Polyester yarns, the most important synthetic fibers produced via melt spinning process, increase its volume every year in textile world. The copolyesters such as ionic dyeability together with modified cross sections for speciality market, create additional benefits like better hand feel and high fastness dyeability with cationic dyes as well as moisture management capability via increased surface of multi channel cross section. On the other hand, spinnability increases with an increase in cohesive energy density. Conversely, any additive present in the polymer such as sulfoisophthalic acid for cationic dyeability (cat dye) causing a decrease in cohesive energy density of the melt would decrease the spinnability of the polymer. In addition to lowered cohesive energy density, modified cross section to a multi channel concept decreases the tensile properties as well. Therefore the goal of this work is to design and develop cationic dyeable multi channel textured yarn as speciality product via implementing statistical and experimental studies on texturing process to design a commercially acceptable product which will further give high margin. To achieve this goal, the DOE; Design of Experiments and Response Surface Methodolgy have been used. Design of Experiments and Response Surface Methodology are difficult for researchers to implement in practice on Industrial Engineering and Statistics science, therefore the studies had remained theoretical and applied research of these methods are very rare or nearly zero in Textile Engineering area. The main goal of this work is to reach to the scientific and optimal solution in a shortest time on value added product design in textile industry and enlight to future developments with this approach via implementing Response Surface Methodology. The studies were carried out in Advansa SASA Polyester Industries Inc. R&D Center.
