Did you know that a midsize production plant of textile yarn has an area size of 24 soccer fields?
When it comes to textiles and fabrics, yarn is an indispensable element. Among the various types of yarn available, draw texturized yarn (DTY) holds a significant place. DTY offers unique qualities that make it ideal for a wide range of applications. In this article, we will delve into the basics of yarn, explore what DTY means, understand the DTY manufacturing process, and discuss the differences between DTY, FDY, and POY.
Getting Started with Yarn: A Primer on the Fundamentals
Yarn is a continuous strand of fibers or filaments that are twisted or spun together to form a cohesive thread-like structure. Yarn serves as the foundation for creating textiles, as it can be woven, knitted, or used in various other techniques to produce fabrics with different characteristics. Yarn can be made from natural fibers like cotton, wool, or silk, as well as synthetic fibers like polyester or nylon.
What is Draw Texturized Yarn (DTY)?
The term "DTY" stands for Draw Texturized Yarn. DTY, also known as crimped yarn, is a type of texturized yarn that possesses excellent elasticity and resilience. It is created through a process called texturing, which imparts stretchability and bulkiness to the yarn. DTY is widely used in the textile industry for manufacturing fabrics that require stretch and recovery properties and the target is to get as close as possible to natural cotton with this manmade product.
24 fields
The DTY Manufacturing Process
The manufacturing process of Draw Texturized Yarn (DTY) involves several steps that transform the initial polymer into a textured yarn with stretch and bulkiness. To create DTY, we first of all need Partially Oriented Yarn (POY), which is essentially another type of yarn and manufacturing process, but regardless it is important to know that POY is the input when initiating the DTY manufacturing process. The process from the POY-bobbin into a final DTY-bobbin is a continuous process with yarn speeds of approximately 1000 m/min. The yarn path of this process can be seen in the image to the right. In an industrial texturizing machine this process is done on up to 384 single yarn paths in parallel.
The core of the texturizing process, marked in the red circle, consists of three main process steps that are carried out simultaneously. Between the feed units G1 and G2, a drawing process is employed to increase molecular orientation, impart strength, and enhance the stability of the yarn. This step aligns the polymer chains, resulting in improved tensile properties.
Within this draw zone, the yarn is twisted between the Friction Unit and the Twist stop. The twisting action causes additional irregular deformation of the individual filaments within the yarn. The outer filaments experience more deformation than the filaments inside the filament bundle. To rectify this deformation, which creates the subsequent crimp in the DTY (Drawn Texturized Yarn), the yarn undergoes a heat treatment above the glass transition temperature.
Below the Friction Unit, the yarn is untwisted again and possesses the characteristic crimp, elasticity, and softness of the DTY. To ensure quality, particularly in terms of consistency over time and across positions, the process is monitored by the Unitens system, which is based on yarn tension. The subsequent steps generate the detailed yarn properties necessary for downstream processing. These steps include intermingling using a tangle jet to create yarn closure, a second heating zone to adjust shrinkage, and an oil application to reduce friction during downstream processing. The final step involves producing the DTY bobbin itself. With precisely defined yarn positioning, the winding system produces bobbins with geometries and properties tailored to the requirements of the subsequent production steps downstream.
This is in a nutshell how manufacturers can produce Draw Texturized Yarn (DTY) with the desired stretchability, bulkiness, and other specific properties needed for various textile applications. The precise control of each stage in the manufacturing process is essential to ensure consistent and high-quality DTY production.
An illustration of a standard Draw Texturized Yarn process.
Unlocking the Textile Puzzle: Decoding the Differences between DTY, FDY, and POY
When it comes to the world of yarn, there are different types that possess unique characteristics and are suitable for various applications. DTY is one, but there are also types such as Fully Draw Yarn (FDY) and Partially Oriented Yarn (POY) for example. While they may sound similar, each of these yarns has its own distinct features and manufacturing processes.
DTY, FDY, and POY differ primarily in their levels of orientation and texturing. DTY undergoes a process that includes drawing and texturing to create a yarn with enhanced elasticity, bulkiness, and stretch. It is often used in sportswear, activewear, and intimate apparel, where flexibility and comfort are essential. Further applications of DTY may include home textile, automotive, medical application and apparel in general.
On the other hand, FDY is fully drawn during a single step spinning process, resulting in a highly oriented yarn with excellent strength and smoothness. It is a flat yarn that does not undergo any texturing, making it suitable for applications that require a sleek and lustrous appearance. FDY is commonly used in the production of fabrics, such as satin, where a smooth and shiny finish is desired.
POY undergoes a spinning process, and as the name suggests, it is only partially oriented during this spinning process and does not undergo any drawing or texturing. It is in a semi-crystalline state and has lower strength and elongation compared to DTY and FDY. It is mainly used as a feedstock for further processing, where it can be drawn and texturized to create DTY as described above.
| Garn Type | Name | Details | Speed | Residual Strain |
|---|---|---|---|---|
| POY | Pre Oriented Yarn |
Preoriented/Draw Yarn |
2800-4200 m/min | 100-120% |
| FDY | Fully Draw Yarn | Fully Oriented/Draw Yarn | 4500-5500 m/min | 20-40% |
| DTY | Draw Texturized Yarn | Stretch Texturized Yarn | 600-1100 m/min | 5-30% |
PET POY Commodity with a size of 12,5-25 micromillimeter and approx. 1,7-4 dtex.
PET DTY Super-Micro with a size of 5 micromillimeter and approx. 0,33 dtex.
From Fashion to Furnishings: Unraveling the Applications and Benefits of DTY
Draw Texturizedd Yarn (DTY) offers several benefits that make it a popular choice in the textile industry. Here are some of the key advantages of DTY:
- Stretch and Elasticity: DTY exhibits excellent stretch and recovery properties, allowing fabrics made from DTY to comfortably conform to body movements. This elasticity is particularly beneficial in applications where flexibility and ease of movement are essential, such as sportswear, activewear, and intimate apparel.
- Bulkiness and Softness: The texturing process imparts bulkiness and softness to DTY, making it suitable for applications that require comfort and a pleasant tactile feel. Fabrics made from DTY provide a cushioned effect, enhancing the garment's comfort and draping characteristics.
- Dimensional Stability: DTY maintains its shape and dimensions even after repeated stretching and washing, thanks to its enhanced molecular orientation. This dimensional stability ensures that the finished products retain their desired fit and shape over time.
- Quick-Drying and Moisture Management: DTY has excellent moisture-wicking properties, allowing it to efficiently transport sweat away from the body. Fabrics made from DTY dry quickly, enhancing comfort during physical activities or in humid environments.
- Durability and Strength: DTY exhibits good tensile strength and durability, making it suitable for applications that require long-lasting and resilient textiles. It can withstand repeated use and washing without losing its performance characteristics.
- Versatility: DTY can be blended with other yarns, such as cotton or wool, to create blended fabrics that combine the benefits of different fibers. This versatility allows for customization of fabric properties, such as moisture management, softness, and breathability.
As mentioned above, DTY is also very versatile and used in many different applications. Some examples of DTY application are:
- Apparel: DTY is widely used in various types of apparel, including sportswear, activewear, athleisure wear, leggings, swimwear, lingerie, and socks. Its stretchability, softness, and moisture-wicking properties make it ideal for creating comfortable and functional garments.
- Home Furnishings: DTY is utilized in the production of home furnishing textiles such as upholstery fabrics, curtains, draperies, beddings, and decorative fabrics. The bulkiness and softness of DTY contribute to the luxurious feel and aesthetic appeal of these textile products.
- Technical Textiles: DTY finds applications in technical textiles, including automotive textiles such as seats and the roof.
- Accessories: DTY is also used in the manufacturing of accessories like elastic bands, ribbons, cords, and trimmings. The elasticity and softness of DTY make it ideal for these applications.
Concluding the Journey of Innovation
Draw texturized yarn (DTY) plays a vital role in the textile industry, offering exceptional stretchability and bulkiness. Through a carefully crafted manufacturing process involving drawing, texturing, and heat treatment, DTY is transformed into a versatile yarn suitable for a wide range of applications. By understanding the differences between DTY, FDY, and POY, manufacturers can select the appropriate yarn to achieve the desired characteristics in their fabrics. With its unique properties, DTY continues to contribute to the innovation and development of textiles around the world.
Discover more about the technology behind this manufacturing process by learning more about texturing machines from Oerlikon Barmag.
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