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Polyester blended yarns are widely used in apparel, home textiles, and industrial fabrics, offering excellent performance at a reasonable cost. However, various yarn defects are prone to occur during the spinning process due to the influence of raw material characteristics and process parameters. This not only affects yarn quality but can also lead to fabric defects and subsequent processing issues.
End-breakage
End-breakage is one of the most common yarn defects in polyester blended yarn spinning. When an end-breakage occurs, the yarn sliver breaks during the drafting or twisting process, resulting in a break in yarn continuity. End-breakage is primarily caused by insufficient raw material strength, uneven fiber length, excessive tension in the spinning equipment, or improper twist control. End-breakage not only affects production efficiency but also creates defects in the fabric, necessitating timely adjustment of spinning parameters or improved raw material selection.
Hairiness and fly
Hairiness and fly are loose fibers formed during the spinning process due to incomplete fiber bonding. In polyester blended yarns, differences in fiber affinity between polyester and natural fibers such as cotton and wool can increase hairiness. Excessive hairiness can affect yarn luster, reduce fabric appearance, and lead to uneven dye absorption during subsequent dyeing and finishing, resulting in color variations.
Knots and Uneven Thickness
Knots are localized bumps on a yarn caused by fiber accumulation. They are often caused by uneven yarn drafting or the presence of short fibers in the raw material. Uneven thickness is a phenomenon in which yarn count fluctuates due to uneven fiber arrangement. In polyester blended yarns, where polyester filaments are mixed with short fibers, uneven thickness is more prominent. Uneven thickness leads to uneven fabric density, affecting the feel and appearance, and reducing dyeing uniformity.
Knots and Agglomeration
Knots are clumps of fibers in the yarn. They often occur when opening is inadequate or the cleaning process is improperly controlled. Agglomerated fibers are difficult to draw evenly during spinning, resulting in locally thicker yarns, which affects yarn strength and fabric appearance. The electrostatic properties of polyester fibers can also exacerbate fiber agglomeration, making knots more pronounced. Preventing knots requires optimizing the opening process and improving combing uniformity.
Spills and Loose Fibers
Spills occur when loose fibers in a yarn are stretched and released from the yarn body due to tension. Polyester blended yarns are prone to fluff during ring or open-end spinning due to fiber length variations and tension fluctuations. Loose fibers not only affect the gloss and feel of the fabric but can also cause ends to break or fuzz during subsequent processing, reducing the overall quality of the yarn.
Color Variation and Uneven Dyeing
During the spinning process of polyester blended yarns, color variation can occur if the raw materials are unevenly dyed or the blending ratio is not accurately controlled. During the spinning stage, color variation manifests as varying shades of color in certain areas of the yarn, significantly impacting the uniformity of the dyed fabric. Controlling color variation requires rigorous raw material selection, maintaining a stable blending ratio, and optimizing the spinning and pretreatment processes.
Pilling and Pilling
During the spinning and subsequent weaving processes of polyester blended yarns, fiber friction or shearing can cause fuzzing and pilling. This is particularly true for staple fibers in cotton and polyester blends, where tiny fiber protrusions are prone to appear on the yarn surface. Pilling affects the appearance and touch of fabrics and is an important indicator of yarn quality control.
