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Brand: Karl Mayer Model: size o matic (SMR) Origin: Switzerland

Technical data
Working width Creel: 1500 - 2800 mm Size box - cylinder box: 1800 - 2800 mm beaming machine: 2600 - 5400 mm Beam creel Warp beam diameter: 800 - 1400 mm Size box First squeezing roller: 12 KN second squeezing roller: 40 KN immersion roller: 1.8 KN Prewetting section First squeezing roller: 12 KN second squeezing roller: 100 KN Cylinder drier

Diameter of the cylinders: 800 mm steam pressure: max. 5 bar Beaming machine Beam diameter: 1016 - 1400 mm speed: 5 - 150 m/min winding tension: 5000 N Size preparation Cooker: 1500L storage tank: 2000 L
Number of cylinder: 12 Creel capacity: 16 Number of size box: 1(with prewettening) Size box capacity: 120 Liter Number of wax box: 1 Cylinder dryer: Teflon coated Tensile strength: 5000-13000N

UNITS OF THE MACHINES 1. Creel or Back Beam unit

2. Size box unit 3. Drying unit 4. Leasing unit 5. Beaming or Take up unit


1. Creel tension 2. Squeezing pressure 3. Drying temperature 4. Speed of sizing 5. Leasing zone tension 6. Beaming tension 7. Beaming pressure


Control KAMCOS Operator Interface-IPC / Touchscreen 12,1", Ethernet interface for networking and connection for relevant data acquisition and Teleservice.

Compact size box (CSB-PW) With prewetting device for saving sizing material and for achieving optimum features in processing.

Dry-separating section, waxing device and cylinder drier Best-sized yarns leave the cylinder dryer and are easy to separate due to their excellent size features.

Beaming machine in a compact construction and user friendly more


Creel for sizing high speed beam

Type of creel: combination vertical and horizontal Type of brake used: pneumatic brake Brake pressure= 300- 500 N Creel capacity=16 Creel height = 1850 mm Peg to peg distance = 1050 mm (vertical) Peg to peg distance = 1100 mm (horizontal) Creel length = 1010 cm Beam width can be used= 2100 mm(maximum) Creel width of sectional warp beam = 800 mm High speed creel to sectional creel = 1500 mm Tension between creel and size box = 550N

SIZE BOX Squeezing pressure is selected based on the following parameters

Viscosity of size solution Ends/ unit length Twist Count Running speed of the machine

DRYING UNIT In these zone 12 cylinders is arranged as shown in the figure. First 8cylinder is in temperature at 105 -1150c Above this 8 cylinder there is a fan to remove the stagnant layers of vapor for efficient and quick drying of warp sheet, so saving the steam and minimize cost. These 8 cylinders is driven by the warp tension as there is little friction to overcome to rotate the cylinder. Rests of the cylinders (4 cylinders) are driven by the driving mechanism. They are driven by the chain and sprocket. Temperature in these 4 cylinders is much lower than first 8 cylinders 85 95oc.

105 115 0c 85-950c

LEASING UNIT After sizing warp yarn become continuous paper like sheet. So it is not possible to leasing, drawing, denting and weaving with such paper like sheet. Hence, we use leasing rod in the leasing unit to split the warp sheet into individual warp end. Leasing zone tension = 98 -1160 N Average tension = 750 N

BEAMING OR TAKE UP UNIT In the beaming unit sized yarn is finally wound on the weaver beam. On the weaver beam pressure is applied by pneumatic pressure is applied.

Beaming pressure: 90 1360N Applied pressure: 960 N Beaming speed: 5- 500m/min Beaming tension: 5000-13000N Working width: 2200 mm maximum

SIZE INGREDIENTS USED: 1. Modified starch 2. Super size: Super size is an organic product. It is a mixture of purified gel and sterified mixed starch with the addition of softener and antistatic agent SIZE RECIPE: Count of the yarn is 40/1 Ne Water = 600 L Modified starch = 97.5 kg Super size = 13.5 kg

Size cooking tank capacity = 1000 L Size storage tank capacity = 1000L SIZE COOKING PROCESS:(open cooker) Temperature = 95 0c Time =30 min At first take 600 L cold water in the size cooking tank Add 97.5 kg modified starch is mixed with cold water After 15 min stirring super size is added in cooking tank

Then cooked the solution with steam for 30 min at cooking temperature of 950c. Finally store the size solution in the storage tank at temperature 800c

SIZE PICK UP PERCENTAGE CALCULATION For calculating the size pick up percentage we take 20 ends of cotton warp of count 40 and each end having 1m length. We take the weight of 20 ends with an electric balance before sizing. Again we take the weight of 20 ends of the same yarn after sizing. From the data given bellow we calculate the size pick up percentage. Weight of 20 ends of 1m length before sizing = 0.24 gm Weight of 20 ends of 1m length after sizing = 0.28 gmSize pick up percentage = (0.275- 0.240) / .24 X100 % = 14.44 % In the mill we find out the size pick % for different count of yarn: count Ne 30/1 Size pick 11 up % 40/1 14.44 50/1 14 60/1 16.66 80/1 16

EXTENSION % CALCULATION In sizing it is essential to maintain some tension in the warp to operate the machine successfully. Without some proper tension it is not possible to size the warp. So some tension is applied to the warp, and this tension causes the extension of warp yarn slightly. And it should be minimum, because more extension in sizing causes more warp breakage.

For calculating the extension after sizing we make mark in the warp yarn during warping. We select the extra warp of the end of the last section. When the mark of the yarn reaches on measuring cylinder we note the reading of the wounded warp length on the monitor of the machine. Then after the winding of 100 meter at slow speed we again mark the yarn on same position on the measuring cylinder. We also note the beam number. Collect the marked warp yarn from the extra warp winder from the let off side of the loom easily. Then we cut the length of the yarn between the two marks. Then measure the length of the length of warp manually with the help of an accurate measuring tape. Then we tabulate the data and calculate the average extension percentage after sizing
Obs. length before sizing cm length after sizing cm extension% average extension %

1 2 3 4 5

10000 10000 10000 10000 10000

10300 10295 10297 10300 10298

3.00 2.95 2.97 3.00 2.98 2.98



For calculating the percentage increase of breaking strength we take 20 ends of unsized cotton warp of count 20 and find out the breaking strength of 20 ends by a strength tester. We make ten observations. Again we find out the breaking strength of same warp of 20 ends after sizing. We calculate the % increase of breaking strength of sized over unsized from the data given below:
no.of obs. 1 2 3 4 5 6 7 8 9 10 average count ne 40 40 40 40 40 40 40 40 40 40 unsized 20 end sized 20 end % increase breaking strength breaking size over lb strength lb unsized 8 11.2 40 7.5 10.5 40 8 11.6 45 8.2 11 35 7.5 10 33 8 11 37 8.2 12 46 8 11 37 7 9.5 36 7.5 10.5 40 = 7.79 = 10.83 = 38.9

From the above table we see that there is increase of breaking strength of 38.9 %

REFRACTROMETER Function: Function of the refractrometer is to determine solid particle percentage with respect to water present in the size solution.

Importance of determining the solid particle: Solid particle percentage indicates the amount of size ingredients in the solution and also the viscosity depends on the amount of size ingredients added. If the count is finer and EPI is high then we generally increased the solid particle percentage. Practically, The lowest solid particle percentage = 8(coarser count) The highest solid particle percentage = 22(very fine count) In the mill we test different size solution for different count and obtain the following value of the solid particle percentage: obs. 1 2 3 4 count 30/1 40/1 50/1 60/1 yarn type combed combed combed compact EPI 72 80 108 130 solid particle % 11 12 15 18

VISCOSITY OF SIZE SOLUTION For better warp sizing it is important to maintain ideal size solution viscosity. If size solution has extreme high viscosity, solution will not permeate the warp yarn. So, warp will be hard and harsh in feeling and 2 or more warp yarn may be bound together. On the other hand if the viscosity is lower than required, SPU will be lower because the size solution may be easily squeezed out. In the mill there is a viscosity cup with the dimension mentioned below: 45 mm 65 mm


56 mm

Viscosity cup


We immerse the viscosity cup in the size cooking tank and full the cup with the size solution. With the stop watch we determine the time of falling of size solution from the cup. We repeat the observation 5 times and tabulated the data in the table given below: observation cunt Ne 1 2 3 4 5 40 40 40 40 40 time sec 16 15 15 16 16 average time sec


In the mill the ideal viscosity is selected with considering the ends per inch and count of the yarn and in accordance with the practical working experience. Ideal viscosity time in sec is used in the mill = 10 20 sec Viscosity time for different count: count Ne viscosity time sec 30/1 15 40/1 15 50/1 17 60/1 18

MOISTURE REGAIN AFTER DRYING: Moisture regain controlling device: Moisture controlling device is a light weight metallic roller. The roller is in continuous contact with the warp sheet. An extremely small electric current varies as the regain changes and these variations are amplified by electronic amplifier. And the output is shown in the monitor through a controlling and recording instrument. Moister regain of cotton directly affect the strength the tensile strength. Over drying not only decreased the tensile strength but also causes the warp to become brittle. Sizing m/c of Karl Mayer is equipped with moisture regain controlling device. The m/c always shows the regain % of the sized yarn in the monitor, it uses the WINDOWS XP operating system. Some time, moisture regain test is also done manually to ensure that the m/c is running efficiently and showing the accurate regain % in the monitor. We also determine the regain % of sized warp. PROCESS: At first we take 5 gm of sized yarn by an electric balance. Then placed sample in the sample dryer at the temperature of 110 0c. We dry the sample 10 min and take the weight of dried sample.

We calculate the weight loss. Again we place the sample in the dryer and calculate the weight loss. We found further weight loss. So we dry the sample for shorter period. Calculate the weight loss again. Finally we found no change in weight loss and take the value of weight loss 0.340 gm We repeated the process for the 10 sample and tabulate them below: obs. sample weight gm dry weight gm 4.64 4.66 4.63 4.67 4.62 4.64 4.65 4.62 4.64 4.63 weight loss gm 0.360 0.340 0.370 0.336 0.380 0.360 0.350 0.385 0.360 0.370 regain% average regain%

1 2 3 4 5 6 7 8 9 10

7.76 7.29 7.99 7.19 8.22 7.76 7.53 8.33 7.76 7.99