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Today, the yarn of choice
for this weaving and coating industry is a staple fiber, most notably
polyester.
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When elevated PIW strengths (Pounds/ Inch Woven) were required,
hybrid yarns were introduced to the process. These yarns were usually
constructed by wrapping a continuous filament fiber with a roving of
staple polyester. The continuous filament is providing the strength
requirement, and the staple roving is providing the adhesion and bulk
properties. These products have remained as the primary choices to this
industry until the introduction of Magic® yarns.
Lost efficiency in the
solid woven industry may occur for the following reasons:
- Yarn Breaks both
in the warp & weft.
- Strip-backs of the
sheathing on hybrid yarns.
- Down time to clean
up the lint build-up created by staple fiber use.
- Increased creeling
time due to requirements for left and right twist products.
Spun yarn today can be
manufactured in a variety of techniques (open end, ring spun, jet spun).
While the equipment has changed over the years, the basic concept that a
group of short staples can be orientated to create a yarn bundle has
remained unchanged for decades. The consistency of the yarn count and the
ability to control the fiber alignment all impact the yarn tenacity.
Depending on the manufacturing process chosen, yarn tenacity can vary from
2.5 to 4.6 grams per denier.
Magic® yarns are processed from continuous filament fibers. The
surface properties of the yarn are modified so that they resemble the
surface properties of staple fibers. Because the process does not depend
on the alignment of short staples the resulting tenacity values are
considerably higher. Tenacity values can range from 4.6 to 6.9 grams per
denier. These values can be modified to your specific requirements.
Because Magic® yarns are produced using continuous
filament fibers, you will also produce a product that can have modified
elongation or shrinkage values.
These yarns are currently
referred to as dreft spun or core wrapped yarns. These products are
manufactured by wrapping a roving around a continuous filament core. The
purpose of the wrapping is to improve the jacketing adhesion. This
wrapping is not fixed to the core and is designed to slide up and down the
core face. The problem with this design is that at some point material
contact will back the roving up enough so that it will no longer pass
through the heddles.
Magic® yarns have the same surface characteristics as dreft or core
wrapped yarns. The primary difference is that the individual filaments
have had their surface characteristics modified so that a sheathing wrap
is not necessary. Because the wrap is not necessary, the possibility of
sheathing strip-backs has been eliminated.
Most weaving operations
that produce a product that is woven from staple fibers will stop their
looms once a shift to remove fly waste. This waste is created because the
yarns are constructed of individual filaments that range in length from
1.25 inches to 2.5 inches. These short fibers break away from the yarn
bundle because of abrasion.
Magic® yarns are constructed using filaments that extend over the
entire length of the yarn carrier. This manufacturing technique eliminates
the possibility of fly waste generation.
The manufacturing process
that is employed to produce staple yarns requires the product to be
twisted. All yarns that are twisted will have torque reserve built into
the product. To negate this torque reserve, most warps use a combination
of opposite twist directions. These combinations result in a balanced
finished product. The need for offsetting twist directions forces the
weavers to carry two raw materials. Each of these two products has the
same nominal count but one will be produced using a left twist and the
other will have a right twist. A torque free product will track better in
the final product.
Magic® yarns are manufactured using a process that produces torque
neutral yarns. Because these products are produced torque neutral, the
requirement to carry two raw materials are eliminated. You will reduce
your intermediate SKU’s by one half. Potential creeling errors will be
eliminated.
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