The Manufacturing Process of Fabric

Fabric Process
The Manufacturing Process of Fabric

Fabric refers to any textile material made through weaving, knitting, flame retardation,
scotch guard treatment etc.The term fabric has its origin in the Latin term fabrica
meaning a workshop. It means that which is put together like building. Fabric can be
classified based on various criteria. On the basis of fiber used for manufacturing, it can
be classified as natural fabrics such as cashmere, cotton, hemp, jute, linen, ramie, silk,
wool and synthetic or man-made fabrics like acetate, acrylic, chiffon, denim, georgette,
lastex, nylon, organza, polyester fabrics, rayon, satin, velvet etc. It can also be
categorized on the basis of its usage for making apparel, curtains, upholstery among
others.
Steps required for fabric production are

mentioned below:
Raw Material Purchased from Outside
Weaving is a major process of making fabric or cloth . In it, two distinct sets of yarns
called the warp and the filling or weft are interlaced with each other to form a fabric.
Yarn is a long continuous length of interlocked fibers. The lengthwise yarns which run
from the back to the front of the loom are called the warp. The crosswise yarns are the
filling or weft. A loom is a device for holding the warp threads in place while the filling
threads are woven through them. Yarns made from natural fibers like cotton, silk, and
wool and synthetic fibers such as nylon and Orlon are commonly used for weaving
textile. But other fibers can also be used for weaving. Yarn intended for the warp goes
through operations such as spooling, warping and slashing to prepare them to withstand
the strain of the weaving process.
Yarn
Yarn is the basic requirement of any textile, apparel or related industry. The
manufacturers require fibers, yarns and threads according to the product they
manufacture. Thus, the fiber manufacturers keep in mind the demands of natural fibers
as well as of synthetic fibers. As far as yarns are concerned, there are different
categories available in the market such as material yarn, yarn by fiber, and yarn by
making process.
Weaving Process
Weaving is a major process of making fabric or cloth . In it, two distinct sets of yarns
called the warp and the filling or weft are interlaced with each other to form a fabric.
Yarn is a long continuous length of interlocked fibers. The lengthwise yarns which run
from the back to the front of the loom are called the warp. The crosswise yarns are the
filling or weft. A loom is a device for holding the warp threads in place while the filling
threads are woven through them. Yarns made from natural fibers like cotton, silk, and
wool and synthetic fibers such as nylon and Orlon are commonly used for weaving
textile. But other fibers can also be used for weaving. Yarn intended for the warp goes
through operations such as spooling, warping and slashing to prepare them to withstand
the strain of the weaving process.
Knitting Process
Knitted fabric is a textile that results from knitting. Its properties are distinct from woven
fabric in that it is more flexible and can be more readily constructed into smaller pieces,
making it ideal for seats.
Its properties are distinct from nonwoven fabric in that it is more durable but takes more
resources to create, making it suitable for multiple uses.
It is a known fact that the main material for fabric construction is yarn. Knitting is the
second most frequently used method, after weaving, that turns yarns or threads into
fabrics. It is a versatile technique that can make fabrics having various properties such
as wrinkle-resistance, stretchability, better fit, particularly demanded due to the rising
popularity of home furnishings. The yarn in knitted fabrics follows a meandering path ,
forming symmetric loops or stitches. When the interlocking loops run lengthwise, each
row is called a wale. A wale can be compared with the warp in weaving. When the loops
run across the fabric, each row is called a course. A course corresponds to the filling, or
weft. There are two major varieties of knitting: weft knitting and warp knitting. In weft
knitting, one continuous yarn forms courses across the fabric. In warp knitting, a series
of yarns form wales in the lengthwise direction of the fabric.
Nonwoven Fabrics
Nonwoven fabrics are made by bonding or interlocking fibers or filaments by
Mechanical, Thermal, Chemical or Solvent means. For making Staple non-woven, fibers
are first spun, cut to a few centimeters length, and put into bales. These bales are then
scattered on a conveyor belt, and the fibers are spread in a uniform web by a wet laid
process or by carding. These nonwovens are either bonded thermally or by using resin.
The Spun laid non-wovens are made in one continuous process. Fibers are spun and
then directly dispersed into a web by deflectors or with air streams. Melt blown
nonwovens have extremely fine fiber diameters but are not strong fabrics. Spun laid is
also bonded either thermally or by using resin. Both staple and spun bonded non-
wovens would have no mechanical resistance without the bonding step.
Process Flow Chart For 100% Polyester Dyeing

Foam Lamination
The lamination of foam to different substrates is either achieved using either adhesive
lamination or flame lamination.
In adhesive foam lamination, as the name implies, adhesives are used to attach the
foam to the substrate.
In flame foam lamination a flame front is used to attach the foam to the substrate. One
example of flame laminated foam would be the lamination of foam to a fabric substrate
in the production of headliners for automobiles.
In either case, foams can be attached to substrates to form bi- or tri-laminates.
Coating
“A material composed of two or more layers, at least one of which is a textile fabric and
at least one of which is a substantially continuous polymeric layer.”
This Polymeric layer is applied in liquid form in a solvent or water base, which
evaporates off to leave the polymer behind, applied to one or both surfaces. Dependant
upon the application method the liquid may require thickening so it does not soak
through the fabric, or an anti-foaming agent to aid processing. The thickness of the
coating, or amount of product applied is controlled. Bonding occurs either through the
drying process (evaporation) or through a curing process, required to provoke
crosslinking.
Flame Retardants: Textile Finishes for Flame

Resistant Fabrics
As the whole environment is going highly technical and risky, the demand for specially
treated textile such as flame resistant fabric has grown significantly. In the process of
meeting with these demands, synthetic fiber has played a significant role. Simply
defined, flame retardants are materials that have the quality of inhibiting or resisting the
spread of fire. Textile is highly ignitable and contribute to rapid fire spread. However, the
ignitable property of a textile can be considerably reduced by any one of the three
methods- by using inorganic materials such as Asbestos, Glass etc; by chemically
treating the textile with flame retardant chemicals; and by modifying the polymer.
Scotchgard fabric (Water Repellant)

Protect the things you love with Scotchgard protected Fabric. Whether it's a brand-new
seats, or your little wall, Scotchgard protected Fabric helps repel liquids and block stains
without changing the look and feel of the fabric. That means you can wipe the surface
clean before the mess sinks in for beautiful, long-lasting using. So host a family get-
together, or your sofa with confidence knowing that Scotchgard protected fabric is your
secret defender from life's little mishaps.

The Manufacturing Process of Fabric

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The Manufacturing Process of Fabric

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Fabric Process

The Manufacturing Process of Fabric

Steps required for fabric production are

Process Flow Chart For 100% Polyester Dyeing

Flame Retardants: Textile Finishes for Flame

Scotchgard fabric (Water Repellant)

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