FDY - Fully Drawn Yarn

Fully Drawn Yarn

Fully Drawn Yarn (FDY) is produced by spinning the yarn at higher speeds coupled with intermediate drawing integrated in the process itself. This allows stabilization through orientation and crystallization. 

Fully Dawn Yarn is used as weft or weaves. It can also be knitted or woven with any other filament yarn in order to produce different varieties of fabrics such as home furnishing fabrics, fashion fabrics, terry towels etc.

FDY is available in 3 lustres, Semi-dull, Bright having circular section & Triloble Bright having triangular cross-sections. Instead of making the fabric with FDY Raw-white first & then dyeing it, Dope Dyed Fully Drawn Yarn can be used to make the colored fabric directly.

Benlon India Limited is producing fully drawn yarn in more than 400 colors. It is being used in sarees fabric in south of India, Varanasi & Mau and furnishing in Panipat.

Benlon India is also manufacturing double colored FDY in 400 and 800 Dn. We take two different color POY components and draw texturize the same together, which gives a fancy effect in furnishing and bed covers.

Fully Drawn Yarns are produced by a continuous polymerisation process. All critical yarn properties such as tenacity, elongation, Uster variation and boiling water shrinkage are closely monitored and controlled. Controlled interlace enables the yarns to be twisted or sized in subsequent operations.

FDY has the following properties -

   1.       Intermingled FDY yarns are suitable for direct twisting, warping and weaving.      

   2.       The fabric made from these yarns have a feel and drape similar to fabrics. Produced from pure silk resulting in high realization of product quality.

   3.       These yarns eliminate draw-twisting and sizing process reducing the cost of products for light and medium range of fabrics.

   4.       There is high efficiency and low breakages in

   5.       Excellent dyeing consistency.

Normal Partially Oriented Yarn (POY) needs to be necessarily texturised before being used for making fabric whereas FDY is drawn fully during the process of spinning itself and therefore does away with the requirement of texturising and can use directly for making fabric.

FDY is generally used for better quality fabric. As the process of texturising is avoided, FDY yields higher contribution as compared to the normal POY. Fully-drawn yarns are used to manufacture textile fabrics without the need for further finishing. Wherever textiles are to hang smoothly or glide fully-drawn yarns are used.

FDY is used in the following products –

    1.       Flags and banners

    2.       Floatation Devices

    3.       Parachutes

    4.       Team Apparel

    5.       Swimwear

    6.       Intimate Apparel

    7.       Compression Fabrics

    8.       Tents

    9.       Cargo Bags

   10.   Upholstery

   11.   Elastic Bands

Manufacturing Process

The Raw material i.e. PET Chips are dried, melted, filtered and then distributed to spinning manifolds followed by spinning position to get fully drawn yarn. To manufacture FDY, PET chips are fed into dryer where the moisture is reduced from 0.30% to 0.0020%. After this, chips are melted, filtered through polymer filter and extruded through the spinnerets. Extruder is electrically heated microprocessor temperature controlled and screw speed is controlled and monitored very precisely to ensure uniform quality. The extruded filaments are cooled by filtered air in the quench chamber with precise temperature control. Air having no turbulence is used to ensure perfect evenness. High quality antistatic lubricating oil is applied to avoid static charges in the yarn. The yarn is taken through heated godets to maintain residual elongation. Air punching is done at regular intervals by intermingling nozzles and finally wound on automatic winder in the take up. The FDY so made is capable of running in high speed warping, sizing, knitting, circular knitting and looms.

Nylon Fully Drawn Yarn

Nylon POY is used as raw material for manufacturing Nylon FDY. For manufacturing FDY one stage high speed process is used. 

The main use of nylon FDY is for stocking, knitting, weaving fabrics, weaving looms and hoovering machines. Also it can be knitted or woven with any other filament yarn to get fabric of various different varieties. It is mainly used in Home Furnishing Fabrics, Fashion Fabrics, Denim, Terry Towel and fishing nets. Nylon FDY is available in bright, semi dull and full dull FDY.

Spinning Speeds

The type of yarn produced during melt spinning is decided by the spinning speed. Low oriented yarn (LOY) is produced at speeds below 1800 m/min. Medium oriented yarns (MOY) are spun between 1800-2800 m/min. Partially oriented yarn (POY) is spun at speeds between 2800 to 4000 m/min., where the yarn is more oriented with a little crystallinity. This gives POY better stability, and therefore, POY is preferred as commercial intermediate for drawn or textured yarns. High oriented yarn (HOY) is spun at 4000-6000 m/min and fully oriented yarn (FOY) is spun at speeds in excess of 6000 m/min.

For nylon-6, the POY speeds are nearly 4000 – 4200 m/min. Nylon-6 spun at lower speeds undergo post spinning crystallization on conditioning. At speeds near to 4000 m/min, nylon-6 POY is stable and essentially consists of crystals, which are deformable during drawing and texturing. Polypropylene has very high rate of crystallization and the material crystallizes in the spinning line at any speed, unless, it is quenched at a fast rate in cold water.

Spinning of fully drawn yarns (FDY) or high performance fibres

High speed spinning of POY at speeds greater than 6000 m/min produces highly oriented and crystalline yarn which may be categorized as fully drawn yarn (FDY). These may be used directly without further drawing, though their properties are inferior to fully drawn yarn obtained by two step process of spinning and drawing. Very high spinning speeds are required to increase the drag force on the spinning filament which in turn increases the stress level in the filament so that polymer chains get oriented and stabilized by stress induced crystallization.

FDY Spinning & Drawing Machine at Benlon India

Benlon India is a quality producer of Fully Drawn Yarn and has latest spinning and drawing machines at its plants. The machines have the following features –

•       Our machines have new type of energy conserving spin beams with 25% less energy consumption compared with conventional ones. 
•            The machines have bottom mounted spin packs bettering evenness of melt flow and the uniformity of spinneret surface temperature and reducing labour as well.
•        New type of quenching system provides smoother air blowing for the better yarn evenness. 
•       The heated godet with thermal tube technology results in more even surface temperature and less energy consumption.
•       Lastly, fully automatic winders with precision winding, maximum 24 packages, leads to higher successful changer-over rate and good package formation.

If you are interested in our products and would like to be part of our growth story, please contact us on sales@benlonindia.com 

For more information about our company and our products, please visit www.benlonindia.com