Partially Oriented Yarn refers to a thread that is produced in the form of a semi-textured molecular structure due to its polymer structure. Which causes an increase in length in the product. It is also known as Polyester Pre-Oriented Yarn. It is the first form of yarn made directly from PTA & MEG or by spinning Polyester PET Chips.
This type of yarn is produced with the use of semi-opaque and bright polyester chips (PET) using the latest and newest machines in white and colored. (Using colored bead masterbatches), so there is no need to be colored in the next levels.
Production Process of POY (Partially Oriented Yarn)
The polymer in the melted form from the polycondensation section is cooled in a polymer cooler, filtered, and after pressure boosting it is distributed to the spinning manifolds and then to the spinning positions. The polyester melt from the spinning position is extruded through spinnerets by variable speed-driven spinning pumps. The extruded filaments are cooled by precisely controlled conditioned and filtered air in the quench chamber. The filaments are then passed through the finished application system. The filaments are taken on take-up winders and finally wound on bobbins. The yarn produced is extremely fine and the unit of fineness is a denier. The spinnerets and spinning manifold are jacketed and heated with vapor.
Application of POY (Partially Oriented Yarn)
POY is mainly used in texturizing to make textured yarn, also known as Polyester Drawn Textured Yarn (DTY). POY can also be used in draw warping for weaving and warp knitting of fabrics. This type of yarn can be used as a base for the production of all types of texturized yarns (DTY, ITY, and ATY) and all types of draw threads (FDY).
POY / PFY is largely used in shirtings and suitings, sarees, ladies’ dress material, and knitwear. POY/ PFY is preferred in men’s wear due to its higher crease recovery, wrinkle resistance, better drape, longer retention of prints and colors, and better abrasion as compared with other fibers, such as PSF, VSF, and NFY. The use of POY / PFY has increased due to the development of crimping, twisting, texturizing, and wet processing technologies. These technologies offer more flexibility in designs and patterns. Moreover, these technologies help increase the air permeability of POY / PFY.
As a result, the fabric would be able to absorb more moisture. POY / PFY is also used in applications, such as soft luggage and specialty fabrics. POY is sold by producers to the texturizing units. The texturizing units process POY and sell it to weavers (largely in the power loom sector). Unlike PSF, PFY is not blended with cotton by blended yarn producers, since it is in the filament form and not in the fiber form. However, in the power loom stage, PFY can be woven with other yarns.
POY yarn is available in different lusters like Semi-Dull POY and Bright POY. The Bright POY has the shine in it due to the cross-sections in the filaments. The fabric made from Bright POY also has a bright luster. Polyester POY yarn is mainly available in Raw White color & is also available in different colors. POY is usually colored by the Dope Dyed technology as it is more efficient & the yarn gets evenly colored at each & every part. Color master-batch is mixed with the raw material to make the dope dyed POY. Dope-dyed POY yarn can be used to make the Dope Dyed DTY yarn.
POY yarn is mainly available in packing of 15 Kg per cheese & is usually packed in pallets.
POY made on Barmarg machines from Germany and TMT machines from Japan have the highest quality.
Polyester FDY is the abbreviation for Polyester Fully Drawn Yarn. It is also known as Polyester Filament Yarn (PFY) or Spin Draw Yarn (SDY). It is fully drawn yarns fixed through stretching, orientation, and crystallization. Fully Drawn Yarn (FDY ) is a type of highly drawn polyester filament yarn that can be used to produce high-strength fabrics and textiles. FDY is mainly used as weft or weaves in making fabrics. This yarn is used as the first material of twisted threads and is also used directly in knitting. FDY can be knitted or woven with any other filament yarn to get fabric of different varieties. Polyester FDY yarn can also be twisted to make Polyester Embroidery Thread that is widely used in sewing. It is mainly used in Home Furnishing Fabrics, Fashion Fabrics, Denim, Terry Towel, and others.
FDY yarn is mainly available in 3 luster – Semi-dull (SD), Bright (BR) having circular section & Triloble Bright (TBR) having triangular cross-sections. Filament yarn having trilobal bright luster is widely used in making curtains, bed-sheets, and carpets. FDY is available in Raw-white as well as dope dyed. Dope Dyed FDY yarn can be used to make the colored fabric directly instead of making the fabric with FDY Raw-white first & then dyeing it. Cationic FDY is another variation of Filament yarn. Cationic FDY yarn is made from Catonic PET Chips.
It is produced during the melting and stretching operations on the POY yarn. It is done in a one-step or two-step fashion.
The process of producing FDY yarns is similar to the production of POY yarn, except that it is fully matched under heat and stretching operations. FDY is produced in a variety of colors from Denier 50 to 1200.
- Yarns are produced by a continuous polymerization process.
- All critical yarn properties such as tenacity, elongation, Uster variation, and boiling water shrinkage are closely monitored and controlled.
- Controlled interlace enables the yarns to be twisted or sized in subsequent operations.
Usage of FDY yarns
FDY threads use different types of shrinkage in different areas of the textile industry. For example, FDY threads with a high shrinkage are used in the fabrication of cloth and curtain fabrics and create a blooming structure on the fabric surface. Low-shrink F.D.Y threads are widely used in the Rachel blanket industry.
FDY is typically used to produce fabrics and textiles for high-end undergarments, high-end sportswear, and home furnishings.
These yarns are used for direct twisting, multiplies yarns, beaming, and direct knitting.
FDY threads are mostly used to make non-textured fabrics.
FDY is generally used for better quality fabric. As the process of texturizing is avoided, FDY yields a higher contribution as compared to the normal POY.
- Industrial (industrial coatings, insulating, flooring, carpeting, etc.)
- Sanitary (wet tissues, sanitary napkins, baby diapers, and …)
- medical (hospital clothes, pads, surgical set, wound healing, bandage …)
Other uses of this kind of yarn are in the production of cloth rings, crepe fabric, curtains, lace fabrics, scarves, women’s t-shirts, sewing and embroidery yarns, shaggy machine carpets, Chanel yarns, sacks, and luggage.
Drawn Textured Yarn (DTY) yarn is made when Polyester POY is simultaneously twisted & drawn. This process disperses, curls, and entangles the filaments composing the POY yarn, which gives DTY a fluffy appearance and gives it the properties of both natural and synthetic fiber. DTY yarns are known as thread, Heat set, and bulky filament. DTY yarn is mainly used in weaving & knitting fabrics for making clothes, home furnishings, seat covers, bags, high-end apparel, high-end sports shoes, sports bags, home furnishings, and zipper tapes, and many other uses. DTY yarn can be in Semi Dull or Bright or Triloble Bright depending upon the type of sections of filaments.
To make the histrionic properties of polyester yarns similar to the natural fibers, In virtual twisting, texturizing process, and friction disk, POY yarns will be changed to textured yarns.
Technical Properties of DTY yarn can be molded in several ways to make the yarn suitable for its vast uses. Different heating techniques can be used to make the yarn set for a specific use – 1 Heater DTY is normally woolly & more stretchable as compared to DTY with 2 Heater. Also, the DTY yarn can be made with several combinations of Intermingle points – it can be Non-Intermingle (NIM) having 0 – 10 knots/meter or Semi-Intermingle (SIM) having 40 – 50 knots/meter or High-Intermingle (HIM) having 100 – 120 knots/meter. These knots are not actually the knots tied when two threads are broken but they are the tangle knots created by heating pressure. These Intermingle yarns, also known as Interlaced yarn, is the replacement for lightly twisted yarns. Polyester DTY yarn can also be twisted to high twists like 1500 TPM or 4000 TPM (twist per meter). Such twisted yarn can also be heat-set to make the yarn permanently thermo-set the twist. Cationic DTY is another variant of Polyester DTY that is mainly used in blankets. Cationic DTY is made from Catonic PET Chips.
Polyester DTY yarn can also be obtained in various colors by the dope-dyed technology or by conventional dyeing. Dope dyed DTY is usually packed on paper bobbins whereas Raw White DTY that will be used for dyeing is loosely packed on a perforated plastic tube so that all the yarn can be easily dyed when the bobbin is dipped in color.
Texturizing is a set of activities in which artificial fibers such as polyester, acrylic nylon, etc., get similar properties to natural fibers (such as cotton, wool, silk, etc.). This means in terms of touching fabrics, the type of tissue, and form, it becomes a suitable fiber for the producing fabrics.
In other words, texturizing can be defined as the set of processes used to prepare artificial fibers for producing fabrics. polyester fibers which are stretched or textured, have the property of spring.
Draw Texturised Yarn (DTY) is a fully drawn, fully oriented polyester multifilament yarn with soft crimp, high bulk, and texture with the cotton feel and very high durability and retention properties. This is manufactured by texturizing partially oriented yarn using texturizing machines.
Types of DTY yarns and usage
Intermingle thread, which is produced in three types( simple, intermingle (knotted) and comingle), is used in sofa fabric, curtain, shirt, linen, suit, worsted, carpet cover, and prayers carpet, machine weaved carpets pile and industrial usages. DTY is suitable for fabric end uses like outer/inner garments, skin-clinging garments, furnishings, upholstery, etc.
Intermingle or knotted threads are consumed commonly as Beam threads.
The other usages of DTY yarns are in Tricot garments, Jeans, Mantua, Rachel blankets and seat covers
- Melange: Sirang Company has the ability to produce each of the above threads in a Melange (double blend and color combination with different deniers) with the customer’s request.
- Lycra: A type of highly durable synthetic fiber that has many applications in the clothing industry. The lycra is highly resistant and has a stretching ability of up to 5 times its normal length. The lycra’s elasticity makes the size of the clothes after washing and use not change and change to its original shape (unlike cotton fabrics that vary in size and shape) and can be used for athletic and winter sports To be used.
- The polyester filament of twisted (white and colored) polyester in a variety of deniers and twists on simple and lattice duke.