Inside a tyre cord factory, molten nylon is extruded into fine filaments.  The yarn is stretched, twisted, woven, and dipped in adhesive under strict controls.Each stage — from spinning to heat-setting — shapes the final fabric that reinforces tire strength, flexibility, and safety. In this post, you’ll learn how nylon tyre cord fabric is manufactured step by step, and why each process matters for modern tire performance.

The Role and Advantages of Nylon Tyre Cord Fabric

Nylon tyre cord fabric is the hidden backbone of every modern tire. Though you won’t see it, it works hard inside — helping tires stay strong, flexible, and safe.

Tyre cords are textile reinforcements built into the tire’s body. They give the tire its structure and hold its shape while driving. Without them, tires would collapse under pressure or deform at high speed. They resist road shock, carry the vehicle’s weight, and keep the tread aligned. Tyre cords are found in the carcass, the main body of the tire, the belts, layers under the tread for strength, and the plies, fabric layers controlling flexibility.

Here’s how tyre cords contribute:

Nylon has become a top choice for tyre cords — and for good reason. It’s strong. It stretches under pressure but snaps back fast. It stays stable in heat and doesn’t soak up much moisture. That makes it ideal for truck tires, motorcycles, and off-road vehicles.

Let’s compare:

Nylon is flexible and tough. It handles twisting and bending well — better than rayon. It’s cheaper than aramid but still durable. That balance of cost, strength, and heat resistance makes nylon the go-to material for tyre cord fabric in many parts of the world.

Step-by-Step Manufacturing Process of Nylon Tyre Cord Fabric

The journey from caprolactam to finished tyre fabric involves precision, timing, and strict control. Let’s walk through each step — from polymerization to heat setting.

1. Polymerization of Nylon-6

Everything begins with caprolactam, a key chemical used to make nylon-6. In the polymerization reactor, heat and pressure open its ring structure. Molecules link up to form long chains — nylon.

There are two main types of processes:

• Batch process – offers more control, but slower

• Continuous process – faster, ideal for large volumes

For industrial tyre cords, we target a relative viscosity of 3.2–3.5. This ensures high tenacity and thermal resistance.

The choice between batch and continuous processes depends on the specific requirements of the tyre cord fabric. Batch processes allow for more precise control over the polymerization conditions, making them suitable for producing specialized grades of nylon with specific properties. Continuous processes, on the other hand, are more efficient for large-scale production, ensuring a steady output of high-quality polymer.

2. Chip Extraction and Drying

After polymerization, nylon solidifies into chips — small white beads. We wash them to remove impurities like acids or by-products. Then dry them using hot air or vacuum dryers.

Even trace moisture can cause filament breaks during spinning. Clean, dry chips mean stronger, more uniform yarns.

The drying process is critical to ensure the integrity of the nylon chips. Moisture content must be minimized to prevent any defects during the subsequent spinning process. Hot air dryers are commonly used for their efficiency, while vacuum dryers provide a more controlled environment to ensure thorough drying.

3. Melt Spinning

Dried chips go into a melt extruder. At around 250–280°C, they melt into a thick liquid. This liquid gets pushed through spinnerets, forming fine filaments. Cooling air — called quenching — solidifies the strands instantly.

Before winding, we apply spin finish: an oil-based solution that reduces friction and static.

There are two spinning methods:

• Two-step: melt spin → wind → draw

• Spin-draw: continuous spinning + drawing

The choice of spinning method impacts the efficiency and quality of the yarn. The two-step process is easier to maintain but requires more space and time. The spin-draw process, while more complex, offers better yarn uniformity and is preferred for high-volume production.

4. Yarn Twisting and Plying

After spinning, we twist the yarn for strength. First twist: usually S-direction, controls individual strand tension. Second twist: usually Z-direction, combines multiple plies into one cord. Twist balance prevents fraying and improves flexibility.

Common configurations include:

• 840/2 – light-duty tires

• 1260/2 – standard car/truck tires

• 1260/3 – off-road/heavy-load tires

• 1680/2 – aircraft or industrial tires

Typical TPM (twist per meter) range: 250–400

Twisting and plying are essential steps to enhance the strength and durability of the yarn. The direction of the twist (S or Z) and the number of plies determine the final properties of the tyre cord. Higher denier and ply configurations are used for heavier-duty applications, ensuring the fabric can withstand greater loads and stresses.

5. Weaving Into Greige Fabric

Twisted cords are woven into greige fabric — raw, undyed cloth. This process needs careful tension balance across warp and weft. Uneven pressure causes distortion or weak spots.

Fabric parameters:

• EPI (Ends per Inch): 14–30

• Width: 900–1500 mm

• Weave Type: plain or special interlock

Consistent structure ensures proper bonding and shape control in later stages.

Weaving is a critical step that transforms the twisted cords into a cohesive fabric. The EPI, fabric width, and weave type are carefully controlled to ensure the fabric’s strength and uniformity. High-speed looms equipped with advanced tension regulators and monitoring systems ensure that every thread is precisely placed, resulting in a strong, flat, and consistent greige fabric.

6. Adhesive Dipping Process (RFL Treatment)

Nylon doesn't naturally stick to rubber. So, we dip the fabric in RFL solution — a mix of:

• Resorcinol

• Formaldehyde

• Latex

This creates a bonding layer between fabric and rubber compound.

Two ways to measure dip pick-up:

• Wet method – weigh before and after dipping

• Dry method – extract and test the solid gain

Ideal pick-up range: 4–6% by weight

The adhesive dipping process is crucial for ensuring the fabric bonds effectively with the rubber in the tire. The RFL treatment provides the necessary adhesion, and accurate measurement of the dip pick-up ensures consistent performance. The wet method is simpler and quicker, while the dry method offers higher accuracy, making it suitable for more precise quality control.

7. Heat Setting

Last step: we heat the dipped fabric under tension. This locks in dimension, prevents shrinkage during tire curing. It also improves thermal stability and bonding strength.

Typical settings:

• Temperature: 180–220°C

• Dwell Time: 30–60 seconds

• Stretch Ratio: 1–2%

Machines use rollers and infrared heaters. The fabric exits stable, smooth, and ready to build into tires.

Heat setting is the final step that ensures the fabric maintains its dimensions and properties during the tire manufacturing process. By carefully controlling the temperature, dwell time, and stretch ratio, the fabric is stabilized and prepared for integration into the tire structure. This step is essential for producing high-quality, durable tyres that meet stringent performance standards.

Quality Control and Testing Parameters

Making nylon tyre cord fabric isn’t just about production — it’s also about strict testing. Every batch is checked for strength, structure, and finish. Quality control is a critical aspect of the manufacturing process, ensuring that the final product meets the stringent requirements necessary for its application in tyres.

Key Fabric Tests

To ensure it performs inside a tire, the fabric goes through multiple tests. Each one checks a different property, from strength to moisture content.

1. Tensile Strength
   Measures how much force the fabric can handle before breaking. This test is crucial for determining the load-bearing ability of the tyre cord fabric. A high tensile strength ensures that the fabric can withstand the pressures and forces experienced during tire operation.

2. Elongation at Break
   Tells us how far it can stretch before snapping — important for flexibility. This test assesses the fabric’s ability to stretch and return to its original shape, which is essential for maintaining the tire’s structural integrity under dynamic conditions.

3. Hot Air Shrinkage (HAS)
   Tests how much the fabric shrinks when exposed to heat. Too much shrinkage causes warping inside the tire. This test ensures that the fabric maintains its dimensions during the tire curing process, preventing defects and ensuring a smooth, uniform tire structure.

4. Twist Per Meter (TPM)
   TPM is checked using tensioned twist testers. Consistent TPM means better fatigue life. This test ensures that the yarns are uniformly twisted, which is essential for the fabric’s durability and resistance to wear and tear.

5. Oil Content
   Residual spin finish is measured — too much oil causes bonding issues. Ideal range: 0.5–1.0%. This test ensures that the fabric has the correct amount of spin finish, which is necessary for reducing friction and preventing static buildup during manufacturing.

6. Moisture Regain
   Nylon absorbs some moisture from the air. We check moisture regain to avoid weight fluctuation and static buildup. This test ensures that the fabric’s moisture content is within acceptable limits, preventing issues such as weight variation and static electricity during processing.

These tests provide a comprehensive evaluation of the fabric’s properties, ensuring that it meets the necessary standards for use in tyres.

Industry Standards

To make sure the fabric meets global specs, manufacturers follow standards. The main ones include:

• JIS (Japanese Industrial Standard)

• IS 11926:1987 – Indian Standard for nylon tyre cord

• ISO – Global standards covering tests, terminology, quality

One example is the definition of twist direction:

These standards provide a common framework for manufacturers to ensure consistency and quality across different production sites and regions. Adhering to these standards ensures that the fabric meets the necessary performance criteria and can be reliably used in tyre manufacturing.

Besides lab tests, we also rely on visual checks:

• Sudare Finish – A clear grid pattern that shows correct weave

• Color Uniformity – No yellowing or oily spots

• Selvage Control – Straight, clean edges without fraying

Trained inspectors review every roll. Defects like missing yarns, streaks, or knots get flagged immediately. These visual inspections complement the lab tests, ensuring that the fabric not only meets the necessary physical and chemical properties but also has a high-quality appearance and finish. Any defects or irregularities are identified and addressed before the fabric is used in tyre production, ensuring the final product’s reliability and performance.

Nylon Tyre Cord Fabric Specifications

Every nylon tyre cord product has a code, a meaning, and a purpose. Understanding these specs helps match the right fabric to the right tire. The specifications of nylon tyre cord fabric are crucial for ensuring that the fabric meets the performance requirements of different types of tires.

Typical Product Codes and Meanings

Product codes may look like numbers and slashes, but they tell us a lot about the structure. Take 840/2 for example:

• 840 = the denier of each yarn

• /2 = two plies twisted together

Here are common types:

Higher denier means more strength, but also more weight. The ply count boosts durability and fatigue resistance. Performance varies by structure:

The denier of the yarn indicates its thickness and, consequently, its strength. Higher denier yarns are stronger but also heavier. The ply count, which refers to the number of yarns twisted together, enhances the fabric’s durability and resistance to fatigue. For instance, an 840/2 cord is suitable for light vehicles and scooters due to its balance of strength and flexibility, while a 1260/3 cord is ideal for heavy-duty applications like trucks and off-road tires, where higher tensile strength and durability are required.

Adhesion, Shrinkage, and Tenacity Values

Top manufacturers like SRF, Toray, and Century Enka release their own reference data for industrial customers. Let’s look at average values from typical spec sheets:

Adhesion strength affects how well the fabric bonds to rubber. Low shrinkage is vital — tires lose shape if fabric pulls back during curing. Each buyer may request custom specs, but these are the typical industrial targets for high-quality nylon tyre cord.

Adhesion is a critical property that ensures the fabric bonds effectively with the rubber compound in the tire. A strong bond, typically measured at over 30 N/cm after vulcanization, ensures that the fabric and rubber work together seamlessly. Hot air shrinkage is another important factor; the fabric must maintain its dimensions during the tire curing process to prevent warping or distortion. A shrinkage rate of less than 6% at 180°C over 2 minutes is the industry standard.

Tenacity, measured in cN/tex, indicates the fabric’s strength. Higher tenacity values mean stronger cords, which are essential for withstanding the forces experienced during tire operation. Elongation, which measures the fabric’s flexibility, is also crucial. A controlled elongation range of 16–22% ensures that the fabric can stretch without breaking, providing the necessary flexibility for tire performance.

Moisture regain is important for maintaining consistent weight and preventing static buildup. Keeping the moisture regain below 4.5% ensures that the fabric remains stable and reliable during manufacturing and use.

These specifications are the backbone of high-quality nylon tyre cord fabric. By adhering to these standards, manufacturers can ensure that their products meet the rigorous demands of the tire industry, providing durability, strength, and reliability in every application.

Challenges and Future Developments

Nylon tyre cord fabric has come a long way, but the road ahead still has bumps and new directions. As the industry continues to evolve, manufacturers face both challenges and opportunities for innovation.

Current Gaps in Technology

Some regions still rely on outdated or fragmented setups. Continuous polymerization, a cleaner and more efficient method, is rarely used outside large global producers. This gap in technology adoption leads to several issues in production.

Developing countries often face:

• High energy use from batch polymerization

• Moisture inconsistency in chips due to poor drying

• Twist imbalance from older cabling machines

• Low automation in dipping and heat-setting

Another challenge is the heavy dependence on imported machinery. Key units — like spin-draw winders, high-speed looms, or RFL ovens — are still sourced from Japan, Germany, or Taiwan. This reliance on foreign equipment can lead to delays in maintenance and upgrades, further hampering production efficiency.

Local engineering upgrades are happening, but progress is uneven. While some manufacturers are investing in modernizing their facilities, others continue to struggle with the limitations of older, less efficient machinery.

Innovations on the Horizon

Some manufacturers are already pushing boundaries. They’re blending nylon with aramid to create hybrid cords. These offer better heat resistance and longer fatigue life. This innovation is particularly promising for high-performance applications where traditional nylon cords may fall short.

We’re also seeing moves toward:

• Low-energy melt spinning – saves power, lowers emissions

• Bio-based finishes – replacing petroleum-derived oils

• AI-based twist monitoring – real-time control of cord balance

• Closed-loop water recycling – greener chip washing

Emerging tech aims to reduce cost, waste, and carbon footprint — without sacrificing strength or reliability. These innovations are not just about improving efficiency but also about creating a more sustainable and environmentally friendly manufacturing process.

The Future of Tyre Cord Fabric

The future of tyre cord fabric isn’t just about more strength — it’s about smarter, cleaner, and more adaptive materials. As the industry continues to innovate, we can expect to see a shift towards more sustainable practices and advanced technologies that enhance both performance and efficiency.

Manufacturers are increasingly looking for ways to integrate these new technologies into their production processes. Hybrid yarns, for example, offer a compelling balance of strength and flexibility, making them suitable for a wide range of applications. Smart tension control systems, powered by AI, ensure consistent quality and reduce the risk of defects, leading to more reliable and durable tyre cord fabric.

Eco-friendly RFL dips and energy-efficient ovens are part of a broader trend towards sustainability. By reducing volatile organic compounds (VOCs) and lowering energy consumption, these innovations help manufacturers meet environmental regulations while also lowering their operational costs.

Conclusion: Precision and Progress in Nylon Tyre Cord Manufacturing

Nylon tyre cord fabric is more than a hidden layer inside your tires — it’s an engineered product born from heat, tension, and chemistry. Every stage, from polymerizing nylon-6 to heat-setting greige fabric, must be tightly controlled to produce cords that are strong, flexible, and adhesive-ready.

Today’s manufacturers balance classic techniques like RFL dipping and dual-twist plying with innovations like AI monitoring and hybrid yarns. While regions with legacy equipment face gaps in consistency and energy efficiency, global trends are shifting toward smarter, cleaner, and more sustainable processes.

The future of nylon tyre cord fabric will depend not just on strength, but on smarter tension control, greener chemistry, and high-efficiency production. Tires may roll on rubber — but it's precision-woven nylon that keeps them road-ready.

FAQ

Q: What is the difference between Nylon-6 and Nylon-6,6?

A: Nylon-6 is made from caprolactam via ring-opening polymerization; Nylon-6,6 uses two monomers. Nylon-6 has better flexibility and is easier to spin.

Q: Why is twisting direction important in yarn?

A: Twist direction (S or Z) affects balance, strength, and fatigue resistance. Correct pairing prevents fraying and improves fabric stability.

Q: What is RFL and why is it necessary?

A: RFL (Resorcinol-Formaldehyde-Latex) is an adhesive treatment. It helps nylon bond with rubber during tire curing.

Q: Can tyre cord fabric be recycled?

A: Recycling is limited due to rubber adhesion. However, efforts are underway to separate and reuse cords for industrial fillers.

Q: How does heat setting improve fabric performance?

A: Heat setting locks fabric dimensions, improves thermal stability, and prevents shrinkage during tire vulcanization.