Melange Yarns

The term mélange is used for such yarns which are produced by the combination of two fibers (whether of same type but different in color or type of fiber used is different). Furthermore, mélange yarn can be classified into two of its very basic types:

Blended Mélange Yarn: Such type of yarn in which different fibers are mixed/blended together in a certain fixed ratio, for instance Polyester Cotton blend.

Non-Blended Mélange Yarn: Yarn in which there are no different fibers blended together, but different colored fibers of same type are used to make the yarn e.g. 100% cotton dyed yarn, 100% bamboo yarn etc.

Melange Yarns also known as "heathers", are a dramatic and innovative mix of different types of fiber to create magical textures in the resultant fabric that is woven and knitted from it. 

Mélange yarns are popular due to their very attractive and unique fabric appearance. The wavy like effect due to different fibers blending and wide range of color tones due to different fibers blending makes it much popular and rich in look. Its fabric smoothness is much better.

Mélange Yarns are being used in knitwear and denim industry. In knitwear, mélange is mostly used in t-shirts, uppers, trousers, under garments, swim wear, socks, bed sheets, curtains, towels. In denim it is mainly used in weft.

Features of mélange yarn

Environmental Friendly: Mélange yarn is a yarn dyed product, which means that part of the fibers are dyed before mixing into the raw fibers for spinning. Mélange yarn processing can save around 50% water compared to the conventional processing of spinning before dying.

Fashion: Mélange yarn can present multiple colors on one single yarn, which gives it rich colors, slenderness and tenderness. Textile made of mélange yarn has a certain ambiguous cyclical effect.

Technology: Mélange yarn has unique dyeing process, and is highly technological in terms of fiber dyes, color matching, and mixed textile of multiple fibers.

Benlon India manufactures melange yarns on technologically advanced machines and are environment friendly, as per latest fashion trends. Our manufacturing process is error free and shades produced are exactly as per our customer’s requirement. Melange Yarns produced by Benlon India are in huge demand both in Indian and international market.

Applications of mélange yarn

Mélange yarn is widely used in warp and weft knitting machines, various V-bed knitting machines, and winding machines. Mélange yarn is applicable to underwear, textile, casual wear, sportswear, shirts, business suites, socks and all sorts of cloth products, as well as bed linens, towels, decorative fabrics and other home fabric products.

Modal Melange

Modal melange yarns are produced by mixing colorful modal fiber in blow room process with demanded melange grade. Different grades of melange can be produced with each color. The final goods which are made from modal melange yarns have a perfect appearance thanks to all superior peculiarities of modal and superior performance.

Modal/Cotton Combed Melanges
Modal/cotton combed melange can be produced from colors which produces modal/melanges.

Viscose Melanges

Viscose melange yarn is produced by mixing colorful viscose fiber in blow room process with demanded melange grade. Different grades of melange can be produced with each color.

Cotton / Polyester and Viscose Polyester Melanges

Cotton/polyester and viscose/polyester melange yarns usually produce grades of gray and anthracite colors.

Manufacturing Process:

1. Preliminaries of the Process:

The production of mélange yarn is similar to the simple (Un‐dyed) yarn, but there are some additional things that need to be discussed here. Initially, the raw cotton is stored in form of bales in godowns. These bales after certain time of conditioning are sent to different processing mills for dyeing. There the bales are opened to flock form and conventionally, disperse dyes, reactive dyes and VAT dyes are used for fiber dyeing. After this is done, the bales are returned to the mill; these bales are again opened, well mixed, conditioned and pressed together in form bales but with a (LOT NUMBER). This number may vary from mill to mill for identification purpose, but this is important to discuss because we are not sure that we get the same type of dyed fibers ( in terms of dye ability, dye affinity, rubbing & washing fastness ) of the fibers every time. This may depend upon the dyeing conditions, dye quality, recipe, process conditions, fiber used (mature/ immature/ dead fiber content). These factors are important to consider because these are some unrevealed factors that causes very common problems in mélange yarn i.e. rejection of the shade. There comes the importance of making the LOTS, so that we can easily track from where the error occurs.

This identification leads us to proper issue of bales for particular order in order to avoid the shade variations. However, another technique may be used which is termed as “SAMPLING”. For every new LOT or new mixing of the running order, a sample should be made and get it cross‐checked with the customer’s sample. In this way we can reduce the chances of error and shade variation can be limited and predicted in advance, so necessary remedies can be taken.

2. Types of Blends:

Normally, we speak of types of blends depending upon the percentage of shade (colored fibers) in the mixing recipe or yarn. So, this classification mainly depends upon the Shade percentage, but it can also be done deliberately to ease and balance the process.

a)      Blow room Blend

b)      Drawing Blend

a) Blow room Blend Shade:

Such shades which are blended through blow room are called “Blow Room blends”. Normally, darker shades and shades constituents variety of colored fibers are run as blow room blend shades. Conventionally, shades having percentage more than 15% are run as blow room blends. This is done to achieve the maximum blending and uniformity in the shade.

It should be clear that by the term “shade” here we only mean the total percentage of colored fibers in the yarn.

b) Drawing Blend Shade:

Such shades which are blended on draw frame in form of alteration in doublings are termed as “Drawing Blends”. Mostly, lighter shades are blended on draw frame, as they are easy to blend and provide ease in balancing the process.

Grey Mélange Yarns

Grey mélange yarn is a special type of yarn and the fabric which is made from grey mélange yarn is also special. After dyeing, grey mélange yarns are used for producing woven and knitted fabrics. Below is the process through which grey mélange yarn is dyed –   

    1.       Firstly, carrier and vessel should be washed by hydrose and caustic at 100⁰ C for 20 min      

    2.       Next, load the package in the carrier and feed the vessel

    3.       Add wetting agent, anti-foaming agent, sequestering agent and run at 60⁰ C for 10 min

    4.       Drain the water solution

    5.       Add wetting agent, sequestering agent, caustic soda, hydrogen peroxide, optical brightening agent       and run at 90⁰ C for single yarn and 100⁰ C for double yarn for 40 min

    6.       Again drain

    7.       Add peroxide killer and run at 90⁰ C for 10 min

    8.       Check peroxide in the package

    9.       Drain again

    10.   Add washing chemical and run at 90⁰ C for 20 min

    11.   Wash the sample and check

    12.   If it is ok, then continue

    13.   Drain again

    14.   Rinse for 10 min

    15.   Add fixing chemical and half actic acid, run at 50⁰ C for 20 min

    16.   Add softening agent and rest half acid, run at 60⁰ C for 20 min

    17.   Now check the finished sample

    18.   All is ok

    19.   Drain

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