Calculating Essential Greige Warp Set Parameters for Shuttleless Weaving
Greige warp parameters require calculating loom reed width from finished dimensions while incorporating weave crimp, size pick-up, and shuttleless selvedge waste.
Dry Size Pick-up
Ingredient Deposition
Sizing dry weight gains represent the actual amount of dry size ingredients deposited onto the warp yarn after the drying process. Calculating the dry size pick-up requires weighing the dry warp before and after the sizing run. This metric determines the protective film thickness on the yarn surface.
Pressure Adjustment
Deposition volume depends on squeeze roll pressure and size box temperature. Adjusting these parameters modifies the dry size pick-up to match the warp yarn construction. A higher viscosity mixture increases the amount of material adhering to the yarn sheet, which requires faster roll settings to squeeze out the excess.
Yarn Protection
A thin size film fails to shield the yarn from abrasive forces during weaving, resulting in high warp breakage rates. When the dry size pick-up is maintained within the recommended range of eight to twelve percent for cotton, yarn strength and abrasion resistance rise. This protection prevents hairiness from causing adjacent warp threads to cling together.
Desizing Efficiency
Applied material must be easily removed during wet processing to allow even dye penetration in later stages. Excessive dry size pick-up can leave residues on the fabric that block dye uptake, leading to pale spots or streaks. Ensuring an optimal starch level on the woven fabric protects the subsequent dyeing run.