Sizing Add-On, Water Evaporated & Cylinder Drying Load

The formula

This is the expression the tool evaluates. Every term is named underneath, with the unit it must be supplied in.

How the result is derived

Step by step, from the values you type to the figure on screen.

1. The 8 inputs are read from the form on every keystroke: Total Ends, Sizing Speed, Yarn Linear Density, Wet Pickup, Size Liquor Solids, Target Moisture after Drying, Steam per Unit Water and Drying Efficiency.
2. Each value is checked against the accepted range in the input table below. A value outside its range stops the calculation rather than producing a misleading figure — the results blank out and a message appears.
3. The validated values are substituted into the expression above, which resolves Size Add-On together with every supporting figure in one pass — no value is carried over from a previous entry.
4. The supporting outputs — Water Evaporated, Steam Demand, Drying Heat Duty, Dry Warp Entering, Sized Warp Leaving, Size Solids Consumed, Size Liquor Picked Up and Water per Kilogram of Warp — come from the same pass, so they always describe the same case as the headline figure.
5. Results are rounded for display only. The full-precision value is used throughout the chain, so reading a rounded intermediate figure back into the tool by hand can shift the last digit.

What each input means

Where to read each value on the floor, the unit it must be in, and the range the tool accepts.

What the tool returns

The headline figure and every supporting value it is built from.

Worked example

Substituting

Fifty-seven kilograms an hour of size solids required three hundred and eighty-four kilograms of water to be boiled off. That ratio - nearly seven to one - is the whole economics of sizing, and it is why low-wet-pickup squeeze systems and high-solids recipes pay for themselves in steam rather than in starch.

How to use it

1. Work through the input groups in order — Warp Through the Box and Size & Drying. The defaults are a realistic case, so you can change one value at a time and watch what moves.
2. There is no calculate button. Every figure recalculates as you type or drag, which is what makes this usable for a what-if sweep rather than a single answer.
3. Read Size Add-On in the dark results panel — that is the headline figure, expressed in %.
4. Check the supporting rows underneath (Water Evaporated, Steam Demand, Drying Heat Duty, Dry Warp Entering, Sized Warp Leaving, Size Solids Consumed, Size Liquor Picked Up and Water per Kilogram of Warp) before acting on the headline — they are where an implausible input usually shows itself first.
5. Reset to defaults returns every field to the reference case, which is the quickest way to check whether a surprising result came from the tool or from an input you had changed earlier.

Where this is used

• Process planning — establishing Size Add-On before a trial is booked, so machine time and material in Warping, Sizing, Weaving & Fabric Formation Control are committed against a calculated figure rather than an estimate.
• Costing and quotation — Size Add-On is an input to the cost sheet, and quoting from a worked number rather than a remembered one is what keeps a margin intact.
• Troubleshooting — when the floor result drifts from plan, entering the measured values (starting with Total Ends) shows how much of the gap in Size Add-On each variable explains.
• Teaching and study — the accepted ranges bracket normal Warping, Sizing, Weaving & Fabric Formation Control practice, so moving one variable at a time shows the shape of the relationship rather than a single answer.

Reading the result

Typical bands and what each one is telling you.

Assumptions and limits

• The balance is per kilogram of dry warp entering the box and assumes the size liquor composition is constant, which drifts in practice as water evaporates from the box and as the warp removes solids preferentially. Wet pickup should be measured by weighing warp before and after the squeeze rolls rather than taken from a setting, since it moves with roll pressure, roll hardness, speed and yarn hairiness. The steam ratio is a lumped figure covering cylinder condensate, flash and radiation losses and varies widely between machines; the heat duty is the more transferable figure. Drying efficiency here covers everything between the steam and the water and should be established for the specific machine. Size recovery and reuse are not modelled.
• Every input is bounded to the range normal practice occupies (Total Ends 100 to 30000, Sizing Speed 5 to 150 m/min and Yarn Linear Density 4 to 200 tex, and so on for the rest). Those bounds are guard rails against typing errors, not a claim that the formula fails one unit outside them.
• The calculation is deterministic: the same inputs always give the same result. It carries no allowance for machine condition, operator skill, ambient conditions or lot-to-lot material variation unless an input above explicitly represents one.
• Nothing is sent anywhere. The maths runs in your browser, so the numbers you type never leave the page.

Standards and further reading

• ASTM D629 - Quantitative Analysis of Textiles, the method that verifies add-on by desizing and reweighing.
• ISO 2060 / ASTM D1907 - linear density for the warp mass.
• ASTM D2654 - moisture in textiles, for the target moisture determination.

Questions people ask