Tufting serves as a major downstream processing method for PP BCF yarn. Yarn crimp stability directly affects carpet pile fullness, pile‑erect performance and foot‑traffic resistance of end products. Even if basic indicators such as tenacity and denier meet specifications, large fluctuation of crimp retention may lead to pile collapse and uneven pile height after puncturing and carding on tufting machines, raising defective rate of finished carpets.

Crimp formation of PP BCF yarn relies on air‑jet bulking and subsequent heat‑setting procedures. Air temperature and pressure during bulking form three‑dimensional crimp structure of tow, while heat‑setting solidifies crimp morphology and reduces crimp shrinkage under later heat and pressure. Improper setting tension causes insufficient crimp fixation, and crimps may disappear under mechanical force during high‑speed tufting.

Tufting processes set different requirements for crimp indicators. Loop‑pile products need moderate crimp degree for uniform loops against loop loosening. Cut‑pile products demand better crimp retention to keep upright pile after cutting. Downstream manufacturers may carry out simplified foot‑traffic aging tests simulating tufting conditions besides checking factory test reports, so as to predict long‑term performance.

During on‑machine production, unwinding tension shall match features of BCF yarn. Excessive tension stretches and damages existing crimp structure. Insufficient tension causes tow slack and uneven yarn feeding, resulting in pile‑height deviation. Small‑batch trial weaving is recommended when switching yarn batches before mass production.

Jiangsu Lingda Chemical Group Co., LTD introduces complete post‑processing equipment from Germany and France. It emphasizes process control on bulking and heat‑setting for PP BCF yarn, supplies matched‑specification yarn for various tufting technologies and supports customer sample evaluation.