Towels are one of the must-haves of any bathroom. And in this post, we are going to talk about how they are made.
Towels And Their Interesting Production Process
Fabrics with a structure called “pile”, which are formed by the threads placed on the fabric in the form of loops or tassels, coming out from the ground to create a different surface feature, are called “pile fabrics”. Blankets, carpets, velvet fabrics, and towels are included in this class.
Blankets gain a pile structure with finishing processes such as brushing and feathering. Velvet fabrics are generally produced by forming loops with the cut ends on the surface with an additional yarn system.
Carpets can be produced by using systems similar to velvet fabric production or by methods of creating non-woven surfaces such as needling and sticking.
Towels are products that are created by using weaving or knitting methods with an additional yarn system, and the surface is covered with a pile in the form of loops, and velvet ones are produced by cutting the said pile.
Bath Towels are textile products of different widths and lengths, woven or knitted in the form of cloth on four sides, which can be piled on one or both sides, and are generally used for drying purposes.
The physical properties of terry cloth and plain woven or knitted fabrics are almost the same, except for some features found only in towels. In them, different concepts such as border, pile efficiency, and short pile distance can be defined.
Raw Materials Used in Production
Towel fabrics should have properties such as high hydrophilicity, high wet strength, good dyeability, high color fastness, washability, soft handle, and anti-allergy. Cotton is the most widely used fiber in production, as yarns made from cotton can provide all of these properties in the most efficient way.
In addition to cotton, fibers such as modal, bamboo, lyocell, soybean, corn, seaweed, and linen can also be used in towel production, albeit at a low rate. Although bamboo fiber can be used in because it is soft, antibacterial, and highly absorbent, it has not yet become widespread due to its low production amount.
On the other hand, the dry strength of flax is higher than cotton, and its wet strength increases by 25%, like cotton. In addition, this fiber, which has very high absorbency, can be used in the production of some special massage and sauna towels, although it has not become very common due to its hard handle and long processing process.
The use of synthetic and synthetic-blend yarns in production is limited, and polyester/cotton blends can rarely be used on the floor and in the weft of regularly washed hotel towels. In this way, it is ensured that they are resistant to frequent washing and that their non-shrinkage properties are improved after washing.
In addition, due to their ability to absorb water up to 5-7 times their weight, yarns made of microfilament polyester have been mixed with cotton and used in towel production in recent years.
The use of modal fiber obtained from 100% beechwood cellulose in production has also increased in recent years. The fiber in question has properties such as extremely high softness, hydrophilicity, color brightness after dyeing, high color fastness, and ease of maintenance compared to cotton. In addition, by mixing it with cotton, the hardening and yellowing problems of cotton after frequent washing are solved to a large extent.
The production process generally consists of yarn, weaving/knitting, finishing, and garment stages.
Weaving is generally preferred as a method of creating texture in terry fabric production. Since natural fibers are usually used as raw materials in towel production, pre-treatment is a very important process step. In the coloring phase, dyeing or printing processes can be applied in fabric form, as well as production with dyed yarns.
Since terry fabrics should have high hydrophilicity, softness, and color fastness due to the place of use, applications are carried out by considering these features in the finishing processes.
In the garment phase, the bath towels in the form of balls that have come out of the finishing process are followed by the longitudinal cutting, longitudinal sewing, transverse cutting, and transverse sewing processes, respectively.
In the first stage, the organic towels, which are woven side by side in the ball, are cut longitudinally with the help of a special machine and separated from each other, and then the long edges are folded inward and sewn in another machine.
Then, these organic towels, which are in a row one after the other, are cut off from the places where their short edges meet, and these edges are folded inward and sewn.