H H

CH2 O H OH H H O OH H

CH2OH O H OH H H H O OH

Amylose and Amylopectin

Amylose
It is a linear polymer of glucose linked with mainly (14) bonds. It can be made of several thousands of glucose units (5,000-20,000). It is one of the two components of starch. The (14) bonds promote the formation of a helix structure. The number of repeated glucose subunits (n) can be many thousands.

CH2OH H OH O H OH O H H H O H

CH2OH O H OH H H H O OH H

CH2OH O H OH H H H O OH H

CH2OH O H OH H H H O OH

 Amylopectin
Amylopectin is formed by non-random (16) branching of the amylosetype (14) D l t (1 4) D-glucose structure. Glucose units are linked i a li t t Gl it li k d in linear way with (14) bonds. Branching takes place with (16) bonds occurring every 24 to 30 glucose units. Starch is made of about 80% amylopectin. Amylopectin is highly branched, being formed of 2,000 to 200,000 l 200 000 glucose units. It inner chains are f it Its i h i formed of 20 24 glucose d f 20-24 l subunits. The glucose residues are linked through alpha-1,4 glycosidic linkages.

CH2OH H OH O O H OH O H H H O H

CH2OH O H OH H H H O OH H H

CH2 O H OH H H O OH H

CH2OH O H OH H H H O OH

 - 1, 4 linked D-glucose
- 1, 4,6 D-glucose branch points

Amylopectin Model Structure

2. Cellulosic Derivatives
Carboxymethyl cellulose y y
Carboxymethyl cellulose ,or CMC ,is a cellulose derivative with carboxymethyl groups (-CH2COOH) bound to some of the hydroxyl groups of the glucopyranose monomers that make up the cellulose polymerIt is synthesized by the alkalicatalyzed reaction of cellulose with chloroacetic acid . l d i f ll l i h hl i id

O H 2C O O CH2 H O OH H O H O H H OH CH2OH H H OH O H O H CH2OH H H OH H O O H O H H O CH2 O CH2 O H 2C O H H OH O H O H CH2OH H H OH H O H O H H OH

OH

OH

 Methyl cellulose
Methylcellulose (or methyl cellulose) is a chemical compound derived from cellulose. It is a hydrophilic white powder in pure form and dissolves in cold (but not in hot) water, forming a clear viscous solution or gel Chemically, methylcellulose is a methyl ether of cellulose, arising from substituting the hydrogen atoms of some of cellulose s hydroxyl groups cellulose's OH with methyl groups -CH3, forming -OCH3 groups.

CH3 CH3 H OH H H CH2 O CH3 OH O H O O H H OH H O CH2 O H O H H O CH3 CH2 O CH3 H H OH O H OH H CH3 O H

 Hydroxyethylcellulose
Hydroxyethylcellulose is a chemical compound which is derived from cellulose. This is soluble in water but not in organic solvents. Hydroxyethylcellulose is formed by treating soda cellulose with ethylene chlorohydrin.

CH2CH2OH CH2CH2OH H OH H H CH2 O CH2CH2OH OH O H O O H H OH H O CH2 O H O H H O CH2CH2OH CH2 O CH2CH2OH H H OH O H OH H CH2CH2OH O H

3. Protein-based starches
Glue
Historically, glue only refers to protein colloids prepared from animal tissues. The meaning has been extended to any type of glue-like substances that are used glue like to attach one material to another.

Gelatin

Gelatin (also gelatine) is a translucent brittle solid substance, colorless or slightly yellow, nearly tasteless and odorless, which is created by li htl ll l t t l d d l hi h i t db prolonged boiling of animal skin, connective tissue or bones. Gelatin is a protein product produced by partial hydrolysis of collagen extracted from skin, bones, cartilage, ligaments

Albumen

Egg white is the common name for the clear liquid (also called albumin or g glair/glaire) contained within an egg. It is the cytoplasm of the egg, which until g ) gg y p gg, fertilization is a single cell. It consists mainly of about 10% proteins dissolved in water.

Synthetic sizing agents

1. Polyacrylates
Polyacrylates are made from acrylate monomers. Acrylate monomers are esters which contain vinyl groups that is two carbon atoms double-bonded to each groups, is, other, directly attached to the carbonyl carbon. Polyacrylate is a water soluble polyelectrolyte that has excellent adhesion to nylon therefore it is used to size filament nylon yarns. The affinity is through hydrogen bonding of the -COOH with amide and amine end groups in the nylon polymer.

2. Modified polyesters,
Water dispersible polyester polymers can be made by incorporating solubilizing groups into the polymer backbone and controlling the molecular weight This weight. is done by including 5-sulfoisophthalic or trimellitic acid as one of the dicarboxylic acid monomers in the synthesis of the polymer. These polymers have particularly good adhesion to polyester fibers and make good sizes for continuous filament yarns. y

3. Polyvinyl alcohols (PVA)

Polyvinyl alcohol is manufactured by hydrolysing polyvinyl acetate. The reason is because vinyl alcohol does not exist as a monomer. y Polyvinyl acetate, however, can be hydrolysed into polyvinyl alcohol under acidic or basic conditions.