Akra Closing Impacts Two-Step Polyester Type 161 Yarns

Introduction:

The recent closure of Alfa Group's polyester business, including the Akra Monterrey plant, has left a significant gap in the supply of type 161 polyester, also known as two step yarn. While most of Akra's industrial polyester production can be easily replaced with Asian yarns, the 2 Step production of type 161ST presents a unique challenge. In this blog, we will delve into the properties of two step yarns, the niche market it serves, and explore potential alternatives that require heavy investment and adjustments in the manufacturing process.

According to the news release by Alfa Group, the closure of the Akra Monterrey plant is primarily driven by the overwhelming competition from Asian production. While most of Akra's industrial polyester production can be replaced with Asian yarns, the discontinuation of the 2 Step production of type 161ST poses a significant challenge. This specialty product offers a unique combination of low elongation and low shrinkage, making it difficult to find direct alternatives.

Properties and Niche Market of Type 161ST Fiber Yarn:

Two step yarns, such as type 161ST, are known for their exceptional properties of low elongation and low shrinkage. These properties are inversely related during the extrusion process, and the second step involves subjecting the yarns to high tension and heat to eliminate shrinkage while minimizing elongation at break. This unique combination of properties makes type 161ST suitable for the niche Mechanical Rubber Goods (MRG) market, particularly for rubber hoses and belt applications.

Limited Alternative Suppliers:

The type 161ST product line is challenging to replace, as there are only two other producers in the world, both located in Germany. To find alternatives, manufacturers must be prepared for heavy investments and/or mandatory changes in the way rubber hoses are manufactured.

Potential Alternative Solutions:

1. Hose Manufacturing: Manufacturers can consider constructing hoses that can accommodate a different set of properties. High Modulus Low Shrinkage (HMLS) one step yarns offer properties that closely resemble those of 2 Step yarns. Although they have higher shrinkage and elongation, adjusting the hose manufacturing process might enable the use of HMLS yarns as a viable alternative.

2. Heat Treating Investment: HMLS yarns are often single-end heat treated to meet the properties of 2 Step yarns. This heat treatment process, similar to the second step in 2 Step yarn production, can help achieve the challenging combination of low elongation and low shrinkage. However, implementing this option requires significant investment and modifications to the manufacturing process.

Time and Considerations:

It is important to note that these alternative options will require time and careful consideration. Manufacturers must assess the impact on production timelines, costs, and overall feasibility before implementing any changes. Collaboration with alternative suppliers and experts in the field can provide valuable insights and guidance during this transition.

Conclusion:

The closure of the Akra Monterrey plant and the subsequent unavailability of Akra's type 161ST polyester has created a challenge for manufacturers in the industrial textile yarn industry. While most of Akra's industrial polyester production can be replaced with Asian yarns, finding alternatives for type 161ST is not as straightforward. Heavy investments and adjustments in the manufacturing process are required to explore potential alternatives such as HMLS yarns and heat treatment. Manufacturers must carefully evaluate these options, considering the impact on production and the feasibility of accommodating different properties. Collaboration with alternative suppliers and industry experts will be crucial in navigating this transition successfully.