Since 1994, the company has started producing different types of acrylics in different sizes.
Acrylic fibers are synthetic fibers made from a polymer (polyacrylonitrile) with an average molecular weight of ~100,000, about 1900 monomer units. For a fiber to be called "acrylic" in the US, the polymer must contain at least 85% acrylonitrile monomer.
Acrylic is lightweight, soft, and warm, with a wool-like feel. It can also be made to mimic other fibers, such as cotton when spun on short staple equipment. Some acrylic is extruded in colored or pigmented form; other is extruded in "ecru", otherwise known as "natural," "raw white," or "undyed".
Pigmented fiber has the highest lightfastness. Its fibers are very resilient compared to both other synthetics and natural fibers. Some acrylic is used in clothing as a less expensive alternative to cashmere, due to the similar feeling of the materials. Some acrylic fabrics may fuzz or pill easily, though there are low-pilling variants. Acrylic takes color well, is washable, and is generally hypoallergenic. End-uses include socks, hats, gloves, scarves, sweaters, home furnishing fabrics, and awnings. Acrylic can also be used to make fake fur and to make many different knitted clothes.
There are a few points to note about acrylic yarn properties
1- It has a longer and more durable life.
2- More resistant to light stability, washing and friction.
3- It has high heat resistance.
4- The smoothness of yarns and bellows further reduces the amount of yarn and causes better coverage of the carpet.
5- It has thermal stabilization and stabilization of the warp.
6- It becomes very softer (to touch).
7- Reduces Rupture in knitting.
Heat Setted Fiber
Today, with the advent of knitting machines, Heat setted fibers has a special place among carpet manufacturers. Basically, the process of heatset and steaming is to enhance the quality of the yarn and finally the carpet. It has been proven that the use of yarn in a single weaving unit has between 7% and 10% increase in production efficiency, which will be very effective in a financial period.
As mentioned, this increase in efficiency is due to the elimination of many thread imperfections in the heat setting process, and this is one of the reasons why heat setted fibers are welcomed by carpet manufacturers. Heat setting is almost a requirement for high-tech carpet knitting machines. Nowadays that knitting speed is increased, and especially in high density carpet yarns, they have to withstand a lot of ruptures, so that much ruptures do not disturb the production.
The most important advantages of Acrylic Heatset yarns include:
1- The smoothness of yarn and bulk, resulting in a reduction in the amount of yarn and better coverage of the carpet.
2- Reduces yarn fluff.
3- Thermal stabilization and bending fixation.
4- It becomes very softer (to touch).
5- Reduces Rupture in knitting.
6- Diagnosis of clips in woven carpets (carpet nailing).
Generally, heatset machines use water vapor as a thermal interfacing of the heatset without sacrificing yarns, in two types of acrylic yarns or all kinds of synthetic yarns.
Basically, the process of steaming acrylic yarns is an essential process for high quality carpet weaving. Steaming produces high tear resistance, high dimensional strength, reduced surface peeling and fluff that is a result of yarn rolling, high color absorption, bulking of yarn, and creating a perfectly uniform surface with soft undercoat.
In order to continue the process, our factory started to produce acrylic fiber with marks of 10.5, 12, 18 and Tau based acrylic yarns with marks of 18, 19, 22, 26, 32 and 36 and 52 and etc...
The fibers that are commonly used in spinning systems are long-length staples. To produce this type of fiber in a fiber manufacturing plant, they are first produced in regular batches of filamentary fibers of a length of thousands of meters called "Tau", and then cut into certain lengths depending on the type of consumption, and ultimately The fibers obtained by the batting and spinning operations turn into wicker.
In this method, it is often not possible to produce more than a mark 27, while more than 1200 combo carpets need yarns that are more delicate and softer. To achieve this, we use the Tau-to-wicker method that can produce delicate yarns such as yarns with 30, 33, 36, 42 marks and above.
In Tau-to-wicker method, fibers are made up of thick strips of thousands of filamente lambs (Tau), fed to a cutting machine known as Stretch Bricker. First, the cloth is heated by hot air or steam. And then pulled up to the tear-line. In the stretching area of the machine, there are blade slider rollers that work from 5 to 15 mm each. When the fibers pass through these pair of rollers, the blades hit the fibers that are pulling and then tear them apart.
The fiber mass, which is in the form of a clay matrix, is immediately taken up by a pair of rollers and directed to the coiler. After cutting, the tabs are fed to the initial gilly box. This machine is known as the rebreaker, and its task is to complete a rupture of the fibers that do not cut in the tearing process to a certain length of time and have very long lengths. This step is done so that the fibers obtained from the Tau cutter have a uniform length of better.
Eventually, the product produced from the rebreaker is fed to a special machine, and continues from this stage to the end of the spinning line.