INTRODUCTION TO POLYESTER..
HOW POLYESTER FIBRE IS BETTER THEN COTTON..
Polyester is a category of polymers which contain the ester functional group in their main chain.
Although there are many polyesters, the term "polyester" as a specific material most commonly
refers to polyethylene terephthalate (PET). Polyesters include naturally-occurring chemicals,
such as in the cutin of plant cuticles, as well as synthetics through step-growth polymerization
such as polycarbonate and polybutyrate. Natural polyesters and a few synthetic ones are
biodegradable, but most synthetic polyesters are not.
Depending on the chemical structure, polyester can be a thermoplastic or thermoset; however,
the most common polyesters are thermoplastics.[1]
Fabrics woven or knitted from polyester thread or yarn are used extensively in apparel and
home furnishings, from shirts and pants to jackets and hats, bed sheets, blankets and
upholstered furniture. Industrial polyester fibers, yarns and ropes are used in tyre
reinforcements, fabrics for conveyor belts, safety belts, coated fabrics and plastic
reinforcements with high-energy absorption. Polyester fiber is used as cushioning and
insulating material in pillows, comforters and upholstery padding.
While synthetic clothing in general is perceived by many as having a less natural feel compared
to fabrics woven from natural fibres (such as cotton and wool), polyester fabrics can provide
specific advantages over natural fabrics, such as improved wrinkle resistance, durability
and high color retention. As a result, polyester fibres are sometimes spun together with
natural fibres to produce a cloth with blended properties. Synthetic fibres also can create
materials with superior water, wind and environmental resistance compared to plant-
derived fibres.
Polyesters are also used to make "plastic" bottles, films, tarpaulin, canoes, liquid crystal displays,
holograms, filters, dielectric film for capacitors, film insulation for wire and insulating tapes.
Polyester fibres have high tenacity and E-modulus as well as low water absorption and minimal
shrinkage in comparison with other industrial fibres.
HOW POLYESTER IS MADE
Basics
Polyester is a synthetic polymer made of purified terephthalic acid (PTA) or its dimethyl ester
dimethyl terephthalate (DMT) and monoethylene glycol (MEG). With 18% market share of all
plastic materials produced, it ranges third after polyethylene (33.5%) and polypropylene
(19.5%).
The main raw materials are described as follows:
Purified terephthalic acid – PTA – CAS-No.: 100-21-0
Synonym: 1,4 benzenedicarboxylic acid,
Sum formula; C6H4(COOH)2 , mol weight: 166.13
Dimethylterephthalate – DMT – CAS-No: 120-61-6
Synonym: 1,4 benzenedicarboxylic acid dimethyl ester
Sum formula C6H4(COOCH3)2 , mol weight: 194.19
Mono Ethylene Glycol – MEG – CAS No.: 107-21-1
Synonym: 1,2 ethanediol
Sum formula: C2H6O2 , mol weight: 62,07
RM USED IN MAKING SOFAS
Raw Materials
The frame of a sofa is made most often wood, though newer options include steel, plastic, and
laminated boards or a combination of the above. Kiln-dried maple wood deemed free of knots,
bark, and compromising defects is used under the upholstery. The show wood of the legs, arms,
and back can also be maple, but sometimes mahogany, walnut, or fruitwoods are used for carved
legs or moldings.
Padding is primarily made from animal hair, particularly hog or horse. Other paddings used in
mass production are foam and polyester fiberfill wrap. Some preprocessing may be necessary, as
with the prematted rubberized hair, where animal hair is arranged and bonded into shape with
glue.
Cushions are fashioned from polyurethane foam, polyester fiber, down, cotton, latex, or cotton-
wrapped springs.
A sofa may be covered with any choice of synthetic, natural, or blended fabric. Wool and nylon
are the best choices in their respective categories of natural and synthetic fibers, but cotton,
acetate, rayon, and polyester have their own functional properties. Exterior fabric may be
finished with a protective anti-stain coating.
When used, springs are made of tempered steel. A typical sofa calls for 15 yd (13.71m) of burlap
and at least 10 yd (9.14 m) of muslin for the interior. All materials are fastened with
approximately 1,000 or more tacks, over 200 yd (182.8 m) of twine, and hundreds of yards of
machine sewing thread.
POLYESTER IN RELIANCE…INTRO ON IT .
Reliance is the largest producer of polyester fibre and yarn in the world, with a capacity of 2.5
million tonnes per annum.
Reliance invests significant amounts on R&D in the polyester sector. Reliance Technology
Center, Reliance Testing Centre and Reliance Fibre Application Centre constantly develop and
introduce innovative products for the textile industry. Reliance enjoys a portfolio of about 120
global patents in the polyester domain.
THEN WE HAVE INTRO OF FBRE FILL IN REL
Recron Fibrefill is India's only hollow Fibre specially designed for filling and insulation
purpose. Made with technology from DuPont, USA, Recron Fibrefill adheres to world-class
quality standards to provide maximum comfort, durability, and ease-of-use in a wide variety of
applications like sleep products, garments and furniture.
PROCESS OF CONVERTING POLYESTER /BALES INTO FIBRE SHEETS
Bale
Compressed rectangular package of fibre, easy for transportation.
Binder
Liquid adhesive used to bond fibres in a batting to each other to increase the strength of the
batting.
Binder fiber
Low melt polyester often used in a blend with other fibres then is run through an oven. When
heated, the melted binder fibre bonds the other fibres together to increase the strength of the
batting. Often, binder fibres are bicomponent, with an inner core of standard polyester and a
sheath of low melting polyester.
Carding Machine
A machine used for opening the tuft of fibre by mechanical combing action.
Crimp
The "waviness" of a single fibre.
Crimp amplitude
The height of one "wave" of a single fibre.
Crimp frequency
The number of crimps, or waves, per inch of fibre.
Denier
The weight in grams of 9,000 meters of a fibre. It is an indication of the thickness of the fibre.
The lower the denier, the finer the fiber.
Fiber migration
Occurs when fibres "leak" through their containing fabric. Migration can be controlled by using
more tightly woven lower air porosity fabrics that do not allow fibres to pass through; or by
using a find denier filling fibre. This is also known as percolation.
Fiberfill
A staple fibre used for cushioning or insulation. It is used in furniture, pillows, mattresses,
comforters, mattress pads, sleeping bags, and insulating apparel.
Flame resistant
The ability to self extinguish after being set on fire and the flame source is removed.
Flame retardant
The ability to resist being set on fire and supporting a flame.
Flammability test
Tests performed to determine the flame resistance and flame retardency of a fabric or fibre.
Garnet
A piece of equipment used to align or straighten fibers, similar to a card. It was originally
designed to convert chindis (small fabric pieces) to fibres.
Hollow Fibre
This fibre is hollow in cross-section as against normal fibre, which is solid.
Low Melt Polyester Fibre
Polyester Fibre has a melting point of about 257oC. Low melt polyester fibre, on the other hand,
has a much lower melting point in the range of 110o-150oC..
Minicard
A small version of the carding machine. Fibre is passed through two moving rollers having rows
of combs. This action individualises the fibre.
Needlepunching
Binding a web to a fabric mechanically using needles. This is also used to make batting dense
and more compact.
Open Fibre
Fibre in the Individualised form.
Percolation
Occurs when fibres "leak" through their containing fabric. Migration can be controlled by using
more tightly woven lower air porosity fabrics that do not allow fibres to pass through; or by
using a finer denier filling fibres. This is also known as fibre migration.
Pinjan
A Manual mechanical blowing machine by which fibre can be opened or indivualised.
Point bonding
Using heat and pressure in a pattern to bind fibres or fabrics.
Polyester
A synthetic fibre made from polymer that is at least 85% by weight of an ester of a dihydric
alchol and terephthalic acid.
Wadding
The fibre product resulting from carding or garneting fibre. A soft web of fibre in sheet form.
WEIGHT
MAKING MACHINE
POLYFIL ROLL [Type a
Recron Fibrefill is a special fibre of international standards, designed specifically for filling
applications and gives the ultimate comfort and durability to the users. The functional properties
of Recron Fibrefill are far superior than cheap fibres. Products made out of Recron Fibrefill are
lighter and softer when compared to cotton filled products. Unlike cotton & other recycle fibres,
Recron Fibrefill is highly resilient and durable and does not form lumps in a short time. Recron
Fibrefill is fully washable and hence products filled with Recron Fibrefill are more hygienic than
cotton as they do not get affected by moisture, dust, germs etc. Part of the higher cost is
compensated due to the lesser filling quantity required when Recron Fibrefill is used. However,
when one makes the cost-benefit analysis, only Recron Fibrefill gives the real value for money.
As Recron Fibrefill is hollow in nature, the products filled with it have better air circulation. This
ensures that no heat is generated, resulting in better comfort.
Recron Fibrefill is very high on hygiene. It is fully washable and non-allergic, thus, being safe
even for infants. Recron Fibrefill is inherently moisture and dust mite resistant and avoids
infestation. Recron Fibrefill filled pillows is also orthopedically recommended. Due to the high
resilience property, they can readily adjust to the shape of the body and recover immediately
after use and retain this property for repeated use. It meets the requirements of Oeko-Tex
standard 100 (product class 1), indicating the absence of harmful substances.
Products made of Recron Fibrefill can be easily washed using normal detergents and left to dry.
However, these products should not be wrung during washing and drying as the physical shape
of the products may get deformed. It is also recommended to use gentle washing method
(preferably hand washing).
Ø End uses of Recron Fibrefill:
Recron Fibrefill is used as filling for pillows, decorative pillows, cushions, bolsters, quilts &
comforters, mattresses, mattress toppers, mattress pads, sleeping bags, furniture cushions,
furniture backs, insulated garments and soft toys.
Ø Comparison between Recron Fibrefill & Cotton :
Due to its outstanding loft, Recron Fibrefill can give the same support level of cotton with 30-
35% less filling quantity. So products made out of Recron Fibrefill are far lighter and softer than
products filled with [Link] cotton, Recron Fibrefill is highly resilient and durable and
does not form lumps in a short time. Recron Fibrefill is fully washable. Products filled with
Recron Fibrefill are far more hygienic than cotton as moisture, dust and germs do not affect
them.