Pre-wetting in sizing

The concept of pre-wetting with hot water before impregnating them with size solution in new, but it has received considerable attention in recent years. Objective Pre-wetting is a washing process which improves specific adhesive force of size on the surface warp yarn and specially hot water is used in pre-wetting before impregnating warp sheet with the size solution. Main Parts and Working The main parts of pre-wetting are guide rollers, immersion rollers, squeezing rollers, hot water tray and pump for water supply. Depending upon the application range and operation, two basic techniques are used in pre-wetting. 1. Pre-wetting in a separate compartment with two immersions and two squeeze rollers. 2. Combined pre-wetting and sizing. In conventional two size box sizing machine is used. The 1stsze box may be used for pre-wetting and the 2nd for sizing. Pre-wetting is done with hot water and temperature is about 90C is used to ensure adequate washing out of pectin in case of cotton yarn. The un-sized warp sheet firstly passes through the 1st box containing hot water. Generally two set of immersion roller and a pair of squeeze rollers is used. This intensive wetting and washing enables the hot water to penetrate the warp sheet. The hot water partially dissolves waxes, dust and other materials loosely held with fiber. The 1st squeezing action holds back the dirt also exerts the air from the yarns so that more water is absorbed during the 2nd immersion. The longer dwell time in the wetting compartment permits the increase in sizing speeds even for coarser yarns. Generally squeezing pressure of upto 10,000 daN is required to ensure adequate pre-wetting and to avoid dilution of size in the size box. The wet sheet is then taken to the 2nd box containing size solution. In the other commercially available system the pre-wetting and sizing compartment are combine in a single unit. But use the same principle as discus above. The improvement in the surface adhesion of the size take place because the outer surface of the yarns is wetted with size, whereas the yarn core already wet with water due to pre-wetting, this will prevent the excessive penetration of size. Such improved surface coating and lesser penetration of size due to prewetting allow the size add-on to be reduce by up to 30 to 50% depending upon the set of fabric and the type of loom on which it is woven.

Figure 1: Pre-wetting with two immersion and two squeezing rollers

Figure 2: Pre-wetting using one immersion and one squeezing rollers.

Advantages Improvement in surface adhesion of the size to the yarn, as the outer surface is wetted with size and the core is wet with hot water due to pre-wetting. The reduction in size add-on results in direct cost saving. It allows the size add on to be reduced by up to 30 to 50%. Better adhesion to the surface; increase yarn strength by 15 to 20% Also reduce the hairiness of the yarn. It is well known that sizing is responsible for 50 to 70% of total effluent pollution. The estimated saving due to reduced size consumption per machine, depending upon the set of fabric, sizing chemicals and yarn characteristics. Improved weaving characteristics during looming process. Lower effluent treatment costs high productivity. Optimal weaving efficiency. Pre-wetting significantly reduces the degree of sizing and cutting down size costs considerably. Additionally, the reduced hairiness cuts down thread breaks during weaving, resulting in increased efficiency.

References Textile Warp Sizing By Goswami, Anandjiwala & Hall