Today the textile industry encompasses a significant number and variety of processes that are adding

value in fiber. These processes may range over the yarn making through the garment stitching, fabric
embossing, and composite production. However, considering the textile fiber as the basic building
unit of any textile product, the textile manufacturing may clearly be identified as the conventional
and technical textiles.

Textile fibers provided an integral component in modern society and physical structure known for
human comfort and sustainability. Man is a friend of fashion in nature. The desire for better garment
and apparel resulted in the development of textile fiber production and textile manufacturing
process.

Primarily the natural textile fibers meet the requirements for human consumption in terms of the
comfort and aesthetic trends. Cotton, wool, and silk were the important natural fibers for human
clothing articles, where cotton for its outstanding properties and versatile utilization was known as
the King Cotton.

Cotton is an important natural fiber produced in Asian and American continent since the last around
5000 years in the countries including the USA, India, China, Turkey, Pakistan, Brazil, etc. [1]. The
advancement of fiber manufacturing introduced several man-made fibers for conventional textile
products; however, cotton is to date a leading textile fiber in home textiles and clothing articles. The
chemistry of cotton fiber is the principal source of interesting and useful properties required in
finished textile products [2]. Strength, softness, absorbency, dyeing and printing properties, comfort,
air permeability, etc. are the important properties of cotton to remain an important textile fiber in
the market. By 2018 cotton fiber was significant with a market share of 39.47% as raw material in
textile products.

Cotton fiber grown with increased environment-friendly properties is called organic cotton. It is
grown without using any synthetic chemicals or pesticides, fertilizers, etc. Organic cotton is produced
through crop with the processing stages in an ecological environment. Turkey, the USA, and India are
the main countries producing organic cotton.
Textile manufacturing process

The conventional textile manufacturing process has a long history of converting the natural fiber into
useful products including fabric, home textiles, and apparel and more recently into a technical textile
through the utilization of special finishing effects (Figure 3).
Textile manufacturing process from fiber to fabric.

The synthetic and semisynthetic fiber manufacturing is diversified with the utilization of monomer,
chemical agent, precursor, catalyst, and a variety of auxiliary chemicals resulting in the formation of
fiber or yarn. However, such man-made fibers are perceived as a separate specialized subject and
beyond the scope of this book. Therefore, the man-made fiber manufacturing is not discussed.

The innovation in textile manufacturing introduced variety in raw materials and manufacturing
processes. Therefore, process control to ensure product quality is desired. Monitoring and
controlling of process parameters may introduce reduction in waste, costs, and environmental
impact [6].

All the processing stages in textile manufacturing from fiber production to finished fabric are
experiencing enhancement in process control and evaluation. It includes textile fiber production and
processing through blow room, carding, drawing, and combing; and fabric production including
knitted, woven, nonwoven, and subsequent coloration and finishing and apparel manufacturing.

Textile Manufacturing

Textile manufacturing is an old but massively important industry. It is a huge and diverse industry
that is basically involved with the conversion of fiber into yarn and then yarn into fabric. These
fabrics are then printed, dyed, or fabricated into clothes, household products, upholstery, and
various industrial products.

Whether it is the clothes we wear, the art we appreciate, or the carpets we walk on, all of these stem
from the same manufacturing processes. They can either provide comfort or are essential for
survival. In fact, textiles are an important staple to culture all around the world and to existence in
general.

In textile manufacturing, different types of fibers are used to produce yarn, but cotton is the most
important natural fiber among them all. What needs to be noted here is that textiles are classified
according to their component fibers into:

Silk

Wool

Cotton

Linen

They can also be classified according to their component synthetic fibers like:
Rayon

Nylon

Polyesters

There are also some inorganic fibers, based on which your textiles can be classified. These are:

Cloth of gold

Glass fiber

Asbestos cloth

Additionally, your textiles are classified further based on their:

Structure or weave

The manner in which weft and warp cross each other in the loom

The factors that will determine the value and quality of your textiles are:

Quality of raw materials used.

The character of the yarn spun from the fibers like clean, fine, smooth, and coarse. It also includes
whether they are soft, hard, or medium twisted.

Density of weave

Finishing processes

One of the modified forms of plain cloth weaving is a tapestry, which is sometimes classed as
embroidery. In fact, the weaving of rugs and carpets is a special branch of the textile industry.

Other specially prepared fabrics that are not woven are felt and bark (or tapa) cloth. These are
beaten or matted together. However, in some cases, like in crochet and netting work and various
laces, a single thread is looped or plaited.

Nowadays, most textiles are produced in factories with the use of highly specialized power looms.
There are, however, certain exceptions to this, like many of the finest brocades, velvets, and table
linens that are still made by hand.

Thus, textile production is a long and complex process that produces tons of different finished
products. These textile production processes can be, but are not limited to:
Spinning

Weaving

Dyeing

Knitting

Bonding

Embroidery

Felting

Tufting

While the term textile comes from the Latin word “textilis” and the french “exere,” which translates
to “to weave,” it was used to refer to only woven fabrics. But today, as the methods and processes
have evolved over time, textiles have come to include many different fabrics and materials.

Process of Textile Manufacturing

Understanding the whole process of textile manufacturing is the key to understanding as well as
optimizing your business. This section of the article will take you through the textile manufacturing
process. This process is as follows:

Source Fiber

The process of textile manufacturing begins with the cultivation of natural textile fibers. This means
that the first step in the production of textiles is harvesting raw fiber and sourcing it.

Fibers are extracted from:

Plant or

Animal or

Mineral sources

They are then processed into a continuous strand known as yarn.

There are many types of fibers like:

Cotton

Linen
Wool

Silk

And so on. Additionally, today, man-made or synthetic fibers are also used in textile manufacturing.
These include but are not limited to the following:

Polyester

Rayon

Nylon

Spinning or Yarn Manufacturing

Yarn manufacturing is the textile process of turning raw materials into yarn. To create the final yarn
of thread, raw materials are sorted, cleaned, and then mixed together. This is used in weaving,
knitting, or crocheting. Yarn can also be called a thread when it is used for sewing purposes.

Yarn manufacturing is known as the mother of the textile manufacturing process. Mainly, yarn is
done by spinning together fibers such as cotton fiber, wool, or synthetic fibers. While originally, the
yarn used to be made from animal hair, today, the same is not the case.

In fact, the market has many different types of yarn today. This is because textile manufacturers have
found ways to make them out of other things like hemp, basalt, or bamboo. Yarn can also be made
from recycled materials like plastic and polyethylene. In the case of synthetic yarn production, it is
turned into petroleum-based products like rayon and polyesters.

While yarn manufacturing is a complex textile manufacturing process that takes place in different
factories based on the type of yarn being created, the main theme of textile processing will always
stay similar.

The first step in yarn manufacturing is raw material preparation. For this, raw materials must be
sorted, cleaned, and mixed together to create the final textile product.

For example, if the raw material is wool or cotton, then you will have to ensure that any debris that
might contaminate a batch is removed. If, however, your raw material is bamboo, then you will need
to strip away its outer layer before spinning it into sewing thread for knitting projects.

After the raw materials are prepared, they are spun into yarn through a process called spinning.
Spinning is done using machines with steel bobbins that have been wound with fiber or spinning
material, known as roving. This can come from natural sources such as wool or cotton.
The machine winds the roving around a bobbin and then pulls it between two rollers that turn at
different speeds to create the yarn. Here, some machines can also “twist” in order to add strength
and elasticity to the final product.

Fabric Manufacturing Process

Also known as weaving, the fabric manufacturing process is the next step in textile production. Here,
yarn is taken from one machine and transferred to another machine in order to create a length of
fabric.

This process is completed using machines that turn yarn into lengths, which are then fed onto a loom
with different types of colors or threads on specific sections called harnesses.

The warp (lengths) must be fitted precisely between the two sides of the heddles before the loom is
turned on and the weaving process begins. Once a length of textile fabric has been created, it is
removed from the looms and then sewn together to create a finished product.

There are four types of fabrics that are produced in the garments industry. These are:

Woven fabric

Knit fabric

Nonwoven fabric

Braided fabric

Fabric Wet Processing

This is a process used to dye and finish textiles. The dyeing process involves the application of
colorants to fabric in order for it to become colored. The wet preparatory processes are:

Fabric inspection

Stitching

Desizing

Scouring

Bleaching

Dyeing

Printing
Finishing

Textile finishing may involve adding additional properties such as soil release, anti-pill, or flame
retardant treatments with different textile auxiliaries. This is applied chemically before packaging and
shipping. What needs to be noted here is that there are several types of textile finishing that can be
done by hand or machine.

Textile printing includes the use of inkjet printing on fabrics like sweatshirts, aprons, children’s
clothes, t-shirts, etc. It also includes screen printing on various types of clothing, including hats,
shirts, etc. Some of the types of textile printing are:

Digital textile printing uses computers/plotters to print onto fabric

Flexography which prints onto plastic film

Gravure printing which prints with engraved cylinders onto paper

Dye sublimation printing, where heat-activated chemicals are transferred onto a carrier medium
from an inkjet printer

Garment Manufacturing Process

Garment manufacturing is the heart of yarn manufacturing. The steps involved in the garment
manufacturing process are:

Garments design- This could be provided by the buyer, or you will need textile design in the
designing section. When garments are received from the buyer, their design starts with a technical
sheet. This step can either be done manually, or it can be automated.

Pattern making- Based on the garments' design, technical sheet, and artwork, the pattern master
makes the pattern for all garments. Today, however, this can be done with an automated machine.
Patterns are drawn, keeping in mind the different components of apparel by standard body
measurements. They are often known as basic blocks or block patterns.

Sample making- After the perfect pattern has been made, a complete apparel sample is made to
ensure that it meets the requirements of your buyers. Once this sample is approved by the buyer as
per their required specifications, it is known as an approved sample.

This will help in ensuring that the pattern adheres to the instructions issued for complete apparel
production. This will help in saving your expenses while also keeping your customers satisfied.

Production pattern making- The approved sample is followed by the counter sample, which is made
for bulk production. Here, an additional extra measurement with exact or actual measurement is
taken. This is known as an allowance, which is crucial for bulk production. Allowance can either be
added manually or using the computer and is often known as a working pattern.
Grading- Grading is the stepwise decrease or increase of the block or master pattern to produce
different patterns and sizes. In bulk garments, production grading is important to maintain the
production's size ratio. It is graded according to the buyer’s instructions.

Marker making- A marker is a thin paper containing every apparel part. Marker-making helps to
produce the cutting process smoothly. This step can be done manually as well as by using
automation.

Fabric spreading- This is one of the crucial parts of the garment production process. This is also
known as fabric lying. This process is undertaken after a process named fabric relaxing is undertaken.

The main objective of fabric relaxation is to relax and contract the fabrics. This makes the fabric ready
for the garment production process.

The benefit of this process is that it not only helps in preventing fabric strain at several stages but
also helps in reducing fabric shrinkage. Post this, the fabric is spread on a long table so that it can be
cut properly.

Currently, fabric spreading is done using automation. However, it still requires skilled manpower to
spread the fabric properly. Thus, it is during the fabric spreading process that any fabric fault from
the production line is detected.

Fabric cutting- The fabrics need to be cut according to the marker. To do so, the process starts with
fabric lying, marking, and then cutting. This is one of the most essential steps, as once the fabric is
cut, there is no going back.

Hence, this can negatively affect your sewing process if not undertaken properly. This process can be
done manually with a straight and sharp knife or through a computerized cutting system.

Cutting parts sorting and bundling- After the errorless cutting, all the parts are sorted out according
to the bundle tag. The bundle tag represents the fabric component bundle to identify the
component. It is required to maximize production and maintain it. However, this step is not required
in cases of single-garment production.

Sewing- Here, all the cutting components of fabric are sewn together to make the garment or part of
the garment as required. This is done manually and depends on the skills of the workers.

Garments inspection- Final garment inspection is an important part of quality control. Higher the
quality of your garment, the better your factory is represented. This step is undertaken manually.

Often, garment factories set a commodity standard to measure production output. Quality control is
the most complicated section where the quality of your garments will be defined based on the
inspection.
Spot removing, ironing, and finishing- This step happens after the production defects are identified in
the quality control, and marked with a sticker. The garments are now taken to the spot cleaning area.
Here, your apparels will be cleaned with the help of hot water, steam, or chemical stain remover.
Then it goes for manual ironing and finishing.

Final inspection- A final quality control check is done to ensure that your buyer’s requirements are
met. Sometimes this is also done by the agents of your buyer. This step is always carried out
manually.

Garments packing- Once all the above-mentioned steps are completed, your garments will be
packed. The packing is carried out by using the buyer’s instructed poly bag. This step can be done
either manually or it can be automated.

Cartooning and shipment- Once your garments are packed, they are cartooned to reduce the damage
of the garments. This is done in accordance with the buyer’s instructions. Post cartooning, shipment
starts.

Different Types of Textile Production

Textile production is the process of interweaving fibers to form a more complex pattern or object.
Currently, there are at least six forms of textile production. These include:

Weaving

Knitting

Braiding

Felting

Bonding

Spread tow

In these crafts, hundreds of separate materials are used. These are categorized into the following
four main groups:

Anima; textiles

Plant textiles

Mineral textiles

Synthetic textiles

Weaving

This is a textile manufacturing method that interlaces long strands of cloth in both horizontal and
vertical patterns. For this textile production, a device called a loom is incorporated. With the loom,
hundreds of different patterns are made possible.
The several examples of woven items range from bed sheets to bulletproof vests and thousands of
creations in between.

Knitting

Traditionally, knitting is a type of textile production that is completed by hand with a needle or a
crochet hook. Today though, industries have incorporated large knitting machines.

Crocheting is another type of textile manufacturing that would fall under this category. In fact, there
are several types of clothing that are produced from knitting, using a variety of materials.

Braiding

This is a form of textile production in which two similar fabrics are taken and then twisted into knots
by using a predefined pattern.

Normally, a braided material has a much greater overall strength if made correctly. This is why
numerous types of ropes are created this way.

Knotting is a similar process that falls under the same category of textile manufacturing. In knotting,
though, the shapes that are created are often not uniform.

Felting

This is a type of textile production that varies vastly from other processes discussed above. In this
method, nothing is being interlaced together physically.

Instead, various components are forced together under large amounts of pressure. They are then
twisted together so that they become entangled.

To prevent them from tearing or breaking during the process, these fibers are normally treated with
some type of lubricant, like a detergent.

Bonding

This is a term that is almost exclusively applicable to synthetic materials like polyester or nylon. It is
that type of textile production where these synthetic components are connected by means of
pressure, heat, or adhesive.
Spread Tow

This method of textile production is similar to weaving. This is because, in this method, small,
lightweight components are made into a tape and then woven together with similar pieces.