Intermingling of wound yarns is an important method of producing cohesiveness between the individual filament yarns. Many researchers have studied the effects of various parameters on yarn production. This paper attempts to investigate the effect of length and cross-sectional area of the yarn channel on yarn properties. A total of nine jets with yarn channel lengths of 20, 30 and 40 mm, and square cross section of 1.5, 2.25 and 3.0 mm were tested. The tests were carried out on the yarns to examine nip stability and microscopic observation of the nip points. It was concluded that, a short and narrow yarn channel may produce a short nip length with maximum nip density and stability. While, a long and wide yarn channel produces a long nip length with lowest nip density and stability. The width of the yarn channel had an effect on loose nips, while in the longest channel (40 mm), there was no difference on loose nips. The last class was two or more parallel structures, which decreased as the width of the yarn channel decreased. Loose nips varied in different channel lengths, though it did not show a specific trend.