Manufacturing Process of Polyester Fibre

Manufacturing Process of Polyester Fibre

 Manufacturing Process of Polyester Fibre

In this article, garments merchandising provides you Manufacturing Process of Polyester Fibre. Polyester may be a fibre derived from coal, air, water, and petroleum. Established during a 20th-century laboratory, polyester fibres are formed from a chemical process between an acid and alcohol. During this reaction, two or more molecules combine to form an oversized molecule whose structure repeats during its length. Polyester fibres can form very ion molecules that are very even and robust.

The Polyester is employed within the manufacture of the many products, as well as clothing, industrial fabrics, home furnishings, recording tapes and computer, and electrical insulation. Polyester has numerous advantages over traditional fabrics like cotton. It doesn’t absorb moisture, but does absorb oil; this quality makes polyester the proper fabric for the appliance of water-, soil-, and fire-resistant surfaces. Its low absorbency also makes it obviously proof against stains. Polyester clothing is preshrunk within the finishing process, and afterwards the material resists lessening and cannot bounce out of shape. The material is definitely dye able, and not spoiled by mildew.  Textured polyester fibres are an efficient, no allergenic insulator, that the material is employed for filling pillows, quilting, outerwear, and sleeping bags.


In 1926, United States-based E.I. du Pont de nemours and Co. began research into very large molecules and artificial fibres. This early research, headed by W.H. Carothers, centered on what became nylon, the primary fibre.

Afterwards, within the years 1939-41, British research chemists took interest within the du Pont studies and lead their own research within the laboratories of Calico Printers Association, Ltd. This work resulted within the formation of the polyester known in England as Terylene.

In 1946, du Pont bought the correct to supply this polyester within the u. s. The corporate lead some further developmental work, and in 1951, began to promote the fibre under the name Dacron. During the following years, quite a few companies took an interest in polyester fibres and produced their own varieties of the merchandise for various uses. Today, there are two primary forms of polyester, PET (polyethylene terephthalate) and PCDT (poly-1, 4-cyclohexylene-dimethylene terephthalate). PET, the more popular type, is appropriate to a wider kind of uses. It’s stronger than PCDT, though PCDT is more flexible and strong. PCDT is right to the heavier consumer uses, like draperies and equipment coverings. PET is used alone or mixed with other fabrics to form clothing that’s wrinkle and stain resistant and holds its shape.

Raw Materials:

Polyester may be a chemical term which may be broken into poly, meaning many, and ester, a basic organic matter. The principle component utilized in the manufacture of polyester is ethylene, which springs from petroleum. During this process, ethylene is that the polymer, the chemical structure block of polyester, and also the natural action that creates the finished polyester is named polymerization.

The Manufacturing  Process

Manufacturing Process of Polyester Fibre
Manufacturing Process of Polyester Fibre

Polyester is synthetic by one in all several methods. The one used depends on the shape the finished polyester will take. The four basic forms are filament, staple, tow, and fibre fill. Within the filament form, each individual strand of polyester is continuous long, producing smooth-surfaced fabrics. In staple form, filaments are move short, predetermined lengths. During this form polyester is less complicated to blend with other fibres. Tow may be a form within which continuous filaments are drawn slackly together. Fibre fill is that the huge form utilized in the manufacture of quilts, pillows, and outerwear. The 2 forms used most often are filament and staple.

Manufacturing Filament Yarn


1) To make polyester, dimethyl terephthalate is first reacted with antifreeze within the presence of a catalyst at the temperature of 302-410°F (150-210°C).

2)  The resulting chemical, a monomer (single, non-repeating molecule) alcohol, is joint with terephthalic acid and raised up to a temperature of 472°F (280°C). Newly-formed polyester, which is obvious and molten, is extruded through a slot to make long ribbons.


3)  Afterwards the polyester arises from polymerization, the long molten ribbons are allowable to cool down until they become brittle. The fabric is delving tiny chips and totally dried to forestall indiscretions in constancy.

Manufacturing Process of Polyester Fibre

Melt spinning

4)  Polymer chips are melted at 500-518°F (260-270°C) to make a syrup-like solution. The answer is put during a metal vessel called a spinneret and made through its tiny holes, which are generally round, but could also be pentagonal or the other shape to supply special fibers. The quantity of holes within the spinneret regulates the dimensions of the yarn, because the developing fibers are brought together to make one strand.

5)  At the stage of spinning, additional chemicals could also be added to the answer to form the resulting material flame retardant, anti static, or easier to dye.

Drawing the fibres

6)  When polyester arises from the spinneret, it’s soft and simply lengthened up to 5 times its unique length. The extending forces the random polyester molecules to align during a parallel formation. This increases the strength, tenacity, and resilience of the fibres. This time, when the filaments dry, the fibres become solid and robust rather than brittle.

7)  Drawn fibres can differ greatly in diameter and length, looking on the characteristics wanted of the finished material. Also, because the fibres are drawn, they will be textured or twisted to make softer or duller fabrics.


8) when the polyester yarn is drawn, it’s twisted on large bobbins or flat-wound packages, able to be woven into material.

Manufacturing Staple Fibres

In creating polyester staple fibre, polymerization, drying, and melt spinning (steps 1-4 above) are much the identical as within the manufacture of filament yarn. Yet, within the melt spinning process, the spinneret has more holes when the merchandise is staple fibres. The rope-like packs of polyester that arise are called tow.

Drawing tow

1)  Newly-formed tow is rapidly cooled in cans that gather the thick fibres. Numerous lengths of tow are gathered and so drawn on heated rollers to a few or fourfold their unique length.


2)  When tows are drawn then these tows are fed into compression boxes, which force the fibres to fold like an accordion, at a rate of 9-15 crimps per inch (3-6 per cm). This procedure helps the fibres grip together through the later manufacturing stages.


3)  After  crimping the tow , heat it at 212-302°F (100-150°C) to totally dry the fibres and set the crimp. A number of the crimp will inescapably be drawn out of the fibres during the subsequent processes.


4)  Following heat setting, tow is turn over smaller lengths. Polyester which will be mixed with cotton is cut in 1.25-1.50 inch (3.2-3.8 cm) pieces; for rayon blends, 2 inch (5 cm) lengths are cut. For weightier fabrics, like carpet, polyester filaments are turn over 6 inch (15 cm) lengths.



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