31 Aug, 2024

Textile Production: How Textile Is Made From Fiber to Fabric

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As a fabric supplier and a textile manufacturer from Taiwan, we know how fabric is made and we know how to make a good fabric. Different types of fabrics require different manufacturing processes. And we can’t wait to show you how these fabrics are made. Let’s dive in.

Read more: Flame Retardant Fabric: Can It Be Non-Toxic?

What is Textile Manufacturing?

Textile manufacturing might be an old industry, but it's still important and incredibly diverse. Basically, it’s all about turning fibers into yarn, then yarn into fabric. From there, these fabrics get printed, dyed, or turned into things we use every day—like clothes, home goods, upholstery, and even industrial products.

Think about it: whether it’s the outfit you’re wearing, the art on your walls, or the carpet under your feet, all of it starts with textile manufacturing. These textiles don’t just provide comfort; they’re essential to our lives and are deeply connected to cultures all around the world.

In textile manufacturing, different fibers are used to create yarn, with cotton being the most common natural fiber. But textiles are classified based on the type of fibers they’re made from. For example:

Natural fibers: silk, wool, cotton, linen
Synthetic fibers: rayon, nylon, polyester
Inorganic fibers: cloth of gold, glass fiber, asbestos cloth

They’re also classified by their structure or weave—how the threads cross each other in the loom. The quality of a textile depends on several factors, like the quality of the raw materials, the character of the yarn, the density of the weave, and the finishing processes.

Interestingly, while most textiles today are produced in factories using power looms, some of the finest fabrics—like brocades, velvets, and table linens—are still made by hand. Textile production is a complex process that includes everything from spinning and weaving to dyeing, knitting, and even embroidery.

While the word "textile" originally referred to just woven fabrics, it now covers a wide range of materials, thanks to the evolution of methods and processes over time. So, next time you think about textiles, remember—they're so much more than just fabric!

Different types of fibers

Before diving into the manufacturing process—since it varies depending on the type of fiber—let’s first break down how fibers are classified. It’s pretty simple: there are natural fibers and human-made fibers. Natural fibers include those that come from animals, plants, and minerals. On the other hand, human-made fibers are categorized into natural polymers, synthetic fibers, and inorganic fibers, with synthetic fibers being the most commonly recognized.

Natural fibers

Animal fibers

These are often called protein fibers or keratin polyesters. You’re probably familiar with fabrics like wool, silk, leather, alpaca, mohair, angora, camel, and vicuña, which all fall under this category.

Vegetable fibers

Also known as cellulosic fibers or glucose polymers, this group includes cotton, linen, ramie, sisal, jute, coir, pineapple, grasses, bananas, kapok, bamboo, and hemp. Essentially, any fibers derived from plants—whether they’re plant fibers, cellulosic fibers, bast fibers, leaf fibers, or seed fibers—belong here.

Mineral fibers

This category includes materials like asbestos and metals such as copper, silver, and gold.

Human-made fibers

Natural polymer/Semi-synthetic

This category includes the popular sustainable fabric TENCEL Lyocell, as well as others like viscose and rubber. What sets these apart from fully synthetic fibers is that they’re made from natural resources like wood pulp or bamboo, which are renewable. The fibers in this category often are used to produce sustainable fabrics.

Synthetic fibers

Synthetic fibers include materials like polyester, nylon, acrylic, spandex (also known as elastane), and polypropylene. These fibers are man-made, typically from petrochemicals, and are engineered to have specific properties such as durability, elasticity, and resistance to wrinkles and shrinking.

Inorganic fibers

Inorganic fibers are a type of man-made fiber that is derived from non-carbon-based materials, meaning they are not organic. These fibers are typically produced from minerals or other non-organic substances and are used in a variety of industrial applications due to their unique properties such as high heat resistance, chemical stability, and strength. Some examples are:

1. Glass Fibers: Made from silica and other raw materials, these fibers are commonly used in fiberglass for insulation, as well as in composite materials for automotive and aerospace industries.

2. Carbon Fibers: Produced from carbon-based materials, carbon fibers are extremely strong and lightweight, making them ideal for use in high-performance applications like aerospace, sports equipment, and automotive components.

3. Ceramic Fibers: Made from materials such as alumina and silica, ceramic fibers can withstand very high temperatures and are used in applications like thermal insulation, fireproofing, and furnace linings.

4. Metallic Fibers: These fibers are made from metals like aluminum, copper, or stainless steel, and are often used in textiles for conductive or shielding purposes, as well as in filters and reinforcement materials.

5. Basalt Fibers: Derived from volcanic basalt rock, these fibers are used in construction, automotive, and aerospace industries due to their high strength, durability, and resistance to extreme temperatures and chemicals.

How textile is made

When it comes to natural fibers, the process is pretty straightforward. First, the fibers are gathered and cleaned, then they’re aligned so they all face the same direction. After that, they’re twisted together to form a strong yarn. Finally, the yarn is woven or knitted into fabric using tools or machines. Think cotton, linen, silk, wool, cashmere, and burlap—these are all examples of natural fabrics.

On the other hand, synthetic fibers start with natural polymers, like petroleum, which go through chemical reactions to create new polymers. Machines then push these polymers through tiny holes, stretching them into long fibers. From there, the process mirrors how natural fabrics are made—twisting the fibers into yarn, which is then woven or knitted into fabric. Polyester, nylon, and acrylic are some of the common synthetic fabrics you might recognize.

There’s also a third category called semi-synthetic fabrics. These are different from fully synthetic fabrics because the natural resources used to create the polymers come from renewable sources like wood pulp or bamboo. Just like synthetic fibers, these are pushed through holes and stretched into long fibers. Rayon (Viscose), Lyocell (Tencel), and Modal fall into this semi-synthetic category.

Natural Fibers

Source: Plants, animals, or minerals
Examples: Cotton, wool, silk, linen, cashmere
Process: Fibers are collected, cleaned, and spun into yarn. The yarn is then woven or knitted into fabric.

Synthetic Fibers

Source: Petroleum-based chemicals
Examples: Polyester, nylon, acrylic
Process: Chemicals are used to create polymers, which are then extruded into fibers and processed into fabric.

Semi-Synthetic Fibers

Source: Wood pulp (a renewable resource)
Examples: Rayon, Lyocell (Tencel), Modal
Process: Similar to synthetic fibers, but starting with wood pulp instead of petroleum.

What is the Process of Textile Production?

The process of textile manufacturing of course is way more complicated than just a few steps. But don’t worry, we will try our best to make it easy to understand.

Step 1: Sourcing fiber

"Sourcing fiber" is the first crucial step in the textile manufacturing process, where the raw materials that will eventually become fabric are gathered. The quality of the final product is super dependent on how well this step is done. For natural fibers like cotton, wool, or silk, this means carefully picking or shearing them from plants or animals at just the right time to make sure they stay strong and soft. For synthetic fibers, it's about acquiring the petroleum-based chemicals that will be processed into polymers and then spun into fibers.

When it comes to making recycled fabrics, "sourcing fiber" takes on a whole new meaning. Instead of harvesting fresh materials, the process starts with collecting and sorting post-consumer waste, like old clothes, plastic bottles, or fishing nets. These materials are cleaned and broken down into their base fibers, which are then re-spun into new yarn.

Step 2: Spinning or Yarn Manufacturing

Spinning, or yarn manufacturing, is all about transforming raw fibers into yarn—a continuous strand that’s essential for weaving, knitting, and other textile production methods. It all starts with prepping the raw materials, like cotton, wool, or synthetics, where the fibers are cleaned and any impurities are removed to make sure the yarn turns out high-quality.

After that, the fibers might be blended or mixed to achieve specific qualities in the final yarn, especially when different types of fibers or recycled materials are involved. The fibers are then aligned and straightened through carding or combing, creating a smooth, continuous sliver that’s ready for spinning.

In the spinning process, the fibers are twisted together to form a strong, continuous yarn, with the twist playing a big role in how strong and elastic the yarn will be. Finally, the spun yarn is wound onto spools or bobbins, making it ready for use in various textile applications. Spinning is crucial because it can help turn raw materials into the yarns that make up all kinds of fabric.

Step 3: Fabric Manufacturing Process

The fabric manufacturing process, often referred to as weaving, is the next step in textile production after spinning. In this stage, yarn is transferred from one machine to another to create fabric. This is done using machines that take the yarn and weave it into lengths, which are then fed onto a loom. The loom has different sections called harnesses, where specific colors or threads are arranged.

To start weaving, the warp (the lengthwise yarn) needs to be carefully aligned between the two sides of the heddles. Once everything is in place, the loom is activated, and the weaving process begins. After the fabric is woven, it's removed from the loom and can be sewn together to create the final product.

In the garment industry, there are four main types of fabrics produced:

Woven fabric

Weaving, in this traditional method, yarns are interlaced at right angles using a loom. The lengthwise yarns, called the warp, are held stationary, while the crosswise yarns, known as the weft, are woven through them to create a fabric.

Knit fabric

Knitting involves interlocking loops of yarn using needles to create a fabric that is typically more stretchy than woven fabrics. Knitting can be done by hand or by machine.

Nonwoven fabric

Nonwoven fabric involves bonding fibers together using heat, chemicals, or mechanical action, without the need for weaving or knitting. Nonwoven fabrics are often used for items like disposable hygiene products, medical supplies, and filters.

Braided fabric

In the braiding technique, three or more yarns are interlaced diagonally to create a strong, flexible fabric often used for ropes, cables, and specialized textile products.

Step 4: Fabric Wet Processing

Fabric wet processing is all about giving textiles those final touches that make them look and feel just right. It’s a series of treatments where water, chemicals, and other liquids work together to bring out the best in the fabric, whether that’s through adding color, improving texture, or enhancing durability. This stage is super important in the world of textile manufacturing because it takes raw fabric and turns it into something truly finished and ready to wear.

Here’s how it works:

First, there’s “pre-treatment”. This is like prepping your canvas before painting. The fabric gets cleaned up—think scouring to remove grease, bleaching to lighten it up, and desizing to get rid of anything leftover from weaving. Then comes the “dyeing” process, where the fabric soaks up color, whether it’s done in big batches or in a continuous, more efficient way.

After that, “printing” might come into play if you want to add patterns or designs. You can go old school with screen printing or get techy with digital printing for those detailed looks. Once the fabric looks the way you want it to, it’s time for “finishing”. This is where you can add flame retardants, make the fabric stronger by applying polyurethane, or even prevent those annoying little fabric balls from forming. Finally, the fabric is “dried” using various methods, making sure it’s ready for whatever comes next.

Overall, fabric wet processing is key to making sure the final product isn’t just a piece of cloth, but something that’s stylish, comfortable, and long-lasting.

Step 5: Garment Manufacturing Process

The garment manufacturing process is all about turning raw fabric into the clothes we wear every day. It’s a detailed journey that covers everything from sketching out designs to stitching the final seams. Let’s break down how it all comes together:

Design and Pattern Making

It all starts with the design phase. Fashion designers draw up their ideas and then create patterns—these are like blueprints for cutting the fabric. Patterns can be drawn by hand or made using computer software.

Fabric Selection and Sourcing

Once the design is ready, the next step is choosing the right fabric. This involves considering the fabric's weight, texture, and color to make sure it matches the design perfectly. After that, the fabric is sourced from suppliers.

Fabric Cutting

Now comes the cutting. The fabric is cut into different pieces based on the pattern templates. This part is super important because precise cutting ensures that everything will fit together smoothly later on. Whether it’s done by hand or with cutting machines, accuracy is key.

Sewing and Assembly

After the fabric is cut, it’s time to sew it all together. This is where the garment really starts to take shape. The pieces are sewn to create the garment, with steps like attaching sleeves, adding zippers, and sewing hems. Skilled workers or automated sewing machines are used to get everything just right.

Fitting and Quality Control

Once the garment is sewn, it goes through a fitting process to make sure it looks and fits the way it’s supposed to. If any adjustments are needed, they’re made here. Quality control checks are also done to catch any defects and ensure the garment meets the required standards.

Finishing

After passing quality control, the garment gets some finishing touches, like ironing, steaming, or pressing, to give it that polished look. Labels, tags, and any extra details are added at this stage.

Packaging and Distribution

Finally, the finished garments are packaged up, usually with protective coverings, and prepared for distribution. They’re sorted by size, color, and other specs before being shipped off to retailers or customers.

In a nutshell, the garment manufacturing process is a carefully planned, detailed series of steps that ensure every piece of clothing is high-quality, stylish, and ready to wear.

Different ways of making textile

There are different ways of making textile, including but not limited to weaving, knitting, braiding, felting, bonding, and spread tow.

1. Weaving

Weaving is one of the oldest and most common methods of creating fabric. It involves interlacing two sets of yarns or threads—called the warp (lengthwise) and the weft (crosswise)—at right angles to each other. This is typically done on a loom, where the warp threads are held taut, and the weft thread is woven over and under them in a specific pattern. The result is a strong and durable fabric, like the ones used for denim, cotton, and many other materials.

2. Knitting

Knitting is a method of creating fabric by interlooping yarns with needles. Unlike weaving, which involves crossing threads, knitting uses a single thread that is looped together in rows, creating a stretchy and flexible fabric. Knitting can be done by hand or with a knitting machine. The most common knitted fabrics are used in sweaters, socks, and t-shirts.

3. Braiding

Braiding involves intertwining three or more strands of yarns or threads to form a fabric. Unlike weaving or knitting, braiding creates a narrow, strong, and flexible textile, often used for ropes, shoelaces, and decorative trims. Braiding can be done by hand or with specialized braiding machines.

4. Felting

Felting is a process that creates fabric by matting, condensing, and pressing fibers together. It usually involves wool or other animal fibers, which are agitated with moisture and heat to form a dense, non-woven fabric. Felt is often used for crafts, hats, and insulating materials because of its softness, thickness, and lack of fraying.

5. Bonding

Bonding, also known as non-woven fabric production, involves creating fabric by bonding or fusing fibers together using adhesives, heat, or chemical processes, without the need for weaving or knitting. This method is used to produce materials like disposable medical fabrics, interfacings, and some types of synthetic leather. Bonded fabrics are known for their durability, lightweight, and resistance to fraying.

6. Spread Tow

Spread tow is a relatively advanced method used primarily for creating high-performance composite materials. In this process, fiber tows (bundles of fibers) are spread out to form thin, flat tapes. These tapes are then layered and bonded together to create a lightweight, strong fabric. Spread tow fabrics are often used in industries like aerospace, automotive, and sports equipment due to their excellent strength-to-weight ratio.

Different Smart Manufacturing Softwares

Smart manufacturing software is revolutionizing the textile industry by streamlining processes, improving efficiency, and enhancing overall production quality. Here’s how different features of this software contribute to the textile manufacturing process:

1. An Unparalleled Auto-Booking System

The auto-booking system is a powerful feature that automates the scheduling and allocation of production resources. It allows manufacturers to automatically book machines, labor, and materials based on real-time data and production needs. This system ensures that resources are optimally utilized, reducing downtime and minimizing bottlenecks. By automating the booking process, textile manufacturers can increase their production efficiency, meet deadlines more consistently, and better manage their workflow.

2. Production Management Tools

Production management tools within smart manufacturing software provide comprehensive oversight of the entire manufacturing process. These tools enable manufacturers to monitor and control every stage of production, from raw material intake to the final product. Key features include real-time tracking of production progress, quality control checks, inventory management, and performance analytics. With these tools, manufacturers can identify inefficiencies, track key performance indicators (KPIs), and make data-driven decisions to optimize production, reduce waste, and improve overall product quality.

3. Software Integrations

Software integrations are critical for creating a seamless and efficient manufacturing ecosystem. Smart manufacturing software can integrate with other enterprise systems such as ERP (Enterprise Resource Planning), CRM (Customer Relationship Management), and supply chain management tools. These integrations allow for the free flow of information across different departments, ensuring that data is consistent, accurate, and up-to-date. For textile manufacturers, this means better coordination between production, sales, and supply chain operations, leading to improved decision-making, enhanced customer service, and a more agile response to market demands.

Traditional vs. Modern Textile Manufacturing

When you compare traditional and modern textile manufacturing techniques, you'll see some pretty big differences in how things are done, how efficient the processes are, and the final results. Here’s a quick breakdown:

Traditional Techniques

Manual Processes

Traditional textile manufacturing is all about hands-on labor. Think hand-spinning, hand-weaving, and hand-dyeing. These processes take time and require a lot of skill.

Natural Materials

Back in the day, textiles were typically made from natural fibers like cotton, wool, silk, and linen. The dyeing process often used natural dyes from plants, insects, and minerals.

Artisanal Craftsmanship

Traditional methods focus on craftsmanship, so each piece tends to be unique since it's handmade. Techniques like hand embroidery and block printing are especially valued for their detailed work.

Modern Techniques

Automation and Machinery

These days, textile manufacturing is driven by advanced machinery and automation. Processes like spinning, weaving, dyeing, and printing are much faster and more efficient thanks to tech advancements.

Synthetic Materials

Along with natural fibers, modern methods make use of synthetic fibers like polyester, nylon, and acrylic. These materials are often designed to have special properties, like moisture-wicking or added stretch.

Mass Production

Modern methods are all about mass production, allowing for the creation of large amounts of textiles at a lower cost, which is key to meeting global demand.

Innovative Technologies

Technologies like digital printing, laser cutting, and 3D knitting have revolutionized textile manufacturing, offering greater precision and the ability to customize products.

Environmental Impact

While modern techniques are more efficient, they often come with a higher environmental cost due to the use of chemicals, water, and energy. But there’s a growing focus on sustainability and eco-friendly practices.

Challenges in Textile Manufacturing

When we talk about textile manufacturing, it’s clear that the industry is up against some serious challenges. One of the biggest hurdles today is addressing sustainability concerns. The environmental impact of traditional textile production is huge, and there’s growing pressure on manufacturers to adopt more sustainable practices—something that’s quickly becoming non-negotiable.

Alongside this, labor issues remain a significant challenge. The industry has a long history of poor working conditions, low wages, and even child labor in some regions. Addressing these issues isn’t just about doing what’s right—it’s also about meeting the rising demand for socially responsible products. Consumers are increasingly looking for fabrics that are made under fair labor conditions, without animal cruelty, and with respect for local communities and the environment. Certifications that focus on these aspects are becoming more important than ever.

The future of textile manufacturing- sustainability

The future of textile manufacturing is all about sustainability, and it's not just a buzzword anymore—it's quickly becoming the core of the entire industry. As consumers and brands alike realize the importance of reducing environmental impact and promoting ethical practices, sustainability is moving from a trend to a necessity.

At the heart of this movement are sustainable fabrics. These materials—like organic cotton, TENCEL Lyocell, hemp, and recycled polyester—are designed to be kinder to the environment. Unlike traditional textiles, which often require a lot of resources and harmful chemicals, sustainable fabrics focus on renewable resources, cutting down water usage, and lowering carbon emissions. Plus, many of these fabrics are made using closed-loop systems that recycle water and chemicals, making them even more eco-friendly.

Looking ahead, the demand for sustainable fabrics is only going to grow. Technological advances are making it easier to produce high-quality, eco-conscious textiles that don’t compromise on style or durability. We’re also seeing more recycled materials—like plastic bottles and old clothes—being turned into new fabrics, which helps reduce waste and the need for new resources.

Transparency and traceability are also set to become big deals in the future of textile manufacturing. Consumers want to know where their fabrics come from and how they’re made, and more brands are stepping up with certifications like GOTS and OEKO-TEX to prove their commitment to the environment and social responsibility.

In short, the future of textile manufacturing is all about going green. By embracing sustainable fabrics and practices, the industry can create a more responsible and eco-friendly future, all while continuing to innovate and meet consumer demands.

How to find a textile manufacturer?

Yu-City is a Taiwanese textile manufacturer that does more than just produce fabrics—we're here to customize any design you need and offer expert consultation for your brand. We've had the privilege of collaborating with top brands like Nuna, Clek, and Mattel, providing them with chemical-free fabrics that meet federal safety flammability standards. We're also passionate about sustainability and are working closely with innovative companies to produce recycled fabrics, aiming to make a real impact in the industry. Got questions about the production process of a specific fabric? Don't hesitate to reach out! We're always here to help.

FAQs

1. What are the steps of the textile process?

The textile process typically involves several key steps:

Sourcing Fiber: Gathering raw materials, whether natural (like cotton or wool) or synthetic (like polyester).
Spinning: Converting fibers into yarn by twisting them together.
Weaving/Knitting: Turning yarn into fabric through weaving (interlacing yarns) or knitting (interlooping yarns).
Fabric Finishing: Enhancing the fabric through processes like dyeing, printing, and finishing to add color, texture, and other qualities.
Cutting and Sewing: Cutting the fabric into pieces and sewing them together to create final products like garments or home textiles.

2. What are the four basic components of textile production?

The four basic components of textile production are:

Fibers: The raw material, either natural or synthetic.
Yarn: The intermediate product, made by spinning fibers together.
Fabric: The material created by weaving, knitting, or bonding yarns.
Finished Products: The final items made from fabric, such as clothing, upholstery, or industrial products.

3. What do textile manufacturers make?

Textile manufacturers produce a wide range of products, including raw fabrics (woven, knitted, non-woven), finished textiles (like dyed or printed fabrics), and end products such as clothing, home furnishings, industrial textiles, and accessories.

4. What is an example of a textile product?

An example of a textile product is a cotton T-shirt. It starts as raw cotton, which is spun into yarn, woven into fabric, and then cut and sewn into a T-shirt.

5. What is the difference between fabric and textile?

The term textile refers to any material made of interlacing fibers, which can include fabrics but also other materials like felt or non-wovens. Fabric specifically refers to material produced by weaving or knitting yarns. Essentially, all fabrics are textiles, but not all textiles are fabrics.

6. What is the most used textile in the world?

The most used textile in the world is cotton. It's widely used in clothing, home textiles, and industrial products due to its softness, breathability, and versatility. However, it’s not considered one of the most sustainable fabrics because traditional cotton farming is incredibly resource-intensive. It requires large amounts of water, often involves the use of harmful pesticides and fertilizers, and can contribute to soil degradation and water pollution. These environmental impacts make conventional cotton less eco-friendly compared to other, more sustainable alternatives like organic cotton, hemp, or recycled materials.

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