Synthetic fibers are the backbone of modern textile and industrial applications, and among them, 15D SD Solid Fibres stand out as a popular choice for products that require loft, durability, and consistency. But how exactly are these fibers made?
This in-depth guide explores the production process of 15D SD Solid Fibres, from raw materials to final output. We’ll look into the equipment, conditions, and quality control methods involved in producing this versatile fiber.
Step-by-Step Process to Make 15D SD Solid Fibres
1. Raw Material Preparation
The primary raw material for 15D SD Solid Fibres is polyester, derived from:
- Purified Terephthalic Acid (PTA) or Dimethyl Terephthalate (DMT)
- Monoethylene Glycol (MEG)
These petrochemical-based ingredients are combined in a process called polymerization.
Additives may also be introduced:
- Titanium Dioxide (TiO₂): Controls the fiber’s luster, giving it the semi-dull (SD) finish.
- Stabilizers and Antioxidants: Enhance UV resistance and fiber stability.
- Delustering Agents: Help control reflectivity and hand feel.
2. Polymerization
The raw ingredients are heated and chemically reacted to form long molecular chains of PET (polyethylene terephthalate). The process includes:
- Esterification (or transesterification): DMT + MEG → ester intermediate.
- Polycondensation: Continues the reaction to form high molecular weight PET.
This molten PET is then filtered to remove impurities and ensure consistency.
3. Melt Spinning
Melt spinning is the most crucial step in fiber formation. Here’s how 15D SD Solid Fibres are formed from molten PET:
- The molten PET is pumped through a spinneret (a metal plate with tiny holes).
- As the polymer is extruded through the spinneret holes, it cools and solidifies into continuous filaments.
- The shape and diameter of the spinneret holes determine the denier (15D in this case) and cross-section (solid).
For 15D fibers, the spinneret is designed to produce relatively thick filaments that maintain integrity during high-speed spinning.
4. Quenching and Drawing
Once extruded, the fiber filaments are:
- Quenched: Cooled rapidly using controlled airflows. This step helps set the fiber structure and stabilize molecular orientation.
- Drawn: The fiber stretched or drawn to align its molecular chains. Drawing improves tensile strength, elasticity, and durability.
In 15D SD Solid Fibres, the draw ratio carefully adjusted to maintain a balance between softness and structural firmness.
5. Heat Setting
The drawn fibers are then heat-set using hot rollers or ovens. Heat setting locks in the fiber’s final shape, size, and luster.
This step is crucial for:
- Dimensional stability
- Shrinkage resistance
- Luster control (especially important for semi-dull finish)
6. Cutting and Crimping
After spinning and setting, the continuous filaments are:
- Crimped: Using mechanical rollers to give the fibers a natural wave or crimp. Crimping increases bulk, loft, and resilience.
- Cut to staple lengths: For 15D SD Solid Fibres, typical cut lengths are 32mm, 51mm, or 64mm depending on the application.
Crimping and cutting help the fiber behave more like natural fibers and improve processing in downstream applications like carding, filling, or nonwoven production.
7. Finishing Treatments
Additional finishing steps can applied to enhance the performance of the 15D SD Solid Fibres:
- Anti-static Finish: Reduces static buildup.
- Siliconized Finish: Makes the fiber smoother and more slippery (optional).
- Fire Retardants: Added for specific applications like mattresses or automotive components.
- Hydrophilic or Hydrophobic Coatings: Adjust the fiber’s moisture behavior.
In the case of standard 15D SD Solid Fibres, siliconized finishes are optional, depending on the end-use requirements.
8. Baling and Packing
Once processing is complete, the fibers baled and packaged:
- Each bale typically weighs between 250 kg to 300 kg.
- Fibers compressed, wrapped in plastic or fabric, and labeled with batch information, denier, cut length, and other specifications.
The final bales are then ready for shipment to customers in various industries.
PRODUCT DESCRIPTION
| Product type | Polyesters Staple Fiber |
| Fineness | 15D |
| Cut length | 32mm / 38mm / 51mm / 64mm / 76mm or follow requirements |
| Color | Raw White |
| Pattern | Solid Non-Siliconized |
| Raw Material | 100% PET flakes |
| Grade | Recycled |
| Features | High bulkiness and easy open, excellent tenacity, high resilience and durability, feather touch, light and soft; Environmentally friendly, excellent filling power, anti-static, durable |
| Application | Pillows, blankets, comforter, toys, filling material for bedding, furniture, spray-bonded cotton, polyester wadding, padding, non-woven, filling quilt, cushion, home textile, etc. |
Why Choose 15D SD Fiber?
Manufacturers and product designers choose 15D SD White Fiber for several key reasons:
Cost-Effective: Offers excellent value compared to natural or specialized synthetic fibers is a semi-dull, thick, solid polyester fiber in a clean white color — designed to offer strength, softness, and visual appeal.
Excellent Loft and Bulkiness: Maintains volume and shape over time.
Soft Yet Firm: A perfect balance for cushions, toys, and furniture.
Durability: Holds up well to compression and repeated use.
Easy to Process: Uniform structure makes it easy to blend, cut, and fill.
Hypoallergenic: Suitable for sensitive users, including babies and pets.
Final Thoughts
The manufacturing process of 15D SD Solid Fibres is a sophisticated blend of chemistry, engineering, and precision control. From raw materials to the final baled product, every step carefully tuned to deliver a fiber that meets the highest industry standards for durability, loft, and aesthetic appeal.
Whether you’re a textile mill, a furniture brand, or a nonwoven product manufacturer, understanding how 15D SD Solid Fibres make helps you appreciate the value they bring to your product line.
About Vietnam Recycled Fiber
VIETNAM RECYCLED FIBER partner with numerous factories and manufacturers in Viet Nam and other Asian countries. In general we supply various fiber such as hollow conjugate siliconized and non-siliconized, hollow non conjugated fiber, Solid Fiber, black solid fiber, brown fiber, green fiber, filling fiber, recycled polyester fiber, spinning fiber… All are GRS and OEKO TEX certified.
Our recycled Polyester Staple Fiber is of good quality and competitive price. We are well-known for our excellent customer service and we would like to have long-term business cooperation with customers from all over the world.
Please contact us for long-term cooperation!
Mr. HARRY
Website: vietnamrecycledfiber.com
Youtube: Vietnam Recycled Polyester Fiber
