POLYESTER

POLYESTER
Polyester are polymers made by a condensation reaction taking place between small
molecules, in which the linkage of the molecules occurs through the formation of
ESTER Groups.
Polyesters polymers are generally made by interaction of a dibasic acid with a dihydric
alcohol:

According to FTC (Federal Trade Commission of USA) Polyester fibers are manufactured fibers in
which fiber forming substance is any long chain synthetic polymer composed of at least 85% by
weight of an ester of a substituted aromatic carboxylic acid.
 History
▪ In 1926 United States based Du Pont de Nemours and Co. began research into very large
molecules and synthetic fibers.
▪ Between 1939 and 1941 Polyester fiber was first developed by J. T. Dickson and J. R.
Whitfield of Calico Printers.
▪ ICI bought the rights to manufacture the fiber in 1945 after the World war, except USA,
where Du Pont was licensed.
▪ ICI named their Polyester TERYLENE and Du Pont named their Polyester DACRON.
▪ Du Pont was able to start commercial production by 1953 earlier than ICI had experienced
with melt spinning of Nylon.
▪ It took until 1954 when the first European polyester plant began production.
 Classification & Chemistry of polyester
Terylene
• In general polyester fibers are (UK)

subdivided into following types based Diolen Dacron

(France) (USA)
on their chemical structures:
❑Polyethylene Terephthalate Fibers (pet Trade or
Polyester Fibers) commercial
names for
Polyester
❑Poly-1,4-cyclohexylene-dimethylene Terenca
(Holland)
fibers: Tetron
(Japan)
Terephthalate Fibers (pcdt Polyester
Fibers)
❑Other Types Of Polyester Fibers Lavson
(Russia)
Torital
(Italy)
 Classification of polyester

https://en.wikipedia.org/wiki/Polyester
 Classification & Polymerization of polyester
Polyethylene terephthalate (PET):
The most important and widely used polyester is known as polyethylene terephthalate. It
is produced from the polymer manufactured by the reaction of terephthalic acid (TPA)
and ethylene glycol (EG).
In USA, PET is known as Dacron but in UK, it is known as Terylene and produced
from the polymer manufactured by the reaction of dimethyl terephthalate (DMT) and
ethylene glycol (EG)

Fig: Dacron
 Classification & polymerization of polyester
Preparation of DMT:
Dimethyl Terephthalate is prepared like below:

Fig:
DMT
From DMT Terylene is synthesized as below:

Fig: Terylene
Classification & polymerization of polyester
 Classification & polymerization of polyester
From the above last reactions, we can clearly see that, both Dacron and Terylene are essentially the
same and they differ in that whereas Terylene contains a methyl ester group at one end of the
macromolecule, Dacron contains an acid group instead.

Poly-1,4-cyclohexylene dimethylene terephthalate (PCDT) or Kodel II (200):

This type of polyester is derived from the polymer manufactured by the reaction of
terephthalic acid (TPA) and 1,4-cyclohexane dimethanol which can be shown as below:

Fig:
PCDT
 Application of Kodel ii (PCDT)
• PCDT is more elastic, offers greater resilience, and is ideal for heavier textiles like
curtains and furniture coverings.
 Classification & polymerization of polyester
Other Types of Polyester Fibers: Vyron
For this type polyester, fiber forming polymer is produced from ethylene glycol and a
mixture of terephthalic and isophthalic acid.

Fig: Vyron
 Flowchart of Polyester Production
Preparation of Raw Materials (Terephthalic Acid, DMT, Ethylene Glycol etc.)

Mixing Tank

Polymerization in reactor (Ester Interchange and Poly condensation, 260~280 Deg, 3~6 Hrs.

Polymer Chips

Melt Spinning

Polyester Filaments produced from spinneret holes (Mono/Multi filament)

Drawing

Texturization and packaging

 PREPARATION OF RAW MATERIALS
• Terephthalic Acid From P-xylene:

Terephthalic Acid is made by oxidizing P-Xylene in presence of air and nitric acid, P-Toluic acid is formed as
intermediate product. Generally temperature required is around 200 Degree Celcius.
 PREPARATION OF RAW MATERIALS
• Dimethyl Terephthalate From Terephthalic Acid:

P-Xylene is oxidized to form P-Toluic acid which is further esterified with methyl alcohol to form Monomethyl
Terephthalate initially and then Dimethyl Terephthalate eventually.
 PREPARATION OF RAW MATERIALS
• Ethylene Glycol from Ethylene:

Ethylene Glycol is made conveniently from Ethane, after catalytic oxidization Ethylene oxide is produced.
Hydration of this yields ethylene glycol.
 POLYMERIZATION

Fig: Dacron

Fig: Terylene
MELT SPINNING
✓ Polyethylene terephthalate melts at about 260 degree Celsius,
then it is stable.
✓ The chips of polymer are dried to remove traces of moisture,
then passed to storage.
✓ The chips are fed as per requirement to spinning machines.
✓ The chips are melted and molten polymers are pumped through
the holes of a spinneret.
✓ As they emerge from holes, they are solidified and wound onto
package of undrawn yarn.

DRAWING
✓ The undrawn yarn is stretched to about five times of original length on
appropriate device.
✓ The stretching usually is carried out at elevated temperature. It is normal to draw
at high temperature as it gives a more uniform product than cold drawing.
✓ If high tenacity yarn is required, the filament are drawn to a higher degree than
in the tenacity of regular yarn.
✓ On the other hand for heavy denier or mono filament drawing, room
temperature is preferred as poor heal conductivity gives irregular weight per
length.
Polyester manufacturing

Fig: Flowsheet of Polyester Manufacturing

Polyester manufacturing
TEXTURING
✓ After producing a great number of filaments, they are brought together to form a heavy tow.
✓ They are drawn and then crimped mechanically, they are applied on fibers generally by heat treatment.
✓ Also texturing can be applied by Twist -> Heat -> Cool -> Untwist
✓ The tow can then be cut into short staple or kept as long continuous filament as per end use requirements.

Fig: Some of the texturizing methods

FINISHING
The finishing process for PET polyester filament yarn maybe arranged in the following 3 sequences:

o Scour – Heat Set – Dye

o Heat Set – Scour – Dye
o Scour – Dye – Heat Set

Here among the 3 sequences, any one can be used according to the requirement,

Sequence 1 is most generally used all over because of following reasons, machine stains and other forms of
contaminations are difficult to remove from filaments which have been heat set; so it is preferable to scour before
heat-set. Also goods which have not been heat set tend to shrink during dyeing and the dyed goods will be
subjected to high temperature after dyeing which can cause to damage dyeing effect.

Sequence 2 is preferable where goods remain clean after being passed through different machines. It is however
very rarely used in case of PET Polyester fibers except in case of curtain nets.

Sequence 3 tends to impart some degree of stiffening of filaments following heat setting. This sequence is limited
by the fastness of available dyestuffs to sublimation under heat-setting conditions.
 PROPERTIES OF POLYESTER
† Physical properties:

• Tenacity: Polyester fibers and filaments are strong to very strong because of their extremely
crystalline polymer orientation. Tenacity remains unaltered even in wet condition because of
completely hydrophobic and extremely crystalline polymer system.
➢ High tenacity filament = 7-8 gm/den
➢ Normal tenacity filament = 4.5-5.0 gm/den
➢ Staple fiber = 3.5-4.0 gm/den

• Elongation: Due to Vander Waal's force at the system they show following extension and elastic
recovery, breaking extension 20-30% in general and elastic recovery 97-100% at 2% extension.
Elongation at break is virtually unaffected by moisture.

• Hygroscopic Nature: Extremely crystalline structure resist the entry of moisture into polymer
system. MR = 0.0 - 0.4%

• Specific Gravity: Dacron 1.38 and Kodel 1.22

 PROPERTIES OF POLYESTER
† Chemical Properties:

▪ Effect of Moisture: Polyester only absorbs small amount of moisture and tenacity and elongation
are completely unaffected.

▪ Effect of Bleaches: Not affected by oxidizing and reducing agents.

▪ Effect of Acid: Highly resistant to mineral and organic acids. Weak acids cannot affect them even on
boiling. Strong acids like sulphuric acid can affect them only after boiling for a long time.

▪ Effect of Alkali: Highly resistant to alkalis, only strong hot alkalis result in slow thinning of the
filament diameter.

▪ Effect of Organic Solvents: Resistant to all dry cleaning solvents.

▪ Dye Ability: Disperse dyes and only some pigments can be used for coloration.

▪ Effect of Sunlight: Have good resistance against sunlight but slowly becomes weaker on long time
exposure to sunlight.
 PROPERTIES OF POLYESTER
† Thermal Properties:
Polyester fiber is the most thermally stable synthetic fiber. If heat setting is not done properly then
shrinkage occurs. At high temperature polyester melts and burns.
❖ Softening temperature: 230-245 C
❖ Melting temperature: 250-268C
❖ Sticking temperature: 230-240 C
❖ Ironing temperature: 135 C
❖ Glass Transition temperature: 70 C

Ω Thermo plasticity
‘Thermo plasticity’ means capable of being shaped or molded when heated. Thermoplastic fibers
heated under strictly controlled temperatures soften and can then be made to conform to a flat, creased
or pleated configuration.
When cooled, thermoplastic fibers will retain the desired configuration that is remain flat, pleated or
creased. Polyester textile materials can be permanently heated.
Textile fibers classed as thermoplastic are acetate, triacetate, acrylic, nylon and polyester.
Polyesters retain a heat set permanently where as acetate fibers do not hold a set as satisfactory.
† Biological properties of Polyester have good resistance against micro organisms, larvae, fungi, mildew and
molds.
 Polyester fabric available in market:
• There are different types of polyester fabric available in the market:
• • Ethylene Polyester
Ethylene polyester is most commonly referred to as polyethylene terephthalate (PET). In the polyester market, this
type of polyester is the most common type of polyester. It is manufactured from a petroleum-derived called
ethylene. They are available in four types depending on the manufacturing method used: filament, staple, tow, and
fiberfill.
• • PCDT Polyester
PCDT refers to (poly-1, 4-cyclohexylene-dimethylene terephthalate). In comparison to PET polyester, PCDT
polyester has less popularity. But, due to its elastic nature, it is used for many applications. The process of
manufacturing PET polyester is similar to the manufacturing process of PCDT polyester. The only difference is in
the chemical structure of both types of polyester. PCDT polyester is more durable hence it is used in heavy-duty
applications such as upholstery and curtains.
• • Plant-Based Polyester
Plant-based polyesters are also manufactured from ethylene glycol and dimethyl terephthalate. The main difference
between plant-based polyester and other types of polyester is that for other polyester ethylene is sourced from
petroleum but for plant-based polyester, ethylene is sourced from renewable sources such as cane sugar, etc. Also,
the plant-based polyester is biodegradable in nature. But, compared to other polyesters, plant-based polyester is
expensive and has less durability.
 END USES
As apparel: Men’s wear, women’s wear, children’s wear, trousers, skirts, suits, jackets, blouses and every form
of clothing are made by polyester fibers. Besides ties, lingerie etc. can also be made by polyester fibers.

As blended fabrics: Polyesters are widely used in blends with cotton, wool, acrylic, nylon etc. fibers for making
quality fabrics. Blends with cotton and virgin wool are very popular. They are often referred to as the
"classical blend". This is normally a combination of 55% polyester and 45% wool.

As home furnishings: Carpets, curtains, draperies, sheets, pillow covers, wall coverings, upholstery etc. are
made of polyester fibers.

As industrial use: Polyester fibers are used in manufacturing of tire cord, power belt, ropes, tarpaulin, nets,
hoses, conveyor belt etc. It is also used in making floppy disk, liners etc.

The use of polyester is higher than any other synthetic fiber due to low cost, more durable, no fading, easy
care, no ironing.
ENVIRONMENTAL CONCERN
MICROPLASTIC
POLLUTION
 CONCERN
NON-RENEWABLE
CARBON INTENSIVE
RESOURCE
PRESENT AND FUTURE
 Source
1. Handbook of Textile Fibers Vol ii – man made fibers by j. Gordon cook
2. Handbook of Properties of Textile and Technical Fibres. https://doi.org/10.1016/B978-0-08-
101272-7.00013-4
3. Technology of textile processing Vol-1, textile fibers by dr. v. a. shenai
4. https://www.mdpi.com/2073-4360/5/1/1/htm
5. https://www.water-pollution.org.uk/microplastic/
6. https://www.photobiocat.eu/tag/microplastics/
7. https://en.wikipedia.org/wiki/Polyester
8. https://cottontoday.cottoninc.com/how-quickly-do-textile-microfibers-degrade-in-aquatic-
environments/
9. https://en.wikipedia.org/wiki/Biodegradation#/media/File:Decomposition_rates_of_marine_deb
ris_items,_OWID.svg
10. https://www.gminsights.com/industry-analysis/polyester-fiber-market
11. https://www.databridgemarketresearch.com/reports/global-polyester-fibre-market
12. Polyester Presentation – Slide share, link: https://www.slideshare.net/tarek1994/polyester-
54326991