The history of polyester yarn and how it was created
According to Textile Learner, Polyester yarn began as a group of polymers in W.H. Carothers’ laboratory. Carothers was working for DuPont -at the time- when he discovered that alcohols and carboxylic acids could be successfully combined to form fibers.
However, polyester was put on the back burner once Carothers discovered nylon. British scientists–J.R. Whinfield, J.T. Dickson, W.K. Birtwhistle, and C.G. Ritchie–took up Carothers’ work in 1939. In 1941 they created the first polyester fiber called Terylene.
In 1946 DuPont bought all legal rights from the Brits and came up with another polyester fiber which they named Dacron.
What is polyester yarn?
Polyester is a synthetic polymer made from PTA and MEG. Polyester yarn is made by directly spinning PTA and MEG or PET Chips.
ScienceDirect Journal explains how polyester yarn is made. Polyester yarns are obtained by melting spinning from a polymeric melt at 265 °C. In Terylene yarns, crystalline and amorphous areas exist. They are a thermoplastic material. The chains have a zig-zag structure and are linked by Van-der-Waals connections.
During the cooling process, crystallization and orientation of the polymeric chains occur.
Polyester yarn types
There are three known, produced, and used Terylene filament yarns, Partially Oriented Yarn, Drawn Textured Yarn, and Fully Drawn Yarn.
Partially Oriented Yarn
Usually called Polyester POY, is an essential kind of Terylene yarn. It’s otherwise called Polyester Pre-Oriented Yarn. It’s the most made yarn style from PTA, MEG, or by turning Terylene PET Chips. POY is used in texturizing to form finished yarn or Polyester Drawn Textured Yarn (DTY).
Arranged yarn is created from the Terylene chip or piece’s liquefying and expulsion (dissolve turning).
The fibers are extended or drawn multiple times to their unique size during the turning system to prepare the polymer to meet the ideal equality, strength, shrinkage, and stretching standards.
The term situated yarn means a multi-fiber that is somewhat extended.
POY has lower tirelessness and is less uniform than completely arranged yarn (FOY). it is utilized in texturizing to make finished yarn and can be used in drawing, twisting for weaving, and twist-sewing textures.
POY yarn is accessible in various lusters like Semi-Dull POY and Bright POY. The intense POY includes a sparkle due to the fibers’ cross-segments. The finish produced using Bright POY encompasses a brilliant gloss. Polyester POY yarn is usually accessible in Raw White tones and various shadings.
POY is usually shaded using the Dope Dye technique because it is advanced, so the yarn gets uniformly and thoroughly hued. The shading ace is mixed with the natural substance to form the nitwit-colored POY. Dope-colored POY yarn is often utilized to create the Dope Dyed DTY yarn.
Drawn Textured Yarn
DTY is created by contorting and drawing polyester-situated yarns (POY) using rapid texturizing machines. These yarns are called Air Textured Yarns (ATY), as the texturizing on the yarn is created by utilizing air.
This course of finishing can create highly durable contortions, creases, circles, curls, or creases on the POY without obliterating the fundamental coherence of the fibers.
This strategy works on the surface of the POY, giving them a delicate and wooly feel. This finishing course expands the glow and solace of the textures made utilizing POY.
The circles or pleats can hold numerous little air pockets, which forestall the air development through filaments and thus hold the texture together.
Fully Drawn yarn
Polyester FDY is also known as Spin Draw Yarn with an acronym of SDY; these Yarns, with their different names, can be woven or knitted with multiple types of filament yarn to get new fabric products. Polyester Fully Drawn Yarn is one of the most used wefts or weaves for making fabrics.
It is also known as Polyester Filament yarns (PFY); we manufacture it at the highest standards to help companies and factories get high-quality weaves, manufacture their products, and provide our clients with various FDY yarns and Embroidery Threads.
At Midani, we manufacture Polyester Filament Yarns with a production process similar to POY, but FDY Yarn is manufactured with higher spinning speeds coupled with integrated drawings.
Here are some of the FDY manufacturing processes:
- FDY yarns are produced through the polymerization process, which allows stabilization with orientation and crystallization.
- We monitor and control all critical yarn properties, such as boiling water shrinkage, elongation, ulster variation, and tenacity.
- We utilize controlled interlace that enables the FDY yarns and Embroidery Thread to be twisted or resized in subsequent operations.
What is the polyester yarn used for?
Polyester yarn is used in different industries. It’s used to manufacture sportswear, curtains, furniture fabrics, carpets, swimsuits, lingerie, fur in toys, etc.
POY Uses:
- Partially oriented yarn products are utilized widely in texturizing to manufacture Polyester Drawn Textured Yarn (DTY), also known as textured yarn.
- POY Yarns can be used to manufacture all types of Draw Threads “FDY” and textured Yarns of DTY, ATY, and ITY.
DTY Uses:
We manufacture our ATY Yarns in three distinctive types, simple, intermingle (Knotted), and blend.
Midani ATY Yarns are versatile; factories and companies utilize them in a wide range to manufacture:
- Curtains, shirts, linens, carpet covers, machine-weaved carpets, prayer carpets, sofa fabrics, suits, and worsted.
- Jeans, Mantua, seat covers, Rachel blankets, and tricot garments.
- Upholstery, skin-clinging garments, furnishings, outer and inner garments.
- Knitting and weaving, making high-end clothes, seat covers, sports shoes, bags, apparel, and zipper tapes.
FDY Uses:
- Home furnishing fabrics, terry towels, denim, fashion fabrics manufacturing, and others.
- Factories can utilize the filament yarn with trilobal bright deniers to manufacture carpets, curtains, bedsheets, and colored fabrics.
Polyester yarn manufacturers in Egypt
Midani Yarns is the leading polyester yarn manufacturer and exporter in Egypt.
Midani has its polyester yarn line, ColorMax, providing polyester yarns internationally with:
- 70% less lead time
- Reduced sea freight rates
- Zero Duty fees
