The graft copolymerization of reactive pregelled starch (PGS) with methacrylonitrile (MAN) was performed and the reaction conditions were optimized using potassium monopersulfate (PMPS) in the presence of ferrous ion redox pair as initiator. Emphasis was directed towards increasing the graft formation and decreasing homopolymerization. The grafting parameters were studied with respect to graft yield and graft reaction efficiency percent. In addition, the newly prepared polymethacrylonitrile (polyMAN)‐pregelled starch graft copolymers were applied to cotton textiles to see their suitability as a new sizing agent. Based on the results obtained, appropriate conditions for grafting MAN onto pregelled starch was established and the graft yield was higher under the following conditions: using 0.004 mol l−1 potassium monopersulfate as initiator, 0.005 mol l−1 ferrous ion concentration, 0.003 mol l−1, sulfuric acid, 50 % MAN concentration (based on weight of substrate), material to liquor ratio 1:2.5, reaction time 60 min, and polymerization temperature 40 °C. Finally, fabric samples sized with polyMAN‐pregelled starch graft copolymers acquired higher tensile strength and abrasion resistance than that sized with original pregelled starch, while elongation at break was unaltered. Copyright © 2004 Society of Chemical Industry