What is Bulk Continuous Filament Yarn?
Summary
Bulk continuous filament yarn is commonly used to produce rugs and carpets. This article looks at Bulk Continuous Filament yarn or BCF yarn, including nylon BCF yarn and polyester BCF yarn.
Classification of BFC yarn and Staple Yarn
There are basically two main types of fibre systems that are used to manufacture carpets and rugs. These are Bulk Continuous Filament yarn (BCF yarn) and staple yarn.
Staple yarn – Staple yarn is produced in filaments of short lengths, which are then spun and twisted together (like cotton for example) to create long threads of yarn. These are then, in turn, tufted into the desired carpet or rug.
BCF yarn – BCF Yarn, including nylon BCF yarn and polyester BCF yarn, is manufactured from one continuous and long strand of fibre. The use of these long and continuous fibres give BFC yarns its name. These continuous filaments of yarn are then twisted together to form yarn or fibre strands that are then further used to create or make sections of rugs or carpets.
Nylon and polyester can be manufactured as both staple and BCF yarns. Cotton and wool, on the other hand, inherently staple, meaning that they can only be produced in staple form. Both triexta (PTT) and olefin (polypropylene) are made in BCF only.
Manufacturing BFC yarn
When Manufacturing Bulk Continuous Filament yarns or BCF yarns, instead of creating multiple 7-inch or 8-inch lengths of strands, as in the production of staple yarn, the continuous filament is made to extrude as one long string. These extruded strings are then twisted together and heat set to form strands of yarn. The yarn can also be texturized to curl, or kink, which, in addition to increasing the bulk of the yarn, gives it more memory that in turn helps in better texture retention as well as wear resistance.
Few Benefits of BFC Yarns
· Lack of Shedding –
One of the main advantages of BCF yarn, including nylon BCF yarn and polyester BCF yarn, is the fact that rugs or carpets made from these fibres will not shed loose fibres as in the case of staple yarn. However, Carpets or rugs made from staple yarn will show an initial period of shedding, meaning that the carpet or rug will shed loose fibres, however, the amount of shedding will reduce in two or three weeks. One must note that the shedding is not indicative of poor quality of carpet. However, carpets and rugs manufactured using BFC Yarns are hypoallergic and kid-friendly.
· Quick and Cost-effective Manufacturing
Owing to evolution in the manufacturing of BFC yarns, it is now more cost-effective and faster to manufacture BCF yarn, including nylon BCF yarn and polyester BCF yarn. Moreover, the use of continuous yarns filaments reduced the production steps and effort over staple yarns.
· Captivating textures and patterns –
One of the main advantages of BCF fibres is the fact that BCF yarn has allowed manufacturers of carpet and rug producers to create filament textures and looks that were not possible to attain in the past. BCF yarns can be used in producing multi-colour products and highly twisted panels, which require less uniformity and offer a captivating outcome.
When purchasing a carpet or rug, it is good to be aware of both BFC and Staple yarn features and benefits to ensure one makes an educated choice. However, both the forms of filaments have their own advantages and the choice between the two is based solely on personal preference.