One of the major applications of polypropylene is its use in textiles. Due to features such as lightweight, resistance to moisture and abrasion, polypropylene yarn is widely used in the production of both home and industrial textiles—from carpets to sportswear. This synthetic fiber, introduced to the textile industry in the 1970s, now ranks fourth in global consumption volume after polyester, nylon, and acrylic.

Unlike many other synthetic fibers mainly used in clothing, the majority of polypropylene usage lies in industrial and technical textiles. This article explores the key applications of polypropylene yarn in the textile industry, its unique technical properties, the advantages and drawbacks of its usage, and its future outlook.

Main Applications of Polypropylene Yarn in Textiles

Carpets and Rugs:
One of the largest applications of polypropylene yarn is in the production of machine-woven carpets, rugs, and textile floor coverings. These yarns are used both as pile yarns and warp yarns and weft yarns. They offer good resistance to pressure, abrasion, and dirt. Carpets made with polypropylene yarn are lighter and, due to their moisture resistance, don’t develop mold or unpleasant odors. In Iran, a large portion of machine-woven carpets are made from polypropylene yarn, making them more affordable and easier to maintain.

Upholstery and Home Textiles:
Polypropylene yarn is used in making upholstery fabrics (sofa covers, curtains, tablecloths). These fabrics are durable against wear and tear and more resistant to stains and dirt, as moisture and dust are less likely to penetrate the non-absorbent fibers. They are also easy to clean—a major advantage.

Sports Textiles and Performance Wear:
Though polypropylene isn’t as widely used in everyday clothing as polyester, it is gaining attention for sportswear and base layers (thermal underwear, sports socks). Its hydrophobic nature helps wick sweat away from the body to the surface of the fabric, where it can evaporate—keeping the skin drier. Its light weight and hypoallergenic properties also make it a great option for functional clothing.

Artificial Turf:
Polypropylene fibers are among the most common materials for artificial turf. These yarns serve as grass blades and are known for their durability under weather conditions, moisture, and foot traffic. The affordability of polypropylene has also made artificial grass made from these fibers more cost-effective compared to other options.

Technical Features of Polypropylene Yarn in Textiles

• Lightweight: With a density of around 0.91 g/cm³, polypropylene is lighter than most synthetic fibers like polyester and nylon. This makes fabrics and carpets woven with it easier to transport and install.
• Moisture Resistance: Naturally hydrophobic, polypropylene absorbs virtually no moisture. Spilled liquids don’t penetrate the yarn, making the fabric quick-drying and mold-resistant—more hygienic and odor-free.
• Chemical Resistance & Stain Repellence: Polypropylene resists acids, bases, and household chemicals. Water-based stains are easy to clean off its surface as they don’t sink into the fiber.
• Tensile Strength & Abrasion Resistance: Though not as strong as nylon, polypropylene offers decent strength and durability, making it effective for high-traffic areas like carpets and wear-resistant furniture textiles.
• Hypoallergenic: Odorless and non-toxic, polypropylene fibers don’t irritate sensitive skin—an asset for wearables and children’s carpets.
• Colorfastness During Production: Through masterbatch dyeing during melt spinning, polypropylene yarns are uniformly colored throughout. The color is wash- and fade-resistant, especially with added UV stabilizers.

Pros and Cons of Using Polypropylene in Textiles

Advantages:

• Cost-Effective: Polypropylene is one of the cheapest synthetic polymers. Its lower production cost reduces the final price of textile products like carpets.
• Easy Maintenance: Polypropylene fabrics are easy to wash and dry quickly. Their resistance to stains makes them ideal for messy environments.
• Mold and Bacteria Resistant: Its non-absorbent nature discourages microbial growth, making it suitable for humid spaces like bathrooms and nurseries.
• Color and Appearance Durability: Its bulk-dyeing process ensures lasting color, even with exposure to sunlight or frequent washing—especially when stabilized with UV additives.

Disadvantages:

• UV Sensitivity: Without stabilizers, polypropylene degrades under UV exposure. Products used outdoors or under direct sunlight may lose quality over time.
• Low Melting Point: With a melting point around 165°C (lower than polyester’s ~260°C), polypropylene fabrics can warp or melt under high heat, making direct ironing risky.
• Flammability: Naturally flammable, though flame-retardant additives can help improve its fire resistance—less safe than inherently flame-resistant fibers like wool.
• Low Breathability: Its moisture resistance reduces air permeability, which can cause overheating in garments unless ventilation is designed into the clothing.

Future Outlook for Polypropylene in Textiles

With evolving textile technologies and market demands, polypropylene’s role is rapidly transforming:

• Improved Sustainability: The textile industry is shifting toward eco-friendlier materials. Polypropylene’s recyclability is a positive, and future innovations may include bio-based polypropylene from renewable sources.
• Smart Textile Applications: As wearable technology and smart fabrics evolve, polypropylene could be enhanced with nanoparticles or coatings for features like conductivity or antibacterial properties.
• Expanded Use in Technical Textiles: Usage is expected to grow in medical textiles, filters, and geotextiles. Through compounding and chemical modification, improvements in thermal and mechanical performance may also open doors in automotive and aerospace applications.

Polypropylene yarn has become a vital material in the textile industry thanks to its balance of light weight, durability, and affordability. From carpets and rugs to high-performance sportswear, its versatile nature has made it a staple. With advancing technology, its presence in the textile landscape is set to grow.
Notably, Sahand Carpet Company is one of Iran’s key producers of high-quality polypropylene yarns used extensively across various industries including carpets.