Sewing Threads are used for sewing, mainly in the textile sector. Depending on the respective application, different parameters determine the properties of a sewing thread. The application of the sewing threads ranges from simple household sewing machines to complex premium sewing constructions for the (large) industrial sector.
Sewing Thread Construction
After selecting the raw material, the properties of a sewing thread are determined by the following parameters:
- Construction Type
While the construction of the yarn defines the individual thread type, twist, ply and cord define the general construction parameters for all sewing threads. The same applies for embroidery threads.
Selection of raw materials
Textile fibers are available as staple fibers or as filaments. According to their origin, they are divided into natural fibers and industrially manufactured man-made fibers. Often - depending on their intended use - the respective positive properties of the individual fiber groups are combined by a targeted mixture of the two.
- natural fibres
- chemical fibres
The construction type is defined based on the different processing methods of the fibres and filaments (schappe or cut staple spuns, smooth continuous filaments, monofilaments, texturised filaments) and their combination. It is important to point out that the construction types are described based on the structure of a single yarn. In general, however, a finished sewing thread consists of two or multiple single yarns,which are twisted together.
With this type of sewing thread the single yarns consist of short, cut staple fibres, twisted together to form a thread. The most frequently used raw materials for this construction type are cotton, polyester and aramids. While natural fibres have a limited length (staple fibres), synthetic fibres are available either as cut staple or as schappe spuns. The filaments of schappe spuns are pulled lengthwise and break at the weak points. This results in irregularly long fibres (20 to 70 mm) with fibre ends of varying thickness. The surface of spun threads is very smooth. In case of cut staple spuns, the filaments are cut to a uniform length (approx. 40 mm, e. g. based on the model of high-quality cotton). The cutting of the fibres results in smooth and equally thick fibre endings. The spun thread obtains a textile look. 28 Cotton spun threads are primarily used for special applications in the apparel sector. The cotton sewing thread in the AMANN product range is MercifilGD. For technical applications, there are synthetic fibre yarns made of para- or meta-aramide. Well-known AMANN products: K-tech and N-tech.
Core spun thread
With core spun threads, the single yarns consist of a continuous filament core surrounded by fine fibres. In sewing thread production, this finished hank is called core yarn. The ratio of core to cover is usually two thirds to one third (the core is sheathed but not fully covered). This can vary according to the specific application field of the sewing thread. The continuous filaments that form the core are usually made from polyester. Very occasionally other raw materials may be used. The spun cover is made of polyester or cotton fibres. A polyester core with polyester cover would be referred to as a polyester/polyester core spun, whilst a polyester core with a cotton cover would be called polyester/cotton core spun. Polyester/polyester core spun threads may have a cut staple or schappe spun cover. The latter is however seldom in use today. Almost all polyester/polyester core spun threads have a cover of polyester cut staple spuns that are cut to a length of 40 mm to match high-quality cotton.
Like spun threads, core spun threads have a smooth and textile surface. Thanks to the combination of continuous filament core and spun cover, core spun threads are extremely high performing. Breaking strength and abrasion resistance are higher in comparison with spun threads. Core spun threads display an outstanding sewability and this provides for trouble-free processing, even in difficult applications such as multidirectional sewing operations and buttonholes in thin fabrics. Therefore, core spun threads are well suited for a huge spectre of applications. The polyester/polyester core spun thread Saba is among the most important products in the AMANN range of products. Rasant is AMANN's polyester/cotton core spun thread.
The single yarns are made of endless fibres (filaments) for continuous filament threads. Partially, up to 200 single filaments make up a single yarn (continuous filament). Raw materials are primarily polyester and polyamide, for technical applications other raw materials like aramids, polyethylene, polytrimethylenterephthalate, polypropylene and polyetheretherketone are used. While the coarser sizes are usually of 3-ply construction, the finer qualities mostly have 2-ply constructions (see Sewing Thread Construction/Ply). Thanks to their construction continuous filaments have a smooth, glossy surface and a consistent thread character. Furthermore, they display a very high breaking strength and abrasion resistance.
Continuous filaments are mainly used for Shoes & Accessories, Home Interior and Techtex. The main products in the AMANN product range: Serafil (polyester continuous filament) and Onyx (polyamide continuous filament). For Techtex: Nc-tech, Kc-tech, C-tech, I-tech, Zyex®. The apparel industry generally utilises only the finer counts. The major field of application here are overlock seams for cut edges and blindstitch seams. Continuous filaments made of trilobal polyester are a classic construction type for embroidery threads. The trilobal filament shape enlarges the light-reflecting material surface and ensures that the finished embroidery design has the desired gloss. Well-known AMANN products: Isacord
Continuous filament, texturised
For this construction type continuous filaments are crimped by a false twisting process. These texturised continuous filaments are mainly made of polyester or polyamide and are bulgy and bulky. Hence, they are often referred to as “bulk yarns”. The crimping of the continuous filaments also provides for a soft grip, a matt look and a high yarn or thread elasticity. Due to their special properties, typical fields of application are serging and flatlock seams in underwear and apparel production as well as edge covering of carpets. Well-known AMANN products: Sabatex.
Continuous filament, braided
In order to obtain a braided continuous filament, 12 to 16 filament yarns (continuous filament bundle) – depending on the ticket size of the finished thread – are wound together on so-called clappers in a circular weaving process. Therefore, it takes longer to produce a braided thread (18 times longer than the production time of a comparable non-braided continuous filament thread). Polyester is the most commonly used raw material for braided continuous filaments.
Thanks to their construction and the continuous filaments in use, braided continuous filaments have a smooth and decorative surface. They have excellent breaking strength and abrasion resistance. Braided continuous filament threads are used for decorative seams on shoes, upholstery and leather products. Because of their special construction type they accentuate the seam. AMANN's braided polyester continuous filament is Serabraid.
Continuous microfilament, texturised
For specially soft seams, a texturised polyester microfilament is recommended. Due to the multitude of fine filaments, the sewing thread becomes extremely soft and smooth, and the seams are barely noticeable. Well-known AMANN products: Sabasoft
Important: The filaments for sewing threads differ significantly from those for applications in 3D printing.
Sewing and Embroidery Production
The production of sewing and embroidery threads is a complex process comprising a number of production steps on different machines and production plants. The production diagram at the end of this chapter shows an overview of the main sewing and embroidery thread types in AMANN's production. In contrast to the general sewing industry, which is generally labour-intensive due to the operation of sewing machines, sewing thread production predominantly involves a high level of machine utilisation. Ultra-modern and often computer-controlled, fully automated production plants characterise the manufacturing process.
The production staff are required mainly for the feeding and cleaning of the machines. The production control is usually fully automated throughout most production steps. Malfunctions are detected by automatic sensors and remedied by the staff. Many production steps have long lead times. In contrast to the apparel production, for example, which calculates in minutes, some positions in the sewing thread production have lead times of several hours, sometimes even days. An optimised process scheduling and controlling is therefore essential for sewing thread production.
Today, sewing thread production refers to the processing of synthetic or partly synthetic preliminary products. Apart from few exceptions, threads completely made from natural fibres are of minor importance nowadays. Because cotton thread is the most important article it is included here in the production diagram at the end of this chapter as well as in the description of the production steps. The production methods for each sewing thread type (core spun thread, spun thread, continuous filaments, texturised continuous filaments, etc.) differ in their process chain and in specific production steps, which are necessary only for specific sewing thread types.
Manufacturer of sewing threads
The AMANN Group is a globally active manufacturer of industrial, sewing and embroidery threads and smart yarns. The company's headquarters are located in Bönnigheim in Baden-Württemberg. From universal sewing thread to high-tech special thread, AMANN offers a wide range for a variety of applications. In Germany, AMANN is the market leader in the industrial sector, AMANN is one of the three largest producers worldwide. In 2019, the company reported sales of EUR 190 million and 2,300 employees.
A&E Gütermann acts as part of Elevate Textiles, INC. Group that operates in both the United States, Mexico and China. Elevate Textiles is a portfolio company of Platinum Equity and therefore an association of different textile brands. With a global product range of fabric and sewing thread solutions, you deal with different areas of application.
Coats is a British company with German roots. Coats employs approximately 18,000 people in around 500 countries. Coats has a wide range of products, from sewing thread to medical seams and fiber optic cables.
Fairs for textiles & sewing threads
- Texprocess - At Texprocess, international exhibitors present the latest machines, systems, processes and services for the assembly of clothing as well as textile and flexible materials. Techtextil, the leading international trade fair for technical textiles and nonwovens, takes place parallel to Texprocess.
- Techtextil - At Techtextil in Frankfurt am Main, international exhibitors show the entire spectrum of technical textiles, functional clothing textiles and textile technologies. Texprocess, the leading trade fair for the clothing and textile processing industry, takes place parallel to Techtextil.
- IILF- The IILF (India International Leather Fair) in Chennai hosts an international trade fair for leather goods every year. Industry focus is leather, leather goods, shoes, leather and shoe machines. The main focus of the offer ranges from leather processing machines to leather aids, sewing machines and handbags, as well as fur skins and tools.
- Cisma - The Cisma (China International Sewing Machinery & Accessories Show) is an international exhibition for sewing machines and accessories. The branches of the trade fairs are textile machines and clothing machines and the product groups sewing machines, clothing machines and accessories, fabrics, CAD / CAM and media.
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