Warping and Sizing

Warping and sizing are the weaving preparation steps that wind hundreds or thousands of warp yarns in parallel onto a beam and coat them with size, a protective film that helps them survive the stresses of weaving.

In warping, yarn packages are mounted on a creel and their ends are wound side by side onto a beam at uniform tension. Direct, or beam, warping suits long runs of plain warps, while sectional warping builds the warp in bands and suits patterned and coloured warps. In sizing, also called slashing, the sheet of warp yarns passes through a size box containing a size formulation, often based on starch, polyvinyl alcohol or acrylic binders, then through squeeze rollers and drying cylinders before being wound onto the weaver's beam.

Size binds protruding fibres, reduces hairiness and increases abrasion resistance, so warp yarns can withstand repeated friction against healds, drop wires and the reed. Well-prepared warps reduce end breaks and loom stoppages, which strongly affects weaving efficiency.

Size add-on, viscosity, temperature, moisture and yarn tension must be controlled, because too little size gives poor protection while too much makes yarn stiff and brittle. Size must later be removed by desizing before dyeing and finishing, which adds water and effluent load. Requirements differ for spun and filament yarns, and warp preparation also includes drawing-in or tying-in of ends to the loom.

Key points

Warping winds many parallel ends onto a beam at uniform tension
Sectional warping suits patterned and coloured warps
Sizing coats warp yarns to reduce hairiness and resist abrasion
Size is removed later by desizing before dyeing and finishing

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Related terms

Terms that refer to Warping and Sizing

Warp KnittingTextile & Automotive Manufacturing