Polar Fleece - Fantastic Addition To Your Winter Closet

The Polar Fleece fabric is a fantastic addition to your winter closet. Its extreme versatility provides you warmness and different levels of comfort. It is used to make sweaters, jackets, hoodies, blankets, hats, sweatpants, cloth diapers, and best outdoor clothing. It imparts you a professional as well as a casual look, which is perfect to wear in the office, cold morning walks, or sitting comfortably on your couch. This fabric is washable and easy to dry. The Polar fleece is considered warmer than the natural wool, even though most of the qualities of this fabric are similar to the wool, but it light in weight.

THE MANUFACTURING PROCESS:

Polyester, made from two petroleum products, terephthalic acid, and ethylene glycol, the Polyester yarn made from recycled plastic bottles, different dyes, and some waterproofed chemicals are required for the manufacturing of the Polar Fleece fabric.

1. POLYESTER PRODUCTION: Polyester is manufactured by heating terephthalic acid and ethylene glycol. Both the chemicals are heated into a vat, at 150-210℃. From the heating of the two compounds, Dihydroxy diethyl terephthalate is created, which is then pumped into an autoclave, and again heated at 280℃. The chemical is then transformed into a Polyester. When it is cooled, it makes a viscous liquid. The liquid is then ejected through a nozzle, dried and fragmented into chips.
2. SPINNERET: The polyester chips are heated again into another vat at 260-270℃, forming a hot liquid. The hot fluid is thrust out through smaller holes in a metal disk called a Spinneret. After taking it out from the spinneret, it is hardened into a fiber foam. A thick rope called Tow is formed after the fibers are wound onto a heated pool.
3. PET CONTAINERS: Recycled bottles are collected by the yarn manufacturers to make polyester. The bottles are inspected fully, non-PET caps or bases, foreign objects, or any unwanted material is removed. The final product is Polyethylene terephthalate (PET) bottles. It is then moved into a sterilizing bath. The clean bottles are then dried and squeezed into tiny chips. After rewashing the chips, the light-colored form of it is then bleached. They are also emptied into the vat and heated and forced into spinnerets.
4. CRIMPING AND DRAWING: The tow from the pool is then dragged through the heated rollers of a drawing machine three to four times of its native length. Pulling increases the strength of the fiber, and aids in setting the crystalline structure of PET molecules into smooth rings. The tow then moves into a crimping machine that flattens the tow and provides a crinkled and accordion-like texture. The crimped tow is then dried and penetrated lengths of few inches, forming a short, fluffy, and hairy fiber, just like wool.
5. YARN SPINNING: The fibers are then inspected for their strength and thickness. It is also passed into a carding machine which orients the thread into thick and rope-like strands. The strands are then coiled into an open container. The thick robes are put into a spinning machine, where the strands are twisted into a fine diameter. The produced yarn is collected from the spinning device onto large spools.
6. DYEING: The yarn is then submerged into heated dye vats in the Dyehouse. The yarn could be dark hue, bleached white, and could be dyed into desired colors. The yarn is then fed into the drying machine by the workers.
7. KNITTING: In a circular knitting machine, the dried yarn is fed. The knitting machine knits the yarn into a continuous tube of cloth. The tube could be several hundred yards long.
8. NAPPING AND SHEARING: The knitted yarn is then fed into a napper to get a fuzzy texture. After it, the cloth is passed to the shearing machine, to cut the fibers with the help of a precision blade. 
9. FINISHING: The fabric is then waterproofed. Some chemical finishers are used to set the texture. The polar fleece fabric suppliers send the the material according to the customer needs, the cut they want, or the patterns.