A natural fabric would last longer than synthetic fabric thus, cotton is one of the most widely used fabrics when it comes to fulfilling our bedding needs. Have you ever wondered how the process of cotton being a finished product takes place from the farm to our bed? Wear your protective gears as we are about to experience a purely sublime journey.

“Blooming Cotton Fields”

Ever witnessed scenery that is pleasant with a soft ambiance? Well, a cotton field in its blooming season is something not to be missed. The scenery is so pleasant for the eyes that it takes you to an awe-inspiring miraculous world, where there is nothing but peace. The cycle of turning raw cotton to fabric begins when seeds are sowed into the fields and, in about three to four months early-season flowers are expected to be seen. With time, the flowers mature turning into a soft fur ball. Of course, the response is highly dependent upon the environmental conditions.

Moreover, when the cotton crops step into the blooming season they are ready to be harvested. It is significant to harvest them soon as further delay might damage the crops. Thus, here ends the first step of turning cotton into fabric by planting and harvesting.

“Combing And Expelling Air Current”

As the cotton crops are harvested, they are moved to the spinning plant to further begin the process. Under this process, machinery is utilized in cleansing and detaching the things into which the cotton crops are wrapped including leaves and seeds. With this, the process proceeds to designate the sheets to the machines, ‘lap’.

“Shrink To Blossom”

This is the most essential and crucial part of the process. Before turning into a yarn, the cotton is placed into a ballroom where the size of the cotton shrinks, turning into smaller pieces. In addition, the fibers (from cotton crops) are converted into yarn. Fibers are worn and crumpled from the cotton stack, where they are placed in mills bringing the fibers in conjunction to give shape to yarn.  Moreover, the process continues to form the size, following the requirement. In machinery, to strengthen the fiber, oils are denoted as an additional element while spinning to decrease the force. As this process ends…Boom, yarn is produced.

The procedure continues with the process of weaving. It proceeds with the deliverance of yarn to the other section where it is joined with another set of yarn and is interlaced. It further continues with the step of placing yarn into a package, which has the capacity of letting in an adequate size of yarn. With that, new and full packages make a place while replacing the other ones.

“Braid- Adding Strength”

Yarns undergo a process where they are combined, forming a sheet. This process is called warping. This is an important step where the initial pace of adding strength to the fiber begins.

“Welcoming The Protective Fillers”

When done with this process of warping, a protective filler is applied to them, this application is called sizing. This step of sizing improves the weaving ability. It is considered an essential part of the weaving process.

“Entice- Last Step Of Weaving”

The warp yarns are sent to a strong beam, former name weaver’s beam, where the last step of weaving kicks off, turning yarns into a fabric. This process is crucial as now the raw material is turning into a semi-finished good, displaying it as raw fabric.

“Affixing Deep And Mysterious Language”

As the raw fabric is ready with the weaving process, the dyeing stage steps in adding colors to lighten up the fabric and finish it with printing. The dyeing process has many factors that it needs to undertake before the process starts. This part of the process is highly dependent on the requirement and is to be followed as it is. Most of the manufacturer dye pieces, this acts as a benefit as they save themselves from piling up the dyeing stock that might not be required and still keep a pile of white fabric that may later be used, as per the requirement. The process is finished in dyeing mills.

“Filling Creative Textures”

This process enhances the fabric through vibrant colors and patterns. Under this process, the manufacturer makes sure that the color of fabric bonds with fiber, to keep the fabric intact and the color everlasting, where if they do not then there are high chances of fabric leaving colors when washed. The designs are based on our preferences as consumers.

“Ameliorating The Shape”

The final stage of production, where the semi-completed fabric is turned into a finished good. This process undertakes different steps before sending the product to customers. These steps consist of sampling; this includes the development of fabric, its patterns, and size.

With that, it moves to the costing step. It determines the cost that occurred in the activities of buying raw materials to designing, processing, and converting goods into finishing products, by calculating all the costs and keeping a percentage of profit, the cost of the final product is charged.

“Scrutiny”

The final inspection is done to see if there is any wear and tear that was added in the boxes or whether the stock is in the right numbers. A proper inspection is done to save oneself from the troubles.

From Blank Canvas To Blossoms

The process reaches its final stage, where the packing of the finished goods is done…Poof, a stock of cardboard boxes is ready to be delivered to the stores and waiting for your arrival to be bought and spread on your bed.

The post The Journey Of Cotton, From Farm Fields To Your Bedroom appeared first on Bedding Republic.

One of the most widely used fabrics for quilt covers in synthetic fibers is polyester. Most of us use this product to meet our bedding needs. It brings us joy as it does not let itself have any wrinkles and it is easily washable. However, with its high absorption quality, it can trap heat, dirt, and oil. In summer, you do not have an uncomfortable sleep by being in a sweatbox at night.

Nevertheless, let us have a look at the synthetic fabric process followed to produce the finished product:

“Mixing a bunch of chemicals…Hello Chemistry”

Science has its way to uncover mysteries. As raw materials of synthetic fibers are chemicals, they do not consist of characteristics that are required for the formation of the fiber. Therefore, the process is prolonged where two or more molecules of the same class are combined, producing a chainlike structure. This is known as ‘Polymerization’.

The weight of the polymer is just not enough to term it as fit to be used. Therefore, the molecules that make up the fiber come into action, known as macromolecules. This manifests that the initial step towards the making of synthetic fabric is to produce polymers out of unprocessed material, called monomeric.

In the production house, a specific portion is deputed to this process. Where through processing the unprocessed monomeric to polymerization. This process is completed to certain degrees.

“Merry Go Round”

As we have played along with chemicals, now it is time for polymers to move to the dizzy part. The spinning is not only processed as one step rather polymers are required to undergo three spinning steps including:

• Dry Spinning- The polymers are incorporated in carbon-based substances, capable of dissolving to create a “spinning solution.” This is done through spinnerette, allowing polymers to thicken.
• Wet Spinning- The procedure is the same except that under wet spinning the polymer is dissolved in a spinning bath, changing into a solid or semi-solid state.
• Melt Spinning- Through this method, synthetic fibers are produced to form fabrics. It requires a cooling system to create melted material into a solid-state.

“The Art”

After the whirling process, the procedure further continues to the polymers being pulled or stretched throughout the longitudinal axis to bring fibers into a line. The process is used for the formation of different types including:

• Synthetic filament- This type of fiber has an indefinite length. Therefore, can be stretched according to the requirement.
• Staple Fibre- This is also known as textile fibers including cotton and wool. They are classified under a certain length where a short length is measured up to 60mm.
• Spun Yarn- Under this process fibers are twisted to form a strand. They are made of continuous fibers, just like a braid. The process takes in all the impurities that are residing in raw fiber.

“Texture: A melody”

To make the yarn smooth and flexible, it is knitted into a fabric. Texturing increases the void spaces through ‘crimp, coil, and loop’ alongside the length of the filament. This changes the physical appearance of the fiber.

Texturing ameliorates the process of trapping air to cut back on the synthetic outlook of the fabric. These curtains can add elasticity to their properties. With that, it further enhances the warmth and the look of the fabric, giving it an appearance not far from a look that a natural fabric holds. There are different types of procedures for texturing including:

• Crimping
• Stuffing
• Air-Jet
• Knitted-Loop

“Affixing AESTHETICS”

Here comes the final procedure, dyeing. Under the process of creating synthetic fabrics, they meet several chemicals to form and ameliorate their look. The dye is usually added after the spinning process. A consistent and interlaced form is found in the synthetic fiber. It is because the molecular network is constant and consists of a high level of crystallization. The settling of dye depends upon which synthetic fiber it is being used in, as each has different properties. Thus, the amount of dye to be added varies with the characteristics. The dye used for synthetic fabrics include:

• Disperse Dye-Used for dyeing polyester.
• Reactive Dye- Used for nylon, viscose, and synthetic velvets.
• Acid Dye- Used on woolen fabrics

Here ends the process of how synthetic fabrics are made. From here they are molded into quilt covers, bed sheets, and pillowcases. with that, they are labeled and packed, waiting patiently for your arrival to be bought and spread on your bed.

The post How Is Synthetic Fabric Made To Meet The Bedding Needs? appeared first on Bedding Republic.