87

Foam Sizing of Cotton and Blend Yarns: Slashing Trials

1
C. G. NAMBOODRI
Research Center, United Merchants & Manufacturers, Inc., Langley, South Carolina 29834, U.S.A.

ABSTRACT
The objective of foam sizing, like other textile foam processing, is to reduce wet
pickups and conserve energy during the drying operation. In foam sizing, a concentrated
size composition is mechanically foamed at room temperature and is applied to the
warp yarns by the Reed-Chatwood applicator. The main feature of the applicator is
a horizontal padder. The foam collapses at the nip of the padder, applying the size
uniformly to the warp yarn at a lower wet pickup. The size add-on is controlled by
the blow ratio and the solid present in the mix. Because of lower wet pickup, energy
savings and increased production speeds are realized. At low wet pickup, less bridging
of yarns and reduced yam hairiness are also anticipated benefits. For colored yarn
warps, foam application at lower pickups results in less color bleeding and reduced
staining of adjacent yams. This paper reviews critical factors in the development of
foam sizes and results from production trials.

Applying foam in the wet processing of textile fabrics

is now a well accepted commercial technology. Sub-
stantial energy savings and increased production speeds
with foam have been reported in textile finishing [2,
4]. The use of foam for slashing warp yams has been
under investigation at United Merchants for the past
several years [ 1, 3]. Foaming characteristics of com-
mercial sizing materials and laboratory slashing test
results have also been reported by Perkins and Walker
[5, 6].
The objective of foam sizing, as in other foam pro-
cessing methods, is to reduce wet pickup, thereby con-
serving energy for drying and for increasing production
speeds in slashing. This paper will review factors critical
to the commercial development of suitable foam sizes
for cotton and polyester/cotton blends and results from
production slashing trials on the Barber-Coleman, now
Reed-Chatwood, foam size applicator. Advantages of
foam sizing over conventional slashing will be dis-
cussed.
Discussion
In a conventional slashing operation of warp yams
of cotton and blends of cotton and polyester, the warp
is immersed in a hot size bath at 180-200F (82.2-
93.3C) and then squeezed using a pair of nip rolls to
remove the excess and dried on drying cans. Figure 1
schematically illustrates a conventional slashing pro-
cedure. Starch, PVA, starch-PVA blends, CMC, acryl-
Presented at the Cotton Textile Conference, Beltwide Cotton Re-
search Conference, New Orleans, Louisiana, January 1985.
FIGURE 1. Schematic diagram of conventional dashing.
ics, and polyester are the principal sizes. In addition
to the size, lubricants are present, generally waxes based
on hydrogenated tallow, tallow glycerides, para~n wax,
or blends. About 10-15~ solids are generally used in
conventional size boxes, and the temperature is main-
tained at 180-200F (82.2-93.3C) by heating coils.
After impregnation and squeezing off, the warp yarns
will generally have a pickup of 90-130%, of which 80-
115% is water to be evaporated during drying.
In order to reduce this large wet pickup and thus
reduce energy costs, researchers have been investigating
numerous methods, including high pressure slashing,
the Cutts system, hot melt sizing, and foam sizing. The
first method uses a pair of high pressure squeeze rolls
to minimize wet pickup. The Cutts system uses a kiss
print roll type application of concentrated size mix. In
the hot melt sizing, a melted wax-based composition
is applied to traveling warp yams through a grooved
applicator roll.
In the United Merchants foam sizing system, a con-
centrated size composition is mechanically foamed at
room temperature. The foam is applied to the yarn by
a pair of horizontal rolls, as shown in Figure 2. There
is no precooking of size, and heated storage tanks or
size boxes are not required in foam sizing, compared

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88

to the line speed of the applicator so as to maintain a

constant contact time between the foam and the yam.
The effect of the gate opening and the range speeds on
wet pickup is discussed in this paper under spun yam
sizing.
VALFOAM® SIZE

ValfoamO size is a compound system containing the

principal film former, lubricants, and foaming agents.
FIGURE 2. Schematic diagram of foam sizing.
Since foam sizing requires the use of high solids/low
viscosity liquors, polymeric dispersions are used in the
to conventional slashing. The foam is applied to both
system rather than solutions. A carboxylated acrylic
sides of the warp yam at the padder and collapses at ester
copolymer dispersion is the principal film former
the nip, uniformly distributing the size liquor. The dry in Valfoam 325-144
size, which is a 36-37% solid car-
add-on of size is controlled by the percent solid in the
boxylated acrylic ester copolymer, white in color, with
mix and the blow ratio, that is, the ratio of the weight a
pH of 3-3.5 and a viscosity of 250-500 cps. The
of a given volume of foam to that of the same volume influence of blow ratio on half life is shown in
of liquid [4]. By using foam, the wet pickup is sub- 4. Half-life is the time
Figure
required to drain half of the
stantially reduced to one half or less that of conven- liquid from foam, which is affected by the higher blow
tional slashing. Following the size application, the yam ratio. The foam
viscosity and the blow ratio relationship
is dried on drying cans. Because of lower moisture for Valfoam size are shown in
Figure 5. The foam vis-
pickup, less energy is required to dry the warp yams. cosity is directly proportional to the blow ratio. For
By using existing plant dryers, increased production selecting the system suitable for foam size applications
speeds can be achieved. Because of the lower wet pickup to control wet pickup, both the blow ratio/viscosity
in foam sizing, less bridging of yams, reduced hairiness,
relationship and the blow ratio/half-life relationships
and less color bleeding of colored yams are also antic- were taken
into account: for a higher pick up a lower
ipated benefits. blow ratio is used, and for a lower pick up a higher
blow ratio is used. In general for most of warp yams,
REED-CHATWOOD FOAM SIZE APPLICATOR a 10:1 to 20:1, range is suitable for foam sizing with

Figure 3 is a schematic diagram of the Reed-Chat- Valfoam. Laboratory single end sizing and yam abra-
wood foam applicator unit. The unit is essentially built sion tests were part of the selection procedure to de-
both film former and the size. Laboratory anal-
on the principle of horizontal padding. In order to
sup- velop
ply foam to vertically traveling warp, a small reservoir yses of the size add-on and pickup were compared for
of foam is used between the pad roll nip and end dams. Valfoam with horizontal pad application on 65/35
There are two catch pans under the pad rolls to collect polyester/cotton yams. The data in Table I indicate
any excess foam.

FIGURE 3. Schematic diagram of foam size applicator.

The plates or gates move up and down depending

on the range speed controlling the foam contact with
the yam. The vertical movement of the gates is slaved FIGURE 4. Half-life versus blow ratio, Valfoam size.

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 89

FIGURE 6. Blow ratio versus add-on, pilot plant trials

using Valfoam size.
FIGURE 5. Viscosity versus blow ratio, Valfoam size.
TABLE 11. Pilot plant trials on a Reed-Chatwood applicator.
TABLE 1. Calculated add-on versus add-on analysis.

a 325-144 on lab. horizontal pad
minute (0.18 mps).
Add-on determined from alkaline desizing of 37/I, 65/35 poly-
ester/cotton warp yarn sized with Valfoam 325-144.
on 65/35, 37/l P/C at 12 yards/
TABLE Ill. Wet *
pickup versus pad pressure.

there is no preferential pickup of size from foam by

yam, and the size add-on can be determined from the
pickup obtained.
SPUN YARN SIZING
Evaluations were made with Valfoam size on the
pilot plant Reed-Chatwood 18&dquo; unit to foam size a spun
37/1 polyester/cotton 65/35 blend for weaving on a
pilot plant shuttle loom. The relationship of blow ratio
and size add-on for Valfoam size on the Reed-Chat-
wood applicator at 60 yards/minute (0.911 mps) is
shown in Figure 6. In order to control size add on, both
solid in the mix and blow ratio adjustments are nec-
essary. Calculated wet pickups at various blow ratios
from percent add-on are given in Table II. The add-
ons were determined by alkaline desizing of the pilot
a
325-144 Size I 5: I ; 0.75 inch ( I .91cm) gate opening-37/t PT/
COT; 65/35 yam at 60 yards/minute (0.91 mps).
Figure 7. A four inch ( 10.16 cm) height at 60 yards/
minute (0.91 mps) gives the same contact time as a
two inch height (5.08 cm) at 30 yards/minute (0.45
mps). The wet pickups do correlate. There is some effect
on wet pickup caused by the gate opening and the con-
tact time of the warp yarns with the foam bank.
Pilot plant weaving trials on shuttle looms indicate
that 10-12~ Valfoam size add-on is required for e~-

cient weaving.
plant trial yams. The calculated wet pickups show that
the wet pickup range at 60 yards/minute (0.91 mps) is
40-50% depending on the blow ratio and solid of the PLANT TRIALS
mix. Data in Table III show that pad pressure has little Plant trials using spun polyester/cotton warp yams
effect on wet pickup. and Valfoam size were conducted on the 66&dquo; Reed-
The effect of the gate height of the applicator on Chatwood applicator, which was installed at Bath Mills
Valfoam size application was studied and is shown in of UM&M. The mechanical foamer used for the pro-

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90
FIGURE 7. Percent wet pickup versus gate height of
.
foam size applicator.
duction trials was made by P. Campen of Denmark.
Because of lower wet pickups, the steam supply to one
half of the dry cans was cut off and comparable plant
production speeds were used. Both 65/35, 37/ and
50/50, 16/1 polyester/cotton spun yams were used for
trials and subsequently woven in the mills.
Figure 8 shows that the production add-on for the
full width unit does correlate with the pilot plant ap-
plicator data. At 25% solid level and 15:1 to 20:1 blow
ratio, add-ons were 10.5 to 12.5% and wet pickups at
these add-on levels were 45-50%.
FIGURE 8. Blow ratio versus add-on, production data compared
to pilot unit data.
From 500 yards (457 m) to 3000 yards (2743 m) of
warp yams were used for trials. The side-center-side
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variation of add-on 65&dquo; Beninger warp was only
on a
0.5%, showing uniformity of application. The weav-
ings were done on Sauer 400 looms. The 65/35 poly-
ester/cotton yarns were yarn dyed and woven at one
mill and the 50/50 polyester/cotton in another UM&M
mill. The colored yams showed very little bleeding in
these trials. Conventional slashing of the colored yams
in hot size mix contributes to excessive color bleeding
and staining problems. Weaving efficiency as such was
not determined in these trials. In some trials using the
325-144 size, the warp breaks were higher for foam
sized yams. We are presently modifying the size mix
to improve weaving efhciency. There was no excessive
shedding or reed build up with foam sized warp com-
pared to conventionally sized.
Figures 9 and 10 compare SEM photomicrographs
of polyester/cotton warp yams from woven fabrics ei-
ther foam sized or conventional starch/PVA sized. The
photomicrographs show good adhesion of foam size
after weaving, indicating excellent abrasion resistance
of size. Cross sections showed no excessive penetration,
which is desirable, and the encapsulation of the yam
was uniform.
FIGURE 9. SEM photomicrograph of foam sized 65/35
PET/COT yarn from fabric (420X). ,
FIGURE 10. SEM photomicrograph of conventional sized 65/35
PET/COT yarn from fabric (420X).

Figures 11 and 12 are photographs of warp yams,
foam sized and conventionally starch/PVA sized. The
yarn hairiness is about the same. We anticipate that
because of less bridging at low wet pickup, foam ap-
plication will reduce yam hairiness.
FIGURE l l. Foam sized yam showing hairiness (6X).
FIGURE 12. Conventionally sized yam showing hairiness (6X).
ENERGY SAVINGS
The list below illustrates the estimated energy savings
obtainable from foam sizing. Steam supply to half of
the drying cans could be cut off if conventional pro-
duction speeds are used. If all the drying cans are op-
erating, then production speeds could be at least dou-
bled (from 80 to 160 yards/minute or 1.22 to 2.44 mps).
Most of the prontability in foam sizing would come
from increased productivity. There is the possibility of
using shorter drying ovens in place of drying cans,
thereby saving energy and space in a slasher room.
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91
DESIZING OF VALFOAM SIZED FABRICS
The Valfoam size can be removed from sized fabrics
by a simple alkaline scouring operation. Table IV il-
lustrates the effectiveness of alkaline desizing of Val-
foam sized polyester/cotton yarn. A 15 minute scouring
of the sized yam at 180F (82.2C) using 0.5% soda
ash and 2% solvent scour removed the size completely.
TABLE IV. Desizing of foam sized polyester/cotton spun yarn
37/ 1, 65/35, PET/COT.
For foam sized fabric scouring in plant, an alkaline
peroxide pad batch procedure was suitable. This
method was particularly good for colored yam fabrics
because the peroxide gave whiteness to undyed yarns
in fabric without color bleeding. Alternatively, an al-
kaline peroxide pad steam procedure could be used in
place of batching for continuous preparation.
ADVANTAGES OF FOAM SIZING
The following possible advantages are realized by
foam sizing method: no size cooking or size box needed,
energy savings in drying or increased production
speeds, use of shorter drying ovens in place of cans,
improved size utilization, ease of removal in desizing,
less color bleeding on dyed yarns, less bridging and
yarn hairiness, less shedding or cleaner loom shed, and
higher weaving efbciency.
We have not yet shown that higher weaving e~-
ciency could be obtained with foam sizing. Also no
experimental verifications have been made as to the
use of short drying ovens in place of can dryers.
.
Conclusions
Foamable size composition for sizing cotton and
polyester/cotton warp has been developed for slashing
on the Reed-Chatwood foam applicator. Preliminary
plant trials with foam sizing and weaving show promise
with spun polyester/cotton yarns. Further improve-
 92
,
.
,

ments on Valfoam size are being investigated to obtain Literature Cited

higher weaving efficiency.
Lower wet pickups with foam save energy and permit 1. Bedenbaugh, R., DOE Final Report No. CS-40334-T2,
higher production speeds, and there is less yam hairi- 1984.
ness from bridging of yams and less color bleeding. 2. Gregorian, R. S., Bafford, R. A., and Namboodri, C. G.,
The process has been proven to be a commercially American Chemical Society Symposium No. 107, p.
practical method, and plant trials are continuing to 155-173, 1979.
optimize the Valfoam size system for production. 3. Namboodri, C. G., DOE Contract Report No. 77CS-
40056-A001-4, 1981.
ACKNOWLEDGMENTS
4. Namboodri, C. G., and Duke, M. W., Foam Finishing
of Cotton-Containing Textiles, Textile Res. J. 49, 156-
I wish to acknowledge the contributions of Rick 162 (1979).
Porter, R. A. Bafford, Larry Smith, Eddie Faircloth, 5. Perkins, W. S., and Walker, R. P., Foam Sizing, Textile
Minh Tran, Michel Avril, and Bruce Henson of United Res. J. 52, 547-554 (1982).
Merchants and of George Dilling and Roger Hartwig 6. Perkins, W. S., and Walker, R. P., Some Observations
of Reed-Chatwood in the development of the process. on Foam Sizing, Textile Chem. Colour. 16
, 89-91 (1984).

Cotton Tenacity Measurements with High Speed Instruments

1
ROBERT A. TAYLOR
USDA, ARS, Cotton Quality Research Station, Clemson, South Carolina 29631, U.S.A.

ABSTRACT
Measuring fiber strength in cotton encompasses sampling, fiber preparation, and
bundle clamping. The precision of the measurement is a function of these steps as
well as the precision of measuring the force and mass of each bundle under test. A
detailed analysis of each step in the tenacity testing sequence is presented here. Com-
parisons between newly developed high volume instruments and conventional methods
(Pressley and Stelometer) show that the conventional methods are biased toward the
long, strong fibers in a cotton, whereas the high speed instruments use less accurate,
indirect methods to measure bundle mass and produce a force measurement that is
confounded by differences in fiber crimp.

A new class of fiber testing instruments is evolving
to meet the demand for increased information and
better precision while measuring the quality of cotton
enroute to market. The quality evaluation procedure
involves removing or cutting two small lint samples
from each bale at the gin during the bale pressing op-
eration. These samples are delivered to a USDA mar-
keting service office for testing in a controlled labora-
, tory. Upon arrival at the laboratory, the samples are
opened and exposed to a controlled environment for
a time sufficient to assure the proper
temperature and
Presented at the Cotton Textile Conference, Beltwide Cotton Re-
search Conference, New Orleans, Louisiana, January 1985.
moisture equilibrium. In offices where the new high
volume instruments (HVI) are being used, measure-
ments of fiber length, length uniformity, strength, fine-
ness, and lint color are currently provided. Trash con-
tent measurements will soon be added to. the systems.
There are two manufacturers of the HVI systems
currently being used in USDA marketing services of-
fices, Motion Control, Inc. (MCI) of Dallas, Texas, and
Special Instruments Laboratory, Inc. (Spinlab) of
Knoxville, Tennessee.2 The length measurements with
2
Trade names are used solely to provide specific information.
Mention of a trade name does not constitute a warranty or an en-
dorsement of the product by the U.S. Department of Agriculture to
the exclusion of other products not mentioned.

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