Introduction
Polypropylene Fabric is a modern textile that is widely used in the production of sportswear and outdoor clothing, as well many other durable everyday products.
These include the likes of reusable shopping bags, medical face masks, upholstered furniture and luggage.
But what do you know about polypropylene fabric?
Allow us to enlighten you!
What is polypropylene fabric?
Polypropylene fabric is a term that is broadly employed to describe any textile product that originates from the thermoplastic polymer polypropylene.
Part of the polyolefin group, this type of plastic is non-polar and partially crystalline. Whilst not widely used in the production of clothing items, outside of sportswear and outdoor apparel, polypropylene fabric is used to make a wide range of products like carpets, tote bags, tents, upholstery and backpacks.
Originally created by Phillips Petroleum in 1951, it is now one of the most commonly manufactured plastic fabrics in the world. Though it took six years of refinement, before polypropylene was modified into a substance appropriate for mass production.
Initially marketed under the name ‘Moplen’, polypropylene is known for being soft, lightfast and very easy to clean. This is because it has no active dye sites. It is also very robust, and bleach can even be used to wash it.
As a textile, polypropylene fabric is nonwoven. This means it is made directly from a material that does not require spinning of weaving.
One of the main characteristics of polypropylene as a fabric is that it cannot absorb any moisture. Instead moisture passes through the fabric completely. This makes it perfect to use in garments that are worn close to the skin.
Polypropylene fabric characteristics
Polypropylene fabric is one of the lightest of all synthetic fibers on the market today. It is also very resistant to many different types of acids and alkalis.
As compared to other synthetic fibers the thermal conductivity of this material is generally much lower, thus rendering it a great fabric to use in cold weather clothing like fleece jackets, thermal underwear or snow pants.
This fabric is very resistant to abrasion. It is also strong and does not fade or stain. This is because polypropylene possesses no active dye sites once it has been synthesized. Which makes it the perfect material to use for upholstery and other everyday textile products.
Polypropylene fabric is susceptible to UV damage when regularly exposed to the sun. It also does not react well to latex or epoxies.
Like most other synthetic textiles available today, polypropylene fabric can have a negative impact on the environment too.
How Is Polypropylene Fabric Made?
Polypropylene is made from substances that are generated from hydrocarbon fuels such as petroleum oil.
The process for making polypropylene fabric is quite technical. But it roughly goes as follows:
- The monomer propylene is extracted in gas form from the crude oil.
- This monomer undertakes a process called chain-growth polymerization. Which makes the polymer polypropylene.
- A solid plastic material is then made when a significant number of propylene monomers are strung together.
- The polypropylene resin is then mixed with various plasticizers, stabilizers and fillers to create a usable textile. Once at a suitable consistency, this plastic is cooled in bricks or pellets.
- These cooling mechanisms are then transported to a textile factory, where they are remelted.
- More often than not the polypropylene is maneuvered into sheets or left to cool in molds.
- If sheets have been created, they are then slit into the required shape, before being glued or sewn to create the finished product.
Polypropylene fabric properties
Polypropylene fabrics have a number of properties which make it instantly recognizable.
These include the following:
- Chemical Resistance.
Polypropylene has a much higher resistance to chemicals than polyethylene does.
It will resist a host of organic solvents, acids, and alkalis. Though it is vulnerable against attack from chlorinated hydrocarbons, aromatics and oxidizing acids.
- Tensile Strength
Polypropylene has very good tensile strength (approx. 4,800 psi). Which allows the material to cope with heavier loads.
- Impact Tolerance.
Polypropylene has less impact resistance than polyethylene.
- Water Absorption
Polypropylene does not absorb moisture at all. Which makes it the perfect material to use for waterproof items.
- Soft Surface
While not the softest by any stretch, Polypropylene is one of the softer fabrics available right now. As it is semi-rigid, it is more likely to bend or flex on impact.
- Melting Temperature.
When exposed to temperatures of 163.8°C) polypropylene will melt. So it is not suitable for any high-temperature applications.
How Is Polypropylene Fabric Used?
Polypropylene is a popular type of fabric and plastic that is widely used around the world in an eclectic range of everyday items.
For the clothing industry it is commonly incorporated in the production of garments that require significant moisture transfer. This includes cold weather gear like ski jackets and snow pants, as well as sportswear, thermal underwear and diapers. In other words, items of apparel that keep you warm, waterproofed, or ensure that your skin does not rash or irritate.
Outside of clothing, polypropylene fabric is used in a wide range of other applications. Which include everything from tote bags, upholstery in furniture and face masks to reusable shopping bags, rugs and also carpets.
Polypropylene plastic is also used to make a range of items like straws, rope, food labels, food packaging, sunglasses, medical applications and products associated with the automotive industry, such as car bumpers and wheel covers.
What Different Types of Polypropylene Fabric Are There?
Overall there are two main different types of polypropylene fabric – Copolymer polypropylene and Homopolymer polypropylene.
Copolymer polypropylene
The majority of polypropylene fabrics takes the form of a copolymer.
This version of polypro plastic can be separated into two more categories – the block copolymer polypropylene and the random copolymer polypropylene.
The key difference between these two categories is that the block form of this plastic is sequenced in consistent square patterns. While with the random copolymer polypropylene is formed, essentially, in random patterns.
Both of these polypropylenes are suitable for fabric applications, though the block polypro plastic is generally used more.
Homopolymer polypropylene
When it is in its original state and free from additives, polypro plastic is generally viewed as a homopolymer.
This type of polypropylene is widely regarded as not being as good a material to use for the production of fabric, as Copolymer polypropylene is seen to be.
Polypropylene advantages and disadvantages
Like all other polymers, polypropylene, has a number of advantages and disadvantages that can be outlined as follows:
Advantages
- Is highly resistant to moisture
- Cost effective material
- Boasts good impact strength
- Possesses good chemical resistance across many bases and acids
- Has high flexural strength on account of its semi-crystalline nature
- Easier to repair from damage
- Is an excellent electrical insulator
Disadvantages
- Is susceptible to UV degradation when exposed for prolonged periods of sunlight
- Has a high thermal expansion coefficient that severely limits its high temperature applications
- Susceptible to oxidation
- Has high flammability
How to care for polypropylene fabrics
It is important to take very good care of clothing items made of polypropylene fabric.
When washing them, it is best to do so in a bucket by hand, in lukewarm, or more preferably, cold water. For best results wash with anti-bacterial soap or a spray.
Always try and air dry these items too, as opposed to putting them in a tumble dryer. As Polypropylene, is a plastic polymer, it has a very low melting point.
So you should also always be mindful of keeping your material away from open flames or high heat, as they tend to be highly flammable.
Where Is Polypropylene Fabric Produced?
With an industry valued at around $6 billion, China is the biggest manufacturer of polypropylene products in the world.
Germany is also a major producer too, with their turnover said to be around $2.5 billion.
While the USA, Italy, Belgium, France and Mexico are all considered to be significant players as well.
How Much Does Polypropylene Fabric Cost?
As a general rule, products made of Polypropylene Fabric are inexpensive to make, and widely available to buy, at quite low prices.
The exception to this is apparel. Where a number of other materials are seen by manufacturers globally as being more cost effective to use for certain clothing items.
Are polypropylene fabrics breathable?
Especially when it comes to clothing, polypropylene fabric is a very breathable type of material.
Infact it is widely used, in these Covid times, in the production of face masks, and especially for sportwear too.
As well as being breathable, polypropylene fabric is also a highly waterproof fabric as well.
Can polypropylene fabric be ironed?
You should never attempt to iron apparel that is made from polypropylene fabric.
Given that it is a plastic based material, any item made of this fabric will quickly melt when exposed to the hot iron.
Instead, after handwashing in cold or lukewarm water, be sure to air dry the clothing items instead.
Is polypropylene fabric soft?
Yes, on the whole polypropylene fabric is very soft.
When it comes to products like rugs and carpets, they feel incredibly soft to the touch.
Even clothing items made of polypropylene fabric like thermal underwear, gloves or socks are very cushiony and won’t irritate your skin when you wear them.
Can polypropylene fabric be washed?
Polypropylene fabric can definitely be washed.
The best way to do it is in a sink or bucket of cold or lukewarm water and with antibacterial soap.
If you choose to use your washing machine, be sure to use the cold, or cool wash setting, and put it on a delicate cycle.
How Does Polypropylene Fabric Impact the Environment?
Unfortunately the production of polypropylene does have a negative impact on the environment.
As polypro plastic comes from hydrocarbon fuels, the production of this material is unsustainable – fossil fuels are, after all, limited resources.
Also various toxic chemicals are used in the production process which are not bio-degradable. So they can damage our ecosystem.
Conclusion
For over half a century polypropylene fabric has been widely used around the world in the production of clothing and other everyday items; and billions of people have relied upon it.
However as we move towards a greater environmental consciousness, its days as a leading textile may well be numbered.
