Fibre Modification
Non-spinnable short by-products from flax scutching undergo mechanical or chemical processing to make them compatible with cotton spinning machinery. The production of cottonized flax tow involves removing the natural lignin and pectin binders that hold individual flax fibres together in bundles. This treatment reduces both the average length and the diameter of the fibres, allowing them to be blended with cotton or synthetic materials on high-speed rotors.
Refining Mechanism
Coarse flax waste is passed through a sequence of carding zones and chemical baths that split the heavy bundles. The resulting cottonized flax tow must match the staple length of cotton to prevent yarn breaks during the subsequent carding and drafting steps. Quality control labs test the modified fibre for residual shive content and fibre fineness, recording the results on the mill batch certificate.
When the average fibre length falls below twenty-five millimetres, the material is graded for industrial non-woven applications rather than apparel yarns.
Blending Parameter
Finished bales are weighed and checked for moisture regain before being delivered to the spinning line. The blending parameter dictates the exact ratio of the modified fibre to cotton in the final yarn mix. This limit is critical for maintaining the tensile strength of the blended yarn.