Steps of Fabric Manufacturing

One of the most crucial steps in the garment industry is fabric manufacturing. The quality of the fabric production process is directly linked to the yarn used. Yarn selection has a significant impact on the fabric's final appearance, durability, comfort, and functionality. The types of yarn derived from different raw materials and fibers affect the final look, durability, comfort, and overall quality of the textile product. So, how should the fabric production process be conducted? What should fabric manufacturers consider when selecting yarn? All the answers to your questions about fabric and manufacturing of fabric are here!

What Are the Stages of Fabric Production?

The fabric manufacturing process involves several steps, and the decisions made at each stage affect the quality of the final product. The main methods used in fabric production include woven fabric production, knitted fabric production, felting, and nonwoven production. The fabric production process will vary depending on the chosen method. Generally, the fabric production stages can be listed as follows:

1. Yarn Selection: Some fabric manufacturing companies produce their own yarn, while others use ready-made yarns. The yarn production stages differ depending on the type of fiber used. For instance, the process for cotton yarn production differs from the process for plastic yarn production. However, in general, yarn production begins with the preparation of raw fibers. In the case of cotton or wool yarn production, natural fibers like cotton and wool are cleaned and purified of foreign substances. Then, the cotton fibers are combed, removing seed and leaf remnants from the fiber mass. For wool yarn, the wool fibers undergo a washing process to remove oil and dirt. Following that, a blending process is applied, allowing the mixing of different fiber types or fibers of the same type but with different qualities and characteristics. This step ensures a more homogeneous yarn production. In the next step, the fibers are aligned parallel in combing machines and collected into a strip. After that, a carding process is done to further organize and thin the fibers. The combing process draws out the fiber strips, making them finer and more uniform. During the roving step, the strips are shaped into a finer form, with a lower twist, in roving machines. In the spinning step, the fibers are turned into yarn. Finally, a twisting process is applied to give the yarn strength. The resulting yarns are wound onto bobbins or spools, and the final processes such as heat treatment, dyeing, or coating are applied as desired.
2. Wowen Fabric Manufacturing: The second step in the production process of fabric manufacturing companies involves weaving and knitting processes. In this step, yarns are processed in weaving looms or knitting machines to form fabric. Then, the fabric is given its final form through processes such as dyeing, finishing, and softening. Each stage in this process is optimized according to the characteristics of the selected yarn type. For example, woven fabric is created by combining weft and warp yarns. In warp preparation, yarns are arranged and tensioned in warp machines. In weft preparation, the weft yarns are prepared to be added to the fabric during the weaving process. Finally, in the weaving preparation, the warp and weft yarns are woven in a specific pattern, such as plain, satin, or dim, on weaving looms. Woven fabrics, which have a wide range of applications, are frequently used in the ready-to-wear sector, the production of home textiles, in technical and industrial fields like tents, tarps, and workwear, as well as in the production of sports and outdoor clothing items.
3. Knitted Fabric Manufacturing: Knitted fabric production is carried out by forming loops. In flat knitting, the loops are produced in sequential rows, while in circular knitting, the loops are formed in cylindrical structures. Due to their structure, knitted fabrics are typically flexible and soft. Additionally, knitted fabrics stand out for their light weight, elasticity, and comfort, making them ideal for use in ready-to-wear production, as well as for lingerie, socks, sweaters, and knitwear items.
4. Nonwowen Fabric Manufacturing: Felt and nonwoven fabrics are produced using methods that do not require weaving or knitting. Felt fabric is created by compressing natural fibers, such as wool through heat, moisture, and pressure. On the other hand, nonwoven fabrics are made by bonding or laminating synthetic fibers to form fabric. Felt and nonwoven fabrics are commonly used in the production of clothing and fashion items such as hats, bags, and coats, as well as in home textiles, sports, and outdoor sectors.
5. Dyeing and Printing Stages: Raw fabrics are typically white or in natural colors, which are then dyed to give them a uniform color. If desired, prints can be added to the fabric using the printing method. During this stage, techniques such as rotary printing and digital printing are used to add patterns and prints to the fabric.
6. Finishing Process: The processes applied to finalize the fabric are referred to as finishing processes. During this stage, softening is done to improve the fabric's texture, and polishing is applied to give the fabric a more attractive appearance. Waterproofing adds water resistance to technical fabrics, and finally, finishing treatments are applied to enhance the fabric's durability and prolong its service life.
7. Cutting and Packaging: After the finishing processes, the fabric is cut according to demand or rolled up. Finally, quality control procedures are carried out, and the product is packaged and prepared for shipment. Fabric production is a process that requires attention and care at every stage. The methods and technologies used determine the fabric's properties and its application areas. With modern textile technologies, these processes have become more efficient and environmentally friendly. If you'd like to learn more about new yarn types and technologies shaping your process of fabric manufacturing, as well as explore new business collaboration opportunities, get your online ticket for the İstanbul Yarn Fair now!

Yarn production generally follows these steps. If you plan to use pre-made yarns in fabric production, it is crucial to choose yarns that are suitable and of high quality for the product you intend to create. If you'd like to explore dozens of different yarn types and meet with key industry figures and companies, we invite you to the 21st International Yarn Fair. Don’t miss the most prestigious event in your industry!

Lastly, remember that choosing the right yarn according to the usage type will directly optimize your production processes. If you'd like to learn more about different yarn types , you can check out our related page.