Functional Yarn Manufacturing Process in 2025
Functional yarn manufacturing on the basis of traditional spinning process, through material innovation and process upgrading to achieve specific properties (such as antibacterial, waterproof, conductive, etc.), the core process is as follows:
1. Raw material pretreatment and functional fiber preparation
Functional additives mixed: in the fiber raw materials (such as polyester, cotton) mixed with silver ions, phase change materials (PCM) or carbon fibers and other additives to give antimicrobial, thermoregulation or conductive properties.
Fiber modification: Through chemical grafting or coating process, make the fiber surface with waterproof (e.g. microfiber layer) or flame retardant properties.
Functional fibers and conventional fibers are mixed proportionally, and the impurities are removed and the fibers are evenly dispersed through the opening and clearing process (gripper and opener).
2. Core Spinning Processes
Carding: carding fiber bundles into a single-fiber state to ensure uniform distribution of functional materials (such as antibacterial fibers evenly embedded in the core).
Drawing: Combine and draw 6-8 slivers to adjust the fiber density and improve the uniformity and strength of the functional yarn.
Ring spinning: Suitable for high strength and abrasion resistant yarns (e.g. aramid blended yarns), the yarn structure is enhanced by twisting.
Sailor spinning / vortex spinning: for composite functional yarns (e.g. antibacterial + moisture wicking), integrating multiple properties through double strand structure.
3. Functional finishing and shaping
Spraying water repellents (e.g. polyurethane coating) or laminating breathable membranes on the yarn surface to enhance waterproof and moisture permeability.
Conductive yarns enhance conductive stability through silver plating process for smart wearable devices.
Color spinning process: functional fibers are pre-dyed (e.g. antimicrobial fibers are colored in the original solution) to avoid destroying the performance by finishing.
Low-temperature dyeing: Adopt environmentally friendly dyes and low-temperature process to reduce the damage to functional materials.
4. Quality control and testing
Physical test: detect yarn strength (tensile testing machine), abrasion resistance (Martindale tester).
Functional test: Verify antibacterial rate (ISO 20743 standard), waterproof grade (AATCC 127 drip test).
Classify and package according to application (e.g. medical antibacterial yarns need to be aseptically encapsulated), and label functional parameters (UPF value, electrical conductivity, etc.).
Antimicrobial yarn: silver ion blended + low temperature color fixation Medical dressings, sports undergarments
Waterproof and Breathable Yarn: Laminated + Cyclo-spun Surfing Clothes, Outdoor Tents
Conductive Yarns: Carbon Fiber Ring Spinning + Silver Plating Post-treatment Smart Heart Rate Monitor Clothing
Functional yarns are manufactured through the combination of raw material modification, process optimization and finishing technology to achieve a full range of performance upgrades from basic protection to intelligent interaction.
