6.

Yarn Sizing
6.5 Numerical Problems
1) 100 kg bone dry warp yarns were sized to the add on of 8% and dried
to an overall (yarn and dry size) moisture content of 10%. Calculate
the final weight of the sized yarns.
Solution:
Bone dry warp = 100 kg
Pick up = 8%
So,

Mass of dry size

100 = 8
Mass of bone dry warp

or,

Mass of dry size

100 = 8
100 kg

or, Mass of dry size = 8 kg

Total mass of bone dry (size +yarn) = 108 kg
Moisture content = 10%
So, 10 =

W
100 , where W is mass of water
W 108

or, W = 12 kg
So, final weight of sized yarn is = (108+12) kg = 120 kg

2) A 20 kg cotton warp, having moisture regain of 8.5%, is sized with a

paste of 15% concentration. If a 10% add on the bone dry weight of
the yarn is aimed then what should be the wet pick up? How much
water has to be evaporated so as to leave 8% moisture content in warp
and size film?
Solution:
Moisture regain (MR) of cotton is 8.5 %
or,

W
100 8.5 , where W= mass of water and D= oven dry mass of yarn
D

or, W = 0.085 D
.
Total mass of yarn = oven dry mass of yarn + mass of water
or, D + 0.085 D = 20 kg
or, D = 18.43 kg
Dry size added
= D

add on %
100

18.43

10
1.843 kg
100

Now, mass of water (W) = (20 -18.43) kg = 1.57 kg

Wet pick up (WPU) =

Add on %
= 10/15 = 0.667
Concentration %

Total mass of size paste picked up by yarn = 0.667 18.43 kg = 12.29 kg

Mass of water within size paste picked up by yarn =

100-Concentration%
12.29

100

100-15
12.29
= 10.45 kg
100
Total mass of water in the yarn after pick-up
= Mass of water in the size paste + Mass of water originally present in yarn
= (10.45 + 1.57) kg = 12.02 kg
Water to be retained (for 8% moisture content in yarn and size film)
=

8
1.843 8
18.43
92
92

= 1.76kg
Therefore, the mass of water to be evaporated = (12.02 1.76) kg = 10.26 kg.

3) A 40 tex cotton yarn has add on of 8%. If the moisture regain of the
yarn is 10% then determine the oven-dry mass of the size added per
kg of the unsized yarn.
Solution:
Size add on = 8%, Moisture regain = 10%
So,

W
100 10 , where W= mass of water and D= oven dry mass of yarn
D

or, W =0.1D
Now, total mass of unsized yarn = 1 kg
So, D+W

= 1 kg

or, D+0.1D = 1 kg
or, D = 0.909 kg
Now, add on is 8%.
So,

Mass of dry size

100 8
Mass of oven dry yarn (D)

or, Dry size = D x 0.08

= 0.073kg = 73 gm.
4) The stretch in a sizing machine is 3%, 5% and 2% in the creel zone,
sizing zone and drying zone respectively. If the warp crimp in the
woven fabric is 10% then determine the length of fabric that could be
produced from 1000 m length warp sheet in each of the warpers beam.
Solution:
Total stretch in sizing can be calculated using the following multiplicative
expression.

Total stretch = 1

3
5
2
1
1

100 100 100

= 1.103
So, length of sized yarn = (Ly) =1.1031000 = 1103 m
Crimp % =10%
So, 10

or,

Lf

Length of yarn(Ly )-Length of fabric(L f )

Length of fabric(L f )

Ly

1103 m
=1002.7 m
1.1
1.1

Length of fabric is 1002.7 m

100

5) A sizing machine is running at 150 m/min with 6000 ends. The add on
requirement is 12% and concentration of the size paste is 18%. If yarn
count is 20 tex (without moisture) and residual moisture content in the
sized yarn and film after drying is 10%, then calculate the number of
drying cylinder required, if one drying cylinder can evaporate 4 kg
water per min.
Solution:
Oven dry mass of yarn=

WPU

150 6000 20
kg = 18 kg
1000 1000

Add on %
12
= 0.667
Concentration % 18

Total mass of size paste = WPU Oven dry mass of yarn

=

12
18 kg = 12 kg
18

Mass of dry size = Mass of size paste concentration

Total mass of yarn and dry size = (18 + 120.18+) kg =

20.16 kg

So, for moisture content of 10%

Mass of water to be retained in yarn and size film
=

1
20.16 kg
9

= 2.24 kg

100-Concentration%
= 9.84 kg
100

Mass of water in size paste of 12 kg= 12

So, water to be evaporated = (9.84 - 2.24) kg/min = 7.6 kg/min

Drying capacity of one cylinder = 4 kg/min.
So, 2 cylinders will be needed.

6) Determine the failure rate of sized yarns if the six yarns tested for
abrasion breaks broke after 1025, 1550, 2232, 3785, 5608 and 7918
cycles. What is the reliability of the yarns at 2000 cycles if the reliability
curve is exponential?
Failure rate = number of failure/cycle =
=

Total number of failure

r
=
Total number of cycles t

6
1025 1550 2232 3785 5608 7918

2.712 10-4 per cycle

Average life ( ) =

Reliability

=e
=e

= 3686

(according to exponential failure where pdf of failure is =

2000
3686

= 0.581

7) Draw the life history curve for the sized yarns from the following
information.
Number of cycles
1-10
11-20
21-30
31-40
41-50
51-60
61-70
71-80
81-90

Number of failures
35
7
6
5
5
6
8
9
19

Number of survivors
65
58
52
47
42
36
28
19
0

Life history curve is obtained by plotting failure rate (Y axis) against number of
cycles (X axis). From the table it is observed that 35 failures have occurred between
the 1st and 10th cycle. As the exact cycle number is not known for these 35 failures,
it is assumed that all the failures have taken place at the mid-point of duration i.e.
5th cycle.
Failure rate (R) =

Number of failures
Mid point of observation number of failures +End point of observation number of survivers
35
0.042
35 5 65 10
6
R3(25.5) =
0.0035
6 25 52 30
5
R5(45.5) =
0.0022
5 45 42 50
8
R7(65.5) =
0.0032
8 65 28 70

7
0.0055
7 15 58 20
5
R4(35.5) =
0.0024
5 35 47 40
6
R6(55.5) =
0.0024
6 55 36 60
9
R8(75.5) =
0.0041
9 75 19 80

R1(5.5) =

R9(85.5) =

R2(15.5) =

19
0.0118
19 85 0 90

Failure rate

Abrasion cycle