carpet yarn processing

Carpet Yarn Processing

Air-Entangling - Yarn is formed by air flow tangling the filaments together. Less expensive than twisting, air entangling is used for reasons of both economy and style.

Plying or Twisting - Two or more yarns are twisted together to form a plied yarn. Twist is measured in the number of turns per inch. Twist can be put in either an "S" or a "Z" configuration. As the twist level goes up, typically the performance level also increases. Lower twist levels tend to give better coverage in products with lower face weights.

Cabling - A process of wrapping one yarn around another.

Cationic Polymer - An additive, introduced at extrusion, that changes the makeup of the yarn so that certain dye sites are closed off and will not accept acid-based stains.

Heatsetting - A process that "locks" in twist by heating yarn to a temperature that loosens the bonds between the molecules. new bonds are formed as the yarn cools.

Types of heatsetting:

Autoclave - A batch process using a large oven where skeins are brought to heatset temperature with pressured steam.

Superba - A continuous process using a chamber heated with presured steam that raises the yarn to heatset temperature.

Seussen - A continuous process using a chamber filled with dry heat that raises yarn to heatset temperature.

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