Analyzing the Influence of Sizing Machine Settings on the Performance of the Sized Cotton Warp Yarns Using Eco-Friendly Carboxymethyl Cellulose from Saudi Wheat Straw

CMCws is a low-cost, biodegradable carboxymethyl cellulose derived from Saudi wheat straw (CMCws) as a sustainable alternative to traditional sizing agents for cotton warp yarns. The effects of key sizing parameters—wet zone yarn tension (350–410 N), squeezing pressure (220–330 N/m), and machine speed (30–70 m/min)—on the weavability performance of CMCws-sized yarns were investigated by analyzing size add-on, tensile properties, hairiness, and abrasion resistance of sized warp yarns. Response surface methodology (RSM) based on a Box–Behnken experimental design comprising 15 runs was employed to optimize the machine settings and processing parameters for CMCws-sized yarns. Increasing wet zone yarn tension and squeezing pressure reduced size add-on and elongation at break, whereas higher sizing machine speed increased size add-on. Squeezing pressure showed a strong positive influence on abrasion resistance and adhesion power, while yarn hairiness increased with wet zone yarn tension and sizing machine speed. Maximum size add-on occurred at 70 m/min, 220 N/m, and 380 N, whereas optimum abrasion resistance was obtained at around 340 N, 330 N/m, and 45 m/min. Numerical optimization predicted minimum hairiness at about 350 N, 320 N/m, and 50 m/min. Overall, optimized settings significantly enhanced yarn mechanical performance and weavability, confirming CMCws as an effective, eco-friendly sizing agent for sustainable textile processing.