Karl Mayer has developed a new sizing machine called PROSIZE that provides several benefits over conventional sizing machines. PROSIZE uses a sponge effect with 3 application zones to increase warp density and a low minimum trough volume to reduce size liquor waste. It ensures 100% bonded yarn transport and application of size through spray bars for more homogeneous sizing. PROSIZE also features a short wet application zone and vertical size box for increased visibility. It can reduce size pickup by 5-10% while maintaining weaving efficiency and has benefits for various fabrics like eliminating sticky ends in bedsheets and stopped marks. PROSIZE represents an innovative breakthrough in sizing technology.

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KARL MAYER PROSIZE® –
A breakthrough innovation in sizing
A.T.E. Enterprises Private Limited
V2.0 May 2017

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What is sizing ?
 The process of coating a yarn surface to improve weaving performance is
called sizing. Sizing is the most important operation to attain maximum
weaving efficiency for all spun yarns and filaments. Sizing is called ‘the heart
of weaving’.
Objectives of sizing
Optimum
end breaks in weaving
size add-on
 To improve the warp yarn strength, smoothness
and abrasion properties without affecting the
elasticity of the yarn
 To improve weaving efficiency by reducing the
warp breaks during weaving
Objectives:
 To provide a protective and lubricating coating
(size) to the surface of the yarn to enable the yam
to withstand abrasion and stress which occurs
during the weaving process

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 It is said that well sized is half woven; however, the variances encountered
during the sizing are manifold and can make or break the weavability of yarn
 The principle sizing factors influencing weaving efficiency are:
● Size pick-up ● Hairiness ● Yarn stretch
 The increase in strength and abrasion resistance of yarn mainly depends on:
 Size recipe mixing
 Size recipe penetration in yarn
 Size recipe pick-up on yarn
 Over all sizing conditions
 The application of size recipe is chosen based on the count of yarn, blends,
twist and uniformity of yarn as well as the construction of fabric to be woven
 Sizing of warp sheets requires strict control and monitoring of the consistency
of the size recipe, the sequence of its mixing, level of size recipe in the saw
box, squeezing pressure, viscosity and temperature
Sizing – a complex process

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 To improve the weavability of warp yarn by making it more resistant to the
action of high speed weaving
 To maintain good fabric quality by reducing hairiness, weakness and by
increasing smoothness and absorbency of yarn
 To increase tensile or breaking strength of cellulosic yarn
 To increase the elasticity and frictional resistance of yarn
 To reduce electrostatic formation
Purpose of sizing

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Limitations of the conventional size application technology
High volume of size bath:
 Difficult to maintain constant temperature and
viscosity in all the size box’s points
 Limitation in the working width
 Not effective cleaning and filtering
 Limitation of cover factor/occupancy of yarn in sizing
Sticky and crossed ends caused by:
 Not complete bounded yarn transport; the yarn is not
clamped when immersed into the size liquor
 Free yarn passage between the squeezing zones
 Long yarn pass in the wet zone
Stop marks problem and broken ends in case of long
machine stops

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Introducing PROSIZE®
A breakthrough innovation in sizing technology

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PROSIZE® – what is it ?
 PROSIZE® is the result of a project started by Karl Mayer in 2011 for the
development of a new machine that could improve all of the following aspects of
the sizing process:
 Reduction of size add on
 Ensure fresh size recipe
applications
 Increase of weaving efficiency
 Better ergonomics and process
transparency
 Increased productivity
The first step was to analyse the limitations of the conventional system

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PROSIZE® – features and benefits
Main technology advantages
 Sponge effect
- 3 high turbulent uniform application zones to increase the maximum warp density
 Lowest minimum trough volume in the market
- Reduction of size liquor sewerage
 100% bonded yarn transport
- Yarn is driven only by the main application roller
- 3 fix squeezing/clamping points (reduction of sticky & cross ends)
- Yarn can reach an optimum (low) stretch.
 Spray bar technology
- Homogeneous & controlled size transfer to the yarn. Furthermore, only cleaned and filtered size
is applied to the yarn
 Short and controlled wet application zone:
- Yarn runs only over one main driven roller
- Total length of wet zone is reduced
- Free yarn passage between the intermediate squeezing zones are eliminated

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PROSIZE® – no limitation in cover factor/occupancy
PROSIZE® ensures practically 100% coverage of yarn in sizing
10 kN
10 kN
40 kN

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 Through advanced control and regulating technology KARL MAYER PROSIZE®
ensures perfect sizing of warp sheets with:
 Uniformly optimal sizing process
 Low hairiness on the warp yarn
 Lowest elongation of yarn during sizing
 Automatic section tension control
 High level of reproducibility with -
- simple operations
- automatic monitoring of all parameters
- comprehensive recipe management
Perfect sizing

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• Full accessibility to each roller. The complexity of
broken end repairing is completely eliminated
• The operator has a complete overview of the
machine process conditions
PROSIZE® – vertical size box (VSB)
You can see the process through a glass
Ergonomics and process transparency

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• Increased working range (20 – 100%)
• Perfect homogeneity of the size liquor
• A VSB in a wide working width is the right solution to replace the double size box system
PROSIZE® 2200
- 20 back beams 2200/1000
- 1 size box VSB
- 10 drying cylinders
- Beamer 2600/1000
Sizing machine suitable for
all narrow width weaving
machines (170 – 230 cm)
Single size box system in large working width
PROSIZE® – vertical size box (VSB)

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Cylinder drier type DU
New bearings and SoftDry
PROSIZE® cylinder drier SoftDry – special features
 The drying cylinder with SoftDry technology is a
complete new design made to perfectly fit with the
VSB
 Equipped with perfectly sealed bearings that do not
need any maintenance
 Stronger and more modern construction
SoftDry –
The innovative yarn motion control
during drying
Even tension increase over the whole
drying process

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SoftDry – the innovative yarn motion control during drying
 On conventional driers, all cylinders are forced to
move together by a chain transmission
 This doesn’t allow any yarn elongation in between
the drying cylinders
 However, yarn is elastic, especially during the
drying phase of the sizing process
 The rigidity of the chain and the elasticity of the
yarn are in conflict
 As the chain always prevails, the consequence is
a slippage of yarn onto one or more cylinders
surface
Conventional chain transmission

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 The purpose of SoftDry technology is an equal
distribution of yarn tension cylinder by cylinder,
leaving the yarn free to elongate or shrink according
to its intrinsic properties, avoiding friction
 As a result, quality is enhanced and the yarn is
softer. Indeed, the weaving is more efficient and
chemicals consumption can be reduced
 SoftDry is fully self-adjustable, regardless of the type
of yarn in use. It does not require any special
settings, calibrations, or additional human
intervention
SoftDry system with 4 cylinders
Yarn tension is smoothly increased,
while its elasticity is preserved
The smart algorithms control each cylinder the way the yarn needs
SoftDry – the innovative yarn motion control during drying

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PROSIZE® – key highlights
 Increase of weaving efficiency, thanks to
better homogeneity and less dust
 Reduction of the size add on and size liquor
sewerage
 20% increase of yarn coverage working
range
 Stop marks strongly reduced in length and in
oversized film, also in case of long machine
down-time
 Machine speed up to 180 m/min
 SoftDry system to guarantees a smooth
increase of the tension and preserves the
elasticity of the yarn
 Possible working width up to 3200 mm
Size application system
Inside view

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1
Irrelevant
2
Sufficient
3
Good
4
Important
5
Remarkable
Size reduction
Productivity
Stop marks
Quality
Lappers
PROSIZE® – additional benefits in grey and apparels
 Thanks to the 20% increase of the yarn
coverage, it is possible to run most of the
articles with single size box instead of
double
 Disposal of the squeezer rollers reduce
extremely the lapper formation

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1
Irrelevant
2
Sufficient
3
Good
4
Important
5
Remarkable
Size reduction
Productivity
Stop marks
Quality
Lappers
 Thanks to the no-immersion system and
the fine filtering, there is no
“contamination” between the different
colors of the yarns
 No stop marks or broken ends after the
preparation of the front reed
PROSIZE® – additional benefits in shirting

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 Running bed sheet articles in 2800 mm
working width with a single size box
gives a more even and uniform yarn
sheet than a conventional sizing
machine with double size box
 Completely eliminated the sticky ends
1
Irrelevant
2
Sufficient
3
Good
4
Important
5
Remarkable
Size reduction
Productivity
Stop marks
Quality
Lappers
PROSIZE® – additional benefits in sheeting

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PROSIZE® – additional benefits in terry
1
Irrelevant
2
Sufficient
3
Good
4
Important
5
Remarkable
Size reduction
Productivity
Stop marks
Quality
Lappers
 Production speed for the pile 180 m/min
 No crossed ends in the terry articles
(very low density)

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1
Irrelevant
2
Sufficient
3
Good
4
Important
5
Remarkable
Size reduction
Productivity
Stop marks
Quality
Lappers
 Thanks to the 20% increase of the yarn
coverage, it is possible to run all the denim
articles with single size box instead of
double
 No sticky ends even with high density
articles
 Less color loss in the size liquor as no
immersion system
PROSIZE® – additional benefits in denim

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PROSIZE® – summary of benefits
 Size pick up reduction between 5 to 10%, without compromising the weaving efficiency
 Running of bed sheet articles on PROSIZE gives a more even and uniform yarn sheet
than a conventional sizing machine with double size box
 No crossed ends in terry articles; even for machines running at 180 m/min
 Elimination of sticky ends in bed sheets
 Stop marks reduced in length and in oversized film, also in case of long machine stops
 Less dust in the dry split field and expansion comb area
 High viscosity range for the size liquor
 Highly flexible system; can run with:
 2 size application points with terry articles
 3 size application points with bed sheet articles

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PROSIZE® – the complete and perfect sizing machine
Worldwide references
Region
Asia
China
India
Western Europe
North America
South America
Africa
Middle East + Turkey
We do not just size warp…..we PROSIZE it !!!
More than 68 PROSIZE®
sold worldwide, including
20 in India

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THANK YOU