Multi-response optimization of physical and mechanical properties of modified polyester/cotton doubled yarn using the desirability function approach

Purpose This study investigates the impact of blend proportion, twist multiplier and linear density on the physical and mechanical properties of polyester/cotton doubled yarns. It explores the structural changes and property modifications resulting from the dissolution of the cotton component to optimise the yarn for enhanced performance. Design/methodology/approach Using a Box–Behnken factorial design, 15 yarn samples were prepared and their properties, including unevenness, hairiness, strength, compressibility and packing fraction, were evaluated before and after cotton dissolution. The desirability function optimisation technique was employed to determine the optimal parameters for maximising overall yarn quality. Findings The study reveals that blend proportion, twist multiplier and linear density significantly influence yarn properties. After treatment, improvements were observed in unevenness, hairiness and compressibility, albeit with a reduction in strength. The desirability values for untreated (0.777) and treated (0.730) yarns were nearly identical, indicating that optimised treated yarns can achieve comparable overall performance. Originality/value This research highlights the novel use of cotton dissolution to introduce porosity in yarns, enhancing their suitability for sportswear applications. The findings contribute to advancing yarn design for optimised comfort and performance, leveraging statistical optimisation for multi-response challenges.