This is a summary of the work thus far done on a new ARS-CRIS project entitled "Development of a new wholesome technology for weaving cotton yarns without, or with reduced, traditional warp sizing." To explore "sizeless or reduced-size weaving," we have prepared an exhaustive, 3-prong research plan with a focus on the following objectives:

1. Without or with reduced traditional warp sizing, try to solve yarn-related problems (such as low abrasion resistance, excessive hairiness, inadequate tensile properties, and excessive twist-liveliness, etc.) that are currently addressed by the use of conventional warp sizing.
2. Try to modify the weaving machine and process to minimize the yarn abrasion, tension fluctuations, torture and, hopefully, failures during weaving.
3. Try to develop a fundamental understanding of the underlying mechanism(s) of the warp yarn failure/breakage during weaving, so that we can develop new approaches to manipulate yarn properties and preparation and thus minimize the yarn failures in weaving both the conventionally-sized yarns and the proposed sizeless or reduced-size yarns.

So far, we have spun rotor open-end cotton yarns of excellent quality, using combed Acala cotton. This was purposely done to try to attain desirable yarn propertties that would solve, to some extent, some of the anticipated problems of sizeless weaving. To verify our new hypothesis on the mechanism of warp yarn breakages during weaving, we have prepared a loom beam of reportedly uniform and consistent yarn tension, taking appropriate steps and precautions in the spinning, winding, warping and beaming operations. We are awaiting delivery of certain specially finished reed and heddles to commence preliminary weaving trials with a conventionally sized warp and an equivalent sizeless warp.

Based on the above premises, we either have conducted or are in the process of conducting research to attain the following specific objectives to solve "anticipated problems" in weaving size-free cotton yarns: