Meridian opens new high-tech yarn dyeing plant in US

Meridian Specialty Yarn Group (MSYG) ushered in a new era for US textile supply chain in July by opening a new, high-tech, yarn dyeing plant at the site of its current operations in Valdese, NC, US. The 116,000 square-foot facility is the first yarn and fibre dyeing operation to be built in US in over two decades and offers the only tow-dyeing capacity.

Until this summer, all producer-dyed acrylic tow was imported from outside US borders. The plant officially went live on July 8 and is equipped to provide a broad number of traditional capabilities, from chemical treatments to dyeing to a combination of the two. Utilising next-generation technology, machines, controls and robotics for package, top and tow dyeing, the plant positions MSYG as North America’s most modern manufacturing operation with regard to dyeing technology and robotic support equipment, said Meridian in a press release.

“Our new technology gives us the capability to process every dyeable fibre in various forms including yarn, tow and top. This is very unusual in the dyed yarn world,” said Tim Manson, president of MSYG. “We can chemically treat or dye all fibre substrates, ranging from cellulosic and animal fibres, to polyester, nylon and dyeable aramids. Most dye houses specialise in certain products, but we are now in a position to source from all over the world, from every type of textile fibre, supporting a wide array of end uses.”

Built next to Meridian’s existing operations in Valdese, the plant literally puts a new spin on the primary staples of the textile industry – fibre and yarn. Renovations are now taking place in the plant’s original manufacturing plant and when that is done, Meridian’s yarn dye operations – which also include several types of space-dyed yarns as well as twisting capabilities – will span both buildings and 284,600 square feet of office, warehouse and manufacturing space.

“Nothing like this has been built before in North America,” Manson said. “This is one of the only ‘green field’ yarn and fibre wet-processing plants to be built in the US in a generation.”

“It’s also a showcase for next-generation yarn dye technology. This includes dye equipment by Galvanin, SpA of Vicenza, Italy; a patented automatic dosing system for dispensing chemicals and auxiliaries from Color Service Dosing Technologies of Dueville VI, Italy; new monitoring and control systems for all of the new dyeing equipment from Adaptive Controls of Huntersville, NC, US; and a new Galvanin skein printing machine along with support equipment.

The package dye technology includes vertical, air pad, low liquor ratio machines that replace all of MSYG’s existing fully-flooded package dye equipment. The new acrylic tow dying capabilities will support the raw material needs at MSYG’s plant in Ranlo, NC, and are also available to outside customers. The skein-printed yarns will go into craft yarns, apparel products and some home furnishings. The top dyed wool capability will support worsted spinners supplying high-end apparel, hosiery and home furnishings.