Evaluation of Tensile and Morphological Properties of Cotton/Polyester Blended Yarns Produced in Kaduna Textile Mills

Cotton/polyester blended yarns represent the dominant raw material for woven fabrics produced in Nigerian textile mills, and understanding the influence of blend ratio on yarn properties is essential for quality production. This study evaluates the tensile and morphological properties of cotton/polyester blended yarns produced at Kaduna Textile Mill in Kaduna State, North West Nigeria. Yarn samples were collected at blend ratios of 100:0, 65:35, 50:50, and 35:65 cotton-to-polyester by weight, processed under identical ring spinning conditions at 20 Ne count. Tensile properties including yarn tenacity, elongation at break, and initial modulus were determined using a universal testing machine following ISO 2062 standard procedures. Yarn evenness was assessed using an Uster evenness tester, and morphological examination was conducted using scanning electron microscopy. Results show that increasing polyester content progressively improved yarn tenacity, from 12.4 cN/tex for pure cotton to 19.8 cN/tex at a 35:65 cotton-to-polyester ratio. Elongation at break increased correspondingly, while Uster evenness improved with higher polyester fraction due to the greater length uniformity of synthetic staple fibres. Scanning electron microscopy revealed uniform fibre distribution within blend yarns but occasional fibre migration and balling in the high-polyester compositions. The 65:35 cotton-to-polyester blend ratio offered the most balanced performance, combining acceptable tensile properties with moisture absorption suitable for apparel fabric applications. The findings provide practical production guidance for yarn manufacturers in North West Nigeria seeking to optimise blend specifications for different end-use markets. Keywords: cotton/polyester blend, yarn tenacity, ring spinning, Kaduna, yarn evenness