Yarn Count and Sizing Chemistry in Warp Preparation
Warp sizing requires matching yarn packing factor to polymer viscosity, adjusting squeeze nip pressure for precise solids add-on, and maintaining elongation.
Split Rod Separation
Yarn Division
Mechanical splitting of sized warp yarns after they leave the drying section of a sizing machine prevents the yarns from sticking together. Sizing operators monitor the split rod separation to ensure the individual flax yarns are completely isolated before being wound onto the warp beam. This process breaks the starch bridges formed during the drying stage.
Its execution is necessary for preventing warp yarn tear-outs during loom operations.
Mechanical Action
After the warp sheet emerges from the sizing bath and dries, the individual yarns are glued together by the starch or synthetic polymer coating. The sheet passes through a series of cylindrical metal rods that force the bonded yarns apart in a vertical and horizontal direction. This split rod separation must be gentle to avoid rubbing the size coating off the flax fibres, which would reduce the yarn’s wear resistance.
If the rods are not positioned correctly, the high tension can break the warp yarns or damage their protective coating. Properly adjusted rods ensure each strand remains separate and retains its full strength.
Sizing Control
Operators inspect the warp sheet at the front of the sizing machine to verify that the yarns are free from adhesive blocks. This inspection ensures that the yarn unwinds smoothly on the loom. Clean yarn division prevents loom stops.