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 

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

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