What is polyester staple fiber?
In the present day, polyester staple fiber is one of the most used fiber types globally for the textile industry. Due to its advantageous characteristics, the global demand for polyester staple fiber has been increasing for decades as an alternative and sustainable option to cotton and natural fibers. Flexibility, durability, high toughness, heat resistance, stain resistance, wrinkle resistance, versatility, and economical price are the main reasons for boosting polyester staple fiber in the global market. Polyester staple fiber is safe not just for humans in textile use, but polyester staple fiber can also be produced as recycled polyester staple fiber, which is environmentally friendly. Global warming and pollution concerns have been the center of the world’s attention nowadays, so it would be wonderful if we started using recyclable products, reusing and reducing them. Polyester recycling production starts with collecting plastic bottles and waste, which are then cleaned. Subsequently, the PET bottles are then cut into small pieces called PET flakes. Then, the flakes are melted into pellets, re-melted using high temperatures, and finally, those pellets are spun into the recycled polyester polymer.
POLYESTER FIBERS & POLY BLENDS
Polyester fibers are powerful and durable—resistant to most chemicals, stretching, shrinking, and wrinkles. Polyester is hydrophobic in nature and quick-drying. It can be used for insulation by manufacturing hollow fibers. Polyester retains its shape and hence is suitable for making outdoor clothing for harsh climates. It is also easily washed and dried.
Polyester Staple Fiber (PSF) is a synthetic, man-made fiber created directly via a polymerization process of polyester material such as PTA (Purified Terephthalic Acid) and MEG (Monoethylene Glycol) under high temperature and pressure. After the spinning and drawing process, the polymer becomes staple fibers and are cut to a specific cut length. Polyester staple fiber plays an essential role in the textile industry due to several advantages of its characteristics. Polyester staple fiber is more durable than cotton or wool. Additionally, polyester staple fiber also has high heat, wrinkle and abrasion resistance; low absorbency; a stretching and shrinking resistance; and quick-dry after washing.
PSF luster refers to the degree of light reflected from surfaces of fibers or the degree of gloss or sheen that the fiber possesses.
1. Fully dull
Full-dull yarns are manufactured from raw materials modified chemically and physically to reduce their normal luster. A few of the qualities of fully dull yarns are that they have high tenacity and strength and look like cotton fiber. In addition, these yarns have a beneficial pendant, a soft visual appeal, and a strong covering. Full-dull yarns have various applications in manufacturing apparel, home textiles, etc.
2. Semi-dull
Semi-dull yarn is manufactured from raw materials with low luster compared to partially oriented bright yarns used to manufacture semi-dull polyester textured yarn.
How is polyester staple fiber made?
Polyester staple fiber is a man-made fiber created from purified terephthalic acid (PTA) and monoethylene glycol (MEG) or from recycled PET chips, polyester waste, or flakes from used PET bottles. The production of polyester staple fiber starts with the polymerization process, where PTA is fed into hot MEG at a high temperature and pressure. Next is the melt-spinning process. The melt spinning technique produces a bundle of continuous filaments (called tow), which undergoes additional processes such as drawing and crimping before being cut into fixed lengths. After the cutting process, these cut fibers are called polyester staple fibers.
What are polyester staple fibers used for?
These are some of the industries that we are currently involved in.
AUTOMOTIVE
Our durable, high-performance shoddy, both natural and synthetic, is a key ingredient in the production of cost-effective acoustical parts and insulation for many automotive manufacturers.
The automotive industry places high expectations on the quality and safety of its components. To meet these expectations, standardized production processes that are subject to comprehensive quality assurance in accordance with standards are indispensable. All raw materials that we supply to our customers in the automotive industry meet these requirements and also guarantee a high level of safety in their production processes.
Examples of applications:
upholstery, safety belts, airbags, seat seams, tire fabric, turbo hoses, nets, sound insulation, interior components, brake pads, clutch disks
BEDDING
Our recycled polyester fibers are often used on mattresses, pillows and quilts.
FURNITURE
Our reprocessed fibers are used for batting, wadding, and needled and bonded felts, which are used in many furniture items. Our products provide a lower-cost alternative than a virgin polyester fiber. Our customers have used our reprocessed fiber in demanding furniture applications while meeting their customers’ expectations for performance.
FILTRATION & ABSORPTION
To meet current needs in the filtration and absorption material market, we offer polyester fiber, which can be mixed with cotton, polypropylene, and acrylic blend fibers for yarn-wound, canister (string), and pleat media filters.
ACOUSTIC INSULATION
Manufacturers of acoustic insulation materials, including those used in automobile parts, office partitions, ceiling tiles, industrial machinery, and household appliances, purchase our fibers. To reduce sound echoes, the open structure of cellulose, cotton, and polyester fibers makes them a trusted choice for soundproofing, especially in spaces filled with air. These manufacturers rely on our precisely modified natural and synthetic fibers for the high acoustical density.
High-quality sound insulation means, above all, better working conditions, a more pleasant living environment, or more comfortable traveling. The enjoyment of music depends to a large extent on the right textile sound insulators. At the same time, however, the correct use of acoustic materials also serves as the basis for effectively targeting any background noise. The materials used also vary depending on the requirements. Our fibers offer the right basis for every desired solution.
Examples of use:
Insulation materials, such as fleece for vehicle interiors, loudspeaker boxes, recording studios, concert halls, machines in general
SPINNING
Polyester staple fiber is mainly used in spinning production in the textile industry. Wherein, the resulting yarns, spun yarns, are used for apparel manufacturing, including sportswear, activewear, and intimate wear. Sewing threads also include shirts, socks, dresses, lingerie, gloves, and suits. In spinning production, polyester staple fiber can be produced individually for 100% polyester spun yarn or combined with cotton, viscose, or wool for blended yarns such as CVC 70/30, which consists of 70% cotton fiber and 30% polyester staple fiber. Compared to cotton fiber, polyester staple fiber has major benefits in terms of cost, thinness, strength, abrasion resistance, water absorption, and multiple designs and colors. Thus, polyester staple fiber can be considered the main cotton fiber alternative for the garment industry.
Characteristics of polyester staple fiber
Polyester staple fiber feels like cotton. In the past, people were more likely to wear apparel made from natural fibers due to their familiarity, softness, and comfortable-to-wear nature. However, synthetic man-made fiber production has continued to develop properties like natural fiber. The end product of polyester staple fiber after the spinning process is called polyester spun yarn. The properties and appearances are very close to cotton yarn. Polyester spun also has the same denier count as cotton, while the price is lower. Polyester staple fiber also has the alternative option to be environmentally friendly by using recycled polyester staple fiber, which is sustainable and eco-friendly. And the production of recycled polyester requires far fewer resources than new fibers and generates fewer CO₂ emissions. Using recycled polyester staple fiber adds significant value to a company and positively impacts its brand image compared to others.
The differences in denier and cut length also affect the difference in hand-feel and product size. The smaller denier and shorter cut length bring a softer and smoother feeling. According to our product, our newly developed item is polyester staple fiber 1.0 D, which is used in spinning spun yarn. Spun yarn made from polyester staple fiber 1.0 D will have a soft feeling to the touch and is very close to spun cotton.
