Growth of acrylic fibers tied to penetration of new markets.

The characteristics imparted by the diversity of acrylic fibers have them showing up in a wider spectrum of the fabric market

1990 may be remembered as a watershed year for acrylic fibers at Cytec Industries Inc.

That was the year the company introduced the first - and still only

The revolutionary new fiber, MICROSUPREME[TM] high-tech acrylic fiber, began modestly in the hosiery market, an area where acrylic fibers already had achieved significant success. This success, however, was mainly in athletic footwear where the inherent properties of acrylic made it extremely desirable.

The advent of MICROSUPREME fiber shattered the constraints of this narrow market appeal for acrylic fibers. MICROSUPREME fiber for hosiery was geared to the men's and women's fashion hosiery market and was an instant success. And, this initial triumph opened the door for using acrylic fiber in a wide range of men's, women's and children's apparel. In fact, today 90 percent of MICROSUPREME high tech acrylic fibers is found in new markets. Over the past several years, sales of MICROSUPREME fiber have increased in the range of 60 percent annually and this extraordinary rate of growth is expected to continue this year.

Technology Alliance

To understand better this enthusiastic acceptance for acrylic fibers, it is important to appreciate the alliance of microdenier technology and acrylic fibers and the synergistic benefits it brings to the marketplace. One of the most important features of acrylic fiber is that it transports (or wicks) moisture away from the skin to a garment's outer surface where it evaporates, keeping the wearer more comfortable in both cold and warm weather. This advantage explains the fiber's popularity for athletic socks and other sports apparel.

Through microdenier technology, acrylic fiber has been transformed into a fiber that is finer than silk, which gives it a natural feel. It offers a luxurious appearance, soft hand and superior drape. The fiber produces bright, colourfast fabrics in practically every colour of the rainbow. Being acrylic, these fabrics resist stains, odour and mildew. In addition, the acrylic fibers provide the fabrics with wrinkle resistance and make them easily washable.

Combining microdenier technology with acrylic has given manufactures the opportunity to produce fabrics that offer style, substance and durability features that consumers not only appreciate but demand. Because of these benefits, fabrics made with MICROSUPREME high tech acrylic fibers have moved quickly from the hosiery marketplace to serving practically the entire spectrum of textile fashion mens's, women's and children's apparel, furnishings and accessories, worn from head to toe, morning through night.

Fastest Growing Fiber

Today dresses, sweaters, shirts, all types of outerwear and skiwear, lingerie, loungewear, leisurewear, sleepwear, fashion thermal underwear, robes, gloves, mittens, hats, throw blankets and numerous other textile products are enjoying the benefits of the microfiber. In fact, MICROSUPREME is the fastest growing fiber used in outerwear and skiwear today where consumer acceptance centers around the fabric's plush hand and its innate ability to retain colour and shape. And, pile fabrics provide bulk without weight.

In intimate apparel, leisurewear, thermal underwear and sleepwear, comfort, luxury and sensuousness are important to consumers. Fabrics made with MICROSUPREME fiber score high in these areas, reflecting the versatility of acrylic fiber and its popularity among designers, manufacturers and the consumer.

CYSTAR[TM] Acrylic Fibers

The remarkable success of the microdenier fiber has helped to bring about renewed interest in other acrylic fibers produced by the company. The company's CYSTAR[TM] acrylic is a long-established fiber for knitwear and fleecewear, and its success in athletic socks has been noted previously. Most recently, CYSTAR[TM] AF antimicrobial-processed acrylic fiber was introduced, and as with MICROSUPREME fiber, its first apparel application was in the hosiery market with athletic socks; and its next targeted apparel market is in activewear. This was a logical first choice for the anti-microbial-processed fiber, but its uses are virtually unlimited. Home textiles are using CYSTAR AF fiber in everything from kitchen wipes to blankets, pillows, mattress pads and mops.

The antimicrobial agent inhibits the growth of a broad spectrum of Gram-negative and Gram-positive bacteria, fungi and yeast. The control of these organisms helps to inhibit odour and prevent contamination of the fiber. The agent maintains effectiveness on the fiber even after multiple washing.

Outdoor Applications

Just last year, the company introduced a new family of weather resistant acrylic fibers specifically for outdoor use. The new fibers are resistant to ultra-violet (UV) light degradation.

CYLIGHT[TM] weather resistant acrylic fiber and CYLIGHT Natural weather resistant acrylic fiber produce fabrics that meet the demands of outdoor use from casual furniture and awnings to marine applications and even indoor applications, where exposure to UV light is a concern, such as drapes and furniture. In addition the fibers resist mould, rot, mildew and odour, and most household chemicals, including chlorine.

Once again, the inherent properties of acrylic fiber make it a popular choice among manufacturers and the end user. The fiber is available in a wide range of designer colours. Its versatility was demonstrated recently when, for the first time, a Jacquard fabric for outdoor furniture use was introduced.

CYLIGHT weather resistant acrylic fibers are solution-dyed and produced in a finer denier than the UV-resistant products of any other acrylic producer. This results in more fibers per cross-section in the same yarn count and a stronger, more dense vain which can increase fabric strength and water repellency.

A Natural

CYLIGHT Natural is the only light-stable natural, or white, acrylic designed specifically for outdoor use. As such, it provides a superior base or background for prints and designs. Designs printed on CYLIGHT Natural weather resistant acrylic fiber are non-yellowing and allow prints to maintain their brightness over years of service. Like MICROSUPREME fiber, CYLIGHT Natural is becoming a "designers' choice" weather resistant fiber because of the versatility it offers.

These aggressive incursions into new market areas, initiated with introduction of MICROSUPREME high tech acrylic fiber, have brought the company's acrylic fibers to the forefront among fabric designers and manufacturers, a position of prominence it has never before experienced. And, based on its remarkable successes in recent years, it would appear that future growth of acrylic fiber is virtually unlimited.

The company produces the fibers at its Santa Rosa plant in Milton, FL, where it also has a dedicated fibers technical service laboratory.

RELATED ARTICLE: The Making of Microdenier

What makes MICROSUPREME[TM] microdenier acrylic fiber so special?

Denier plays a significant role. Denier is a combination of fiber length and weight. Fiber is measured in lengths of 9000 meters.

For example, MICROSUPREME high tech acrylic fiber is 0.9 denier which means it weighs 0.9 of a gram in the 9000 meter length. Compare this to acrylic fiber used in athletic socks which is in the range of two to three denier, or cotton which is two denier. Silk is 1.5 denier. With these we are talking about weights of 1.5 to 3.0 grams compared to the 0.9 of a gram for MICROSUPREME fiber. In fact, MICROSUPREME acrylic fiber denier is finer than any natural fiber. Significantly, the lower the denier, the softer the fiber. Carpeting fiber weighs in at around 20 denier and is very coarse. And, if silk is soft, MICROSUPREME fiber is softer, much softer.

Softness is just one of many features of microdenier fibers. Other advantages, which include better moisture transport (especially with acrylic microdenier fibers) and strength can be attributed to the production process.

The main difference in microdenier fiber production, compared with other fiber production, is that the microdenier process, in the same manufacturing time frame, produces two-and-one-half times as many filaments. That means there are significantly more filaments for the same weight. Therefore, the diameter of the fiber is extremely small and more tightly packed. It is through this microdenier process that advantages of softer hand, improved moisture transport, and stronger yarn are imparted to MICROSUPREME high tech acrylic fiber.

RELATED ARTICLE: Cytec's Acrylic Fibers for Industry

The vast majority of acrylic fiber produced by Cytec is used to make fabrics for clothing, furniture and other consumer items. But, the fiber also has industrial uses, and the upward growth for Cytec's acrylic fiber in industrial applications began in 1988.

In that year the company introduced a new, highly fibrillated acrylic fiber known as CFF[R] fibrillated fiber. This fiber now has a wide range of applications from non-wovens to friction material and serves as a high-efficiency, high-strength, thermally-stable binder.

Advancement in fibrillation technology allowed the fiber to be used in high-performance applications for the first time. The new fiber contains more than 90 percent polyacrylonitrile, has no surface finish or other additives and only a slightly anionic surface charge.

The fiber was developed specifically to replace asbestos as a processing aid and immediately found acceptance as a friction material used in brakes both in aftermarket and OEM applications.

Once again, versatility has been a reason for the fiber's success. In addition to CFF fibrillated fiber, the company recently introduced a new family of acrylic fibers known as CPF processing fibers. These fibers can be tailored to meet specific customer requirements and this has led to uses in new and diverse product applications such as gaskets and specialty papers used for filtration. Currently, the product is being used in the automotive, industrial filtration, aerospace, military and off-highway equipment industries, among others.

Cytec's acrylic fibers for industrial use also have experienced significant growth in the first half of this decade.

David A. Lyttle is the Director, Sales and Marketing, Fibers Business at Sterling Chemicals Inc, West Paterson, NJ. Sterling recently purchased the acrylic fibers business of Cytec Industries Inc.