Spinning, cheese dyeing, knitting and weaving process of a high performance flame-resistant modacrylic/cotton safety apparel fabric

A method of cheese dyeing a yarn, comprising the steps of:

• coning a grey yarn, loading the coned grey yarn, pre-treatment, dyeing, post processing, hydro extraction, drying, coning, and packaging;
• wherein the yarn is composed of the percentage of components selected from the group consisting of the following recipes:
• a. 60% modacrylic/40% cotton;
• b. 60% modacrylic/37%-40% cotton with anti-static blend, wherein the anti-static blend is chosen from anti-static yarn or fiber and is present at ≦3%;
• c. 60% modacrylic/35% cotton/5% nylon;
• d. 60% modacrylic/32-35% cotton/5% nylon with anti-static blend, wherein the anti-static blend is chosen from anti-static yarn or fiber and is present at ≦3%;
• e. 60% modacrylic/30-32% cotton/5% nylon/3-5% aramid;
• f. 60% modacrylic/29-32% cotton/5% nylon/3% aramid with anti-static blend, wherein the anti-static blend is chosen from anti-static yarn or fiber and is present at ≦3%;
• wherein the dyeing comprises 2 stages, stage 1 is dyeing the modacrylic fiber with cationic dyes;
• stage 2 is dyeing the cotton fibers with reactive dyes;
• wherein the hydro extraction comprises reducing water content to 45%;
• and
• wherein the drying is carried out at a radio frequency (RF) drying speed of 6 m/h for 24 hours.