Drawing and Texturization
Module 3
Drawing
o After spinning, manmade fibers have very
high extensibility and low strength.
o Drawing is carried out to reduce
elongation and increase strength to
desired level.
o The process by which the yarn/fiber is
elongated by passing it through a series of
pair of rollers, in which each pair moving
faster than the previous one is called
drawing.
o It is a system which removes instable,
weak and brittle properties of filament.
Objectives
1. To increase strength
2. To increase orientation and crystallinity
3. To reduce elongation at break
4. To reduce creep
Principles of Drawing
o Fibers are run between two sets of rollers, the second of which runs at a faster surface speed and
the ratio of the speeds determines the amount of draw.
o For drawing to be done satisfactorily, the fiber should be in plastic condition.
o Some fibers are plastic at room temperature but some have to be heated to near their Tg or
plasticized to be drawn without any break or damage.
Types of Drawing
1. Drawing during spinning (LOY-Low Oriented Yarn, POY- Partially Oriented Yarn)
2. Drawing in unplasticized condition (hot, PET, 80°C; cold, nylon 6/66)
3. Drawing in plasticized condition (Acetate/triacetate)
4. Draw-warping (for flat yarn)
5. Draw-texturization (DTY)
6. FDY (Fully Drawn Yarn) method (≈6,000 m/min, flat yarn, directly used in
weaving/knitting)
7. H4S method (10,000 m/min, High Speed Spinning Stretching
Steaming)
Draw Ratio and Stretch Ratio
oThe ratio of surface speeds between drawing rollers and feeding rollers is
called draw ratio [≈1.2 (cellulosics), 3-5 (thermoplastics), 10 (acrylic)].
oHigher draw ratio usually indicates technical textiles applications
oDepends on types of fiber, production process and end use characteristics.
oThe draw ratio to which the yarn can be further drawn to make it suitable
for textile application (FDY) is called residual draw ratio.
oThe ratio between drawn and undrawn length is called stretch ratio. Stretch
ratio is slightly lower than draw ratio depending on elastic recovery.
Texturization
The process by which flat
filament yarn is distorted
by introducing crimp,
curl, loop etc. along the
length of the filaments to
impart bulk, stretch and
absorbency.
Effects of Texturization
oImproved softness, elasticity and better hand
oGreater fullness, bulk and covering power
oHigher thermal insulation and warmth
oBetter moisture absorbency and transport
oReduced resistance to abrasion and pilling
oLower resistance to soiling
Types of Textured Yarns
Process of Texturization
1. False twist method
2. Air Jet method
3. Stuffer box method
4. Gear box method
5. Knit – de knit method
6. Stress – curled method
7. Knife – edge crimping method
8. Physical/ chemical crimping method
False Twist Texturization Method
o First machine was invented in 1954.
o Much faster (1,500 m/min, 900,000 twist/min, spindle type and 2 million twist/min
for disc type) and continuous method.
o Can produce stretch filament yarn.
o The false twist method is the most important and the most widely used technique
for producing texturized Yarn.
o The false twist method combines all three stages –
1. Twisting
2. Heat setting
3. Untwisting in one continuous operation
False Twist Texturization Method
False Twist Texturization Method
False Twist Texturization Method
o The false twist type yarn machines currently used for manufacturing stretch and
modified stretch yarn.
o The yarn is drawn from the supply package, fed at control tension over the heater
and through the false twist spindles and finally wound on a package.
o The twist in the yarn is set when it is between the input feed roll and the false
twist spindle by heating and cooling before it leaves the false twist spindle.
o The productivity of false twist machine depends on spindle speed.
o Basically two types of twisting techniques used on false twist texturing machines –
1. Twist tube (Spindle)
2. Friction twisting
o Nylon, Polyester, Viscose, Acetate and Poly propylene are texturized by this
method.
Air Jet Texturizing Method
o The air jet texturizing
method is one of the most
widely used techniques
for texturizing synthetic
fibers, especially in the
production of polyester,
nylon and viscose yarns.
o This process is designed to
impart bulk, texture, and a
soft feel to yarns,
mimicking the properties
of natural fibers like
cotton and wool.
Air Jet Texturizing Method
Here's how the method works, and its specific use for different fibers:
o For polyester and nylon, both air and steam are passed over the untextured
yarn. The jet of air creates a turbulent flow, which is essential for the entangling
process. The heat from the steam helps to soften the fiber, allowing it to form
loops and crimps, which contribute to the desired texture.
o When working with viscose yarns, only air is used in the process. This is
because steam or water can reduce the strength of viscose fibers. The air jet
creates a twisting and crimping effect, similar to what is achieved with steam in
other fibers but without the risk of weakening the yarn.
Air Jet Texturizing Method
Key Features and Benefits
1. Efficiency: The air jet texturizing process is efficient, requiring minimal
equipment and offering high-speed production rates.
2. Bulk and Softness: The method imparts bulk and softness to the yarn,
creating a more luxurious feel while maintaining strength.
3. Cost-effective: As it requires less mechanical manipulation, it is generally
considered a cost-effective method compared to other texturizing
techniques like false twisting.
Intermingling, Heat Setting, Spin Finish &
Additives
(a) Intermingling
oFilament yarns wound on bobbins lack cohesion or inter-fiber friction
like other twisted yarns.
oMay break during winding and processing.
oInterlacing is applied instead of twisting or sizing for cohesion between
filaments.
oRelative costs sizing:twisting:interlacing = 100:72:11
oAir Jet method is highly popular while other methods like spot welding
by hot pin may be used.
oFilaments will be intertwined and mingled with each other to produce
a compact yarn.
Intermingling
Point of Entanglements in intermingled yarns
(b) Heat Setting
The process of imparting dimensional stability to fiber, yarns, fabrics or
garments with successive heating and cooling in dry and moist
conditions is called heat setting.
Heat setting provides dimensional stability to thermoplastic fibers.
Setting is required to stabilize distorted shapes in the textured yarn
and to achieve a stable shrinkage.
For Polyester, the setting temperature is between 180°C to 220°C.
(c) Spin Finish
Spin finishes are usually organic fluids applied to the fiber surface to
improve their subsequent performance and processing.
Objectives-
1. To lubricate the fiber surface
2. To impart anti-static property
3. To provide cohesion of the filaments
Different type of spin finishes
Lubricants: Used to control the friction of the fiber.
Example: Oils, polyglycols, ester of fatty acid.
Plasticizers: Plasticizers make the fiber more flexible by reducing the glass transition
temperature and also reduce brittleness.
Example: Dibutyl phthalate, Silicate esters.
Antistatic agents: Antistatic agents are hygroscopic chemicals which can conduct the static
charge from fiber to air or earth to improve dielectric constant and to reduce co-efficient
of friction.
Example: Inorganic salt (such as lithium chloride)
Ester of fatty acid (Butyl stearate)
Alcohols, amide (NN-dihydroxy ethyl stearamide)
Poly oxyethylene derivatives etc.
Desirable Properties of Spin Finish
o Lubricity o Reasonable price
o Anti static property o Not encourage bacterial growth
o Provide cohesion of the filaments o Should be chemically inert
o Should not get oxidized o Wettability
o Should have reproducibility o Non yellowing
o Non carcinogenic o No objectionable color/odor
o Biodegradable o Easily available
(d) Additives
Additives are chemical compounds that are added during
polymerization or in the spinning dope in order to add desirable
properties to the manmade fiber.
Most usable additives are-
1. Delustrant
2. Pigments for Mass Coloration
3. Optical Brightener
4. Heat Stabilizer
5. Light Stabilizer
1. Delustrant
oReduce transparency, increase whiteness
and prevent undesirable gloss in the fiber
oFine particles (0.1 - 0.8 µm) of titanium
dioxide is dispersed within the fiber
oWhite pigments scatter light, impart a
subdued luster in the fiber (dull, 2% & semi-
dull 0.5% owf)
oChemically inert, available in fine particles,
will not choke the spinneret Semi-dull 100% Polyester
2. Pigments for Mass Coloration
The process of adding colorants are also
called mass or spin or dope or solution
dyeing
Inorganic pigments added in polymer melt
or spinning solution
Stable & superior color fast yarn is
produced
Better color reproducibility and consistency
No drying, re-winding or water usage
Less labor intensive and carbon footprint
3. Optical Brightener
FWAs (Fluorescent Whitening Agents) are
colorless dyes, derivatives of
stilbene, coumarine, pyrazoline
etc.
Absorbs invisible UV rays (300-
390 nm) and reflect in 400-500
nm range (visible blue light)
Makes whiter and brighter
4. Heat Stabilizer
Added to impart heat or flame
resistance properties
Salts of Mn and Cu containing
phosphates and phosphites e.g. tris
(2,3 dibromopropyl) phosphate
tris (2,3 dibromopropyl) phosphate in
powder form
5. Light Stabilizer
oProtect the fiber from photochemical
degradation
oMay be colorless absorbers UV
(polyamides,
polyhydroxybenzophenones) or
hindered amine type
Thank
You