Effect of Sizing Optimization on Yarn Breakages in Poly/Modal Weaving

Textile Engineering

This study explores Poly/modal blended yarns are extensively used in modern textile applications due to their excellent combination of softness, strength, moisture management, and wearer comfort. However, during high-speed weaving, these yarns often experience frequent warp breakages caused by abrasion, yarn hairiness, electrostatic charge accumulation, and insufficient yarn cohesion. These breakages result in frequent loom stoppages, reduced weaving efficiency, and inferior fabric quality. This research investigates the impact of sizing optimization on reducing yarn breakages in 40s poly/modal (70% modal / 30% polyester) warp yarns. The study evaluates pre-sizing and post-sizing yarn characteristics including tensile strength, elongation, evenness, hairiness, abrasion resistance, and count strength product (CSP). A carefully optimized sizing formulation consisting of binders, lubricants, antistatic agents, and film-forming components was applied using a Karl Mayer sizing machine. Weaving trials were conducted to assess warp breakage rate, loom efficiency, and fabric defects. The results demonstrate that optimized sizing significantly enhances yarn performance, minimizes breakages, and improves overall weaving efficiency and fabric quality.

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.