Everything you need to about Polyester Fabric and its Manufacturing

Everything you need to about Polyester Fabric and its Manufacturing

Polyester is a fabric that is made up using petroleum products. Polyester is one of the most famous fabrics worldwide and is used in millions of different industrial and consumer applications. In technical terms, it is a polymer mainly composed of compounds of ester functional cluster. Most of the synthetic fibers are made from ethylene, which is derived from petroleum. Some of the forms are biodegradable, and most are not, and using this increases air pollution worldwide. 

One of the primary use of polyester fabric is done by the apparel industry combined with cotton or other natural fiber products. This fabric is the most cost-effective in production and for consumers, but it could also be uncomfortable to wear, especially in countries with warm weather. This fabric also reacts badly against the sweat and makes it heavy to wear, thus decreasing the overall comfortability of the dress. When this fabric is blended with cotton, it improves the shrinkage and also makes it wear-friendly in warm weather conditions as well. Because of its high stability, it is widely used in outdoor applications. 


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How is the Polyester fabric made?


Creating of Monomer

The process starts with the reaction between dimethyl terephthalate and ethylene glycol in high heat.


Creating a Polymer

The monomer is then reacted with dimethyl terephthalate to create a polymer.



The polymer is taken out from the chamber in lengthy strips and allowed to cool down and dry. 

After drying, they are broken into small pieces. 



These small chips or pieces are again melted to create a honey-type of substance and extruded to form fibers. 



These fibers are further reacted with different chemicals as required by the application and end result. 


Ethylene Polyester


Ethylene polyester (PET) is the most common form of solid polyester fiber which is widely produced. The key factor of PET is petroleum which is derived from ethylene, and during the procedure of making polyester fiber, ethylene assists as the polymer that is related to other chemicals to make a solid and durable fibrous compound.

To make PET fiber, there are four methods discussed below, and the production of the polyester method is all depend on which process is used:




Polyester filaments are continual fibers, and these fibers make soft and smooth fabrics.




Polyester staples are similar to the staples which are used to make cotton yarn, and compared to cotton staples, polyester staples are frequently turned into yarn-like material.




Polyester tow is similar to the polyester filament; however, in polyester tow, the filaments are arranged loosely together.




Fiberfill comprises continual polyester filaments, but these are specifically produced to get the most achievable volume to produce products in bulk like outerwear, pillows, and filling for stuffed animals. 

The procedure of producing polyester fiber starts with reacting ethylene glycol with dimethyl terephthalate at the highest temperature. The outcome of the reaction is in a monomer, which afterward is reacted again with dimethyl terephthalate to produce a polymer.


This melted polyester polymer is released in long strips from the reaction chamber, and these strips are set to cool and dry, then separated and broken into smaller pieces. The proceeded chips are again liquified to produce a substance like honey, which is squeezed out through a spinneret to make fibers.

Depending upon Whether you want filaments, tow, staple, or fiberfill fibers, polyester filaments that are resulted may be cut or reacted with several chemicals to attain the accurate result. In the majority of applications, polyester fibers are turned into yarn before they are dyed or exposed to other processes of post-production.


PCDT Polyester


The method of designing PCDT polyester is the same as the process of producing PET polyester, but this variant of polyester has a distinct chemical structure. Although PCDT also comprises ethylene glycol reacted with dimethyl terephthalate, various production procedures are used to create these two frequent polyester variations. 


Plant based polyester


Some kinds of plant-based polyester are also created from ethylene glycol reacted with dimethyl terephthalate. However, petroleum is the basis of the ethylene used in PET and PCDT polyester, makers of plant-based polyester practice ethylene sources like can sugar in its place.


Purpose of Polyester Fabric


It is necessary to know that the PET used to produce solid polyester fiber is similar kind of the petroleum-based plastic used to create several of the artificial customer products which we use in our routine lives. For example, this plastic is used to produce water bottles, food containers, and other types of various consumer and industrial products.

As a polyester fabric form, PET is used in hundreds of several user applications. Usually, PET is used as an alternative to cotton, and in a few applications, it might assist as an appropriate substitute for other natural fibers such as silk and wool.

Fundamentally, any product made from cotton can also be created with polyester. The clothing applications of solid polyester fabric are never ending when it comes to everyday shirts and pants to trendy evening wear. The producers are using polyester fabric to make jackets, suits, shirts, socks, and any kind of apparel that you can wear for business, formal or casual occasions. 


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Moreover, the designers also use polyester to craft many types of homeware. Precisely, a specific type of polyester which is called microfiber has obtained importance in the kitchen and bath homeware category. Customers usually value the absorbency and softness of microfiber in applications such as face towels, bath towels, and kitchen towels. The producers might also use polyester to create homewares like rugs, blankets, curtains, and upholstery.

We Dragon Lake Import and Export are one of the leading and reliable designers of environment-friendly solid polyester fiber. Our products are in demand worldwide, and we look forward to serving them for many years to come. 


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