Mechanically Covered Yarn

Mechanically covered yarn is a type of composite yarn made by wrapping one or more yarns around a core yarn.

Mechanically Covered Yarn

Table of Contents

    Introduction to Mechanically Covered Yarn

    Mechanically covered yarn is a type of composite yarn made by wrapping one or more yarns around a core yarn. This provides certain advantages over single ply yarns, such as high elasticity, good abrasion resistance, and the ability to combine different fiber properties in one yarn. Mechanically covered yarns are used in a variety of textile applications from hosiery to upholstery fabrics.

    Manufacturing Process of Mechanically Covered Yarn

    The manufacturing process for mechanically covered yarns involves feeding the core yarn through a ring or roller covering device. The covering yarn is wrapped helically around the core under controlled tension. The amount of turns per inch determines the cover factor. After covering, the yarn is wound onto packages ready for downstream processes.

    Types of Mechanically Covered Yarn

    There are two main types of mechanically covered yarn: single covered yarn (SCY) which has one layer of covering, and double covered yarn (DCY) with two covering layers. The core and cover components can be made of natural fibers like cotton or wool, synthetics such as polyester or nylon, or blends. The cover yarn often has more elasticity than the core.

    Video: Covered Yarn Factory
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    Properties and Applications of Mechanically Covered Yarn

    Mechanically covered yarns have greater elasticity, bulk, moisture absorption and insulation versus regular spun yarns. Key applications include circular knitted fabrics for activewear and socks, woven upholstery, furniture fabrics, and elastic narrow fabrics like braids. The abrasion resistance and durability make them popular for high wear end uses.

    Comparison between Mechanically Covered Yarn and Air Covered Yarn

    While both are composite yarns, mechanically covered uses physical wrapping while air covered uses air vortex spinning. Air covered yarns have a more irregular appearance versus the uniform coverage of mechanical wrapping. Mechanical has higher tenacity and more consistent elasticity. Air covered provides better heat insulation properties.

    Advantages of Using Mechanically Covered Yarn

    The advantages of mechanically covered yarns include high elasticity and recovery, good strength, abrasion resistance and durability, versatility in combining components, and the ability to modify fabric aesthetics and performance. The covering supports the core while the core provides strength. Bulk can be added without increasing weight.

    Limitations of Mechanically Covered Yarn

    Limitations include less moisture absorption than natural fibers, potential shedding of the cover with abrasion, and a harsher hand versus other yarns. There is also more yarn preparation needed and a more complex manufacturing process. Costs are higher than regular spun yarns, and dyes must have affinity for different components.

    Innovations in Mechanically Covered Yarns

    Recent innovations include using new covering materials like recycled polymer fibers for sustainability benefits. High elastic specialty fibers and spandex provide further stretch and recovery options. Using different colors in the core and cover creates visually interesting yarns. Hybrid yarn structures combine covering with air texturing.

    Testing Standards for Mechanically Covered Yarns

    Key tests per standards like ASTM D6822 and DIN 53835 include: linear density, twist direction and turns per meter, breaking force and elongation, abrasion resistance, core proportion, and cover factor. These tests ensure quality and consistency for downstream processing and end product performance.


    • What are the main advantages of mechanically covered yarns?

    They have high elasticity, good abrasion resistance and durability, and allow combining different fiber properties in one yarn.

    • What are the key applications for mechanically covered yarns?

    Activewear, hosiery, upholstery, furniture fabrics, elastic narrow fabrics.

    • How do mechanically covered yarns differ from air covered yarns?

    Mechanical uses physical wrapping for uniform coverage while air uses vortex spinning for irregular wrap.

    • What tests are used to control quality of mechanically covered yarns?

    Key tests cover linear density, twist, breaking force, elongation, abrasion resistance and cover factor.

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