Polyester Spun Yarn
Author : Kanokluck Permpreedanun
Textile specialist
What is Polyester spun yarn
Polyester spun yarn is created by spinning Polyester Staple Fiber (PSF). It can be obtained from both virgin polyester staple fiber and recycled polyester staple fiber. This type of yarn is mainly used for knitting and weaving fabrics, sewing thread production, and embroidery.
Polyester spun yarn was created to imitate cotton fiber, the most common fiber used in multiple industry applications in the past. Cotton fibers, composed of pure cellulose, offer a soft, fluffy, comfortable, and breathable texture. However, cotton products have a relatively short lifespan, are susceptible to price fluctuations because of their natural source, and are considered commodity items.
In contrast, Polyester spun yarn has been available for over half a century. It boasts improved wrinkle resistance, reduced fading, and increased durability, making it a longer-lasting and more robust choice.
Thai Polyester Company (TPC) is a professional manufacturer of 100% polyester fiber and yarn, the biggest polyester spun yarn supplier in Thailand. Plus, Thai Polyester Company provides considerable quantities of Polyester ring spun yarn and Polyester OE spun yarn. National and international thread suppliers, and knitting and weaving manufacturers rely on us.
According to our company's sustainable concept, TPC has started producing recycled polyester fiber and yarn made from PET bottles and reduced using virgin polyester. The company has also certified the recycled international standard by Global Recycled Standard (GRS) to guarantee that our product is high-quality and genuinely recycled. The company provides recycled and virgin polyester spun yarn to suit all customers' usages.
Types of Polyester spun yarn
1. Ring spun yarn
Polyester ring spun yarn is produced using the ring spinning method, the oldest spinning system still in use today. Ring spun production capacity is low compared to the rotor or open-end. However, the quality of the finished product is better than the others because the ring-spinning system continues using the widest range of yarn count as much as possible and produces the finest yarns.
In the ring-spinning process, roving is fed into the system and guided through typically three rolls that draft or spread out the fibers. These fibers are then twisted into yarn by a spindle with an attachable bobbin. The yarn gets wound onto this bobbin with the help of tools called a traveler and a ring.
Ring spinning requires a subsequent winding step. To make a larger package suitable for weaving or knitting, a full bobbin needs to be wound onto a cone. These additional steps of roving and winding, along with the slower production rate (compared to rotor spinning), are the primary reasons for the higher cost differences for ring-spun yarn.
(ref. https://www.textileschool.com/349/ring-spinning-process/)
2. Open-End(OE) spun yarn
Open-end (OE) spun yarn is created using a rotor or open-end spinning technique, which is significantly faster than ring spinning—up to 10 times faster per spindle. From a cost standpoint, it does not require the roving process, and it does not require an extra winding step. The yarn is ready to use directly from the machine. Nowadays, the process is highly automated, including automatic piecing (restarting broken ends) and doffing (removing complete packages).
Rotor spinning can seem complex at first. In this process, a sliver (a bundle of fibers) is fed into a small machine called an opening roll, which separates and arranges the fibers. These separated fibers are then drawn into a spinning rotor cup that's constantly rotating. Inside, they connect to an existing yarn end, which is why it's called open-end spinning. The yarn is then continuously pulled out, making the entire process ongoing.
(ref. https://www.sciencedirect.com/topics/engineering/open-end-rotor-spinning)
Classification of Polyester spun yarn
Virgin polyester spun yarn
Virgin polyester yarn is created from a non-renewable resource using an energy-intensive process. So, virgin polyester spun yarn is produced from non-renewable polyester staple fiber. The colors we provide are:
1.1 Raw White (RW)
RW refers to the natural color of polyester without any added dyes or colors.
1.2 Dope-Dyed Black (DDB)
DDB involves adding a black masterbatch at the beginning of the polyester staple fiber manufacturing process. This method produces a DDB spun yarn with non-staining feature and a subtle hue.
Recycled Polyester spun yarn
Recycled polyester yarn is made from 100% waste PET and post-consumer PET bottles (flakes). Recycled polyester yarn, also known as r-PET, is obtained by melting down existing plastic and re-spinning it into new polyester fiber. Another good choice for diverting plastics from landfills and producing recycled polyester requires far fewer resources than new fibers and generates fewer carbon dioxide emissions. The colors we provide are:
2.1 Raw White (RW)
Raw white recycled polyester is slightly different from virgin polyester; its color is yellowish naturally.
2.2 Dope-Dyed Black (DDB)
Dope-dyed black recycled polyester looks exactly like virgin polyester because the black masterbatch is mixed in the melting process before being injected. We cannot separate DDB virgin and DDB recycle by vision. But there is a mechanical test to detect which is recycled or virgin. Our recycled product is certified by GRS, a voluntary standard that tracks and verifies the recycled content in the final product.
Polyester Spun yarn Luster
Luster refers to the degree of light reflected from fiber surfaces or the degree of gloss or sheen the fiber possesses.
1. Full dull
Polyester spun yarn with a "full dull" finish is a type of yarn with a matte or non-reflective appearance. This means that it lacks the shine or gloss. The full dull finish is achieved by modifying the surface of the polyester fibers to reduce light reflection, resulting in a soft, natural, and matte appearance.
2. Semi-dull
Polyester spun yarn with a "semi-dull" finish falls between high shine and full dullness extremes. It has a moderate gloss or luster level, making it less glossy than bright or shiny polyester yarn but more reflective than full dull yarn.
Applications of Polyester spun yarn
Polyester spun yarns are long and continuous fibers suitable for applications in various industries, such as
Apparel and Clothing
Polyester spun yarn is widely favored in the fashion industry for crafting various clothing items, such as shirts, blouses, dresses, pants, and skirts.
Home Textiles
Polyester spun yarn is employed in manufacturing various home textiles, including bed linens, curtains, upholstery fabrics, and decorative pillows.
Sewing
Polyester spun yarn is commonly used in sewing for various applications, both in hand sewing and machine sewing.
Crocheting
Polyester spun yarn is an excellent choice for crafting various crocheting items, including blankets, scarves, hats, gloves, socks, and stuffed toys.
Embroidery
Polyester spun yarn is ideal for embroidering logos on clothing, personalizing gifts, and adding decorative elements to various fabric-based projects.
Rope making
Polyester spun yarn is frequently used in rope making and cords because of its robustness, long-lasting quality, and ability to withstand environmental factors like moisture and UV radiation.
Type, Count (Ne), and Color
| YARN TYPE | NE | LUSTER | TYPE | COLOR |
|---|---|---|---|---|
| OE SPUN | 10/1, 12/1, 14/1 | SD | Virgin & Recycled | RW, DDB, MELANGE, DYED YARN |
| 18/1, 20/1 | ||||
| 10/2 | ||||
| 20/2 | ||||
| RING SPUN | 18/1, 20/1 | SD | Virgin & Recycled | RW, DDB, MELANGE, DYED YARN |
| 18/1, 30/1, 32/1 | ||||
| 10/2 | ||||
| 20/2 | ||||
| 30/2 |
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