Sustainable Textile Ecosystem: Eco-Conscious Fabric Production for a Circular Future

The Birth of Fabric (Upstream Raw Materials)

The Production of Fabric - Fabric is initially made from petroleum products that are transformed into chemical pellets, and then further processed. The specific steps are as follows:

1. Spinning: Chemical pellets are used to draw out yarn through a process, and the thickness of the yarn is determined. Factories generally purchase yarn cakes directly (this process is not completed in the factory).

2. Warping: Gather the scattered yarn cakes onto a warp beam. The number of warp beams is related to the pattern of the yarn.

3. Doubling: Combine the yarns from two or more warp beams onto one warp beam. For example, 600D yarn can be formed by combining two 300D yarns.

4. Sizing: Apply sizing solution after doubling the yarn to make the yarn stronger.

5. Drawing-in: Use a machine to make the warp yarns stagger in an upper-lower interval so that the weft yarns can pass through.

6. Weaving: There are two types of weaving, knitting and plain weaving, which are mainly reflected in different patterns.
6.1 Water Jet Loom: Usually, the fabric woven by the F6000 water jet loom is relatively flat and uniform.
6.2 Air Jet Loom: Suitable for natural fibers such as cotton fabric and canvas.
6.3 Rapier Loom

7. Dyeing: There are several methods:

1. Spray Dyeing: The fabric remains stationary, and the dye is sprayed onto the fabric by moving the spray device. This method is mainly used in BEAM dyeing machines and has a high cost.

2. Flat Dyeing: Generally used for nylon. The dye remains stationary, and the fabric is moved for dyeing. This method is mainly used in JIGGER dyeing machines and is relatively convenient.

3. Crinkled Dyeing: Generally used for polyester. The fabric and the dye are moved simultaneously for dyeing. This method is mainly used in RAPD high-temperature dyeing machines.

Note: Spray dyeing has the best effect. Pay special attention to the color fastness, which is tested by sunlight, perspiration, and friction. Also, avoid the presence of azo dyes.

Note: Some color difference problems in dyeing mainly include: 1. Vat Difference: For fabrics of the same batch, there are color differences in the fabrics dyed in different vats (this problem often occurs with domestic fabrics).

2. Batch Difference: Color differences are caused by different batches.

3. Color Difference within the Same Bundle of Fabric: Generally, it is a machine problem, such as domestic 600D/PE fabric.

4. Setting: (Dyeing may cause the fabric to wrinkle and shrink. Through setting, the wrinkled fabric can be flattened, and the fabric can be prevented from skewing (especially for checkered fabric)).

5. Sizing: Apply a layer of glue to the surface yarn to make it more firm.

6. Water Repellent Treatment: To prevent the fabric from渗水 (seeping water), this process is generally applicable to fabrics with Epu rubber bottoms.

7. Calendering and Brushing: Calendering is to press down the fuzz on the surface of the surface yarn, and brushing is to make the surface of the surface yarn fuzz up.

8. Laminating: There are different methods for applying different base adhesives.

Applying PE/PVC Base Adhesive:
A. Cold Pressing: Produce raw rubber bottoms and then press. After the base adhesive is prepared, the base adhesive and the surface yarn are combined together through physical and chemical actions.
B. Hot Pressing: The base adhesive is melted and pressed at the same time, generally relying on heat for pressing.

Applying PU/AC Ultrasuede Base Adhesive:
Gluing by Scraping: Through a fixed roller, move the fabric. Apply glue on the roller and let the roller rotate and come into contact with the fabric, thus applying the base adhesive to the fabric (usually there are transparent glue, white glue, silver glue, gold glue, and colored glue).

Note: The processes of hot pressing and gluing by scraping are similar, but the distance between the roller and the fabric is different. Among them, the steps from spinning to weaving are the fabric weaving process, the processes of dyeing, calendering, and brushing are the dyeing and finishing process, and finally, there is laminating. These are the three basic processes.