Regular rayon (or viscose) is the most widely produced form of rayon.

This method of rayon

production has been used since the early 1900s and it has the ability to produce either filament or
staple fibers. The process is as follows:
1. Cellulose: Production begins with processed cellulose(obtained from wood pulp and plant
fibers).
2. Immersion: The cellulose is dissolved in caustic soda: (C6H10O5)n + nNaOH
(C6H9O4ONa)n + nH2O
3. Pressing: The solution is then pressed between rollers to remove excess liquid
4. White Crumb: The pressed sheets are crumbled or shredded to produce what is known as
"white crumb"
5. Aging: The "white crumb" is aged through exposure to oxygen
6. Xanthation: The aged "white crumb" is mixed with carbon disulfide in a process known as
Xanthation, the aged alkali cellulose crumbs are placed in vats and are allowed to react with
carbon disulfide under controlled temperature (20 to 30 C) to form cellulose xanthate:
(C6H9O4ONa)n + nCS2 (C6H9O4O-SC-SNa)n
7. Yellow Crumb: Xanthation changes the chemical makeup of the cellulose mixture and the
resulting product is now called "yellow crumb"
8. Viscose: The "yellow crumb" is dissolved in a caustic solution to form viscose
9. Ripening: The viscose is set to stand for a period of time, allowing it to ripen: (C 6H9O4O-SCSNa)n + nH2O (C6H10O5)n + nCS2 + nNaOH
10.Filtering: After ripening, the viscose is filtered to remove any undissolved particles
11. Degassing: Any bubbles of air are pressed from the viscose in a degassing process
12.Extruding: The viscose solution is extruded through a spinneret, which resembles a shower
head with many small holes
13.Acid Bath: As the viscose exits the spinneret, it lands in a bath of sulfuric acid, resulting in
the formation of rayon filaments: (C6H9O4O-SC-SNa)n + nH2SO4 (C6H10O5)n+ nCS2 +
nNa2SO4

14.Drawing: The rayon filaments are stretched, known as drawing, to straighten out the fibers
15.Washing: The fibers are then washed to remove any residual chemicals
16.Cutting: If filament fibers are desired the process ends here. The filaments are cut down
when producing staple fibers[1]
High wet modulus rayon (HWM) is a modified version of viscose that has a greater strength when
wet. It also has the ability to be mercerized like cotton. HWM rayons are also known as "polynosic".
Polynosic fibers are dimensionally stable and do not shrink or get pulled out of shape when wet like
many rayons. They are also wear resistant and strong while maintaining a soft, silky feel. They are
sometimes identified by the trade name Modal.[9]
High-tenacity rayon is another modified version of viscose that has almost twice the strength of
HWM. This type of rayon is typically used for industrial purposes such as tire cord. [9]
Cuprammonium rayon has properties similar to viscose but during production, the cellulose is
combined with copper and ammonia (Schweizer's reagent). Due to the environmental effects of this
production method, cuprammonium rayon is no longer produced in the United States.[9]

To make rayon, sheets of purified cellulose are steeped in caustic soda, dried, shredded into crumbs, and then
aged in metal containers for 2 to 3 days. The temperature and humidity in the metal containers are carefully
controlled.

After ageing, the crumbs are combined and churned with liquid carbon disulfide, which turns the mix into
orange-colored crumbs known as sodium cellulose xanthate. The cellulose xanthate is bathed in caustic soda,
resulting in a viscose solution that looks and feels much like honey.

While there are many variations in the manufacturing process that exploit the versatility
of the fiber, the following is a description of the procedure that is used in making regular
or viscose rayon.
Regardless of whether wood pulp or cotton linters are used, the basic raw material for
making rayon must be processed in order to extract and purify the cellulose. The
resulting sheets of white, purified cellulose are then treated to form regenerated
cellulose filaments. In turn, these filaments are spun into yarns and eventually made into
the desired fabric.

Processing purified cellulose

1 Sheets of purified cellulose are steeped in sodium hydroxide (caustic soda),

which produces sheets of alkali cellulose. These sheets are dried, shredded into
crumbs, and then aged in metal containers for 2 to 3 days. The temperature and
humidity in the metal containers are carefully controlled.

2 After ageing, the crumbs are combined and churned with liquid carbon
disulfide, which turns the mix into orange-colored crumbs known as sodium
cellulose xanthate. The cellulose xanthate is bathed in caustic soda, resulting in a
viscose solution that looks and feels much like honey. Any dyes or delusterants in
the design are then added. The syrupy solution is filtered for impurities and
stored in vats to age, this time between 4 and 5 days.

Producing filaments

3 The viscose solution is next turned into strings of fibers. This is done by forcing
the liquid through a spinneret, which works like a shower-head, into an acid bath.
If staple fiber is to be produced, a large spinneret with large holes is used. If
filament fiber is being produced, then a spinneret with smaller holes is used. In
the acid bath, the acid coagulates and solidifies the filaments, now known as
regenerated cellulose filaments.

Spinning

4 After being bathed in acid, the filaments are ready to be spun into yarn.
Depending on the type of yarn desired, several spinning methods can be used,
including Pot Spinning, Spool Spinning, and Continuous Spinning. In Pot
Spinning, the filaments are first stretched under controlled tension onto a series
of offsetting rollers called godet wheels. This stretching reduces the diameter of
the filaments and makes them more uniform in size, and it also gives the
filaments more strength. The filaments are then put into a rapidly spinning
cylinder called a Topham Box, resulting in a cake-like strings that stick to the
sides of the Topham Box. The strings are then washed, bleached, rinsed, dried,
and wound on cones or spools.
Spool Spinning is very similar to Pot Spinning. The filaments are passed through
rollers and wound on spools, where they are washed, bleached, rinsed, dried,
and wound again on spools or cones.
In Continuous Spinning, the filaments are washed, bleached, dried, twisted, and
wound at the same time that they are stretched over godet wheels.

5 Once the fibers are sufficiently cured, they are ready for post-treatment
chemicals and the various weaving processes necessary to produce the fabric.
The resulting fabric can then be given any of a number of finishing treatments.
These include calendaring, to control smoothness; fire resistance; pre-shrinking;
water resistance; andwrinkle resistance.

are synthetic fibers made from a polymer (polyacrylonitrile) with an average molecular
weight of ~100,000, about 1900 monomer units. To be called acrylic in the U.S, the
polymer must contain at least 85% acrylonitrile monomer. Typical comonomers are vinyl
acetate or methyl acrylate. The Dupont Corporation created the first acrylic fibers in
1941 and trademarked them under the name "Orlon".

Raw Material
Acrilonitrile is the main main raw material for the manufacture of acrylic fibres. It is made
by different methods. In one commercial method, hydrogen cyanide is treated with
acetylene:
1st Method
Acetylene + Hydrogen cyanide --> Acrilonitrile
2nd Method
Ethylene--Air Oxidation--> Ethylene oxide + HCN--> Ethylene cyanahydrin--Dehydration
at 300 deg C (catalyst)--> Acrylonitrile

Production Process of Acrylic Fiber

The acrylic process is a "one step technology", with the following main characteristics:
1.

Polymerization in solution

2.

Direct feeding of the dope to spinning

3.

Wet spinning

4.

DMF as solvent for both polymerization and spinning

Production Process of Acrylic Fiber

In a continuous polymerisation process, 95% acrylonitrile and 6% methyl acrylate (400
parts) 0.25% aqueous solution of K2S2O8(600 parts), 0.50 % Na2S2O5 solution ( 600
Parts) and 2N sulphuric acid (2.5 Parts) are fed into the reaction vessel at 52 deg C
under nitrogen atmosphere giving a slurry with 67% polymer. The slurry is continuously
withdrawn, filtered and washed till it is free from salts and dried.
Acrilonitrile is dry spun. The material is dissolved in dimethyl formamide, the solution
contains 10-20 polymers. It is heated and extruded into a heated spinning cell. A heated
evaporating medium such as air, nitrogen or steam moves counter current to the travel
of filaments and removes the solvent to take it to a recovery unit. The filaments are hot
stretched at 100 to 250 C depending on the time of contact in the hot zone, to several
times their original length.

Properties of Acrylic Fibers

1.

Acrylic has a warm and dry hand like wool. Its density is 1.17 g/cc as compared
to 1.32 g/cc of wool. It is about 30% bulkier than wool. It has about 20% greater
insulating power than wool.

2.

Acrylic has a moisture regain of 1.5-2% at 65% RH and 70 deg F.

3.

It has a tenacity of 5 gpd in dry state and 4-8 gpd in wet state.

4.

Breaking elongation is 15% ( both states)

5.

It has a elastic recovery of 85% after 4% extension when the load is released
immediately.

6.

It has a good thermal stability. When exposed to temperatures above 175 deg C
for prolonged periods some discolouration takes place.

7.

Acrylic shrinks by about 1.5% when treated with boiling water for 30 min.

8.

It has a good resistance to mineral acids. The resistance to weak alkalies is fairly
good, while hot strong alkalies rapidly attack acrylic.

9.

Moths, Mildew and insects do not attack Acrylic.

10.

It has an outstanding stability towards commonly bleaching agents.

Uses of Acrylic Fiber

1.

Knit Jersey, Sweater, blankets

2.

Wrinkle resistant fabrics.

3.

Pile and Fleece fabrics

4.

Carpets and rugs.

Precaution of Acrylic Fiber

Wash delicate items by hand in warm water. Static electricity may be reduced by
using a fabric softener in every third or fourth washing. Gently squeeze out water,
smooth or shake out garment and let dry on a non-rust hanger. (Sweaters,
however, should be dried flat.)

When machine washing, use warm water and add a fabric softener during the
final rinse cycle.

Machine dry at a low temperature setting. Remove garments from dryer as soon
as tumbling cycle is completed.

If ironing is required, use a moderately warm iron. (For specific instructions, refer
to garment's sewn-in care label.)

Polyester is a synthetic fiber derived from coal, air, water, and petroleum. Developed in a
20th-century laboratory, polyester fibers are formed from a chemical reaction between
an acid and alcohol. In this reaction, two or more molecules combine to make a large
molecule whose structure repeats throughout its length. Polyester fibers can form very
iong molecules that are very stable and strong.
Polyester is used in the manufacture of many products, including clothing, home
furnishings, industrial fabrics, computer and recording tapes, and electrical insulation.
Polyester has several advantages over traditional fabrics such as cotton. It does not
absorb moisture, but does absorb oil; this quality makes polyester the perfect fabric for
the application of water-, soil-, and fire-resistant finishes. Its low absorbency also makes

it naturally resistant to stains. Polyester clothing can be preshrunk in the finishing

process, and thereafter the fabric resists shrinking and will not stretch out of shape. The
fabric is easily dyeable, and not damaged by mildew. Textured polyester fibers are an
effective, nonallergenic insulator, so the material is used for filling pillows, quilting,
outerwear, and sleeping bags.
Polyester is a chemical term which can be broken into poly, meaning many, and ester, a
basic organic chemical compound. The principle ingredient used in the manufacture of
polyester is ethylene, which is derived from petroleum. In this process, ethylene is
the polymer, the chemical building block of polyester, and the chemical process that
produces the finished polyester is called polymerization.

The Manufacturing
Process
Polyester is manufactured by one of several methods. The one used depends on the
form the finished polyester will take. The four basic forms are filament, staple, tow, and
fiberfill. In the filament form, each individual strand of polyester fiber is continuous in
length, producing smooth-surfaced fabrics. In staple form, filaments are cut to
short, predetermined lengths. In this form polyester is easier to blend with other fibers.
Tow is a form in which continuous filaments are drawn loosely together. Fiberfill is the
voluminous form used in the manufacture of quilts, pillows, and outerwear. The two
forms used most frequently are filament and staple.

Manufacturing Filament Yarn

Polymerization

1 To form polyester, dimethyl terephthalate is first reacted with ethylene glycol in the
presence of a catalyst at a temperature of 302-410F (150-210C).

2 The resulting chemical, a monomer (single, non-repeating molecule) alcohol, is

combined with terephthalic acid and raised to a temperature of 472F (280C). Newlyformed polyester, which is clear and molten, is extruded through a slot to form long
ribbons.

Drying

3 After the polyester emerges from polymerization, the long molten ribbons are allowed
to cool until they become brittle. The material is cut into tiny chips and completely dried
to prevent irregularities in consistency.

Melt spinning

4 Polymer chips are melted at 500-518F (260-270C) to form a syrup-like solution. The
solution is put in a metal container called a spinneret and forced through its tiny holes,
which are usually round, but may be pentagonal or any other shape to produce special
fibers. The number of holes in the spinneret determines the size of the yarn, as the
emerging fibers are brought together to form a single strand.

5 At the spinning stage, other chemicals may be added to the solution to make the
resulting material flame retardant, antistatic, or easier to dye.

Drawing the fiber

6 When polyester emerges from the spinneret, it is soft and easily elongated up to five
times its original length. The stretching forces the random polyester molecules to align in
a parallel formation. This increases the strength, tenacity, and resilience of the fiber. This
time, when the filaments dry, the fibers become solid and strong instead of brittle.

7 Drawn fibers may vary greatly in diameter and length, depending on the characteristics
desired of the finished material. Also, as the fibers are drawn, they may be textured or
twisted to create softer or duller fabrics.

Winding

8 After the polyester yarn is drawn, it is wound on large bobbins or flat-wound packages,
ready to be woven into material.

Manufacturing Staple Fiber

In making polyester staple fiber, polymerization, drying, and melt spinning (steps 1-4
above) are much the same as in the manufacture of filament yarn. However, in the melt
spinning process, the spinneret has many more holes when the product is staple fiber.
The rope-like bundles of polyester that emerge are called tow.

Drawing tow

1 Newly-formed tow is quickly cooled in cans that gather the thick fibers. Several lengths
of tow are gathered and then drawn on heated rollers to three or four times their original
length.

Crimping

2 Drawn tow is then fed into compression boxes, which force the fibers to fold like an
accordion, at a rate of 9-15 crimps per inch (3-6 per cm). This process helps the fiber
hold together during the later manufacturing stages.

Setting

3 After the tow is crimped, it is heated at 212-302F (100-150C) to completely dry the
fibers and set the crimp. Some of the crimp will unavoidably be pulled out of the fibers
during the following processes.

Cutting

4 Following heat setting, tow is cut into shorter lengths. Polyester that will be blended
with cotton is cut in 1.25-1.50 inch (3.2-3.8 cm) pieces; for rayon blends, 2 inch (5 cm)
lengths are cut. For heavier fabrics, such as carpet, polyester filaments are cut into 6
inch (15 cm) lengths.

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