The effect of core materials produced by intermingling technique on hybrid yarn and fabric performance

Purpose Stretchable dual-core yarns have obtained attention in denim fabric manufacturing to enrich stretch properties, comfort and overall performance. This study aims to explore the development of yarns using various filaments and their influence on yarn and fabric performance. It investigates the characteristics of three types of yarns with similar counts and fabrics produced from them. Design/methodology/approach The yarns were manufactured using a revised ring-spinning setup, where the core materials (polybutylene terephthalate [PBT], polyester [PES], and T400®) were intermingled with elastane. One-way analysis of variance (ANOVA) was applied as a statistical tool to evaluate the significant variations in yarn and fabric performance by considering all core elements. Findings This study revealed significant differences in the strength, elongation and other performance metrics of both yarn and fabric based on the type of filament used. Practical implications This study suggests that selecting PES as the core filament can optimize fabric characteristics such as high strength, while PBT may be preferred where superior elasticity is required. These insights can guide manufacturers in selecting suitable core materials for targeted denim performance. Originality/value This research presents a clear analysis of three specific dual-core yarn structures and demonstrates how core filament selection directly affects both yarn and fabric performance parameters.