Manufacturer of Core Spun Yarn

Are you considering using core spun yarn for manufacturing your textile product? Well, we think that’s definitely a great option.

Manufacturing any product comes with the great responsibility of providing the best; for that reason, using suitable materials to come up with the final product is essential.

The same is the scenario for textiles. One of the yarns being used in recent times is core spun yarn, thanks to the advantages it has to offer with the final textile product.

If you want to know more about core spun yarn and everything related to it, look no more, as we have all the necessary information covered for you under one roof.

Core Spun Yarn Definition

The core spun yarn definition in the textile industry is: A core spun yarn refers to a composite yarn combined by a core yarn and an outer yarn; generally with a filament as a core yarn, the short fiber is an outer yarn.

What is Core Spun Yarn

Core-spun yarns are generally made of synthetic fiber filaments with good strength and elasticity as the core yarn, with short fibers such as cotton, wool, and viscose fibers being twisted together. The core-spun yarn has the excellent properties of filament core yarn and short-wrapped fiber. The more common core-spun yarn is polyester-cotton core-spun yarn, which is manufactured from polyester filament as the core yarn and wraps cotton fibers. There is also spandex core-spun yarn, which is a yarn made of spandex filament as the core yarn and other fibers as outer yarn. The knitted fabric or jeans material made of this core-spun yarn can stretch freely and fit comfortably when wearing.

At this stage, under the competition of the yarn manufacturers, the core-spun yarn has developed into many types, which can be summarized as three types: short fiber and short fiber core-spun yarn, chemical filament and short fiber core-spun yarn, chemical filament and chemical filament core-spun yarn. At present, most core-spun yarns are generally composed of chemical fiber filaments as the core yarn and wrapped with various short fibers to form a unique structure of core-spun yarn. Commonly used chemical fiber filaments for its core yarns include polyester filaments, nylon filaments, and spandex filaments. The outer short fibers include cotton, polyester cotton, polyester, nylon, acrylic and wool fibers.

The structure of the core spun yarn

As above, the core spun yarn is manufactured by twisting staple fibers around a central core of the filament. This filament usually comprises polyester to give the additional strength that is required by the majority of textile products. In simpler words, this kind of yarn is made using twisting fibers around an existing yarn, creating a shell-core type of structure as the final product.

The yarn has two main parts:

• Center or core: the continuous filament which is being covered by the twisting staple fibers is the core of the yarn.
• Sheath: The staple fibers are used as the sheath covering of the filament.

Both these parts contribute to providing the excellent performance that this thread offers.

The continuous polyester filament used in between the wrapping staple fibers makes up approximately 60% of the thread construction which contributes to the following:

• Greater uniformity in strength, size, and other physical properties.
• Better ply security.
• Higher strength or tenacity per size compared to standard threads.
• Superior durability and abrasion resistance.
• Reduced seam puckering and better loop formation.

The outer fibers can be of staple polyester or staple cotton both. These outer fibers give the thread a fibrous surface which contributes in:

• Matte finish stitch appearance.
• Softer hand or feel than 100% continuous filament threads.
• Superior color fastness.
• Superior friction characteristics.

Core Spun Yarn Advantages

In addition to its special manufacturing process, core-spun yarn has many advantages. It can take advantage of the excellent physical properties of the core yarn (chemical fiber filaments), and the performance and surface characteristics of outer short fibers, which is a great way to give full play to the characteristics of the inner and outer fibers and make up for their shortcomings.

For example, polyester-cotton core-spun yarn has the advantages of polyester filaments, which are, crisp, crepe-resistant, and easy to wash and dry. Meanwhile, it can also take advantage of outer cotton fiber, so that it has good moisture absorption and low static electricity, and it is not easy to fuzz and pill. Obviously, it can utilize the different properties of chemical fiber filaments and the outer fiber.

Due to the difference between the inner and outer fibers, during the dyeing and finishing of the fabric, a part of the outer fiber is rotten by chemicals to a burnt-out exterior, and the fabric made of it is of a three-dimensional pattern appearance.

Its advantages are summarized as follows:

(1) It feels very comfortable, simulating the feel of expensive fibers such as cashmere, and can even achieve the effect of being fake.

(2) Cheap price is the biggest advantage of core-spun yarn. Guess how cheap it is? For example, the price of woolen wool this year is about 220 yuan per kilogram; for cashmere, it is about 850 yuan per kilogram; even the yarn with 60% wool is more than 40 yuan per kilogram. According to our 10+ years of experience in core spun yarn manufacturing, the price of core-spun yarn is only RMB 30 per kilogram.

These two biggest advantages have made core-spun yarn a kind of yarn that has been particularly favored in the past two years. Regardless of whether it is marketed or branded, many clothing manufacturers are using it. Of course, many high-end clothing may not use core-spun yarn, after all, the textile industry knows that it is a low-end category of yarn.

Here are some more advantages that this amazingly unique yarn has in store for you:

• Due to this yarn's exceptional strength, the final product made using this yarn provides high performance.
• The wash and wear performance of the products made using this yarn is excellent.
• While maintaining and improving the properties of the fabric made using core spun yarn, it reduces its weight too.
• It is around 40 to 50 times tougher than the yarn that has the same weight.
• While stitching the denim seams and hems, the use of this yarn cuts down the number of broken stitches. This, in turn, paves the way for garments that are tougher than the standard ones.
• The yarn possesses excellent resistance to wear and tear.
• The use of this yarn improves the breathability and durability of the fabric.

Core Spun Yarn Disadvantages

To be honest, as a core-spun yarn supplier, we understand all aspects of its properties, and really can’t find out its big shortcomings. You said that core-spun yarn pilled, it does pilling; but it is undeniable that wool and cashmere will also pilling.

The only disadvantage of core-spun yarn, in my opinion, is that it is heavier. If you use it to make clothes, there will be the following unsatisfactory aspects:

(1) The fluffy feeling of clothes will not be as good as wool clothes.

(2) Clothes cannot be made into sweaters that are light and thick. If they are thick, the clothes will be very heavy, and they will feel tired when worn on the body.

Uses of Core Spun Yarn

Core-spun yarn is currently the most widely used product for knitwear manufacturing, due to its far low price compared with wool yarn and its good performance in garments. It can be used to produce school uniforms, work clothes, shirts, bathrobe fabrics, skirt fabrics, sheets and decorative fabrics. Bed sheets, bedspreads, pillowcases, sofa covers, curtains, tablecloths and other series of matching front bedding and interior decoration products made of core-spun fabrics through dyeing and printing are ideal high-end textiles.

According to the different uses of core-spun yarn, the current types of core-spun yarn mainly include: core-spun yarn for clothing fabrics, core-spun yarn for elastic fabrics, core-spun yarn for decorative fabrics, and core-spun yarn for sewing threads. There are also many spinning methods for core-spun yarn: ring spinning, electrospinning, vortex spinning, self-twisting spinning, etc. At present, China's cotton spinning industry mostly uses cotton ring spinning to spin core-spun yarn.

There are tons of daily life applications where core spun yarn is used:

• Since the most common combination used in the core spun yarn is polyester as the core and cotton as the skin, it can easily be used to make work clothes, students' uniforms, shirts, bathrobe fabrics, etc.
• Due to their excellent durability, core spun yarns are also used in producing leather products such as women's shoes, handbags, etc.
• The immense strength and durability of the products made using this yarn make it suitable to be used for rice bags too.
• Core spun yarns are mostly preferred for denim because it is around 40-40% stronger than the threads used of the same size, provide superior sew-ability on manual and automatic machines both, and there are very few interruptions and fewer restitched seams, also allow the use of smaller diameter thread, and helps in minimizing broken stitches and cuts in the final product.

Core Spun Yarn Type

According to the different uses of core-spun yarns, the main types of core-spun yarns currently include: core-spun yarns for apparel fabrics, core-spun yarns for stretch fabrics, core-spun yarns for decorative fabrics, and core-spun yarns for sewing threads. There are also many spinning methods for core-spun yarn: ring spinning, electrostatic spinning, vortex spinning, self-twist spinning and so on. At present, China's cotton spinning industry mostly uses cotton ring spinning to spin core-spun yarn. However, there are still many core spun yarn manufacturers focusing on some special kinds of products.

1 Classification by product use

It can be divided into core spun yarn for sewing, core spun yarn for rotten fabric, elastic fabric (including knitted fabric, woven fabric) core spun yarn, fancy core spun yarn (such as hollow core-wrapped yarn, multi-color core spun yarn,  bamboo core spun yarn, etc.), functional and high-performance fabric core spun yarn, etc.

2 Classification by core filament

In this case, core spun yarn can be divided into rigid core-spun yarns and elastic core-spun yarns. The former include polyester, acrylic, nylon, etc., and the latter includes spandex, PTT fiber, PBT fiber, etc.

3 Classification by outer fiber

Usually, the outer fiber contains cotton, wool, silk, hemp (including ramie, flax, hemp, etc.), colorful cotton and other natural fibers; Sticky fiber, MODAL, TENCEL, soybean fiber, milk fiber, bamboo pulp fiber, polyester fiber, acrylic fiber and all kinds of colored chemical fiber can be used for core-spun fiber.

4 Classification by spinning equipment

At present, ring spinning, rotary spinning, friction spinning, air jet spinning, and other spinning devices can be used to produce different kinds of core-spun yarn. The different spinning devices are basically the same.

5 Classification by filament (the core yarn) content

Filament content is the main index of core-spun yarns, which has a great influence on yarn performance and cost. For example, the spandex core spun yarn uses the spandex yarn as the core yarn. Generally, core spun yarn with filament content below 10% is called low ratio core-spun yarn; that with filament content of 10%~40% is called medium ratio core-spun yarn; that with filament content over 40% is called high ratio core-spun yarn.

Filament content of elastic core-spun yarn is generally less than 10%, 3%~5%, the higher the proportion, the higher the cost. Pure polyester sewing core-spun yarn is of filament content up to 50~60%. The filament content of the core spun yarn used in the rotten fabric is 40~60%, and that of general rigid core spun yarn is 20~40%. The filament content of core spun yarn should not be too high, and is restricted. Theoretically, the covering width of the outer fiber should be larger than the surface perimeter of the core filament yarn, otherwise, defects will occur.

6 Classification by yarn density

In the same classification method as traditional yarns, core spun yarns of 32tex and above are classified as coarse special core spun yarns, those of 21-30tex are medium special core spun yarns, and those of 11-20tex are fine special core spun yarns. The density of core-spun yarn is normally between 16tex and 70tex. You might need a yarn count converter.

Common Core Spun Yarn Specifications

Below are the common specifications that most core spun yarn manufacturers provide in China.

The difference between core spun yarn and covered yarn

The difference between core-spun yarn and covered yarn, we take spandex core-spun yarn and spandex covered yarn as examples:

Spandex core-spun yarn is spandex wrapped with short fibers, with spandex as the core and non-elastic short fibers outsourcing. When the spandex core-spun yarn is stretched, the core yarn is generally not exposed.

Spandex covered yarn is an elastic yarn formed by covering the spandex with the filament of chemical fiber, which is also made of spandex as the core, and the non-elastic staple fiber or filament is wrapped in a spiral manner to cover the elongated spandex yarn. The core filament of covered yarn will expose when being stretched.

The core-spun yarn has poor elasticity, but the core yarn is not easy to be exposed to produce aurora; covered yarn is easy to produce aurora, but the elastic elongation ability is better.

Core spun yarn manufacturing process in our factory

As a core-spun yarn factory, we feel it is necessary to show everyone the production process of core-spun yarn, so that everyone can better understand what kind of core-spun yarn is. The following is a brief description of the core spun yarn production process, you can also click here to learn more about the core spun yarn production process.

In our core-spun yarn factory, the production of core-spun yarn is divided into the following processes:

opening and cleaning→ carding→ drawing→ roving→ spinning→ post processing.

After this series of processes, the selected staple fiber will eventually become the finished core-spun yarn.

1 Opening and cleaning process

The first process is opening and cleaning, which can mix the different fibers and make them into a uniform fiber bundle, as well as remove the impurities.  This process will last 3 times to ensure core spun yarn purity. We control the workshop moisture and temperature in all the processes to ensure the yarn strength and quality. In this process, the short fiber is made into a uniform fiber roll to create conditions for carding process.

2 Carding process

After the opening and cleaning process, the fibers were loose and contained 40% to 50% impurities. Carding process can mix the fibers evenly and bundle them with a single fiber that is parallel to normal, while also removing impurities with strong adhesion. The fiber bundles will go through the carding machine, to make themselves completely decompose into single fibers. The product after this process is a card sliver. It is worth noting that the humidity setting of this process will affect the quality of the final core-spun yarn, and the humidity needs to be set according to the fiber composition of the core-spun yarn.

3 Drawing process

The quality of the card slivers is not good enough, and it needs to be processed into the drawn sliver. We will operate the drawing process 2 times to ensure the yarn is of great evenness. In the drawing process, after the fiber strip is mechanically processed, the distance between the fiber and the fiber becomes closer, and the mixed composition and color of the fiber are more uniform. The treated fiber strips are wound into appropriate packages for use in subsequent processes of core spun yarn manufacturing.

4 Roving process

Next is the roving process, where the drawn sliver is processed into roving yarn, preparing for the spinning process. The main task of the roving process is to stretch and draw the fiber strips according to certain technical parameters, improve the parallel elongation of the fiber, and at the same time, the fiber gets the appropriate twist and is wound into shape, so as to facilitate the storage and use of the next process. In the spinning process, the rovings here will be processed into core spun yarns as outer fibers together with the core yarns.

5 Spinning process

The spinning process is to spin the roving yarn into the spun yarn with certain specifications and quality standards. This process will determine the direction of the twist. We have 50 sets of spinning machines, and our daily capacity of core spun yarn is about 20 tons.

The spinning process is to spin the roved fiber into a spun yarn. During the process, a proper twist is added to make the spinning yarn have a certain strength, elasticity, gloss, feel, and other physical and mechanical properties. After this, the spun yarn would be ready for the subsequent process.

6 Post-processing

Although the previous processes have basically completed the spinning task, to be used in textile manufacturing, it still needs to go through post-processing to become the final core spun yarn. In addition to the filling yarn directly from the spinning workshop to the weaving workshop, other varieties according to the processing requirements need to undergo appropriate post-processing. The yarn processing process after the spinning process is collectively referred to as the post-processing process, which mainly has the following four purposes:

(1) Improve the internal performance of core spun yarn.

(2) Improve the appearance quality of core sun yarn.

(3) Stabilize the structural state of the core spun yarn.

(4) Make the appropriate roll form.

6.1 Winding process

The spun yarn is not big and convenient enough for textile manufacturing. Therefore, we will wind them into the bigger cone yarn.  If the core spun yarn is used for the industries like fabric manufacturing, then the cone yarn is the final product after this process.

6.2 Plying Process

If the core spun yarn is used for the industries like sweater manufacturing, then the plying process is necessary. This process will make 2 of the single yarn into 1 double plied yarn, and make sure all of them are at the same weight.

6.3 Twisting Process

Next is the twisting process, which is to make the core spun yarn have higher strength and elasticity. It can also make fabric and sweaters to achieve the anti-pilling effect.

6.4 Dyeing Process

Color accuracy, moisture content and color fastness are very important indicators of yarn quality, and these quality indicators are strictly followed in our core spun yarn factory.

Factors Affecting Core Spun Yarn Production

A few factors make the core spun yarn unique and stronger than all the others present in the market today. These factors include:

Stress Tests for Core Filament

The thread used as the core of the core spun yarn is first passed through various stress tests to make sure it is durable enough and then prepared for further processing.

Doubling Techniques for Manufacturing

What strengthens the core spun yarn is the fact that the manufacturing method uses various doubling techniques in which multiple layers are folded on each other for strengthening the thread.

Lubricating the Thread

In core spun yarn, there is a method of lubricating the thread which is specifically done to make the final product more breathable and provide better-cooling properties in the garments made using this yarn.

Testing the thermal performance of the yarn

Additionally, to make the fabric made using core spun yarn more durable, the thermal performance of the yarn is also tested. The thermal performance of the yarn is made better using a process called hot stretching. This process makes the yarn more stretchable, making the final product more durable than the standard ones.

Will textiles made of core-spun yarn be pilling?

Generally speaking, pilling is a common feature of all wool products, and most of them will pill during wearing. Pilling is related to the performance of sweater raw materials, spinning and dyeing and finishing processes, and other aspects. , It's not simply that the yarn material is inferior.

The core-spun yarn will pill, because it will be woven with a variety of fibers, and when short fibers are used, the surface may have pilling, so the textile made of the core-spun yarn will pill, but This phenomenon can be reduced by technological treatment. Its problem is actually not serious, only slightly pilling, even much better than most knitted fabrics, if pilling can be removed by rolling brush, and when washing, use appropriate Detergent can slightly reduce pilling.

Is core-spun yarn pilling serious?

Although the core-spun yarn will pill, the situation is not serious. Compared with most knitwear yarns, such as wool yarn, the core-spun yarn has a good performance in anti-pilling, and it has less static electricity and better hygroscopicity. Well, of course, compared with some non-knitted fabrics, the performance in anti-pilling is definitely a little weaker.

Is core spun yarn single-ply?

Core spun yarns are available in single-ply or multiple plies. Their difference is that the more plies, the stronger the yarn. In addition, the price of multi-ply core spun yarn is also higher because it needs special equipment for plying process. From the point of view of the gloss effect of the cloth surface, the effect of the fabric with double plies core spun yarn will be better than that of single core spun yarn.

Core spun yarn examples

For those who are new in the textile industry, this is a good and easy-understanding video example of how core spun yarn is made.

Raw material of Core Spun Yarn

Choice of core yarn

The fineness of the core filament and the number of single filaments in it should be selected according to the use of the fabric and the spinning count. For core filaments of the same size, the thinner the filaments, the more the number of filaments, and the softer and smoother the fabric; on the contrary, the fewer the number of core filaments, the more rigid and stiff the fabric. For coated products, there is no need to consider the luster of the core wire, and the light core wire can be used to reduce production costs; if the exposed product is produced, the luster of the core wire should be considered. Effect. If producing 11.8tex (50s) polyester-cotton core-spun yarn for skirt materials and shirt fabrics, it is advisable to use ordinary low-strength and high-elongation 5.56tex(50D)/24F semi-gloss polyester filament as the core yarn. When core-spun yarn is used as sewing thread, generally select high-strength, low-elongation bright polyester filament with a large number of monofilaments above 7.78tex(70D)/36F. When used as burnt-out outerwear, bright polyester filaments below 7.56tex(68D)/36F can be used. But for the core-spun yarn used in burnt-out fabrics, the fineness of the core yarn should be too large. Generally, 7.22-8.33tex (65-75D)/36F matt or semi-gloss polyester filament is used to prevent burnt-out. Part is too thin, too thin and cause aurora. For the core-spun yarn used in elastic fabrics, the fineness of the core yarn can be selected according to the purpose of the fabric. Generally, polyester 7.78tex (70D) spandex yarn is used, and the draft ratio is about 3.8 times. For the medium (medium-low count) spandex core-spun yarn for warp-directed strong corduroy and stretch work cloth, the spandex yarn draft should be larger, about 3.8-4.0 times, which can ensure the wearing of stretch pants. At this time, the hips and knees have better resilience.

Choice of Outer Fiber

If cotton fiber is used as the outer fiber, theoretically, raw cotton with long length, high count and good maturity should be used as much as possible. But it should depend on the purpose of the product. If you are not making high-speed sewing threads, but making shirt fabrics or skirt materials, or other burnt-out decorative fabrics, you do not need to use good raw cotton, because they do not need to withstand high-speed sewing threads. The test of that kind of strong friction and high-temperature melting will not produce "skinning" phenomenon, so 30mm long raw cotton can meet the requirements. However, the outer cotton used as the core-spun yarn of burnt-out fabrics has less neps and impurities. It is better if rayon is used as the outer fiber, with low strength, good dyeing performance and less neps and impurities.

Core Spun Yarn Manufacturer - Salud Style

Now that you know all the major facts about core spun yarn, which core spun yarn manufacturer should you opt for when choosing one for your textile products?

We at Salud Style are independently manufacturing and developing various core spun yarns. With around 10+ years of experience, not only can we develop but also recommend the core spun yarn specifications that you, as a customer, require to meet all your production needs.

We have numerous colors of core spun yarn available on our color card, out of which you can easily find the one that meets your color requirements.

As a core spun yarn manufacturer, we are very proud of our product quality. We strictly control the moisture regain of the core spun yarn, which means we'll not treat our customers with moisture issues or any other issues.

Besides, we won't decrease the quality to compete with other core spun yarn suppliers. Maybe our price is not the lowest, but you can always trust on our quality of core spun yarn.

If you are confused about anything related to core spun yarns or which one to choose, depending on your demands, you can contact us through our website and get all the necessary information and guidance that you need.

Get in touch with us through the means provided below, and our experts shall get back to you (in a maximum of one business day) as soon as possible!