Textile Raw Materials-II

1. Discuss the functions of spin pack with figure.

Spin pack is the heart of the spinning system.  It has a reservoir of polymeric fluid. A filter pack-
that removes the solid particles (i.e., contamination etc) from the melt. Normally a filter is a set of
filters containing 3-5 individual filter meshes, where the first filter is a coarser filter followed by
the finer ones.  Improper filtration will clog the spinneret hole leading to a lower throughput and
a lower denier of that filament, and eventually, result in a break of the spinning filament. Once
the polymer is filtered, it reaches a distributor. Function of the distributor is to ensure proper
supply of the polymer melt to all spinneret holes.

Figure-1: Spin packs assembly.

2. Write a short note on, “Spinneret”.

The most important of all components in the spin-pack is a spinneret plate. It is simply a thick
metal plate with fine holes. The hole has larger diameter towards the inside surface with conical
entry. Spinneret plates for monofilaments have single spinneret hole with diameter of about 0.5-1
mm, while those for multifilament have several holes with diameters in a range of 0.5-0.05 mm.
The main role of a spinneret is to impart cross sectional shape to the extruded filaments. The
cross section may vary from circular to trilobal, to hexalobal or hollow, etc.

3. Enlist the post spinning process of manufactured filament.

1. Drawing: Extension of the filaments to many times their original length is done by drawing. By
this process, randomly oriented molecules are aligned in longitudinal direction.
2. Setting: Temperature treatment (steam or hot air) is used to achieve the desired residual
shrinkage.
3. Spin finish: It is a thin surface coating of artificial fibers that reduces the friction and
electrostatic charges.
4. Crimping: Manufactured smooth fibers must be crimped to ensure better blending, handle and
volume of finished product.
5. Drying: Drawn, lubricated and crimped filament have to be dried with drum dryer.
6. Cutting: To form staple fibers, filament has to cut.
7. Pressing: finally, staples fibers are compressed in box to form bale of staple fibers.

4. Describe the polymer system of polyester fiber.

 Textile Raw Materials-II

The polyester polymer is linear and is usually polyethylene terephthalate (PET). It is a condensed
polymer.

The degree of polymerization ranges from 115 to 140, results in a polymer length of about 120
nm to 150 nm, and thickness of about 0.6 nm. The polymer system of polyester consists of 65-85
percent crystalline regions, and about 35-15 percent amorphous regions. This results in the
hydrophobic nature, poor dyeability. Melting at 256 deg C and has a molecular weight of 8000-
10000.
The significant and predominant forces of attraction in the polymer system of polyester filaments
or staple fibers are Van der Waals forces. Weakly polar carbonyl oxygen atoms cause adjacent
methylene hydrogen atoms to develop polarity to form very weak hydrogen bonds.
5. Describe the manufacturing process of polyester filament with flow diagram.

Polyester fibers or largely PET fibers dominate the world synthetic fiber industry. In 1935, the
DuPont Chemical Company created polyester. These fibers are also known as Terylene, Dacron. 
The name polyester refers to the linkage of several monomers (ester) within the fibers. Esters are
formed when alcohol reacts with a carboxylic acid. Most polyester is made from petroleum from
which the acid and alcohols are derived.
Here is the general description of how polyester is synthesized:

1. Polymerization: Today over 70-75% of polyester is produced by CP (continuous polymerization)

process using PTA (purified Terephthalic Acid) and Mono Ethylene Glycol (MEG). The old
process is called Batch process using dimethyl terephthalate (DMT) and MEG. The polymer is
made by heating teraphthalic acid with excess of ethylene glycol in an atmosphere of nitrogen
initially at atmospheric pressure. A catalyst like hydrochloric acid speeds up the reaction. The
excess of ethylene glycol is distilled off. The resulting polymer is hard and almost white
substance. It is extruded in the form of ribbon from the autoclave, which is cut into chips by the
cutter. This is followed by the drying (at 120 °C) operation to dry the wet chips.

2. Spinning: The polymer chips are put in hopper for melting. Then it is heated, extruded through
the spinneret, and cools upon hitting the air. As a result polyester filament is formed.
3. Drawing: This filament yarn is taken to the drawing, where the undrawn filaments are drawn to
about 4–5 times its original length. The stretching is carried out at elevated temperatures.
4. Winding: Finally drawn filament is wound on the packages.
 Textile Raw Materials-II

6. Write some major applications of polyester fiber.

Apparel: Every form of clothing
Home Furnishings: Carpets, curtains, draperies, sheets and pillow cases, wall coverings, and
upholstery Other Uses: hoses, power belting, ropes and nets, thread, tire cord, auto upholstery,
sails, floppy disk liners, and fiberfill for various products including pillows and furniture

7. Discuss the properties of polyester fiber.

-Due to the extreme crystallinity of the polyester polymer system which prevents the entry of any
acid and water molecules.
-The acid resistance of polyesters helps to protect polyester textile materials from acidic nature of
polluted atmospheres.
-The benzene rings of the polyester polymer give stability to the polymer against sun's ultraviolet
radiation.
- The melting point of polyester is 250°C.
- The extreme crystallinity of the polymer system prevents the polyester fiber from bending
which results in crease resistance.
- This high crystallinity ensures the formation of the very effective Van der Waals forces as well
as the weak hydrogen bonds, resulting in the very good tenacity.
- The hydrophobic polyesters readily develop static electricity, which attracts airborne dust and
grease particles, leading to rapid soiling.
- Density 1.38g/cc
-Moisture regain =0.4%

8. How polyester fiber can be identified?

-It dissolved completely in chloro phenol.
- It burns slowly and shrinks away.
-Odor during burning is slightly sweetish.
 Textile Raw Materials-II

9. Why solution spinning method is used? Mention the types of solution spinning.
When melt spinning cannot be carried out because polymer degrades before melting or thermally
unstable, then solution spinning is done. In solution spinning polymer are dissolved in a solvent
then spinning is performed. However, two types of solution spinning are 1. Dry spinning and 2.
Wet spinning.
10. Describe the basic mechanism of dry spinning process with diagram.
The polymer is dissolved in a volatile solvent and the solution is pumped through a spinneret with
numerous holes (1 to 1000). As the fibers exit the spinneret, Hot air is used to to evaporate the
solvent so that the fibers solidify. The concentration of the polymer is increased as solvent
evaporates. The solvent is recovered and recycled. Non-polar solvents are often preferred because
of their low boiling points and heats of vaporization. The filament is finally collected on take-up
wheel. This process may be used for production of acetate, acrylic, spandex etc.

Fig: A dry spinning unit