Impact of nap-processing and weft density on the functionalization and protection properties of polyester uniforms produced with fancy weaves

Purpose One important aspect of a quality work environment is its ability to protect workers from potential hazards while providing comfort, especially during long hours. This study aims to improve the properties of the polyester fabric used for uniforms by enhancing its ultraviolet (UV) protection factor (UPF), reducing electrostatic charge and increasing comfort. Design/methodology/approach Six different samples of polyester woven fabric were manufactured using a yarn count of 150/144 denier for the warp and 300/96 denier for the weft. Honeycomb and Bedford cord structures were performed with three different weft densities, 36, 45 and 55 weft/cm. The napping process was conducted on one side for all fabrics, and several tests were conducted before and after napping, including thickness, weight, tensile strength, elongation, air and water permeability, UPF and electrostatic charges. Findings The results were collected, tabulated and statistically analysed. Three different tools were used, given as follows: Column chart to define the behaviour of produced fabrics at each property; ANOVA test with p-value = 0.05 to indicate the significant and non-significant effects of different parameters; and Radar chart area to rank fabrics and demonstrate the preferable performance. Originality/value According to the investigated study, the produced fabrics were affected by the parameters, where despite the nap process increasing the fluffy surface and promoting airflow, UV protection and electrostatic charge, it aids in deteriorating mechanical properties and relatively reducing absorbency. Additionally, the weft densities are striking in various fabric characteristics and performances relating to the fancy weave structure.