Core Spun Yarn vs Blended Yarn

Core spun yarn and blended yarn are two common types of textile yarn used in the textile industry. While both have their own advantages and applications, there are some key differences between them.

Core Spun Yarn vs Blended Yarn

Table of Contents

    Introduction to Core Spun Yarn and Blended Yarn

    Core spun yarn and blended yarn are two common types of textile yarn used in the textile industry. While both have their own advantages and applications, there are some key differences between them. Core spun yarn has an inner core made of one or more strands, wrapped by an outer sheath of another fiber. This provides strength and stability from the core, along with desired texture, color and feel from the outer fiber. Blended yarn is made by mixing two or more different types of fibers together into a single yarn, without a distinct core and sheath structure. By blending fibers, blended yarns gain properties of the components like softness, absorbency, elasticity etc. This article will discuss acrylic core spun yarn and viscose core spun yarn, and acrylic blended yarn in detail.

    50% Viscose 28% PBT 22% Nylon Core Spun Yarn

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    Core Spun Yarn

    Features

    • Excellent performance of filament core yarn
    • Excellent performance of outer short fiber

    Applications

    • Sweaters
    • Socks
    • Sheet
    • Sofa cover
    • Scarf
    • Gloves
    • Hats

    72% Viscose 28% PBT Blended Yarn

    Features

    • Soft, comfortable, durable, elastic.
    • Suitable for t-shirts, underwear, linings.
    • Viscose for breathability, PBT for shape retention.
    • Balances natural and synthetic fibers for comfort and longevity.
    • Less tangling compared to all-viscose yarns.

    Applications

    • Intimates
    • Base layers
    • T-shirts
    • Underwear
    • Linings

    Manufacturing Process of Core Spun Yarn

    The manufacturing process of core spun yarn involves first producing the core yarns on separate spinning machines. These core yarns are then fed through a special core spinning machine simultaneously with the wrapping fibers. The core yarns pass through a conical hole and the sheath fibers are wrapped around it as it emerges. The sheath fibers adhere to the core yarn due to twisting action. Finally, the core spun yarn is wound onto packages ready for use in weaving and knitting applications. Some key steps are sizing the core yarn, ensuring proper wrapping tension, and controlling the twist. The ratio of core to sheath fibers can be adjusted as per requirements. This unique process results in durable yarns with desired aesthetics and performance.

    Video: Core Spun Yarn Spinning Process
    Video: Blended Yarn Factory

    Key Properties of Core Spun Yarn

    Some key properties that make core spun yarns advantageous are:

    • High strength and durability from the core fibers
    • Versatility since different core and wrap combinations are possible
    • Good aesthetics and hand feel based on sheath fiber properties
    • Enhanced drying rate due to less fiber saturation
    • High abrasion resistance and longevity
    • Dimensional stability and reduced likelihood of pilling
    • Suitability for fabrics like denim, home textiles, athletic wear etc.
    • Ease in spinning multi-colored effects by using different sheath fibers

    The core provides tenacity while the sheath provides comfort, flexibility, moisture wicking and other desirable properties to the yarn. Polyester core spun yarn and nylon core spun yarn are popular besides viscose and acrylic varieties.

    Viscose Core Spun Yarn Varieties and Applications

    Viscose core spun yarn is commonly available in varieties like:

    • 28s/2 viscose core spun yarn- Made of 50% viscose core and 50% polyester sheath. Used for shirts, dresses, home textiles etc.
    • 48nm/2 viscose core spun yarn- Made of 80% viscose core and 20% nylon sheath. Used for athletic wear and sportswear.

    The absorbent and breathable viscose core provides comfort, while the polyester/nylon sheath lends durability, stretch and abrasion resistance.

    Viscose core spun yarns are preferred for apparel like t-shirts, leggings, towels, bed linens, etc. The viscose core has good moisture absorption and color brightness, while the wrapping fiber adds strength. Brands like Zara, H&M use viscose core spun yarns for many apparel items.

    Manufacturing Process of Blended Yarn

    Blended yarns are produced by mixing two or more different staple fibers in the blowroom, then passing the intimately mixed fibers through the regular spinning processes of carding, drawing and spinning. The blending proportions, fiber length and fineness are carefully controlled to obtain the desired outcome. The main steps are:

    • Blending fibers in blowroom
    • Carding to make webs
    • Drawing to arrange fibers parallel
    • Spinning into blended yarn packages

    Various techniques like intimately mixing unlike fibers or sandwiching layers of different fibers are used in the blowroom stage to achieve proper blending. The remaining processes evenly distribute the dissimilar fibers into the yarn. This is simpler than core spinning but produces yarns with homogeneous mixing of properties.

    Key Properties of Blended Yarn

    Some advantages and characteristics of blended yarns are:

    • More economical than core spun yarns
    • Softer hand feel and good comfort
    • Enhanced moisture absorption and movement
    • Wider range of fiber properties in one yarn
    • Better dye uptake and color fastness
    • Scope for novelty effects by mixing colored fibers
    • Versatility in applications - apparel, home textiles, accessories
    • Synergistic properties by combining suitable fibers

    Common blended yarns include polyester-cotton, polyester-viscose, nylon-wool, acrylic-wool, etc. Popular varieties like acrylic blended yarn provide wool-like softness at a lower cost.

    Acrylic Blended Yarn Varieties and Applications

    Some commonly used acrylic blended yarns are:

    • 70/30 acrylic/polyester- Soft, warm, durable and affordable. Used for sweaters, scarves, blankets.
    • 85/15 acrylic/polyester- Provides elasticity, shape retention and fade resistance. Used for apparel like tracksuits.
    • 95/5 acrylic/spandex- Imparts stretch and flexibility. Used for sportswear and activewear where stretch is required.

    Acrylic blended yarns are easier to care for, resistant to moths/beetles, and retain color well. They provide wool-like warmth and softness at a lower cost. Popular for apparel, home furnishings, upholstery and accessories like shawls, coat linings, socks, beanies, etc. The acrylic component provides warmth and softness, while the other fiber lends the required functionality.

    Comparison between Core Spun Yarn and Blended Yarn

    Some key differences between core spun and blended yarns:

    • Core spun has distinct core and sheath, blended is a homogeneous mix
    • Core spun is stronger, blended has softer feel
    • Core spun is more durable and dimensionally stable
    • Blended yarns are more economical
    • Core spun dries faster, blended provides better moisture absorption
    • Core spun has higher abrasion resistance and colorfastness
    • Blended can pill more easily compared to core spun
    • Core spun allows combining disparate fibers impossible to spin alone
    • Blended yarn properties are more uniform throughout the yarn

    So while core spun yarn has higher tenacity and longevity, blended yarn provides better comfort and moisture management at a lower cost.

    How to Choose Between Core Spun Yarn and Blended Yarn

    The choice depends on the application:

    • For denim, towels, home textiles favoring strength - core spun yarn
    • For t-shirts, leggings, sweatshirts needing softness - blended yarn
    • For athletic wear, swimwear needing stretch - core spun yarn
    • For upholstery, accessories needing durability - core spun yarn
    • For uniforms, activewear needing moisture control - blended yarn
    • For apparel needing vibrant colors - blended yarn

    So consider the required functionality, cost constraints, aesthetic needs and care requirements when deciding between core spun and blended yarns. Testing prototypes during product development also helps make the optimal choice.

    FAQ

    What are the key differences between core spun yarn and blended yarn?

    Core spun yarn has a distinct core and outer sheath, while blended yarn is a homogeneous mix of fibers. Core spun is stronger and more durable, blended has a softer hand feel.

    What are some popular varieties of acrylic core spun yarn?

    40/30/30 acrylic/PBT/nylon in 18s/2 and

    40/40/20 acrylic/cotton/nylon in 24s/2 are popular varieties.

    What blended yarn is used for t-shirts and activewear?

    Acrylic/polyester and acrylic/nylon blends are commonly used for t-shirts and activewear. Popular options are 70/30 and 85/15 acrylic/polyester blends.

    When is blended yarn a better choice over core spun yarn?

    For applications needing softness, moisture absorption and color vibrance rather than high strength. Examples are t-shirts, leggings, scarves and other apparel.

    What are the benefits of viscose core spun yarn?

    It provides the comfort and moisture absorption of viscose along with durability, stretch and easy care from the core yarn. It is smooth and absorbent.

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