Use of Alpenol-FNR is very simple. All that is required is to add the material to water in the proportion recommended (160 liters for each 25 Kg bag of Alpenol-FNR) and to raise the temp to about 90°C and maintain the same for about 15 – 20 minutes and then start the sizing process. The detailed description for the method of cooking is provided below:


Method Of Cooking:

1a. Take the required quantity of water in the open-vessel.
1b. For each 25 Kg bag of Alpenol-FNR, 160 liters of water are needed.

2. Sprinkle Alpenol-FNR in water and keep stirring continued.
Note: Use full bag. Do not split the bag.

3a. Open the steam-condensate valve to remove water / iron-rust from the steam pipe-line.
3b. This avoids increasing water level in the cooking vessel and also avoids contamination of size with iron-rust of steam pipe.
3c. Remove the water condensate from steam pipe-line along with iron-rust till the steam starts coming out with force.
3d. Close the steam-condensate valve and keep some leakage so that water along with some steam keeps coming out.

4a. Open the steam valve in the cooking vessel and start heating.
4b. Continue stirring the water + Alpenol-FNR mixture.

5. Alpenol-FNR starts gelatinizing at ~75°C. After gelatinization, stable viscosity is attained at around 85°C - 90°C.

6a. Allow the temperature of the mixture to rise to 95°C.
6b. Maintain the temperature of 95°C for another 10 minutes, to uniform cook the mixture.

7a. Transfer the cooked paste to a storage tank using a suitable pump.
7b. Maintain temperature of mixture in storage tank at 95°C and keep stirring continued till the entire quantity of size-paste is consumed in sizing warp yam.

8. Maintain the sow-box temperature between 90°C - 92°C throughout the sizing operation.

De-Sizing Procedure:

Alpenol can be easily de-sized. 70% by a single detergent wash; and with 2 such washes up to 91%. Hence use of amylase enzymes is greatly reduced, thereby saving on time and cost. The effluent of the de-sizing process can be simply discharged without being hazardous to the eco-system.

In contrast, PVA (poly-vinyl alcohol) based sizing agents cannot be de-sized and discharged directly, since PVA is hazardous to the eco-system. PVA needs to be extensively treated before it is discharged.

Notes:

1a. Unlike most sizing compounds, Alpenol-FNR doesn't need hot temperatures like 120°C – 130°C; and therein lies the great advantage:
1b. Alpenol-FNR does not require a pressure cooker for its preparation. An open vessel will work just as well.
1c. Since the cooking temperature is lower, there is saving on power.
1d. Since the cooking temperature is lower, the entire sizing process takes shorter time, thereby increasing production throughput.
1e. Elimination of a pressure-cooker increases overall safety in the work-environment.
1f. No pressure in the cooking vessel, translates into lower wear-tear of equipment.

2. Alpenol completely penetrates the fiber instead of merely coating it (as most sizing agents do); thereby adding to it’s elasticity and tensile strength. This will lead to less warf breakages and once again improve the efficiency and increase the yardage.

3a. The size which is produced is extremely homogenous with low viscosity, leading to excellent coating and penetration in cotton and blended fiber. In the case of pure synthetic fiber, one only needs to suitably increase the squeeze roll pressure.
3b. Does not show lumpiness on standing, left over size can be reused. Hence there is no dead loss & further saving on cost of inputs.

4. The product has an indefinite shelf life. Hence, the use of an anti-mildew agent is not required.

5. Humidification is not required in the weaving shed; or may be progressively reduced to a great extent as per the technical assessment of the weaving master; thereby again saving on cost of input.

6. Flow viscosity is ~14 seconds, whereas for ordinary starch it is 16 - 18 seconds. Modified starch (like Alpenol) should have a viscosity which is approximately 20% less than ordinary starch.

7. Ash content of Alpenol-FNR is nil. Hence ash content of the sizing mixture and the resultant sized-yarn would also be nil.

8. Moisture content of about 10% to 12% allowed.

9. 10% paste should form a firm jelly.

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