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The plying and twisting stage combines two or more single ends to form a yarn. They may be 2-ply, 3-ply, or more, depending on the number of bundles wound together. The yarn is heatset to assure retention of the twist and bulk development. For most contract carpet, 2-ply and 3-ply yarns are sufficient, however, there are special applications that dictate the need for 4-ply or larger yarns.
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Different textural appearances may be produced during the fiber manufacturing process. Both continuous filament and staple yarns have their own textural appearance, which is determined by ply and twist level. Twist is the number of turns per inch and the direction of turning of the pile fibers or ply or yarn strands placed together. Twist direction is either right (Z-twist) or left (S-twist). Most carpet yarns range between 4.0 and 6.0 turns per inch (TPI).
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