SIZING CALCULATIONS
and
GENERAL RULES OF THUMB
General Rules of Thumb:
1. Water weights 8.33 #/gal.
2. Cooked size weights 8.25 #/gal.
3. Starch contains 88-90% solids.
4. PVA contains 95% solids.
5. Wax contains 100% solids.
6. Dry bIends contain approximately 93% solids. (depending on PVA/starch/wax percentages)
7. Expansion of cooked size due to steam and temperature increase is considered to be
approximately 17%.
8. Liquid resins have varying solids (MSDS information must be used for accurate calculations)
and displace water gallon for gallon.
9. One pound of PVA, starch, CMC, or blends will displace 0.075 gallons of water.
10. One pound of compound or wax will displace 0.0725 gallons of water.
1 1. Wet Pick-Up = % Add-On Size x 100
% Solids in Mix
a) Conventional rolls (45-55 durometer reading)
100% Cotton -) 140-150%
50150 PIC 3 115-125%
100% Poly 80- 100%
100% Rayon + 150% or more
b) High Pressure rolls (SO+ durometer reading)
100% Cotton 3 90-100%
50/50 PIC 3 70-85%
100% Poly + 50-70%
100% Rayon + loo+ %
Courtesy: SeydeWooley Corporation
I
12. Assumed expansion of total size mix from start water.
a) Solids of 7% + = 130%
b) Solids of 3-7% = 125%
c) Solids of < 3% = 120%
13. Moisture contents of sized yarns
a) 100% Cotton + 6-8%
b) 50150 PIC + 4-6%
c) 100% Poly + 3%
14. Proper moisture content eliminates static and shedding.
15. 90% of add-on occurs in first dip of a double dip operation.
16. Increased roll pressures reduce the size add-on, but increase penetration.
17. Increased speed increases size add-on (less time in nip).
18. High viscosity means more surface size, less penetration-low viscosity means opposite-strive
for happy medium
19. Higher yarn counts tend to pick up less than lower yarn counts in the same situation.
20. Temperature of size solutions:
a) Higher temperature + pick-up decreased
b) Lower temperature + pick-up increased
21. As box occupation increases, size add-on decreases.
22. Kettle capacity = gallodich of depth x height + capacity of the concave or
J (diameter x -0034) x kettle height1 + rdiameter x .0034 x concave height1
2
23. Size box level should be run to cover approximately one half of immersion roll.
a) Low level causes low and inconsistent size add-on
b) High level can cause ends to roll and possible break-outs on fiont of slasher.
24. A dry lease should be used to eliminate crossed ends AFTER each warp.
25. To insure proper bust up fiont there should be no less than one less bust rod than number
section beams in the creel.
26. If the size mix passes through your zahn cup at the same speed or faster than water you
should go to a lower numbered cup. Water passes through #2, #3, and #4 zahn cups in 16,9,
and 7 seconds respectively.
2
27. Refkctometers read % solids for cooked size. Temperature can affect the reading you
obtain. As size cools on the refiactometer, solids reading will rise. Be consistent.
28. Paddles in storage kettles generally run at 112 the speed than those in the cooking kettle.
46 RPM-cooking
29. Theoretical size add-on % = Calculated Solids x Wet Pick-Up.
30. Theoretical % solids = % Size Add-On x 100
% Wet Pick-Up
3 1. Wax content in formulation for 100% cotton usually should be at 5-7% of dry solids.
(100% PVA-higher)
32. Pick-up or add-on is the % size on a yam sample, based on the weight of the bone dry sized
sample.
*To Calculate % Solids in Formulation.
To begin calculation of finished gallons, it is important to understand what is meant by (A)
displacement factors, and (B) expansion due to steam and temperature.
A) DISPLACEMENT: When x amount of water is used to start a formulation and x amount of
ingredients (both dry and liquid) are added. The level obtained after these ingredients are added
would represent the displacement of x amount of water by the foreign ingredients.
B) EXPANSION: The amount by which water and ingredients expand due to heat and steam.
STEP I:
Finished gallons = [Start water + displacement of ingredients] x expansion
Sample formula: 230 gallons water
100 # PVA
100 # starch
40 # bider (liquid)
PVA Starch Wax Binder
= [230 + (100 x .075) + (100 x .075) + (15 x .0725) + (40/8.33)] x 1.17
= 251 x 1.17
= 294 Finished gallons
STEP 11:
Calculate dry solids in formulation.
100 #s PVA @ 95% solids = 95 #s dry solids
100 #s Starch @ 88% solids = 88 #s dry solids
40 #s Binder @ 30% solids = 12 #s dry solids
15 #s Wax @ 100% solids = 15 #s dry solids
255 #s product in mix 210 #s dry solids in mix
STEP 111:
To Calculate % Solids in Mix
A) % Solids = dry solids in mix x 100
(tinished gallon x 8.25)
% Solids = 210 x 100
2425.5
% Solids = 8.66
B) % Solids = (Dry Solids x 16) 1(1.33 x Finish Gallons)
% Solids = (210 x 16) l(1.33 x 294)
% Solids = 8.6
*To Calculate Cost 100 #s Slashed as sum in^ 100% Cotton Yarn and 13%Add-On.
Cost/100 #s slashed = Kettle Cost x Add-On x 100
#s Dry Solids
STEP I:
Calculate Kettle Cost
Dry Solids #s in Formula Cost Kettle Cost
95 100 # PVA . x 95 cents -
- $95.00
88 100 # Starch x 16 cents -
- $ 16.00
12 40 # Binder x 50 cents -
- $20.00
x -
-
-
15 15#Wax 40 cents $ 6.00
210 #s Total Kettle Cost = $137.00
*Two ways to Calculate Start Water When Finished Gallons and In~redientsare Unknown.
Start Water = Finish Gallons - Displaced Gallons
1.17
Start Water = 294.00 - 21.00
1.17
Start Water = 230 Gallons
Start Water = Finish Gallon x .855 - Displaced Gallons
Start Water = 294 x $55 - 21
Start Water = 230
*To Calculate Pounds Material to Size x Number of Yards of Yarn.
16,000 yard set
3,500 ends
18 yarn count
50150 polylcotton
-
STEP I:
Total #s yarn to size -
- Number yards in set x number of ends
840 yards/lb. x yarn count
-
- 3704 #s of yarn in the set
STEP n:
#s Dry solids needed -
- Pick-up x total #s
- 10% x 3704
- 370 #s dry solids
STEP 111:
Dry Solids in Formula % Material Solids Information
PVA 100 x .95 = 95 45.2%
Starch 100 x .88 = 88 41.9%
Binder 40x .30 = 12 5.7%
Wax 15 x 1 = 15 7.2%
Total 210 100%
STEP IV:
# of Cooks = 370 Solids = 1.76'Cooks
210 Solids
*To Calculate Dry Solids Cost.
To calculate dry solids cost of a particular product you must first know the dry solids of that product
and second the actual price per pound of that product.
Dry Solids Cost = 100% x Cost/#
Actual Solids
For exampIe, the ingredients in our fonnula are:
PVA at 95 cents/#
Starch at 16 cents/#
Binder at 50 cents/#
Wax at 40 cents/#
PVA -
- 100% x .95 - $0.999 or $ 1.00/#
95%
Starch - 100% x .16 - $0.182/#
88%
Binder -
- 100% x .50 - $1.67/#
30%
wax -
- 100% x .40 - $0.40/#
100%
*To Calculate Box Occu~ation.
To cal&ate box occupation, you first must have a table which describes the number of threads which
will occupy one inch when placed side by side. Secondly, you must know the section beam distance
between flanges and lastly, the number of ends being run. With this information, you can then
calculate % occupation For 54 inch beams, 15's, 50150 P/C yarn with 3000 ends:
% occupation = # of ends being run x 100
threads at 100% x section beam distance between flanges
% occupation = 3000 x 100
105 x 54
% occupation = 300.000
5,670
% occupation = 52.9% occupied
Occupation Table
Yam # Yarn Dia. 100% for 1 inch
5/1 .O 165 60.55
6/1 .0151 66.22
7/ 1 .0140 71.43
8/1 .0131 76.33
9 .0123 81-24
10 -0117 85.67
11 .0111 90.09
12 .O 107 93.81
13 .0102 98.03
14 .0099 101.31
15 .0095 104.93
16 .0092 108.70
17 .0090 111.74
18 .0087 114.94
19 .0085 117.65
20 .0083 120.48
21 .008 1 123.46
22 .0079 126.58
23 .0077 129.87
24 .0075 133.33
25 ,0074 135.14
26 .0072 138.89
27 .0071 140.85
28 .0070 142.86
29 .0069 144.93
30 .0067 149.25
31 .0066 151.52
32 .0065 153.85
33 .0064 156.25
34 .0063 158.73
35 .0062 161.29
36 .0062 162.61
37 .0061 163.93
38 .0060 166.67
39 ,0059 169.49
40 .0058 172.41
41 .0055 181.81
50 .0052 192.31
55 .0050 200.00
60 .0048 208.33
100 % occupancy: no space between ends
75% occupancy: 113 yarn diameter between ends
65% occupancy: 112 yarn diameter between ends
50% occupancy: 1 yarn diameter between ends
40% occupancy: 1 1I2 yarn diameter between ends
