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What is POY Yarn
POY is the abbreviation of "Partially Oriented Yarn", and its Chinese name is Pre-oriented yarn. It is an intermediate product in the production process of synthetic fibers (commonly polyester fibers, also known as polyester), and it belongs to a filamentous material that has not been fully stretched. The production process of POY mainly involves melt spinning technology. Polymer materials (such as polyester chips) are heated and melted, then extruded through a spinneret to form filament bundles. During the spinning process, the filament bundles are stretched at a relatively high winding speed (typically 3000-3500 meters per minute), causing partial orientation of the molecular chains, but with a relatively low degree of crystallinity. This partially oriented state endows POY with unique properties, making it an important raw material for subsequent processing.
The production process of POY Yarn
Raw material preparation
Usually, polyester chips are used as raw materials, and these chips need to undergo strict screening to ensure that the quality meets the standards. The purity of raw materials, molecular weight distribution and other factors have a significant impact on the performance of the final POY. For instance, high-purity polyester chips can ensure that POY has better color and stability.
Melt extrusion
The selected polyester chips are fed into the screw extruder. Under high-temperature conditions, the chips gradually melt into a uniform melt. The screw extruder not only needs to complete the melting of the slices, but also needs to mix and measure the melt for extrusion to ensure stable melt quality and uniform extrusion volume. During this process, the precise control of parameters such as temperature and screw speed is of vital importance, directly affecting the fluidity and uniformity of the melt.
Pre-filtering
Due to the possible presence of mechanical impurities and unmelted gel particles in the melt, pre-filtration is required to improve the spinning performance and extend the service life of the spinning components. High-precision filter materials are generally used to effectively remove impurities and ensure the smooth progress of the spinning process. If the filtration is not thorough, impurities may clog the spinneret holes and affect the quality of the filament bundle.
Melt distribution pipeline
The melt is conveyed to each spinning body through distribution pipes. The pipeline design should be as short as possible to ensure uniform transportation time of the melt in each box, reduce heat dissipation, and there should be no dead corners of the melt to prevent performance changes of the melt due to excessive residence time.
Static mixing (optional)
Installing a static mixer in the melt pipeline can reduce the stratified flow caused by the high viscosity within the melt and prevent differences in the physical properties of the melt. If the melt has been thoroughly mixed in the screw extruder and there are no dead corners in the melt distribution pipe, this step can be omitted.
Spinning assembly
The spinning assembly is composed of spinnerets, distribution plates, melt filter materials, etc. Its functions include filtering the melt and further removing mechanical impurities and gel particles. Ensure the melt is thoroughly mixed to eliminate viscosity differences; Evenly distribute the melt into each small hole of the spinneret. During high-speed spinning, the extrusion volume is large and the flow resistance is high. Therefore, there are special requirements for the particle size of the filter material and the length-to-diameter ratio of the filament holes to adapt to high shear stress.
Cooling and forming
The fine stream of melt ejected from the spinneret holes is cooled through the side blowing window of the spinning. During the solidification of the melt and the cooling of the filament, a large amount of heat is dissipated into the surrounding air. High-speed spinning has a large output and releases a lot of heat, so it requires higher wind speed, humidity and lower air temperature. Meanwhile, under the action of the winding traction force, the melt fine flow is subjected to 100 to 250 times the spinning stretch, which is much greater than that of conventional spinning.
Cluster oiling
After the fibers are cooled and formed, they need to be oiled in bundles before entering the spinning channel. Oiling can reduce the winding tension and improve the processability of the filament bundle. The oiling methods include oiling from an oil pan and oiling through an oil nozzle. Due to the high running speed of the filament in high-speed spinning, oiling through an oil nozzle ensures accurate measurement and can keep the oil fresh and clean. Currently, it is more widely used.
Winding of POY
High-speed winding is a key link in high-speed spinning. Under high-speed conditions, it is necessary to ensure that the equipment operates smoothly, the filament barrel is well formed, and the operation is convenient. The winding tension, winding speed, and the speeds of the guide disk, roller, and transverse guide device, etc. need to be kept stable to ensure the uniformity of the structure and linear density of the initial fibers.
The features of POY Yarn
Physical properties
Strength and elongation: The POY strength is relatively low, but the elongation is high, generally ranging from 150% to 100% at break. This is because its molecular chains are only partially oriented and not fully stretched, thus retaining a relatively large degree of extensibility. For instance, in the subsequent stretching process, POY can be further stretched to the appropriate strength and elongation to meet the requirements of different products.
Surface and structure: The surface is relatively smooth, while the structure is rather loose. This characteristic makes POY feel soft to the touch, but it is not suitable for direct weaving. It needs to undergo subsequent processing, such as stretching deformation or full stretching, to improve its structure and enhance its strength before it can be used in textile production.
Appearance characteristics
Glossiness: POY can present different gloss levels, commonly including semi-matte, fully matte and glossy (bright) types. Bright POY, due to the cross-sectional structure of the fibers in the filament, has a distinct luster and is often used in products with high requirements for luster. Semi-matte and fully matte POY are achieved by adding matting agents and are suitable for products with lower gloss requirements and a pursuit of a soft appearance.
Color: The initial POY is mainly white, but it can also be made into POY of various colors through masterbatch addition technology, that is, color-spun POY. During the production process of color-spun POY, the color masterbatch is mixed with the raw materials to ensure that the color is evenly distributed throughout the filaments. The dyeing effect is long-lasting and uniform, and it has more advantages compared to subsequent dyeing processes.
Processing characteristics
Spinnability: POY has excellent spinnability and is suitable for various textile processing techniques, such as knitting and weaving. During the knitting process, POY can smoothly pass through the needle hooks of the knitting machine to form various knitting structures. In weaving, POY can be used as a warp or weft yarn to interweave with other yarns to form fabrics of different structures.
Post-processing adaptability: As an intermediate product, POY is mainly used for subsequent processing into other types of yarns, such as being made into stretched filament (DTY) through stretching deformation process, or into fully stretched filament (FDY) through full stretching process. During these post-processing procedures, POY can adjust its own performance according to different technological requirements to meet the diverse product demands.
The application fields of POY Yarn
The field of clothing
Sportswear: The fabric made from POY after processing has good elasticity and breathability, and is widely used in sportswear, such as yoga wear and running equipment. Its elasticity can stretch along with body movement, providing a comfortable wearing experience. Breathability helps to expel sweat produced during exercise and keeps the body dry.
Casual wear: In casual wear, POY fabric is often used to make T-shirts, shirts, trousers, etc. Through different textile techniques and post-treatment processes, POY fabrics can present various textures and styles, meeting consumers' pursuit of fashion and comfort.
Underwear: POY fabric is soft and comfortable, fitting the skin well and is suitable for making underwear. Its excellent moisture absorption and breathability can provide a comfortable close-fitting feeling for the wearer. Moreover, after special treatment, it can have functions such as antibacterial and deodorizing.
Home textile field
Bedding: POY is used to make bed sheets, quilt covers, pillowcases and other bedding items. Its softness and durability provide a comfortable guarantee for sleep. Meanwhile, through dyeing and printing techniques, it can present a rich variety of patterns and colors, enhancing the overall aesthetic appeal of the bedroom.
Curtains: Curtains made of POY fabric have excellent light-blocking properties and a good drape. The light-blocking property can effectively regulate indoor light and create a comfortable indoor environment. The drape makes the curtains look more elegant and grand, enhancing the home decoration effect.
Carpet: In carpet manufacturing, POY can be used as a pile yarn, endowing carpets with a soft touch and good wear resistance. Through different weaving techniques and dyeing treatments, carpets of various styles and colors can be produced to meet the decoration needs of different places.
Industrial field
In the automotive industry, POY can be used to manufacture automotive interiors, such as seat fabrics and roof linings. Its high strength and wear resistance can withstand the friction and pressure during the daily use of automobiles. Meanwhile, through special treatment, it can meet the requirements of automotive interiors for fire resistance, anti-fouling and other performance aspects. In terms of automotive tire cord, POY, after processing, can provide the strength and stability required by tires, ensuring their safety performance during high-speed driving and complex road conditions.
In the medical field: POY that has undergone special treatment can be used to make medical supplies, such as surgical gowns, bandages, sutures, etc. Surgical gowns require the fabric to have good barrier properties to prevent the penetration of bacteria and blood. POY fabric can meet this requirement after special treatment. Bandages and sutures require materials with certain strength and flexibility. The characteristics of POY make it a suitable choice.
Other industrial applications: POY is also widely used in industrial filter materials, conveyor belts, ropes, etc. Industrial filter materials need to have good filtration performance and durability. Filter materials made of POY can effectively filter impurities and can be used for a long time in harsh environments. Conveyor belts and ropes require materials with high strength and wear resistance. POY can meet these performance requirements and ensure the smooth progress of industrial production.
Market Situation of POY Yarn
Main production areas
Asia: Asia is the world's largest producer of POY. Countries such as China, India, South Korea and Japan play an important role in POY production. As the world's largest producer of polyester fibers, China has a huge POY production capacity. Its production technology is constantly improving, and the quality and variety of products are increasingly rich. The POY industry in India has also developed rapidly. With its labor cost advantage and the continuously expanding domestic market demand, its share in the global market has gradually increased. South Korea and Japan mainly focus on high-end POY products, emphasizing technological innovation and product differentiation, and have strong competitiveness in the field of high-performance fibers.
Other regions: Besides Asia, there is also a certain scale of POY production in Europe and North America. European POY producers attach great importance to environmental protection and sustainable development, and have made significant investments in production processes and product research and development. The POY products they produce have a high level of quality and environmental protection performance. POY production in North America mainly serves the local market, and its products have a wide range of applications, covering multiple fields such as clothing, home textiles, and industry.
Market development trend
Demand growth: With the global population growth, economic development and the continuous increase in consumers' demand for textiles, the market demand for POY has shown a steady growth trend. Especially in emerging market countries such as China, India, and Southeast Asia, with the increase in residents' income levels and the acceleration of urbanization, the demand for textiles such as clothing and home textiles has continued to rise, driving the development of the POY market.
Product diversification: Consumers' demands for textiles are becoming increasingly diverse, which puts forward higher requirements for the performance and quality of POY products. To meet market demands, enterprises are constantly developing new products, such as functional POY fibers (with functions like antibacterial, UV protection, moisture absorption and sweat wicking), fine denier and ultra-fine denier POY fibers, and differentiated POY fibers. These products have higher added value and broad market prospects.
Environmental protection and sustainable development: Against the backdrop of growing environmental awareness, environmental protection and sustainable development have become important trends in the POY industry. The enterprise is committed to developing environmentally friendly production processes to reduce energy consumption and pollutant emissions during the production process. At the same time, efforts should be made to increase the research and development and production of recyclable polyester fibers to achieve the recycling of resources. For instance, some enterprises use bio-based raw materials to produce polyester fibers, reducing their reliance on fossil resources such as petroleum and lowering carbon emissions.
Conclusion
POY Yarn, as an important raw material in the textile industry, demonstrates unique characteristics in terms of production process, features, application fields and market conditions. Its production process is complex and meticulous, and each link has a crucial impact on product quality. The characteristics of POY determine that it has extensive applications in numerous fields such as clothing, home textiles and industry, meeting the diverse demands of different industries for material performance. From a market perspective, the POY market presents a diversified competitive landscape globally, with demand continuously growing and products constantly evolving towards diversification, high performance and environmental friendliness. With the continuous advancement of technology and the changes in market demand, POY Yarn will continue to play an important role in the textile industry and promote the innovation and development of the entire industry.
