Imagine a soft, close-fitting sports bra that feels almost unrestrained but stretches with the rhythm of exercise. Or a lightweight home blanket that feels fluffy but supportive, making you want to wrap yourself in it when you get home from get off work - all these wonderful experiences come from the "first step" of knitting: the choice of yarn. The right yarn is like high-quality ingredients in cooking, which determines the taste and flavor of the final "dish".
Overview of twisted polyester yarn: Why is it a good partner for knitting?
In the textile industry, polyester has become a mainstream raw material for its wear resistance, easy dyeing, wrinkle resistance and cost control. The twisting process is to apply "gentle twisting" to the continuous polyester filaments, so that the yarn has natural elasticity and fluffy feeling:
- Fluffy elasticity: the twisted polyester yarn forms fine ripples in the fabric, which improves the rebound ability.
- Upgraded feel: compared with the "stiffness" of straight yarn, the twisted yarn is softer and more comfortable to the skin.
- Three-dimensional appearance: the surface of the fabric presents a slightly wavy luster, making the color richer and more vivid.
- Cost and stability are taken into account: no additional blending is required, and a variety of hand feels can be achieved by mechanical twisting.
On this basis, Sinrylion has deepened the twisting technology, flexibly adjusting the twist distance and relaxation to meet the diverse needs from light and close to thick and warm.
Visible feel: the influence of yarn fineness and twist on fabric texture
The "fineness" of the yarn is like the thickness of a pencil of fabric - the thinner the thinner, the thinner, and the thicker the stiffer. Twist is like putting a spring on a pencil: it feels more elastic and more durable.
Key points for selecting fineness:
Thin underwear/base shirts: It is recommended to prefer fine yarn (such as 30-50D), the fabric is light and breathable。
Autumn and winter sweaters: 100D or above can be selected to increase warmth and durability.
Twist adjustment skills:
Low twist (10-15 TPI) → ultra-soft and fluffy, suitable for home blankets and toy fabrics.
Medium twist (15-25 TPI) → balance elasticity and stiffness, the first choice for sportswear.
High twist (25-35 TPI) → good rebound and pilling resistance, but the hand feels stiffer, suitable for clothing that requires strong support.
Tactile performance: How to select yarn from the perspectives of moisture absorption, elasticity, rebound, etc.?
In addition to the "visible" thickness and elasticity, the "touchable" performance of the yarn is also crucial, especially the most commonly mentioned functions of knitted fabrics, such as moisture absorption, breathability, and rebound. The following is a breakdown from three core dimensions to help you choose a more suitable polyester twisted yarn.
Moisture absorption and breathability: not only dry, but also comfortable
Principle analysis: Polyester itself has poor hydrophilicity, but through twisting and special finishing (such as hydrophilic treatment or composite microporous coating), the fabric's absorption and discharge speed of sweat can be significantly improved.
Application scenarios: high-intensity sportswear, yoga suits, quick-drying underwear.
Landing skills:
- Sample fabric test: Use a standard sweat drop tester (or a simple wet cloth bonding method) to judge the drying speed by body feeling.
- Finishing customization: Consult the supplier for "hydrophilic treatment" or "porous coating" solutions, and compare the feel after washing.
Elastic rebound: "Second layer of skin" in sports
Why it is important: Sufficient elasticity and high resilience make the fabric close to the body without compression, full of dynamics while avoiding looseness and deformation.
Evaluation method:
- Stretch-rebound test: Pull the fabric to a certain proportion (such as 50%) and then release it, and observe the rebound speed and remaining deformation.
- Hand feel comparison: Samples of the same fineness and different twists are stretched in the hand and rebounded.
Practical suggestions:
- For high-intensity sports such as running and fitness, give priority to the "medium-high twist" formula.
- For scenes such as yoga and Pilates that require a large stretch range, a small amount of spandex can be added to the formula or twisted yarn with a higher relaxation rate can be selected to obtain more elongation space.
Durable anti-pilling: "Frequent washing and always new" is no longer a dream
Key factors: smoothness of polyester filament, yarn twist and finishing process. Twisted yarn with moderate twist can form a fine protective layer on the surface of the fabric, reducing the tiny fibers produced by friction.
Simple detection:
- Use sandpaper or a test bench to perform a light friction test and observe the pilling of the surface.
- Touch and appearance inspection after multiple washings, at least 5 cycles are recommended.
Intimate tips:
- Try to avoid the hard feeling caused by too high twist - hard and solid yarn is more likely to break in friction.
- Coordinate with the dyeing and finishing department to control the dye bath and setting temperature to reduce damage to the fiber surface.
Practical guide: Three-step evaluation, let the sample yarn "springboard" transition to mass production
If you want to efficiently cross from the sample yarn stage to mass production, you might as well follow the following three core steps. Each step is in line with actual combat, so you can avoid detours.
Step 1: Multi-dimensional experience of sample yarn and initial weaving
Multi-scenario trial weaving
- Weave 1 square meter on single-sided, double-sided, ribbed and other models, focusing on observing the operation status of the loom and the density of the finished fabric.
- Write down the machine parameters, such as needle pitch, speed, and the matching degree with different yarn formulas.
Wearing experience
- Make simple samples or samples, let team members "wear them on the spot", and focus on recording subjective feedback: whether there are pressure points, body temperature, and wrapping feeling.
Step 2: Quick small batch test (100–500 meters)
Comparison of return data
- Compare the sample yarn test report with the actual data of the sample fabric after trial weaving, including weight, thickness and elastic recovery rate.
- Prioritize the elimination of solutions that are more than 10% different from the expected.
Linkage between dyeing and finishing
- Perform small batch dyeing at the same time to observe the dyeing uniformity, color difference and setting effect.
- If possible, try a simple washing test to evaluate the initial pilling and shrinkage.
Step 3: Parameter solidification before mass production
Develop SOPs
- Document the yarn formula, machine settings, and dyeing and finishing parameters that perform best in the trial production.
- Mark the key control points (temperature, tension, speed) on the production order for the workshop operator to execute.
Quality checklist
- Establish a three-level QC checklist of "incoming materials-online-finished products", including sampling frequency and indicators (rebound, rips, dyeing fastness, etc.).
- Review the list regularly to make it a tool for continuous improvement rather than a rigid table.
Toolbox Secrets: From Twist Tester to Hand Feel Test, Easily Master Yarn Quality
Without supporting tools, even the best theories are difficult to implement. The following "common and practical" small devices can help you get nearly professional judgments in the office, laboratory, and workshop.
Portable Twist Tester
- Affordable price and simple operation, just clamp about 10 cm of yarn and read TPI within half a minute.
Hand Feel Score Card
- Make a set of "soft-hard" and "fluffy-flat" touch color cards to allow different people to give quantifiable hand feel scores.
Simple Moisture Absorption Test Box
- Clamp the fabric with two acrylic plates of the same size, put a small cup of water in the middle, and see how fast the water marks spread after the fabric absorbs moisture.
Mobile phone slow motion rebound test
- Stretch the fabric and release it, use the mobile phone to record the rebound process in slow motion, and observe the rebound speed and residual deformation from the video.
Desktop peeling strength meter (DIY version)
- Use a small tensile gauge combined with a fixed fixture to measure the peeling strength between fabric layers and evaluate wear resistance and structural stability.
These tools are easy to use and carry, and are also enough for daily QC judgments like "opening your eyes to see the world".
Common problems in yarn selection: Don't be afraid, teach you to use five minutes of self-inspection to clear mines
"Fabric is too hard" → Check whether the twist is too high.
"Severe pilling" → Try to reduce the twist by 5 TPI, or add a post-finishing anti-pilling agent.
"Large shrinkage" → Confirm the relaxation rate data with the supplier, or add a pre-relaxation process in the finalization stage.
"Uneven color" → Check the uniformity of monofilament dyeing and whether the dye circulation system is unobstructed.
"Slow rebound" → Strengthen the hydrophilic or spandex ratio, or increase the twist length.
Use this "quick self-inspection checklist" to quickly eliminate 80% of the problems when the first round of sample fabrics is released.
Action suggestion: Join hands with Sinrylion to make products more "substantial" and more outstanding
Take the first step: organize product requirements documents, and focus on "the feel I need", "the performance I care about", and "the cost range I can accept".
Communication iteration: Communicate the requirements with Sinrylion engineers one-on-one, and quickly find the ideal formula through sample yarns and test results.
Establish a feedback mechanism: During the small batch trial production and mass production stages, maintain regular communication and make timely adjustments to cope with market and process changes.
Choosing Sinrylion is equivalent to having a "yarn R&D laboratory + process optimization team", so that your knitted products will win at the starting line from the source. Looking forward to working with you to make "comfort within reach" a daily routine for consumers.