Polyester Yarn

What is Polyester Yarn?

Polyester encompasses a wide range of synthetic polymers, where the repeating units, or monomers, are linked by ester bonds. The most commonly used polyester in textiles is polyethylene terephthalate (PET). Due to its properties such as strength, elasticity, and low cost, PET is widely used in the textile industry and geotextiles. Polyesters are thermoplastic materials that have both amorphous and crystalline regions in their structure. The polyester chain has a zig-zag configuration, and these chains are held together by Van der Waals forces.

Production of Polyester Yarn

Since polyester is a type of thermoplastic polymer, it can be produced through various spinning methods such as melt spinning, wet spinning, and dry spinning. In wet and dry spinning processes, the polymer is dissolved in a solvent, and after the solvent is removed, the fibers are collected. In the melt spinning process, polyester granules or chips are first dried in a crystallizer at a temperature above the polymer’s glass transition temperature (Tg) to remove moisture, which enhances the crystallinity in the amorphous regions. After this step, the granules are further dried, removing any remaining moisture, making them ready for melt spinning.

The prepared chips are melted in an extruder, and fibers are produced through a spinneret. These fibers are then solidified using a quenching process and undergo stretching and thermal processes to achieve better polymer orientation in the yarn.

Types of Polyester Yarn

Polyester yarns are categorized into different types, each having distinct production methods, applications, and properties, used in a wide range of textile industry applications. The three main types of polyester yarns are:

  • Filament Yarn
  • Spun Yarn
  • Textured Yarn

 

Filament Yarn 

Filament yarn consists of layers of fibers produced using spinning machines. These yarns can be twisted or untwisted, where fibers are laid parallel to each other without separation. Filament yarns are divided into two categories: monofilament and multifilament (multi-filament). They are produced with high strength for industrial uses and with regular strength for weaving applications.

Types of Filament Yarn 

  • POY (Partially Oriented Yarn) :

Used as a raw material in the texturizing process for producing DTY, ATY, and ITY yarns. After passing through the extruder and spinneret, continuous filaments are produced. In a subsequent process, these yarns undergo partial orientation to form semi-drawn yarn.

  • FDY (Fully Drawn Yarn)

This type of filament yarn undergoes simultaneous heat treatment and stretching, resulting in higher strength and lower shrinkage, making it suitable for high-quality fabrics and textiles like sportswear and home furnishings. FDY yarn is directly used in weaving and knitting, offering a regular polymer structure with high uniformity.

  • ITY (Intermingled Textured Yarn) 

Composed of POY and FDY components, ITY yarn can be produced using single-stage or two-stage processes. In the single-stage process, both components are produced simultaneously and connected by air jets to create intermingling. In the two-stage process, each component is produced separately and then intermingled using air jets. Due to differential shrinkage of each component, this yarn is also known as Bi-shrinkage yarn.

  • Spun Yarn

Spun yarn is produced with PCDT or PET cut, characterized by a bulky and wavy texture, and is used in weaving and sewing applications. In fact this type of yarn is the result of the spinning process of the staple polyester fiber, sometimes combined with cotton or Viscose fiber.

  • Textured Yarn

Textured yarns are created using multifilament fibers, employing various processes such as twisting and stretching to produce two main types: ATY (Air Textured Yarn) and DTY (Draw Textured Yarn). These yarns provide a soft feel and suitable texture for consumers.

  • DTY (Draw Textured Yarn)

Polyester textured yarn with virtual twisting is drawn and bulked to mimic the properties of natural fibers. During production, DTY yarns are stretched, twisted, and heat-treated, resulting in a soft, bulky yarn used in textiles like clothing, home furnishings, and carpets.

  • ATY (Air Textured Yarn)

Resembling spun fibers due to small loops created, ATY yarns are also known as cotton-like polyester fibers. With a texture similar to cotton, ATY yarn is used in clothing, sportswear, carpets, and socks.

Applications of Polyester Yarn

Due to their high tensile strength, low shrinkage, and suitable luster, polyester yarns are used in a wide range of products. Different types of sportswear, upholstery and decorative material are only a small part of the application.

Advantages of Polyester Yarn

In the world of apparel and the textile industry, polyester yarn stands out as a distinctive and appealing product meeting the industry’s needs. The unique features of this yarn make it a key driver of innovation in textile production. Here are some of the benefits of polyester yarn:

Strength and Durability

Polyester yarns have high strength and durability, making them ideal for textiles exposed to frequent movement and tension. As a result, they are used in sportswear and uniforms.

Cost-Effective and Affordable

Since these fibers are produced chemically in large volumes, they are much cheaper than natural fibers, making them suitable for economical production.

Versatility

Polyester is used in various applications and is often blended with other fibers to create a product with broad applications. For example, polyester-cotton blends are used to make garments requiring high strength but limited breathability.

Recyclability

As a thermoplastic material, polyester can be melted and converted into other products, making it a sustainable alternative to other synthetic fibers like polyamides (e.g., nylon).

At ShivaElyaf, we leverage our extensive experience and global network in the textile industry to source the finest Polyester Yarn. We know the best suppliers in the world, allowing us to deliver yarns that meets your quality requirements.