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Chapter 1: Polymerization: Definition, Objects, Types: POY and TEXTURISING Process
Chapter 1: Polymerization: Definition, Objects, Types: POY and TEXTURISING Process
1.1 Introduction
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POY and TEXTURISING process
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POY and TEXTURISING process
1. Natural polymers
2. Synthetic polymers
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2.1 Principle
The principle behind manufacturing a thread is always
the same: spinning pumps press the polymer melt through
micro-fine spinnerets under extremely high pressure. The
filament created are then bundled into threads, drawn over
godets and wound using a winder.
2.2 Diagram
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2.3 Flowchart
Extrusion Intermingling
Chips to melt by For intermingled knots
heating
Godets
Manifold To regulate the yarn
Distribution of melt Tension and for FDY
heated godet to stretch
the yarn
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1. Bagging system
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Full dull
Semi dull
Bright
As per requirement from market this 3 chamber is filled
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Dryer
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4.2 Feauture
Crystalline and amorphous chips can be dried, due to
incorporated crystallizer
Low energy consumption, also at reduced capacity
high flexibility 40-110% without mechanical
modification
Residual moisture of chips as low as 15ppm
Extremely sharp hold up spectrum ensures the
same treatment for all chips
Drying by hot dry air, no nitrogen required
Heat recovery is not required, due to special design
No maintenance and no cleaning required for
the dryer
No cooling water required, due to special design
Continuous operation, throughput is controlled
by extruder
Large number of sizes allows optimum selection
of dryer closed air circuit
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4.4 Applications
Drying of polyester chips or polyamide chips to 15 ppm
moisture for:
textile filaments
micro filaments
staple fiber
technical yarns
POY, FOY, FDY
Non woven spinning
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Typical Setting
Drying
parameter
Residual time Minimum 4 hrs Minimum 2 hrs
Air temperature 80˚ C 100˚ C
Air dew point -40˚C -40˚C
Air flow rate >.25 >.25
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5.1 Extruder
In earlier days, the polymer chips were melted using
heating grids however now extruder completely replaced
melting arrangement. Extruder compresses the fluid to
remove any trapped gasses including air that is drawn along
with the chips as they enter the extruder. There are two
types of extruder one is single screw and other is double
screw extruder.
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5.2 Function
5.3 Process
Extrusion technology is aimed at achieving a high output
capacity in connection with an optimization in melt quality,
respectively product quality. Melt quality means a
homogeneous melt stream at any time and any place.
Homogeneity in time can be described through constant
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Extruder parameter
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6.1 Burnout
Burnout is separate part but link with extruder and spinning
area. Here the employers do many things like assembling the
packs, pump, cleaning the part of extruder like candle,
spinneret and etc.
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6.4.3 Gasket
An effective compression ring-type gasket has been provided
to overcome this problem, The gasket is made of cold
flowable material and has an inner peripheral surface that
includes a circumferential groove. This structural
arrangement facilitates the outward diametrical expansion of
the ring as it is being compressed between the two parts
forming the seal.
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The melt of the spin body will be fixed inside the body so to
remove the melt of this delicate part some cleaning
equipments are used in burnout section.
The unit include a basket and lid made from stainless steel.
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6.5.2 HYPOX
HYPOX is a polymer removal system developed by
MOVEngineering, Italy that can be used for all type of parts.
It is safe, easy to operate, chemical-free cleaning system that
utilize the hydrolysis, pyrolysis and oxidation of resin for the
automatic removal of polymers adhered to spinning
nozzles(for fiber manufacturing), filter, gear pump, and
extruder screw and molds. It can also be used to remove that
are difficult to remove using conventional cleaning methods,
such as carbons, oligomers, and gels without damaging any
parts.
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7.1.1 Advantage
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8.1 Principle
A method for winding pre-oriented, non-crystalline
polyester filaments onto a spool at a winding speed of at
least 4,200 m/min, in which the wound filament is wound
over the width of the spool by means of a flying traverse arm
and is turned by a driven Sensing roller with an applied
pressure between 8 and 18 kg on the circumference of a
Spool placed on a driven Spool-locating pin. The filaments for
winding are introduced to the traverse thread guide at a
thread tension of between 0.03 cN/dtex and 0.20 cN/dtex.
The Sensing roller is driven at an overspeed of preferably
between 0.3 and 1.2%, in comparison with the Spool
circumferential Speed. The thread laying angle is Set
between 3.5 and 7.5 by means of the spool travel. The above
method permits a good spool formation even at high
spooling speed
8.1 Process
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Purpose
This instruction defined the procedure to be followed
for calibration of DYNAFIL.
Equipment
1. Weight
2. Move strobe
3. Venier
4. Master temp.sensor
Procedure
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Temperature Calibrate
I. Put the Master Temperature sensor inside the
heater tube after pressing the black knob given on
the tube
II. Connect the Master Temperature indicator with the
Master temp. sensor
III. Set the temp. at 50˚C amd switch on the heating.
IV. Note down the display of both the indicators after
the temperature stability
V. Repeat step no. III & IV for temperature settings of
100, 200 and 250˚C Temp. difference should be
within 1.0+0.005*Temp.
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Precaution
1. Ensure valid calibration status of test and measuring
equipments used for calibration.
2. Ensure valid calibration status of weighing balance
used for weighing the Hank.
Purpose
This instruction defined the procedure to be followed
for calibration
Scope
This instruction is applicable to calibration of statimate.
Equipment
1. Weight
2. Stop watch
3. Scale
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Precaution
1. Ensure valid calibration status of test and measuring
equipment
Purpose
This instruction defined the procedure to be followed
for calibration
Scope
This instruction is applicable to calibration of
UNEVENESS TESTER.
Equipment
1. Movie strobe
2. Vernier
3. Frequency counters
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Procedure
1. Check the instrument for functional check
2. Calibration of speed
3. Check the diameter of 0% roller with vernier (X mm)
4. Calculator meter of yarn in one round of roller by
formula 2πr(Y mt.)
5. Calibrate the speed at spot of 100, 150 & 200 mpm.
Programmed the computer to the require spot (speed)
and run.
6. Check the RPM with movie strobe keeping the
sensation at height. Note the RPM and divide by 4.
This is actual RPM of roller. (Z)
7. Calculate speed = Y*Z mt. /min.
Calibration of frequency
1. In the unevenness body two capacitor are arrange in
such a way that in between them frequency difference
of 120 ± 5 kHz is there. We have to measure this
frequency difference with the help of frequency
counter.
2. Open the top cover of unevenness tester body and
connect the lid to the machine. Other end of lid should
be connected to the frequency counter (10Hz-15Mhz)
point. Push the resolution to 10 Hz. Switch on the
frequency counter, frequency reading will be appear
on counter. It should be 120 ± 5. Adjust the frequency
with the help of screw driver.
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POY and TEXTURISING process
Precaution
1. Ensure valid calibration status of test and measuring
equipments used during calibration
Purpose
This instruction defines the procedure to be followed
for moisture check
Scope
This instruction is applicable to % moisture check of
polymer chips.
Equipment
1. Physical apparatus
2. Heater
3. Thermometer
4. Lift jack
5. High vacuum pump
6. Torr meter
7. Sample bottle 250 ml.
8. Sample glass tube
Reagents
1. Copper sulphate (CuSO4. 5H20)
2. Silicon grease
3. Paraffin oil
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vi. Take out heater and cool the tube at room temp.
vii. Take the weight of sample
viii. Calculation
Weight of sample
Precaution
i. Ensure identification / traceability to line, position,
dryer & suppliers
ii. Ensure valid calibration status of test & measuring
equipments.
iii. While taking moisture of dried chips sample
collocation from dryer should be done very
carefully.
iv. Lid of sample bottle should be tightly closed.
v. Leakage of apparatus should be checked very
carefully.
vi. While inserting sample tube in aluminum block,
heater, care should be taken otherwise tube will
break and injured the hand.
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Purpose
This instruction defines the procedure to be followed
for I. V. Checking.
Scope
This instruction is applicable to I.V. Checking of
polyester chips & POY yarn.
Definition
I.V.: The value of the viscosity number of dilute
polymer extrapolated to infinite dilution.
Equipment
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Chemicals
1. Phenol crystal
2. 1,1,2,2 Tetra chloro ethane
Sampling
1. At least Once / Source (Challan no. for outside chips
and Silo for captive consumption be written in I.V.
Register.
2. For poly batch at least after 15 min after the start up of
the batch.
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1.48(𝑅𝑉−1)
I.V. = √1 + ∗ 𝑐𝑜𝑛𝑐 - 1
.74
Purpose
This instruction defines the procedure to be followed
for OPU
Scope
This instruction is applicable to OPU check of POY.
Definition
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Equipment
1. Oil extract (Soxhlet assembly)
2. Oven
3. 250 ml. Round bottom flask of B-24 joint.
4. Desicator
5. Balance
6. Six flask assembly heater
7. Reeling machine
8. Distillation assembly
Chemicals
Petroleum ether (40 -60˚C boiling range
Sampling
1. Take sample as defined in sampling plan for process
feedback.
2. Collect clean sample from process stage.
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Precaution
1. P.E. is highly inflammable so, while doing the
experiment P.E should be drop on heater otherwise
fire will catch
2. Heater should not be ignited.
3. Keep heater temp. up to 60˚C
4. Always keep P.E. bottle away from heater.
5. CO2 fire extinguisher should be always in ready
position
Purpose
This instruction defines the procedure to be followed
for End Group (-COOH-Gps.) checking.
Scope
This instruction is applicable to check End Gps. of
polyester chips & POY yarn.
Definition
End Group : Carboxyl group (-COOH) at the end of a
polymer chain, which must necessarily be different from
the regular repeat unit due to its being bound to the
polymer chain by only one chemical bound rather than
two. Expressed as mili equivalent per kilogram
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Equipments required
1. Condenser
2. Burette
3. 100 Ml. Beaker
4. 25 Ml. Measuring cylinder
5. 100 Ml. Conical flask
6. Balance
Chemicals
1. Phenol + chloroform (40:60)
2. 0.1 N KOH in Benzyl Alcohol
3. Bromo Phenol Blue as indicator
Sampling
1. Once/Source (For outside supply)
2. For poly batch at least after 15 min after the start up of
batch.
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Precaution :
1. Analyst must wear protection glass and gloves
2. Ensure identification / traceability to line, position,
dryer & suppliers.
3. Ensure valid calibration status of test & measuring
equipments
9.2 Defect
The defects are the undesired effects of a product from
point of view of the customer. In the melt spinning, from
the quench chamber filament falls through the duct and
thread are wound on the bobbins of the take up unit. The
winder may have 4 to 6 bobbins on the same bobbin
chuck. The winder is having friction drum, grooved drum,
bobbin chuck, reversing mechanism, reversing shaft,
bobbin push off device, intermingling jets etc.
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1. Ribbon formation
2. Jali formation
Jali or the net effect is also known a stitching. It is
related to the improper tension in the yarn. It may
occur due to low or high tension in the yarn. When the
yarn falls out of the drum, it may cause the slippage of
winding layer and lead to jail formation. It is very
difficult to unwind the thread from such type of
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5. Loops
The loop will occur in the POY bobbins. It could be due
to grooved drum, spinneret, and traverse guide. To
avoid loops in the packages, check the grooves of the
drum, fix TG properly, change pack etc.
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10.1 Introduction
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.
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11.1 Packaging
Material used for covers or protect goods.
The two system is available in packaging of POY and
FDY:
Carton system
Pallet system
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POY/FDY
Denier
Grade
Merge no.
Shade
Gross Wt (Kgs)
Tare Wt (Kgs)
Net Wt (Kgs)
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12.1 Introduction
The man-made fibers were developed basically to replace
naturals, which were becoming scarce and costly. However,
the wide difference in the properties and appearance
between the synthetic filaments and spun yarns with natural
spun yarns prevented the former from competing effectively
with natural spun yarns.
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12.1.1 Texturising
It is the process by which synthetic fiber are modified
to change their textured the physical appearance of the fibre.
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All the twist will vanish on realeasing the twisting point. This
was false twist created by us. False twist principle is being
applied by contemporary texturising machines.
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Shaft 1 is the input feeding device for the POY. From here the
yarn has to be drawn. The speed of shaft 2 is always higher
by factor of the necessary draw ratio for the particular yarn
and process. The yarn is simultaneously twisted and drawn.
The twisting is done with a friction device, such as a set of
rotating friction disk. But there is other twisting device such
as belts. After Shaft 1 there is a yarn heater, which heats the
yarn to a temperature where it can be thermo-set. Right
after the heater is normally a cooling plate, which must cool
the yarn as a substantially lower temperature in order to
permanently thermo-set the twist. As the yarn is released
from Shaft 2 we observe how each single filament is trying to
assume the 3-dimensional helix formation it was set in. The
result is a voluminous bulked stretch yarn.
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1. 125/36 75/36
2. 160/48 100/48
3. 256/141 150/141
4. 160/36 100/36
5. 130/48 75/48
6. 240/216 150/48
7. 265/48 150/48
8. a. 125/36 150/75
b. 250/72
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1. Bottom break
2. Splice fail
3. Fluff
4. Last layer
5. Poy exhaust
6. Body break
7. Filamentation
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Yarn path start from POY creel and end to winding. POY is
loaded to creel and the parameter of the machine will be
set. The suction pipe of the machine will suck the POY yarn.
It goes to cutter. Then yarn goes to input (v1) and also known
as draw ratio. Now with help of feed pipe it comes telephonic
guide. It has 2 guide in it one is eyelet and despa guide. Now
it goes to primary heater if max goes to 220˚C and min
180˚C. After the primary heater for cooling it comes to
cooling pipe. This is heart of the false twist texturising known
as positorque (false twist spindle). Now it comes D/Y or
intermediate which draw the max area. The secondary
heater comes here now. The SOF comes here also known as
output. The oiling device comes which just oil the textured
yarn. At last take up come which help to wind the yarn to
doffer.
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telephonic guide
Primary heater: The role of primary heater is to
mobilize the molecules and gives the
desired yarn properties with the help of
Draw ratio and D/Y.
Cooling pipe: The function of cooling pipe is only to
maintain the temperature.
Positorque: It also known as spindle it is the heart of
the machine. It gives the twist n untwist
to the yarn
Olt sensor: This is the sensor which gives the fault
with the help of computer. We can see
this from graph which display in computer
Intermediate: (V2): It stretch the yarn from V1 to V2 . It
also known as D/Y.
Jet (Intermingling): It helps implant knot to the yarn.
Except NIM all quality of yarn will
go under jet
2B Shaft (NFR): It helps to give pressure in punching.
The pressure will help the knotting
so that it may not open.
Secondary heater: The secondary heater makes the
texturised yarn stable and taken
for further process.
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PURPOSE
This instruction defines the procedure to be followed for
DENIER checking
Scope
This instruction is applicable to DENIER checking of POY
DEFINITION
Denier: Weight of 9000mts of yarn in grams.
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Equipment Required
1. Reeling machine
2. Suction gun
3. Electronic balance
4. Wooden tray
5. Scissor
Sampling
As per sampling plan.
Take sample as defined in quality plan for process
feedback
Collect samples from process stage and clean using
suction gun.
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Precaution
1. Ensure zero setting start.
2. In case yarn breaks while reeling, across the lee and
start again
3. Ensure identification / traceability to line & position
4. Keep wooden tray clean
5. Do not put hand/ touch the m/c while running /
reeling.
Apparatus
1. Hot air oven
2. Water bath
3. Wrap reel
Principle
The specimens in the form of skeins are treated in a
water bath at 95 ± 2 °C for 10 minutes, dried and
conditioned in the standard atmosphere of 27 ± 2°C
temperatures and 65+ 2 per cent relative humidity for
two hours.
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Procedure
Wind sufficient lengths of yarn (say about 10 turns of
1m each) on a wrap reel at a tension of 1cN/Tex)
0.2g/denier. Prepare hanks for measuring residual yarn
shrinkage. Measure the original length of the skeins L o in
mm at a tension of 500 g. Place the hanks in a boiling
water bath at 95 ± 2 °C for 10 minutes, then dry in a
free state. Condition the hanks for 120 minutes in the
standard atmosphere of 27 ± 2 °C and 65 ± 2% RH after
drying. Measure the final skeins length Lf in mm under
the same tension (500 g) and
Calculate the yarn shrinkage, percent as follows:
Yarn shrinkage, % = [(Lo – Lf) / (Lo)] × 100
Apparatus
Draw-texturing machine
Instron/Statimat tensile tester
Wrap reel
Microscope Digital balance
Hot box oven
Meter rule
Conditioning of Samples
The samples shall be allowed to condition at
temperature of 27 ± 2°C and a relative humidity of 65 ±
2% before carrying out the tests. All tests shall also be
performed under standard condition
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Apparatus
1. Precision Balance
2. Stainless Steel
3. Vessels Conical Flasks
4. Bowls
5. Forceps
Procedure
Take the hank (normally, prepared for denier check) of
textured yarn for the analysis. Note down the actual
weight of the sample. Take required amount of
petroleum ether along with sample in the vessel /
conical flask. Immerse the yarn sample in petroleum
ether for extraction of oil for 15 minutes. After 15
minutes take out sample, squeeze it completely and
then place the yarn in the tray kept in open air for 20
minutes. Then put the hanks in oven at temp 85° C Take
out the yarn from the oven after drying up to 15
Minutes. Keep the yarns for cooling room temperature
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Calculations
Calculate the per cent oil pick up (OPU) by the
following formula:
OPU per cent = Weight of Sample – Weight of the
yarn after drying x 100
Sample weight
16.6 Defect
The defects are the undesired effects of a product from
the point of view of the customer.
Yarn break: The yarn break rate is the no. of yarn break
that take place/ unit weight of the texturised yarn
produced yarn break can create short yarn package.
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1. Description
Long length of the texturised yarn having little or
no bulk: when knitted and dyed, we get short
pattern effect which is permanent.
Missing of texturised effect for long lengths of a
texturised yarn.
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2. Causes
High U% of POY:
Higher unevenness of POY results in intabilty in the
yarn while texturising and leads to tension
variation. Because of this tension variation, the
yarn momentarily loses contact with the friction
disc leading to the untexturised yarn.
3. Effects
When knitted and dyed, it shows as a permanent
effect
4. Remedies
POY used should be uniform with U% of less than
1%
POY having spin-finish below 0.40% to be used.
Uniformity of spin-finish is very important
Optimize DR
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Undrawn Yarn
1. Description
The texturised yarn which escapes the effects of
drawing is called the undrawn yarn.
The undrawn/partially drawn gives high
shrinkage and low tenacity causes defective
fabric
2. Causes
Yarn not in the grip of the first nip roller:
When the throw of the traverse mechanism fitted
at the first nip roller region has larger amplitude,
the yarn often comes out from the grip of the first
roller causing no drawing of the yarn leading to
UDY.
3. Effects
When knitted and dyed, UDY produce pattern
effects.
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4. Remedies
Adjust traverse mechanism and ensure that the
yarn does not come to the edge of the rollers.
Periodically check the pressure on the nip rollers
and ensure it as adequate.
Bulk variation
1. Description :
Differential bulk along the length of the yarn as
bulk variation
2. Causes
Low DR:
The yarn property if it is not homogenous along the
yarn length is mainly responsible for thread line
tension variation at high speed texturising.
Tension variations:
The yarn property is not homogenous along the
yarn length, which is mainly responsible for thread
line tension variation at high-speed texturisng.
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3. Effects
Causes the variation in weight per unit area in the
fabric.
4. Remedies
Optimized DR to be used
Nip variation
1. Description
Non-uniformity in the number of nips along the
yarn length is known as nip variation
2. Causes
Improper jet selection:
The quality of nips depends on the diameter of the
nozzle. The higher the yarn denier, the more is the
requirement of the compressed air for
intermingling and so also the nozzle diameter
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Chocking of nozzle:
Compressed air sometimes contains contaminants
such as grease, oil, along with mud and sand of
unclean rusted air conveying pipe.
3. Effect
Nip variation causes pattern effect in the fabrics by
taking dyes in a different way
4. Remedies
Selection of right type of nozzle
Use jet pipe cleaned by organic solvent
Periodically clean the intermingling jets in
ultrasonic fluid bath.
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17.1 Packaging
There are mainly 3 types of products, those produce in the
dept. they are:
NIM- no intermingling
SIM- sub intermingling
HIM- High intermingling
On the basis the product are divided in three qualities:
First quality
Printing quality
Claimless quality
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Bibliography
Texturising defects, causes, effects, remedies and
prevention through quality management by H.V
Sreenivasamurthy and B. Purushothama
Quality assurance of texturising by author experienced
in JBF INDUSTRY
Quality assurance of POY by author experienced in JBF
INDUSTRY
Melt spinning by K. scharfler
Packaging of POY and TEXTURISING by author
experienced in JBF INDUSTRY
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Webliography
http://www.lorandisilos.in/storage_silos/textile_
silos.html
https://textilelearner.blogspot.com/2013/02/te
xtile-dryer-working-principle-of.html
http://shfutai.com/chips_dryer_for_textile.html
http://encyclopedia.che.engin.umich.edu/Pages/
SeparationsChemical/Dryers/Dryers.html
http://www.jbfindia.com/product.html
http://textilelibrary.weebly.com/false-twist-
texturizing.html
https://www.healinggardenswur.nl/7948-
dowtherm/boiler.html
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