The quality of textiles relies on both raw material selection and processes like spinning and sizing. One critical issue is yarn hairiness, which impacts weaving efficiency and the appearance of fabrics. Understanding what causes yarn hairiness and how to address it is essential for improving textile quality and lowering production costs. This article will explore the factors that contribute to yarn hairiness and suggest practical solutions. Readers will gain insights into common problems and their fixes in the textile sizing process.
1. Causes and Solutions for Yarn Hairiness
Yarn hairiness refers to the tiny fibers on the yarn’s surface that can affect fabric quality. There are three types of hairiness:
- Original hairiness (from spinning)
- Sizing hairiness (from the sizing process)
- Regenerated hairiness (from weaving).
2. Original Hairiness
This type of hairiness occurs during spinning when some fibers stick out from the yarn as they are twisted and pulled. The amount of hairiness depends on the quality of the yarn and the spinning method.
3. Sizing Hairiness
Sizing hairiness happens when the yarn is coated with a sizing solution. The coated fibers can change the yarn’s appearance and affect weaving quality. Studies show that more sizing can lead to more hairiness.
3.1 Characteristics
- Higher amounts of PVA and sizing lead to worse effects during weaving.
- The hairiness sizing rate is higher than the yarn sizing rate. Microscopic analysis shows hairiness sizing can be 1-2 times its weight. Sometimes, the ends of the fibers even form small lumps, making the hairiness more damaging.
3.2 Causes
- Wrong sizing material: If the sizing solution doesn’t work well with the yarn, the coating can break, leading to more hairiness. Using too much fully hydrolyzed PVA can cause issues.
- Incorrect sizing rate: Too much sizing increases resistance during drying, while too little sizing can’t cover the hairiness properly. Research shows that hairiness can hold 1-2 times its own weight in sizing.
- Low moisture content: If the yarn is too dry, the coating becomes brittle, reducing adhesion and flexibility. This leads to more broken fibers and hairiness during the drying process.
3.3 Solutions
- Use the right sizing solution: Follow the “like with like” rule to pick a solution that matches the yarn. This ensures the coating is strong and durable, preventing breaks. Using less PVA or avoiding it entirely helps reduce hairiness.
- Control the sizing rate: Adjust the amount of sizing to match the yarn and weaving needs. Testing different rates is the best way to find the right balance.
- Maintain proper moisture levels: Keep the yarn moist, especially in dry seasons, to prevent excess hairiness. Water-soluble polyester chips from our company adjust to seasonal conditions, helping reduce dryness issues.
3.4 Other Solutions
- Wet splitting: Splitting the yarn before it’s completely dry reduces drying resistance and minimizes hairiness.
- Layered pre-drying: Drying the yarn in layers prevents breaks in the coating, reducing hairiness.
- Anti-stick coating: Coating the drying cylinder with a non-stick material lowers the separation force between the yarn and the dryer, protecting the coating.
- High-pressure sizing: Using high pressure during sizing helps the solution stick tightly to the yarn, reducing hairiness.
- Smooth rubber rollers: Rubber rollers with moderate hardness and a compression width of no more than 15mm work best for reducing hairiness.
- Higher machine speeds: Fast machine speeds during sizing and drying help the yarn separate quickly from the metal rollers, making it smoother.
- Wax coating: Applying wax after sizing reduces surface friction and static, making it easier to split the yarn and lowering hairiness.
Yarn hairiness is a tricky problem, but we can fix it with some simple changes and better sizing materials. By knowing what causes yarn hairiness and adjusting the sizing rates and materials, we can make better textiles. Improving our processes and using new technologies will help the textile industry produce higher-quality products.
