Assigning Spinning versus Sizing Root Causes in High Speed Weaving Faults
Differentiating spinning and sizing root causes requires cross-sectional microscopy and high-speed tensile testing to map size encapsulation against yarn mass variation.
Size Spots
Localized Irregularity
Hardened clumps of sizing material that adhere to the fabric surface create visible defects in the finished weave. These size spots usually originate from dried skin forming on the surface of the size mix or from splashes in the drying section. They prevent the even penetration of dyes and chemicals, leading to light or dark patches in the colored cloth.
Identifying these defects early in the inspection process is a priority for mill quality control.
Process Cause
Poor agitation in the size box or inadequate cleaning of the immersion rollers often leads to the formation of these lumps. When the sizing machine stops for a long period, the size can dry on the yarn or the equipment, later breaking off and sticking to the warp. Modern mills use circulating pumps and enclosed boxes to minimize the risk.
Regular maintenance schedules include a thorough cleaning of all surfaces that contact the wet yarn.
Finishing Rejection
Fabric containing frequent size spots is often classified as seconds and sold at a discount. Because these hardened areas are difficult to remove in the standard desizing wash, they remain a permanent flaw in the cloth. Customers for high-end linen expect a surface free from any chemical or mechanical contamination.